Bobcat 320 322 Service Manual 6902668 (10-12) – PDF DOWNLOAD

Description

Bobcat 320 322 Service Manual 6902668 (10-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 320 322 Service Manual 6902668 (10-12) – PDF DOWNLOAD

Language : English
Pages : 707
Downloadable : Yes
File Type : PDF
Size:19.8 MB

DESCRIPTION:

Bobcat 320 322 Service Manual 6902668 (10-12) – PDF DOWNLOAD

320 – S/N 223911001 & Above
322 – S/N 224011001 & Above
(G Series)

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

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.

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 shop-type service and repair work.
• The Compact Excavator Operator Training Course is available through your local dealer or at This course is intended to provide rules and practices of correct operation of the Bobcat excavator. The course is available in English and Spanish versions.
• Service Safety Training Courses are available from your Bobcat dealer or at .bobcat.com or They provide information for safe and correct service procedures.
• The Bobcat compact excavator Safety Video is available from your Bobcat dealer or at

TABLE OF CONTENTS:

Bobcat 320 322 Service Manual 6902668 (10-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
SWING LOCK 23
LIFTING THE EXCAVATOR 25
OPERATOR CAB ROPS/TOPS 27
Emergency Exits 27
Cab Door 27
Front Window 28
Right Side Windows 30
TRANSPORTING THE EXCAVATOR 31
TAILGATE 33
Opening And Closing The Tailgate 33
Adjusting The Bumper 33
Adjusting The Tailgate Latch 33
SERVICE SCHEDULE 35
Chart 35
AIR CLEANER SERVICE 37
Daily Check 37
Replacing The Filters 37
HEATER AIR FILTERS 39
Recirculation Filter 39
Fresh Air Filter 39
ENGINE COOLING SYSTEM 41
Cleaning The Cooling System 41
Checking Coolant Level 41
Replacing The Coolant 42
FUEL SYSTEM 45
Fuel Specifications 45
Filling The Fuel Tank 45
Removing Water From The Fuel Filter 46
Replacing The Fuel Filter 46
Draining The Fuel Tank 47
Removing Air From The Fuel System 47
ENGINE LUBRICATION SYSTEM 49
Checking Engine Oil 49
Oil Chart 49
Replacing Oil And Filter 50
HYDRAULIC SYSTEM 51
Checking And Adding Hydraulic Oil 51
Diagnostic Couplers 51
Replacing The Hydraulic Filter 52
Replacing Hydraulic Oil 52
LUBRICATION OF THE HYDRAULIC EXCAVATOR 55
TRAVEL MOTOR 59
Checking Oil Level 59
Draining The Travel Motor 59
SPARK ARRESTOR MUFFLER 61
ALTERNATOR BELT 63
Adjusting The Alternator Belt 63
SEAT BELT 65
Inspection And Maintenance 65
CONTROL CONSOLE LOCKOUTS 67
Inspection And Maintenance 67
HYDRAULIC SYSTEM 69
HYDRAULIC/HYDROSTATIC SCHEMATICS 73
HYDRAULIC SYSTEM INFORMATION 77
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators 77
Troubleshooting The Hydraulic Circuit 80
Troubleshooting The Cylinder Circuit 81
Troubleshooting The Swing (Upperstructure Slew) Circuit 82
Troubleshooting The Travel Circuit 83
BOOM CYLINDER 85
Testing 85
Removal and Installation 87
Parts Identification 89
Disassembly 90
Assembly 91
ARM CYLINDER 95
Testing 95
Removal and Installation 96
Parts Identification 98
Disassembly 99
Assembly 101
BOOM SWING CYLINDER 105
Testing 105
Removal and Installation 106
Parts Identification 109
Disassembly 110
Assembly 112
BUCKET CYLINDER 115
Testing 115
Removal and Installation 116
Parts Identification 118
Disassembly 119
Assembly 121
BLADE CYLINDER 125
Testing 125
Removal and Installation 127
Parts Identification 129
Disassembly 130
Assembly 132
TRACK FRAME EXPANSION CYLINDER 135
Testing 135
Removal And Installation 136
Parts Identification 140
Disassembly 141
Assembly 142
MAIN RELIEF VALVE 147
Testing And Adjusting The Main Relief Valve 147
PORT RELIEF VALVES 149
Testing And Adjusting The Port Relief Valve Pressure 149
CROSSPORT RELIEF VALVES 151
Testing And Adjusting The Crossport Relief Valve 151
PRESSURE REDUCING VALVE 153
Testing And Adjusting The Pressure Reducing Valve 153
HYDRAULIC CONTROL VALVE (320 / 322) 155
Description 155
Removal And Installation 155
Parts Identification 158
Disassembly 159
Auxiliary Valve Section Disassembly And Assembly 160
Blade Valve Section Disassembly And Assembly 164
Slew Valve Section Disassembly And Assembly 167
Left Travel Valve Section Disassembly and Assembly 171
Boom Valve Section Disassembly and Assembly 174
Bucket Valve Section Disassembly and Assembly 177
Arm Valve Section Disassembly and Assembly 181
Boom Swing Valve Section Disassembly And Assembly 184
Right Travel Valve Section Disassembly And Assembly 187
Assembly 191
HYDRAULIC CONTROL VALVE (320L) 197
Description 197
Removal And Installation 197
Parts Identification 200
Disassembly 201
Auxiliary Valve Section Disassembly And Assembly 202
Blade Valve Section Disassembly And Assembly 206
Slew Valve Section Disassembly And Assembly 209
Left Travel Valve Section Disassembly And Assembly 213
Boom Valve Section Disassembly And Assembly 216
Bucket Valve Section Disassembly And Assembly 219
Arm Valve Section Disassembly And Assembly 223
Boom Swing Valve Section Disassembly And Assembly 226
Right Travel Valve Section Disassembly And Assembly 229
Assembly 233
HYDRAULIC PUMP 239
Testing The Hydraulic Pump 239
Removal And Installation 241
Coupler Removal And Installation 242
Parts Identification 243
Disassembly 244
Assembly 246
MANIFOLD ASSEMBLY/ACCUMULATOR 251
Description 251
Removal And Installation 251
Parts Identification (S/N 223911001 – 223911247 & S/N 224011001 – 224012293) 253
Disassembly (S/N 223911001 – 223911247 & S/N 224011001 – 224012293) 254
Assembly (S/N 223911001 – 223911247 & S/N 224011001 – 224012293) 263
Parts Identification (S/N 223911248 & Above & S/N 224012294 & Above) 272
Disassembly (S/N 223911248 & Above & S/N 224012294 & Above) 273
Assembly (S/N 223911248 & Above & S/N 224012294 & Above) 286
TRAVEL MOTOR 299
Removal and Installation 299
Parts Identification 300
Disassembly 301
Assembly 308
SWIVEL JOINT 317
Removal And Installation 317
Parts Identification 320 320
Parts Identification 322 321
Disassembly 322
Assembly 326
SWING MOTOR 331
Removal and Installation 331
Parts Identification 332
Disassembly 333
Assembly 339
CONTROL PATTERN SELECTOR VALVE 347
Removal And Installation 347
Parts Identification 349
Disassembly 350
Assembly 351
RIGHT CONTROL LEVER (JOYSTICK) 353
Testing 353
Handle Removal And Installation 355
Removal And Installation 356
Parts Identification 358
Disassembly 359
Assembly 364
LEFT CONTROL LEVER (JOYSTICK) 371
Testing 371
Handle Removal And Installation 373
Removal And Installation 375
Parts Identification 376
Disassembly 377
Assembly 382
HYDRAULIC FILTER MOUNT 387
Removal and Installation 387
HYDRAULIC RESERVOIR 389
Removal and Installation 389
OIL COOLER 391
Removal And Installation 391
UNDERCARRIAGE 393
BLADE 395
Extension Removal And Installation 395
Blade Removal And Installation 395
TRACKS 397
Track Lug Height 397
Adjustment 398
Removal And Installation 400
TRACK FRAME 401
Disassembly And Assembly 401
Removal And Installation Of Expandable Track Frame (322 Only) 402
Recoil Spring Disassembly And Assembly 403
TRACK DAMAGE IDENTIFICATION 405
Cutting Of The Steel Cords 405
Causes Of The Damage 405
Abrasion Of Embedded Metals 406
Separation Of Embedded Metals 407
Separation Of Embedded Metals Due To Corrosion 408
Cuts On The Lug Side Rubber 409
Cracks On The Lug Side Rubber Due To Fatigue 410
Lug Abrasion 411
Cracks And Cuts On The Lug Side Rubber 412
Abrasion Of The Track Roller Side 413
Cuts On The Edges Of The Track Roller Side 414
TRACK IDLER 417
Parts Identification 417
Disassembly 418
Assembly 420
TRACK ROLLER 423
Parts Identification 423
Disassembly 424
Assembly 426
SWING CIRCLE GEAR 429
Removal and Installation 429
UPPERSTRUCTURE & SWING SECTION 431
UPPERSTRUCTURE 435
Removal 435
Installation 437
ROPS CANOPY 439
Removal And Installation 439
CAB 443
Removal And Installation 443
Door Removal And Installation 447
Front Window Removal And Installation 448
Right Side Rear Sliding Window Removal And Installation 451
Right Side Front Sliding Window Removal And Installation 452
Glass Removal 452
Glass Installation 453
Glass Installation (Cont’d) 454
SEAT AND SEAT MOUNT 455
Removal And Installation 455
RIGHT CONSOLE 457
Console Cover Removal And Installation (Cab Models 320L, 320, 322 & ROPS Canopy Model 320L) 457
Console Cover Removal And Installation (ROPS Canopy Models 320 & 322) 460
Gas Spring Removal And Installation (ROPS Canopy Models 320 & 322) 463
Lock Lever Removal And Installation (ROPS Canopy Models 320 & 322) 464
Adjustment (ROPS Canopy Models 320 & 322) 466
Latch Hook Removal And Installation (ROPS Canopy 320 & 322) 466
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320 & 322) 467
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L) 468
Upper Console Removal And Installation 469
Console Base Removal And Installation 470
LEFT CONSOLE 473
Console Cover Removal And Installation 473
Gas Spring Removal And Installation 475
Lock Lever Removal And Installation 476
Adjustment 478
Latch Hook Removal And Installation 479
Latch Hook Disassembly And Assembly 480
Upper Console Removal And Installation 481
Console Base Removal And Installation 482
ENGINE SPEED CONTROL 485
Removal and Installation 485
Engine Speed Control Cable Removal and Installation 486
BLADE CONTROL 489
Removal and Installation 489
Disassembly And Assembly 490
RIGHT PEDAL 493
Right Pedal Removal And Installation 493
Disassembly And Assembly 494
Linkage Removal And Installation 495
Linkage Disassembly And Assembly 495
LEFT PEDAL 497
Removal And Installation 497
Disassembly And Assembly 498
TRAVEL CONTROLS 499
Removal And Installation 499
Disassembly And Assembly 499
CONTROL LINKAGE ASSEMBLY 501
Removal And Installation 501
Left Pedal Linkage Disassembly And Assembly 502
Right Travel Control Linkage Disassembly And Assembly 503
Left Travel Control Linkage Disassembly And Assembly 504
Linkage Rod Removal And Installation 505
Linkage Rod Adjustment 506
FLOORMAT AND FLOORPLATES 507
Removal and Installation 507
FUEL TANK 511
Removal and Installation 511
HORN 513
Removal and Installation 513
SWING FRAME 515
Removal And Installation 515
Bushing Replacement 517
Swing Frame Bushing Removal 518
Swing Frame Bushing Installation 518
Boom Pivot Bushing Removal And Installation 519
BOOM 521
Removal And Installation 521
Boom Bushing Removal And Installation 523
ARM 525
Removal And Installation 525
Arm To Boom Bushing Removal And Installation 526
Arm To Bucket And Bucket Link Bushing Removal And Installation 527
BUCKET 529
Removal And Installation 529
TAILGATE 531
Removal And Installation 531
Latch Removal And Installation 532
SWING LOCK 533
Removal and Installation 533
BLADE EXTENSION TRAY 535
Removal And Installation 535
LEFT PEDAL 537
Not Available At Time Of Print 537
ELECTRICAL SYSTEM AND ANALYSIS 539
ELECTRICAL SCHEMATICS 541
ELECTRICAL SYSTEM 542
Troubleshooting Chart 542
Description 543
Fuses 543
Relays And Diodes 543
BATTERY 546
Servicing 546
Removing And Installing The Battery 547
Using A Booster Battery (Jump Starting) 548
ALTERNATOR 550
Description 550
Tests 550
Alternator Output Test 551
Full Field Test 551
Alternator Regulator Test 552
Alternator Regulator Test With Voltmeter 552
Removal And Installation 553
Parts Identification 555
Disassembly And Assembly 555
STARTER 556
Removal And Installation 556
Parts Identification 557
Disassembly And Assembly 557
Cleaning and Inspection 557
LIGHTS 558
Upper Structure Light Removal And Installation 558
Boom Light Removal And Installation 559
Boom Light Disassembly And Assembly 560
Light Switch Removal And Installation 561
TWO-SPEED SWITCH 562
Removal And Installation 562
FUEL LEVEL SENDER 564
Removal and Installation 564
Testing 564
MICROSWITCH 566
Adjustment 566
Testing 568
Removal And Installation 569
ENGINE SERVICE 570
TROUBLESHOOTING 574
Chart 574
SPARK ARRESTOR MUFFLER 576
Removal And Installation 576
AIR CLEANER 578
Removal And Installation 578
RADIATOR 580
Removal And Installation 580
ENGINE COMPONENTS AND TESTING (S/N 223911001 – 223911621, S/N 224011001 – 224013374) 586
Valve Clearance Adjustment 586
Engine Compression Checking 586
Fuel Shut-Off Solenoid Removal And Installation 587
Fuel Shut-Off Timer Removal And Installation 587
Fuel Injection Pump Check 588
Fuel Injection Pump Removal And Installation 589
Fuel Injection Pump Timing 590
Fuel Injector Removal And Installation 592
Fuel Injector Checking 593
Glow Plug Removal And Installation 594
Glow Plug Checking 595
ENGINE COMPONENTS AND TESTING (S/N 223911622 & Above, S/N 224013375 & Above) 596
Valve Clearance Adjustment 596
Engine Compression Checking 597
Fuel Shut-Off Solenoid Removal And Installation 597
Fuel Shut-Off Timer Removal And Installation 598
Fuel Injection Pump Check 598
Fuel Injection Pump Removal And Installation 599
Fuel Injection Pump Timing 601
Fuel Injector Removal And Installation 602
Fuel Injector Checking 603
Glow Plug Removal And Installation 605
ENGINE 606
Removal and Installation 606
ENGINE FLYWHEEL 614
Removal And Installation 614
Hydraulic Pump Coupler 615
Flywheel Ring Gear 615
RECONDITIONING THE ENGINE (S/N 223911001 – 223911621, S/N 224011001 – 224013374) 616
Cylinder Head Removal And Installation 616
Cylinder Head Disassembly And Assembly 617
Cylinder Head, Servicing 618
Cylinder Head Top Clearance 619
Valve Guide, Checking 619
Valve And Valve Seat Reconditioning 621
Valve Spring 622
Rocker Arm And Shaft, Checking 622
Timing Gearcase Cover Removal And Installation 623
Idler Gear And Camshaft Removal And Installation 624
Idler Gear and Shaft, Servicing 627
Timing Gears Checking Backlash 628
Fuel Camshaft Removal And Installation 628
Fuel Camshaft Governor 629
Crankshaft Gear Removal And Installation 629
Oil Pump Removal And Installation 630
Oil Pump, Service 630
Engine Oil Pressure, Checking 631
Relief Valve 632
Piston And Connecting Rod Removal And Installation 632
Piston And Connecting Rod, Servicing 634
Connecting Rod Alignment 636
Crankshaft And Bearings Removal And Installation 637
Crankshaft And Bearings, Servicing 639
Cylinder Bore, Checking 641
Water Pump Removal And Installation 641
Water Pump Disassembly And Assembly 641
RECONDITIONING THE ENGINE (S/N 223911622 & Above, S/N 224013375 & Above) 642
Cylinder Head Removal And Installation 642
Cylinder Head Disassembly And Assembly 643
Cylinder Head, Servicing 644
Cylinder Head Top Clearance 645
Valve Guide, Checking 645
Valve And Valve Seat Reconditioning 647
Valve Spring 648
Rocker Arm And Shaft, Checking 648
Timing Gearcase Cover Removal And Installation 649
Idler Gear And Camshaft Removal And Installation 650
Idler Gear and Shaft, Servicing 653
Timing Gears Checking Backlash 654
Fuel Camshaft Removal And Installation 654
Fuel Camshaft Governor 655
Crankshaft Gear Removal And Installation 655
Oil Pump Removal And Installation 656
Oil Pump, Service 656
Engine Oil Pressure, Checking 657
Relief Valve 658
Piston And Connecting Rod Removal And Installation 658
Piston And Connecting Rod, Servicing 660
Connecting Rod Alignment 662
Crankshaft And Bearings Removal And Installation 663
Crankshaft And Bearings, Servicing 665
Cylinder Bore, Checking 667
Water Pump Removal And Installation 667
Water Pump Disassembly And Assembly 667
HEATER 668
HEATER 670
Removal And Installation 670
SPECIFICATIONS 672
SPECIFICATIONS 674
320/322 Excavator Machine Dimensions 674
Performance 676
Controls 676
Engine 676
Hydraulic System 676
Hydraulic Cylinders 677
Hydraulic Cycle Times 677
Drive System 677
Under Carriage 678
Track 678
Electrical 678
ENGINE SPECIFICATIONS 680
Fuel Injection Nozzles 680
Fuel Injection Pump 680
Cylinder Head 680
Valves 680
Valve Springs 681
Rocker Arms 681
Camshaft 681
Cylinders 682
Piston Rings 682
Pistons 682
Connecting Rods 682
Oil Pump 682
Crankshaft 683
Timing Gear 683
Thermostat 683
Engine Bolt Torque 684
Crankshaft Re-Grind Data 685
TORQUE SPECIFICATIONS 686
Torque For General SAE Bolts 686
Torque For General Metric Bolts 687
HYDRAULIC CONNECTION SPECIFICATIONS 688
O-ring Face Seal Connection 688
Straight Thread O-ring Fitting 688
Tubelines And Hoses 688
Flare Fitting 689
O-ring Flare Fitting 690
Port Seal Fitting 692
HYDRAULIC FLUID SPECIFICATIONS 694
Specifications 694
FUEL, COOLANT AND LUBRICANTS 696
Chart 696
CONVERSIONS 698
Decimal And Millimeter Equivalents 698
U S To Metric Conversion Chart 698
SMR 700
320/322-1 700
320/322-2 702
320/322-3 704
320/322-4 706

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M