Bobcat 320, 322 G-Series Excavator Repair Service Manual – 6902668

320 (S/N: 223911001 & Above) – 322 (S/N: 224011001 & Above) (G Series)
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This workshop repair service manual PDF download for the 320 / 322 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

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

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM AND ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902668 (7-06)
Total Pages : 705

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
SAFETY INSTRUCTIONS
Fire Prevention
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
SWING LOCK
LIFTING THE EXCAVATOR
OPERATOR CAB ROPS/TOPS
Emergency Exits
Cab Door
Front Window
Right Side Windows
TRANSPORTING THE EXCAVATOR
TAILGATE
Opening And Closing The Tailgate
Adjusting The Bumper
Adjusting The Tailgate Latch
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing The Filters
HEATER AIR FILTERS
Recirculation Filter
Fresh Air Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Removing Water From The Fuel Filter
Replacing The Fuel Filter
Draining The Fuel Tank
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Oil
Diagnostic Couplers
Replacing The Hydraulic Filter
Replacing Hydraulic Oil
LUBRICATION OF THE HYDRAULIC EXCAVATOR
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
SPARK ARRESTOR MUFFLER
ALTERNATOR BELT
Adjusting The Alternator Belt
SEAT BELT
Inspection And Maintenance
CONTROL CONSOLE LOCKOUTS
Inspection And Maintenance

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
BOOM CYLINDER
Testing
Removal and Installation
Parts Identification
Disassembly
Assembly
ARM CYLINDER
Testing
Removal and Installation
Parts Identification
Disassembly
Assembly
BOOM SWING CYLINDER
Testing
Removal and Installation
Parts Identification
Disassembly
Assembly
BUCKET CYLINDER
Testing
Removal and Installation
Parts Identification
Disassembly
Assembly
BLADE CYLINDER
Testing
Removal and Installation
Parts Identification
Disassembly
Assembly
TRACK FRAME EXPANSION CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Testing And Adjusting The Main Relief Valve
PORT RELIEF VALVES
Testing And Adjusting The Port Relief Valve Pressure
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valve
PRESSURE REDUCING VALVE
Testing And Adjusting The Pressure Reducing Valve
HYDRAULIC CONTROL VALVE (320 / 322)
Description
Removal And Installation
Parts Identification
Disassembly
Auxiliary Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly and Assembly
Boom Valve Section Disassembly and Assembly
Bucket Valve Section Disassembly and Assembly
Arm Valve Section Disassembly and Assembly
Boom Swing Valve Section Disassembly And Assembly
Right Travel Valve Section Disassembly And Assembly
Assembly
HYDRAULIC CONTROL VALVE (320L)
Description
Removal And Installation
Parts Identification
Disassembly
Auxiliary Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Right Travel Valve Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Testing The Hydraulic Pump
Removal And Installation
Coupler Removal And Installation
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR
Description
Removal And Installation
Parts Identification (S/N 223911001 – 223911247 & S/N 224011001 – 224012293)
Disassembly (S/N 223911001 – 223911247 & S/N 224011001 – 224012293)
Assembly (S/N 223911001 – 223911247 & S/N 224011001 – 224012293)
Parts Identification (S/N 223911248 & Above & S/N 224012294 & Above)
Disassembly (S/N 223911248 & Above & S/N 224012294 & Above)
Assembly (S/N 223911248 & Above & S/N 224012294 & Above)
TRAVEL MOTOR
Removal and Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification 320
Parts Identification 322
Disassembly
Assembly
SWING MOTOR
Removal and Installation
Parts Identification
Disassembly
Assembly
CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER MOUNT
Removal and Installation
HYDRAULIC RESERVOIR
Removal and Installation
OIL COOLER
Removal And Installation

UNDERCARRIAGE
BLADE
Extension Removal And Installation
Blade Removal And Installation
TRACKS
Track Lug Height
Adjustment
Removal And Installation
TRACK FRAME
Disassembly And Assembly
Removal And Installation Of Expandable Track Frame (322 Only)
Recoil Spring Disassembly And Assembly
TRACK DAMAGE IDENTIFICATION
Cutting Of The Steel Cords
Causes Of The Damage
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Abrasion Of The Track Roller Side
Cuts On The Edges Of The Track Roller Side
TRACK IDLER
Parts Identification
Disassembly
Assembly
TRACK ROLLER
Parts Identification
Disassembly
Assembly
SWING CIRCLE GEAR
Removal and Installation

UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Removal
Installation
ROPS CANOPY
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
Right Side Front Sliding Window Removal And Installation
Glass Removal
Glass Installation
Glass Installation (Cont’d)
SEAT AND SEAT MOUNT
Removal And Installation
RIGHT CONSOLE
Console Cover Removal And Installation (Cab Models 320L, 320, 322 & ROPS Canopy Model 320L)
Console Cover Removal And Installation (ROPS Canopy Models 320 & 322)
Gas Spring Removal And Installation (ROPS Canopy Models 320 & 322)
Lock Lever Removal And Installation (ROPS Canopy Models 320 & 322)
Adjustment (ROPS Canopy Models 320 & 322)
Latch Hook Removal And Installation (ROPS Canopy 320 & 322)
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320 & 322)
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L)
Upper Console Removal And Installation
Console Base Removal And Installation
LEFT CONSOLE
Console Cover Removal And Installation
Gas Spring Removal And Installation
Lock Lever Removal And Installation
Adjustment
Latch Hook Removal And Installation
Latch Hook Disassembly And Assembly
Upper Console Removal And Installation
Console Base Removal And Installation
ENGINE SPEED CONTROL
Removal and Installation
Engine Speed Control Cable Removal and Installation
BLADE CONTROL
Removal and Installation
Disassembly And Assembly
RIGHT PEDAL
Right Pedal Removal And Installation
Disassembly And Assembly
Linkage Removal And Installation
Linkage Disassembly And Assembly
LEFT PEDAL
Removal And Installation
Disassembly And Assembly
TRAVEL CONTROLS
Removal And Installation
Disassembly And Assembly
CONTROL LINKAGE ASSEMBLY
Removal And Installation
Left Pedal Linkage Disassembly And Assembly
Right Travel Control Linkage Disassembly And Assembly
Left Travel Control Linkage Disassembly And Assembly
Linkage Rod Removal And Installation
Linkage Rod Adjustment
FLOORMAT AND FLOORPLATES
Removal and Installation
FUEL TANK
Removal and Installation
HORN
Removal and Installation
SWING FRAME
Removal And Installation
Bushing Replacement
Swing Frame Bushing Removal
Swing Frame Bushing Installation
Boom Pivot Bushing Removal And Installation
BOOM
Removal And Installation
Boom Bushing Removal And Installation
ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
BUCKET
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
SWING LOCK
Removal and Installation
BLADE EXTENSION TRAY
Removal And Installation
LEFT PEDAL
Not Available At Time Of Print

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM
Troubleshooting Chart
Description
Fuses
Relays And Diodes
BATTERY
Servicing
Removing And Installing The Battery
Using A Booster Battery (Jump Starting)
ALTERNATOR
Description
Tests
Alternator Output Test
Full Field Test
Alternator Regulator Test
Alternator Regulator Test With Voltmeter
Removal And Installation
Parts Identification
Disassembly And Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly And Assembly
Cleaning and Inspection
LIGHTS
Upper Structure Light Removal And Installation
Boom Light Removal And Installation
Boom Light Disassembly And Assembly
Light Switch Removal And Installation
TWO-SPEED SWITCH
Removal And Installation
FUEL LEVEL SENDER
Removal and Installation
Testing
MICROSWITCH
Adjustment
Testing
Removal And Installation

ENGINE SERVICE
TROUBLESHOOTING
Chart
SPARK ARRESTOR MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
ENGINE COMPONENTS AND TESTING (S/N 223911001 – 223911621, S/N 224011001 – 224013374)
Valve Clearance Adjustment
Engine Compression Checking
Fuel Shut-Off Solenoid Removal And Installation
Fuel Shut-Off Timer Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Removal And Installation
Fuel Injector Checking
Glow Plug Removal And Installation
Glow Plug Checking
ENGINE COMPONENTS AND TESTING (S/N 223911622 & Above, S/N 224013375 & Above)
Valve Clearance Adjustment
Engine Compression Checking
Fuel Shut-Off Solenoid Removal And Installation
Fuel Shut-Off Timer Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Removal And Installation
Fuel Injector Checking
Glow Plug Removal And Installation
ENGINE
Removal and Installation
ENGINE FLYWHEEL
Removal And Installation
Hydraulic Pump Coupler
Flywheel Ring Gear
RECONDITIONING THE ENGINE (S/N 223911001 – 223911621, S/N 224011001 – 224013374)
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head, Servicing
Cylinder Head Top Clearance
Valve Guide, Checking
Valve And Valve Seat Reconditioning
Valve Spring
Rocker Arm And Shaft, Checking
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Idler Gear and Shaft, Servicing
Timing Gears Checking Backlash
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump, Service
Engine Oil Pressure, Checking
Relief Valve
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod, Servicing
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings, Servicing
Cylinder Bore, Checking
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
RECONDITIONING THE ENGINE (S/N 223911622 & Above, S/N 224013375 & Above)
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head, Servicing
Cylinder Head Top Clearance
Valve Guide, Checking
Valve And Valve Seat Reconditioning
Valve Spring
Rocker Arm And Shaft, Checking
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Idler Gear and Shaft, Servicing
Timing Gears Checking Backlash
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump, Service
Engine Oil Pressure, Checking
Relief Valve
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod, Servicing
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings, Servicing
Cylinder Bore, Checking
Water Pump Removal And Installation
Water Pump Disassembly And Assembly

HEATER
HEATER
Removal And Installation

SPECIFICATIONS
SPECIFICATIONS
320/322 Excavator Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Drive System
Under Carriage
Track
Electrical
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Pistons
Connecting Rods
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Bolt Torque
Crankshaft Re-Grind Data
TORQUE SPECIFICATIONS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
FUEL, COOLANT AND LUBRICANTS
Chart
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart

SERVICE MANUAL REVISION
320/322-1
320/322-2
320/322-3

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