Bobcat Dozer 96 Inch Service Repair Manual Instant Download (96 Inch SN 224400101 AND Above)

1
.Bobcat.
Dozer 96 Inch
Service Manual
(96 Inch) S/N 224400101 Above
600BBB3 (10-12) 1 al fi8
Printed in U.S.A
0 Bobcat Company 200B
2
ALPHABETICAL INDEX ACD (ATTACHMENT CONTROL
DEVICE) ..........................30-10-1 ATTACHME
NT DELIVERY REPORT ............. . .......
....... .. III CUTTING EDGE .....................
..........................30-40-1 ELECTRICAL
SCHEMATIC-7 PIN CONNECTOR ..................SPEC-2
0-1 ELECTRICAL SCHEMATIC-7 PIN CONNECTOR WITH 14
PIN ADAPTER HARNESS.............................
SPEC-20-1 HYDRAULIC CONTROL VALVE
..................................20-10-1 HYDRAULI
C CYLINDER .......................................
.20-20-1 HYDRAULIC SCHEMATIC .....................
...............SPEC-30-1 INSPECTION . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
.10-20-1 IDENTIFICATION ... ........ .........
...... . ................ . IV MOLDBOARD
.................................................3
0-20-1 MOUNTING FRAME AND ROTATING SECTION
.....................30-30-1 LUBRICATION . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .10-40-1
SERIAL NUMBER LOCATION ..................
...... . ........ III SPECIFICATIONS. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . SPEC-10-1 TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .10-10-1
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SAFETY AND MAINTENANCE
CONTENTS
ATTACHMENT DELIVERY REPORT .....
III
HYDRAULIC SYSTEM
IDENTIFICATION AND MACHINE SIGNS (DECALS) SERIAL
NUMBER LOCATION ........ . ....... SAFETY AND
MAINTENANCE.
. IV
MAIN FRAME
. 10-01
HYDRAULIC SYSTEM ...... MAIN FRAME
............... .... SPECIFICATIONS AND SCHEMATICS
. 20-01
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS
AND AND
SCHEMATICS SCHEMATICS
. 30-01
. SPEC-01
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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.
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SERIAL NUMBER LOCATION
ATTACHMENT DELIVERY REPORT
Figure 1
Figure 2
Always use the serial number of the Dozer when
requesting service information or when ordering p
Early or later models (identification made by
serial
The Attachment Delivery Report must be filled out
by the dealer and signed by the owner or operator
when the Dozer is delivered. An explanation of
the form must be given to the owner. Make sure it
is filled out completely Figure 2.
arts.
number) may use different parts, or it may be
necessary to use a dif ferent procedure in doing
a specific service
operation Figure 1.
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96 Inch Dozer Service Manual
III
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IDENTIFICATION AND MACHINE SIGNS (DECALS)
HYDRAULIC CONTROLVALVE
6701391
CUTTING EDGE
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HYDRAULIC COUPLERS
STEP
AWARhIING
7105979
A WARNING
7105980 (2)
BLADE
6594488
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SAFETYAND MAINTENANCE
SAFETY AND MAINTENANCE TROUBLESHOOTING ......
........ . 10-10-1 INSPECTION ....................
................. 10-20-1 Cutting Edge
Inspection...........................
10-20-3 Dozer Mount Inspection....................
....... 10-20-3 Hand Lever Bob-Tach
Inspection.................... 10-30-1 Power
Bob-Tach Inspection ........................
10-20-2
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TROUBLESHOOTING
PROBLEM CAUSE CORRECTION
Dozer does not mount properly on the Bob-Tach. Bob-Tach wedges are not fully retracted before installation. Retract Bob-Tach wedges before installation.
Dozer does not mount properly on the Bob-Tach. Mud, dirt or stones are lodged between the Bob-Tach and the Dozer mount. Remove debris between Bob-T ach and Dozer mount.
Dozer does not rot ate or oscillate. No hydraulic flow. Activate loader front auxiliary hydraulics.
Dozer does not rot ate or oscillate. No hydraulic flow. Check quick couplers connection. Check for damaged hose ends and fittings.
Dozer does not rot ate or oscillate. Electrical harness not installed. Install electrical harness from the Dozer to the loader.
Dozer does not rot ate or oscillate. No electrical current flow through harness. Check Dozer electrical harness for damage to connector or harness.
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10-10-1
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INSPECTION
If the wedge does not contact the lower edge of
the hole the attachment will be loos e and can
come of f the Bob- Tach. Figure 10-20-3
Hand Lever Bob-Tach Inspection
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and
locked. Failure to secure wedges can allow
attachment to come off and cause injury or
death. W-2102-0497 Figure 10-20-1
lnspect the mounting frame on the att achment and
the Bob-Tach, linkages and wedges for excessive
wear or damage. Replace any p arts that are
damaged, bent, or a missing Figure 10-20-3.
Keep all fasteners tight. Look for cracked
welds. Cont act your Bobcat dealer for ,_ repair
or replacement parts.
O Lubricate the wedges. (See the correct Loader
Operation Maintenance Manual for LUBRICATION OF
THE ' BOBCAT MACHINE.)
P10631
Move the Bob-Tach levers down to engage the
wedges Figure 10-20-1. The levers and wedges
must move freely.
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The wedges must extend through the holes in the
attachment mounting frame (Item 2) Figure
10-20-2. The spring loaded wedge (Item 1) must
contact the lower edge of the hole in the att
achment (Item 2) Figure 10- 20-2.
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INSPECTION (CONT'D)
Figure 10-20-5
Power Bob-Tach Inspection
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and
locked. Failure to secure wedges can allow
attachment to come off and cause injury or
death. w-a10z-ag7 Figure 10-20-4 The wedges must
extend th rough the holes in the attachment
mounting frame (Item 2) Figure 10-20-5. The
spring loaded wedge (Item 1) must contact the
lower edge of the hole in the att achment (Item
2) Figure 10- 20-5. If the wedge does not cont
act the lower edge of the hole Figure 10-20-5
the att achment will be loose and can come off
the Bob-Tach. Figure 10-20-6
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B 17 0
NOTE The Power Bob-Tach system has continuous
pressurized hydraulic oil to keep the wedges
in the engaged position and prevent
attachment disengagement. Because the
wedges can slowly lower, the operator may need
to reactivate the switch BOB-TACH WEDGES UP)
to be sure both wedges are fully raised before
installing the attachment.
Push and hold the BOB-TACH WEDGES UP switch until
wedges are fully raised. Pu sh and hold the BOB-T
ACH WEDGES DOWN switch until Figure 10-20-4
the wedges are fully down.
The wedges must move freely.
Inspect the mounting frame on the att achment and
the Bob-Tach, linkages and wedges for excessive
wear or damage Figure 10-20-6. Replace any
parts that are damaged, bent, or missing. Keep
all fasteners tight. Inspect the hoses and
fittings for leaks. Look for cracked welds. Cont
act your Bobcat dealer for repair or replacement
parts. Lubricate the wedges. (See the correct
loader Operation Maintenance Manual
for LUBRICATION OF THE BOBCAT LOADER.j
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INSPECTION (CONT'D)
Cutting Edge Inspection
Dozer Mount Inspection
Figure 10-20-8
Figure 10-20-7
The one piece cutting edge (Item 1) Figure
10-20-8 is reversible. When the cutting edge
becomes worn or damaged, remove the cutting edge,
rotate it 180 degrees and reinstall. (See Removal
And Installation on Page 30- to-1.)
lnspect the Bob-Tach wedge mounts (Item 1),
mounting flange (Item 2) on the Dozer mount for
wear and damage each time the Dozer is removed
from the machine Figure 10-20-7.
Replace the cutting edge as needed.
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96 Inch Dozer Service Manual
10-20-3
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HYDRAULIC SYSTEM HYDRAULIC CONTROL
VALVE....................... 20-10-1
Assembly............ ..... ....... .... 20-10-9
Disassembly. . .. . . . . . . . . . . . . . . . . . 20-10-4
Parts Identification..... ..... ...... .... 20-10-3
Removal And Installation. .... ...... .... 20-10-1
HYDRAULIC SYSTEM
HYDRAULIC CYLINDER ............................
20-20-1 Assembly .................................
..... 20-20-7 Disassembly. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
20-20-4 Parts Identification .....................
.......... 20-20-3 Oscillating Cylinder Removal
And Installation .......... 20-20-1 Angle
Cylinder Removal And Installation..............
20-20-2
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HYDRAULIC CONTROL VALVE
Figure 20-10-2
Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic
systems, clean the work area before disassembly
and keep all parts clean. Always use caps and
plugs on hoses, tubelines and ports to keep dirt
out. Dirt can quickly damage the
system. 1-2003-0888
Remove the male quick coupler hydraulic hose
(Item 1) and female quick coupler hydraulic hose
(Item 2) Figure 20-10-2.
IMPORTANT
Figure 20-10-3
Contain and dispose of any oil leakage in
an environmentally safe manner. 1-2066-0395
Left Cylinder
Figure 20-10-1
P-57862 Remove the rod end hydraulic hose (Item
1) and base end hydraulic hose (Item 2) Figure
20-10-3. Figure 20-10-4 Right Cylinder
Remove cable ties (Item 1) Figure
20-10-1. Remove the three bolts (Item 2)
Figure 20-10-1. NOTE Removing the three
bolts will allow the hydraulic control valve
to move, exposing the complete auxiliary
hydraulic hose fittings. Installation Tighten
bolts to 25-28 f t.-lb. (34-38 Nm) torque.
P-57863 Remove the rod end hydraulic hose (item
1) and base end hydraulic hose (Item 2) Figure
20-10-4.
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HYDRAULIC CONTROL VALVE (CONT'D)
Figure 20-10-7
Removal And Installation (Cont'd) Figure
20-10-5 Oscillating Cylinder
Remove the control valve (Item 1) Figure
20-10-7. Figure 20-10-8 Remove rod end
hydraulic hose (Item 1) and base end hydraulic
hose (Item 2) Figure 20-10-5. Figure 20-10-6
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Remove electrical connector (Item 1) Figure
20-10-8. Installation Connector (Item
1) Figure 20-10-8 is marked with a white
cable tie. Remove electrical connector (Item 2)
Figure 20-10-8. Installation Connector (Item
2) Figure 20-10-8 is marked with a brown
cable tie. Remove electrical connector (Item 3)
Figure 20-10-8. Installation Connector (Item
3) (Figure 20-10-8 is marked with a purple
cable tie. Remove electrical connector (Item 4)
Figure 20-10-8. /nsta/lation Connector (Item
4) Figure 20-10-8 is marked with a red cable
tie.
Remove the four bolts (Item 1) Figure 20-10-6.
Installation Tighten bolts to 25-28 f t.-lb.
(34-38 Nm) torque. Remove cover (Item
2) Figure 20-10-6 and control valve.
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HYDRAULIC CONTROL VALVE (CONT'D) Parts
ldentification

1. Nut
2. Coil
3. Spacer
4. Directional control Valve
5. Chrome Ball
6. Spring
7. Plug
8. Orifice (0.080 dia.)
9. Block

16
17
3
18

1. Double Pilot Piston
2. Check Valve
3. Logic Element
4. Orifice (0.020 dia.)
5. Orifice (0.080 dia.)
6. Orifice (0.078 dia.)
7. White Cable Tie
8. Brown Cable Tie
9. Purple Cable Tie
10. Red Cable Tie

2
3
19
4
4
7
7
15
8
I I
6
11
! i i
10
9

10
11
14 (Qfiy. 2)
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