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Bobcat Excavator (320 325 331 Series) Service Manual

Service Manual And Owners Manual, to Bobcat Excavator (320 325 331 Series).

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LANGUAGE: English.
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PAGES: 3240
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BOBCAT EXCAVATOR (320 325 331 SERIES) - SERVICE AND OWNERS MANUAL

- Service Manual And Owners Manual, to Bobcat Excavator (320 325 331 Series).



CONTENTS:


320 6722640 OM 2-97
 
- OPERATOR SAFETY WARNINGS
- CONTENTS
- REGULAR MAINTENANCE ITEMS
- FOREWORD
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- SAFETY
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- MACHINE SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- GETTING ON AND OFF THE MACHINE
- SEAT
- CONTROL LEVER (JOYSTICK) LOCK
- INSTRUMENT PANEL
- AUDIBLE ALARM
- KEY SWITCH
- LIGHT SWITCH
- AUXILIARY POWER OUTLET
- CAB ELECTRICAL (If Equipped)
- HEATER
- WINDSHIELD WASHER TANK (If Equipped)
- CONTROL LEVERS (JOYSTICKS)
- Operation Of Left Control Lever (ISO)
- Operation Of Right Control Lever (ISO)
- Operation Of Left Control Lever (STANDARD)
- Operation Of Right Control Lever (STANDARD)
- SWING LOCK
- HORN BUTTON
- SPEED CONTROL LEVER
- ENGINE STOP CONTROL
- STEERING LEVERS/FOOT PEDALS
- Forward And Reverse Travel
- Turning
- BOOM SWING PEDAL (AND LOCK/FOOT REST)
- BLADE CONTROL LEVER
- AUXILIARY HYDRAULIC PEDAL
- DAILY INSPECTION
- STARTING THE ENGINE
- Normal Starting Procedure (With Engine Warm)
- Cold Temperature Starting Procedure
- OPERATING PROCEDURES
- Breaking In A New Machine
- General Operation Suggestions
- Operating On Slopes
- Operating In Water
- PARKING THE HYDRAULIC EXCAVATOR
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- LIFTING THE HYDRAULIC EXCAVATOR
- LIFTING A LOAD
- BUCKET
- Removal
- Installation
- CAB OPTION
- Opening The Front Window
- Closing The Front Window
- Front Window
- Emergency Exit
- CAB/CANOPY
- CAB/CANOPY FOPS (Falling Object ProtectiveStructure)
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel System Maintenance
- Fuel Filters
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Service The Electrical System
- Using A Booster Battery (Jump Starting)
- Removal And Installation Of The Battery
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Diagnostic Couplers
- Replacement of the Hydraulic Filter
- Hydraulic Reservoir
- Filter Screen (Factory Installed)
- In–Line FIlter (Service Replacement)
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- FINAL DRIVE CASE
- Checking Oil Level
- Replacing Final Drive Case Oil
- TRACK TENSION
- Adjustment
- JOYSTICK CONTROL CHANGE
- ISO To Standard Control Pattern
- Standard To ISO Control Pattern
- MACHINE SIGN TRANSLATIONS
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity
- OPERATIONS & PERFORMANCE
- ENGINE
- HYDRAULIC SYSTEM
- SWING SYSTEM
- HYDRAULIC CYLINDERS
- DRIVE SYSTEM
- BRAKES
- UNDERCARRIAGE
- TRACK
- CAPACITIES
- DIGGING FORCE
- FUEL, COOLANT AND LUBRICANTS
- ENGINE OIL SPECIFICATIONS
- Description
- Ethlene Glycol
- Propylene Glycol
- BUCKET SPECIFICATIONS
- ADDITIONAL PUBLICATIONS
- WARRANTY

320 6722642 SM 4-94

- MAINTENANCE SAFETY
- CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- PREVENTIVE MAINTENANCE
- SERVICE SCHEDULE
- ENGINE COVER
- Opening the Cover
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel System Service
- Maintenance
- Fuel Filter

- ENGINE LUBRICATION SYSTEM
- Engine Oil and Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- HYDRAULIC SYSTEM
- Checking and Add Fluid
- Diagnostic Couplers
- Replacement of the Hydraulic Filter
- Hydraulic Reservoir
- Replacement of the Hydraulic Fluid
- USING A BOOSTER BATTERY (JUMP STARTING)
- Procedure
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- Procedure
- HYDRAULIC SECTION
- HYDRAULIC SCHEMATICS
- HYDRAULIC SYSTEM TROUBLESHOOTING
- HYDRAULIC SERVICE INFORMATION
- Checking the Main Relief Valves
- Checking the Hydraulic Pump
- HYDRAULIC PUMP
- Disassembly
- Assembly
- HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411)
- Removal And Installation
- Parts Identification
- Disassembly
- Inlet Section (R.H. and L.H. Travel)
- Disassembly
- Assembly
- Valve Sections (Boom, Bucket & Arm)
- Disassembly
- Assembly
- Valve Sections (Auxiliary)
- Disassembly
- Assembly
- Assembly
- Port Relief Valve
- Disassembly
- Assembly
- Adjustment
- Main Relief Valve
- Disassembly
- Assembly
- Adjustment
- HYDRAULIC CONTROL VALVE (3–Spool) DUKESVALVE (S/N 511720001–511721411)
- Removal And Installation
- Parts Identification
- Disassembly
- Inlet Section (Housing Swing)
- Disassembly
- Assembly
- End Cover (Boom Swing) and Valve Section (Blade)
- Disassembly
- Assembly
- Load Check Block
- Disassembly
- Assembly
- Build–Up Valve
- Assembly
- Main Relief Valve
- Disassembly
- Assembly
- Adjustment
- HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above)
- Parts Identification
- Disassembly
- Inlet Section Disassembly And Assembly
- Right Hand & Left Hand Travel Section
- Disassembly
- Assembly
- Boom, Bucket & Arm Section
- Disassembly
- Assembly
- Auxiliary Section
- Disassembly
- Assembly
- PORT RELIEF VALVES HUSCO VALVE
- Parts Identification
- Port Relief Valve Pressure Setting
- Disassembly
- Assembly
- Adjustment
- MAIN RELIEF VALVES HUSCO VALVE
- Parts Identification
- Disassembly
- Assembly
- Adjusting The Main Relief Valves
- HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above)
- Parts Identification
- Disassembly
- Blade And Boom Swing Section
- Disassembly
- Assembly
- Lockout Valve Assembly
- Disassembly
- Lockout Valve Assembly
- Swing Motor Valve Section
- Disassembly
- Assembly
- Build–Up Valve Disassembly
- Build Up Valve Assembly
- Build Up Valve Test Procedure
- BOOM CYLINDER
- Removal And Installation
- Boom Shield
- Boom Cylinder
- ARM CYLINDER
- Removal And Installation
- BUCKET CYLINDER
- Removal And Installation
- BLADE CYLINDER
- Removal And Installation
- BOOM SWING CYLINDER
- Removal And Installation
- HYDRAULIC CYLINDER
- Disassembly
- Assembly
- Disassembly
- Assembly
- HYDRAULIC FILTER ASSEMBLY
- Removal And Installation
- AUXILIARY COUPLERS
- Removal And Installation
- JOYSTICK MANIFOLD WITH ACCUMULATOR
- Removal And Installation
- Disassembly And Assembly
- DRAIN BLOCK
- Filter Screen
- Removal And Installation
- OIL COOLER
- Removal And Installation
- JOYSTICK CONTROL CHANGE
- DRIVE SECTION
- FLOORMAT AND FLOOR PANELS
- Removal and Installation
- LEFT CONTROL CONSOLE
- Microswitch Adjustment Procedure
- Lockout Microswitch Removal and Installation
- Console Cover Removal and Installation
- Joystick Removal and Installation
- Removal and Installation
- FUEL TANK
- Removal and Installation
- LOCK LEVER
- Left Hand Removal and Installation
- Adjustment Procedure
- LATCH HOOK
- Left Hand Removal and Installation
- GAS SPRING
- Left Hand Removal and Installation
- UPPER CONSOLE
- Left Hand Removal and Installation
- RIGHT CONTROL CONSOLE
- ROPS Canopy Models
- Cab Models
- Console Cover Removal and Installation
- Joystick Removal and Installation
- Control Console Removal and Installation
- Hydraulic Tank Removal and Installation
- TRAVEL LEVERS
- Removal and Installation
- RIGHT HAND PEDAL (Boom Swing)
- Removal and Installation
- LEFT HAND PEDAL (Auxiliary)
- Removal and Installation
- ROCKERSHAFT
- Removal and Installation
- LINKAGE RODS
- Removal and Installation
- BLADE LEVER
- Removal and Installation
- FINAL DRIVE
- Removal and Installation
- DRIVE MOTOR ASSEMBLY (Kayaba) (S/N 511720001 – 23974)
- Parts Identification
- Disassembly
- Assembly
- Checking Oil Level
- Draining Final Drive Case
- DRIVE MOTOR (SOM) (S/N 23975 & Above)
- Parts Identification
- Disassembly
- Assembly
- Checking Oil Level (S/N 23975 & Above)
- JOYSTICK
- Parts Identification
- Disassembly and Assembly
- UPPER WORKS AND SWING SECTION
- SWING MOTOR
- Testing the Cross Ports Reliefs
- Start the Engine
- Removing the Cross Port Reliefs
- Removal and Installation
- Disassembly
- Assembly
- Motor Timing
- CROSS PORT RELIEF VALVE
- Disassembly
- Assembly
- Description
- UPPERSTRUCTURE
- Removal
- Installation
- CENTER SWIVEL JOINT
- Removal And Installation
- Disassembly and Assembly
- SWING CIRCLE GEAR
- Removal And Installation
- ROPS CANOPY
- Removal And Installation
- CAB
- Removal And Installation
- Door (Removal And Installation)
- Front Window (Removal And Installation)
- Front Lower Glass (Removal And Installation)
- Front Upper Plexiglass (Removal And Installation)
- Door Glass (Removal And Installation)
- Left Hand Side Glass (Removal And Installation)
- Rear Glass (Removal And Installation)
- Right Hand Side Glass (Removal And Installation)
- CAB/CANOPY REAR COVER
- Removal
- Installation
- AIR BAFFLE (Cab Models Only)
- Removal And Installation
- BELLY PAN (Field Installed)
- Removal And Installation
- MAIN FRAME AND TRACKS
- ENGINE COVER
- Removal and Installation
- REAR CORNER POSTS
- Removal and Installation
- SEAT AND SEAT MOUNT
- Removal and Installation
- SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING
- Removal and Installation
- BUCKET
- Removal and Installation
- Installation
- ARM
- Removal and Installation
- BOOM
- Removal and Installation
- SWING POST
- Removal And Installation
- Bushing Replacement
- Swing Post Bushing Removal
- Bushing Installation
- TRACK
- Track Tension Adjustment
- Removal and Installation
- Damage Identification and Causes
- TRACK FRAME
- Disassembly and Assembly
- TRACK IDLER
- Parts Identification
- Disassembly
- Assembly
- TRACK ROLLER
- Parts Identification
- Disassembly
- Assembly
- TRACK
- Damage Identification and Causes
- ELECTRICAL SYSTEM
- ELECTRICAL SCHEMATIC
- TROUBLESHOOTING
- ELECTRICAL SYSTEM
- Description
- Fuses
- Electrical System Service
- BATTERY
- Checking the Battery
- Removal and Installation
- BATTERY BOX
- Removal and Installation
- CAB ELECTRICAL (Cab Option)
- ALTERNATOR
- Checking the Alternator Output
- Belt Adjustment
- Electrical Connection
- Removal and Installation
- Check the Alternator Output
- Alternator Output Test
- Alternator Regulator Test
- Disassembly and Assembly
- Stator Continuity Test
- Stator Ground Test
- Rotor Continuity Test
- Rotor Ground Test
- Rectifier Continuity (Diode) Test
- Disassembly and Assembly (New Style)
- STARTER
- Removal and Installation
- Disassembly and Assembly
- Cleaning and Inspection
- HORN
- Removal and Installation
- FUEL LEVEL SENDER
- Removal and Installation
- ENGINE SERVICE
- TROUBLESHOOTING
- VALVE CLEARANCE
- Adjustment
- ENGINE COMPRESSION
- Checking
- FUEL FILTER
- Element
- Removing Air from the Fuel System
- Removal and Installation
- FUEL INJECTION PUMP
- Checking the Injection Pump
- Removal and Installation
- Timing the Injection Pump
- FUEL INJECTOR NOZZLES
- Checking the Injector Nozzle
- GLOW PLUGS
- Removal and Installation
- Checking the Glow Plug
- ENGINE
- Removal and Installation
- SPARK ARRESTOR MUFFLER
- RADIATOR
- Checking the Radiator and Radiator Cap
- Removal and Installation
- Hydraulic Pump Coupler
- CYLINDER HEAD
- Removal of the Cylinder Head
- Disassembly of the Cylinder Head
- Servicing the Cylinder Head and Valves
- Checking Valve Springs
- Checking Rocker Arm and Shaft
- Installing the Cylinder Head
- TIMING GEAR COVER
- Removal and Installation
- TIMING GEAR, CAMSHAFT AND OIL PUMP
- Removal and Installation
- Oil Pump Service
- Servicing the Camshaft
- CRANKSHAFT AND PISTONS
- Removal and Installation
- Crankshaft Service
- Servicing the Connecting Rods and Pistons
- CYLINDER LINERS
- Checking the Cylinder Liners
- Cylinder Liner Installation
- WATER PUMP
- Removal and Installation
- Disassembly and Assembly
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity
- SPECIFICATIONS
- ENGINE SPECIFICATIONS
- Engine
- Fuel Injector Nozzles
- Fuel Injection Pump
- Cylinder Head
- Valves
- Valve Springs
- Rocker Arms
- Camshaft
- Cylinders
- Piston Rings
- Pistons
- Crankshaft
- Oil Pump
- Thermostat
- Engine Torque
- Crankshaft Re–Grind Data
- FUEL, COOLANT AND LUBRICANTS
- OIL SPECIFICATIONS
- BUCKET SPECIFICATIONS
- SERVICE MANUAL REVISON
- 320-1
- 320-2
- 320-3
- 320-4

320 6724026 OM 9-96

- CONTENTS
- FOREWORD
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION
- SAFETY
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- MACHINE SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- GETTING ON AND OFF THE MACHINE
- SEAT
- CONTROL LEVER (JOYSTICK) LOCK
- INSTRUMENTS
- OPERATOR’S HANDBOOK
- STORAGE COMPARTMENT
- AUDIBLE ALARM
- KEY SWITCH
- LIGHT SWITCH
- AUXILIARY POWER OUTLET
- CAB ELECTRICAL (Cab Option)
- HEATER
- WINDSHIELD WASHER TANK (If equipped)
- CONTROL LEVERS (JOYSTICKS)
- Operation of Left Control Lever (ISO)
- Operation of Right Control Lever (ISO)
- CONTROL LEVERS (STANDARD)
- Operation of Left Control Lever (STANDARD)
- Operation of Right Control Lever (STANDARD)
- SWING LOCK
- HORN BUTTON
- SPEED CONTROL LEVER
- ENGINE STOP CONTROL
- STEERING LEVERS/FOOT PEDALS
- Forward and Reverse Travel
- Turning
- BOOM SWING PEDAL AND LOCK
- BLADE CONTROL LEVER
- AUXILIARY OPERATION PEDAL
- Flush Face Couplers
- DAILY INSPECTION
- STARTING THE ENGINE
- Normal Starting Procedure (With Engine Warm)
- Cold Temperature Starting Procedure
- OPERATING PROCEDURE
- Breaking in a New Machine
- General Operation Suggestions
- Operating in Water
- PARKING THE HYDRAULIC EXCAVATOR
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- LIFTING THE EXCAVATOR
- LIFTING A LOAD
- BUCKET
- Removal
- Installation
- CAB/CANOPY
- CAB/CANOPY FOPS (Falling Object Protective Structure)
- Front Window
- Emergency Exit
- CAB OPTION
- Opening the Front Window
- Closing the Front Window
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- Daily Check
- Filter Replacement
- FUEL SYSTEM
- Fuel Specification
- Filling the Fuel Tank
- Fuel System Maintenance
- Fuel Filters
- Removing Air from the Fuel System
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- Propylene Glycol
- SPARK ARRESTOR MUFFLER
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Service the Electrical System
- Using A Booster Battery (Jump Starting)
- Removal and Installation of the Battery
- HYDRAULIC SYSTEM
- Checking and Adding Fluid
- Diagnostic Couplers
- Replacement of the Hydraulic Filter
- Hydraulic Reservoir
- Replacement of the Hydraulic Fluid
- Filter Screen
- In–Line FIlter (S/N 511724187 & Above)
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- FINAL DRIVE CASE
- Checking Oil Level (S/N 511721116–511723974)
- Replacing Final Drive Case Oil (S/N 511721116–511723974)
- Checking Oil Level (S/N 511723975 & Above)
- Replacing Final Drive Case Oil (S/N 511723975 &Above)
- TRACK TENSION
- Adjustment
- JOYSTICK CONTROL CHANGE
- ISO to Standard Control Pattern
- Standard to ISO Control Pattern
- MACHINE SIGN TRANSLATIONS
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity
- WEIGHTS
- CONTROLS
- ENGINE
- ELECTRICAL
- HYDRAULIC SYSTEM
- SWING SYSTEM
- HYDRAULIC CYLINDERS
- DRIVE SYSTEM
- BRAKES
- UNDERCARRIAGE
- STD TRACK SHOES
- CAPACITIES
- DIGGING FORCE
- FUEL, COOLANT AND LUBRICANTS
- ENGINE OIL SPECIFICATIONS
- Description
- Propylene Glycol (Factory Installed)
- BUCKET SPECIFICATIONS
- WARRANTY

320 6724893 OM 3-99

- OPERATOR SAFETY WARNINGS
- CONTENTS
- REGULAR MAINTENANCE ITEMS
- FOREWORD
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- SAFETY
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- MACHINE SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- INSTRUMENT PANEL
- KEY SWITCH
- STEERING LEVERS/FOOT PEDALS
- Forward And Reverse Travel
- Turning
- Right Turn
- Left Turn
- AUXILIARY POWER OUTLET
- CAB/CANOPY
- CAB/ CANOPY FOGS (Falling Object Guards)
- CAB OPTION
- Emergency Exit
- Cab Door
- Front Window
- CAB OPTION (Later Models)
- Opening The Front Window
- Closing The Front Window
- CAB OPTION (Early Models)
- Opening The Front Window
- Closing The Front Window
- ELECTRICAL
- WINDSHIELD WASHER TANK (If Equipped)
- HEATER CONTROL
- LIGHT SWITCH (Cab/Canopy)
- FUSES
- AUDIBLE ALARM
- HORN BUTTON
- SEAT
- SPEED CONTROL LEVER
- OPERATOR'S HANDBOOK
- STORAGE COMPARTMENT
- ENGINE COVER
- TOOL BOX
- AUXILIARY HYDRAULIC PEDAL
- Flush Face Couplers
- BLADE CONTROL LEVER
- SWING LOCK
- BOOM SWING PEDAL
- CONTROL LEVERS (JOYSTICKS)
- Operation Of Left Control Lever (ISO)
- Operation Of Right Control Lever (ISO)
- Operation Of Left Control Lever (Standard)
- Operation Of Right Control Lever (Standard)
- CONTROL LEVER (JOYSTICK) LOCK
- TWO SPEED TRAVEL FOOT PEDAL
- GETTING ON AND OFF THE MACHINE
- DAILY INSPECTION
- STARTING THE ENGINE
- Normal Starting Procedure (With Engine Warm)
- Cold Temperature Starting Procedure
- BUCKET
- Removal
- Installation
- OPERATING PROCEDURE
- Operating On Public Roads
- Lifting A Load
- Excavating
- Boom Offset
- Back Filling
- Driving The Excavator
- Operating On Slopes
- Operating In Water
- PARKING THE HYDRAULIC EXCAVATOR
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- LIFTING THE HYDRAULIC EXCAVATOR
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- Adjustment Of The Engine Cover Latch
- AIR CLEANER SERVICE
- Daily Check
- Filter Replacement
- FUEL SYSTEM
- Filling The Fuel Tank
- Fuel Filter
- Fuel System Maintenance
- Removing Air From The Fuel System
- Fuel Specification
- ENGINE LUBRICATION SYSTEM
- Checking Engine Oil
- Replacement Of Oil And Filter
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Electrical Relays And Diodes
- Fuses
- Service The Electrical System And Battery
- Using A Booster Battery (Jump Starting)
- Removal And Installation Of The Battery
- Electrical Solenoid (Engine Stop)
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Diagnostic Couplers
- Replacement Of The Hydraulic Filter
- Hydraulic Reservoir
- Case Drain Hydraulic Filter
- SPARK ARRESTOR MUFFLER (If So Equipped)
- TRACK TENSION
- Adjustment
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- JOYSTICK CONTROL CHANGE
- ISO To Standard Control Pattern
- Standard To ISO Control Pattern
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- HEATER AIR FILTER (With Cab Option Only)
- MACHINE SIGN TRANSLATIONS
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity
- WEIGHTS
- CONTROLS
- ENGINE
- ELECTRICAL
- HYDRAULIC SYSTEM
- SWING SYSTEM
- HYDRAULIC CYLINDERS
- DRIVE SYSTEM
- BRAKES
- UNDERCARRIAGE
- STD TRACK SHOES
- CAPACITIES
- DIGGING FORCE
- FUEL, COOLANT AND LUBRICANTS
- Chart
- ENGINE OIL SPECIFICATIONS
- Description
- Propylene Glycol (Factory Installed)
- BUCKET SPECIFICATIONS
- ADDITIONAL PUBLICATIONS & TRAINING MATERIALS
- WARRANTY

320 6724910 SM 1-97

- MAINTENANCE SAFETY
- ALPHABETICAL INDEX
- CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- Adjustment of the Engine Cover Latch
- AIR CLEANER SERVICE
- Daily Check
- Filter Replacement
- FUEL SYSTEM
- Filling the Fuel Tank
- Fuel Filter
- Fuel System Maintenance
- Removing Air From the Fuel System
- Fuel Specification
- ENGINE LUBRICATION SYSTEM
- Checking Engine Oil
- Replacement of Oil and Filter
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- Propylene Glycol (Factory Installed)
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Electrical Relays and Diodes
- Fuses
- Service the Electrical System (and Battery)
- Removal and Installation of the Battery
- Electric Solenoid (Engine Stop)
- HYDRAULIC SYSTEM
- Checking and Adding Fluid
- Diagnostic Couplers
- Hydraulic Reservoir
- Replacement of the Hydraulic Filter
- Case Drain Hydraulic Filter
- TRACK TENSION
- Adjustment
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- JOYSTICK CONTROL CHANGE
- ISO to Standard Control Pattern
- Standard to ISO Control Pattern
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- HEATER AIR FILTER (With Cab Option Only)

- HYDRAULIC SECTION
- HYDRAULIC SCHEMATICS
- TROUBLESHOOTING
- HYDRAULIC SERVICE INFORMATION
- Checking the Main Relief Valves and Cross Port Relief Valve
- Checking the Hydraulic Pump
- HYDRAULIC PUMP
- Removal and Installation
- Coupler Removal and Installation
- Hydraulic Pump Assembly
- Disassembly
- Assembly
- HYDRAULIC CONTROL VALVE
- Description
- Removal and Installation
- Disassembly
- Outlet Section Disassembly
- Outlet Section Assembly
- Mid Inlet Section Disassembly
- Mid Inlet Section Assembly
- Left Travel, Right Travel, Auxiliary and Blade Disassembly
- Left Travel, Right Travel, Auxiliary and Blade Assembly
- Boom, Bucket Arm and Swing Disassembly
- Boom, Bucket, Arm and Swing Assembly
- Utility Block Disassembly
- Utility Block Assembly
- Boom Swing Disassembly
- Boom Swing Assembly
- Boost Disassembly
- Boost Assembly
- Assembly
- PORT RELIEF VALVES
- Parts Identification
- Port Relief Valve Pressure Setting
- Disassembly
- Assembly
- Adjustment Procedure
- Disassembly
- Assembly
- Adjusting the Main Relief Valves
- ACCUMULATOR
- Pressure Reducing Valve (Description)
- Removal and Installation
- Disassembly (S/N 562313001 – 562320721 &517811001 – 517811977)
- Assembly (S/N 562313001 – 562320721 & 517811001– 517811977)
- Parts Identification (S/N 562320721 & Above & 517811978 & Above)
- Disassembly (S/N 562320721 & Above & 517811978 & Above)
- Assembly (S/N 562320721 & Above & 517811978 & Above)
- Testing (All Models)
- BOOM CYLINDER
- Removal and Installation
- ARM CYLINDER
- Removal and Installation
- BUCKET CYLINDER
- Removal and Installation
- BLADE CYLINDER
- Removal and Installation
- BOOM SWING CYLINDER
- Removal and Installation
- TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above)
- HYDRAULIC CYLINDER
- Disassembly
- Assembly
- Disassembly
- Assembly
- HYDRAULIC FILTER ASSEMBLY
- Removal and Installation
- AUXILIARY FLUSH FACE COUPLERS
- Removal and Installation
- DRAIN BLOCK
- Removal and Installation
- OIL COOLER
- Removal and Installation
- JOYSTICK CONTROL CHANGE
- ISO To Standard
- Standard to ISO
- DRIVE SECTION
- FLOORMAT AND FLOOR PANELS
- Removal and Installation
- MICROSWITCH
- Adjustment
- Removal and Installation
- CONSOLE COVER LEFT HAND
- Removal and Installation
- JOYSTICK
- Removal and Installation
- CONTROL CONSOLE LEFT HAND
- Removal and Installation
- FUEL TANK
- Removal and Installation
- LOCK LEVER
- Removal and Installation
- Adjustment
- LATCH HOOK
- Removal and Installation
- GAS SPRING
- Removal and Installation
- UPPER CONSOLE
- Removal and Installation
- CONTROL CONSOLE RIGHT HAND
- Rops Canopy Models
- Cab Models
- CONSOLE COVER RIGHT HAND
- Removal and Installation
- CONTROL CONSOLE RIGHT HAND
- Removal and Installation
- HYDRAULIC RESERVOIR
- Removal and Installation
- TRAVEL LEVERS
- Removal and Installation
- Disassembly and Assembly
- PEDAL RIGHT HAND
- Removal and Installation
- Disassembly and Assembly
- PEDAL LEFT HAND
- Removal and Installation
- Disassembly and Assembly
- ROCKERSHAFT
- Removal and Installation
- Disassembly and Assembly
- LINKAGE RODS
- Removal and Installation
- BLADE LEVER
- Removal and Installation
- Disassembly and Assembly
- DRIVE MOTOR
- Removal and Installation
- Parts Identification
- Disassembly
- Assembly
- JOYSTICK
- Parts Identification
- Disassembly
- Assembly
- Troubleshooting
- UPPER WORKS AND SWING SECTION
- SWING MOTOR
- Removal and Installation
- Disassembly
- Assembly
- Motor Timing
- CENTER SWIVEL JOINT (S/N 562313001 – 562319999)
- Removal and Installation
- Disassembly and Assembly
- CENTER SWIVEL JOINT 320 (S/N 562320000 &Above) and 322 (S/N 517811001 & Above)
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- UPPERSTRUCTURE
- Removal
- Installation
- SWING CIRCLE GEAR
- Removal and Installation
- ROPS CANOPY
- Removal and Installation
- CAB
- Removal and Installation
- Door (Removal and Installation)
- Front Window Removal and Installation
- Front Lower Window Removal and Installation
- Front Upper Window Removal and Installation
- Door Glass (Removal and Installation)
- Left Hand Side Glass (Removal and Installation)
- Right Hand Side Window Removal and Installation
- Right Hand Window Assembly Removal and Installation
- Rear Window Removal and Installation
- CAB/CANOPY REAR COVER
- Removal
- Installation
- AIR BAFFLE (Cab Models Only)
- Removal and Installation
- BELLY PAN (Field Installed)
- Removal and Installation
- MAIN FRAME AND TRACKS
- ENGINE COVER
- Removal and Installation
- CORNER POSTS
- Removal and Installation
- COUNTERWEIGHT
- Removal and Installation
- SEAT AND SEAT MOUNT
- Removal and Installation
- SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING
- Removal and Installation
- BUCKET
- Removal and Installation
- Installation
- ARM
- Removal and Installation
- ARM BUSHINGS
- Arm To Boom Bushing Removal And Installation
- Arm To Bucket and Bucket Link Bushing Removal and Installation
- BOOM
- Removal and Installation
- BOOM BUSHING
- Removal And Installation
- SWING POST
- Removal and Installation
- Bushing Replacement
- Swing Post Bushing Removal
- Bushing Installation
- TRACK
- Adjustment 320 (S/N 562313001 – 562319999)
- Adjustment 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)
- Removal and Installation
- Track Damage Identification and Causes
- TRACK FRAME
- Disassembly and Assembly 320 (S/N 562313001 – 562319999)
- Disassembly and Assembly 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)
- Recoil Spring Cylinder Disassembly And Assembly
- Removal and Installation of Expandible Track Frame (322 only)
- TRACK DAMAGE IDENTIFICATION
- Cutting of the Steel Cords
- Abrasion of Embedded Metals
- Separation of Embedded Metals Due to External Forces
- Separation of Embedded Metals Due To Corrosion
- Cuts On The Lug Side
- Cracks On The Lug Side Rubber Due To Fatigue
- Lug Abrasion
- Cracks and Cuts on the Lug Side Rubber at the Edges of the Embedded Metals
- Abrasion Of The Track Roller Side Rubber Surface
- Cuts On The Edges Of The Track Roller Side
- ELECTRICAL SYSTEM
- ELECTRICAL SCHEMATICS
- TROUBLESHOOTING
- Chart
- ELECTRICAL SYSTEM
- Description
- Fuses
- Electrical System Service
- Electrical Relays and Diodes
- BATTERY
- Using A Booster Battery (Jump Starting)
- Removal and Installation
- BATTERY BOX
- Removal and Installation
- CAB ELECTRICAL (Cab Option)
- Removal and Installation
- ALTERNATOR
- Checking the Alternator Output
- Removal and Installation
- Belt Adjustment
- STARTER
- Removal and Installation
- Disassembly and Assembly
- Cleaning and Inspection
- HORN
- Removal and Installation
- FUEL LEVEL SENDER
- Removal and Installation
- LIGHT SWITCH
- Removal and Installation
- TWO SPEED SWITCH
- Removal and Installation
- ENGINE SERVICE
- TROUBLESHOOTING
- Chart
- VALVE CLEARANCE
- Adjustment
- ENGINE COMPRESSION
- Checking
- FUEL SHUTOFF SOLENOID
- Removal and Installation
- Timer Module Removal and Installation
- FUEL INJECTION PUMP
- Checking the Injection Pump
- Timing the Injection Pump
- FUEL INJECTOR NOZZLES
- Removal and Installation
- Checking the Injector Nozzle
- GLOW PLUGS
- Removal and Installation
- Checking the Glow Plug
- BELT GUARD
- Removal and Installation
- RADIATOR
- Removal and Installation
- SPARK ARRESTOR MUFFLER (If Equipped)
- Cleaning Spark Chamber
- Removal and Installation
- AIR CLEANER
- Removal and Installation
- ENGINE
- Removal and Installation
- ENGINE FLYWHEEL (EARLY MODELS)
- Removal and Installation
- Hydraulic Pump Coupler
- ENGINE FLYWHEEL (LATER MODELS)
- Removal And Installation
- Hydraulic Pump Coupler
- Flywheel Ring Gear
- CYLINDER HEAD
- Removal and Installation
- Disassembly and Assembly
- Servicing the Cylinder Head
- Top Clearance
- VALVE, VALVE SEAT AND GUIDE
- Checking the Valve Guide
- Reconditioning the Valve and Valve Seat
- Valve Spring
- ROCKER ARM AND SHAFT
- Checking
- TIMING GEARCASE COVER
- Removal and Installation
- IDLER GEAR AND CAMSHAFT
- Removal and Installation
- Servicing the Idler Gear and Shaft
- TIMING GEARS
- Checking Backlash
- FUEL CAMSHAFT
- Removal and Installation
- CRANKSHAFT GEAR
- Removal and Installation
- OIL PUMP
- Removal and Installation
- Oil Pump Service
- Checking Engine Oil Pressure
- Relief Valve
- PISTON AND CONNECTING ROD
- Removal and Installation
- Servicing the Piston and Connecting Rod
- Connecting Rod Alignment
- CRANKSHAFT AND BEARINGS
- Removal and Installation
- Servicing the Crankshaft and Bearings
- CYLINDER BORE
- Checking the Cylinder Bore
- WATER PUMP
- Removal and Installation
- Disassembly and Assembly
- TECHNICAL DATA
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- SPECIFICATIONS
- ENGINE SPECIFICATIONS
- Engine
- Fuel Injector Nozzles
- Fuel Injection Pump
- Cylinder Head
- Valves
- Valve Springs
- Rocker Arms
- Camshaft
- Cylinders
- Piston Rings
- Pistons
- Crankshaft
- Oil Pump
- Thermostat
- ENGINE BOLT TORQUE
- Re–Grinding The Crankshaft
- HYDRAULIC FLUID SPECIFICATIONS
- Specifications
- FUEL, COOLANT AND LUBRICANTS
- Chart
- SERVICE MANUAL REVISION
- 320-1
- 320-2
- 320/322-3
- 320/322-4
- 320/322-5

325 6722714 OM 9-97

- OPERATOR SAFETY WARNINGS
- CONTENTS
- REGULAR MAINTENANCE ITEMS

- FOREWORD
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- SAFETY
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- MACHINE SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- GETTING ON AND OFF THE MACHINE
- SEAT
- CONTROL CONSOLE LEVER LOCK
- INSTRUMENT PANEL
- FUSES
- AUDIBLE ALARM
- KEY SWITCH
- LIGHT SWITCH
- AUXILIARY POWER OUTLET
- CAB ELECTRICAL (Cab Option)
- HEATER CONTROL
- WASHER
- CONTROL LEVERS
- Operation Of Left Control Lever (ISO)
- Operation Of Right Control Lever (ISO)
- Operation Of Left Control Lever (STANDARD)
- Operation Of Right Control Lever (STANDARD)
- SWING LOCKING LEVER
- HORN BUTTON
- SPEED CONTROL LEVER
- ENGINE STOP CONTROL
- STEERING LEVERS/FOOT PEDALS
- Forward and Reverse Travel
- Turning
- Making A Counter–Rotation Turn
- BOOM SWING PEDAL
- AUXILIARY OPERATION PEDAL LOCK/FOOTREST
- BLADE CONTROL LEVER
- DAILY INSPECTION
- STARTING/STOPPING THE ENGINE
- Normal Starting Procedure (With Engine Warm)
- Cold Temperature Starting Condition
- OPERATING PROCEDURE
- Breaking In A New Machine
- Operating On Slopes
- Operating in Water
- PARKING THE HYDRAULIC EXCAVATOR
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- LIFTING THE EXCAVATOR
- LIFTING A LOAD
- BUCKET
- Removal
- Installation
- OPERATOR’S HANDBOOK (If Equipped)
- STORAGE COMPARTMENT (If Equipped)
- CAB OPTION
- Opening the Front Window
- Closing the Front Window
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel Specifications
- Fuel System Service
- Fuel Filter
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- Ethylene Glycol
- Propylene Glycol
- ALTERNATOR/FAN BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Fuses
- Service The Electrical System
- Using A Booster Battery (Jump Starting)
- Removal and Installation of the Battery (S/N 511820001–511820294)
- Removal and Installation of the Battery (S/N 511820295 & Above)
- HYDRAULIC SYSTEM
- Checking and Adding Fluid
- Replacement of the Hydraulic Filter
- Hydraulic Reservoir
- Case Drain Line Filter
- Diagnostic Couplers
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- TRACK TENSION
- Adjustment
- Rubber Tracks
- Steel Tracks
- JOYSTICK CONTROL CHANGE
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity
- OPERATION & PERFORMANCE
- ENGINE
- HYDRAULIC SYSTEM
- SWING SYSTEM
- CYLINDER CYCLE TIMES
- HYDRAULIC CYLINDERS
- DRIVE SYSTEM
- UNDERCARRIAGE
- BRAKES
- TRACKS
- CAPACITIES
- DIGGING FORCE
- FUEL, COOLANT AND LUBRICANTS
- ENGINE OIL SPECIFICATIONS
- Description
- Ethylene Glycol
- Propylene Glycol
- BUCKET SPECIFICATIONS
- ADDITIONAL PUBLICATIONS
- WARRANTY

325 6722849 SM 4-94

- MAINTENANCE SAFETY
- ALPHABETICAL INDEX
- FOREWORD
- CONTENTS
- SAFETY INSTRUCTIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- PREVENTIVE MAINTENANCE
- SERVICE SCHEDULE
- ENGINE COVER
- Procedure
- AIR CLEANER SERVICE
- Replacing The Filter Element
- FUEL SYSTEM
- Fuel Specification
- Fuel System Service
- Fuel Filter
- Maintenance
- Removal And Installation
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Checking The Engine Oil
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Replacement Of The Hydraulic Filter
- Hydraulic Reservoir
- USING A BOOSTER BATTERY (Jump Starting)
- Procedure
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- Procedure
- FINAL DRIVE CASE
- Chec