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Bobcat T320 Compact Track Loader Service Manual SN A7MP11001 – A7MP59999 – PDF DOWNLOAD
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Bobcat T320 Compact Track Loader Service Manual SN A7MP11001 – A7MP59999 – PDF DOWNLOAD
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Description
Bobcat T320 Compact Track Loader Service Manual SN A7MP11001 – A7MP59999 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T320 Compact Track Loader Service Manual SN A7MP11001 – A7MP59999 – PDF DOWNLOAD
Language : English
Pages : 940
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T320 Compact Track Loader Service Manual SN A7MP11001 – A7MP59999 – PDF DOWNLOAD
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 SN A7MP11001 – A7MP59999 – 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 AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing.............................................................................. 23 Removing................................................................................ 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising................................................................................. 25 Lowering................................................................................ 27 Cab Door Sensor......................................................................... 28 Special Applications Kit Inspection And Maintenance..................................... 28 TRANSPORTING THE LOADER ON A TRAILER........................................................ 29 Loading And Unloading................................................................... 29 Fastening............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START TOOL KIT-MEL1563............................................................... 33 Remote Start Tool - MEL1563............................................................. 33 Service Tool Harness Control - MEL1565.................................................. 34 Service Tool Harness Communicator - MEL1566............................................. 35 Remote Start Procedure.................................................................. 36 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 6689778.............................................. 40 Loader Service Tool Harness - 6689747................................................... 41 Computer Service Tool Harness - 6689746................................................. 42 Remote Start Procedure.................................................................. 43 SERVICE SCHEDULE............................................................................ 47 Chart................................................................................... 47 AIR CLEANER SERVICE......................................................................... 49 Replacing Filter Elements............................................................... 49 ENGINE COOLING SYSTEM....................................................................... 51 Cleaning................................................................................ 51 Checking Level.......................................................................... 52 Removing And Replacing Coolant.......................................................... 52 FUEL SYSTEM................................................................................. 53 Fuel Specifications..................................................................... 53 Biodiesel Blend Fuel.................................................................... 53 Filling The Fuel Tank................................................................... 54 Fuel Filter............................................................................. 54 Removing Air From The Fuel System....................................................... 55 ENGINE LUBRICATION SYSTEM................................................................... 57 Checking And Adding Engine Oil.......................................................... 57 Engine Oil Chart........................................................................ 57 Removing And Replacing Oil And Filter................................................... 58 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 59 Checking And Adding Fluid............................................................... 59 Hydraulic / Hydrostatic Fluid Chart..................................................... 59 Removing And Replacing Hydraulic Fluid.................................................. 60 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 61 Removing And Replacing Case Drain Filters............................................... 62 Removing And Replacing Hydraulic Charge Filter.......................................... 63 Breather Cap............................................................................ 64 BOB-TACH (HAND LEVER)....................................................................... 65 Inspection And Maintenance.............................................................. 65 BOB-TACH (POWER)............................................................................ 67 Inspection And Maintenance.............................................................. 67 LUBRICATING THE LOADER...................................................................... 69 Lubrication Locations................................................................... 69 SPARK ARRESTOR MUFFLER...................................................................... 71 Cleaning Procedure...................................................................... 71 PIVOT PINS.................................................................................. 73 Inspection And Maintenance.............................................................. 73 LOADER STORAGE AND RETURN TO SERVICE........................................................ 75 Storage................................................................................. 75 Return to Service....................................................................... 75 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 77 Procedure............................................................................... 77 Emergency Exit.......................................................................... 78 HYDRAULIC SYSTEM................................................................................ 81 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 87 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).............................................................................117 Testing.................................................................................117 Removal And Installation................................................................118 Base End Pivot Pin Removal And Installation.............................................120 Parts Identification....................................................................121 Disassembly.............................................................................122 Assembly................................................................................124 CYLINDER (BOB-TACH).........................................................................127 Testing.................................................................................127 Removal And Installation................................................................128 Parts Identification....................................................................129 Disassembly.............................................................................130 Assembly................................................................................131 MAIN RELIEF VALVE...........................................................................135 Description.............................................................................135 Testing.................................................................................136 Adjusting...............................................................................138 Removal And Installation................................................................139 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................141 Description.............................................................................141 Removal And Installation................................................................142 Identification Chart....................................................................146 Mount Bracket Removal And Installation..................................................147 Lift Load Check Valve Removal And Installation..........................................147 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................148 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................148 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........149 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........150 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............150 Port Relief Valve Removal And Installation..............................................151 Plug Removal And Installation...........................................................152 Rubber Boot Removal And Installation....................................................153 End Cap Block Removal And Installation..................................................154 Lift Spool And Detent Removal And Installation..........................................155 Tilt Spool Removal And Installation.....................................................165 Auxiliary Spool Removal And Installation................................................167 Auxiliary Solenoid Removal And Installation.............................................169 Solenoid Removal And Installation.......................................................170 Lock Valve Removal And Installation.....................................................171 Lift Arm Bypass Orifice Removal And Installation........................................173 Main Relief Valve Removal And Installation..............................................173 Check Valve Removal And Installation....................................................174 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................175 Description.............................................................................175 Removal And Installation................................................................176 Actuator Removal And Installation (In Loader)...........................................180 Actuator Removal And Installation (Out Of Loader).......................................182 Identification Chart....................................................................185 Mount Bracket Removal And Installation..................................................186 Lift Load Check Valve Removal And Installation..........................................186 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................187 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................188 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........189 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........189 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............190 Port Relief Valve Removal And Installation..............................................190 Plug Removal And Installation...........................................................191 End Cap Block Removal And Installation..................................................192 Lift Spool And Detent Removal And Installation..........................................193 Tilt Spool Removal And Installation.....................................................198 Auxiliary Spool Removal And Installation................................................200 Auxiliary Solenoid Removal And Installation.............................................202 Solenoid Removal And Installation.......................................................203 Lock Valve Removal And Installation.....................................................204 Lift Arm Bypass Orifice Removal And Installation........................................206 Main Relief Valve Removal And Installation..............................................206 Check Valve Removal And Installation....................................................207 LIFT ARM BYPASS CONTROL VALVE...............................................................209 Description.............................................................................209 Testing.................................................................................209 Removal And Installation................................................................210 Disassembly And Assembly................................................................211 HYDRAULIC PUMP (STANDARD)...................................................................213 Description.............................................................................213 Pump Test At Quick Couplers.............................................................214 Direct Pump Test (Standard Section).....................................................215 Direct Pump Test (Charge Section).......................................................217 Removal And Installation................................................................221 Hydraulic Pump Start Up.................................................................223 Parts Identification....................................................................224 Disassembly And Assembly................................................................225 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).......................................................227 Description.............................................................................227 Pump Test At Quick Couplers.............................................................228 Direct Pump Test (Standard Section).....................................................229 Direct Pump Test (Charge Section).......................................................231 Direct Pump Test (High Flow Section)....................................................235 High Flow Relief Valve Adjustment.......................................................237 High Flow Relief Valve Removal And Installation.........................................239 Solenoid Removal And Installation.......................................................240 Removal And Installation................................................................241 Hydraulic Pump Start Up.................................................................243 Parts Identification....................................................................244 Disassembly And Assembly................................................................245 HYDRAULIC PUMP (SJC)........................................................................247 Description.............................................................................247 Pump Test At Quick Couplers.............................................................248 Direct Pump Test (Standard Section).....................................................249 Direct Pump Test (Charge Section).......................................................251 Removal And Installation................................................................255 Hydraulic Pump Start Up.................................................................257 Parts Identification....................................................................258 Disassembly And Assembly................................................................259 HYDRAULIC PUMP (SJC) (HIGH FLOW)............................................................261 Description.............................................................................261 Pump Test At Quick Couplers.............................................................262 Direct Pump Test (Standard Section).....................................................263 Direct Pump Test (Charge Section).......................................................265 Direct Pump Test (High Flow Section)....................................................269 High Flow Relief Valve Adjustment.......................................................271 High Flow Relief Valve Removal And Installation.........................................273 Solenoid Removal And Installation.......................................................274 Removal And Installation................................................................275 Hydraulic Pump Start Up.................................................................277 Parts Identification....................................................................278 Disassembly And Assembly................................................................279 HYDRAULIC / HYDROSTATIC FILTERS.............................................................281 Description.............................................................................281 Housing Removal And Installation........................................................281 Charge Filter Housing Removal And Installation..........................................283 HYDRAULIC FLUID RESERVOIR...................................................................285 Description.............................................................................285 Removal And Installation................................................................285 Hydraulic Fluid Screen..................................................................288 OIL COOLER..................................................................................289 Description.............................................................................289 Removal And Installation................................................................289 BUCKET POSITION VALVE.......................................................................291 Description.............................................................................291 Solenoid Removal And Installation.......................................................292 Solenoid Testing........................................................................292 Removal And Installation................................................................293 Disassembly And Assembly................................................................293 REAR AUXILIARY DIVERTER VALVE...............................................................295 Description.............................................................................295 Solenoid Testing........................................................................295 Removal And Installation................................................................296 Disassembly And Assembly................................................................298 BOB-TACH (POWER) BLOCK......................................................................305 Description.............................................................................305 Removal And Installation................................................................305 Disassembly And Assembly................................................................307 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................311 Description.............................................................................311 Removal And Installation................................................................311 Disassembly And Assembly................................................................312 HYDROSTATIC SYSTEM..............................................................................315 HYDROSTATIC SYSTEM INFORMATION..............................................................317 Troubleshooting.........................................................................317 Description.............................................................................318 HYDROSTATIC MOTOR...........................................................................319 Description.............................................................................319 Removing And Replacing Oil..............................................................319 Removal And Installation................................................................320 Parts Identification....................................................................322 Disassembly And Assembly................................................................324 CHARGE PRESSURE.............................................................................337 Description.............................................................................337 Testing.................................................................................338 Sender Removal And Installation.........................................................339 Adjusting...............................................................................340 HYDROSTATIC PUMP............................................................................343 Description.............................................................................343 Removal And Installation................................................................344 Hydrostatic Pump Start Up...............................................................346 Replenishing / High Pressure Relief Valve Removal And Installation......................347 Parts Identification (Left Half)........................................................348 Parts Identification (Right Half).......................................................349 Disassembly.............................................................................350 Assembly................................................................................357 HYDROSTATIC PUMP (SJC)......................................................................363 Description.............................................................................363 Hydraulic Controller Removal And Installation...........................................364 Removal And Installation................................................................366 Hydrostatic Pump Start Up...............................................................368 Parts Identification....................................................................369 High Pressure Relief And Bypass Valve...................................................370 Charge Relief Valve.....................................................................371 Disassembly And Assembly................................................................372 Mechanical Neutral Adjustment...........................................................389 Hydraulic Controller Neutral Adjustment.................................................392 DRIVE BELT..................................................................................395 Description.............................................................................395 Shield Removal And Installation.........................................................395 Adjusting...............................................................................396 Belt Removal And Installation...........................................................396 Tensioner Pulley Removal And Installation...............................................397 Tensioner Pulley Disassembly And Assembly...............................................398 Tensioner Pulley Tension Spring Removal And Installation................................399 Tensioner Pulley Tension Spring Disassembly And Assembly................................399 CASE DRAIN FILTER...........................................................................401 Description.............................................................................401 Disassembly And Assembly................................................................401 DRIVE SYSTEM....................................................................................403 BRAKE.......................................................................................405 Description.............................................................................405 Block Removal And Installation..........................................................405 Block Disassembly And Assembly..........................................................406 TRACK CARRIAGE COMPONENTS (SOLID- MOUNTED UNDERCARRIAGE)....................................409 Description.............................................................................409 Checking Tension........................................................................410 Adjusting Tension.......................................................................411 Track Removal And Installation..........................................................412 Idler (Front) Removal And Installation..................................................415 Idler (Rear) Removal And Installation...................................................418 Roller Removal And Installation.........................................................418 Sprocket Removal And Installation.......................................................419 Track Housing Removal And Installation..................................................420 Track Damage Identification.............................................................421 MAIN FRAME......................................................................................431 SEAT BAR....................................................................................435 Description.............................................................................435 Removal And Installation................................................................435 Disassembly And Assembly................................................................437 Compression Spring Disassembly And Assembly.............................................438 OPERATOR CAB................................................................................439 Gas Cylinder Removal And Installation...................................................439 Gas Cylinder Bracket Disassembly And Assembly...........................................441 Removal And Installation................................................................442 OPERATOR SEAT (SUSPENSION)..................................................................445 Removal And Installation................................................................445 Slide Rail Removal And Installation.....................................................446 Seat Belt Removal And Installation......................................................446 Lower Cushion Removal And Installation..................................................447 Back Cushion Removal And Installation...................................................448 Shock Removal And Installation..........................................................448 3-Point Seat Belt Removal And Installation..............................................449 BOB-TACH (HAND LEVER).......................................................................451 Description.............................................................................451 Removal And Installation................................................................451 Lever And Wedge Disassembly And Assembly................................................454 Pivot Pin Bushing And Seal Removal And Installation.....................................455 BOB-TACH (POWER - OPTION)...................................................................457 Description.............................................................................457 Removal And Installation................................................................457 Lever And Wedge Disassembly And Assembly................................................460 Pivot Pin Bushing Removal And Installation..............................................461 LIFT ARMS...................................................................................463 Stabilizer Bar Removal And Installation.................................................463 Link Removal And Installation...........................................................464 Removal And Installation................................................................465 REAR GRILL..................................................................................469 Removal And Installation................................................................469 REAR DOOR...................................................................................471 Removal And Installation................................................................471 Striker Removal And Installation........................................................472 Striker Disassembly And Assembly........................................................472 Striker (Adjusting).....................................................................473 Latch Removal And Installation..........................................................473 FUEL TANK...................................................................................475 Removal And Installation................................................................475 Fuel Level Sender Removal And Installation..............................................477 Fuel Fill Screen Removal And Installation...............................................477 CONTROL PEDALS AND LINKAGES.................................................................479 Description.............................................................................479 Pedal Removal And Installation..........................................................480 Linkage Removal And Installation........................................................481 Pedal (Adjusting).......................................................................482 CONTROL PEDALS (ACS)........................................................................483 Description.............................................................................483 Foot Sensor Removal And Installation....................................................484 Foot Pedal Removal And Installation.....................................................485 Foot Pedal Linkage Disassembly And Assembly.............................................485 CONTROL PANEL (S/N A7MP11204 & BELOW).......................................................487 Description.............................................................................487 Removal And Installation................................................................488 Shock Removal And Installation..........................................................490 Shaft Removal And Installation..........................................................490 Shaft Disassembly And Assembly..........................................................491 Linkage Removal And Installation........................................................492 Pintle Arm Disassembly and Assembly.....................................................496 Linkage Neutral (Adjusting).............................................................497 Linkage Travel (Adjusting)..............................................................501 CONTROL PANEL (S/N A7MP11205 - A7MP59999)...................................................505 Description.............................................................................505 Removal And Installation................................................................506 Shock Removal And Installation..........................................................508 Shaft Removal And Installation..........................................................509 Linkage Removal And Installation........................................................510 Pintle Arm Disassembly and Assembly.....................................................514 Linkage Neutral (Adjusting).............................................................515 Linkage Travel (Adjusting)..............................................................519 CONTROL PANEL (S/N A7MP11204 & BELOW) (SJC).................................................523 Description.............................................................................523 Removal And Installation................................................................524 CONTROL PANEL (S/N A7MP11205 - A7MP59999) (SJC).............................................527 Description.............................................................................527 Removal And Installation................................................................528 CONTROL HANDLE / LEVER......................................................................531 Description.............................................................................531 Lever Removal And Installation..........................................................531 Boot Removal And Installation...........................................................532 CONTROL HANDLE / LEVER (ACS)................................................................533 Description.............................................................................533 Handle Sensor Removal And Installation..................................................533 Handle Removal And Installation.........................................................536 Handle Disassembly And Assembly.........................................................537 Lever Removal And Installation..........................................................538 Boot Removal And Installation...........................................................539 CONTROL HANDLE / LEVER (SJC)................................................................541 Description.............................................................................541 Joystick Testing........................................................................542 Joystick Removal And Installation.......................................................543 Joystick Mount Removal And Installation.................................................544 ACCESS PANEL (INSIDE).......................................................................545 Removal And Installation (Left).........................................................545 Removal And Installation (Right)........................................................545 ACCESS PANEL (INSIDE) (SJC).................................................................547 Removal And Installation (Left).........................................................547 Removal And Installation (Right)........................................................548 WINDOW (REAR)...............................................................................551 Removal.................................................................................551 Installation............................................................................551 WINDOW (TOP)................................................................................553 Removal And Installation................................................................553 WINDOW (SIDE)...............................................................................555 Removal And Installation................................................................555 WINDOW (FRONT DOOR).........................................................................557 Removal (Standard Window)...............................................................557 Installation (Standard Window)..........................................................558 Removal And Installation (Special Applications Window)..................................560 CAB DOOR....................................................................................561 Description.............................................................................561 Removal And Installation................................................................561 Aligning................................................................................562 Adjusting...............................................................................563 Checking Operation......................................................................563 ELECTRICAL SYSTEM & ANALYSIS....................................................................565 ELECTRICAL SCHEMATICS.......................................................................569 ELECTRICAL SYSTEM INFORMATION...............................................................575 Glossary Of Electrical Symbols..........................................................575 Cab Harness Connectors..................................................................578 Mainframe Harness Connectors............................................................579 Description.............................................................................581 Fuse And Relay Location / Identification................................................582 Troubleshooting.........................................................................583 Solenoid Testing........................................................................584 BATTERY.....................................................................................585 Servicing...............................................................................585 Using A Booster Battery (Jump Starting).................................................585 Removal And Installation................................................................587 ALTERNATOR..................................................................................589 Belt Adjustment.........................................................................589 Belt Replacement........................................................................589 Charging System Inspection..............................................................590 Alternator Voltage Testing..............................................................591 Low Voltage Testing.....................................................................591 High Voltage Testing....................................................................592 Removal And Installation................................................................593 Parts Identification....................................................................594 STARTER.....................................................................................595 Testing.................................................................................595 Removal And Installation................................................................596 Parts Identification....................................................................597 INSTRUMENT PANELS...........................................................................600 Left Panel..............................................................................600 Standard Key Panel......................................................................602 Deluxe Instrumentation Panel............................................................603 Side Panel..............................................................................604 Front Panel.............................................................................604 Front Panel Removal And Installation....................................................605 Removal And Installation (Left And Right)...............................................605 Key Switch Removal And Installation.....................................................608 Alarm Removal And Installation..........................................................609 LIGHTS......................................................................................611 Front Removal And Installation..........................................................611 Rear Removal And Installation...........................................................612 Cab Light Removal And Installation......................................................612 BOBCAT CONTROLLER (MAIN)....................................................................613 Description.............................................................................613 Connector Identification................................................................614 Removal And Installation................................................................616 BOBCAT CONTROLLER (ACS).....................................................................617 Description.............................................................................617 Connector And Wire Identification.......................................................618 Removal And Installation................................................................619 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................621 Description.............................................................................621 Connector Identification................................................................622 Removal And Installation................................................................624 SPEED SENSORS (SJC).........................................................................625 Description.............................................................................625 Testing.................................................................................625 Removal And Installation................................................................627 DIAGNOSTIC SERVICE CODES....................................................................629 Viewing Service Codes (Key Switch)......................................................629 Viewing Service Codes (Keyless).........................................................629 Service Codes List......................................................................630 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......................................................635 Description.............................................................................635 Inspecting The BICS Controller (Engine STOPPED - Key ON)................................636 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....636 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................636 Inspecting The Traction Lock (Engine RUNNING)...........................................636 Inspecting The Lift Arm Bypass Control..................................................636 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)........................636 Troubleshooting.........................................................................637 Troubleshooting Chart...................................................................638 SEAT BAR SENSOR.............................................................................639 Description.............................................................................639 Troubleshooting.........................................................................640 Testing.................................................................................641 Removal And Installation................................................................642 Bobcat Interlock Control System (BICS) Circuit Test.....................................643 TRACTION LOCK...............................................................................645 Description.............................................................................645 Troubleshooting.........................................................................646 Inspecting..............................................................................647 CONTROL SYSTEM (ACS)........................................................................649 Description.............................................................................649 Troubleshooting Chart...................................................................650 Handle Sensor Connector Disassembly And Assembly........................................651 Switch Handle Removal...................................................................652 Switch Handle Installation..............................................................654 Actuator Connector Disassembly And Assembly.............................................657 Handle Lock Solenoid Removal And Installation...........................................658 Handle Lock Solenoid Disassembly And Assembly...........................................659 Foot Sensor Disassembly And Assembly....................................................659 Foot Lock Solenoid Removal And Installation.............................................660 ELECTRICAL / HYDRAULIC CONTROLS.............................................................661 Identification Chart....................................................................661 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................663 Identification Chart....................................................................663 SERVICE PC (LAPTOP COMPUTER)................................................................667 Connecting Remote Start Tool............................................................667 Connecting Remote Start Tool (Service Tool).............................................667 CALIBRATION.................................................................................669 Description.............................................................................669 Actuator Testing........................................................................669 Lift And Tilt Calibration (ACS).........................................................671 Lift And Tilt Calibration (SJC).........................................................673 Hydrostatic Pump Calibration (SJC)......................................................675 STEERING DRIFT COMPENSATION.................................................................681 Description.............................................................................681 Selecting And Adjusting.................................................................681 Exiting And Saving......................................................................682 FLYWHEEL RPM SENSOR.........................................................................683 Description.............................................................................683 Adjustment..............................................................................684 CONTROL PANEL SETUP.........................................................................685 Right Panel Setup (Keyless).............................................................685 Attachment Control Information (Keyless)................................................686 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).............................................687 Password Description....................................................................687 Changing The Owner Password.............................................................687 Changing The User Passwords.............................................................688 Password Lockout Feature................................................................688 MAINTENANCE CLOCK...........................................................................689 Description.............................................................................689 Setup...................................................................................690 Reset...................................................................................694 BACK-UP ALARM SYSTEM........................................................................695 Description.............................................................................695 Inspecting..............................................................................695 Adjusting Switch Position...............................................................696 Troubleshooting (Standard And ACS)......................................................697 Troubleshooting (Joystick)..............................................................698 Alarm Removal And Installation..........................................................699 Switch Removal And Installation.........................................................699 ENGINE SERVICE..................................................................................701 ENGINE INFORMATION..........................................................................705 Description.............................................................................705 Specifications..........................................................................706 Torque Values...........................................................................711 Troubleshooting.........................................................................712 Engine Removal And Installation.........................................................714 Engine Mount Replacement................................................................723 Compression - Checking..................................................................724 ENGINE SPEED CONTROL........................................................................725 Removal And Installation................................................................725 Cable Removal And Installation..........................................................726 ENGINE SPEED CONTROL (SJC)..................................................................727 Removal And Installation................................................................727 Disassembly And Assembly................................................................729 Cable Removal And Installation..........................................................731 MUFFLER.....................................................................................733 Removal And Installation................................................................733 AIR CLEANER.................................................................................735 Housing Removal And Installation........................................................735 ENGINE COOLING SYSTEM.......................................................................737 Radiator Removal And Installation.......................................................737 Radiator Mount Removal And Installation.................................................739 Hydraulic Fan Motor Description (S/N A7MP40000 & Below).................................740 Axial Fan Housing Removal And Installation (S/N A7MP40000 & Below)).....................740 Axial Fan Removal And Installation (S/N A7MP40000 & Below)..............................742 Hydraulic Fan Motor Removal And Installation (S/N A7MP40000 & Below)....................744 Hydraulic Fan Motor Disassembly And Assembly (S/ N A7MP40000 & Below)...................744 Hydraulic Fan Motor Description (S/N A7MP40001 - A7MP59999).............................745 Axial Fan Housing Removal And Installation (S/N A7MP40001 - A7MP59999)..................745 Axial Fan Removal And Installation (S/N A7MP40001 - A7MP59999)..........................748 Hydraulic Fan Motor Removal And Installation (S/N A7MP40001 - A7MP59999)................749 Hydraulic Fan Motor Disassembly And Assembly (S/ N A7MP40001 - A7MP59999))..............750 Water Pump Removal And Installation.....................................................751 Water Pump Disassembly And Assembly.....................................................752 Thermostat Housing Removal And Installation.............................................752 LUBRICATION SYSTEM..........................................................................755 Oil Pan Removal And Installation........................................................755 Oil Pump Removal And Installation.......................................................756 Oil Pump Inspection.....................................................................756 Oil Filter Cooler Removal And Installation..............................................759 Engine Oil Pressure - Testing...........................................................760 FUEL SYSTEM.................................................................................761 Fuel Shutoff Solenoid - Checking........................................................761 Fuel Shutoff Solenoid - Removal And Installation........................................761 Fuel Injection Pump Assembly Removal....................................................762 Fuel Injection Pump Assembly Installation...............................................765 Governor Housing Disassembly And Assembly...............................................768 Governor Disassembly And Assembly.......................................................770 Fuel Camshaft Removal And Installation..................................................772 Fuel Injection Pump Removal.............................................................774 Injection Pump Timing...................................................................780 Fuel Injector Removal And Installation..................................................783 Fuel Injector Nozzle Pressure - Checking................................................784 Nozzle Spraying Condition...............................................................785 Valve Seat Tightness....................................................................785 CYLINDER HEAD...............................................................................787 Intake Air Heater - Testing.............................................................787 Intake Air Heater Removal And Installation..............................................787 Valve Clearance Adjustment..............................................................788 Valve Timing - Checking.................................................................790 Cylinder Head Removal And Installation..................................................791 Cylinder Head Top Clearance.............................................................793 Cylinder Head Disassembly And Assembly..................................................795 Cylinder Head - Servicing...............................................................795 Valve Guide - Checking..................................................................796 Reconditioning The Valve And Valve Seat.................................................798 Valve Spring............................................................................800 Valve Tappets...........................................................................801 Rocker Arm And Shaft - Checking.........................................................802 CRANKSHAFT AND PISTONS......................................................................803 Piston And Connecting Rod Removal And Installation......................................803 Piston And Connecting Rod - Servicing...................................................805 Cylinder Bore Checking..................................................................810 Connecting Rod Alignment................................................................811 Crankshaft Gear Removal And Installation................................................811 Crankshaft And Bearings Removal.........................................................812 Crankshaft And Bearings Installation....................................................814 Crankshaft And Bearings - Servicing.....................................................816 CAMSHAFT AND TIMING GEArS...................................................................823 Timing Gearcase Cover Removal And Installation..........................................823 Timing Gears Backlash - Checking........................................................824 Idler Gear And Camshaft Removal and Installation........................................824 Camshaft - Servicing....................................................................825 Idler Gear And Shaft - Servicing........................................................827 TURBOCHARGER................................................................................829 Description.............................................................................829 Testing.................................................................................829 Removal And Installation................................................................831 FLYWHEEL AND HOUSING........................................................................833 Flywheel Removal And Installation.......................................................833 Ring Gear Removal And Installation......................................................833 Housing Removal And Installation........................................................834 HEATING, VENTILATION, AIR CONDITIONING..........................................................835 AIR CONDITIONING SYSTEM FLOW................................................................838 Description.............................................................................838 Chart...................................................................................839 Components..............................................................................840 Safety Equipment........................................................................843 REGULAR MAINTENANCE.........................................................................845 Filter Elements Removal And Installation................................................845 Compressor Drive Belt Inspection........................................................846 Condenser...............................................................................847 Air Conditioning Service Chart..........................................................848 A/C Evaporator Coil And Heater Coil.....................................................849 TROUBLESHOOTING.............................................................................851 Blower Motor Does Not Operate...........................................................851 Blower Motor Operates Normally, But Air Flow Is Insufficient............................851 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............851 The Compressor Does Not Operate At All Or Operates Improperly...........................851 Gauge Pressure Related Troubleshooting..................................................852 Troubleshooting Tree....................................................................854 Temperature / Pressure Chart............................................................858 Poor A/C Performance....................................................................860 HVAC Repair And Leaks...................................................................861 Electrical System.......................................................................862 Engine Coolant Bypassing The Heater Valve...............................................869 Heater Valve Not Opening Or Closing.....................................................870 SYSTEM CHARGING AND RECLAMATION.............................................................871 Refrigerant Identification..............................................................871 Reclamation And Charging With Recovery / Charging Unit..................................872 Charging With A Manifold Gauge Set......................................................874 COMPRESSOR..................................................................................877 Belt Adjustment.........................................................................877 Removal And Installation................................................................877 Oil.....................................................................................878 Oil Check...............................................................................879 Clutch Disassembly And Assembly.........................................................880 CONDENSER...................................................................................885 Removal And Installation................................................................885 RECEIVER / DRIER............................................................................887 Receiver / Drier Removal And Installation...............................................887 Pressure Relief Valve Removal And Installation..........................................888 Pressure Switch Removal And Installation................................................889 Schraeder Valve Removal And Installation................................................889 EVAPORATOR / HEATER UNIT....................................................................891 Removal And Installation................................................................891 THERMOSTAT..................................................................................893 Removal And Installation................................................................893 EXPANSION VALVE.............................................................................895 Removal And Installation................................................................895 EVAPORATOR COIL.............................................................................897 Removal And Installation................................................................897 HEATER COIL.................................................................................899 Removal And Installation With A/C.......................................................899 Removal And Installation Without A/C....................................................901 BLOWER FAN..................................................................................903 Removal And Installation................................................................903 Disassembly And Assembly................................................................904 Connector Identification................................................................906 HEATER VALVE................................................................................907 Removal and Installation................................................................907 Disassembly And Assembly................................................................908 SPECIFICATIONS..................................................................................909 (T320) LOADER SPECIFICATIONS................................................................911 Machine Dimensions......................................................................911 Performance.............................................................................912 Controls................................................................................912 Engine..................................................................................912 Hydraulic System........................................................................913 Electrical..............................................................................914 Drive System............................................................................914 Capacities..............................................................................914 Tracks..................................................................................914 Ground Pressure.........................................................................914 TORQUE SPECIFICATIONS FOR BOLTS.............................................................915 Torque For General SAE Bolts............................................................915 Torque For General Metric Bolts.........................................................916 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................917 O-ring Face Seal Connection.............................................................917 Straight Thread O-ring Fitting..........................................................918 Tubelines And Hoses.....................................................................918 Flare Fitting...........................................................................919 Port Seal Fitting.......................................................................920 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................921 Specifications..........................................................................921 CONVERSIONS.................................................................................923 Decimal And Millimeter Equivalents......................................................923 U.S. To Metric Conversion Chart.........................................................923 SERVICE MANUAL REVISION.........................................................................925 Revision No: T320 - 1.......................................................................925 Revision No: T320 - 2.......................................................................927 Revision No: T320 - 3.......................................................................929 Revision No: T320 - 4.......................................................................931 Revision No: T320 - 5.......................................................................933 Revision No: T320 - 6.......................................................................935 Revision No: T320 - 7.......................................................................937 Revision No: T320 - 8.......................................................................939
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