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Bobcat 320 322 Compact Excavator Service Repair Manual sn562313001 Above
Bobcat 320 322 Compact Excavator Service Repair Manual sn562313001 Above
Bobcat 320 322 Compact Excavator Service Repair Manual sn562313001 Above
Excavator
Service
Manual
(S/N 562313001 & Above)
(S/N 517811001 & Above)
MAIN FRAME
& TRACKS
ELECTRICAL
SYSTEM
ENGINE
SERVICE
TECHNICAL
DATA
320/322 Excavator
Revised July 05 i Service Manual
FOREWORD
This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing and
adjustment procedures for the hydraulic excavator 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 hydraulic excavator has had service
or repair:
1. Check that the ROPS/TOPS/ 9. Safety treads must in good
FOGS is in good condition condition.
and is not modified.
3. The seat belt must be correctly 11. Check hydraulic fluid level,
installed, functional and in engine oil level and fuel supply.
good condition.
4. Inspect for loose or broken 12. Inspect for fuel, oil or hydraulic
parts or connections. fluid leaks.
7. Inspect the air cleaner for Recommend to the owner that all
damage or leaks. Check the necessary corrections be made
condition of the element. before the machine is returned to
service.
320/322 Excavator
Revisedy July 05 iii Service Manual
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read and understand the Operation &
Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or
death. W–2003–0903
The following publications provide information on the safe use and maintenance of the BobcatR machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the ma-
chine 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 pro-
vided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your BobcatR dealer.
• Machine signs (decals) instruct on the safe operation and care of your BobcatR machine or attachment. The signs
and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your
BobcatR dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The hand-
book is available from your dealer in an English edition or one of many other languages. See your BobcatR 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 shop–type service
and repair work.
• The Compact Excavator Operator Training Course is available through your local dealer or at www.bobcat.com. This
course is intended to provide rules and practices of correct operation of the BobcatR Excavator. The course is avail-
able in English and Spanish versions.
• Service Safety Training Courses are available from your BobcatR dealer or at www.bobcat.com. They provide infor-
mation for safe and correct service procedures.
• The BobcatR Compact Excavator Safety Video is available from your BobcatR dealer or at www.bobcat.com.
SI EXC–0705
320/322 Excavator
Revised July 05 v Service Manual
SAFETY INSTRUCTIONS (Cont’d)
FIRE PREVENTION
The machine and attachments have components that are at high temperature under normal operating conditions. The
primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly
maintained, can be a source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will
increase fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential
hazard.
The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but
the muffler and the exhaust gases are still hot.
• Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust
or gases.
• The operator cab, engine compartment, and engine cooling system must be inspected every day and cleaned if necessary
to prevent fire hazard and overheating.
• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure
you or bystanders.
• Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover
rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good
ventilation when grinding or welding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can
be produced.
• Stop the engine and let it cool before adding fuel. NO SMOKING!
• Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.
• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).
• Know where fire extinguishers and first aid kits are located
and how to use them. Fire extinguishers are available from
A
your BobcatR dealer [A].
SI EXC–0705
320/322 Excavator
Revised July 05 vii Service Manual
SERIAL NUMBER LOCATIONS
Always use the FULL serial number (including the first
A
four digits) when requesting service or when ordering
parts. Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
HYDRAULIC EXCAVATOR SERIAL NUMBER
The excavator serial number is on the right front side of
the machine frame [A].
N–00806
ENGINE SERIAL NUMBER
The engine serial number is located on the engine block,
near the fuel injection pump [B].
B
P–11102
DELIVERY REPORT
C
The Delivery Report items must be explained to the
owner/operator by the dealer. The dealer is to fill out the
form and the owner/operator signs the form to indicate his
understanding [C].
320/322 Excavator
Revised July 05 viii Service Manual
HYDRAULIC EXCAVATOR IDENTIFICATION
320ServiceManual#6724910S/N562313001&Above–ContentsSection
GRAB HANDLES
CONTROL LEVERS (JOYSTICK)
CANOPY
(ROPS)
ENGINE COVER
UPPERSTRUCTURE
TRACK FRAME
TRACK
GRAB HANDLES
OPERATORS HANDBOOK
ARM CYLINDER
OPERATOR SEAT
AUXILIARY
LINES
BLADE CYLINDER
BUCKET
BOOM
BLADE
B–14408
BOOM CYLINDER B–14407
320/322 Excavator
Added July 05 ix Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
COOLING SYSTEM
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Propylene Glycol (Factory Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
ELECTRICAL SYSTEM
Electrical Relays and Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Electric Solenoid (Engine Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Removal and Installation of the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Service the Electrical System (and Battery) . . . . . . . . . . . . . . . . . . . . . . . 1–12
ENGINE COVER
Adjustment of the Engine Cover Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
ENGINE LUBRICATION SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
FINAL DRIVE CASE
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Fuel Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
HEATER AIR FILTER (With Cab Option Only) . . . . . . . . . . . . . . . . . . . . . . 1–23
HYDRAULIC SYSTEM
Case Drain Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
JOYSTICK CONTROL CHANGE
ISO to Standard Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
Standard to ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . 1–21
MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
SPARK ARRESTOR MUFFLER (if equipped) . . . . . . . . . . . . . . . . . . . . . . 1–16
TRACK TENSION
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
320/322 Excavator
Revised July 05 –1–1– Service Manual
MAINTENANCE SAFETY 2. Do not continuously apply more than 200 V.
• Never service the machine without instructions. 3. Install the ground cable (from welder) at least 3 ft. (1
m) away from the part being welded.
• Cleaning and maintenance are required daily.
4. When attaching ground cable (from welder) make
sure there are no seals or bearings between
• Keep engine cover closed except for service. Close the ground and the part to be welded.
and latch the cover before operating.
• Lead–acid batteries produce flammable and
• Never fill the fuel tank with the engine running, while explosive gases. Keep arcs, sparks, flames and
smoking or when near open flame. lighted tobacco away from batteries.
• Never modify equipment or add attachments not • Do not handle electrical equipment while wearing wet
approved by Melroe Company. gloves, or in wet places, this can cause an electrical
shock.
• Stop, cool and clean the engine of flammable
materials before checking fluid levels. • Do not allow unauthorized personnel near the
machine during maintenance.
• Never service or adjust machine with engine running
• When working under the machine, always place
unless instructed to do so in this manual. signs to that effect on the operator’s seat and around
the machine.
• Keep body, loose objects and clothing away from
moving parts, electrical contracts, hot parts and • When maintenance is done with equipment raised,
exhaust. Never wear loose clothing or jewelry it must be securely blocked.
around machinery.
Relieve pressure on work cylinders as follows:
• Avoid contact with leaking hydraulic fluid or diesel
fuel which is under pressure, it can penetrate the skin 1. Lower work equipment to the ground. Stop the
and eyes. engine.
Wear safety glasses to prevent eye injury when any of the 2. Operate all the control levers through their functions.
following conditions exist:
NOTE: Control console must be lowered to the
• When fluids are under pressure. latched position with the key in the run
position to activate the joystick function and
• Flying debris or loose material is present. relieve the accumulator pressure.
• Engine is running. 3. Loosen the cap on the hydraulic tank.
• Tools are being used. • When working on rocky ground, avoid damage to the
under carriage. Check for loose nuts and bolts,
cracks and other damage.
• Do not check alternator belt tension with engine
running. Stop the engine before inspecting any • Before working in water, rain or snow, check that
rotating parts. plugs and valves are tightened. When finished, wash
the machine, then check for cracks, loose or missing
• Always disconnect the negative (–) cable from the nuts or bolts. Lubricate the machine.
battery before doing electrical maintenance or
welding.
320/322 Excavator
Revised July 05 –1–3– Service Manual
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SERVICE SCHEDULE
320/322 Excavator
Revised July 05 –1–4– Service Manual
ENGINE COVER
A
AVOID INJURY
Never service or adjust the machine when the
engine is running unless instructed to do so
in this manual.
W–2012–0290
W–2141–0189
B
Open the engine cover to service the engine. Pull on the
latch and lift the engine cover up until it is fully raised [A]. 3
P–11059
1
P–11060
320/322 Excavator
–1–5– Service Manual
AIR CLEANER SERVICE (Cont’d)
A
Filter Replacement
Remove the wing nut (Item 1) [A] and the filter element
(Item 2) [A].
2
P–11061
1
P–11062
320/322 Excavator
–1–6– Service Manual
FUEL SYSTEM
Filling the Fuel Tank
A
2
Stop and cool the engine before adding fuel. 1
NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W–2063–0887
P–11035
The fuel level in the tank is indicated by the fuel gauge
(Item 1) [A] when the ignition switch is ON.
NOTE: When the fuel level reaches the .8 gals. (3.1 B
L.) fuel level, the low fuel light (Item 2) [A] will
come ON to alert the operator of this
condition.
Use the key to unlock the left side cover [B].
Turn the fuel cap to remove it [C].
Use a clean, approved safety container to add fuel to the
tank.
Add fuel only in an area that has a free movement of air
and no flames or sparks. NO SMOKING!
After the tank is full, install and tighten the fuel cap. Close P–11063
and lock the fuel door.
Fuel Filter
P–11064
See the SERVICE SCHEDULE Page 1–4 for the service
interval when to replace the fuel filter.
The fuel filter is located under the left hand side of the D
excavator
Loosen the drain (Item 1) [D] at the bottom of the filter
element to drain any water from the fuel filter.
Tighten the drain when all the water has been removed.
2
Remove the filter element (Item 2) [D]. 1
Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter and
hand tighten.
Remove the air from the fuel filter. P–11065
320/322 Excavator
–1–7– Service Manual
FUEL SYSTEM (Cont’d)
Fuel System Maintenance
A
See the SERVICE SCHEDULE Page 1–4 for the correct
service intervals.
To remove water and sediment from the fuel tank, turn the
upperstructure until the fuel tank is centered between the
rear tracks.
Open the drain valve (Item 1) [A] at the bottom of the fuel 1
tank.
Drain contaminated fuel into a container.
Removing Air From the Fuel System P–11066
After replacing the fuel filter or when the fuel tank has run
out of fuel, the air must be removed from the fuel system
before starting the engine.
B
Open the vent (Item 1) [B] on the fuel filter housing.
1
P–11065
D
Always clean up spilled fuel or oil. Keep heat,
flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285
1
P–11068
320/322 Excavator
–1–8– Service Manual