Bobcat T200 Turbo Series Track Loader Complete Workshop Service Repair Manual

6901397 (7-10) Printed in U.S.A. ©Bobcat Company 2010 Service Manual S/N 518915001 & Above S/N 516815001 & Above S/N 517515001 & Above EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

6901397 (4-01) Printed in U.S.A. ©Bobcat Company 2001

MAINTENANCE SAFETY WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0807 Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. Never service the Bobcat Compact Track Loader without instructions. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. B-15659 CORRECT P-90216 CORRECT B-15660 CORRECT B-15664 WRONG WRONG B-15661 WRONG B-15662 WRONG B-6589 B-15663 WRONG WRONG B-15665 MSW09-0409 Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

ALPHABETICAL INDEX ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL .............. 60-01 ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL............................... 60-01 AIR CLEANER ........................................................ 70-01 AIR CLEANER SERVICE ....................................... 10-01 AIR CONDITIONING SERVICE .............................. 80-01 AIR CONDITIONING SYSTEM FLOW ................... 80-01 ALTERNATOR (90 AMP) ........................................ 60-01 BASIC TROUBLESHOOTING ................................ 80-01 BATTERY ................................................................ 60-01 BICS™ SYSTEM .................................................... 60-01 BOB-TACH .................................................... 10-01,50-01 BOBCAT CONTROLLER ........................................ 60-01 BRAKE .................................................................... 40-01 BUCKET POSITION VALVE ................................... 20-01 CHARGE PRESSURE ............................................ 30-01 COMPONENTS ...................................................... 80-01 COMPRESSOR ...................................................... 80-01 CONDENSER ......................................................... 80-01 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL .............................................................. 50-01 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL... 50-01 CONTROL PANEL .................................................. 50-01 CONTROL PEDALS ............................................... 50-01 CONTROL PEDALS (ACS) .................................... 50-01 CONVERSIONS ................................................ SPEC-01 COOLING FAN ....................................................... 70-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (POWER BOB-TACH).......................... 20-01 CYLINDER (TILT) ................................................... 20-01 DIAGNOSTICS ................................................ 60-01 DRIVE BELT ........................................................... 30-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ELECTRICAL / HYDRAULIC CONTROLS REFERENCE .......................................................... 60-01 ENGINE & ENGINE MOUNTS ............................... 70-01 ENGINE COMPONENTS AND TESTING .............. 70-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPEED CONTROL .................................. 70-01 EVAPORATOR........................................................ 80-01 EVAPORATOR / HEATER UNIT ............................. 80-01 EXPANSION VALVE ............................................... 80-01 FAN GEARBOX ...................................................... 10-01 FLYWHEEL AND HOUSING................................... 70-01 FRONT AUXILIARY PRESSURE RELIEF BLOCK 20-01 FUEL SYSTEM ....................................................... 10-01 FUEL TANK ............................................................. 50-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES ........................................................... 80-01 HEATER COIL ......................................................... 80-01 HEATER VALVE ...................................................... 80-01 HEATER / AC FAN .................................................. 80-01 HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) ................................... 20-01 HYDRAULIC CONNECTION SPECIFICATIONS ............................................. SPEC-01 HYDRAULIC CONTROL VALVE (FOOT) ................ 20-01 HYDRAULIC FILTER HOUSING ............................. 20-01 HYDRAULIC FLUID RESERVOIR .......................... 20-01 HYDRAULIC PUMP ................................................ 20-01 HYDRAULIC PUMP (HI FLOW) .............................. 20-01 HYDRAULIC SYSTEM INFORMATION .................. 20-01 HYDRAULIC / HYDROSTATIC FILTER ................. 20-01 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS ............................................. SPEC-01 HYDRAULIC / HYDROSTATIC SYSTEM ................ 10-01 HYDROSTATIC MOTOR ......................................... 30-01 HYDROSTATIC PUMP ............................................ 30-01 HYDROSTATIC SYSTEM INFORMATION.............. 30-01 INSTRUMENT PANEL............................................. 60-01 LIFT ARM ................................................................ 50-01 LIFT ARM BYPASS CONTROL VALVE .................. 20-01 LIFT ARM SUPPORT DEVICE................................ 10-01 LIFTING AND BLOCKING THE LOADER............... 10-01 LIGHTS.................................................................... 60-01 LOADER SPECIFICATIONS ............................. SPEC-01 LOADER TORQUE............................................ SPEC-01 LUBRICATION OF THE BOBCAT LOADER ........... 10-01 MAIN RELIEF VALVE .............................................. 20-01 MUFFLER................................................................ 70-01 OIL COOLER........................................................... 30-01 OPERATOR CAB .......................................... 10-01,50-01 OPERATOR SEAT................................................... 50-01 OPERATOR SEAT (SUSPENSION) ........................ 50-01 POWER BOB-TACH ................................................ 50-01 POWER BOB-TACH (OPTION)............................... 10-01 POWER BOB-TACH BLOCK................................... 20-01 PRESSURE RELIEF VALVE ................................... 80-01 PRESSURE SWITCH.............................................. 80-01

ALPHABETICAL INDEX RADIATOR............................................................... 70-01 REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) ................................................... 20-01 REAR DOOR ........................................................... 50-01 REAR GRILL ........................................................... 50-01 RECEIVER / DRIER ................................................ 80-01 RECONDITIONING ................................................. 70-01 REGULAR MAINTENANCE .................................... 80-01 REMOTE START ..................................................... 10-01 RPM SENSOR .....................................................70-01 SAFETY ................................................................... 80-01 SEAT BAR ............................................................... 50-01 SEAT BAR SENSOR ............................................... 60-01 SELECT VALVE....................................................... 20-01 SERVICE SCHEDULE ............................................ 10-01 SPARK ARRESTOR MUFFLER .............................. 10-01 STARTER ................................................................ 60-01 SYSTEM CHARGING AND RECLAMATION .......... 80-01 SYSTEM TROUBLESHOOTING CHART ............... 80-01 TEMPERATURE / PRESSURE ............................... 80-01 THERMOSTAT......................................................... 80-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01 TOWING THE LOADER .......................................... 10-01 TRACTION LOCK.................................................... 60-01 TRANSPORTING THE BOBCAT LOADER ............. 10-01 TROUBLESHOOTING............................................. 70-01 TURBOCHARGER .................................................. 70-01 ACS-ADVANCED CONTROL SYSTEM AHC-ADVANCED HAND CONTROL SYSTEM BICS-BOBCAT INTERLOCK CONTROL SYSTEM

T200 Bobcat Loader I Service Manual CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SAFETY & HYDROSTATIC MAINFRAME SYSTEM SYSTEM DRIVE ELECTRICAL MAINTENANCE SYSTEM ENGINE SERVICE ENGINE SPECIFICATIONS HVAC SPECIFICATIONS HYDRAULIC SYSTEM

T200 Bobcat Loader II Service Manual FOREWORD This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc. A general inspection of the following items must be made after the loader has had service or repair: FW SSL-1008 SM 1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified. 9. The parking brake must function correctly. 2. Check that ROPS mounting hardware is tightened and is Bobcat approved. 10. Enclosure door latches must open and close freely. 3. The seat belt must be correctly installed, functional and in good condition. 11. Bob-Tach wedges and linkages must function correctly and be in good condition. 4. The seat bar must be correctly adjusted, clean and lubricated. 12. Safety treads must be in good condition. 5. Check lift arm support device, replace if damaged. 13. Check for correct function of indicator lamps. 6. Machine signs (decals) must be legible and in the correct location. 14. Check hydraulic fluid level, engine oil level and fuel supply. 7. Steering levers, hand controls and foot pedals must return to neutral (as applicable). 15. Inspect for fuel, oil or hydraulic fluid leaks. 8. Check for correct function of the work lights. 16. Lubricate the loader.

T200 Bobcat Loader III Service Manual FW SSL-1008 SM 17. Check the condition of the battery and cables. 23. Operate the machine and check all functions. 18. Inspect the air cleaner for damage or leaks. Check the condition of the element. 24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer. 19. Check the electrical charging system. 25. Check for proper function of front horn and back-up alarm (if equipped). 20. Check tires for wear and pressure. Check tracks for wear and tension. Use only approved tires or tracks. 26. Check function or condition of all equipped options and accessories (examples: fire extinguisher, rotating beacon, lift kits, etc.). 21. Inspect for loose or broken parts or connections. 27. Recommend to the owner that all necessary corrections be made before the machine is returned to service. 22. Check for any field modification not completed. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.

T200 Bobcat Loader IV Service Manual

Bobcat T200 Turbo Series Track Loader Complete Workshop Service Repair Manual

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