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Bobcat T76 Troubleshooting

The Bobcat T76 compact track loader driveline system components: a 146.5 cu.in (2.4L) Bobcat Doosan D24 4-cylinder turbocharged diesel engine with a rated power of 74 hp (55.2 kW), and 1-speed or 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated flow of 23.3 gpm (88.1 lpm). The system pressure is 3550 psi (245 bar). The Bobcat T76 is equipped with a vertical-lift loader boom, rubber tracks, and hydraulic track tension system. The loader has a boom lift force of 6788 lbs (3078 kg) and bucket breakout force of 6285 lbs (2850 kg). The rated operating capacity is 2900 lbs (1315 kg), and tipping load is 8680 lbs (3937 kg).

Engine Troubleshooting

Engine difficult to start or doesn't start
Air in the fuel system - Air bleeding.
Fuel filter plugged - Filter maintenance required.
Fuel injection nozzles are clogged or faulty - Install a new kit of correctly balanced nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Improper valve clearance - Adjust valve clearance.
Fuel injection pump is broken - Repair or change injection pump.

Engine starts but then stalls
Air filter is plugged - Replace or clean air filter element.
Clogged fuel filter - Change or clean the filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Clogged or defective injectors - Clean or replace fuel injectors.
Damaged fuel injection pump - Replace or repair injection pump.

Engine stalls after running
Low coolant temperature - Warm up the engine.
Fuel filter plugging - Replace the filter element.
Air in the fuel lines - Bleed the fuel lines.
Defective or clogged injection nozzle - Change fuel injection nozzles.
Incorrect adjustment of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stops at idle
Incorrectly adjusted low idle speed - Normalize low idle speed.
Fuel injection pump is not operating properly - Replace injection pump or repair it.
Damaged or clogged injectors - Replace fuel injectors.
Incorrect valve clearance - Check and adjust as required.

Engine lacks power
Dirty air cleaner - Clean or change.
Clogged or defective injection nozzles - Replace injection nozzles.
Fuel injection pressure is incorrect - Check the fuel injection pressure and adjust if necessary.
Valve clearance is not correct - Adjust to proper valve clearance.
Incorrect low idle speed adjustment - Test and adjust.
Restricted fuel hoses or lines - Clean fuel hoses and lines.
Cylinder head gasket defective - Install a new gasket.
Piston rings are leaking or defective - Replace the piston rings as required.

Engine overheating
Engine has a lack of coolant - Refill to the correct level and inspect system for leaks.
Engine oil level is low - Checking oil level and add if necessary.
Defective radiator cap or clogged radiator fins - Clean radiator or install new cap.
Excessive wear of the fan belt - Install new fan belt.
Engine overload - Reduce load on the engine.

Oil pressure is low
Not enough oil in the engine - Checking oil level and add if necessary.
Oil filter element is dirty - Replace or service engine oil filter.
Different type of engine oil - Fill up with the proper oil viscosity.
Incorrect oil clearance in crankshaft bearing - Replace bearings.
Oil pump malfunction - Remove and inspect oil pump.

Abnormal engine noise or knocking
Low engine oil level - Check and refill engine oil.
Low coolant temperature - Warm up the engine.
Fuel injection pump timing is wrong - Adjust as recommended.
Incorrectly set low idle speed - Correct the settings.
Fuel injector fault - Replace fuel injectors.
Connecting rod misalignment or failure - Connecting rod must be aligned or replaced.
Piston wear or scoring - Install new pistons.

Drive System Troubleshooting

Drive system won't work in one direction or either direction
Low hydraulic oil level - Check and refill the hydraulic oil.
Damaged or jammed track mechanism - Remove jamming or repair tracks.
Relief valve is defective - Repair or change.
Suction line or hydraulic filter is plugged - Replace hydraulic filter or clean suction line.
Foot or hand controls are defective - Change or repair.
Drive pump or motor is damaged - Replace or repair faulty component.

Machine won't move straight or moves jerky
Undercarriage tracks are jammed or defective - Repair or remedy jamming.
Tracks are worn or loose - Adjust track tension as required or replace tracks.
Undercarriage track frame is clogged with debris, or foreign objects - Clean undercarriage track frame, remove foreign objects and debris.

Low power
Hydraulic oil filter is clogged - Replace or service hydraulic filter.
Relief valve is damaged or open - Close or change relief valve.
Transmission components are damaged or faulty - Inspect and replace defective parts.
Input drive shaft is worn - Service or change faulty drive shaft.
Air in hydraulic system - Need to bleed air.

Drive system overheating
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Hydraulic fluid filter is clogged - Check, clean, or change as necessary.
Defective or worn relief valve - Relief valve need to be replaced or repair.
Defective drive pump or hydraulic motor - Replace or repair faulty component.
Oil cooler is clogged - Cooling fins need to be cleaned.
Drive system overload - Load should be reduced.

Excessive noise
Oil viscosity is incorrect - Use oil of correct viscosity.
Air leaks in hydraulic system - Need to bleed air.
Hydraulic motor or drive pump is defective - Check and repair if required.
Worn or damaged mechanical parts of drive system - Inspect the components for worn or defect and repair as required.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is not correct - Correct adjustment is required.
Defective or misadjusted main relief valve - Adjust relief valve or change if required.
Hydraulic oil is dirty - Hydraulic oil change required.
Not enough hydraulic fluid in the system - Fill the hydraulic system with oil.
Hydraulic pump is defective - Repair or change pump if required.

Boom does not raise or lower
Lift controls are defective - Replace or repair.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Damaged hydraulic cylinder - Change or repair lift cylinder.
Low hydraulic fluid level - Add fluid as required.

Bucket won't move
Bucket controls failure - Check and repair as required.
Hydraulic pump malfunction - Replace or repair pump if necessary.
Defective hydraulic control valve - Change or repair hydraulic valve.
Damaged bucket cylinder - Repair or change cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.

Slow bucket or lift arm operation
Defective hydraulic pump - Check pump capacity and change if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Defective or not adjusted hydraulic control valve - Repair or adjust correctly.
Hydraulic pressure has dropped - Adjust pressure as required.

Lift arm or bucket movements are jerky
Hydraulic system is leaking air - Air bleeding is required.
Hydraulic oil filter element is dirty - Service or replace the hydraulic filter.
Hydraulic oil is dirty - The oil must be changed.
Scratched cylinder rod or tube - Replace damaged component.

Hydraulic pump makes excessive noise
Hydraulic leaks or low oil level - Add hydraulic oil or correct system leaks.
Clogged hydraulic filter - Service or change hydraulic filter.
Suction line is dirty - Need to clean the suction line.
Pump is sucking air - Bleed air.
Pump components are damaged - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose cable connections - Service or tighten cable connections.
Defective electrical terminal connectors - Replace terminal connectors.
Battery failing - Use a new battery.
Damaged or loose belt - Replace belt or adjust belt tension.

Starter turns slowly
Low battery output - Recharge the battery.
Battery is not holding charge - Service battery or replace it.
Corroded battery terminals or disconnected wires - Check cable connections and replace or service terminals.

Starter is not working
Battery is low or faulty - Change or recharge battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Battery capacity is low - Recharge the battery.
Defective starter motor - Starter needs to be replaced.