Bobcat 3200 Utility Vehicle Service Manual SN AJNS11001 & Above – PDF DOWNLOAD

Description

Bobcat 3200 Utility Vehicle Service Manual SN AJNS11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat 3200 Utility Vehicle Service Manual SN AJNS11001 & Above – PDF DOWNLOAD

Language : English
Pages : 445
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 3200 Utility Vehicle Service Manual SN AJNS11001 & Above – PDF DOWNLOAD

FOREWORD

This manual is for the Utility Vehicle mechanic. It provides necessary servicing and adjustment procedures for the Utility Vehicle and its component parts and systems. Refer to the for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS

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.

IMPORTANT

This notice identifies procedures which must be followed to avoid damage to the machine

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments / implements:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment / implement contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment / implement. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the 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.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bobcat 3200 Utility Vehicle Service Manual SN AJNS11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY........................................................  3
CONTENTS..................................................................  5
FOREWORD..................................................................  7
	FOREWORD..............................................................  9
	SAFETY INSTRUCTIONS................................................... 11
	FIRE PREVENTION....................................................... 13
		Maintenance....................................................... 13
		Operation......................................................... 13
		Electrical........................................................ 13
		Fueling........................................................... 13
		Starting.......................................................... 13
		Spark Arrester Exhaust System..................................... 13
		Welding And Grinding.............................................. 13
		Fire Extinguishers................................................ 14
	SERIAL NUMBER LOCATIONS............................................... 15
		Utility Vehicle Serial Number..................................... 15
		Engine Serial Number.............................................. 15
	DELIVERY REPORT....................................................... 16
	UTILITY VEHICLE IDENTIFICATION (3200)................................. 17
SAFETY & MAINTENANCE...................................................... 19
	LIFTING AND BLOCKING THE UTILITY VEHICLE.............................. 21
		Procedure......................................................... 21
	ROLLOVER PROTECTIVE STRUCTURE (ROPS).................................. 23
		Description....................................................... 23
	TRANSPORTING THE UTILITY VEHICLE ON A TRAILER......................... 25
		Loading And Unloading............................................. 25
		Fastening......................................................... 26
	TOWING THE UTILITY VEHICLE............................................ 27
		Procedure......................................................... 27
	SERVICE SCHEDULE...................................................... 29
		Chart............................................................. 29
	AIR CLEANER SERVICE................................................... 31
		Pre-Filter Element................................................ 31
		Replacing Filter Element.......................................... 32
		Engine Breather Filter............................................ 32
	ENGINE COOLING SYSTEM................................................. 33
		Checking Level.................................................... 33
		Cleaning.......................................................... 34
		Removing And Replacing Coolant.................................... 35
	FUEL SYSTEM........................................................... 37
		Fuel Specifications............................................... 37
		Replacing The Fuel Filter......................................... 37
		Filling The Fuel Tank............................................. 38
		Filling A Portable Fuel Container................................. 38
	ENGINE LUBRICATION SYSTEM............................................. 39
		Checking And Adding Engine Oil.................................... 39
		Engine Oil........................................................ 39
		Removing And Replacing Oil And Filter............................. 40
		Oil Pump Priming Procedure........................................ 42
	CONTINUOUS VARIABLE TRANSMISSION (CVT)................................ 43
		CVT Drying........................................................ 43
		CVT Filter........................................................ 44
	GEARCASE (S/N AJNS19999 & Below)...................................... 45
		Checking Transmission Fluid....................................... 45
		Transmission Fluid................................................ 45
		Adding Transmission Fluid......................................... 45
		Removing And Replacing Transmission Fluid......................... 45
	GEARCASE (S/N AJNS20001 - AJNS29999, AJNS30001 & Above)............... 47
		Checking Transmission Fluid....................................... 47
		Transmission Fluid................................................ 47
		Adding Transmission Fluid......................................... 47
		Removing And Replacing Transmission Fluid......................... 47
		Checking Front Gear Case Fluid.................................... 48
		Front Gear Case Fluid............................................. 48
		Adding Front Gear Case Fluid...................................... 48
		Removing And Replacing Front Gear Case Fluid...................... 48
	TIRE MAINTENANCE...................................................... 49
		Tires............................................................. 49
		Tire Tread Depth.................................................. 49
		Axle And Wheel Nut Torque......................................... 49
		Wheel Removal And Installation.................................... 50
		Mounting.......................................................... 51
		Tire Pressure..................................................... 51
	SPARK ARRESTER MUFFLER................................................ 53
		Cleaning Procedure................................................ 53
	UTILITY VEHICLE STORAGE AND RETURN TO SERVICE......................... 55
		Storage........................................................... 55
		Return To Service................................................. 55
	STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE................... 57
		Procedure......................................................... 57
DRIVE SYSTEM.............................................................. 59
	BRAKE................................................................. 63
		General Specifications............................................ 63
		Torque Specifications............................................. 63
		System Service Notes.............................................. 64
		Noise Troubleshooting............................................. 65
		System Troubleshooting............................................ 66
		Hydraulic Brake System Operation.................................. 67
		System Parts Identification....................................... 68
		Master Cylinder Removal And Installation.......................... 69
		Foot Brake Pedal Removal And Installation......................... 70
		Bleeding / Fluid Removal And Installation......................... 71
		Brake Inspection.................................................. 73
		Brake Pad Inspection.............................................. 73
		Burnishing........................................................ 73
	BRAKE (FRONT)......................................................... 75
		Pad Removal....................................................... 75
		Pad Installation.................................................. 77
		Caliper Removal................................................... 78
		Caliper Parts Identification...................................... 79
		Caliper Disassembly............................................... 80
		Caliper Inspection................................................ 81
		Caliper Assembly.................................................. 82
		Caliper Installation.............................................. 83
		Disc Inspection................................................... 84
		Disc Removal And Installation..................................... 85
	BRAKE (REAR).......................................................... 87
		Pad Removal....................................................... 87
		Pad Installation.................................................. 88
		Caliper Removal................................................... 89
		Caliper Parts Identification...................................... 90
		Caliper Disassembly............................................... 91
		Caliper Inspection................................................ 92
		Caliper Assembly.................................................. 93
		Caliper Installation.............................................. 93
		Disc Inspection................................................... 94
		Disc Removal And Installation..................................... 95
	BRAKE (PARK).......................................................... 97
		Inspection And Maintenance........................................ 97
		Parts Identification.............................................. 98
		Lever Removal And Installation.................................... 99
		Cable Tension Inspection..........................................100
		Cable Adjustment..................................................100
		Caliper Removal...................................................101
		Caliper Parts Identification......................................102
		Caliper Disassembly...............................................103
		Caliper Inspection................................................103
		Pad Installation..................................................104
		Caliper Assembly..................................................104
		Disc Inspection...................................................105
		Disc Removal And Installation.....................................106
		Caliper Installation..............................................107
	GEARCASE (TRANSMISSION)...............................................109
		General Operation.................................................109
		System Troubleshooting............................................110
		Shift Lever Removal And Installation..............................111
		Shift Cable Inspecting............................................112
		Shift Cable Adjustment............................................112
		Removal And Installation..........................................113
		Parts Identification..............................................118
		Disassembly.......................................................120
		Gear Cluster Disassembly..........................................124
		Assembly..........................................................126
	DRIVE BELT............................................................133
		Removal...........................................................133
		Installation......................................................134
		Belt Inspection...................................................134
	CONTINUOUS VARIABLE TRANSMISSION (CVT)................................135
		CVT System Overview...............................................135
		Drive Clutch Operation............................................135
		Driven Clutch Operation...........................................135
		CVT Break-In (Drive Belt / Clutches)..............................135
		Maintenance And Inspection........................................136
		Overheating Troubleshooting.......................................137
		System Troubleshooting............................................138
		CVT Sealing, Guard And Ducting Components Parts Identification....140
		CVT (Outer) Cover Removal And Installation........................141
		CVT (Inner) Cover Removal And Installation........................142
		Clutch Alignment..................................................143
		Clutch Offset.....................................................144
		Clutch Center Distance............................................144
	CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH).................145
		Removal And Installation..........................................145
		Spring Specifications.............................................146
		Shift Weights.....................................................147
		Parts Identification..............................................148
		Inspection........................................................149
		Button To Tower Clearance Inspection..............................150
		Disassembly.......................................................151
		Movable Sheave Bushing Removal And Installation...................155
		Clutch Cover Bushing Removal And Installation.....................157
		Assembly..........................................................159
	CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)................163
		Removal And Installation..........................................163
		Parts Identification..............................................164
		Disassembly.......................................................165
		Bushing Removal...................................................167
		Bushing Installation..............................................169
		Assembly..........................................................170
	FINAL DRIVE...........................................................173
		Description.......................................................173
		Front Hub And Spindle Removal.....................................174
		Front Hub And Spindle Installation................................176
		Rear Bearing Carrier Inspection...................................178
		Rear Bearing Carrier Removal......................................178
		Rear Bearing Carrier Disassembly And Assembly.....................180
		Rear Bearing Carrier Installation.................................182
		Rear Drive Shaft Removal And Installation.........................184
		Outer CV Joint And Boot Removal And Installation..................185
		Inner Plunging Joint And Boot Removal And Installation............188
MAINFRAME.................................................................191
	ROLL OVER PROTECTIVE STRUCTURE (ROPS).................................193
		Removal And Installation..........................................193
	OPERATOR SEAT.........................................................195
		Seat Back Removal And Installation................................195
		Seat Base Removal And Installation................................195
		Seat Belt Removal And Installation................................196
	DASH..................................................................197
		Front Access Cover Removal And Installation.......................197
		Left Dash Removal And Installation................................197
		Right Dash Removal And Installation...............................199
		Center Dash Removal And Installation..............................200
	BUMPER COVER..........................................................201
		Removal And Installation..........................................201
	STRUT.................................................................203
		Strut Cartridge Removal And Installation..........................203
	STEERING COLUMN (S/N AJNS19999 & BELOW)...............................205
		Steering Wheel Removal And Installation...........................205
		Parts Identification..............................................206
		Steering Shaft Removal And Installation...........................207
	STEERING COLUMN (S/N AJNS20001 & ABOVE, AJNS30001 & Above)............209
		Description.......................................................209
		Tilt Steering Shock Removal And Installation......................209
		Parts Identification..............................................210
		Steering Wheel Removal And Installation...........................211
		Steering Shaft Removal And Installation...........................212
		Pivot Tube Bearing Removal And Installation.......................215
	STEERING BOX..........................................................217
		Removal And Installation..........................................217
	FUEL TANK.............................................................219
		Removal And Installation..........................................219
	SHOCKS................................................................221
		Removal And Installation..........................................221
		Shock Spring Removal And Installation.............................222
	CONTROL ARMS..........................................................223
		Removal And Installation (Rear Lower Arm).........................223
		Removal And Installation (Upper Arm)..............................223
		Removal And Installation (Rear Upper Arm).........................224
		Removal and Installation (Front Arm)..............................224
		Inspection........................................................225
		Ball Joint Removal And Installation...............................226
	TIE ROD...............................................................227
		Description.......................................................227
		Removal And Installation..........................................227
		Toe Adjustment Procedure..........................................228
	TAILGATE..............................................................229
		Removal And Installation..........................................229
		Latch Removal And Installation....................................230
	CARGO BOX.............................................................231
		Removal And Installation..........................................231
	FENDER................................................................233
		Removal And Installation (Front)..................................233
		Removal And Installation (Rear)...................................233
		Flare Removal And Installation....................................235
	REAR STABILIZER BAR / LINKAGE.........................................237
		Removal And Installation..........................................237
		Inspection........................................................238
ELECTRICAL SYSTEM & ANALYSIS..............................................239
	ELECTRICAL SCHEMATICS.................................................241
	ELECTRICAL SYSTEM INFORMATION.........................................242
		Glossary Of Electrical Symbols....................................242
		Description.......................................................245
		Troubleshooting...................................................246
		Fuse And Relay Location - Cab Panel...............................247
	BATTERY...............................................................248
		Removal And Installation..........................................248
		Servicing.........................................................249
		Using A Booster Battery (Jump Starting)...........................250
	CHARGING SYSTEM.......................................................252
		Current Draw - Key OFF............................................252
		Break Even Test...................................................253
		Stator Testing....................................................254
		Stator Plate Assembly Removal.....................................255
		Stator Plate Assembly Installation................................257
		Testing Flow Chart................................................259
	STARTER SYSTEM........................................................260
		Testing...........................................................260
		Removal And Installation..........................................261
		Parts Identification..............................................262
		Starting Testing Flow Chart.......................................263
	REGULATOR / RECTIFIER.................................................264
		Location..........................................................264
		Removal And Installation..........................................264
		Testing...........................................................265
	LIGHTS................................................................266
		Headlight Removal And Installation................................266
		Headlight Adjustment..............................................267
		Tail Light / Brake Light Removal And Installation.................267
		Indicator Lamp Removal And Installation...........................268
	VEHICLE CONTROL MODULE................................................270
		Description.......................................................270
		Removal And Installation..........................................270
	DC / CDI IGNITION SYSTEM..............................................272
		Description.......................................................272
		CDI Module Removal And Installation...............................272
		Testing...........................................................272
		Ignition System Troubleshooting...................................273
		Ignition System Testing Flow Chart................................274
	SWITCH (HEADLIGHT)....................................................276
		Removal And Installation..........................................276
		Testing...........................................................276
	SWITCH (BRAKE LIGHT)..................................................278
		Removal And Installation..........................................278
		Testing...........................................................278
	SWITCH (PARKING BRAKE)................................................280
		Description.......................................................280
		Removal And Installation..........................................280
		Testing...........................................................281
	SWITCH (2WD / TURF)...................................................282
		Removal And Installation..........................................282
		Testing...........................................................282
	SWITCH (IGNITION).....................................................284
		Removal And Installation..........................................284
	SWITCH (GEAR SELECTOR)................................................286
		Removal And Installation..........................................286
	TEMPERATURE SENSOR....................................................288
		Removal And Installation..........................................288
		Testing...........................................................288
	DIFFERENTIAL SOLENOID.................................................290
		Description.......................................................290
		Removal And Installation..........................................290
	DIFFERENTIAL SOLENOID (REAR RELAY)....................................292
		Description.......................................................292
		Removal And Installation..........................................292
	AIR SOLENOID..........................................................294
		Description.......................................................294
		Removal And Installation..........................................294
	HOURMETER.............................................................296
		Removal And Installation..........................................296
	BACK-UP ALARM SYSTEM (IF EQUIPPED)....................................298
		Description.......................................................298
		Inspecting........................................................298
		Removal And Installation..........................................299
ENGINE SERVICE............................................................300
	ENGINE INFORMATION....................................................304
		Description.......................................................304
		Specifications (Engine Model EH460PLE040).........................305
		Torque Values.....................................................309
		Troubleshooting...................................................310
		Accessible Engine Components......................................313
		Engine Removal And Installation...................................314
		Engine Installation Notes.........................................321
		Engine Mount Replacement..........................................322
		Compression - Checking............................................323
	THROTTLE SYSTEM.......................................................324
		Throttle Pedal Removal And Installation...........................324
		Throttle Cable Removal And Installation...........................326
		Throttle Freeplay.................................................328
		Inspection And Maintenance........................................328
		Throttle Freeplay Adjustment......................................328
	MUFFLER...............................................................330
		Removal And Installation..........................................330
	AIR CLEANER...........................................................332
		Housing Removal And Installation..................................332
	ENGINE COOLING SYSTEM.................................................334
		Cooling System Pressure Test......................................334
		Radiator Cap Pressure Test........................................334
		Radiator Removal And Installation.................................335
		Cooling Fan Removal And Installation..............................337
		Shroud Removal And Installation...................................338
		Water Pump Housing Cover Removal And Installation.................339
		Water Pump Disassembly And Assembly...............................339
		Water Pump Mechanical Seal Removal (Engine Installed).............340
		Thermostat Housing Removal And Installation.......................342
		Thermostat Removal And Installation...............................342
	LUBRICATION SYSTEM....................................................344
		Oil Tank Removal And Installation.................................344
		Engine Oil Pressure - Testing.....................................345
		Oil Flow Diagram..................................................346
		Oil Flow Chart....................................................346
	FUEL SYSTEM (CARBURETOR)..............................................348
		Fuel Pump Removal And Installation................................348
		Carburetor Jetting................................................349
		Jetting Guidelines................................................350
		Carburetor Parts Identification...................................352
		System Function - Mikuni CV Carb..................................353
		Vent Systems - Mikuni CV Carb.....................................353
		Operation - Mikuni CV Carb........................................354
		Pilot System (Idle And Slow Speed)................................355
		Starter System (Choke Or Enrichment)..............................355
		Float System......................................................356
		Main System.......................................................356
		Pilot Screw.......................................................357
		Pilot Screw Adjustment............................................358
		Idle Speed Adjustment.............................................358
		Choke Cable Adjustment............................................359
		Choke Cable Removal And Installation..............................360
		Removal And Installation..........................................361
		Disassembly.......................................................362
		Cleaning..........................................................363
		Inspection........................................................364
		Float Height Adjustment...........................................364
		Fuel Level........................................................365
		Assembly..........................................................365
	ENGINE DISASSEMBLY AND ASSEMBLY.......................................366
		Cam Chain Tensioner / Rocker Arm / Camshaft Removal...............366
		Cam Chain Tensioner Inspection....................................368
		Rocker Shaft / Rocker Arm Assembly Removal........................369
		Rocker Arm / Shaft Inspection.....................................369
		Rocker Shaft / Rocker Arm Assembly Installation...................371
		Valve Clearance Adjustment (Intake And Exhaust)...................372
		Camshaft Removal..................................................374
		Automatic Compression Release Removal / Inspection................376
		Automatic Compression Release Installation........................377
		Camshaft Inspection...............................................378
		Cam Chain / Camshaft Installation.................................379
		Camshaft Timing...................................................379
		Engine Parts Illustration.........................................381
		Cylinder Head Removal.............................................382
		Cylinder Head Warpage.............................................383
		Cylinder Head Disassembly.........................................383
		Valve Inspection..................................................385
		Combustion Chamber................................................386
		Valve Seat Reconditioning.........................................387
		Cylinder Head Assembly............................................391
		Valve Sealing Test................................................391
		Cylinder Head Installation........................................392
		Cylinder Removal..................................................393
		Cylinder Inspection...............................................394
		Cylinder Hone Selection / Honing Procedure........................396
		Cleaning The Cylinder After Honing................................396
		Cylinder Installation.............................................397
		Piston Removal....................................................399
		Piston - To - Cylinder Clearance..................................400
		Piston / Rod Inspection...........................................400
		Piston Ring Installed Gap.........................................402
		Piston Ring Installation..........................................403
		Piston Installation...............................................404
		Crankcase Disassembly.............................................405
		Starter Drive Removal And Installation............................405
		Flywheel Removal And Installation.................................406
		Stator Removal / Inspection.......................................407
		Stator Installation...............................................408
		Cam Chain / Tensioner Blade.......................................409
		Cam Chain Drive Sprocket Removal And Installation.................409
		One Way Valve Removal And Installation............................410
		Crankcase Separation..............................................411
		Crankcase Inspection..............................................411
		Crankcase Assembly................................................411
		Oil Pump Removal / Inspection.....................................412
		Oil Pump Assembly.................................................413
		Counter Balancer Shaft Removal / Inspection.......................414
		Crankshaft Removal / Inspection...................................415
		Crankshaft Straightening..........................................416
		Crankcase Bearing Inspection......................................417
		Oil Seal / Mechanical Seal Removal (Engine Disassembled)..........417
		Pump Shaft Oil Seal Installation..................................418
		Water Pump Mechanical Seal Installation...........................418
		Bearing Installation..............................................419
		End Play Inspection / Adjustment..................................419
		Crankshaft End Play Adjustment....................................419
		Counter Balancer Shaft End Play Adjustment........................421
		Oil Pump Shaft End Play Adjustment................................422
		Crankshaft / Counter Balance / Oil Pump Installation..............423
		Oil Pump Priming Procedure........................................424
SPECIFICATIONS............................................................426
	(3200) UTILITY VEHICLE SPECIFICATIONS.................................428
		Utility Vehicle Dimensions........................................428
		Performance.......................................................429
		Controls..........................................................429
		Engine............................................................429
		Electrical........................................................430
		Drive System......................................................430
		Fluid And Capacities..............................................430
		Tires.............................................................431
	TORQUE SPECIFICATIONS FOR BOLTS.......................................432
		Torque For General SAE Bolts......................................432
		Torque For General Metric Bolts...................................433
	CONVERSIONS...........................................................434
		Decimal And Millimeter Equivalent Chart...........................434
		U.S. To Metric Conversion Chart...................................435
	SERVICE TOOLS REQUIRED................................................436
		Hydraulic Tools...................................................436
		Transmission / Clutch / Drive Tools...............................437
		Engine Tools......................................................440
		HVAC Tools........................................................443
ALPHABETICAL INDEX........................................................444

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• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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S.M