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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