3. 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.
2. Check that ROPS/TOPS
mounting hardware is
tightened and is Melroe
approved.
3. The seat belt must be correctly
installed, functional and in
good condition.
5. Machine signs must be legible
and in the correct location.
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.
7. Inspect the air cleaner for
damage or leaks. Check the
condition of the element.
8. Check the electrical charging
system.
9. Safety treads must in good
condition.
10. Check for correct function of
indicator lamps (Optional on
some models).
11. Check hydraulic fluid level,
engine oil level and fuel supply.
12. Inspect for fuel, oil or hydraulic
fluid leaks.
13. Lubricate the excavator.
14. Check the condition of the
battery and cables.
4. Inspect for loose or broken
parts or connections.
Recommend to the owner that all
necessary corrections be made
before the machine is returned to
service.
CALIFORNIA
PROPOSITION 65 WARNING
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
iii Service Manual
Revisedy July 05
4. 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 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.
SAFETY INSTRUCTIONS
W–2003–0903
Warnings on the machine and in the
manuals are for your safety. Failure to
obey warnings can cause injury or
death.
W–2044–1285
This notice identifies procedures
which must be followed to avoid
damage to the machine.
I–2019–0284
Safety Alert Symbol
This symbol with a warning statement means:
”Warning, be alert! Your safety is involved!”
Carefully read the message that follows.
SI EXC–0705
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v Service Manual
Revised July 05
5. A
SAFETY INSTRUCTIONS (Cont’d)
• 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 ifnecessary
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
your BobcatR dealer [A].
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.
SI EXC–0705
320/322 Excavator
vii Service Manual
Revised July 05
6. 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].
ENGINE SERIAL NUMBER
The engine serial number is located on the engine block,
near the fuel injection pump [B].
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 formtoindicatehis
understanding [C].
A
N–00806
C
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B
P–11102
7. TRACK FRAME
B–14408
ENGINE COVER
TRACK
OPERATOR SEAT
TOOL BOX
(Operator’s Manual Location)
BLADE CYLINDER
ARM CYLINDER
B–14407
CANOPY
(ROPS)
CONTROL LEVERS (JOYSTICK)
SEAT BELT
GRAB HANDLES
BUCKET CYLINDER
ARM
BUCKET LINK
BUCKET
BOOM CYLINDER
GRAB HANDLES
OPERATORS HANDBOOK
BOOM
AUXILIARY
LINES
UPPERSTRUCTURE
BLADE
HYDRAULIC EXCAVATOR IDENTIFICATION
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ServiceManual#6724910S/N562313001&Above–ContentsSection
Added July 05
9. MAINTENANCE SAFETY
• 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.
• 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.
• 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.
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.
2. Do not continuously apply more than 200 V.
3. Install the ground cable (from welder) at least 3 ft. (1
m) away from the part being welded.
4. When attaching ground cable (from welder) make
sure there are no seals or bearings between
the ground and the part to be welded.
• Lead–acid batteries produce flammable and
explosive gases. Keep arcs, sparks, flames and
lighted tobacco away from batteries.
• Donot handle electrical equipment while wearingwet
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 operator’s seat and around
the machine.
• When maintenance is done with equipment raised,
it must be securely blocked.
Relieve pressure on work cylinders as follows:
1. Lower work equipment to the ground. Stop the
engine.
2. Operate all the control levers through their functions.
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.
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10. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
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click on the link above,
please download the PDF
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11. 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 & Check fluid level & add as needed. Check for damage & leaks.
Tubelines 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.
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.
Instructions 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.
W–2003–1089
ITEM SERVICE REQUIRED 8–10 50 250 1000
100 500
SERVICE SCHEDULE
*
*
**
**
**
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12. ENGINE COVER
Keep the engine cover closed when operating
the machine.
W–2141–0189
AVOID INJURY
Never service or adjust the machine when the
engine is running unless instructed to do so
in this manual.
W–2012–0290
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].
AIR CLEANER SERVICE
See the SERVICE SCHEDULE Page 1–4 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].
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.
A
P–11057
C
P–11059
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2
D
P–11060
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P–11058
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1
2
3
13. AIR CLEANER SERVICE (Cont’d)
Filter Replacement
Remove the wing nut (Item 1) [A] and the filter element
(Item 2) [A].
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.
A
P–11061
1
2
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P–11062
1
14. FUEL SYSTEM
Filling the Fuel Tank
Stop and cool the engine before adding fuel.
NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W–2063–0887
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.
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
Fuel Filter
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
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.
A
P–11035
2
1
C
P–11064
D
P–11065
1
2
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P–11063
15. FUEL SYSTEM (Cont’d)
Fuel System Maintenance
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
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.
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
+15°(9°c) 100% 0%
Down to –20° (–29°c) 50% 50%
Below –20° (–29°c) 0% 100%
For local recommendations, the operator can contact his
fuel supplier.
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
A
P–11066
1
D
P–11068
1
C
P–11065
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P–11067
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