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Download Bobcat T320 Compact Track Loader Service Manual 6987046 (5-11) PDF
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Bobcat T320 Compact Track Loader Service Manual 6987046 (5-11) – PDF DOWNLOAD
S/N A7MP60001 & Above
S/N AAKZ11001 & Above
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Description
Bobcat T320 Compact Track Loader Service Manual 6987046 (5-11) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T320 Compact Track Loader Service Manual 6987046 (5-11) – PDF DOWNLOAD
Language : English
Pages : 1026
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T320 Compact Track Loader Service Manual 6987046 (5-11) – PDF DOWNLOAD
S/N A7MP60001 & Above
S/N AAKZ11001 & Above
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:
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check hydraulic fluid level, engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• 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 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. 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 AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat T320 Compact Track Loader Service Manual 6987046 (5-11) – PDF DOWNLOAD
MAINTENANCE SAFETY...................................................................................... 3 ALPHABETICAL INDEX...................................................................................... 5 CONTENTS................................................................................................ 7 FOREWORD............................................................................................ 8 SAFETY INSTRUCTIONS................................................................................. 11 FIRE PREVENTION..................................................................................... 13 Maintenance..................................................................................... 13 Operation....................................................................................... 13 Electrical...................................................................................... 13 Hydraulic System................................................................................ 13 Fueling......................................................................................... 13 Starting........................................................................................ 13 Spark Arrestor Exhaust System................................................................... 13 Welding And Grinding............................................................................ 14 Fire Extinguishers.............................................................................. 14 SERIAL NUMBER LOCATIONS............................................................................. 15 Loader Serial Number............................................................................ 15 Engine Serial Number............................................................................ 15 DELIVERY REPORT..................................................................................... 16 LOADER IDENTIFICATION............................................................................... 17 SAFETY & MAINTENANCE.................................................................................... 19 LIFTING AND BLOCKING THE LOADER..................................................................... 23 Procedure....................................................................................... 23 LIFT ARM SUPPORT DEVICE............................................................................. 25 Installing...................................................................................... 25 Removing........................................................................................ 26 OPERATOR CAB........................................................................................ 27 Description..................................................................................... 27 Raising......................................................................................... 28 Lowering........................................................................................ 29 Cab Door Sensor................................................................................. 30 Special Applications Kit........................................................................ 30 Special Applications Kit Inspection And Maintenance............................................. 30 Forestry Door And Window Kit.................................................................... 31 Forestry Door And Window Kit Inspection And Maintenance......................................... 31 TRANSPORTING THE LOADER ON A TRAILER................................................................ 33 Loading And Unloading........................................................................... 33 Fastening....................................................................................... 33 TOWING THE LOADER................................................................................... 35 Procedure....................................................................................... 35 REMOTE START TOOL KIT-MEL1563....................................................................... 37 Remote Start Tool - MEL1563..................................................................... 37 Service Tool Harness Control - MEL1565.......................................................... 38 Service Tool Harness Communicator - MEL1566..................................................... 39 Remote Start Procedure.......................................................................... 40 REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...................................................... 43 Description..................................................................................... 43 Remote Start Tool (Service Tool) - 7003030...................................................... 44 Loader Service Tool Harness - 6689747........................................................... 45 Computer Service Tool Harness - 6689746......................................................... 46 Remote Start Procedure.......................................................................... 47 SERVICE SCHEDULE.................................................................................... 51 Chart........................................................................................... 51 AIR CLEANER SERVICE................................................................................. 53 Replacing Filter Elements....................................................................... 53 ENGINE COOLING SYSTEM............................................................................... 55 Maintenance Platform............................................................................ 55 Description..................................................................................... 55 Cleaning (Earlier Models)....................................................................... 55 Cleaning (Later Models)......................................................................... 56 Removing And Replacing Coolant.................................................................. 58 Checking Level.................................................................................. 58 FUEL SYSTEM......................................................................................... 59 Fuel Specifications............................................................................. 59 Biodiesel Blend Fuel............................................................................ 59 Filling The Fuel Tank........................................................................... 60 Fuel Filter..................................................................................... 60 Removing Air From The Fuel System............................................................... 61 ENGINE LUBRICATION SYSTEM........................................................................... 63 Checking And Adding Engine Oil.................................................................. 63 Engine Oil Chart................................................................................ 63 Removing And Replacing Oil And Filter........................................................... 64 HYDRAULIC / HYDROSTATIC SYSTEM...................................................................... 65 Checking And Adding Fluid....................................................................... 65 Hydraulic / Hydrostatic Fluid Chart............................................................. 65 Removing And Replacing Hydraulic Fluid.......................................................... 66 Removing And Replacing Hydraulic / Hydrostatic Filter........................................... 67 Removing And Replacing Case Drain Filters....................................................... 68 Removing And Replacing Hydraulic Charge Filter.................................................. 69 Breather Cap.................................................................................... 70 BOB-TACH (HAND LEVER)............................................................................... 71 Inspection And Maintenance...................................................................... 71 BOB-TACH (POWER).................................................................................... 73 Inspection And Maintenance...................................................................... 73 LUBRICATING THE LOADER.............................................................................. 75 Lubrication Locations........................................................................... 75 SPARK ARRESTER MUFFLER.............................................................................. 77 Cleaning Procedure.............................................................................. 77 PIVOT PINS.......................................................................................... 79 Inspection And Maintenance...................................................................... 79 LOADER STORAGE AND RETURN TO SERVICE................................................................ 81 Storage......................................................................................... 81 Return To Service............................................................................... 81 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 83 Procedure....................................................................................... 83 EMERGENCY EXIT...................................................................................... 85 Rear Window..................................................................................... 85 Front Door...................................................................................... 85 SEAT BELT........................................................................................... 87 Inspection And Maintenance...................................................................... 87 HYDRAULIC SYSTEM........................................................................................ 89 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 95 HYDRAULIC SYSTEM INFORMATION........................................................................ 103 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 103 Troubleshooting................................................................................. 107 CYLINDER (LIFT)..................................................................................... 109 Testing......................................................................................... 109 Removal And Installation........................................................................ 110 Parts Identification............................................................................ 112 Disassembly..................................................................................... 113 Assembly........................................................................................ 115 CYLINDER (TILT)..................................................................................... 119 Testing......................................................................................... 119 Removal And Installation........................................................................ 120 Base End Pivot Pin Removal And Installation..................................................... 122 Parts Identification............................................................................ 123 Disassembly..................................................................................... 124 Assembly........................................................................................ 126 CYLINDER (BOB-TACH)................................................................................. 129 Testing......................................................................................... 129 Removal And Installation........................................................................ 130 Parts Identification............................................................................ 131 Disassembly..................................................................................... 132 Assembly........................................................................................ 133 MAIN RELIEF VALVE................................................................................... 137 Description..................................................................................... 137 Testing......................................................................................... 138 Adjusting....................................................................................... 140 Removal And Installation........................................................................ 141 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 143 Description..................................................................................... 143 Removal And Installation........................................................................ 144 Identification Chart............................................................................ 148 Mount Bracket Removal And Installation.......................................................... 149 Lift Load Check Valve Removal And Installation.................................................. 149 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 150 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 150 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 151 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 152 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 152 Port Relief Valve Removal And Installation...................................................... 153 Plug Removal And Installation................................................................... 154 Rubber Boot Removal And Installation............................................................ 155 End Cap Block Removal And Installation.......................................................... 156 Lift Spool And Detent Removal And Installation.................................................. 157 Tilt Spool Removal And Installation............................................................. 167 Auxiliary Spool Removal And Installation........................................................ 169 Auxiliary Solenoid Removal And Installation (S/N A7MP62999 & Below And AAKZ34999 & Below)....... 171 Auxiliary Solenoid Removal And Installation (S/N A7MP63001 & Above And AAKZ35001 & Above)....... 172 Solenoid Removal And Installation............................................................... 173 Lock Valve Removal And Installation............................................................. 174 Lift Arm Bypass Orifice Removal And Installation................................................ 176 Main Relief Valve Removal And Installation...................................................... 176 Check Valve Removal And Installation............................................................ 177 HYDRAULIC CONTROL VALVE (ACS) OR (SJC).............................................................. 179 Description..................................................................................... 179 Removal And Installation........................................................................ 180 Actuator Removal And Installation (In Loader)................................................... 184 Actuator Removal And Installation (Out Of Loader)............................................... 186 Identification Chart............................................................................ 189 Mount Bracket Removal And Installation.......................................................... 190 Lift Load Check Valve Removal And Installation.................................................. 190 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 191 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 192 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 194 Port Relief Valve Removal And Installation...................................................... 194 Plug Removal And Installation................................................................... 195 End Cap Block Removal And Installation.......................................................... 196 Lift Spool And Detent Removal And Installation.................................................. 197 Tilt Spool Removal And Installation............................................................. 202 Auxiliary Spool Removal And Installation........................................................ 204 Auxiliary Solenoid Removal And Installation (S/N A7MP62999 & Below And AAKZ34999 & Below)....... 206 Auxiliary Solenoid Removal And Installation (S/N A7MP63001 & Above And AAKZ35001 & Above)....... 207 Solenoid Removal And Installation............................................................... 208 Lock Valve Removal And Installation............................................................. 209 Lift Arm Bypass Orifice Removal And Installation................................................ 211 Main Relief Valve Removal And Installation...................................................... 211 Check Valve Removal And Installation............................................................ 212 LIFT ARM BYPASS CONTROL VALVE....................................................................... 213 Description..................................................................................... 213 Testing......................................................................................... 213 Removal And Installation........................................................................ 214 Disassembly And Assembly........................................................................ 215 HYDRAULIC PUMP (STANDARD)........................................................................... 217 Description..................................................................................... 217 Pump Test At Quick Couplers..................................................................... 218 Direct Pump Test (Standard Section)............................................................. 219 Direct Pump Test (Charge Section)............................................................... 221 Removal And Installation........................................................................ 225 Hydraulic Pump Startup.......................................................................... 227 Parts Identification............................................................................ 228 Disassembly And Assembly........................................................................ 229 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)............................................................... 231 Description..................................................................................... 231 Pump Test At Quick Couplers..................................................................... 232 Direct Pump Test (Standard Section)............................................................. 233 Direct Pump Test (Charge Section)............................................................... 235 Direct Pump Test (High Flow Section)............................................................ 239 High Flow Relief Valve Adjustment............................................................... 241 High Flow Relief Valve Removal And Installation................................................. 243 Solenoid Removal And Installation............................................................... 244 Removal And Installation........................................................................ 245 Hydraulic Pump Startup.......................................................................... 247 Parts Identification............................................................................ 248 Disassembly And Assembly........................................................................ 249 HYDRAULIC PUMP (SJC)................................................................................ 251 Description..................................................................................... 251 Pump Test At Quick Couplers..................................................................... 252 Direct Pump Test (Standard Section)............................................................. 253 Direct Pump Test (Charge Section)............................................................... 255 Removal And Installation........................................................................ 259 Hydraulic Pump Startup.......................................................................... 261 Parts Identification............................................................................ 262 Disassembly And Assembly........................................................................ 263 HYDRAULIC PUMP (SJC) (HIGH FLOW).................................................................... 265 Description..................................................................................... 265 Pump Test At Quick Couplers..................................................................... 266 Direct Pump Test (Standard Section)............................................................. 267 Direct Pump Test (Charge Section)............................................................... 269 Direct Pump Test (High Flow Section)............................................................ 273 High Flow Relief Valve Adjustment............................................................... 275 High Flow Relief Valve Removal And Installation................................................. 277 Solenoid Removal And Installation............................................................... 278 Removal And Installation........................................................................ 279 Hydraulic Pump Startup.......................................................................... 281 Parts Identification............................................................................ 282 Disassembly And Assembly........................................................................ 283 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 285 Description..................................................................................... 285 Housing Removal And Installation................................................................ 285 Charge Filter Housing Removal And Installation.................................................. 287 HYDRAULIC FLUID RESERVOIR........................................................................... 289 Description..................................................................................... 289 Removal And Installation........................................................................ 289 Hydraulic Fluid Screen.......................................................................... 292 OIL COOLER.......................................................................................... 293 Description..................................................................................... 293 Removal And Installation........................................................................ 293 BUCKET POSITION VALVE............................................................................... 297 Description..................................................................................... 297 Solenoid Removal And Installation............................................................... 298 Solenoid Testing................................................................................ 298 Removal And Installation........................................................................ 299 Disassembly And Assembly........................................................................ 299 REAR AUXILIARY DIVERTER VALVE....................................................................... 301 Description..................................................................................... 301 Solenoid Testing................................................................................ 301 Removal And Installation........................................................................ 302 Disassembly And Assembly........................................................................ 304 BOB-TACH (POWER) BLOCK.............................................................................. 311 Description..................................................................................... 311 Removal And Installation........................................................................ 311 Disassembly And Assembly........................................................................ 313 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 317 Description..................................................................................... 317 Removal And Installation........................................................................ 317 Disassembly And Assembly........................................................................ 318 HYDROSTATIC SYSTEM...................................................................................... 321 HYDROSTATIC SYSTEM INFORMATION...................................................................... 323 Description..................................................................................... 323 Troubleshooting................................................................................. 324 HYDROSTATIC DRIVE MOTOR............................................................................. 325 Description..................................................................................... 325 Removing And Replacing Oil...................................................................... 325 Removal And Installation........................................................................ 326 Parts Identification............................................................................ 328 Disassembly And Assembly........................................................................ 330 CHARGE PRESSURE..................................................................................... 343 Description..................................................................................... 343 Testing......................................................................................... 343 Sender Removal And Installation................................................................. 345 Adjusting....................................................................................... 346 HYDROSTATIC PUMP.................................................................................... 349 Description..................................................................................... 349 Removal And Installation........................................................................ 350 Hydrostatic Pump Startup........................................................................ 352 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 353 Parts Identification (Left Half)................................................................ 354 Parts Identification (Right Half)............................................................... 355 Disassembly..................................................................................... 356 Assembly........................................................................................ 363 HYDROSTATIC PUMP (SJC) (S/N A7MP60001 - A7MP62125 AND AAKZ11001 - AAKZ35000)........................ 369 Description..................................................................................... 369 Hydraulic Controller Removal And Installation................................................... 370 Removal And Installation........................................................................ 372 Hydrostatic Pump Startup........................................................................ 374 Parts Identification............................................................................ 375 High Pressure Relief And Bypass Valve........................................................... 376 Charge Relief Valve............................................................................. 377 Disassembly And Assembly........................................................................ 378 Mechanical Neutral Adjustment................................................................... 395 Hydraulic Controller Neutral Adjustment......................................................... 398 HYDROSTATIC PUMP (SJC) (S/N A7MP62126 & ABOVE AND AAKZ35001 & ABOVE)................................ 401 Description..................................................................................... 401 Hydraulic Controller Removal And Installation................................................... 402 Removal And Installation........................................................................ 404 Hydrostatic Pump Startup........................................................................ 405 Parts Identification............................................................................ 406 High Pressure Relief And Bypass Valve........................................................... 407 Charge Relief Valve............................................................................. 408 Disassembly And Assembly........................................................................ 409 Mechanical Neutral Adjustment................................................................... 422 Hydraulic Controller Neutral Adjustment......................................................... 425 DRIVE BELT.......................................................................................... 429 Description..................................................................................... 429 Shield Removal And Installation................................................................. 429 Adjusting....................................................................................... 430 Belt Removal And Installation................................................................... 430 Tensioner Pulley Removal And Installation....................................................... 431 Tensioner Pulley Disassembly And Assembly....................................................... 432 Tensioner Pulley Tension Spring Removal And Installation........................................ 433 Tensioner Pulley Tension Spring Disassembly And Assembly........................................ 433 CASE DRAIN FILTER................................................................................... 435 Description..................................................................................... 435 Disassembly And Assembly........................................................................ 435 DRIVE SYSTEM............................................................................................ 437 BRAKE............................................................................................... 439 Description..................................................................................... 439 Block Removal And Installation.................................................................. 439 Block Disassembly And Assembly.................................................................. 440 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (RUBBER TRACK) (S/N A7MP60452 & BELOW AND AAKZ11042 & BELOW).... 443 Description..................................................................................... 443 Checking Tension................................................................................ 444 Adjusting Tension............................................................................... 445 Track Removal And Installation.................................................................. 446 Idler (Front) Removal And Installation (S/N A7MP60283 & Below And AAKZ11027 & Below)............ 448 Idler (Front) Removal And Installation (S/N A7MP60284 & Above And AAKZ11028 & Above)............ 450 Idler (Rear) Removal And Installation........................................................... 456 Roller Removal And Installation................................................................. 456 Sprocket Removal And Installation............................................................... 457 Track Housing Removal And Installation.......................................................... 458 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (RUBBER TRACK) (S/N A7MP60453 & ABOVE AND AAKZ11043 & ABOVE).... 459 Description..................................................................................... 459 Checking Tension................................................................................ 460 Adjusting Tension............................................................................... 461 Track Removal And Installation.................................................................. 462 Idler (Front) Removal And Installation.......................................................... 464 Idler (Rear) Removal And Installation........................................................... 469 Roller Removal And Installation................................................................. 469 Sprocket Removal And Installation............................................................... 470 Track Housing Removal And Installation.......................................................... 471 TRACK UNDERCARRIAGE (ROLLER SUSPENSION) (RUBBER TRACK).............................................. 473 Description..................................................................................... 473 Checking Tension................................................................................ 474 Adjusting Tension............................................................................... 475 Track Removal And Installation.................................................................. 476 Idler (Front) Removal And Installation (S/N A7MP60163 & Below And AAKZ11007 & Below)............ 478 Idler (Front) Removal And Installation (S/N A7MP60164 & Above And AAKZ11008 & Above)............ 480 Track Tensioner Disassembly And Assembly (S/N A7MP60163 & Below And AAKZ11007 & Below).......... 483 Track Tensioner Disassembly And Assembly (S/N A7MP60164 & Above And AAKZ11008 & Above).......... 484 Idler (Rear) Removal And Installation........................................................... 486 Roller Removal And Installation................................................................. 486 Leaf Spring Removal And Installation............................................................ 487 Sprocket Removal And Installation............................................................... 488 Track Housing Removal And Installation.......................................................... 489 TRACK UNDERCARRIAGE (STEEL TRACK)................................................................... 491 Description..................................................................................... 491 Checking Tension................................................................................ 492 Adjusting Tension............................................................................... 493 Track Shoe Removal And Installation............................................................. 494 Track Removal................................................................................... 494 Track Installation.............................................................................. 496 Idler (Front) Removal And Installation.......................................................... 498 Track Tensioner Removal......................................................................... 498 Track Tensioner Installation.................................................................... 499 Track Tensioner Disassembly And Assembly........................................................ 500 Idler (Rear) Removal And Installation........................................................... 501 Roller Removal And Installation................................................................. 502 Top Roller Removal And Installation............................................................. 502 Sprocket Removal And Installation............................................................... 503 Track Housing Removal And Installation.......................................................... 504 TRACK MAINTENANCE (RUBBER TRACK).................................................................... 505 Track Damage Identification..................................................................... 505 MAINFRAME............................................................................................... 517 SEAT BAR............................................................................................ 521 Description..................................................................................... 521 Removal And Installation........................................................................ 521 Disassembly And Assembly........................................................................ 522 Compression Spring Disassembly And Assembly..................................................... 523 OPERATOR CAB........................................................................................ 525 Gas Cylinder Removal And Installation........................................................... 525 Gas Cylinder Bracket Disassembly And Assembly................................................... 527 Removal And Installation........................................................................ 528 OPERATOR SEAT (SUSPENSION).......................................................................... 531 Removal And Installation........................................................................ 531 Slide Rail Removal And Installation............................................................. 532 Seat Belt Removal And Installation.............................................................. 532 Lower Cushion Removal And Installation.......................................................... 533 Back Cushion Removal And Installation........................................................... 534 Shock Removal And Installation.................................................................. 534 3-Point Seat Belt Removal And Installation...................................................... 535 BOB-TACH (HAND LEVER)............................................................................... 537 Description..................................................................................... 537 Removal And Installation........................................................................ 537 Lever And Wedge Disassembly And Assembly........................................................ 540 Pivot Pin Bushing And Seal Removal And Installation............................................. 541 BOB-TACH (POWER).................................................................................... 543 Description..................................................................................... 543 Removal And Installation........................................................................ 543 Lever And Wedge Disassembly And Assembly........................................................ 546 Pivot Pin Bushing Removal And Installation...................................................... 547 LIFT ARMS........................................................................................... 549 Stabilizer Bar Removal And Installation......................................................... 549 Link Removal And Installation................................................................... 550 Removal And Installation........................................................................ 551 REAR GRILLE......................................................................................... 555 Removal And Installation........................................................................ 555 REAR DOOR (TAILGATE)................................................................................ 557 Removal And Installation........................................................................ 557 Striker Removal And Installation................................................................ 558 Striker Disassembly And Assembly................................................................ 558 Striker (Adjusting)............................................................................. 559 Latch Removal And Installation.................................................................. 560 FUEL TANK........................................................................................... 561 Removal And Installation........................................................................ 561 Fuel Level Sender Removal And Installation...................................................... 563 Fuel Fill Screen Removal And Installation....................................................... 563 CONTROL PEDALS AND LINKAGES......................................................................... 565 Description..................................................................................... 565 Pedal Removal And Installation.................................................................. 566 Linkage Removal And Installation................................................................ 567 Pedal (Adjusting)............................................................................... 568 CONTROL PEDALS (ACS)................................................................................ 569 Description..................................................................................... 569 Foot Sensor Removal And Installation............................................................ 570 Foot Pedal Removal And Installation............................................................. 571 Foot Pedal Linkage Disassembly And Assembly..................................................... 571 CONTROL PANEL....................................................................................... 573 Description..................................................................................... 573 Removal And Installation........................................................................ 574 Shock Removal And Installation.................................................................. 576 Shaft Removal And Installation.................................................................. 577 Linkage Removal And Installation................................................................ 578 Pintle Arm Disassembly and Assembly............................................................. 582 Linkage Neutral (Adjusting)..................................................................... 583 Linkage Travel (Adjusting)...................................................................... 587 CONTROL PANEL (SJC)................................................................................. 591 Description..................................................................................... 591 Removal And Installation........................................................................ 592 CONTROL HANDLE / LEVER.............................................................................. 595 Description..................................................................................... 595 Lever Removal And Installation.................................................................. 595 Boot Removal And Installation................................................................... 596 CONTROL HANDLE / LEVER (ACS)........................................................................ 597 Description..................................................................................... 597 Handle Sensor Removal And Installation.......................................................... 597 Handle Removal And Installation................................................................. 600 Handle Disassembly And Assembly................................................................. 601 Lever Removal And Installation.................................................................. 602 Boot Removal And Installation................................................................... 603 CONTROL HANDLE / LEVER (SJC)........................................................................ 605 Description..................................................................................... 605 Joystick Testing................................................................................ 606 Joystick Removal And Installation............................................................... 607 Joystick Mount Removal And Installation......................................................... 608 ACCESS PANEL (INSIDE)............................................................................... 609 Removal And Installation (Left)................................................................. 609 Removal And Installation (Right)................................................................ 609 ACCESS PANEL (INSIDE) (SJC)......................................................................... 611 Removal And Installation (Left)................................................................. 611 Removal And Installation (Right)................................................................ 612 WINDOW (REAR)....................................................................................... 615 Removal......................................................................................... 615 Installation (Split Molding).................................................................... 615 Installation (Continuous Molding)............................................................... 617 WINDOW (TOP)........................................................................................ 619 Removal And Installation........................................................................ 619 WINDOW (SIDE)....................................................................................... 621 Removal And Installation........................................................................ 621 WINDOW (CAB DOOR)................................................................................... 623 Removal (Standard Window)....................................................................... 623 Installation (Standard Window).................................................................. 624 Removal And Installation (Special Applications Window).......................................... 626 CAB DOOR............................................................................................ 627 Description..................................................................................... 627 Removal And Installation........................................................................ 627 Aligning........................................................................................ 628 Adjusting....................................................................................... 629 Checking Operation.............................................................................. 629 ELECTRICAL SYSTEM & ANALYSIS............................................................................ 631 ELECTRICAL SCHEMATICS............................................................................... 637 ELECTRICAL SYSTEM INFORMATION....................................................................... 643 Glossary Of Electrical Symbols.................................................................. 643 Cab Harness Connectors.......................................................................... 646 Mainframe Harness Connectors.................................................................... 647 Description..................................................................................... 649 Troubleshooting................................................................................. 650 Fuse And Relay Location / Identification........................................................ 651 Solenoid Testing................................................................................ 652 BATTERY............................................................................................. 653 Removal And Installation........................................................................ 653 Servicing....................................................................................... 654 Using A Booster Battery (Jump Starting)......................................................... 655 ALTERNATOR.......................................................................................... 657 Belt Adjustment................................................................................. 657 Belt Replacement................................................................................ 657 Charging System Inspection...................................................................... 658 Alternator Voltage Testing...................................................................... 659 Low Voltage Testing............................................................................. 659 High Voltage Testing............................................................................ 660 Removal And Installation........................................................................ 661 Parts Identification............................................................................ 662 STARTER............................................................................................. 663 Testing......................................................................................... 663 Removal And Installation........................................................................ 664 Parts Identification............................................................................ 665 INSTRUMENT PANELS................................................................................... 668 Left Panel...................................................................................... 668 Standard Key Panel.............................................................................. 670 Keyless Start Panel............................................................................. 670 Deluxe Instrumentation Panel.................................................................... 671 Side Panel...................................................................................... 672 Front Panel..................................................................................... 672 Front Panel Removal And Installation............................................................ 673 Removal And Installation (Left And Right)....................................................... 673 Key Switch Removal And Installation............................................................. 675 Alarm Removal And Installation.................................................................. 676 LIGHTS.............................................................................................. 677 Front Removal And Installation.................................................................. 677 Rear Removal And Installation................................................................... 678 Cab Light Removal And Installation.............................................................. 678 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)........................................................... 679 Description..................................................................................... 679 Connector Identification........................................................................ 680 Removal And Installation........................................................................ 686 BOBCAT CONTROLLER (ACS)............................................................................. 687 Description..................................................................................... 687 Connector And Wire Identification............................................................... 688 Removal And Installation........................................................................ 689 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 691 Description..................................................................................... 691 Connector Identification........................................................................ 692 Removal And Installation........................................................................ 694 SPEED SENSORS (SJC)................................................................................. 695 Description..................................................................................... 695 Testing......................................................................................... 695 Removal And Installation........................................................................ 697 DIAGNOSTIC SERVICE CODES............................................................................ 699 Viewing Service Codes (Standard Key Panel And Keyless Start Panel).............................. 699 Viewing Service Codes (Deluxe Instrumentation Panel)............................................ 699 Service Codes List.............................................................................. 700 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 705 Description..................................................................................... 705 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 706 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)............ 706 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 706 Inspecting The Traction Lock (Engine RUNNING)................................................... 706 Inspecting The Lift Arm Bypass Control.......................................................... 706 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)................................ 706 Troubleshooting................................................................................. 707 SEAT BAR SENSOR..................................................................................... 709 Description..................................................................................... 709 Troubleshooting................................................................................. 709 Testing......................................................................................... 710 Removal And Installation........................................................................ 711 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 714 TRACTION LOCK....................................................................................... 717 Description..................................................................................... 717 Troubleshooting................................................................................. 718 Inspecting...................................................................................... 719 CONTROL SYSTEM (ACS)................................................................................ 721 Description..................................................................................... 721 Troubleshooting................................................................................. 722 Handle Sensor Connector Disassembly And Assembly................................................ 723 Switch Handle Removal........................................................................... 724 Switch Handle Installation...................................................................... 726 Actuator Connector Disassembly And Assembly..................................................... 729 Handle Lock Solenoid Removal And Installation................................................... 730 Handle Lock Solenoid Disassembly And Assembly................................................... 731 Foot Sensor Disassembly And Assembly............................................................ 731 Foot Lock Solenoid Removal And Installation..................................................... 732 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 733 Identification Chart............................................................................ 733 Description..................................................................................... 734 Identification Chart ACD Group 0................................................................ 735 Identification Chart ACD Group 1................................................................ 736 Identification Chart ACD Group 2................................................................ 737 Identification Chart ACD Group 3................................................................ 738 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 739 Identification Chart............................................................................ 739 Description..................................................................................... 740 Identification Chart ACD Group 0................................................................ 741 Identification Chart ACD Group 1................................................................ 742 Identification Chart ACD Group 2................................................................ 743 Identification Chart ACD Group 3................................................................ 744 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 745 Identification Chart............................................................................ 745 Description..................................................................................... 746 Identification Chart ACD Group 0................................................................ 747 Identification Chart ACD Group 1................................................................ 748 Identification Chart ACD Group 2................................................................ 749 Identification Chart ACD Group 3................................................................ 750 SERVICE PC (LAPTOP COMPUTER)........................................................................ 751 Connecting Remote Start Tool.................................................................... 751 Connecting Remote Start Tool (Service Tool)..................................................... 751 CALIBRATION......................................................................................... 753 Description..................................................................................... 753 Actuator Testing................................................................................ 753 Lift And Tilt Calibration (SJC)................................................................. 756 Hydrostatic Pump Calibration (SJC).............................................................. 758 Lift And Tilt Calibration (ACS)................................................................. 763 STEERING DRIFT COMPENSATION......................................................................... 765 Description..................................................................................... 765 Operation....................................................................................... 765 FLYWHEEL RPM SENSOR................................................................................. 767 Description..................................................................................... 767 Adjusting....................................................................................... 767 CONTROL PANEL SETUP................................................................................. 769 Right Panel Setup (Deluxe Instrumentation Panel)................................................ 769 Attachment Control Information (Deluxe Instrumentation Panel)................................... 770 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................... 771 Password Description............................................................................ 771 Changing The Owner Password..................................................................... 771 Changing The User Passwords..................................................................... 772 Password Lockout Feature........................................................................ 772 PASSWORD SETUP (KEYLESS START PANEL)................................................................ 773 Password Description............................................................................ 773 Changing The Owner Password..................................................................... 773 Password Lockout Feature........................................................................ 773 MAINTENANCE CLOCK................................................................................... 775 Description..................................................................................... 775 Setup........................................................................................... 776 Reset........................................................................................... 779 BACK-UP ALARM SYSTEM................................................................................ 781 Description..................................................................................... 781 Inspecting...................................................................................... 781 Adjusting Switch Position....................................................................... 782 Troubleshooting (Standard And ACS).............................................................. 783 Troubleshooting (Joystick)...................................................................... 784 Alarm Removal And Installation.................................................................. 785 Switch Removal And Installation................................................................. 785 ENGINE SERVICE.......................................................................................... 787 ENGINE INFORMATION.................................................................................. 791 Description..................................................................................... 791 Specifications.................................................................................. 792 Troubleshooting................................................................................. 798 Engine Removal And Installation................................................................. 800 Engine Mount Replacement........................................................................ 806 Compression - Checking.......................................................................... 807 ENGINE SPEED CONTROL................................................................................ 809 Removal And Installation........................................................................ 809 Cable Removal And Installation.................................................................. 810 ENGINE SPEED CONTROL (SJC).......................................................................... 811 Removal And Installation........................................................................ 811 Disassembly And Assembly........................................................................ 813 Cable Removal And Installation.................................................................. 815 MUFFLER............................................................................................. 817 Removal And Installation........................................................................ 817 AIR CLEANER......................................................................................... 819 Housing Removal And Installation................................................................ 819 ENGINE COOLING SYSTEM............................................................................... 821 Radiator Removal And Installation............................................................... 821 Radiator Mount Removal And Installation......................................................... 823 Hydraulic Fan Motor Description................................................................. 824 Axial Fan Housing Removal And Installation...................................................... 825 Axial Fan Removal And Installation.............................................................. 827 Hydraulic Fan Motor Removal And Installation.................................................... 829 Hydraulic Fan Motor Disassembly And Assembly.................................................... 829 Water Pump Removal And Installation............................................................. 831 Water Pump Disassembly And Assembly............................................................. 831 Thermostat Housing Removal And Installation..................................................... 832 Thermostat - Checking........................................................................... 832 LUBRICATION SYSTEM.................................................................................. 833 Oil Pan Removal And Installation................................................................ 833 Oil Pump Removal And Installation............................................................... 834 Oil Pump Inspection............................................................................. 834 Oil Filter Cooler Removal And Installation...................................................... 837 Engine Oil Pressure - Testing................................................................... 838 FUEL SYSTEM......................................................................................... 839 Fuel Shutoff Solenoid - Checking................................................................ 839 Fuel Shutoff Solenoid Removal And Installation.................................................. 839 Fuel Injection Pump Assembly Removal............................................................ 840 Fuel Injection Pump Assembly Installation....................................................... 843 Governor Housing Disassembly And Assembly....................................................... 846 Governor Disassembly And Assembly............................................................... 848 Fuel Camshaft Removal And Installation.......................................................... 850 Fuel Injection Pump Removal..................................................................... 852 Fuel Injection Pump Installation................................................................ 854 Fuel Injection Pump - Timing.................................................................... 858 Fuel Injector Removal And Installation.......................................................... 861 Fuel Injector Nozzle Pressure - Checking........................................................ 862 Nozzle Spraying Condition....................................................................... 863 Valve Seat Tightness............................................................................ 863 CYLINDER HEAD....................................................................................... 865 Intake Air Heater - Testing..................................................................... 865 Intake Air Heater Removal And Installation...................................................... 865 Valve Clearance Adjustment...................................................................... 866 Valve Timing - Checking......................................................................... 868 Cylinder Head Removal And Installation.......................................................... 869 Cylinder Head Disassembly And Assembly.......................................................... 872 Cylinder Head - Servicing....................................................................... 872 Cylinder Head Top Clearance..................................................................... 873 Valve Guide - Checking.......................................................................... 874 Reconditioning The Valve And Valve Seat......................................................... 876 Valve Spring.................................................................................... 878 Valve Tappets................................................................................... 879 Rocker Arm And Shaft - Checking................................................................. 880 CRANKSHAFT AND PISTONS.............................................................................. 881 Piston And Connecting Rod Removal And Installation.............................................. 881 Piston And Connecting Rod - Servicing........................................................... 883 Cylinder Bore - Checking........................................................................ 888 Connecting Rod Alignment........................................................................ 889 Crankshaft Gear Removal And Installation........................................................ 889 Crankshaft And Bearings Removal................................................................. 890 Crankshaft And Bearings Installation............................................................ 892 Crankshaft And Bearings - Servicing............................................................. 894 CAMSHAFT AND TIMING GEARS........................................................................... 901 Timing Gearcase Cover Removal And Installation.................................................. 901 Timing Gears Backlash - Checking................................................................ 902 Idler Gear And Camshaft Removal and Installation................................................ 902 Camshaft - Servicing............................................................................ 903 Idler Gear And Shaft - Servicing................................................................ 905 TURBOCHARGER........................................................................................ 907 Description..................................................................................... 907 Testing......................................................................................... 907 Removal And Installation........................................................................ 909 FLYWHEEL AND HOUSING................................................................................ 911 Flywheel Removal And Installation............................................................... 911 Ring Gear Removal And Installation.............................................................. 911 Housing Removal And Installation................................................................ 912 HEATING, VENTILATION, AIR CONDITIONING.................................................................. 913 AIR CONDITIONING SYSTEM FLOW........................................................................ 916 Description..................................................................................... 916 Chart........................................................................................... 917 Components...................................................................................... 918 Safety Equipment................................................................................ 921 REGULAR MAINTENANCE................................................................................. 923 Filters......................................................................................... 923 Compressor Drive Belt Adjustment................................................................ 924 Compressor Drive Belt Replacement............................................................... 924 Condenser....................................................................................... 925 Air Conditioning Lubrication.................................................................... 925 Air Conditioning Service Chart.................................................................. 926 Evaporator / Heater Coil........................................................................ 927 TROUBLESHOOTING..................................................................................... 929 Blower Motor Does Not Operate................................................................... 929 Blower Motor Operates Normally, But Air Flow Is Insufficient.................................... 929 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...................... 929 The Compressor Does Not Operate At All Or Operates Improperly................................... 929 Gauge Pressure Related Troubleshooting.......................................................... 930 Troubleshooting Tree............................................................................ 932 Temperature / Pressure Chart.................................................................... 936 Poor A/C Performance............................................................................ 938 HVAC Repair And Leaks........................................................................... 939 Electrical System............................................................................... 940 Engine Coolant Bypassing The Heater Valve....................................................... 947 Heater Valve Not Opening Or Closing............................................................. 948 SYSTEM CHARGING AND RECLAMATION..................................................................... 949 Refrigerant Identification...................................................................... 949 Reclamation And Charging With Recovery / Charging Unit.......................................... 950 Charging With A Manifold Gauge Set.............................................................. 952 COMPRESSOR.......................................................................................... 955 Removal And Installation........................................................................ 955 Oil............................................................................................. 956 Oil Check....................................................................................... 957 Clutch Disassembly And Assembly................................................................. 958 CONDENSER........................................................................................... 963 Removal And Installation........................................................................ 963 RECEIVER / DRIER.................................................................................... 965 Receiver / Drier Removal And Installation....................................................... 965 Pressure Relief Valve Removal And Installation.................................................. 966 Pressure Switch Removal And Installation........................................................ 967 Schraeder Valve Removal And Installation........................................................ 967 EVAPORATOR / HEATER UNIT............................................................................ 969 Removal And Installation........................................................................ 969 THERMOSTAT.......................................................................................... 971 Description..................................................................................... 971 Removal And Installation........................................................................ 972 EXPANSION VALVE..................................................................................... 973 Removal And Installation........................................................................ 973 EVAPORATOR COIL..................................................................................... 975 Removal And Installation........................................................................ 975 HEATER COIL......................................................................................... 977 Removal And Installation With A/C............................................................... 977 Removal And Installation Without A/C............................................................ 979 BLOWER FAN.......................................................................................... 981 Removal And Installation........................................................................ 981 Disassembly And Assembly........................................................................ 982 Connector Identification........................................................................ 984 HEATER VALVE........................................................................................ 985 Removal and Installation........................................................................ 985 Disassembly And Assembly........................................................................ 986 SPECIFICATIONS.......................................................................................... 987 (T320) LOADER SPECIFICATIONS........................................................................ 989 Machine Dimensions.............................................................................. 989 Performance..................................................................................... 990 Engine.......................................................................................... 990 Drive System.................................................................................... 990 Hydraulic System................................................................................ 991 Controls........................................................................................ 991 Electrical...................................................................................... 992 Capacities...................................................................................... 992 Tracks.......................................................................................... 992 Ground Pressure................................................................................. 992 TORQUE SPECIFICATIONS FOR BOLTS..................................................................... 993 Torque For General SAE Bolts.................................................................... 993 Torque For General Metric Bolts................................................................. 994 HYDRAULIC CONNECTION SPECIFICATIONS................................................................. 995 O-ring Face Seal Connection..................................................................... 995 Straight Thread O-ring Fitting.................................................................. 996 Tubelines And Hoses............................................................................. 996 Flare Fitting................................................................................... 997 Port Seal Fitting............................................................................... 998 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................ 999 Specifications.................................................................................. 999 CONVERSIONS.........................................................................................1001 Decimal And Millimeter Equivalent Chart.........................................................1001 U.S. To Metric Conversion Chart.................................................................1001 SERVICE MANUAL REVISION.................................................................................1003 Revision No: T320 - 1...............................................................................1003 Revision No: T320 - 2...............................................................................1005 Revision No: T320 - 3...............................................................................1007 Revision No: T320 - 4...............................................................................1009 Revision No: T320 - 5...............................................................................1011 Revision No: T320 - 6...............................................................................1013 Revision No: T320 - 7...............................................................................1015 Revision No: T320 - 8...............................................................................1017 Revision No: T320 - 9...............................................................................1019 Revision No: T320 - 10..............................................................................1021 Revision No: T320 - 11..............................................................................1023 Revision No: T320 - 12..............................................................................1025
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