Bobcat 321-323 Compact Excavator Service Manual – PDF DOWNLOAD

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Bobcat 321-323 Compact Excavator Service Manual – PDF DOWNLOAD

FILE DETAILS:

Bobcat 321-323 Compact Excavator Service Manual – PDF DOWNLOAD

Language : English
Pages : 643
Downloadable : Yes
File Type : PDF
Size:19.4 MB

DESCRIPTION:

Bobcat 321-323 Compact Excavator Service Manual – PDF DOWNLOAD

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 321-323 Compact Excavator Service Manual – PDF DOWNLOAD

ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 12
Maintenance 12
Operation 12
Electrical 12
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor Exhaust System 13
Welding And Grinding 13
Fire Extinguishers 13
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
UPPERSTRUCTURE SLEW LOCK 23
LIFTING THE EXCAVATOR 25
OPERATOR CAB (ROPS / TOPS) (If Equipped) 27
Emergency Exits 27
Cab Door 27
Front Window 28
Front Window Wiper 29
Window Washer Reservoir 29
Right Side Windows 29
TRANSPORTING THE EXCAVATOR 31
TAILGATE 33
Opening And Closing The Tailgate 33
Adjusting the Bumper 33
Adjusting The Tailgate Catch 33
SERVICE SCHEDULE 35
Chart 35
AIR CLEANER SERVICE 37
Daily Check 37
Replacing The Filters 37
CAB FILTER 39
Cleaning And Maintenance 39
ENGINE COOLING SYSTEM 41
Cleaning The Cooling System 41
Checking The Coolant Level 41
Replacing The Coolant 41
FUEL SYSTEM 43
Fuel Specifications 43
Filling The Fuel Tank 43
Removing Water From The Fuel Filter 43
Replacing The Fuel Filter 43
Draining The Fuel Tank 44
Removing Air From The Fuel System 44
ENGINE LUBRICATION SYSTEM 45
Checking Engine Oil 45
Replacing Oil And Filter 45
HYDRAULIC SYSTEM 47
Checking And Adding Hydraulic Oil 47
Diagnostic Connectors 47
Replacing The Hydraulic Filter 48
Replacing Hydraulic Oil 48
LUBRICATION OF THE HYDRAULIC EXCAVATOR 49
Rear Door Hinges 49
Blade 49
Boom Swing And Boom Base 50
Boom, Middle 51
Boom And Arm 51
Frame Fittings 52
Track Expansion Tube 52
TRAVEL MOTOR 53
Checking Oil Level 53
Draining The Drive Motor 53
SPARK ARRESTER MUFFLER 55
Cleaning Procedure 55
ALTERNATOR BELT 57
Adjusting The Alternator Belt 57
SEAT BELT 59
Inspection And Maintenance 59
CONTROL CONSOLE LOCKOUTS 61
Inspection And Maintenance 61
DE-AERATION 63
Procedure 63
HYDRAULIC SYSTEM 67
HYDRAULIC SCHEMATIC 71
HYDRAULIC SYSTEM INFORMATION 73
Glossary Of Hydraulic / Hydrostatic Symbols 73
Troubleshooting The Hydraulic Circuit 77
Troubleshooting The Cylinder Circuit 78
Troubleshooting The Swing (Upperstructure Slew) Circuit 79
Troubleshooting The Travel Circuit 80
BOOM CYLINDER 81
Testing 81
Removal and Installation 82
Parts Identification 84
Disassembly 85
Assembly 87
ARM CYLINDER 91
Testing 91
Removal and Installation 93
Parts Identification 94
Disassembly 95
Assembly 97
BOOM SWING CYLINDER 101
Testing 101
Removal and Installation 102
Parts Identification 104
Disassembly 105
Assembly 107
BUCKET CYLINDER 111
Testing 111
Removal and Installation 112
Parts Identification 114
Disassembly 115
Assembly 117
BLADE CYLINDER 121
Testing 121
Removal and Installation 122
Parts Identification 124
Disassembly 125
Assembly 127
TRACK FRAME EXPANSION CYLINDER 131
Testing 131
Removal And Installation 132
Parts Identification 136
Disassembly 137
Assembly 139
MAIN RELIEF VALVE 143
Testing And Adjusting The Main Relief Valve 143
PORT RELIEF VALVES 145
Testing And Adjusting The Port Relief Valve Pressure 145
CROSSPORT RELIEF VALVES 147
Testing And Adjusting The Crossport Relief Valve 147
PRESSURE REDUCING VALVE 149
Testing And Adjusting The Pressure Reducing Valve 149
HYDRAULIC CONTROL VALVE 151
Description 151
Removal And Installation 151
Parts Identification 153
Disassembly 154
Right Travel Valve Section Disassembly And Assembly 155
Boom Swing Valve Section Disassembly And Assembly 159
Arm Valve Section Disassembly and Assembly 162
Bucket Valve Section Disassembly And Assembly 165
Auxiliary Valve Section Disassembly And Assembly 168
Boom Valve Section Disassembly And Assembly 173
Left Travel Valve Section Disassembly And Assembly 176
Swing (Slew) Valve Section Disassembly And Assembly 180
Blade Valve Section Disassembly And Assembly 183
Assembly 187
HYDRAULIC PUMP 193
Description 193
Torque Adjustment 193
Testing The Piston Pump 194
Testing The Gear Pump 196
Testing Auxiliary Hydraulic Flow 197
Removal And Installation 198
Parts Identification 201
Disassembly 202
Gear Pump Disassembly 203
Piston Pump Disassembly 205
Piston Pump Assembly 214
Gear Pump Assembly 223
Assembly 225
MANIFOLD ASSEMBLY / ACCUMULATOR 227
Description 227
Removal And Installation 227
Parts Identification 230
Disassembly 231
Assembly 242
ACCUMULATORS 253
Removal And Installation 253
TRAVEL MOTOR 255
Description 255
Removal And Installation 255
Parts Identification 256
Disassembly 257
Assembly 264
SWIVEL JOINT 273
Description 273
Removal And Installation 273
Parts Identification 276
Disassembly 277
Assembly 279
SWING MOTOR 283
Description 283
Removal And Installation 283
Parts Identification 284
Disassembly 285
Assembly 291
RIGHT CONTROL LEVER (JOYSTICK) 299
Description 299
Testing 299
Handle Removal And Installation 301
Removal And Installation 302
Parts Identification 303
Disassembly 304
Assembly 309
LEFT CONTROL LEVER (JOYSTICK) 313
Description 313
Testing 313
Handle Removal And Installation 315
Removal And Installation 317
Parts Identification 318
Disassembly 319
Assembly 324
HYDRAULIC FILTER MOUNT 329
Description 329
Removal And Installation 329
HYDRAULIC RESERVOIR 331
Description 331
Removal And Installation 331
OIL COOLER 333
Description 333
Removal And Installation 333
BLADE / TRACK EXPANSION SOLENOID BLOCK 335
Description 335
Block Removal and Installation 335
Solenoid Removal and Installation 336
Block Disassembly And Assembly 337
SLEW LOCK VALVE (FOR S/N A76511001 & ABOVE, A01711001 & ABOVE) 339
Description 339
Removal And Installation 339
Parts Identification 341
Disassembly And Assembly 342
UNDERCARRIAGE 347
BLADE 349
Description 349
Extension Removal And Installation 349
Blade Removal And Installation 350
TRACKS 351
Track Lug Height 351
Track Tension Adjustment 351
Removal And Installation 354
TRACK FRAME 355
Disassembly And Assembly 355
Removal And Installation Of Expandable Track Frame 356
TRACK DAMAGE IDENTIFICATION 359
Cutting Of The Steel Cords 359
Causes Of The Damage 359
Abrasion Of Embedded Metals 360
Separation Of Embedded Metals 361
Separation Of Embedded Metals Due To Corrosion 362
Cuts On The Lug Side Rubber 363
Cracks On The Lug Side Rubber Due To Fatigue 364
Lug Abrasion 365
Cracks And Cuts On The Lug Side Rubber 366
Abrasion Of The Track Roller Side 367
Cuts On The Edges Of The Track Roller Side 368
TRACK IDLER 371
Parts Identification 371
Disassembly 372
Assembly 374
TRACK ROLLER 377
Parts Identification 377
Disassembly 378
Assembly 380
SWING CIRCLE GEAR 383
Removal and Installation 383
UPPERSTRUCTURE AND SWING SECTION 385
UPPERSTRUCTURE 389
Description 389
Removal 389
Installation 391
ROPS CANOPY 393
Removal And Installation 393
CAB 397
Removal And Installation 397
Door Removal And Installation 401
Front Window Removal And Installation 402
Right Side Rear Sliding Window Removal And Installation 405
Right Side Front Sliding Window Removal And Installation 406
Glass Removal 406
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 407
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 407
Glass Installation 408
SEAT AND SEAT MOUNT 411
Removal And Installation 411
RIGHT CONSOLE 413
Description 413
Joystick Console Cover (Bottom) Removal And Installation 413
Joystick Console Cover (Top) Removal And Installation 414
Joystick Console Cover (Top) Disassembly And Assembly 415
Compression Spring Removal And Installation (Canopy Only) 416
Compression Spring Disassembly And Assembly (Canopy Only) 417
Lever Removal And Installation (Canopy Only) 418
Joystick Console Frame Removal And Installation 420
Joystick Console Frame Disassembly And Assembly 421
Right Rear Console Cover Removal And Installation 422
Right Rear Console Cover Disassembly and Assembly 423
Right Rear Console Frame Removal And Installation 424
LEFT CONSOLE 427
Description 427
Joystick Console Cover (Bottom) Removal And Installation 427
Joystick Console Cover (Top) Removal And Installation 428
Compression Spring Removal And Installation 429
Compression Spring Disassembly And Assembly 430
Lever Removal And Installation 432
Joystick Console Frame Removal And Installation 433
Joystick Console Frame Disassembly And Assembly 434
Left Rear Console Cover Removal And Installation 434
Left Rear Console Frame Removal And Installation 435
ENGINE SPEED CONTROL 437
Removal and Installation 437
Cable Removal and Installation 438
BLADE CONTROL 441
Removal and Installation 441
Disassembly And Assembly 442
Cable Removal and Installation 444
UPPERSTRUCTURE SLEW LOCK 445
Removal and Installation 445
Disassembly And Assembly 445
RIGHT PEDAL 447
Removal And Installation 447
Disassembly And Assembly 447
TRAVEL CONTROLS 449
Removal And Installation 449
Disassembly And Assembly 449
LEFT PEDAL 451
Removal And Installation 451
Disassembly And Assembly 451
CONTROL LINKAGE ASSEMBLY 453
Description 453
Removal And Installation 453
Right Half of Control Linkage Disassembly And Assembly 455
Left Half of Control Linkage Disassembly And Assembly 457
Bracket of Control Linkage Disassembly And Assembly 460
FLOOR MAT AND FLOOR PANELS 461
Description 461
Removal and Installation 461
FUEL TANK 463
Removal and Installation 463
HORN 465
Removal And Installation 465
SWING FRAME 467
Description 467
Removal And Installation 467
Bushing Removal and Installation 468
Swing Frame Bushing Removal 469
Swing Frame Bushing Installation 470
Boom Pivot Bushing Removal 470
Boom Pivot Bushing Installation 471
BOOM 473
Description 473
Removal And Installation 473
Boom Bushing Removal And Installation 474
ARM 475
Description 475
Removal And Installation 475
Arm To Boom Bushing Removal And Installation 476
Arm To Bucket And Bucket Link Bushing Removal And Installation 477
BUCKET 479
Removal And Installation 479
TAILGATE 481
Removal And Installation 481
Latch Removal And Installation 482
ELECTRICAL SYSTEM AND ANALYSIS 483
ELECTRICAL SCHEMATIC 485
ELECTRICAL SYSTEM INFORMATION 486
Glossary Of Electrical Symbols 486
Troubleshooting 489
Description 490
Fuse And Relay Location / Identification 490
Fuel Timer And Diode Location / Identification 491
BATTERY 492
Servicing 492
Removal and Installation 493
Using A Booster Battery (Jump Starting) 494
ALTERNATOR 496
Description 496
Tests 496
Alternator Output Test 497
Full Field Test 497
Alternator Regulator Test 498
Alternator Regulator Test With Voltmeter 498
Removal And Installation 499
Belt Adjustment 500
Charging System Inspection 502
Parts Identification 503
STARTER 504
Removal And Installation 504
Parts Identification 505
Cleaning And Inspection 506
LIGHTS 508
UpperStructure Light Removal And Installation 508
UpperStructure Light Disassembly and Assembly 508
Boom Light Removal And Installation 509
Boom Light Disassembly And Assembly 509
Light Switch Removal And Installation 510
MICROSWITCH 512
Testing Left Console Microswitch 512
Left Console Microswitch Removal And Installation 513
Testing Right Console Microswitch 513
Right Console Microswitch Removal And Installation 515
TWO-SPEED BOOST SWITCH 516
Description 516
Removal And Installation 516
FUEL LEVEL SENDER 518
Removal And Installation 518
Testing 518
ENGINE SERVICE 520
TROUBLESHOOTING 522
Chart 522
SPARK ARRESTOR MUFFLER 524
Removal And Installation 524
AIR CLEANER 526
Removal And Installation 526
RADIATOR 528
Removal And Installation 528
ENGINE COMPONENTS AND TESTING 534
Valve Clearance Adjustment 534
Engine Compression Checking 535
Fuel Shutoff Solenoid – Checking 535
Fuel Shutoff Solenoid Removal And Installation 536
Fuel Shutoff Timer Removal And Installation 536
Fuel Injection Pump Check 536
Fuel Injection Pump Removal And Installation 537
Fuel Injection Pump Timing 539
Fuel Injector Removal And Installation 540
Fuel Injector Checking 541
Glow Plug Removal And Installation 543
ENGINE 544
Description 544
Specifications 545
Engine 545
Fuel Injector Nozzles 545
Fuel Injection Pump 545
Cylinder Head 545
Valves 545
Valve Springs 545
Rocker Arms 546
Camshaft 546
Cylinders 546
Piston Rings 546
Pistons 547
Connecting Rods 547
Crankshaft 547
Oil Pump 547
Thermostat 548
Torque Values 549
Engine Removal and Installation 550
Engine Mount Replacement 557
FLYWHEEL AND HOUSING 558
Flywheel Housing Removal And Installation 558
Hydraulic Pump Coupler Removal And Installation 559
Flywheel Removal 559
Flywheel Installation 560
Rear End Plate Removal And Installation 560
RECONDITIONING THE ENGINE 562
Cylinder Head Removal And Installation 562
Cylinder Head Disassembly And Assembly 563
Cylinder Head, Servicing 564
Cylinder Head Top Clearance 565
Valve Guide, Checking 565
Valve Timing, Checking 567
Valve And Valve Seat Reconditioning 567
Valve Seat Tightness 568
Valve Spring 569
Valve Tappets 570
Rocker Arm And Shaft, Checking 571
Timing Gearcase Cover Removal And Installation 571
Idler Gear And Camshaft Removal And Installation 573
Idler Gear and Shaft, Servicing 576
Timing Gears Checking Backlash 577
Fuel Camshaft Removal And Installation 577
Fuel Camshaft Governor 578
Crankshaft Gear Removal And Installation 578
Oil Pan Removal And Installation 579
Oil Pump Removal And Installation 580
Oil Pump, Service 580
Engine Oil Pressure, Checking 581
Relief Valve 582
Piston And Connecting Rod Removal And Installation 582
Piston And Connecting Rod, Servicing 584
Connecting Rod Alignment 586
Crankshaft And Bearings Removal And Installation 586
Crankshaft And Bearings, Servicing 588
Cylinder Bore, Checking 590
Water Pump Removal And Installation 591
Water Pump Disassembly And Assembly 591
Thermostat Removal And Installation 592
Testing The Thermostat 592
HEATER 594
HEATER SYSTEM 596
Description 596
Components 596
REGULATOR MAINTENANCE 598
Filter Element Removal And Installation 598
Heater Coil 598
HEATER UNIT 600
Removal And Installation 600
Louver Removal and Installation 601
Threaded Insert Removal And Installation 601
HEATER COIL 602
Removal And Installation 602
HEATER FAN 606
Removal And Installation 606
HEATER VALVE 610
Removal And Installation 610
SPECIFICATIONS 612
SPECIFICATIONS 321 EXCAVATOR 614
Machine dimensions 614
Working range 615
Lift Capacity (Object handling applications excluded) 616
Performance 617
Function Time 617
Weights 617
Controls 617
Engine 618
Electrical 618
Hydraulic system 618
Hydraulic cylinders 619
Drive system 619
Traction 619
Brakes 620
Slew system 620
Serviceability 620
Fluid capacities 621
Fluid specifications 621
Environmental 622
Instrumentation 622
Safety 622
Standard features 623
Options 623
Attachments 623
Bucket 623
SPECIFICATIONS 323 EXCAVATOR 624
Machine dimensions 624
Working range 625
Lift Capacity (Object handling applications excluded) 626
Performance 627
Function time 627
Weights 627
Controls 627
Engine 628
Electrical 628
Hydraulic system 628
Hydraulic cylinders 629
Drive system 629
Traction 629
Brakes 630
Slew system 630
Serviceability 630
Fluid capacities 631
Fluid specifications 631
Environmental 632
Instrumentation 632
Safety 632
Standard features 633
Options 633
Attachments 633
Buckets 633
TORQUE SPECIFICATIONS FOR BOLTS 634
Torque For General SAE Bolts 634
Torque For General Metric Bolts 635
HYDRAULIC CONNECTION SPECIFICATIONS 636
O-ring Face Seal Connection 636
Straight Thread O-ring Fitting 637
Tubelines And Hoses 637
Flare Fitting 638
Port Seal Fitting 639
HYDRAULIC FLUID SPECIFICATIONS 640
Specifications 640
CONVERSIONS 642
Decimal And Millimeter Equivalents 642
U S To Metric Conversion Chart 642

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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