Bobcat T190 G-Series Compact Track Loader Service Manual – 6901117 (2-06)

(S/N: 519311001 & Above) – (S/N: 519411001 & Above)
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This workshop repair service manual PDF download for the T190 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 T190
G Series
TURBO – HIGH FLOW
S/N: 519311001 & Above
S/N: 519411001 & Above

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901117 (2-06)
Total Pages : 869

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 LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
Single Point Lift
LIFT ARM SUPPORT DEVICE
Installing Lift Arm Support Device
Removing 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 (S/N 519313197 & BELOW)
Procedure
TOWING THE LOADER (S/N 519313198 & ABOVE)
Procedure
REMOTE START
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
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 Hydraulic Fluid
Breather Cap
FAN GEARBOX
Checking And Maintaining
BOB-TACH
Inspection And Maintenance
POWER BOB-TACH (OPTION)
Inspection And Maintenance
LUBRICATION OF THE BOBCAT LOADER
Procedure
SPARK ARRESTOR MUFFLER
Cleaning Procedure

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
Tighten Procedures
CYLINDER (LIFT)
Checking
Removal And Installation
Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Base End Pivot Pin Replacement
Rod End Pivot Pin Bushing And Seal Replacement
Parts Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH)
Checking
Removal And Installation
Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Checking
Adjustment
Removal and Installation
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
Removal And Installation
BICS™ Valve Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
BICS™ Valve, Check Valve Disassembly And Assembly
BICS™ Valve Lock Valve Disassembly And Assembly
BICS™ Valve Solenoid Disassembly And Assembly
BICS™ Valve Solenoid Testing
Identification Chart
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation Valve/Port Relief Valve
Anti-Cavitation Valve
Rubber Boot
Lift And Tilt Lock Block
Lift Spool and Detent
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid Disassembly
Port-Auxiliary Section Disassembly
Cleaning And Inspection
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
Removal And Installation
BICS™ Valve Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Dissembly And Assembly
BICS™ Valve, Check Valve Dissembly And Assembly
BICS™ Valve Lock Valve Dissembly And Assembly
BICS™ Valve Solenoid Dissembly And Assembly
BICS™ Valve Solenoid Testing
Actuator Removal And Installation
Identification Chart (Hand Control)
Identification Chart (ACS)
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
Port-Auxiliary Section Disassembly
Cleaning And Inspection
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Check The Output Of The Hydraulic Pump Without Power Bob-Tach
Check The Output Of The Hydraulic Pump With Power Bob-Tach.
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC PUMP (HIGH FLOW)
Check The Output Of The Hydraulic Pump Without Power Bob-Tach (S/N 519315699 & Below)
Check The Output Of The Hydraulic Pump With Power Bob-Tach (S/N 519315699 & Below)
Check The Output Of The Hydraulic Pump (Standard)(S/N 519315700 & Above)
Check The Output Of The Hydraulic Pump (High Flow)(S/N 519315700 & Above)
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC 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
SELECT VALVE (S/N 519315699 & BELOW)
Checking The High Flow Pump Relief Valve
Removal And Installation
Disassembly And Assembly
Solenoid Testing
HIGH FLOW VALVE (S/N 519315700 & ABOVE)
Checking The High Flow Relief Valve
High Flow Relief Valve Adjustment Procedure
Removal And Installation
Disassembly And Assembly
Solenoid Testing
REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) (S/N 519315699 & BELOW)
Removal And Installation
Disassembly And Assembly
Solenoid Testing
Inspection
REAR AUXILIARY DIVERTER VALVE (S/N 519315700 & Above)
Removal And Installation
Disassembly And Assembly
Solenoid Testing
Inspection
POWER BOB-TACH BLOCK (S/N 519315202 & below)
Removal And Installation
Disassembly And Assembly
POWER BOB-TACH BLOCK (S/N 519315203 & Above)
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY PRESSURE RELIEF BLOCK
Removal And Installation (519312091 & Below)
Disassembly And Assembly (519312091 & Below)
Solenoid Testing
Solenoid Inspection
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Removal and Installation (519312092 & Above)
Disassembly And Assembly (519312092 & Above)

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
HYDROSTATIC MOTOR
Replacing the Motor Oil (Motor S/N 428302 & Above)
Removal And Installation
Parts Identification (Motor S/N 428301 & Below)
Parts Identification (Motor S/N 428302 & Above)
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
Switch Operated Parking Brake
Brake Engaged (Dragging) Test (S/N 519313197 & Below)
Block Removal And Installation (S/N 519313197 & Below)
Block Disassembly And Assembly (S/N 519313197 & Below)
Traction Lock By-Pass Knob (S/N 519313197 & Below)
BRAKE (S/N 519313198 AND ABOVE)
Pressure Relief Valve 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) Parts Identification (S/N 519313368 & Below)
Track Idler (Front) Disassembly (S/N 519313368 & Below)
Track Idler (Front) Assembly
Track Idler (Rear) Removal And Installation
Track Idler (Rear) Parts Identification (S/N 519313368 & Below)
Track Idler (Rear) Disassembly (S/N 519313368 & Below)
Track Idler (Rear) Assembly (S/N 519313368 & Below)
Track Roller Removal And Installation
Track Roller Parts Identification (S/N 519313368 & Below)
Track Roller Disassembly (S/N 519313368 & Below)
Track Roller Assembly
Track Idler (Front) Parts Identification (S/N 519313369 & Above)
Track Idler (Front) Disassembly (S/N 519313369 & Above)
Track Idler (Front) Assembly (S/N 519313369 & Above)
Track Idler (Rear) End Play Specifications (S/N 519313369 & Above)
Track Idler (Rear) Parts Identification (S/N 519313369 & Above)
Track Idler (Rear) Removal And Installation (S/N 519313369 & Above)
Track Idler (Rear) Disassembly (S/N 519313369 & Above)
Track Roller Assembly End Play Specifications (S/N 519313369 & Above)
Track Roller Parts Identification(S/N 519313369 & Above)
Track Roller Removal And Installation (S/N 519313369 & Above)
Track Roller Disassembly (S/N 519313369 & Above)
Track Roller Assembly (S/N 519313369 & Above)
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
Seat Belt Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail 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
Pivot Pin Bushing And Seal Replacement
POWER BOB-TACH
Removal And Installation
Power Bob-Tach Lever And Wedge
Pivot Pin Bushing And Seal Replacement
LIFT ARM
Removal And Installation
Link Removal And Installation
Stabilizer Bar Removal And Installation
REAR GRILL
Gas Cylinder Removal And Installation (Earlier Models Only)
Removal And Installation (Earlier Models)
Removal And Installation (Later Models)
REAR DOOR
Removal And Installation
Door Latch And Catch Adjustment (519311949 & Below)
Door Latch Removal And Installation (519311949 & Below)
Striker Removal and Installation (S/N 519311950 & Above)
Striker Disassembly and Assembly (S/N 512261536 & Above)
Adjusting The Striker (S/N 519311950 & Above)
Latch Removal and Installation (S/N 519311950 & Above)
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
Removal and Installation
Shock Removal And Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Linkage Adjustment
Linkage Neutral Adjustment
CONTROL HANDLE
Control Lever Removal And Installation
Control Lever Boot
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND 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
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
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Wiring Schematics
Troubleshooting Chart
Description
Fuse Location
Relay Switch Location
Solenoid Test
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR (90 AMP)
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 (NIPPONDENSO)
Checking
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
No Load Test
Assembly
STARTER (VALEO)
Checking
Removal And Installation
Parts Identification
Disassembly and Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Left Panel (Standard)
Right Panel-Standard Instrument Panel (With Key Switch)
Right Panel – (Deluxe) (With Keyless Start)
Right Panel Setup Display Options (Deluxe)
Option and Field Accessory Panels
Removal And Installation
Front Accessory Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT CONTROLLER
Identification Chart (S/N 519313304 & Below)
Identification Chart (S/N 519313305 & Above)
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
Additional Inspection For Loaders With Advanced Hand Controls (AHC)
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) ADVANCED HAND 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
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 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 (S/N 519314343 & BELOW)
Removal And Installation
RADIATOR (S/N 519314344 & ABOVE)
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 Shut-Off Solenoid, Checking
Fuel Shut-Off Solenoid, Adjusting
Fuel Shut-Off Solenoid Removal And Installation
Checking
Fuel Injection Pump Removal And Installation
ENGINE COMPONENTS AND TESTING (CONT’D)
Timing The Injection Pump
Fuel Injector Removal And Installation
Fuel Injector Checking
Fuel Injector Disassembly
Fuel Injector Assembly
Valve Clearance Adjustment
Rocker Arm And Shaft Checking
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-V2003T-EB (TURBO)
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Servicing
Cylinder Head Top Clearance
Checking The Valve Guide
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
Servicing The Camshaft
Servicing The Idle Gear And Shaft
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
Relief Valve
Piston And Connecting Rod Removal And Installation
Servicing The Piston And Connecting Rod
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Servicing The Crankshaft And Bearings
Checking The Cylinder Bore
Water Pump Disassembly And Assembly
TURBOCHARGER
Troubleshooting
Description
Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation (Cont’d)
Compressor Drive Belt Inspection
Cleaning The Condenser
Filter Elements Removal And Installation
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
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
HEATER/AC FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal and Installation
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
LOADER SPECIFICATIONS
Loader Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tracks
Ground Pressure
ENGINE SPECIFICATIONS – KUBOTA V2003T-EB (TURBO)
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinder Liner
Piston Rings
Pistons
Connecting Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
Crankshaft Re-Grind Data
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General 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/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
Revision No: T190-1
Revision No: T190-2
Revision No: T190-3
Revision No: T190-4
Revision No: T190-5
Revision No: T190-6
Revision No: T190-7

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