PDF Service Manual Bobcat T190 Track Loader - 6 MB
This is the comprehensive service manual for the Bobcat T190 Track Loader.
It provides detailed instructions on maintenance, repair, and troubleshooting for all major systems, including hydraulics, engine, and drivetrain.
This manual is used by Bobcat technicians to perform precise and efficient service.
Keep your T190 in peak condition with this essential guide.
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--- Page 1 ---
Service Manual
T190 Track Loader
S/N 531611001 - 531659999
S/N 531711001 - 531759999
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)
6904146 (8-09) Printed in U.S.A. © Bobcat Company 2009
--- Page 3 ---
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
DANGER available through your local dealer or at
www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
WARNING • The Skid-Steer Loader Safety Video is available from
your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1008 SM
V T190 Service Manual
--- Page 4 ---
LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
WARNING
AVOID INJURY OR DEATH
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
P-43747
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death. Always park the loader on a level surface.
W-2003-0807
Put floor jack under the rear of the loader [Figure 10-10-
Figure 10-10-1 2].
Lift the rear of the loader and install jackstands [Figure
10-10-2].
Figure 10-10-3
B-7023A
WARNING P-24646
Put jackstands under the front axles and rear corners
Put the floor jack under the front of the loader [Figure 10-
of the frame before running the engine for service.
10-3].
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Lift the front of the loader and put jackstands under the
W-2017-0286
axle tubes [Figure 10-10-3].
NOTE: Make sure the jackstands do not touch the
tracks. Make sure the tracks clear the floor or
any obstacles.
10-10-1 T190 Service Manual
--- Page 5 ---
TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a
recommended towing procedure.
• The loader can be lifted onto a transport vehicle.
• The loader can be skidded a short distance to move
for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1 & 1/2
times the weight of the loader. (See Performance on
Page SPEC-10-2.)
10-50-1 T190 Service Manual
--- Page 6 ---
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-7
6689779 (CONT'D)
Loader Service Tool Harness - 6689747 2
Figure 10-61-5
1
1
P-76452
2
Loaders with an attachment control harness (7 pin or 14
pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-7].
The loader service tool harness (Item 1) [Figure 10-61-5] When the remote start procedure is completed, replace
is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-6] or
(Item 2) [Figure 10-61-5] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-7].
Figure 10-61-6
1
P-76451
Loaders without an attachment control harness, remove
the loader harness cap (Item 1) [Figure 10-61-6] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
10-61-3 T190 Service Manual
--- Page 7 ---
ENGINE COOLING SYSTEM Figure 10-90-2
Check the cooling system every day to prevent over-
heating, loss of performance or engine damage.
1
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any 2
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
P-76189
• Tools are being used.
W-2019-0907
NOTE: Be careful when raising and lowering the air
Cleaning conditioning condenser so that the air
conditioning condenser does not fall on the
oil cooler and damage the fins.
Open the rear door. (See REAR DOOR on Page 50-70-
1.) Raise the air conditioning condenser (Item 1) and use
low air pressure or water pressure to clean the top of the
Remove the rear grill. (See REAR GRILL on Page 50-60- oil cooler (Item 2) [Figure 10-90-2].
1.)
Figure 10-90-3
Figure 10-90-1
1 2
2
1
P-76190
P-39459
NOTE: Be careful when raising and lowering the oil
cooler so that the oil cooler does not fall on
Use low air pressure or water pressure to clean the top of
the radiator and damage the fins.
the air conditioning condenser (Item 1) [Figure 10-90-1],
if equipped. Raise the oil cooler (Item 1) and use low air pressure or
water pressure to clean the top of the radiator (Item 2)
Raise the overflow tank (Item 2) slightly and remove the [Figure 10-90-3].
two fasteners (Inset) [Figure 10-90-1].
Lower the oil cooler.
Lower the air conditioning condenser, if equipped.
Install the fasteners and lower the overflow tank. Check
the cooling system for leaks.
Install the rear grill and close the rear door.
10-90-1 T190 Service Manual
--- Page 8 ---
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
Removing And Replacing Hydraulic / Hydrostatic not use your bare hand. Wear safety goggles. If fluid
Filter enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
For the correct service interval (See SERVICE W-2072-0807
SCHEDULE on Page 10-70-1.)
Stop the engine and check for leaks at the filter.
Open the rear door.
Check the fluid level in the reservoir and add as needed.
Figure 10-120-4 (See Checking And Adding Fluid on Page 10-120-1. )
1
P-48470
Remove the filter (Item 1) [Figure 10-120-4].
Clean the surface of the filter housing where the filter
seal contacts the housing.
Put clean oil on the seal of the new filter element. Install
and hand tighten the filter element.
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Start the engine and operate the loader hydraulic
controls.
WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
10-120-3 T190 Service Manual
--- Page 9 ---
SPARK ARRESTOR MUFFLER Figure 10-150-1
Cleaning Procedure
Use the correct service interval for cleaning the spark
arrestor muffler.
Do not operate the loader with a defective exhaust 1
system.
IMPORTANT
This loader is factory equipped with a U.S.D.A. P-48476
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The Stop the engine and open the rear door.
spark arrestor muffler must be serviced by dumping
Remove the plug (Item 1) [Figure 10-150-1] from the
the spark chamber every 100 hours of operation.
bottom of the muffler.
If this machine is operated on flammable forest,
Start the engine and run for about 10 seconds while a
brush or grass covered land, it must be equipped
second person, wearing safety glasses, holds a piece of
with a spark arrestor attached to the exhaust system
wood over the outlet of the muffler.
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442 This will force contaminants out through the cleanout
PRC. hole.
Consult local laws and regulations for spark arrestor Stop the engine.
requirements
I-2022-0807
Install and tighten the plug.
Close the rear door.
WARNING WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles. AVOID INJURY OR DEATH
Failure to obey can cause serious injury. When an engine is running in an enclosed area, fresh
W-2011-1285 air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
WARNING
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
WARNING
death.
W-2006-0284 Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285
10-150-1 T190 Service Manual
--- Page 10 ---
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . 20-40-9
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
End Cap/Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . 20-40-14
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-40-33
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-40-15
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . . . . 20-40-8
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End) 20-40-10
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 20-40-10
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End). 20-40-11
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
HYDRAULIC/HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Charge Filter Housing Removal And Installation. . . . . . . . . . . . . . . . . . . . . . 20-80-3
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP (STANDARD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Charge Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Pump Test at Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Continued On Next Page
20-03 T190 Service Manual
--- Page 11 ---
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
T190 (S/N 531611001 - 531659999)
(S/N 531711001 - 531759999)
(PRINTED FEBRUARY 2008)
V-0742legend
LEGEND
1 RESERVOIR: 16 33 FILTER - BICS CONTROL VALVE 50 RELIEF VALVE - 3300 PSI (228 bar)
SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL (SCREEN)
51 DUMP VALVE - (ON/OFF)
2 SPRING LOADED FILTER BY-PASS 34 CHECK VALVE - BUCKET POSITION
VALVE: 45-55 PSI (3,1-3,8 bar) 17 PILOTED ACTIVATED DIRECTIONAL
VALVE 52 CHECK VALVE
CONTROL VALVE - TILT CONTROL
3 DIFFERENTIAL PRESSURE SWITCH:
18 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION 53
36-44 PSI (2,5-3,0 bar) AUXILIARY HYDRAULIC PUMP -
Normally Closed CONTROL VALVE - LIFT CONTROL 9.2 GPM (34,8 L/min) at High Engine Idle
19 PULL BUTTON ACTIVATED 36 VARIABLE CAPACITY DISPLACEMENT 54
4 DRIVE MOTOR SHUTTLE VALVE CHECK VALVE - With 300 PSI (20,7 bar) Spring
DIRECTIONAL CONTROL VALVE - BI-DIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 37 SHUTTLE RELIEF VALVE 55 SOLENOID ACTIVATED CONTROL
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set) VALVE - FORWARD/REVERSE
CONTROL VALVE - UNLOADING 65 PSI (4,5 bar) 56 SERVO PISTON -Swash Plate
6 RELIEF VALVE - CHARGE INLET: SPOOL
360 PSI (24,8 bar) 38 FIXED CAPACITY DISPLACEMENT 57 POSITION SENSOR -Swash Plate
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - FLOW CONTROL MOTOR 58 CHARGE PRESSURE SENSOR
SPOOL
7 FRONT AUXILIARY MANUAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 59
22 FLOW DIVIDER ADJUSTMENT VALVE CHARGE PUMP -
PRESSURE BLEED-OFF VALVE 12.8 GPM (48,5 L/min) at High Engine Idle
8 HYDRAULIC PUMP . . . . . . . Gear Type 40 SOLENOID ACTIVATED DIRECTIONAL
23 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION 60 FIXED CAPACITY DISPLACEMENT
16.3 GPM (61,6 L/min.) at High Engine Idle
CONTROL VALVE - BASE VALVE (ON/OFF) HYDRAULIC MOTOR
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL 61
41 CHECK VALVE - BICS CONTROL VALVE ANTICAVITATION VALVE
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD
at Front Quick Couplers 62 PROPORTIONAL RELIEF VALVE –
42 RESTRICTION - 0.343 inch (8,7 mm)
25 LOAD SHUTTLE VALVE - BLEED OFF
10 PORT RELIEF/ANTICAVITATION VALVE (Fan Speed Regulator):
3500 PSI (241,3 bar) 43 FILTER - Bob-Tach Valve 1566 - 1784 PSI (108 - 123 bar)
26 SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 44 63 CHECK VALVE
PILOT ACTIVATED DIRECTIONAL
27 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH 64 SOLENOID ACTIVATED DIRECTIONAL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
CONTROL VALVE - BRAKE
CONTROL VALVE - AUXILIARY 45
28 RESTRICTOR - 0.140 inch (3,6 mm) RESTRICTION - 0.089 inch (2,26 mm) 65 HYDRAULIC BRAKE - SPRING APPLIED
13 PORT RELIEF/ANTICAVITATION VALVE: - PRESSURE RELEASE
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) 46 RESTRICTION - 0.025 inch (0,6 mm)
3500 PSI (241,3 bar)
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 47 RELIEF VALVE - 2000 PSI (137 bar)
15 LIFT CYLINDER SPOOL - MADE TO 48 RELIEF VALVE - 1200 PSI (83 bar) NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP 32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
BRONZE) CONTROL VALVE (TWO COIL) V-0742legend (2-12-08)
Printed in U.S.A.
--- Page 12 ---
CYLINDER (LIFT) (CONT’D) Figure 20-20-8
Removal And Installation (Cont’d)
Figure 20-20-6
1
1 2
N-18782
Remove the retainer bolt (Item 1) [Figure 20-20-8] and
P-34049A nut from the lift cylinder pivot pin.
Installation: Tighten the bolt and nut to standard torque.
Use a slide hammer, remove the lift cylinder rod end pivot
pin (Item 1) [Figure 20-20-6]. Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-8].
Figure 20-20-7
1
2
P-34047A
Install a smaller pin (Item 1) [Figure 20-20-7] to hold the
cylinder in place.
Disconnect the hose (Item 2) [Figure 20-20-7] from the
lift cylinder rod end port.