X 320/322 Excavator Service Manual (S/N 562313001 & Above) (S/N 517811001 & Above)
6724910 (1–97)
Printed in U.S.A.
© Bobcat Company 1997
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MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine, Read and understand the 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. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0199
Safety Alert Symbol: This symbol is used for important safety messages. When you see this symbol, follow the safety message to avoid personal injury or death.
CORRECT
CORRECT
CORRECT
B–10731
B–14148
B–14142
Never service the Hydraulic Excavator instructions.
Bobcat without
WRONG
B–14147
Use the correct procedure to lift and support the excavator. Always lift the blade fully before installing jackstands.
Cleaning and maintenance are required daily.
WRONG
WRONG
B–14141
B–14145
Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust fumes can kill without warning.
Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Bobcat Company.
WRONG
WRONG
WRONG
B–14146
B–14143
B–6589
Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the excavator.
Lead–acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.
Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.
Stop, cool and clean engine of flammable materials before checking fluid. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in this manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.
MSW20–0500
ALPHABETICAL INDEX ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR BAFFLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY FLUSH FACE COUPLERS . . . . . . . . . . .
2–1 4–1 7–1 1–1 6–1 1–1 5–1 5–1 2–1 2–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELLY PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .
6–1 6–1 4–1 7–1 2–1 3–1 5–1 5–1 2–1 2–1 5–1 2–1 8–1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB/CANOPY REAR COVER . . . . . . . . . . . . . . . . . . . CAB ELECTRICAL (Cab Option) . . . . . . . . . . . . . . . . . CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . CONTROL CONSOLE LEFT HAND . . . . . . . . . . . . . . CONTROL CONSOLE RIGHT HAND . . . . . . . . . . . . . CONSOLE COVER LEFT HAND . . . . . . . . . . . . . . . . . CONSOLE COVER RIGHT HAND . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . CORNER POSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COUNTER WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . . . CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1 4–1 6–1 4–1 3–1 3–1 3–1 3–1 1–1 5–1 5–1 7–1 7–1 7–1 7–1
DRAIN BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . 1–1, 6–1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . 1–1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8–1 FAN GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOOR MAT AND FLOOR PANELS . . . . . . . . . . . . . . FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . .
7–1 1–1 3–1 7–1 8–1 7–1
FUEL FUEL FUEL FUEL FUEL
INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . SHUTOFF SOLENOID . . . . . . . . . . . . . . . . . . . . SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1 6–1 7–1 1–1 3–1
GAS SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HEATER AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . . HYDRAULIC FILTER ASSEMBLY . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SERVICE INFORMATION . . . . . . . . . . . HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .
1–1 6–1 2–1 2–1 8–1 2–1 2–1 3–1 2–1 1–1
IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . . 7–1 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 JOYSTICK CONTROL CHANGE . . . . . . . . . . . . 1–1, 2–1 LATCH HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINKAGE RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION OF THE HYDRAULIC EXCAVATOR
3–1 6–1 3–1 3–1 1–1
MAIN RELIEF VALVES (Adjustable) . . . . . . . . . . . . . . 2–1 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . 1–1 MICROSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 PEDAL LEFT HAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . PEDAL RIGHT HAND . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . .
3–1 3–1 7–1 2–1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . ROCKERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1 7–1 3–1 4–1
SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . 5–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . 1–1, 7–1 SPEED CONTROL LEVER/SWING LOCK LEVER . 5–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 SWING POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Continued On Next Page
Revised July 05
320/322 Excavator Service Manual
ALPHABETICAL INDEX (CONT’D) TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIMING GEARCASE COVER . . . . . . . . . . . . . . . . . . . . 7–1 TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TRACK DAMAGE IDENTIFICATION . . . . . . . . . . . . . . 5–1 TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TRACK FRAME EXPANSION CYLINDER (322 (S/N 517811001 & Above) . . . . . . . . . . . . . . . . . . 2–1 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TRAVEL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . 2–1, 6–1, 7–1 TWO SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 UPPER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . 7–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Revised July 05
320/322 Excavator Service Manual
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . ix PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
DRIVE SYSTEM
UPPER WORKS & SWING SYSTEM
MAIN FRAME & TRACKS
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
Revised July 05
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Revised July 05
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320/322 Excavator Service Manual
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.
9. Safety treads must in good condition.
2. Check that ROPS/TOPS mounting hardware is tightened and is Melroe approved.
10. Check for correct function of indicator lamps (Optional on some models).
3. The seat belt must be correctly installed, functional and in good condition.
11. Check hydraulic fluid level, engine oil level and fuel supply.
4. Inspect for loose or broken parts or connections.
12. Inspect for fuel, oil or hydraulic fluid leaks.
5. Machine signs must be legible and in the correct location.
13. Lubricate the excavator.
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.
14. Check the condition of the battery and cables.
7. Inspect the air cleaner for damage or leaks. Check the condition of the element.
Recommend to the owner that all necessary corrections be made before the machine is returned to service.
8. Check the electrical charging system.
Revisedy July 05
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. iii
320/322 Excavator Service Manual
Revised July 05
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320/322 Excavator Service Manual
SAFETY INSTRUCTIONS Safety Alert Symbol This symbol with a warning statement means: ”Warning, be alert! Your safety is involved!” Carefully read the message that follows.
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. W–2003–0903
Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.
This notice identifies procedures which must be followed to avoid damage to the machine. I–2019–0284
W–2044–1285
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 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 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 available in English and Spanish versions.
• Service Safety Training Courses are available from your BobcatR dealer or at www.bobcat.com. They provide information for safe and correct service procedures.
• The BobcatR Compact Excavator Safety Video is available from your BobcatR dealer or at www.bobcat.com. SI EXC–0705
Revised July 05
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320/322 Excavator Service Manual
SAFETY INSTRUCTIONS (Cont’d) The dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.
Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)
SI EXC–0705
Revised July 05
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320/322 Excavator Service Manual
SAFETY INSTRUCTIONS (Cont’d) 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.
• 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 if necessary 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].
A
SI EXC–0705
Revised July 05
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320/322 Excavator Service Manual
SERIAL NUMBER LOCATIONS
A
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].
N–00806
ENGINE SERIAL NUMBER
B
The engine serial number is located on the engine block, near the fuel injection pump [B].
P–11102
C
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 form to indicate his understanding [C].
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HYDRAULIC EXCAVATOR IDENTIFICATION
320ServiceManual#6724910S/N562313001&Above–ContentsSection
GRAB HANDLES CONTROL LEVERS (JOYSTICK) CANOPY (ROPS)
ENGINE COVER UPPERSTRUCTURE TRACK FRAME TRACK
OPERATORS HANDBOOK
GRAB HANDLES
ARM CYLINDER
OPERATOR SEAT AUXILIARY LINES BUCKET CYLINDER
SEAT BELT
ARM
TOOL BOX (Operator’s Manual Location)
BUCKET LINK
BLADE CYLINDER BUCKET BOOM BLADE BOOM CYLINDER Added July 05
ix
B–14408 B–14407
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320/322 Excavator Service Manual
PREVENTIVE MAINTENANCE Page Number
PREVENTIVE MAINTENANCE
AIR CLEANER SERVICE Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Propylene Glycol (Factory Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 ELECTRICAL SYSTEM Electrical Relays and Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Solenoid (Engine Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . Service the Electrical System (and Battery) . . . . . . . . . . . . . . . . . . . . . . .
1–11 1–13 1–12 1–13 1–12
ENGINE COVER Adjustment of the Engine Cover Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 FINAL DRIVE CASE Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 FUEL SYSTEM Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–7 1–7 1–8 1–8 1–8
HEATER AIR FILTER (With Cab Option Only) . . . . . . . . . . . . . . . . . . . . . . 1–23 HYDRAULIC SYSTEM Case Drain Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–15 1–14 1–15 1–15 1–15
JOYSTICK CONTROL CHANGE ISO to Standard Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 Standard to ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . 1–21 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 SPARK ARRESTOR MUFFLER (if equipped) . . . . . . . . . . . . . . . . . . . . . . 1–16 TRACK TENSION Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Revised July 05
–1–1–
320/322 Excavator Service Manual
Revised July 05
–1–2–
320/322 Excavator Service Manual
MAINTENANCE SAFETY
2.
Do not continuously apply more than 200 V.
•
Never service the machine without instructions.
3.
Install the ground cable (from welder) at least 3 ft. (1 m) away from the part being welded.
•
Cleaning and maintenance are required daily.
4.
•
Keep engine cover closed except for service. Close and latch the cover before operating.
When attaching ground cable (from welder) make sure there are no seals or bearings between the ground and the part to be welded.
•
Never fill the fuel tank with the engine running, while smoking or when near open flame.
•
Lead–acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries.
•
Never modify equipment or add attachments not approved by Melroe Company.
•
•
Do not handle electrical equipment while wearing wet gloves, or in wet places, this can cause an electrical shock.
Stop, cool and clean the engine of flammable materials before checking fluid levels.
•
Do not allow unauthorized personnel near the machine during maintenance.
•
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.
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:
Avoid contact with leaking hydraulic fluid or diesel fuel which is under pressure, it can penetrate the skin and eyes.
1.
Lower work equipment to the ground. Stop the engine.
Wear safety glasses to prevent eye injury when any of the following conditions exist:
2.
Operate all the control levers through their functions.
•
When fluids are under pressure.
•
Flying debris or loose material is present.
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.
•
Engine is running.
3.
Loosen the cap on the hydraulic tank.
•
Tools are being used.
•
•
Do not check alternator belt tension with engine running. Stop the engine before inspecting any rotating parts.
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.
•
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.
Revised July 05
–1–3–
320/322 Excavator Service Manual
SERVICE SCHEDULE 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
Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Cab Seat Belt Safety Signs (Decals) Tracks All Machinery Pivot Points Hyd. Fluid, Hoses & Tubelines Battery
Check and empty dust cap as required. Check the oil level & add oil as needed. Check radiator coolant level. Check for correct operation. Check the fastening bolts, nuts, & condition of cab/canopy. Check the condition & that fasteners are tight. Check for damaged signs (decals) replace as needed. Check & adjust tension. Lubricate 21 grease fittings. Check fluid level & add as needed. Check for damage & leaks. Repair & replace as needed. Check & clean cable ends & check electrolyte level. Add distilled water as needed. Drain water & sediment from fuel tank/fuel filter. Lubricate two grease fittings. Lubricate one grease fitting. Clean spark chamber. Check & adjust tension. Replace oil & filter element. Check fluid level & add oil as needed. Replace filter element. Replace Air Cleaner Element Clean the radiator fins. Check the condition and connections. Replace filter element. Replace filter. Check and adjust as needed Drain, flush & add new coolant to the cooling system. Change the fluid, clean fill neck strainer. Change the oil. Clean the filter.
Fuel Tank/Fuel Filter Swing Circle Swing Pinion Spark Arrestor Muffler Alternator/Fan Belt Engine Oil & Filter Final Drive Case Fuel Filter Air Cleaner Element Cooling System Alternator & Starter Hydraulic Filter Case Drain Hydraulic Filter Engine Valve Clearance Cooling System Hydraulic Tank Final Drive Case Cab Heater Air Filter
8–10
50
100
250
500 1000
* *
** **
**
*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.
Revised July 05
–1–4–
320/322 Excavator Service Manual
ENGINE COVER
A
AVOID INJURY Never service or adjust the machine when the engine is running unless instructed to do so in this manual. W–2012–0290
Keep the engine cover closed when operating the machine.
P–11057
W–2141–0189
B Open the engine cover to service the engine. Pull on the latch and lift the engine cover up until it is fully raised [A].
3
Adjustment of the Engine Cover Latch Open the engine cover.
2
Loosen the nuts and adjust the stop (Item 1) [B]. Tighten the nuts when the stop (Item 1) [B] is in the correct position.
1
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].
2
AIR CLEANER SERVICE
P–11058
C
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.
2
Remove the cover (Item 2) [C].
1
P–11059
D
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.
1 P–11060
–1–5–
320/322 Excavator Service Manual
AIR CLEANER SERVICE (Cont’d)
A
Filter Replacement Remove the wing nut (Item 1) [A] and the filter element (Item 2) [A].
2 1
P–11061
Check the air cleaner housing for damage.
B
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.
1
–1–6–
P–11062
320/322 Excavator Service Manual
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