Bobcat A300 Skid-Steer Loader Repair Service Manual – 6902728

(S/N: 526411001 & Above – S/N: 526511001 & Above)
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This workshop repair service manual PDF download for the A300 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader A300
BOBCAT SKID-STEER LOADER
With ALL WHEEL STEER (AWS)
S/N: 526411001 & Above
S/N: 526511001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATION
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902728 (1-06)
Total Pages : 802

This A300 Bobcat Loader Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
Fire Prevention
SERIAL NUMBER LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing The Lift Arm Support Device
Removing The Lift Arm Support Device
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE BOBCAT LOADER
Procedure
TOWING THE LOADER
Procedure
REMOTE START
Procedure For Loader W/O Attachments Control Harness
Procedure For Loader With Attachments Control Harness
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Cleaning Cooling System
Checking The Coolant Level
Adding The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic Fluid Chart
Hydraulic/Hydrostatic Filter Replacement
Replacing Hydraulic Fluid And Case Drain Filters
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing The Oil
FAN GEARBOX
Checking And Adding Oil
BOB-TACH
Inspection And Maintenance
POWER BOB-TACH
Inspection And Maintenance
LUBRICATING THE LOADER
Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting
Tighten Procedures
CYLINDER (LIFT)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Base Pin Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (STEERING)
Removal (Front)
Removal (Rear)
MAIN RELIEF VALVE
Checking Main Relief
Adjustment
Removal And Installation
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
Identification
Removal And Installation
Actuator Removal And Installation (In Loader)
Actuator Removal And Installation (Out Of Loader)
BICS™ Valve Removal And Installation
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation
BICS™ Valve Check Valve Removal And Installation
BICS™ Valve Lock Valve Removal And Installation
BICS™ Valve Solenoid Removal And Installation
BICS™ Valve Solenoid Testing
Identification Chart
Lift Base End Restrictor
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation Valve/Port Relief Valve
Anti-Cavitation Valve
Lift Spool Removal And Installation
Tilt Spool Removal And Installation
Lift And Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid Disassembly And Assembly
Port-Auxiliary Section Disassembly
Cleaning And Inspection
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
Identification
Removal And Installation
Actuator Removal And Installation (In Loader)
Identification Chart
BICS™ Valve, Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Anti-Cavitation Valve (Lift, Rod End)
Port Relief/Anti-Cavitation Valve (Lift, Base End)
Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Port Relief Valve
Plug Removal
End Cap Block Removal and Installation
Lift Spool Removal and Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Disassembly and Assembly
BICS™ Valve Solenoid Disassembly And Assembly
BICS™ Valve, Lock Valve Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
Main Relief Valve
BICS™ Valve, Check Valve Removal And Installation
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Additional Inspection For Loaders W/Advanced Hand Controls
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Checking The Output Of The Auxiliary Pump
Checking The Output Of The Steering Pump
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (HIgh FLOW)
Checking The Output Of The High Flow Pump (30 GPM And 40 GPM)
Removal And Installation (30 GPM And 40 GPM)
Parts Identification (30 GPM And 40 GPM)
Disassembly And Assembly (30 GPM And 40 GPM)
HYDRAULIC/HYDROSTATIC FILTER
Housing Removal And Installation
Mount Removal And Installation
HYDRAULIC FLUID RESERVOIR
Fluid Removal
Removal And Installation
Hydraulic Fluid Screen
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
HIGH FLOW VALVE
Checking The High Flow Relief Valve
High Flow Relief Valve Adjustment Procedure
Removal and Installation
Disassembly And Assembly
Solenoid Testing
REAR AUXILIARY DIVERTER VALVE
Removal And Installation
Disassembly And Assembly
Solenoid Testing
Inspection
POWER BOB-TACH BLOCK
Removal And Installation
Disassembly And Assembly
Front Auxiliary hydraulic coupler Block
Removal and Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC MOTOR CARRIER
Removal And Installation
Parts Identification
Disassembly
Assembly
CHARGE PRESSURE SENDER
Testing
Removal And Installation
HYDROSTATIC PUMP
Pump Controller Removal And Installation
Hydrostatic Pump Calibration
Removal And Installation
Parts Identification (Right Half)
Parts Identification (Left Half)
System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)
Charge Relief Valve
Pump Separation
Shaft Seal And Shaft Replacement
Shaft Seal And Shaft Installation
Charge Pump Removal
Charge Pump Inspection
Charge Pump Installation
Disassembly
Inspection
Assembly
Pump Neutral Adjustment
Pump Controller Neutral Adjustment
DRIVE BELT
Shield Removal And Installation
Adjustment
Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Tension Spring
OIL COOLER (SEAL TO CONNECT) (STC)
Hydraulic Oil Cooler Removal And Installation

DRIVE SYSTEM
BRAKE
Block Removal And Installation
Block Disassembly And Assembly
STEERING BLOCK
Identification
Removal And Installation
Disassembly And Assembly
DRIVE COMPONENTS
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Drive Chain Removal And Installation
CHAINCASE
Front Chaincase Cover Removal And Installation
Rear Chaincase Cover Removal And Installation
HUB
Removal
Installation
Disassembly
Inspection
Assembly

MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation (Early Models)
Gas Cylinder Removal And Installation (Later Models)
Gas Cylinder Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal And Installation
Cushion Removal And Installation
Back Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
POWER BOB-TACH
Removal And Installation
Power Bob-Tach Lever And Wedge
Pivot Pin Bushing And Seal Replacement
LIFT ARMS
Stabilizer Bar Removal And Installation
Link Removal And Installation
Removal And Installation
Installation Of Lift Arms
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Striker Removal and Installation
Striker Disassembly and Assembly
Door Latch and Catch Adjustment
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender
CONTROL
Joystick Testing (Right & Left)
Joystick Removal (Right & Left)
Joystick Boot Removal (Right & Left)
Lever Assembly Removal (Right & Left)
CONTROL PANEL
Removal And Installation
INSIDE ACCESS PANEL
Panel Removal (Right)
Panel Removal (Left)

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting
Description
Fuse Location
Relay Switch Location
Solenoid Test
BATTERY
Removal And Installation
Servicing The Electrical System
Using A Booster Battery (Jump Starting)
ALTERNATOR
Adjusting The Alternator Belt
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Removal And Installation
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER
Checking
Removal And Installation
Parts Identification
Disassembly And Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Left Panel
Right Panel – (Standard) (With Key Switch)
Right Panel – (Deluxe) (With Keyless Start)
Right Panel Set Up Display Options (Deluxe)
Option and Field Accessory Panels (If Equipped)
Standard Panel Removal And Installation (Right Side)
Deluxe Panel Removal And Installation (Right Side)
Standard & Deluxe Panel Removal And Installation (Left Side)
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT CONTROLLER
Identification Chart
Removal And Installation
AWS CONTROLLER
Removal
Identification Chart
SPEED SENSOR
Testing
Removal
DIAGNOSTICS SERVICE CODES
Display
Number Codes List
STEERING SOLENOID
Removal
BICS™ SYSTEM
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Troubleshooting
Troubleshooting Chart
SEAT BAR SENSOR
Troubleshooting Chart
Test
Removal And Installation
BICS™ Circuit Test
TRACTION LOCK
Troubleshooting
Description Of The Control System
Inspecting The Control System
WHEEL POSITION SENSORS
Operation
Wheel Alignment (Failed Sensor)
Testing
Sensor Removal And Installation
Wheel Alignment (Field Adjustment)
Wheel Alignment (Calibration)
SERVICE PC (LAPTOP COMPUTER)
Connecting The Service PC To Remote Start Tool
CALIBRATION
Lift And Tilt Calibration Procedure
Hydrostatic Pump Calibration
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
FLYWHEEL RPM SENSOR
Adjustment

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal
Disassembly
Speed Control Cable
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
RADIATOR
Removal And Installation
Mount Removal (Early Loaders)
Mount Removal (Later Loaders)
COOLING FAN
Drive Tension Pulley Removal And Installation
Gearbox/Blower Housing Removal And Installation
Blower Removal And Installation
Gearbox Parts Identification
Gearbox Disassembly
Gearbox Assembly
Gearbox, Checking Backlash
ENGINE
Removal And Installation
Mount Replacement
Removal And Installation Tools
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Flywheel Housing Removal And Installation
RECONDITIONING THE ENGINE
Engine Tools Identification Chart
Compression Pressure
Cylinder Head Clearance
Valve Cover, Injector Nozzle And Seal Removal And Installation
Checking Nozzle Injection Pressure
Nozzle Spraying Condition
Valve Seat Tightness
Rocker Arm And Push Rod Disassembly And Assembly
Valve Clearance
Cylinder Head And Tappet Disassembly And Assembly
Selecting Cylinder Head Gasket Disassembly And Assembly
Valve Disassembly And Assembly
Engine Timing (TDC)
Injection Pump Housing Removal
Injection Pump Governor Housing Removal And Installation
Injection Pump Governor Fork Lever Removal And Installation
Injection Pump Governor Lever Removal And Installation
Injection Pump Stop Lever Removal And Installation
Injection Pump Fuel Camshaft And Governor Weight Removal And Installation
Injection Pump Removal and Installation
Injection Pump Housing Installation
Injection Pump Timing
Fan Drive Pulley Disassembly And Assembly
Water Pump Disassembly And Assembly
Oil Cooler And Water Pipe Disassembly And Assembly
Gearcase Cover Disassembly And Assembly
Idle Gear And Camshaft Disassembly And Assembly
Oil Pan And Oil Strainer Disassembly And Assembly
Connecting Rod Cap Disassembly And Assembly
Piston Disassembly And Assembly
Piston Ring And Connecting Rod Disassembly And Assembly
Flywheel And Crankshaft Disassembly And Assembly
Bearing Case Cover Disassembly And Assembly
Flywheel Housing Disassembly And Assembly
Crankcase No. 2 Disassembly And Assembly
Crankcase No. 1 And No. 2 Disassembly And Assembly
Crankshaft Disassembly And Assembly
Cylinder Head Surface Flatness
Cylinder Head Flaw
Valve Recessing
Valve Lapping
Clearance Between Valve Stem And Valve Guide
Replacing Valve Guide
Correcting Valve And Valve Seat
Free Length And Tilt Of Valve Spring
Valve Spring Setting Load
Oil Clearance Between Rocker Arm Shaft And Bearing
Oil Clearance Between Tappet And Tappet Guide Bore
Timing Gear Backlash
Idler Gear Side Clearance
Camshaft Side Clearance
Camshaft Alignment
Cam Height
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing
Replacing Idler Gear Bushing
Piston Pin Bore I.D.
Oil Clearance Between Piston Pin And Small End Bushing
Replacing Small End Bushing
Clearance Between Piston Ring And Groove
Piston Ring Gap
Connecting Rod Alignment
Crankshaft Side Clearance
Crankshaft Alignment
Oil Clearance Between Crankpin And Crankpin Bearing
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing
Replacing Crankshaft Sleeve
Cylinder Bore I.D.
Correcting Cylinder (Oversize +0.5 mm)
Engine Oil Pressure
Rotor Lobe Clearance
Clearance Between Outer Rotor And Pump Body
Clearance Between Rotor And Cover
Relief Valve
Thermostat Valve Opening Temperature
Radiator Water Leakage
Radiator Cap Air Leakage
Thermostat Assembly
Intake Air Heater
Air Cleaner, Intake Pipe, Inlet Pipe And Muffler
Oil Pipe
Turbocharger

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Compressor Drive Belt Inspection
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Compressor Drive Belt Inspection
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
Charging Procedure
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/HEATER UNIT
Removal And Installation
Disassembly And Assembly
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
HEATER COIL
Removal And Installation With A/C
Removal And Installation Without A/C
BLOWER FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal and Installation
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
A300 LOADER SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS
General
Fuel System
Valve And Valve Timing
Valve Spring
Piston And Piston Ring
Connecting Rod
Cylinder Head
Crankshaft
Cylinder Bore
Oil Pump
Rocker Arm
Tappet
Camshaft
Thermostat
Timing Gear
Intake Air Heater
Turbocharger Compressor Shaft
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
Torque For Kubota Metric Engine Bolts
Tightening Torques For General Use Screws, Bolts And Nuts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents

SERVICE MANUAL REVISIONS
A300-1
A300-2
A300-3
A300-4

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