BOBCAT 320 322 COMPACT EXCAVATOR Service Repair Manual Instant Download (SN 562313001 & Above)

1
X 320/322
Excavator Service Manual (S/N 562313001 Above)
(S/N 517811001 Above)
6724910 (197)
Printed in U.S.A.
? Bobcat Company 1997
2
MAINTENANCE SAFETY
Instructions are necessary before operating or
servicing machine, Read and understand the
Operation Maintenance Manual, 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. W20030199 Safety Alert Symbol This
symbol is used for important safety messages.
When you see this symbol, follow the safety
message to avoid personal injury or death.
CORRECT B10731
CORRECT B14148
CORRECT B14142
Use the correct procedure to lift and support
the excavator. Always lift the blade fully
before installing jackstands.
Cleaning and maintenance are required daily.
Never service the Bobcat Hydraulic Excavator
without instructions.
WRONG B14141
WRONG B14145
WRONG B14147
Have good ventilation when welding or grinding
painted parts. Wear dust mask when grinding
painted parts. Toxic dust and gas can be
produced.
Vent exhaust to outside when engine must be run
for service. Exhaust system must be tightly
sealed. Exhaust fumes can kill without warning.
Always lower the bucket and blade to the ground
before doing any maintenance. Never modify
equipment or add attachments not approved by
Bobcat Company.
WRONG B14146
WRONG B14143
WRONG B6589
Stop, cool and clean engine of flammable
materials before checking fluid. Never service
or adjust machine with the engine running unless
instructed to do so in the manual. Avoid contact
with leaking hydraulic fluid or diesel fuel
under pressure. It can penetrate the skin or
eyes. Never fill fuel tank with engine running,
while smoking or when near open flame.
Keep body, jewelry and clothing away from moving
parts, electrical contacts, hot parts and
exhaust. Wear eye protection to guard from
battery acid, compressed springs, fluids under
pressure and flying debris when engines are
running or tools are used. Use eye protection
approved for type of welding. Keep rear door
closed except for service. Close and latch door
before operating the excavator.
Leadacid batteries produce flammable and
explosive gases. Keep arcs, sparks, flames and
lighted tobacco away from batteries. Batteries
contain acid which burns eyes or skin on
contact. Wear protective clothing. If acid
contacts body, flush well with water. For eye
contact flush well and get immediate medical
attention.
Maintenance procedures which are given in the
Operation Maintenance Manual can be performed
by the owner/operator without any specific
technical training. Maintenance procedures which
are not in this manual must be performed ONLY BY
QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW200500
3
ALPHABETICAL INDEX
ACCUMULATOR . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 21 AIR BAFFLE . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 41 AIR CLEANER . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 71 AIR
CLEANER SERVICE . . . . . . . . . . . . . . . . .
. . . . . . 11 ALTERNATOR . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 61
ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . .
. . 11 ARM . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
51 ARM BUSHINGS . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 51 ARM CYLINDER .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 21 AUXILIARY FLUSH FACE COUPLERS . .
. . . . . . . . . 21
FUEL INJECTION PUMP . . . . . . . . . . . . . . .
. . . . . . . . 71 FUEL LEVEL SENDER . . . . . .
. . . . . . . . . . . . . . . . . . . 61 FUEL
SHUTOFF SOLENOID . . . . . . . . . . . . . . . .
. . . . 71 FUEL SYSTEM . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 11 FUEL
TANK . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 31
GAS SPRING . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 31 GLOW PLUGS . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 71
HEATER AIR FILTER . . . . . . . . . . . . . . . .
. . . . . . . . . . . 11 HORN . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 61 HYDRAULIC CONTROL VALVE . . . .
. . . . . . . . . . . . . 21 HYDRAULIC CYLINDER
. . . . . . . . . . . . . . . . . . . . . . . .
21 HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . .
81 HYDRAULIC FILTER ASSEMBLY . . . . . . . . .
. . . . . . . 21 HYDRAULIC PUMP . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
21 HYDRAULIC RESERVOIR . . . . . . . . . . . . .
. . . . . . . . . 31 HYDRAULIC SERVICE
INFORMATION . . . . . . . . . . . 21 HYDRAULIC
SYSTEM . . . . . . . . . . . . . . . . . . . . .
. . . . . 11
BATTERY . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 61 BATTERY BOX .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 61 BELLY PAN . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
41 BELT GUARD . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 71 BLADE
CYLINDER . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 21 BLADE LEVER . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
31 BOOM . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 51 BOOM
BUSHING . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 51 BOOM CYLINDER . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
21 BOOM SWING CYLINDER . . . . . . . . . . . . .
. . . . . . . . . 21 BUCKET . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 BUCKET CYLINDER . . . . . . . . . . . .
. . . . . . . . . . . . . . . 21 BUCKET
SPECIFICATIONS . . . . . . . . . . . . . . . . .
. . . . 81
IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . .
. . . . . 71
JOYSTICK . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 31 JOYSTICK
CONTROL CHANGE . . . . . . . . . . . . 11, 21
CAB . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 41
CAB/CANOPY REAR COVER . . . . . . . . . . . . . .
. . . . . 41 CAB ELECTRICAL (Cab Option) . . . .
. . . . . . . . . . . . . 61 CENTER SWIVEL JOINT
. . . . . . . . . . . . . . . . . . . . . . . 41
CONTROL CONSOLE LEFT HAND . . . . . . . . . . .
. . . 31 CONTROL CONSOLE RIGHT HAND . . . . . .
. . . . . . . 31 CONSOLE COVER LEFT HAND . . . .
. . . . . . . . . . . . . 31 CONSOLE COVER RIGHT
HAND . . . . . . . . . . . . . . . . 31 COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 11 CORNER POSTS . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
51 COUNTER WEIGHT . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 51 CRANKSHAFT AND
BEARINGS . . . . . . . . . . . . . . . . . 71
CRANKSHAFT GEAR . . . . . . . . . . . . . . . . .
. . . . . . . . . 71 CYLINDER BORE . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
71 CYLINDER HEAD . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 71
LATCH HOOK . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 31 LIGHT SWITCH . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 61 LINKAGE RODS . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 31 LOCK
LEVER . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 31 LUBRICATION OF THE
HYDRAULIC EXCAVATOR 11
MAIN RELIEF VALVES (Adjustable) . . . . . . . . .
. . . . . 21 MAINTENANCE SAFETY . . . . . . . .
. . . . . . . . . . . . . . . 11 MICROSWITCH . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 31
OIL PUMP . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 71 OIL
SPECIFICATIONS . . . . . . . . . . . . . . . . .
. . . . . . . . . 81
PEDAL LEFT HAND . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 31 PEDAL RIGHT HAND . . .
. . . . . . . . . . . . . . . . . . . . . . . 31
PISTON AND CONNECTING ROD . . . . . . . . . . .
. . . . 71 PORT RELIEF VALVES . . . . . . . . .
. . . . . . . . . . . . . . . . 21
DRAIN BLOCK . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 21 DRIVE MOTOR . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31
RADIATOR . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 71 ROCKER ARM
AND SHAFT . . . . . . . . . . . . . . . . . . . .
. 71 ROCKERSHAFT . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 31 ROPS CANOPY .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 41
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . .
. . . . 11, 61 ENGINE . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 71 ENGINE COMPRESSION . . . . . . . . . . . .
. . . . . . . . . . . 71 ENGINE COVER . . . . .
. . . . . . . . . . . . . . . . . . . . . 11,
51 ENGINE FLYWHEEL . . . . . . . . . . . . . . .
. . . . . . . . . . . . 71 ENGINE LUBRICATION
SYSTEM . . . . . . . . . . . . . . . . 11 ENGINE
SPECIFICATIONS . . . . . . . . . . . . . . . . .
. . . . 81
SEAT AND SEAT MOUNT . . . . . . . . . . . . . . .
. . . . . . . . 51 SERVICE SCHEDULE . . . . . .
. . . . . . . . . . . . . . . . . . . . 11
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . .
11, 71 SPEED CONTROL LEVER/SWING LOCK LEVER .
51 STARTER . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 61 SWING
CIRCLE GEAR . . . . . . . . . . . . . . . . . . .
. . . . . . 41 SWING MOTOR . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 41 SWING
POST . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 51
FAN GUARD . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 71 FINAL DRIVE CASE
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 FLOOR MAT AND FLOOR PANELS . . . . . .
. . . . . . . . 31 FUEL CAMSHAFT . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 71
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . .
. . 81 FUEL INJECTOR NOZZLES . . . . . . . . .
. . . . . . . . . . . . 71
Continued On Next Page
320/322 Excavator Service Manual
Revised July 05
4
ALPHABETICAL INDEX (CONTD) TIMING GEARS . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 71 TIMING GEARCASE COVER . . . . . . . . .
. . . . . . . . . . . 71 TRACK . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 51 TRACK DAMAGE IDENTIFICATION . .
. . . . . . . . . . . . 51 TRACK FRAME . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 TRACK FRAME EXPANSION CYLINDER (322
(S/N 517811001 Above) . . . . . . . . . . . . .
. . . . . 21 TRACK TENSION . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 11 TRAVEL
LEVERS . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 31 TROUBLESHOOTING . . . . . .
. . . . . . . . . . . 21, 61, 71 TWO SPEED
SWITCH . . . . . . . . . . . . . . . . . . . . .
. . . . 61 UPPER CONSOLE . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
31 UPPERSTRUCTURE . . . . . . . . . . . . . . .
. . . . . . . . . . . . 41 VALVE CLEARANCE . .
. . . . . . . . . . . . . . . . . . . . . . . . .
71 VALVE, VALVE SEAT AND GUIDE . . . . . . . .
. . . . . . . 71 WATER PUMP . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 71
320/322 Excavator Service Manual
Revised July 05
5
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
6
CONTENTS
PREVENTIVE MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . iii SAFETY INSTRUCTIONS . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . v SERIAL NUMBER
LOCATIONS . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . viii DELIVERY
REPORT . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
viii HYDRAULIC EXCAVATOR IDENTIFICATION . . . .
. . . . . . . . . . . . . . . . . . . . . ix
PREVENTIVE MAINTENANCE . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
11 HYDRAULIC SYSTEM . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 21 DRIVE SYSTEM . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 31 UPPER WORKS
SWING SYSTEM . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 41 MAIN FRAME TRACKS
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 51 ELECTRICAL
SYSTEM . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
61 ENGINE SERVICE . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 71 TECHNICAL DATA . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 81
HYDRAULIC SYSTEM
DRIVE SYSTEM
UPPER WORKS SWING SYSTEM MAIN FRAME
TRACKS
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
320/322 Excavator Service Manual
Revised July 05
i
7
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/ FOGS is in
good condition and is not modified.
9. Safety treads must in good condition.
2. Check that ROPS/TOPS
10. Check for correct function of indicator
lamps (Optional on some models).
mounting hardware is
tightened and is Melroe approved.
3. The seat belt must be correctly installed,
functional and in good condition.
11. Check hydraulic fluid level, engine oil
level and fuel supply.
12. Inspect for fuel, oil or hydraulic fluid
leaks.
4. Inspect for loose or broken parts or
connections.
5. Machine signs must be legible and in the
correct location.
13. Lubricate the excavator.
6. Steering levers, control levers and foot
pedals must return to neutral. Check that foot
pedals lock and control lever locks are in
working condition.
14. Check the condition of the battery and
cables.
7. Inspect the air cleaner for damage or leaks.
Check the condition of the element.
Recommend to the owner that all necessary
corrections be made before the machine is
returned to service.
8. Check the electrical charging system.
CALIFORNIA PROPOSITION 65 WARNIN9 Diesel engine
exhaust and some of its constituents are know to
the state of California to cause cancer, birth
defects and other reproductive harm.
320/322 Excavator Service Manual
Revisedy July 05
iii
8
SAFETY INSTRUCTIONS
Safety Alert Symbol This symbol with a warning
statement means Warning, be alert! Your safety
is involved! Carefully read the message that
follows.
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation Maintenance Manual, Operators
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.
W20030903
Warnings on the machine and in the manuals are
for your safety. Failure to obey warnings can
cause injury or
This notice identifies procedures which must be
followed to avoid damage to the
machine. I20190284
death.
W20441285

• 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 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 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 Operators Handbook fastened to the operator
  cab. Its 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 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.
• 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 Bobcat Excavator. The course is avail-
  able in English and Spanish versions.
• Service Safety Training Courses are available
  from your Bobcat dealer or at www.bobcat.com.
  They provide infor- mation for safe and correct
  service procedures.
• The Bobcat Compact Excavator Safety Video is
  available from your Bobcat dealer or at
  www.bobcat.com.
• SI EXC0705

9

• SAFETY INSTRUCTIONS (Contd)
• 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.

• Know where fire extinguishers and first aid kits
  are located
• and how to use them. Fire extinguishers are
  available from your Bobcat dealer A.

A
SI EXC0705 320/322 Excavator Service Manual
Revised July 05
vii
10
SERIAL NUMBER LOCATIONS Always use the FULL
serial number (including the first 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.
A

N00806
ENGINE SERIAL NUMBER The engine serial number is
located on the engine block, near the fuel
injection pump B.
B

P11102
C
DELIVERY REPORT 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 Service Manual
Revised July 05
viii
11
HManual YSD/N562313R001 AboAve
ContUentsSectiLon IC EXCAVATOR
IDENTIFICATION
GRAB HANDLES CONTROL LEVERS (JOYSTICK)
CANOPY (ROPS)
ENGINE COVER UPPERSTRUCTURE
TRACK FRAME
TRACK
GRAB HANDLES
OPERATORS HANDBOOK
ARM CYLINDER
OPERATOR SEAT
AUXILIARY LINES
BUCKET CYLINDER
SEAT BELT
ARM
TOOL BOX (Operators Manual Location)
BUCKET LINK
BLADE CYLINDER
BUCKET
BOOM
BLADE
B14408 B14407
BOOM CYLINDER
320/322 Excavator Service Manual
Added July 05
ix
12
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Page Number
AIR CLEANER SERVICE Daily Check . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 15 Filter
Replacement . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
16 ALTERNATOR BELT ADJUSTMENT . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 111
COOLING SYSTEM Coolant Level . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 110 Coolant
Replacement . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
110 Propylene Glycol (Factory Installed) . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
110 ELECTRICAL SYSTEM Electrical Relays and
Diodes . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 111 Electric
Solenoid (Engine Stop) . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113
Fuses . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 112 Removal and Installation
of the Battery . . . . . . . . . . . . . . . . .
. . . . . . . . . 113 Service the Electrical
System (and Battery) . . . . . . . . . . . . . .
. . . . . . . . . 112 ENGINE COVER Adjustment of
the Engine Cover Latch . . . . . . . . . . . . .
. . . . . . . . . . . . . . 15 ENGINE
LUBRICATION SYSTEM Checking Engine Oil . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 19 Replacement of Oil
and Filter . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 19 FINAL DRIVE
CASE Checking Oil Level . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 118 Draining Final Drive Case . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 118 FUEL SYSTEM Filling the
Fuel Tank . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
17 Fuel Filter . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 17 Fuel Specification . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 18 Fuel System
Maintenance . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
18 Removing Air From the Fuel System . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
18 HEATER AIR FILTER (With Cab Option Only) . .
. . . . . . . . . . . . . . . . . . . . 123
HYDRAULIC SYSTEM Case Drain Hydraulic Filter . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 115 Checking and Adding
Fluid . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 114 Diagnostic
Couplers . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
115 Hydraulic Reservoir . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 115 Replacement of the Hydraulic
Filter . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 115 JOYSTICK CONTROL
CHANGE ISO to Standard Control Pattern . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 119 Standard to ISO Control Pattern . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 120 LUBRICATION OF THE HYDRAULIC
EXCAVATOR . . . . . . . . . . . . . . . . 121
MAINTENANCE SAFETY . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
13 SERVICE SCHEDULE . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 SPARK ARRESTOR MUFFLER (if equipped) .
. . . . . . . . . . . . . . . . . . . . . 116
TRACK TENSION Adjustment . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 117
320/322 Excavator Service Manual
Revised July 05
11
13
MAINTENANCE SAFETY

• Do not continuously apply more than 200 V.
• Install the ground cable (from welder) at least 3
  ft. (1 m) away from the part being welded.
• When attaching ground cable (from welder) make
  sure there are no seals or bearings between the
  ground and the part to be welded.
• Leadacid batteries produce flammable and
  explosive gases. Keep arcs, sparks, flames and
  lighted tobacco away from batteries.
• Do not handle electrical equipment while wearing
  wet gloves, or in wet places, this can cause an
  electrical shock.
• Do not allow unauthorized personnel near the
  machine during maintenance.
• When working under the machine, always place
  signs to that effect on the operators seat and
  around the machine.
• When maintenance is done with equipment raised,
  it must be securely blocked.

• Never service the machine without instructions.
• Cleaning and maintenance are required daily.
• Keep engine cover closed except for service.
  Close and latch the cover before operating.

• Never fill the fuel tank with the engine running,
  while smoking or when near open flame.

• Never modify equipment or add attachments not
  approved by Melroe Company.

• Stop, cool and clean the engine of flammable
  materials before checking fluid levels.

• Never service or adjust machine with engine
  running unless instructed to do so in this
  manual.

• Keep body, loose objects and clothing away from
  moving parts, electrical contracts, hot parts and
  exhaust. Never wear loose clothing or jewelry
  around machinery.

• Relieve pressure on work cylinders as follows
• Lower work equipment to the ground. Stop the
  engine.
• Operate all the control levers through their
  functions.

• Avoid contact with leaking hydraulic fluid or
  diesel fuel which is under pressure, it can
  penetrate the skin and eyes.

Wear safety glasses to prevent eye injury when
any of the following conditions exist

• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
• Do not check alternator belt tension with engine
  running. Stop the engine before inspecting any
  rotating parts.

NOTE Control console must be lowered to the
latched position with the key in the run
position to activate the joystick function and
relieve the accumulator pressure.

• 3. Loosen the cap on the hydraulic tank.
• When working on rocky ground, avoid damage to the
  under carriage. Check for loose nuts and bolts,
  cracks and other damage.
• Before working in water, rain or snow, check that
  plugs and valves are tightened. When finished,
  wash the machine, then check for cracks, loose
  or missing nuts or bolts. Lubricate the machine.

• Always disconnect the negative () cable from the
  battery before doing electrical maintenance or
  welding.

• When tracks are adjusted, do not put your
  fingers between the track and rollers.
• Perform only the service procedures shown in this
  manual unless you have had special Bobcat
  Hydraulic Excavator training.
• When welding on the machine, do the following
• 1. Disconnect the negative () cable at the
  battery.

320/322 Excavator Service Manual
Revised July 05
13
14
SERVICE SCHEDULE Maintenance work must be done
at regular intervals. Failure to do so will
result in excessive wear and early failures. The
service schedule is a guide for correct
maintenance of the Hydraulic Excavator. Instructi
ons are necessary before operating or servicing
machine. Read Operation Maintenance Manual,
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. Failure to follow instructions can
cause injury or death. W20031089

ITEM SERVICE REQUIRED 810 50 100 250 500 1000
Engine Air Cleaner Check and empty dust cap as required.
Engine Oil Check the oil level add oil as needed.
Engine Coolant System Check radiator coolant level.
Indicator Lights Check for correct operation.
Operator Cab Check the fastening bolts, nuts, condition of cab/canopy.
Seat Belt Check the condition that fasteners are tight.
Safety Signs (Decals) Check for damaged signs (decals) replace as needed.
Tracks Check adjust tension.
All Machinery Pivot Points Lubricate 21 grease fittings.
Hyd. Fluid, Hoses Tubelines Check fluid level add as needed. Check for damage leaks. Repair replace as needed.
Battery Check clean cable ends check electrolyte level. Add distilled water as needed.
Fuel Tank/Fuel Filter Drain water sediment from fuel tank/fuel filter.
Swing Circle Lubricate two grease fittings.
Swing Pinion Lubricate one grease fitting.
Spark Arrestor Muffler Clean spark chamber.
Alternator/Fan Belt Check adjust tension.
Engine Oil Filter Replace oil filter element.
Final Drive Case Check fluid level add oil as needed.
Fuel Filter Replace filter element.
Air Cleaner Element Replace Air Cleaner Element
Cooling System Clean the radiator fins.
Alternator Starter Check the condition and connections.
Hydraulic Filter Replace filter element.
Case Drain Hydraulic Filter Replace filter.
Engine Valve Clearance Check and adjust as needed
Cooling System Drain, flush add new coolant to the cooling system.
Hydraulic Tank Change the fluid, clean fill neck strainer.
Final Drive Case Change the oil.
Cab Heater Air Filter Clean the filter.

• After the first 50 hours of machine operation do
  the following
• Replace the engine oil and filter.
• Check the condition of the alternator/fan belt.
• After the first 100 hours of machine operation
  do the following procedures
• Change oil in final drive case.
• Clean case drain filter.
• Replace hydraulic filter. Or Every 12 Months.

320/322 Excavator Service Manual
Revised July 05
14
15
ENGINE COVER
A

P11057
AVOID INJURY Never service or adjust the machine
when the engine is running unless instructed to
do so in this manual. W20120290 Keep the
engine cover closed when operating the
machine. W21410189
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. Adjustment of the Engine
Cover Latch Open the engine cover. Loosen the
nuts and adjust the stop (Item 1) B. Tighten
the nuts when the stop (Item 1) B is in the
correct position. Loosen the two bolts (Item 2)
B and adjust the striker plate (Item 3) B
until it is in the correct position. Tighten the
two bolts (Item 2) B.
3
2
1
2
P11058
AIR CLEANER SERVICE See the SERVICE SCHEDULE
Page 14 for the correct service
interval. Service the air cleaner as
follows Daily Check. Loosen the clamp (Item 1)
C on the air cleaner. Remove the cover (Item
2) C.
C
2 1 2 1 2 1
P11059
D
Remove the dust cup (Item 1) D from the
cover. Remove the left side cover and visually
inspect the filter element. Do not remove the
element unless it is plugged and replacement is
necessary.
1
P11060
320/322 Excavator Service Manual
15
16
AIR CLEANER SERVICE (Contd) Filter
Replacement Remove the wing nut (Item 1) A and
the filter element (Item 2) A.
A
2 1 2 1 2 1
P11061
Check the air cleaner housing for damage. Wipe
the canister and the seal surface clean with a
clean cloth. Do Not use compressed air. Check
the seal (Item 1) B for damage. Do not use an
air filter element with a damaged seal. Install
a new air filter element. Install and tighten the
wing nut. Install the dust cup and cover so the
arrow points up. Check that all the air cleaner
hose clamps are tight.
B
1
P11062
320/322 Excavator Service Manual
16
17
FUEL SYSTEM Filling the Fuel Tank
A
2 1 2 1 2 1
P11035
Stop and cool the engine before adding fuel.
NO SMOKING! Failure to obey warnings can cause
an explosion or fire. W20630887
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 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
and lock the fuel door.
B

P11063
C

P11064
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. W21031285 Fuel Filter See
the SERVICE SCHEDULE Page 14 for the service
interval when to replace the fuel filter. The
fuel filter is located under the left hand side
of the 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. Remove the
filter element (Item 2) D. 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.
D
2 1 2 1 2 1
P11065
320/322 Excavator Service Manual
17
18
FUEL SYSTEM (Contd) Fuel System Maintenance See
the SERVICE SCHEDULE Page 14 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 tank. Drain contaminated fuel
into a container. Removing Air From the Fuel
System 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. Open the vent (Item 1) B on the
fuel filter housing.
A
1 1 1
P11066
B
1 1 1
P11067
Operate the hand pump (priming bulb) (Item 1) C
until the fuel flows from the vent with no air
bubbles. Tighten the vent plug. Start the
engine. It may be necessary to open the vent
(Item 1) D at the fuel injection pump briefly
until the engine runs smoothly. Fuel
Specification Use only clean, high quality diesel
fuel, Grade No. 1 or Grade No.2. The following
is suggested blending guideline which should
prevent fuel gelling problems. Temp. F? No. 2 No.
1
C
15?(9?c) Down to 20? (29?c) Below 20? (29?c)
100 50 0
0 50 100
For local recommendations, the operator can
contact his fuel supplier.
1
P11065
D
1 1 1
P11068
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. W21031285
320/322 Excavator Service Manual
18
19
ENGINE LUBRICATION SYSTEM Checking Engine
Oil Check the engine oil every day. Stop the
engine. Open the engine cover. Remove the
dipstick (Item 1) A. Keep the oil level between
the marks on the dipstick. Use a good quality
motor oil that meets the correct API Service
Classification. (See Fuel, Coolant and
Lubrication Chart, Page 81.) Replacement of
Oil and Filter See the SERVICE SCHEDULE Page 14
for the correct service interval. Run the
engine until it is at operating temperature. Stop
the engine. Open the engine cover. Remove the
drain plug (Item 1) B from the oil pan. Drain
the oil into a container.
A
1 1 1
P11069
B
1 1 1
P11070
Remove the oil filter (Item 1) C, using a
filter wrench. Clean the filter housing surface.
Put clean oil on the filter gasket. Install the
new filter and hand tighten only. Install and
tighten the oil drain plug.
C
1
P11071
D
1 1 1
P11072
Remove the oil fill cap (Item 1) D. Put in 3.4
qts. (3,2 L) of oil into the engine. (See Fuel,
Coolant and Lubricants Chart, Page 81.) Start
the engine and let it run for several
minutes.Stop the engine. Check for leaks at the
oil filter and the oil drain plug. Check the
oil level and add oil as needed if it is not at
the top mark on the dipstick.
320/322 Excavator Service Manual
19
20
COOLING SYSTEM Coolant Level When the engine is
cool, remove the radiator cap (Item 1) A. The
coolant level must be 3/4 to 1 inch (19 to 25 mm)
below the filler neck. If the coolant level is
low, add premixed coolant to the radiator. (See
type of coolant information below.) Coolant
Replacement Turn the upperstructure so there is
access to the engine and radiator from between
the tracks. Stop the engine. When the engine is
cool, loosen and remove the radiator cap (Item
1) A. Open the radiator drain valve (Item 1)
B at bottom of radiator. Drain the coolant
into a container.
A
1 1 1
P11073
B
1 1 1
P11074
C
Open the engine block drain valve (Item 1) C
and drain the coolant into a container. After
all the coolant is removed, close both drain
valves.
Propylene Glycol (Factory Installed) Add
premixed coolant 47 water and 53 propylene
glycol to the recovery tank if the coolant level
is low. 1 gallon and 1 pint of propylene glycol
mixed with 1 gallon of water is the correct
mixture of coolant to provide a 34?F (37?C)
freeze protection. Use a refractometer to check
the condition of propylene glycol in your
cooling system. Fill the radiator with the
premixed coolant until it is 3/4 to 1 in. (19 to
25 mm) below the filler neck. Run the engine at
idle speed for about 5 to 10 minutes to remove
the air from the cooling system (leave the
radiator cap off during this operation). Stop
the engine. Check the coolant level and add as
needed to bring it up to the radiator filler
neck. Install the radiator cap and tighten.
1
P11075
Do not remove radiator cap when the engine is
hot. You can be seriously burned. W20701285
320/322 Excavator Service Manual
110
21
ALTERNATOR BELT ADJUSTMENT To adjust the belt
tension, use the following procedure Stop the
engine. Open the engine cover. The belt should
deflect about 1/2 in. (13 mm) when pressed
between the water pump pulley and crankshaft
pulley with approximately 13 ft.lb. (58 Nm)
pressure A. If the tension is not
correct, Loosen the alternator mounting bolt
(Item 1) A. Loosen the alternator adjustment
bolt (Item 2) A. Move the alternator until the
belt tension is correct. Tighten the adjustment
bolt and mounting bolt. Replace the belt if it
has stretched or there are cracks in the belt.
Check the pulley grooves, make sure the belt is
not in contact with the bottom of the grooves in
the pulleys. ELECTRICAL SYSTEM Electrical
Relays and Diodes The 3 engine harness
electrical relays (Item 1) B and the fuel shut
off timer (Item 2) B are located in the engine
compartment to the right of the air cleaner. The
3 relays (Item 1) B control the starter, glow
plugs and switched power circuits. The 2 diodes
(Item 1) C, are for alternator feedback
protection and the glow plug during start
function.
A
2 1 2 1 2 1
P11076
B
1 2 1 2 1 2
P11036
C
1 1 1
P11077
320/322 Excavator Service Manual
111
22
ELECTRICAL SYSTEM (Contd) The excavator has a
12 volt, negative ground electrical
system. Fuses The fuses are located in the right
side of the engine compartment A.
A

P11036

• FUSE 10 AMP This fuse supplies power to the
  instrument circuit B.
• FUSE 15 AMP This fuse supplies power to any
• accessory that is powered when the key is in the
  run position B.
• FUSE 20 AMP This fuse supplies power to the
• ignition circuit B.
• FUSE 15 AMP This fuse supplies power to the
  cab wiring (if equipped) B.
• FUSE 15 AMP This fuse supplies power to any
• accessory that has constant power B.
• FUSE 15 AMP This fuse supplies power to the
  timer B.
• FUSE 15 AMP This fuse supplies power to the
• timer when it is powered by the ignition switch
  B.
• NOT USED

B
6
3
4
5
Replace all fuses with the same type and
capacity. NOTE Before replacing any fuse, find
and fix the problem that caused the circuit
overload. Make sure the key switch is in the OFF
position before replacing the fuse. Service the
Electrical System (and Battery) Remove the left
side cover C, using the ignition key to unlock
the cover. The battery cables must be clean and
tight. Remove any acid or corrosion from the
battery and cables using a sodium bicarbonate
and water solution. Cover the battery terminals
and cable ends with battery saver grease
D. Check for broken or loose connections. If
the battery cables are removed for any reason,
disconnect the negative () cable first and when
installing the battery cables, make the last
connection the negative () cable to the
battery. With factory equipped battery, no
maintenance is needed as this is a maintenance
free battery. If the machine has a Bobcat parts
replacement battery installed, check the
electrolyte level in the battery. If it is lower
than 1/2 in. (13 mm) above the plates, add
distilled water only.
7
1
2
8
B14855
C

P11063
D

P11098
Batteries contain acid which burns eyes and skin
on contact. Wear goggles and protective
clothing to keep acid off body. In case of acid
contact, wash immediately with water for several
minutes and get medical attention in case of eye
contact. W22010595
320/322 Excavator Service Manual
112
23
ELECTRICAL SYSTEM (Contd) Removal and
Installation of the Battery Remove the side
cover. (See Page 112.) Disconnect the negative
() cable (Item 1) A first. Disconnect the
positive () cable (Item 2) A.
A
2 1 2 1 2 1
P11098
Remove the bolt (Item 1) B and remove the hold
down clamp (Item 2) B.
B
2 1 2 1 2 1
P11100
Remove the battery from the compartment
C. Always clean the terminals and the cable
ends, even when installing a new
battery. Install the battery. Install the hold
down clamp and tighten the bolt. Connect the
battery cables. Connect the negative () cable
(Item 1) A last to prevent sparks at the
terminal.
C

P11101
Batteries contain acid which burns eyes and skin
on contact. Wear goggles, protective clothing
and rubber gloves to keep acid off body. In case
of acid contact, wash immediately with water for
several minutes and get medical attention in
case of eye contact. W20651286 Electric
Solenoid (Engine Stop) The electric solenoid
(Item 1) D shuts off fuel supply and stops the
engine when the key is turned to the OFF
position.
D
1 1 1
P11078
320/322 Excavator Service Manual
113
24
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
25
HYDRAULIC SYSTEM Checking and Adding Fluid To
check and add hydraulic fluid to the reservoir,
use the following procedure Put the machine on
a flat level surface. Retract the arm and bucket
cylinders, put the bucket on the ground and
raise the blade. Stop the engine. Check the
hydraulic fluid level, it must be visible in the
sight gauge (Item 1) A located on the side of
the hydraulic reservoir.
A
1 1 1
P11079
B

P11080
If the fluid level is not correct, use the
ignition key and open the right side cover B.
Remove oil fill cap C.
C

P11081
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. W21031285
Check the condition of the fill strainer D. The
screen must be installed in fill neck when
adding oil. Add the correct fluid to the
reservoir until it is visible in the sight
gauge. (See Fuel, Coolant and Lubricants Chart,
Page 81.) Install the reservoir cap. Close and
lock the access door.
D

P11103
320/322 Excavator Service Manual
114
26
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com