Bobcat 321, 323 Compact Excavator Repair Manual

$16.00 – $33.00

🚜 Equipment
Brand	Bobcat
Type	Compact Excavator
Model	321, 323
📄 Documents
Language	English
Format	PDF
Serial Number	Manual	Pages
321 : S/N A76511001 & Above 323 : S/N A01711001 & Above	Repair Manual	643
321 : S/N A76511001 & Above 323 : S/N A01711001 & Above	Operation & Maintenance	119

FOREWORD

This manual is the core workshop reference for Bobcat excavator mechanics. It combines all factory-approved procedures for inspection, maintenance, adjustment and complete overhaul of the machine.

Every section begins with safety—fire-prevention rules, lift points, lockouts and serial-number verification—so each job starts under controlled conditions. From there you will find clear diagnostics and step-by-step service instructions for the engine, hydraulics, undercarriage, upperstructure, electrical and HVAC systems, backed by precise specifications and torque data.

Follow the service schedule and post-repair inspection checklist before returning the excavator to work; doing so ensures reliability, operator safety and full compliance with Bobcat standards.

Manual	Repair Manual, Operation and Maintenance

Table of Content

📙 Table of Contents

Alphabetical Index

ALPHABETICAL INDEX

Contents

CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
  - Maintenance
  - Operation
  - Electrical
  - Hydraulic System
  - Fueling
  - Starting
  - Spark Arrestor Exhaust System
  - Welding And Grinding
  - Fire Extinguishers
- SERIAL NUMBER LOCATIONS
  - Excavator Serial Number
  - Engine Serial Number
- DELIVERY REPORT
- BOBCAT EXCAVATOR IDENTIFICATION

Safety And Maintenance

SAFETY AND MAINTENANCE
- LIFTING AND BLOCKING THE EXCAVATOR
  - Procedure
- UPPERSTRUCTURE SLEW LOCK
- LIFTING THE EXCAVATOR
- OPERATOR CAB (ROPS / TOPS) (If Equipped)
  - Emergency Exits
  - Cab Door
  - Front Window
  - Front Window Wiper
  - Window Washer Reservoir
  - Right Side Windows
- TRANSPORTING THE EXCAVATOR
- TAILGATE
  - Opening And Closing The Tailgate
  - Adjusting the Bumper
  - Adjusting The Tailgate Catch
- SERVICE SCHEDULE
  - Chart
- AIR CLEANER SERVICE
  - Daily Check
  - Replacing The Filters
- CAB FILTER
  - Cleaning And Maintenance
- ENGINE COOLING SYSTEM
  - Cleaning The Cooling System
  - Checking The 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
  - Replacing Oil And Filter
- HYDRAULIC SYSTEM
  - Checking And Adding Hydraulic Oil
  - Diagnostic Connectors
  - Replacing The Hydraulic Filter
  - Replacing Hydraulic Oil
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
  - Rear Door Hinges
  - Blade
  - Boom Swing And Boom Base
  - Boom, Middle
  - Boom And Arm
  - Frame Fittings
  - Track Expansion Tube
- TRAVEL MOTOR
  - Checking Oil Level
  - Draining The Drive Motor
- SPARK ARRESTER MUFFLER
  - Cleaning Procedure
- ALTERNATOR BELT
  - Adjusting The Alternator Belt
- SEAT BELT
  - Inspection And Maintenance
- CONTROL CONSOLE LOCKOUTS
  - Inspection And Maintenance
- DE-AERATION
  - Procedure

Hydraulic System

HYDRAULIC SYSTEM
- HYDRAULIC SCHEMATIC
- HYDRAULIC SYSTEM INFORMATION
  - Glossary Of Hydraulic / Hydrostatic Symbols
  - 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
  - Description
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Right Travel Valve Section Disassembly And Assembly
  - Boom Swing Valve Section Disassembly And Assembly
  - Arm Valve Section Disassembly and Assembly
  - Bucket Valve Section Disassembly And Assembly
  - Auxiliary Valve Section Disassembly And Assembly
  - Boom Valve Section Disassembly And Assembly
  - Left Travel Valve Section Disassembly And Assembly
  - Swing (Slew) Valve Section Disassembly And Assembly
  - Blade Valve Section Disassembly And Assembly
  - Assembly
- HYDRAULIC PUMP
  - Description
  - Torque Adjustment
  - Testing The Piston Pump
  - Testing The Gear Pump
  - Testing Auxiliary Hydraulic Flow
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Gear Pump Disassembly
  - Piston Pump Disassembly
  - Piston Pump Assembly
  - Gear Pump Assembly
  - Assembly
- MANIFOLD ASSEMBLY / ACCUMULATOR
  - Description
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Assembly
- ACCUMULATORS
  - Removal And Installation
- TRAVEL MOTOR
  - Description
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Assembly
- SWIVEL JOINT
  - Description
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Assembly
- SWING MOTOR
  - Description
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Assembly
- RIGHT CONTROL LEVER (JOYSTICK)
  - Description
  - Testing
  - Handle Removal And Installation
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Assembly
- LEFT CONTROL LEVER (JOYSTICK)
  - Description
  - Testing
  - Handle Removal And Installation
  - Removal And Installation
  - Parts Identification
  - Disassembly
  - Assembly
- HYDRAULIC FILTER MOUNT
  - Description
  - Removal And Installation
- HYDRAULIC RESERVOIR
  - Description
  - Removal And Installation
- OIL COOLER
  - Description
  - Removal And Installation
- BLADE / TRACK EXPANSION SOLENOID BLOCK
  - Description
  - Block Removal and Installation
  - Solenoid Removal and Installation
  - Block Disassembly And Assembly
- SLEW LOCK VALVE (FOR S/N A76511001 & ABOVE, A01711001 & ABOVE)
  - Description
  - Removal And Installation
  - Parts Identification
  - Disassembly And Assembly

Undercarriage

UNDERCARRIAGE
- BLADE
  - Description
  - Extension Removal And Installation
  - Blade Removal And Installation
- TRACKS
  - Track Lug Height
  - Track Tension Adjustment
  - Removal And Installation
- TRACK FRAME
  - Disassembly And Assembly
  - Removal And Installation Of Expandable Track Frame
- 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 And Swing Section

UPPERSTRUCTURE AND SWING SECTION
- UPPERSTRUCTURE
  - Description
  - 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
  - Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
  - Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
  - Glass Installation
- SEAT AND SEAT MOUNT
  - Removal And Installation
- RIGHT CONSOLE
  - Description
  - Joystick Console Cover (Bottom) Removal And Installation
  - Joystick Console Cover (Top) Removal And Installation
  - Joystick Console Cover (Top) Disassembly And Assembly
  - Compression Spring Removal And Installation (Canopy Only)
  - Compression Spring Disassembly And Assembly (Canopy Only)
  - Lever Removal And Installation (Canopy Only)
  - Joystick Console Frame Removal And Installation
  - Joystick Console Frame Disassembly And Assembly
  - Right Rear Console Cover Removal And Installation
  - Right Rear Console Cover Disassembly and Assembly
  - Right Rear Console Frame Removal And Installation
- LEFT CONSOLE
  - Description
  - Joystick Console Cover (Bottom) Removal And Installation
  - Joystick Console Cover (Top) Removal And Installation
  - Compression Spring Removal And Installation
  - Compression Spring Disassembly And Assembly
  - Lever Removal And Installation
  - Joystick Console Frame Removal And Installation
  - Joystick Console Frame Disassembly And Assembly
  - Left Rear Console Cover Removal And Installation
  - Left Rear Console Frame Removal And Installation
- ENGINE SPEED CONTROL
  - Removal and Installation
  - Cable Removal and Installation
- BLADE CONTROL
  - Removal and Installation
  - Disassembly And Assembly
  - Cable Removal and Installation
- UPPERSTRUCTURE SLEW LOCK
  - Removal and Installation
  - Disassembly And Assembly
- RIGHT PEDAL
  - Removal And Installation
  - Disassembly And Assembly
- TRAVEL CONTROLS
  - Removal And Installation
  - Disassembly And Assembly
- LEFT PEDAL
  - Removal And Installation
  - Disassembly And Assembly
- CONTROL LINKAGE ASSEMBLY
  - Description
  - Removal And Installation
  - Right Half of Control Linkage Disassembly And Assembly
  - Left Half of Control Linkage Disassembly And Assembly
  - Bracket of Control Linkage Disassembly And Assembly
- FLOOR MAT AND FLOOR PANELS
  - Description
  - Removal and Installation
- FUEL TANK
  - Removal and Installation
- HORN
  - Removal And Installation
- SWING FRAME
  - Description
  - Removal And Installation
  - Bushing Removal and Installation
  - Swing Frame Bushing Removal
  - Swing Frame Bushing Installation
  - Boom Pivot Bushing Removal
  - Boom Pivot Bushing Installation
- BOOM
  - Description
  - Removal And Installation
  - Boom Bushing Removal And Installation
- ARM
  - Description
  - 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

Electrical System And Analysis

ELECTRICAL SYSTEM AND ANALYSIS
- ELECTRICAL SCHEMATIC
- ELECTRICAL SYSTEM INFORMATION
  - Glossary Of Electrical Symbols
  - Troubleshooting
  - Description
  - Fuse And Relay Location / Identification
  - Fuel Timer And Diode Location / Identification
- BATTERY
  - Servicing
  - Removal and Installation
  - 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
  - Belt Adjustment
  - Charging System Inspection
  - Parts Identification
- STARTER
  - Removal And Installation
  - Parts Identification
  - Cleaning And Inspection
- LIGHTS
  - UpperStructure Light Removal And Installation
  - UpperStructure Light Disassembly and Assembly
  - Boom Light Removal And Installation
  - Boom Light Disassembly And Assembly
  - Light Switch Removal And Installation
- MICROSWITCH
  - Testing Left Console Microswitch
  - Left Console Microswitch Removal And Installation
  - Testing Right Console Microswitch
  - Right Console Microswitch Removal And Installation
- TWO-SPEED BOOST SWITCH
  - Description
  - Removal And Installation
- FUEL LEVEL SENDER
  - Removal And Installation
  - Testing

Engine Service

ENGINE SERVICE
- TROUBLESHOOTING
  - Chart
- SPARK ARRESTOR MUFFLER
  - Removal And Installation
- AIR CLEANER
  - Removal And Installation
- RADIATOR
  - Removal And Installation
- ENGINE COMPONENTS AND TESTING
  - Valve Clearance Adjustment
  - Engine Compression Checking
  - Fuel Shutoff Solenoid – Checking
  - Fuel Shutoff Solenoid Removal And Installation
  - Fuel Shutoff 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
  - Description
  - Specifications
  - Engine
  - Fuel Injector Nozzles
  - Fuel Injection Pump
  - Cylinder Head
  - Valves
  - Valve Springs
  - Rocker Arms
  - Camshaft
  - Cylinders
  - Piston Rings
  - Pistons
  - Connecting Rods
  - Crankshaft
  - Oil Pump
  - Thermostat
  - Torque Values
  - Engine Removal and Installation
  - Engine Mount Replacement
- FLYWHEEL AND HOUSING
  - Flywheel Housing Removal And Installation
  - Hydraulic Pump Coupler Removal And Installation
  - Flywheel Removal
  - Flywheel Installation
  - Rear End Plate Removal And Installation
- RECONDITIONING THE ENGINE
  - Cylinder Head Removal And Installation
  - Cylinder Head Disassembly And Assembly
  - Cylinder Head, Servicing
  - Cylinder Head Top Clearance
  - Valve Guide, Checking
  - Valve Timing, Checking
  - Valve And Valve Seat Reconditioning
  - Valve Seat Tightness
  - Valve Spring
  - Valve Tappets
  - 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 Pan 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
  - Thermostat Removal And Installation
  - Testing The Thermostat

Heater

HEATER
- HEATER SYSTEM
  - Description
  - Components
- REGULATOR MAINTENANCE
  - Filter Element Removal And Installation
  - Heater Coil
- HEATER UNIT
  - Removal And Installation
  - Louver Removal and Installation
  - Threaded Insert Removal And Installation
- HEATER COIL
  - Removal And Installation
- HEATER FAN
  - Removal And Installation
- HEATER VALVE
  - Removal And Installation

Specifications

SPECIFICATIONS
- SPECIFICATIONS 321 EXCAVATOR
  - Machine dimensions
  - Working range
  - Lift Capacity (Object handling applications excluded)
  - Performance
  - Function Time
  - Weights
  - Controls
  - Engine
  - Electrical
  - Hydraulic system
  - Hydraulic cylinders
  - Drive system
  - Traction
  - Brakes
  - Slew system
  - Serviceability
  - Fluid capacities
  - Fluid specifications
  - Environmental
  - Instrumentation
  - Safety
  - Standard features
  - Options
  - Attachments
  - Bucket
- SPECIFICATIONS 323 EXCAVATOR
  - Machine dimensions
  - Working range
  - Lift Capacity (Object handling applications excluded)
  - Performance
  - Function time
  - Weights
  - Controls
  - Engine
  - Electrical
  - Hydraulic system
  - Hydraulic cylinders
  - Drive system
  - Traction
  - Brakes
  - Slew system
  - Serviceability
  - Fluid capacities
  - Fluid specifications
  - Environmental
  - Instrumentation
  - Safety
  - Standard features
  - Options
  - Attachments
  - Buckets
- TORQUE SPECIFICATIONS FOR BOLTS
  - 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
  - Port Seal Fitting
- HYDRAULIC FLUID SPECIFICATIONS
  - Specifications
- CONVERSIONS
  - Decimal And Millimeter Equivalents
  - U.S. To Metric Conversion Chart

Specification

Model	Years	Engine (disp / cyl)	HP	Fuel (gal)	Width (in)	Max Dig Depth (in)	Operating Weight (lbs)
321	2007-2009	0.72 L / 3-cyl	13.3	—	38.6	89.1	3 527
323	2005-2009	0.72 L / 3-cyl	13.9	7.3	38.6	90.4	3 655

Buyer Questions & Answers

Frequently Asked Questions❔

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