Bobcat T140 Compact Track Loader Repair Service Manual – 6903153

(S/N: 527111001 & Above) – (S/N: 527211001 & Above)
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This workshop repair service manual PDF download for the T140 Bobcat Compact Track 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 T140
S/N: 527111001 & Above
S/N: 527211001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6903153 (2-06)
Total Pages : 616

This service manual / repair manual / 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 LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing 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
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Checking
Replacing Filter Element(s)
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Replacing 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
Replacing Hydraulic/Hydrostatic Filter
Replacing Hydrostatic Motor Case Drain Filter(s)
Replacing Hydraulic Fluid
Breather Cap
FAN GEARBOX
Checking And Maintaining
BOB-TACH™
Inspection And Maintenance
POWER BOB-TACH™
Inspection And Maintenance
LUBRICATION OF THE BOBCAT LOADER
Procedure
SPARK ARRESTOR MUFFLER
Servicing

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols
Tighten Procedures
Troubleshooting Chart
CYLINDER (LIFT)
Checking
Removal And Installation
Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Rod End Pivot Pin Bushing And Seal Replacement
Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH™)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Checking
Adjustment
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
Removal And Installation
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
Rubber Boot Removal and Installation
End Cap/Spool Lock Block Removal and Installation
Lift Spool and Detent Removal and Installation
Tilt 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, Check Valve Removal And Installation
BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
Main Relief Valve
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
Removal And Installation
Actuator Removal And Installation (Out of Loader)
Identification Chart (ACS)
BICS Valve, Load Check Valve Removal And Installation (Lift)
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
Tilt 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, Check Valve Removal And Installation
BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
Main Relief Valve
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Check The Output Of The Hydraulic Pump Without Rear Auxiliary
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTER
Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Removal And Installation
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
REAR AUXILIARY DIVERTER VALVE
Removal And Installation
Disassembly And Assembly
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
Replacing the Motor Oil
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
CHARGE PRESSURE
Sender Removal And Installation
Checking Charge Pressure
Adjusting
HYDROSTATIC PUMP
Replenishing/High Pressure Relief Valve
Removal And Installation
Parts Identification (Right Half)
Parts Identification (Left Half)
Hydraulic Pump Removal And Installation
Pump Separation
Disassembly
Assembly
DRIVE BELT
Shield Removal And Installation
Adjusting
Drive Belt Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Parts Identification
Tensioner Pulley Disassembly
Tensioner Pulley Assembly
OIL COOLER
Removal and Installation

DRIVE SYSTEM
BRAKE
Pressure Relief Valve Test
Right Motor Brake Test
Left Motor Brake Test
Block Removal And Installation
Block Disassembly And Assembly
DRIVE COMPONENTS
Track Tension
Track Tension Adjusting
Track Removal And Installation
Track Idler (Front) Removal And Installation
Track Idler (Front) Disassembly and Assembly
Track Idler (Rear) End Play Specifications
Track Idler (Rear) Removal And Installation
Track Idler (Rear) Disassembly and Assembly
Track Roller Assembly End Play Specifications
Track Roller Removal And Installation
Track Roller Disassembly and Assembly
Track Housing Removal And Installation
Track Damage Identification

MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Disassembly
Removal And Installation
OPERATOR SEAT
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
Bob-Tach Stops
POWER BOB-TACH™
Removal And Installation
Power Bob-Tach Lever And Wedge
LIFT ARM
Removal And Installation
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
Fuel Fill Screen
Fuel Pickup Screen
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
Crossbar Linkage Removal And Installation
Lift Foot Pedal Linkage Removal And Installation
Tilt Foot Pedal Linkage Removal And Installation
CONTROL PEDALS (ACS)
Foot Sensor Removal And Installation
Foot Pedal Removal And Installation
Foot Pedal Linkage Disassembly And Assembly
CONTROL PANEL
Description
Removal and Installation
Shock Removal And Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Pintle Arm Disassembly and Assembly
Linkage Neutral Adjustment
Linkage Travel Adjustment
CONTROL HANDLE
Control Lever Removal And Installation
Rubber Boot Replacement
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal and Installation
Control Handle Disassembly and Assembly
Control Lever Removal and Installation
Control Lever Boot

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Relay Switch Location
Fuse Location
BATTERY
Removal And Installation
Servicing
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 Setup Display Options (Deluxe)
Option And Field Accessory Panels (If Equipped)
Removal And Installation
Front Accessory Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT CONTROLLER
Identification Chart
Removal And Installation
DIAGNOSTIC SERVICE CODES
Display
Number Codes List
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)
Inspecting The Lift Arm By-Pass Control
Troubleshooting Chart
Troubleshooting Guide
SEAT BAR SENSOR
Troubleshooting Chart
Test
Removal And Installation
BICS Circuit Test
TRACTION LOCK
Troubleshooting Chart
Description Of The Control System
Inspecting The Control System
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL
Components Identification
Troubleshooting Guide
Controller, Connector And Wire Identification
ACS Controller Removal And Installation
Handle Sensor Connector
Switch Handle Removal
Switch Handle Installation
Actuators Disassembly And Assembly
Handle Lock Solenoid Removal And Installation
Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Connector
Calibration Of The ACS System
Switchable Hand/Foot Controls Calibration Procedure
Foot Sensor Disassembly And Assembly
Foot Sensor Connector
Foot Lock Solenoid Removal And Installation
Foot Lock Solenoid Connector
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
FLYWHEEL RPM SENSOR
Adjustment

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
Disassembly
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
COOLING FAN
Drive Tension Pulley Removal And Installation
Gearbox/Blower Housing Removal And Installation
Blower Housing Grill Removal And Installation
Blower Disassembly And Assembly
Gearbox Parts Identification
Gearbox Disassembly
Gearbox Assembly
Gearbox Checking Backlash
ENGINE COMPONENTS AND TESTING
Compression Checking
Glow Plugs Checking
Glow Plugs Removal And Installation
Fuel Shutoff Solenoid, Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Removal And Installation
Timing The Injection Pump
Fuel Injector Removal And Installation
Checking Nozzle Injection Pressure
Nozzle Spraying Condition
Valve Seat Tightness
Valve Clearance Adjustment
Valve Timing, Checking
ENGINE
Removal And Installation
Engine Mount Replacement
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
RECONDITIONING THE ENGINE
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Servicing
Cylinder Head Top Clearance
Valve Guide Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Rocker Arm And Shaft Checking
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Camshaft Servicing
Idler Gear And Shaft Servicing
Timing Gears Checking Backlash
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Valve Tappets
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings, Servicing
Cylinder Bore, Checking
Water Pump Removal And Installation
Water Pump Disassembly And Assembly

HEATER
COMPONENTS
Identification
REGULAR MAINTENANCE
Filter Elements Removal And Installation
BASIC TROUBLESHOOTING
Cleaning The Heater Coil
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM TROUBLESHOOTING CHART
Blower Motor Does Not Operate
Blower motor operators normally, but air flow is insufficient
HEATER UNIT
Removal And Installation
Disassembly And Assembly
HEATER COIL
Removal And Installation
HEATER FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal and Installation
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
LOADER SPECIFICATIONS (T140)
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tracks
Ground Pressure
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinders
Piston Rings
Pistons
Connecting Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
Torque For Kubota Metric Bolts
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
U.S. To Metric Conversion

SERVICE MANUAL REVISION
T140-1

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