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
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
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
Never service the Hydraulic Excavator instructions.
Bobcat without
WRONG
B–14147
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
i
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
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
v
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
vii
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].
Revised July 05
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320/322 Excavator Service Manual
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
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
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
FUEL SYSTEM
A
Filling the Fuel Tank
2 1
Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W–2063–0887
P–11035
The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the ignition switch is ON.
B
NOTE: When the fuel level reaches the .8 gals. (3.1 L.) fuel level, the low fuel light (Item 2) [A] will come ON to alert the operator of this condition. Use the key to unlock the left side cover [B]. Turn the fuel cap to remove it [C]. Use a clean, approved safety container to add fuel to the tank. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING! After the tank is full, install and tighten the fuel cap. Close and lock the fuel door.
P–11063
C
Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285
Fuel Filter P–11064
See the SERVICE SCHEDULE Page 1–4 for the service interval when to replace the fuel filter.
D
The fuel filter is located under the left hand side of the excavator Loosen the drain (Item 1) [D] at the bottom of the filter element to drain any water from the fuel filter. Tighten the drain when all the water has been removed.
2
Remove the filter element (Item 2) [D].
1
Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter and hand tighten. Remove the air from the fuel filter.
P–11065
–1–7–
320/322 Excavator Service Manual
FUEL SYSTEM (Cont’d)
A
Fuel System Maintenance See the SERVICE SCHEDULE Page 1–4 for the correct service intervals. To remove water and sediment from the fuel tank, turn the upperstructure until the fuel tank is centered between the rear tracks.
1
Open the drain valve (Item 1) [A] at the bottom of the fuel tank. Drain contaminated fuel into a container.
P–11066
Removing Air From the Fuel System After replacing the fuel filter or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.
B
Open the vent (Item 1) [B] on the fuel filter housing. Operate the hand pump (priming bulb) (Item 1) [C] until the fuel flows from the vent with no air bubbles.
1
Tighten the vent plug. Start the engine. It may be necessary to open the vent (Item 1) [D] at the fuel injection pump briefly until the engine runs smoothly. Fuel Specification
P–11067
Use only clean, high quality diesel fuel, Grade No. 1 or Grade No.2.
C
The following is suggested blending guideline which should prevent fuel gelling problems. Temp. F°
No. 2
No. 1
+15°(9°c) Down to –20° (–29°c) Below –20° (–29°c)
100% 50% 0%
0% 50% 100%
For local recommendations, the operator can contact his fuel supplier.
1 P–11065
D Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285
1 P–11068
–1–8–
320/322 Excavator Service Manual
ENGINE LUBRICATION SYSTEM
A
Checking Engine Oil Check the engine oil every day. Stop the engine. Open the engine cover. Remove the dipstick (Item 1) [A]. Keep the oil level between the marks on the dipstick.
1
Use a good quality motor oil that meets the correct API Service Classification. (See Fuel, Coolant and Lubrication Chart, Page 8–1.) P–11069
Replacement of Oil and Filter
B
See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Run the engine until it is at operating temperature. Stop the engine.
1
Open the engine cover. Remove the drain plug (Item 1) [B] from the oil pan. Drain the oil into a container.
P–11070
Remove the oil filter (Item 1) [C], using a filter wrench.
C
Clean the filter housing surface. Put clean oil on the filter gasket. Install the new filter and hand tighten only. Install and tighten the oil drain plug.
1 Remove the oil fill cap (Item 1) [D]. Put in 3.4 qts. (3,2 L) of oil into the engine. (See Fuel, Coolant and Lubricants Chart, Page 8–1.)
P–11071
D
Start the engine and let it run for several minutes.Stop the engine. Check for leaks at the oil filter and the oil drain plug. Check the oil level and add oil as needed if it is not at the top mark on the dipstick.
1
P–11072
–1–9–
320/322 Excavator Service Manual
COOLING SYSTEM
A
Coolant Level When the engine is cool, remove the radiator cap (Item 1) [A]. The coolant level must be 3/4 to 1 inch (19 to 25 mm) below the filler neck. If the coolant level is low, add premixed coolant to the radiator. (See type of coolant information below.)
1
Coolant Replacement Turn the upperstructure so there is access to the engine and radiator from between the tracks. Stop the engine.
P–11073
When the engine is cool, loosen and remove the radiator cap (Item 1) [A].
B
Open the radiator drain valve (Item 1) [B] at bottom of radiator. Drain the coolant into a container.
1 P–11074
C
Open the engine block drain valve (Item 1) [C] and drain the coolant into a container. After all the coolant is removed, close both drain valves.
Propylene Glycol (Factory Installed)
1
Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.
P–11075
1 gallon and 1 pint of propylene glycol mixed with 1 gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection. Use a refractometer to check the condition of propylene glycol in your cooling system. Fill the radiator with the premixed coolant until it is 3/4 to 1 in. (19 to 25 mm) below the filler neck.
Do not remove radiator cap when the engine is hot. You can be seriously burned.
Run the engine at idle speed for about 5 to 10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation).
W–2070–1285
Stop the engine. Check the coolant level and add as needed to bring it up to the radiator filler neck. Install the radiator cap and tighten. –1–10–
320/322 Excavator Service Manual
ALTERNATOR BELT ADJUSTMENT
A
To adjust the belt tension, use the following procedure: Stop the engine. Open the engine cover. The belt should deflect about 1/2 in. (13 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 13 ft.–lb. (58 NSm) pressure [A].
2
If the tension is not correct, Loosen the alternator mounting bolt (Item 1) [A].
1
Loosen the alternator adjustment bolt (Item 2) [A].
P–11076
Move the alternator until the belt tension is correct.
B
Tighten the adjustment bolt and mounting bolt. Replace the belt if it has stretched or there are cracks in the belt. Check the pulley grooves, make sure the belt is not in contact with the bottom of the grooves in the pulleys. ELECTRICAL SYSTEM
1
Electrical Relays and Diodes
2
The 3 engine harness electrical relays (Item 1) [B] and the fuel shut off timer (Item 2) [B] are located in the engine compartment to the right of the air cleaner.
P–11036
The 3 relays (Item 1) [B] control the starter, glow plugs and switched power circuits.
C
The 2 diodes (Item 1) [C], are for alternator feedback protection and the glow plug during start function.
1
P–11077
–1–11–
320/322 Excavator Service Manual
ELECTRICAL SYSTEM (Cont’d)
A
The excavator has a 12 volt, negative ground electrical system. Fuses The fuses are located in the right side of the engine compartment [A]. 1. FUSE – 10 AMP: This fuse supplies power to the instrument circuit [B]. 2. FUSE – 15 AMP: This fuse supplies power to any accessory that is powered when the key is in the run position [B]. 3. FUSE – 20 AMP: This fuse supplies power to the ignition circuit [B]. 4. FUSE – 15 AMP: This fuse supplies power to the cab wiring (if equipped) [B]. 5. FUSE – 15 AMP: This fuse supplies power to any accessory that has constant power [B]. 6. FUSE – 15 AMP: This fuse supplies power to the timer [B]. 7. FUSE – 15 AMP: This fuse supplies power to the timer when it is powered by the ignition switch [B]. 8. NOT USED
P–11036
B 3
4
6
5
Replace all fuses with the same type and capacity. NOTE: Before replacing any fuse, find and fix the problem that caused the circuit overload. Make sure the key switch is in the OFF position before replacing the fuse.
2
Service the Electrical System (and Battery)
1
8
Remove the left side cover [C], using the ignition key to unlock the cover.
7 B–14855
C
The battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery saver grease [D]. Check for broken or loose connections. If the battery cables are removed for any reason, disconnect the negative (–) cable first and when installing the battery cables, make the last connection the negative (–) cable to the battery. With factory equipped battery, no maintenance is needed as this is a maintenance free battery. If the machine has a BobcatR parts replacement battery installed, check the electrolyte level in the battery.
P–11063
If it is lower than 1/2 in. (13 mm) above the plates, add distilled water only.
D +
–
Batteries contain acid which burns eyes and skin on contact. Wear goggles and protective clothing to keep acid off body. In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact. W–2201–0595
P–11098
–1–12–
320/322 Excavator Service Manual
ELECTRICAL SYSTEM (Cont’d)
A
Removal and Installation of the Battery Remove the side cover. (See Page 1–12.) Disconnect the negative (–) cable (Item 1) [A] first. Disconnect the positive (+) cable (Item 2) [A].
2
1
P–11098
Remove the bolt (Item 1) [B] and remove the hold down clamp (Item 2) [B].
B
2 1
P–11100
Remove the battery from the compartment [C].
C
Always clean the terminals and the cable ends, even when installing a new battery. Install the battery. Install the hold down clamp and tighten the bolt. Connect the battery cables. Connect the negative (–) cable (Item 1) [A] last to prevent sparks at the terminal.
P–11101
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
D
In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact.
1
W–2065–1286
Electric Solenoid (Engine Stop) The electric solenoid (Item 1) [D] shuts off fuel supply and stops the engine when the key is turned to the OFF position. P–11078
–1–13–
320/322 Excavator Service Manual
HYDRAULIC SYSTEM
A
Checking and Adding Fluid To check and add hydraulic fluid to the reservoir, use the following procedure: Put the machine on a flat level surface. Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine. Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [A] located on the side of the hydraulic reservoir.
1 P–11079
B
If the fluid level is not correct, use the ignition key and open the right side cover [B].
P–11080
Remove oil fill cap [C].
C
Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285 P–11081
Check the condition of the fill strainer [D]. The screen must be installed in fill neck when adding oil.
D
Add the correct fluid to the reservoir until it is visible in the sight gauge. (See Fuel, Coolant and Lubricants Chart, Page 8–1.) Install the reservoir cap. Close and lock the access door.
P–11103
–1–14–
320/322 Excavator Service Manual
HYDRAULIC SYSTEM (Cont’d)
A
Diagnostic Couplers The diagnostic couplers are located on each hydraulic pump (Item 1) [A]. The couplers can be used to check circuit pressures. (Refer to the Service Manual.) Hydraulic Reservoir See the SERVICE SCHEDULE Page 1–4 for the correct service interval.
1 P–11082
Move the upperstructure so there is clearance for the reservoir drain between the tracks.
B
Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine. Remove and replace the hydraulic filter (See below). Remove the drain plug from the bottom of the reservoir [B]. Drain the fluid into a container. Install the drain plug. Add approximately 3.65 gals. (13,8 L) of fluid to the reservoir. (See Fuel, Coolant and Lubricants Chart, Page 8–1.)
N–00805
Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed.
C
Replacement of the Hydraulic Filter See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Open the engine cover. Use a filter wrench and remove the filter element (Item 1) [C]. Clean the housing contact.
where the filter
gasket makes
1
Put clean hydraulic fluid on the gasket. Install the new filter element and hand tighten only.
P–11083
Start the engine. Run the machine through the hydraulic functions. Stop the engine. Check the fluid level at the reservoir and add as needed. Check around the filter for leaks.
D
Case Drain Hydraulic Filter See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Open the right side cover. (See Page 1–12.)
1
Remove the case drain filter (Item 1) [D]. Install a new case drain filter. P–11084
–1–15–
320/322 Excavator Service Manual
SPARK ARRESTOR MUFFLER (if equipped)
A
See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Do not operate the excavator with a defective exhaust system.
This excavator is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.
1
If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.
P–11085
When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.
Make reference to local laws and regulations for spark arrestor requirements. I–2061–0195
W–2050–1285
Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.
Stop the engine. Open the engine cover.
W–2011–1285
Remove the plug (Item 1) [A] from the bottom of the muffler.
Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.
Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. (The carbon deposits will be forced out of the muffler plug hole.)
W–2068–1285
Stop the engine. Install and tighten the plug. Close the engine cover.
When the engine is running during service, the steering levers must be in neutral. Failure to do so can cause injury or death. W–2203–0595
–1–16–
320/322 Excavator Service Manual
TRACK TENSION
A
NOTE: The wear of the parts on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. (See SERVICE SCHEDULE Page 1–4 for the correct service interval.) Adjustment Raise 1 side of the machine (approximately 4 in. [102 mm]) using the boom and arm as shown in [A]. Raise the blade fully and install jackstands under the blade and the track frame [A]. Operate the boom until all machine weight is on the jackstands.
P–02239
B
Stop the engine.
AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension. W–2142–0189
Measure the distance between the frame and the top of the track. If the distance is between 2.25 to 2.50 in. (57 to 63 mm), the track tension is correct [B].
P–11086
C
If not, loosen 1 bolt (Item 1) [C] and remove the other bolt (Item 2) [C] from the cover. Add grease to the fitting (Item 1) [D] until the track tension is correct. If track tension is too tight, decrease the track tension pressure by loosening the bleed screw (Item 2) [D] (maximum of 1 turn) and allow grease to flow out of the bleed screw. When the tension is correct, tighten the bleed screw.
1 2
Repeat the procedure for the other side. If the track tension is still loose after adjusting to the above mentioned limit, it indicates the track is worn. See your dealer for repairs.
P–11087
D 2
AVOID INJURY Do not loosen the grease fitting more than one complete rotation. Also, be careful not to loosen any part other than the grease fitting. If the grease fitting or any part is loosened too much, it can fly off under high pressure. If the grease does not ooze smoothly, try moving the machine back and forth for a short distance.
1
W–2143–0189 P–11088
–1–17–
320/322 Excavator Service Manual
FINAL DRIVE CASE
A
Checking Oil Level
2
Put the machine on a level surface with the plugs positioned as shown in figure [A]. Remove the plug (Item 1) [A]. The oil level should be at the bottom edge of the plug hole.
1
Add gear lube 90W through the hole (Item 2) [A] if the oil level is below the hole (Item 1) [A]. (See Fuel, Coolant and Lubricant Chart, Page 8–1) Install and tighten both plugs. P–11166
Repeat the procedure for the other side.
B
Draining Final Drive Case See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Put the machine on a level surface with the plugs positioned as shown in figure [B].
2
Remove the bottom plug (Item 1) [B] and top plug (Item 2) [B]. After all the gear lube is removed, rotate the drive motor as shown in figure [A].
1
Add 0.30 quarts (0,3 L) of gear lube to the top plug hole (Item 2) [A] (or until the gear lube level is at the bottom edge of the plug hole (Item 1) [A]). Install and tighten the plug.
P–11090
Repeat the procedure for the other side.
–1–18–
320/322 Excavator Service Manual
JOYSTICK CONTROL CHANGE
A
ISO to Standard Control Pattern To change from ISO to STANDARD joystick controls, do the following procedure: Open the tool box door. Remove the hose cover plate [A].
P–11091
B
Remove the bottom plate from the tool box [B].
PI–12908
C
Mark and remove hoses (Items 1, 2, 3 & 4) [C] from the bulkhead elbows.
3
1 2
4
P–02348
Install the hoses onto the new locations as shown (Items 1, 2, 3 & 4) [D].
D
Install new decals (P/N 6587427) onto the right hand console and (P/N 6587428) onto the left hand console.
4 3
2 1
After exchange of the hoses, the right joystick will now control arm (raise and lower) and the bucket (curl). The left joystick will control the boom (raise and lower) and the upperstructure (swing).
P–02348
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320/322 Excavator Service Manual
JOYSTICK CONTROL CHANGE (Cont’d)
A
Standard to ISO Control Pattern To change from STANDARD to ISO joystick controls, do the following procedure:
1
3 4
2
Open the tool box door. Remove the hose cover plate. Remove the bottom plate from the tool box. Mark and remove hoses (Items 1, 2, 3 & 4) [A] from the bulkhead elbows. P–02348
B
Install the hoses onto the new locations as shown (Items 1, 2, 3 & 4) [B]. Install new decals (P/N 6587425) onto the right hand console and (P/N 6587426) onto the left hand console.
2 1
4 3
After exchange of the hoses, the right joystick will now control boom (raise and lower) and the bucket (curl). The left joystick will control the arm (raise and lower) and the upperstructure (swing).
P–02348
–1–20–
320/322 Excavator Service Manual
LUBRICATION OF THE HYDRAULIC EXCAVATOR
A
Lubricate the Hydraulic Excavator as specified in the Service Schedule, Page 1–1 for the best performance of the machine. Record the operating hours each time you lubricate the Hydraulic Excavator. Always use a good quality lithium based multi–purpose grease when lubricating the machine. Apply the lubricant until extra grease shows. Ref.
2
1
2 3
Description (# of Fittings)
1. Blade Cylinder Rod End, every 8 to 10 hours (1) [A]. 2. Blade Pivots, every 8 to 10 hours (2) [A]. 3. Blade Cylinder Base End, every 8 to 10 hours (1) [A].
P–11089
B 4. Boom Swing Cylinder Rod End, every 8 to 10 hours (1) [B]. 5. Boom Cylinder Base End, every 8 to 10 hours (1) [B]. 6. Boom Base Pivot, every 8 to 10 hours (1) [B].
6 4 5 P–11092
C
7. Boom Swing Bracket Pivot, every 8 to 10 hours (2) [C]. 8. Frame Swing Bracket Pivot, every 8 to 10 hours (1) [C].
7 8
P–11093
D 9. 10. 11. 12. 13.
Boom Cylinder Rod End, every 8 to 10 hours (1) [D]. Arm Cylinder Base End, every 8 to 10 hours (1) [D]. Arm Cylinder Rod End, every 8 to 10 hours (1) [D]. Arm Base Pivot, every 8 to 10 hours (1) [D]. Bucket Cylinder Base End, every 8 to 10 hours (1) [D].
10
11 12
9 13 P–11094
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320/322 Excavator Service Manual
LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)
A
15
14. Bucket Cylinder Rod End, every 8 to 10 hours (1) [A]. 15. Bucket Link Pivots, every 8 to 10 hours (2) [A]. 16. Bucket Pivots, every 8 to 10 hours (3) [A].
16
14
P–02223
B
17. Boom Swing Cylinder Base End, every 8 to 10 hours (1) [B].
17
NOTE: Access to the grease fitting is from under the upperstructure, right side.
P–02227
18. Swing Circle Ball Bearing, every 50 hours (2) [C].
C
NOTE: Do not over grease the swing circle or damage to the seal could result. Install 4 to 5 pumps of grease from a grease gun into each of the 2 grease fittings. Rotate the upperstructure 90o and install 4 to 5 pumps of grease into each of the 2 grease fittings.
18
P–11095
19. Swing Circle Pinion, every 50 hours (Item 1) [D]. Install 4 pumps of grease from a grease gun into the grease fitting. Rotate the upperstructure 180° and install 4 more pumps of grease into the grease fitting.
D 19
N–00806
–1–22–
320/322 Excavator Service Manual
HEATER AIR FILTER (With Cab Option Only)
A
See the SERVICE SCHEDULE Page 1–1 for the correct service interval.
1
Remove the air filter (Item 1) [A] from the back of the heater by lifting up on the tab on the top of the filter. Clean the filter element with compressed air only. Install the filter element in the back of the heater.
P–09446
–1–23–
320/322 Excavator Service Manual
HYDRAULIC SECTION Page Number ACCUMULATOR Assembly (S/N 562313001–562320721 & 517811001–517811977) . . Assembly (S/N 562320722 & Above & 517811978 & Above) . . . . . . . . Disassembly (S/N 562313001–562320721 & 517811001–517811977) Disassembly (S/N 562320722 & Above & 517811978 & Above) . . . . . Parts Identification (S/N 562320722 &Above & 517811978 & Above) . Pressure Reducing Valve (Description) . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–59 2–65 2–57 2–63 2–62 2–56 2–56 2–68
HYDRAULIC SYSTEM
ARM CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–71 AUXILIARY FLUSH FACE COUPLERS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–89 BLADE CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–73 BOOM CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–70 BOOM SWING CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74 BUCKET CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–72 DRAIN BLOCK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–90 HYDRAULIC CONTROL VALVE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom, Bucket, Arm and Swing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Boom, Bucket, Arm and Swing Disassembly . . . . . . . . . . . . . . . . . . . . . . Boom Swing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Swing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Travel, Right Travel, Auxiliary and Blade Assembly . . . . . . . . . . . . Left Travel, Right Travel, Auxiliary and Blade Disassembly . . . . . . . . . Mid Inlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mid Inlet Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outlet Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outlet Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–48 2–34 2–31 2–40 2–38 2–45 2–43 2–22 2–25 2–29 2–27 2–26 2–26 2–26 2–26 2–22 2–37 2–36
Continued On Next Page
Revised July 05
–2–1–
320/322 Excavator Service Manual
HYDRAULIC SECTION (Cont’d) Page Number HYDRAULIC CYLINDER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly – For Cylinder Using Piston Retaining Bolts . . . . . . . . . . . . . Assembly – For Cylinder Using Piston Retaining Lock Nuts . . . . . . . . . Disassembly–For Cylinders Using Piston Retaining Bolts . . . . . . . . . . . Disassembly–For Cylinders Using Piston Retaining Lock Nut . . . . . . . Disassembly–For Pistons with Three Ring Grooves . . . . . . . . . . . . . . . .
2–81 2–86 2–86 2–79 2–79 2–82
HYDRAULIC FILTER ASSEMBLY Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–89 HYDRAULIC PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–19 2–15 2–17 2–16 2–14
HYDRAULIC SERVICE INFORMATION Checking the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 Checking the Main Relief Valves and Crossport Relief Valves . . . . . . . 2–8 JOYSTICK CONTROL CHANGE ISO to Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–91 Standard to ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–91 MAIN RELIEF VALVES (Adjustable) Adjusting the Main Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–55 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 PORT RELIEF VALVES Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Relief Valve Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–52 2–52 2–51 2–50 2–51
TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Revised July 05
–2–2–
320/322 Excavator Service Manual
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