Bobcat X320 Excavator Sn 511720001 Above Service Repair.pdf by www.heydownloads.com

X 320 Excavator Service Manual (S/N 511720001 & Above)

6722642 (4–94)

Printed in U.S.A.

MAINTENANCE SAFETY WARNING

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 W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

B-10731a

Never service the Hydraulic Excavator instructions.

Bobcat without

CORRECT

B-14148

Use the correct procedure to lift and support the excavator. Always lift the blade fully before installing jackstands.

B-14142

Cleaning and maintenance are required daily.

WRONG

B-14147

B-14141

B-14145

Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

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

B-14146

B-14143 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids. 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.

Keep body, jewelry and clothing away from moving parts, electrical contact, 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.

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 the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW20-0805

CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . iii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

DRIVE SECTION

UPPER WORKS & SWING SECTION

MAIN FRAME & TRACKS

ELECTRICAL SYSTEM

ENGINE SERVICE

SPECIFICATIONS

–1

320 (S/N 511720001 & Above) 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/FOPS (Including sidescreens) is in good condition and is not modified.

9. Safety treads must in good condition.

2. Check that ROPS 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 loader.

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.

320 (S/N 511720001 & Above) Excavator Service Manual

SAFETY INSTRUCTIONS

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–2003–0797

The following publications provide information on the safe use and maintenance of the loader 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 excavator gives operating information as well as routine maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat Excavator dealer.

• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator dealer.

• The Bobcat Hydraulic Excavator has a plastic Operator’s Handbook fastened to the operator cab. It’s brief instructions

are convenient to the operator. The handbook is available from your dealer in an English, French, German, Dutch, Italian, Spanish, Portugese, Finnish, Danish, and Swedish editions.

• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals. • The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

• The Bobcat compact Excavator Operator Training Course is available through your local dealer. This course is intended to provide rules and practices of correct operation of the Hydraulic Excavator.

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

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.

iii

320 (S/N 511720001 & Above) Excavator Service Manual

SAFETY INSTRUCTIONS (Cont’d) • Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing the excavator. Safety glasses, hear-

ing protection or loader special application kits are required for some work. See your dealer for Melroe Safety equipment.

• Know where fire extinguishers and first aid kits are located and how to use them. • Do not use the Bobcat excavator where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent a 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.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze. • Do not use ether or starting fluids on an engine that has glow plugs. These starting aids can cause an explosion and injure you or bystanders.

• Always clean the excavator and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the excavator 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 or Service Manuals for connecting the battery.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/city for information about burried lines (telephone, cable TV, water, sewer, gas,etc.).

320 (S/N 511720001 & Above) Excavator Service Manual

SERIAL NUMBER LOCATIONS

Always use the serial number of the loader when requesting service information 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 front of the machine frame, to the left of the boom [A].

P–2216

ENGINE SERIAL NUMBER

The engine serial number is located on the engine block, near the fuel injection pump [B].

XXXX–XXXXX

P–0842

DELIVERY REPORT

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. The form contents must be explained to the owner. Make sure it is filled out completely [C].

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR IDENTIFICATION 320ServiceManual(S/N511720001&Above)#6722642–ContentSection

GRAB HANDLES CONTROL LEVERS (JOYSTICK) CANOPY (ROPS)

ENGINE COVER UPPER STRUCTURE TRACK FRAME TRACK

OPERATORS HANDBOOK ARM CYLINDER

GRAB HANDLES

BOOM OPERATOR SEAT

AUXILIARY LINES BUCKET CYLINDER

SEAT BELT

ARM

TOOL BOX (Operator’s Manual Location)

BUCKET LINK

BLADE CYLINDER BUCKET BOOM CYLINDER BLADE vi

B–14408 B–14407

320 (S/N 511720001 & Above) Excavator Service Manual

PREVENTIVE MAINTENANCE Page Number AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ENGINE COVER Opening the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ENGINE LUBRICATION SYSTEM Engine Oil and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 To Add Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 FUEL SYSTEM Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–4 1–3 1–3 1–4

HYDRAULIC SYSTEM Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–7 1–7 1–8 1–8

LUBRICATION OF THE HYDRAULIC EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 USING A BOOSTER BATTERY (JUMP STARTING) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

PREVENTIVE MAINTENANCE

–1–0–

320 (S/N 511720001 & Above) 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 Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Canopy Seat Belt Safety Signs (Decals) Tracks Hydraulic Reservoir All Machinery Pivot Points Fuel Tank/Fuel Filter Swing Circle Swing Pinion Engine Oil & Filter Alternator Belt Hydraulic Filter Fuel Filter Battery Air Cleaner Cooling System Alternator & Starter Engine Valve Clearance Cooling System Case Drain Return Screen Hydraulic Tank Final Drive Case

SERVICE REQUIRED

8–10

100

250

500 1000

Check & empty dust cup 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. Check the condition & that fasteners are tight. Check for damaged signs (decals) replace as needed. Check & adjust tension. Check fluid level. Lubricate 22 grease fittings. Drain water and sediment from fuel tank/filter. Lubricate two grease fittings. Lubricate one grease fitting. Replace oil & filter element. Check & adjust tension. Replace filter element. Replace filter element. Check & clean cable ends & check electrolyte level. Replace the filter element. Clean the radiator fins. Check the condition. Check & adjust valve clearance. Drain, flush & add new coolant to the cooling system. Clean the screen with solvent. Change the fluid, clean fill neck strainer. Change the oil.

After the first 250 hours of machine operation do the following:

• Change oil in final drive case. • Check and adjust engine valve clearance.

–1–1–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE COVER

Opening the Cover

AVOID INJURY Never service or adjust the machine when the engine is running unless instructed to do so in this manual. W–2012–0290 P–2218

Keep the engine cover closed when operating the machine.

W–2141–0189

Open the engine cover to service the engine. Pull on the latch and lift the engine cover up until it is fully raised [A]

AIR CLEANER SERVICE See the Service Schedule Page 1–3 for the correct service interval. Service the air cleaner as follows: P–2188

Daily Check: 1. Loosen the clamp on the air cleaner [B].

2. Remove the cover (Item 1) [C]. Empty the dust cup. Visually inspect the filter element. Do Not remove the element unless plugged and replacement is necessary.

Filter Replacement: 3. Remove the wing Nut (Item 3) [C].

2 1 P–2185

4. Remove the filter element [D].

5. Check the air cleaner housing for damage.

6. Wipe the canister clean with a clean cloth. Do Not use compressed air. 7. Check the seal (Item 1) [D]. 8. Install a new air filter element. Install and tighten the wing nut. 9. Install the dust cup and cover so the arrow points up. 10. Check that all the air cleaner hose clamps are tight.

P–2187

–1–2–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL SYSTEM

Use Number 2 diesel fuel in the engine. When the temperature goes below 14°F (–10°C), Number 1 fuel can be used. (See fuel, coolant and lubricants chart, Page 8–1.)

Stop and cool the engine before adding fuel, NO SMOKING! Failure to obey warnings can cause an explosion or fire.

P–0805

W–2063–0887

Fuel System Service

The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the ignition key in in the ON position. NOTE: When the fuel level reaches the 1/8 fuel setting, the low fuel light (Item 2) [A] will come ON to alert the operator of this condition. Use the key to un–lock the fuel fill door [B]. Turn the fill cap to remove it [C]. Use a clean, approved safety container to add fuel to the tank.

P–2208

Add fuel only in an area that has a free movement of air and no open flames or sparks. NO SMOKING!

After the tank is full, install and tighten the fuel fill cap. Close and lock the fuel fill door.

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.

P–2206

W–2103–1285

Maintenance The excavator is equipped with a fuel drain valve in the bottom of the fuel tank.

Turn the upperstructure until access to the bottom of the fuel tank is available [D]. Open the drain valve (Item 1) [D] and drain all water and sediment into a container. NOTE: A hose can be installed onto the drain valve to prevent fuel from spilling while draining the tank.

P–2187

–1–3–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL SYSTEM (Cont’d) Fuel Filter See the Service Schedule Page 1–3 for the service interval. To remove water from filter, open drain valve (Item 1) [A] at the bottom of the fuel filter. Drain water and sediment into a container. Use a filter wrench to remove the fuel filter element [A].

Cleaner filter housing surface. Put clean oil on the filter gasket. Install the new element and hand tighten only.

P–2217

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. Open the vent (Item 1) on the fuel filter housing [B].

P–0727

Open the bleed screw on the top of the fuel filter housing (Item 1) [C].

C 1

Squeeze the primer bulb to fill the filter [D]. P–2350

When fuel, free of air bubbles, emerges from the filter housing, close the bleed screw (Item 1) [C].

Leave the vent (Item 1) [B] on the injection pump open slightly. Start the engine. When the engine runs smoothly, close the vent screw on the injection pump. NOTE: If engine fails to start after the above procedure is performed, it will be necessary to bleed the injector lines; do the following: 1. Loosen the three (3) injector line locknuts, one turn. 2. While cranking the engine and fuel emerges from the injector lines, slowly tighten the injector line lock nuts.

P–2184

–1–4–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE LUBRICATION SYSTEM

Check the engine oil every day. Stop the engine. Open the engine cover. Remove the dipstick [A]. Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Clarification of CE or CD. (See Fuel, Coolant and Lubricants Chart, Page 8–1.)

P–2194

Engine Oil and Filter Replacement

See the Service Schedule Page 1–3 for the correct service interval. Use the following procedure to change the oil and filter: 1. Run the engine until it is at operating temperature. 2. Turn the upperstructure so there is clearance for the engine oil drain plug between the tracks. Stop the engine.

3. Remove the drain plug (Item 1) [B]. Drain the oil into a container. P–2231

NOTE: Some excavators may have a field installed belly pan (available from Melroe Parts). This belly pan has a rectangular hole for access to the oil pan drain plug.

4. Remove the oil filter (Item 1) [C], using a filter wrench. 5. Clean the filter housing surface. Put clean oil on the filter gasket. Install the new filter and hand tighten only.

6. Install and tighten the oil drain plug. P–2191

To Add Oil to Engine:

7. Remove the dipstick [A]. 8. Remove the dipstick fill tube cap [D].

P–2195

–1–5–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

To Add Oil to Engine (Cont’d) 9. Install a funnel into the dipstick fill tube [A]. Put 4.5 quarts (4,3 L) of oil into the engine. (See Fuel, Coolant and Lubricants Chart, Page 8–1.) 10. Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter and drain plug. 11. Check the oil level and add oil as needed to bring it to the top mark on the dipstick. Optional engine oil fill location [B]. The valve cover oil fill cap can be used for adding oil in place of the dipstick tube. Use protective, heat resistant shield over the muffler to protect yourself from the HOT muffler.

P–2196

COOLING SYSTEM Coolant Level When the engine is cool, remove the radiator cap [C]. The coolant level must be 3/4–1 inch (19–25 mm) below the filler neck at the radiator. If the coolant level is low, add pre–mixed coolant (50% water and 50% ethylene glycol) to the radiator. Coolant Replacement

P–2209

C Do not remove radiator cap when the engine is hot. You can be seriously burned. W–2070–1285

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used. W–2019–1285

1. Turn the upperstructure so there is access to the engine and radiator from underneath. Stop the engine. 2. Loosen and remove the radiator cap [C]. 3. Open the radiator drain valve (Item 1) [D]. 4. Drain all the coolant from the system. 5. When all the coolant is removed, close the drain valve. 6. Pre–mix 50% water and 50% ethylene glycol in a separate container. Fill the radiator with the pre–mixed coolant until it is full. 7. Run the engine at idle speed for about 5–10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation). 8. Stop the engine. Check the coolant level and add as needed to bring it 3/4–1 inch (19–25 mm) below the filler neck. Install the radiator cap and tighten.

P–2199

1 P–2198

–1–6–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM

Checking and Add Fluid To check and add hydraulic fluid to the reservoir, use the following procedure:

Prior to checking the hydraulic fluid level, retract the arm and bucket cylinder, put the bucket on the ground and raise the blade.

P–2203

I–2076–0795

B 1. Put the machine on a flat level surface. 2. Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine. 3. The hydraulic fluid level must be visible in the sight gauge (Item 1) [A].

4. If fluid level is not correct, open the hydraulic fill door and remove the hydraulic cap [B].

P–2192

5. Remove the screen from the fill neck and replace it if damaged [C]. Install the screen before adding fluid. 6. Add the correct fluid to the reservoir until it is visible in the center of the sight gauge [A]. (See Fuel, Coolant and Lubricants Chart, Page 8–1.) 7. Install the reservoir cap.

P–2204

Diagnostic Couplers

Diagnostic couplers are located at each hydraulic pump (Item 1) [D]. The couplers can be used to check circuit pressures. Refer to Page 2–1 for test procedure and tools needed for testing.

1 P–2341

–1–7–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM (Cont’d)

Prior to checking the hydraulic fluid level, retract the arm and bucket cylinder, put the bucket on the ground and raise the blade.

I–2076–0795

P–2189

Replacement of the Hydraulic Filter See the Service Schedule Page 1–3 for the correct service interval.

1. Open the engine cover. 2. Use a filter wrench and remove the filter element (Item 1) [A]. 3. Clean the housing where the filter gasket makes contact.

1 4. Put clean hydraulic fluid on the gasket. Install the new filter element and hand tighten only. 5. 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 the filter area for leaks.

P–2226

Hydraulic Reservoir Replacement of the Hydraulic Fluid See the Service Schedule Page 1–3 for the correct service interval. 1. Turn the upperstructure until the reservoir drain valve is between the tracks.

2. Retract the arm and bucket cylinder, lower the bucket to the ground. Stop the engine.

W–2103–1285

3. Remove the hydraulic filter element [A]. 4. Remove the drain plug (Item 1) [B] from the bottom of the reservoir. 5. Drain the fluid into a container (approximately 3.65 gals. (13.8 L). 6. Install the drain plug. 7. Install a new hydraulic filter. 8. Add the correct fluid to the reservoir until it is visible in the sight gauge (approximately 3.65 gals. (13,8 L.) to fill only the reservoir). (See Fuel, Coolant and Lubricants Chart, Page 8–1.) 9. Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed. –1–8–

320 (S/N 511720001 & Above) Excavator Service Manual

USING A BOOSTER BATTERY (JUMP STARTING)

Procedure If it is necessary to use a booster battery to start the engine, BE CAREFUL! Make sure the swing locking lever is in the engaged position. The key switch must be in the OFF position. The booster battery must be 12 volt. Open the engine cover [A].

P–2218

Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the starter positive (+) battery cable terminal (Item 1) [B] & [C].

Connect the end of the second cable to the negative (–) terminal of the booster battery. Connect the other end of the same cable to the machine frame (Item 2) [B] & [C]. NOTE: Also see Cold Starting Procedure, Operation & Maintenance Manual.

Start the engine. After the engine is running, remove the cable (Item 2) [B] & [C] connected to the frame first. Disconnect the cable from the starter terminal (Item 1) [B] & [C]. P–2215

C If jump starting the excavator from a second machine: When jump starting the excavator from a battery installed in a second machine. Make sure that the second machine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

1 2

I–2060–0195

P–2213

Damage to the alternator can occur if:

• Engine is operated with battery cables • •

Keep arcs, sparks, flames and lighted tobacco away from batteries. When ‘‘jumping’’ from booster battery make final connection (negative) at engine frame.

disconnected. Battery cables are connected when using a fast charger or when welding on the loader (Remove both cables from the battery). Extra battery cables (booster cables) are connected wrong.

Do not jump start or charge a frozen battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

I–2023–1285

Battery gas can explode and cause serious injury. W–2066–0490 –1–9–

320 (S/N 511720001 & Above) Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

Procedure

Lubricate the Hydraulic Excavator as specified in the Service Schedule Page 1–1 for the best performance of the machine. Always use a good quality lithium based multi–purpose grease when lubricated the machine. Apply the lubricant until extra grease shows.

Ref. Description (# of Fittings)

1. Blade Cylinder Rod End, every 8–10 hours (1) [A]. 2. Blade Pivots, every 8–10 hours (2) [A]. 3. Blade Cylinder Base End, every 8–10 hours (1) [A].

P–2224

4. Boom Swing Cylinder Rod End, every 8–10 hours (1) [B]. 5. Boom Cylinder Base End, every 8–10 hours (1) [B]. 6. Boom Base Pivot, every 8–10 hours (1) [B].

7. Swing Circle Pinion, every 50 hours (1) [B], 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.

P–2222

8. Boom Swing Bracket Pivot, every 8–10 hours (2) [C].

9. Frame Swing Bracket Pivot, every 8–10 hours (1) [C].

P–2228

10. 11. 12. 13.

Boom Cylinder Rod End, every 8–10 hours (1) [D]. Arm Cylinder Base End, every 8–10 hours (1) [D]. Arm Cylinder Rod End, every 8–10 hours (1) [D]. Arm Base Pivot, every 8–10 hours (1) [D].

14. Bucket Cylinder Base End, every 8–10 hours (1) [D].

P–2220

–1–10–

320 (S/N 511720001 & Above) Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

A 16

Procedure (Cont’d) Ref. Description (# of Fittings)

15. Bucket Cylinder Rod End, every 8–10 hours (1) [A]. 16. Bucket Link Pivots, every 8–10 hours (2) [A]. 17. Bucket Pivots, every 8–10 hours (3) [A].

P–2223

18. Boom Swing Cylinder End, every 8–10 hours (1) [B].

18 P–2227

19. Swing Circle Ball Bearing, every 50 hours (2) [C] & [D]. Located 180 degrees apart on the bearing. NOTE: Do Not overgrease the swing circle or damage to the seal could result, Install 4 to 5 pumps of grease gun into each of the 2 grease fittings. Rotate the upperstructure 90° and install 4 to 5 pumps of grease into each of the 2 grease fittings.

P–2230

D 19

CD–9144

–1–11–

320 (S/N 511720001 & Above) Excavator Service Manual

320ServiceManual(S/N511720001&Above)#6722642–PreventiveMaintenanceSection

–1–12–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SECTION

Page Number

ARM CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–71 AUXILIARY COUPLERS Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–84

HYDRAULIC SYSTEM

BLADE CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–73 BOOM CYLINDER Boom Cylinder Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–70 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–70 BOOM SWING CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74 BUCKET CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–72 DRAIN BLOCK Filter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–88 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–88 HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet Section (R.H. & L.H. Travel) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Sections (Auxiliary) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Sections (Boom, Bucket and Arm) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Build Up Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–23 2–16 2–18 2–17 2–26 2–26 2–26 2–15 2–24 2–24 2–24 2–14 2–22 2–21 2–20 2–19

2–36 2–37 2–37 2–29

Continued On Next Page Revised June 98

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SECTION (Cont’d)

Page Number

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d) End Cover (Boom Swing) and Valve Section (Blade) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet Section (Housing Swing) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Check Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE (S/N 511721412 & Above) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom, Bucket & Arm Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Hand And Left Hand Travel Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blade And Boom Swing Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockout Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockout Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Build Up Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Build Up Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Build Up Valve Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Motor Valve Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–33 2–31 2–30 2–30 2–35 2–35 2–38 2–38 2–38 2–28 2–27

2–50 2–49 2–48 2–46 2–45 2–40 2–41 2–39 2–43 2–42

2–67 2–62 2–60 2–64 2–63 2–69 2–69 2–69 2–59 2–58 2–66 2–65

HYDRAULIC CYLINDER Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–79 Continued On Next Page

Revised June 98

–2––2o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SECTION (Cont’d)

Page Number

HYDRAULIC FILTER ASSEMBLY Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–84 HYDRAULIC PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 HYDRAULIC SERVICE INFORMATION Checking The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Checking The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 HYDRAULIC SYSTEM TROUBLESHOOTING Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 JOYSTICK MANIFOLD WITH ACCUMULATOR Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–85 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–87 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–85 JOYSTICK CONTROL CHANGE ISO to Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–90 Standard to ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–90 MAIN RELIEF VALVES HUSCO VALVE Adjusting The Main Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–57 2–56 2–56 2–55

OIL COOLER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–89 PORT RELIEF VALVES HUSCO VALVE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Revised June 98

–2––1–

2–54 2–54 2–53 2–52

320 (S/N 511720001 & Above) Excavator Service Manual

Revised June 98

–2–0o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING

TROUBLESHOOTING THE COMMON CIRCUIT PROBLEM

CAUSE

CORRECTION

No hydraulic operation at one or Hydraulic oil level low. more circuits. Hydraulic pump drive coupling damaged.

Oil temperature too high.

1–7

Replace.

7–20

Repair or replace.

Main relief valve defective.

Readjust or replace.

2–6, 2–26, 2–38, 2–57

Readjust or replace.

2–6, 2–26, 2–38, 2–57

Hydraulic oil level or viscosity incorrect.

Refill or replace.

1–7, 8–10

Engine RPM reduced.

Readjust or replace.

Control valve linkage defective.

Check, repair or replace.

2–14, 2–27

Hydraulic pump volume low.

Check, repair or replace.

2–7, 2–8,

Oil cooler or radiator fins plugged.

Clean oil cooler external surface.

––

Hydraulic oil level low.

Refill or replace.

1–7

Non recommended hydraulic oil.

Replace.

8–10

Relief valve activated.

Use proper operating procedures.

excessively

One or more relief valves not set correctly. Extreme operating conditions. High ambient temperature (IE: Enclosed structure).

Revised June 98

Refill with proper oil.

Hydraulic pump defective.

Hydraulic power insufficient to one Main relief valve pressure setting incorrect. or more circuits. Hydraulic speed too slow.

PAGE

–2–1–

Readjust or replace.

2–7, 2–8,

7–1

–– 2–26,2–38, 2–57 ––

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE CYLINDER CIRCUIT PROBLEM Cylinder inoperable.

Cylinder force insufficient.

Cylinder speed too slow.

Cylinder drift excessive.

Revised June 98

CAUSE

CORRECTION

PAGE

Control console(s) raised.

Lower control console(s).

––

Loose fittings or broken hoses.

Repair or replace.

––

Lever linkage misadjusted.

Readjust.

Control console lockout switch.

Readjust or replace.

Cylinder excessive.

Repair or replace.

internal

leakage

3–34, 3–37 3–3, 3–4, 3–19 2–75

Joystick manifold solenoid coil. defective.

Replace.

2–85, 2–87

Joystick manifold solenoid valve defective.

Repair or replace.

2–86, 2–87

Joystick manifold pressure reducing valve defective.

Repair or replace.

2–86, 2–87

Joystick excessive.

Repair or replace.

3–8, 3–27, 3–62

Main relief valve pressure too low.

Readjust or replace.

2–6, 2–27, 3–55

Work port relief pressure too low.

Readjust or replace.

2–24, 2–52

Lever linkage misadjusted.

Readjust.

3–34, 3–37

Cylinder excessive.

leakage

Repair or replace.

2–75

Joystick manifold solenoid valve defective.

Repair or replace.

2–85, 2–87

Joystick manifold pressure reducing valve defective.

Repair or replace.

2–85, 2–87

Control valve internal leakage excessive.

Repair or replace.

2–15, 2–28 2–39, 2–58

Joystick excessive.

internal

leakage

Repair or replace.

3–8, 3–27, 3–62

Cylinder excessive.

internal

leakage

Repair or replace.

2–75

internal

leakage

internal

Work port relief valve seals leaking.

Check, repair or replace.

2–24, 2–52

Control valve internal leakage excessive.

Repair or replace.

2–39, 2–58

–2–2o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE SWING (SLEW) CIRCUIT PROBLEM Swing not operating.

Swing force.

Swing speed too slow.

Swing over run excessive.

Revised June 98

CAUSE

CORRECTION

PAGE

Control console(s) raised.

Lower control console(s).

Control console lockout switch defective.

Readjust or replace.

3–3, 3–4, 3–19

Swing lock pin engaged.

Disengage lock pin.

5–3

Joystick manifold pressure reducing valve defective.

Repair or replace.

Joystick manifold solenoid coil. defective.

Replace.

Joystick manifold solenoid valve defective.

Repair or replace.

2–86, 2–87

Swing motor gear defective.

Repair or replace.

4–2

Joystick excessive.

Repair or replace.

3–8, 3–27, 3–62

Swing motor defective.

Repair or replace.

4–1, 4–2

Main relief valve set too low.

Readjust or replace.

2–6, 2–7, 2–39, 2–55

Swing motor relief valve pressure too low.

Readjust or replace.

4–1, 4–2

Pump flow low.

Check, repair or replace.

2–7, 2–8

Blocked or restricted line to swing motor.

Replace.

Joystick excessive.

leakage

Repair or replace.

3–8, 3–27, 3–62

Control valve internal leakage excessive.

Repair or replace.

2–28, 2–58

Swing motor internal leakage excessive.

Repair or replace.

4–1, 4–2

Control valve spool sticking.

Repair or replace.

2–28, 2–58

Joystick spool sticking.

Repair or replace.

3–8, 3–27, 3–62

Swing motor relief valves set too low.

Repair or replace.

4–2

Swing motor internal leakage excessive.

Repair or replace.

4–1, 4–2

internal

leakage

internal

–2–3–

––

2–57, 2–86, 2–87 2–86

––

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE TRAVEL CIRCUIT PROBLEM Travel system inoperable.

CAUSE

Speed too slow.

Revised June 98

PAGE

Lever linkage misadjusted.

Readjust.

3–28

Track tension to tight.

Readjust.

5–10

Defective pump.

Check, repair or replace.

Travel motor spool sticking.

Travel power.

CORRECTION

2–7, 2–8,

counterbalance

Repair or replace.

3–42

Travel motor internal leakage excessive.

Repair or replace.

3–40, 3–42

Travel motor defective.

Repair or replace.

3–40, 3–42

Travel motor gears defective.

Repair or replace.

3–42

Swivel joint defective.

Repair or replace.

4–8

Main relief valve pressure too low.

Readjust or replace.

Track tension too tight.

Readjust.

Main relief valve pressure too low.

Readjust or replace.

Travel motor spool sticking.

Repair or replace.

3–42

Lever linkage misadjusted.

Readjust.

3–28

Swivel joint excessive.

leakage

Repair or replace.

4–8

Control valve internal leakage excessive.

Repair or replace.

2–15,2–28 2–39, 2–58

Low pump pressure,

Check, repair or replace.

Travel motor internal leakage excessive.

Repair or replace.

counterbalance

internal

–2–4o

2–6, 2–7, 2–39, 2–55 5–10 2–6, 2–7, 2–39, 2–55

2–7, 2–8 3–40, 3–42

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE TRAVEL CIRCUIT (Cont’d) PROBLEM

CAUSE

CORRECTION

PAGE

Lever linkage misadjusted.

Readjust.

3–28

Track tension to tight.

Readjust.

5–10

Pump output unequal.

Repair or replace.

2–7, 2–8

Travel motor internal leakage unequal.

Repair or replace.

3–42

Travel motor spool sticking.

counterbalance

Repair or replace.

3–42

Main relief valves pressure set too low.

Repair or replace.

2–6, 2–7, 2–39, 2–58

Swivel joint excessive.

leakage

Repair or replace.

4–8

Control valve internal leakage excessive.

Repair or replace.

2–15,2–28 2–39, 2–58

Machine will not hold on slope or Track motor counterbalance valve leakage excessive. while digging.

Repair or replace.

3–42

Machine not running straight.

internal

Hose damaged.

Replace.

––

Readjust.

3–28

Repair or replace.

2–75

Control valve internal leakage excessive.

Repair or replace.

3–15, 3–28

Swivel joint internal leakage from travel motor pressure circuit into blade cylinder circuit.

Repair or replace.

4–8

Blade drops while machine is Lever linkage misadjusted. moving. Cylinder internal leakage excessive.

Revised June 98

–2–5–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SERVICE INFORMATION

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I–2003–0888 P–02341

Checking the Main Relief Valves

The hydraulic system has three main relief valves protecting the hydraulic pump from high pressure. The hydraulic pump has three diagnostic couplers for checking each pump section pressure [A]. The following tools will be needed for the Diagnostic Coupler Check: MEL1355 – Test Kit MEL1355–3 – 5000 PSI Gauge MEL1355–12 – Coupler MEL1355–4 – Hose Connect the coupler and gauge from the test kit to the hose.

P–02354

Stop the engine. Connect the coupler to the diagnostic coupler on the pump section being tested [B]. Start the engine and run at full RPM. Warm the hydraulic fluid to 140°F (60°C). Stroke a cylinder to its limit, to open the relief valve: PUMP 1: Extend the bucket cylinder. PUMP 2: Extend the arm cylinder. PUMP 3: Retract the blade cylinder. NOTE: Pump section 1 is the closest to the engine. The system relief valve pressure for each pump section, recorded at the pump, should be as follows [A]: PUMP 1: 2350–2400 PSI (16207–16551 kPa) PUMP 2: 2350–2400 PSI (16207–16551 kPa) PUMP 3: 2350–2400 PSI (16207–16551 kPa) Stop the engine. Move the coupler to the next pump section being tested.

Revised June 98

–2–6o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

Checking the Hydraulic Pump The hydraulic pump flow should be 4 GPM (16 L/min.) on a new pump at 2500 RPM. The following tools will be needed for hydraulic pump test: MEL10003 – Hydraulic Tester Stop the engine. Raise the engine cover. Remove the outlet hose from the hydraulic pump section being tested [A].

P–02366

Connect the hose removed from the pump to the outlet of the tester [B].

Connect the inlet hose of the tester to the fitting on the pump [B]. NOTE: The tester connection will be the same for each pump section. NOTE: Open the flow control knob (Item 1) fully to prevent pump damage [B].

Start the engine and run at low RPM. Make sure that the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong. P–02355

Increase the engine speed to full RPM. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor valve until the gauge reads approximately 1000 PSI (6895 kPa). Do not exceed system pressure. After the temperature is correct, open the restrictor valve fully. Record the pump free flow GPM (L/min.). Close the flow control knob (Item 1) [B] slowly, to approximately 100 PSI below the relief valve setting which is (2350–2450 PSI/16207–16897 kPa). Record the pump high pressure flow GPM (L/min.). NOTE: The high pressure flow must be at least 80% of free flow. %=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

x 100

If the high pressure flow is less than 80% of free flow, remove the hydraulic pump for repair or replacement. Repeat the testing procedure and use the same readings as shown above for each pump section.

Revised June 98

–2–7–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC PUMP 1. 2. 3. 4. 5. 6. 7. 8. 9.

PLATE GEAR SHAFT GEAR SEAL PLATE PLATE COVER BOLT

7 3

7 4

8 4

NOTE: Check the Parts Fiche for serviceable parts. Revised June 98

B–14045

–2–8o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Disassembly

1 2

5 4

6 7

CD–00222

I–2003–0888

Using a center punch, mark both sides of each separation point (Items 1–6) [A] on the inlet side of the pump, as shown, with the corresponding separation point number.

No Inlet Port Section 1

Tape the shaft splines (Item 7) [A] to ensure that the splines will not damage the oil seal when the shaft is removed. Put the pump, mounting flange down, in a protect jaw vise. Remove the four assembly bolts [B]. NOTE: The pump has only two inlet ports. The pump section without the inlet port is located in section 1 (closest to the input shaft) [B].

CD–00193

Remove the end cap (or separating plate) and two dowel pines (Item 1) [C].

C 1 1

CD–00223

Remove the gear housing and two dowel pins (Item 1) [D].

D Remove The O–ring From Each End of The Housing

Remove the O–ring from each end of the gear housing.

CD–00224

Revised June 98

–2–9–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Disassembly (Cont’d)

Back–Up Ring (White) E–Seal (Black)

Remove the upper bearing [A]. Remove the back–up ring and E–seal from the bearing.

CD–00196

Remove the drive and idler gears [B].

CD–00197

Remove the lower bearing [C]. Remove the back–up ring and E–seal from the bearing.

CD–00198

Remove the coupling [D]. Repeat Page 2–10, step [C] through Page 2–11, step [D] to disassemble each of the remaining pump sections. Keep the parts from each section separate from other sections. NOTE: The gear housing, two bearings, drive gear and idler gear in each pump section are not serviced separately. These parts are matched sets which are run in at the factory. If any part is damaged, the entire section must be replaced.

CD–00226

Revised June 98

–2–10o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Disassembly (Cont’d) Remove the retaining ring (Item 1) [A] from the mounting flange. Using a seal puller, remove the oil seal. Use the correct size driver and install a new oil seal (seal lips to inside of pump) into the mounting flange. Install the retaining ring (Item 1) [A].

Apply a light coating of grease to the seal lips. Assembly All parts must be clean before assembly. Clean all parts in clean solvent. Use air pressure to dry.

CD–00209

Apply a light coating of grease in the E–seal groove of each bearing. Install a new E–seal (Item 1) [B] stepped side up, into each E–seal groove. Push each E–seal down into the groove.

Apply a light coating of grease to each back–up ring (Item 2) [B]. Install the back–up ring into the groove made by the E–seal and bearing. Push the back–up ring down flush with the E–seal.

2 3

NOTE: There is a notch (Items 3 & 4) [B] in the center of the back–up ring and E–seal. When installing the back–up ring, make sure that these notches are aligned. If the back–up ring or E–seal is not installed correctly the back–up ring will not sit flush with the E–seal.

1 CD–00192

Put the mounting flange, oil seal side down, in a protected jaw vise [C].

Install two dowel pins (Item 1) [C] into the mounting flange (or separating plate). Install the lower bearing, seal side down, on the mounting flange (or separating plate). The open side of the E–seal must point toward the inlet port side (marked side) of the pump [C].

Open Side of E–Seal Must Go Towards The Inlet Ports On Housings

1 1

CD–00201

Tape the splined end (Item 1) [D] of the drive gear to ensure that the splines will not damage the oil seal during installation.

Apply oil to the drive gear and idler gear and to the side faces of the gears. Install the gears into the lower bearing [D].

CD–00202

Revised June 98

–2–11–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Assembly (Cont’d) Install the upper bearing, seal side up, on the drive and idler gears. The open side of the E–seal must point toward the inlet port side (marked side) of the pump [A].

CD–00203

Apply a light coating of grease to and install a new O–ring on each end of the gear housing. Align the marks made during disassembly on the gear housing and mounting flange (or separating plate). Carefully install the gear housing over the bearings and gears.

Install O–ring On Each Side Of The Housing

Upper Bearing Must Be Slightly Lower Than Housing

1 1

NOTE: The upper bearing must be slightly lower than the gear housing. If the bearing is higher than the housing, disassemble the pump section to verify that the E–seal, back–up ring, or O–ring have not moved out of position. CD–00229

Install two dowel pins (Item 1) [B] into the gear housing. Apply oil to the coupling. Install the coupling into the drive gear [C].

CD–00226

NOTE: When installing the first section gear housing (with no inlet port), make sure that the oil passage in the housing and the separation plate align. Section one gear housing must receive oil flow through this passage from section two (center) gear housing [D].

P–00207

Revised June 98

–2–12o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Assembly (Cont’d) Align the marks made during disassembly on the separating plate and gear housing. Install the separating plate [A].

CD–00227

Repeat Page 2–12, Step [B] through Page 2–14, Step [A] to assemble pump section 2. Repeat Page 2–12, Step [B] through Page 2–13, Step [B] to assemble pump section 3. Align the marks made during disassembly on the end cap and gear housing. Install the end cap [B].

CD–00223

Install the four assembly bolts [C]. Evenly tighten the bolts to a final torque of 50–55 ft.–lbs. (68–75 Nm). Rotate the input shaft periodically while tightening the bolts to make sure the pump is assembled correctly. Using a locking plier, rotate the pump shaft to be sure there is no binding.

CD–00193

Revised June 98

–2–13–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411)

Removal And Installation

CD–12878

I–2003–0888

B Remove the floor panels. (Page 3–1.) Mark all the hose and tubelines for correct installation. Disconnect all hoses and tubelines from the top of the control valve [A]. Disconnect the six pilot tubelines from the control valve and the bulkhead elbows [B].

CD–12879

Remove the three cotter pins (Item 1) [C] and the clevis pins (Item 2) [C] from the valve spools.

1 2

CD–12876

Remove the three bolts holding the valve mounting plate to the frame [D].

CD–12877

Revised June 98

–2–14o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Turn the valve over and remove the three bolts holding the mounting plate to the valve [A].

CD–12880

Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9.

MAIN RELIEF VALVE PORT RELIEF VALVE PORT RELIEF VALVE INLET SECTION (R.H. Travel) BOOM SECTION (ISO) ARM SECTION (STANDARD) BUCKET SECTION AUXILIARY SECTION ARM SECTION (ISO) BOOM SECTION (STANDARD) INLET SECTION (L.H. Travel)

2 4

8 3

6 3

D–02099

Revised June 98

–2–15–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

P–00287

I–2003–0888

B Clean the control valve assembly with solvent. Disassembly Mark the sections for ease of assembly. Remove the nuts and washers from the three thru studs [A]. Set the valve assembly on its end and remove the inlet valve section from the valve assembly [B]. P–00291

Continue to remove all the valve sections [C]. NOTE: Between sections 3 and 4 and sections 4 and 5 is a metal disc that blocks the oil flow. Make a note of these locations as these discs must be reinstalled in these locations for correct valve operation.

P–00292

Remove the four O–rings from the side face of each of the valve sections [D].

NOTE: If only the valve section O–rings need replacing, clean and dry the side faces of the sections and the O–ring glands. Install new O–rings and reassemble the valve. See Page 2–23 for tightening torque.

P–00264

Revised June 98

–2–16o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Inlet Section (R.H. and L.H. Travel) Disassembly Use a vise with protective jaws and clamp the valve section. Remove the main relief valve from the valve section [A]. Installation: Tighten the relief valve to 35–40 ft.–lbs. (47–54 Nm) torque. NOTE: If the relief valve is disassembled, the relief pressure setting must be reset.

P–00689

See Page 2–26 for relief valve repair.

Remove the two bolts from the end cap and remove the end cap from the valve section [B]. Installation: Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00691

Insert a pin into the hole in the actuating end of the spool to retain the spool from turning. Loosen the spring retaining bolt from the end of the spool [C]. Do Not use any type of tool to grip the finished surface of the spool or the spool will be damaged.

NOTE: The spring is under pressure, use care when removing the spring retaining bolt. The spool and the housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housing. P–00692

Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [D].

P–00275

Revised June 98

–2–17–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Inlet Section (R.H. and L.H. Travel) (Cont’d) Disassembly (Cont’d) Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [A].

P–00277

Use a brass tool and position the O–ring firmly into the O–ring gland [B].

P–00275

Assembly

Apply LOCTITE 242 to the threads of the spring retaining bolt. Install the spacer, spring, spring retainer and the spring retaining bolt into the end of the spool. Insert a pin through the hole in the spool and tighten the spring retaining bolt [C]. Tighten the bolt to 2–3 ft.–lbs. (2–4 Nm) torque.

P–00271

Install the end cap over the spring and install the two lock washers and bolts [D].

Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00266

Revised June 98

–2–18o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Valve Sections (Boom, Bucket & Arm) Disassembly Use a vise with protective jaws and clamp the valve section [A]. For Sections With Port Relief Valves Remove the work port relief valve from the section [A]. Installation: Tighten the port relief valve to 25–30 ft.–lbs. (34–40 Nm) torque. P–00289

NOTE: If the relief valve is disassembled, the relief pressure setting must be reset.

See Page 2–25 for port relief valve repair. For Sections With Port Relief Plugs Remove the port relief plug from the valve section [B]. Installation: Tighten the port relief plugs to 25–30 ft.–lbs. (34–40 Nm) torque.

P–00293

Remove the O–ring (Item 1) [C], back–up ring (Item 2) [C] and the O–ring (Item 3) [C] from the relief plug (Item 4) [C].

C 4 3 2

P–00294

Loosen the four bolts from the spool cover [D].

Installation: Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00300

Revised June 98

–2–19–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Valve Sections (Boom, Bucket & Arm) (Cont’d) Disassembly (Cont’d)

Remove the bolts (Item 1) [A], lock washers (Item 2) [A], spool cover (Item 3) [A], O–ring (Item 4) [A], spool stop (Item 5) [A] and the spring (Item 6) [A].

Repeat steps [D] (on previous page) and step [A] to disassemble the opposite end of the valve section. The spool and the housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings. The spools must be reinstalled in the same orientation as originally installed.

1 P–00302

Turn the valve section over and remove the plug (Item 1) [B], spring (Item 2) [B] and the load check plug (Item 3) [B].

3 2

Remove the O–ring (Item 4) [B] from the plug (Item 1) [B].

Installation: Tighten the plug to 15–20 ft.–lbs. (20–27 Nm) torque. NOTE: When installing the load check poppet, make sure that the poppet is inserted into the housing with the grooves in the poppet towards the spring and the plug.

P–00295

Assembly Clean parts in solvent and dry. Use new O–rings and assemble components in reverse order. Apply oil to the O–rings and the load check poppet when assembling.

Revised June 98

–2–20o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Valve Sections (Auxiliary) Disassembly

Use a vise with protective jaws and clamp the valve section [A].

P–00294

Remove the port relief plugs from the valve section [A]. Installation: Tighten the relief plug to 25–30 ft.–lbs. (34–40 Nm) torque. Remove the O–ring (Item 1) [A], back–up ring (Item 2) [A] and the O–ring (Item 3) [A] from the relief plug (Item 4) [A].

P–00290

Remove the two bolts and lock washers and the end cap from the valve section [B].

P–00299

Insert a pin into the hole in the actuating end of the spool to retain the spool from turning [C]. Loosen the spring retaining bolt from the end of the spool [C]. Do Not use any type of tool to grip the finished surface of the spool or the spool will be damaged. NOTE: The spring is under pressure, use care when removing the spring retaining bolt.

P–00301

Remove the spring retaining bolt (Item 1) [D], spring retainer (Item 2) [D], spring (Item 3) [D] and the spacer (Item 4) [D] from the end of the spool. Remove the O–ring (Item 5) [D] from the spring retaining bolt (Item 1) [D].

D 4

Installation: Apply LOCTITE 242 to the spring retaining bolt threads and tighten the bolt to 2–3 ft.–lbs. (2–4 Nm) torque.

5 2 1

P–00298

Revised June 98

–2–21–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Valve Sections (Auxiliary) (Cont’d) Disassembly (Cont’d) Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [A]. Use a brass tool to remove the O–ring. Do Not scratch the bore of the valve section while removing the O–ring or leakage may occur. Check the O–ring gland for contamination and clean as necessary. P–00275

NOTE: The spool and the section housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [B].

P–00277

Use a brass tool and position the O–ring firmly into the O–ring gland [C].

P–00275

Turn the valve section over and remove the plug from the bottom of the valve section [D].

Remove the O–ring from the plug [D]. Installation: Tighten the plug to 15–20 ft.–lbs. (20–27 Nm) torque. Assembly Clean the parts in solvent and dry. Use new O–rings and assemble parts in reverse order. Apply oil to the O–rings during assembly. P–00297

Revised June 98

–2–22o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Assembly Apply oil to the new section O–rings and install the O–rings onto the side face of the valve sections [A]. Install a washer and a nut onto one end of the thru studs with a lest two threads extending past the nut.

P–00694

Install the three bolts through the inlet section and place the inlet section on a bench with the O–rings facing upwards [B]. Check each valve section for location marks. Make sure that the valve sections are installed in the correct order. Install the valve sections onto the thru studs. Make sure that the two metal discs are installed between sections 3 and 4 and sections 4 and 5 [B]. Install the three washers and nuts on the thru studs, finger tighten only at this time.

P–00292

Place the valve assembly on a flat surface with the mounting feet facing upwards. Make sure that the center sections are flush. Snug up the nuts on the thru studs. Turn the valve assembly over and place it on the mounting feet. Be sure that the mounting feet protrude below the hex plugs on all the center sections. Finish tightening the nuts [C]. Tighten the nuts to 12–15 ft.–lbs. (16–20 Nm) torque. Recheck the mounting feet for level setting, and the center sections for proper clearance.

P–00287

Revised June 98

–2–23–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Port Relief Valve

6 Port Relief Valve Pressure Setting

Boom relief set at: (Rod End) Front . . . . . . . . . . . . . 3000 PSI (20690 kPa) (Base End) Rear . . . . . . . . . . . . 3000 PSI (20690 kPa)

3 9

Arm relief set at: (Rod End) Rear . . . . . . . . . . . . . 3000 PSI (20690 kPa) (Base End) Front . . . . . . . . . . . . 3000 PSI (20690 kPa)

7 5

Bucket relief set at: (Rod End) Front . . . . . . . . . . . . . 3000 PSI (20690 kPa) (Base End) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . NONE

4 P–00296

Disassembly Remove the end plug (Item 1) [A] from the housing (Item 2) [A]. Remove the spring (Item 3) [A], shims (Item 4) [A] and the poppet (Item 5) [A].

Wear safety glasses to prevent eye injury when any of the following conditions exist:

Remove the O–ring (Item 6) [A], back–up ring (Item 7) [A] and the O–ring (Item 8) [A] from the housing (Item 2) [A].

• • • •

Remove the O–ring (Item 9) [A] from the end plug (Item 1) [A].

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used. W–2019–1285

Clean all parts in solvent and dry. Inspect the poppet for scratches or wear at the pilot point. If damage is found, a new port relief valve assembly will need to be ordered from Melroe parts. Assembly Apply oil to the O–rings and back–up rings and install. Be careful not to overstretch these parts during installation. Apply oil to the poppet and install in the housing. Install the shims onto the poppet shaft with the thickest shims next to the poppet. Install the spring and the end plug. Tighten the end plug to 15–20 ft.–lbs. (20–27 Nm) torque. Install the port relief valve into the appropriate valve section. Tighten the end plug to 25–30 ft.–lbs. (34–40 Nm) torque. Adjustment A portable hydraulic hand pump will be used to test the work port relief valves. The hand pump must have clean hydraulic fluid that is compatible with the Melroe hydraulic fluid or use SAE 30W motor oil.

Revised June 98

–2–24o

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–HydraulicSectionPart1of4

Port Relief Valve (Cont’d) Adjustment (Cont’d) Install the hand pump hose and a pressure gauge (minimum of 5000 PSI) into the valve section work port in which the port relief valve is located [A]. Pressurize this section with the hand pump until the port relief valve opens and make a note of the pressure reading.

P–00747

If the port relief pressure setting needs to be adjusted, release the hand pump pressure valve and then remove the port relief end plug and spring [B]. Remove shim(s) to reduce the pressure or add shim(s) to increase the pressure setting [B]. NOTE: The shims will vary in thickness (0.021 or 0.0035) and in quantities. Reinstall the springs and the end plug and retests and readjust the port relief valve until the correct settings are obtained.

P–00304

Revised June 98

–2–25–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Main Relief Valve Main relief valves set at 2350–2400 PSI (16207–16552 kPa)

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

1 P–00267

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.

B 5

W–2019–1285

Disassembly

Remove the main relief valve (Item 1) [A] from the valve assembly (Item 2) [A]. If the valve assembly is not being disassembled, plug the main relief cavity to avoid contamination.

Remove the O–ring (Item 1) [B], back–up washer (Item 2) [B], O–ring (Item 3) [B] and back–up washer (Item 4) [B] from the housing (Item 5) [B]. Remove the adjusting bolt assembly (Item 6) [B] from the housing (Item 5) [B] and remove the sealing washer (Item 7) [B] from the adjusting bolt. The jam nut (Item 8) [B] does not need to be removed from the adjusting bolt.

6 P–00279

Assembly Apply oil to the O–rings, back–up washers and the sealing washers and install. Be careful not to overstretch these parts during installation. Install the adjusting bolt into the relief housing. Leave the adjusting bolt loose until the adjustment procedure is performed. Install the main relief valve into the valve housing [A]. Tighten the main relief to 35–40 ft.–lbs. (47–54 Nm) torque. Adjustment

P–00288

Install the valve into the excavator. Install all hoses and tubelines. Install all control linkages. Test the relief valve pressure settings per information on Page 2–6. If the relief valves need to be adjusted, do the following: Loosen the jam nut on the relief valve adjusting bolt [C]. Turn the bolt clockwise to increase the pressure, counterclockwise to decrease the pressure. When the correct pressure setting is obtained, tighten the jam nut while holding the adjusting bolt from turning [C]. Recheck the gauge reading after tightening the jam nut to assure that the correct setting has been maintained. Revised June 98 –2–26–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411)

Removal And Installation

CD–12881

I–2003–0888

Remove the floor panels. (Page 3–1.) Mark all the hose and tubelines for correct installation. Disconnect all hoses and tubelines from the top of the control valve [A]. Disconnect the two pilot tubelines from the control valve and the bulkhead elbows [B].

CD–12882

Remove the two cotter pins (Item 1) [C] and the clevis pins (Item 2) [C] from the valve spools.

2 CD–12978

Remove the three bolts holding the valve mounting plate to the frame [D].

CD–12883

Revised June 98 –2–27–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Removal And Installation (Cont’d) Turn the valve over and remove the three bolts holding the mounting plate to the valve [A].

CD–12884

Parts Identification 1. MAIN RELIEF VALVE 2. BUILD–UP VALVE 3. INLET SECTION HOUSE SWING (SLEW) 4. BLADE SECTION 5. END COVER VALVE (BOOM SWING) 6. LOAD CHECK BLOCK

4 2

D–02118

Revised June 98 –2–28–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

P–00262

Clean the control valve assembly with solvent.

Disassembly Mark the sections for ease of assembly. Remove the nuts and washers from the three thru studs [A]. Set the valve assembly on its end and remove the valve sections from the valve assembly [B].

P–00265

Remove the four O–rings from the side face of the valve section [C]. Do Not scratch the side faces of the valve sections.

P–00264

Revised June 98 –2–29–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Inlet Section (Housing Swing) Disassembly Use a vise with protective jaws and clamp the valve section [A]. Remove the relief valve from the inlet section [A]. Installation: Tighten the relief valve to 35–40 ft.–lbs. (47–54 Nm) torque. See Page 2–38 for relief valve repair.

P–00267

Loosen the four bolts from the spool cover [B].

Remove the four bolts (Item 1) [C], lock washers (Item 2) [C], cover (Item 3) [C], O–ring (Item 4) [C], spool stop (Item 5) [C] and spring (Item 6) [C] from the end of the valve section.

P–00269

Installation: Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque. Repeat step [C] to disassemble the opposite end of the valve section. The spool and the housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

Turn the valve section over and remove the plug (Item 1) [D], spring (Item 2) [D] and the lock check poppet (Item 3) [D]. Remove the O–ring (Item 4) [D] from the plug (Item 1) [D].

Installation: Tighten the plug to 15–20 ft.–lbs. (20–27 Nm) torque.

P–00270

NOTE: When installing the load check poppet, make sure that the poppet is inserted into the housing with the grooves in the poppet towards the spring and the plug.

Assembly

Clean all parts in solvent and dry. Use new O–rings and reassemble the components in reverse order.

Apply oil to the O–rings and the load check poppet when assembling components.

P–00285

Revised June 98 –2–30–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

End Cover (Boom Swing) and Valve Section (Blade) Disassembly NOTE: The photos may not show the valve section exactly as it appears; but the procedure is correct for these valve sections except as noted in the steps. Use a vise with protective jaws and clamp the valve section [A]. (For End Cover [Boom Swing] Section Only)

P–00272

Remove the build up valve from the end cover section [A].

See Page 2–37 for build up valve repair. Remove the four bolts holding the load check block to the top of the valve section [B].

P–00268

Lift the load check block off of the valve section [C].

See Page 2–35 for load check block disassembly.

P–00273

Remove the two O–rings from the top face of the valve section [D].

NOTE: Use care not to scratch or mar the machined surfaces of the valve section.

P–00274

Revised June 98 –2–31–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

End Cover (Boom Swing and Valve Section (Blade) (Cont’d) Disassembly (Cont’d) Remove the two bolts and lock washers from the end cap and remove the end cap from the valve section [A].

P–00266

Insert a pin into the hole in the actuating end of the spool to retain the spool from turning. Loosen the spring retaining bolt from the end of the spool [B]. Do Not use any type of tool to grip the finished surface of the spool or the spool will be damaged.

NOTE: The spring is under pressure, use care when removing the spring retaining bolt.

P–00271

Remove the spring retaining bolt (Item 1) [C], spring retainer (Item 2) [C], spring (Item 3) [C] and spacer (Item 4) [C] from the end of the spool.

3 2

Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [D].

P–00276

Use a brass tool to remove the O–ring. Do Not scratch the bore of the valve section while removing the O–ring or leakage may occur. Check the O–ring gland for contamination and clean as necessary. NOTE: The spool and the section housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

P–00275

Revised June 98 –2–32–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

End Cover (Boom Swing) and Valve Section (Blade) (Cont’d) Assembly Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [A].

P–00277

Use a brass tool and position the O–ring firmly into the O–ring gland [B].

P–00275

Apply LOCTITE 242 to the threads of the spring retaining bolt.

Install the spacer, spring, spring retainer and the spring retaining bolt into the end of the spool. Insert a pin through the hole in the spool and tighten the spring retaining bolt [C]. Tighten the bolt to 2–3 ft.–lbs. (2–4 Nm) torque.

P–00271

Install the end cap over the spring and install the two lock washers and bolts [D].

Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00266

Revised June 98 –2–33–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

End Cover (Boom Swing) and Valve Section (Blade) (Cont’d) Assembly (Cont’d) Check the top face O–ring grooves for contamination and clean as necessary [A]. Install the two new O–rings onto the top face of the valve section [A].

P–00281

Install the load check block onto the valve section [B].

P–00273

Install the four bolts thru the load check valve and into the valve section [C].

Tighten the bolt to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00268

(For End Cover [Boom Swing] Section Only)

Apply oil to the O–ring and install the build up valve into the valve section [D]. Tighten the build up valve to 2025 ft.–lbs. (27–34 Nm) torque.

P–00267

Revised June 98 –2–34–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Load Check Block Disassembly Install the load check block into a vise with protective jaws [A]. Remove the check valves from both ends of the load check block [A].

P–00278

Remove the two check valves (Item 1) [B] and the spool (Item 2) [B].

1 2

P–00280

Remove the O–ring (Item 1) [C], back–up washer (Item 2) [C] and the O–ring (Item 3) [C] from the check valve. Assembly

Clean the check valve in solvent and dry. Lubricate the new seals with oil and install new O–ring (Item 3) [C], back–up washer (Item 2) [C] and O–ring (Item 1) [C] onto the check valves. Apply oil to the O–rings and to the spool and reassemble the load check block.

Tighten the check valves to 15–20 ft.–lbs. (20–27 Nm) torque.

Revised June 98 –2–35–

P–00282

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Assembly Apply oil to the new section O–rings and install the O–rings onto the side face of each of the valve sections block [A]. Install a washer and a nut onto one end of the thru studs with at least two threads extending past the nut.

P–00694

Install the three thru bolts thru the inlet section and place the inlet section on a bench with the O–rings facing upwards [B].

Check each valve section for location marks. Make sure that the valve sections are installed in the correct order. Install the three washers and nuts on the thru studs, finger tighten only at this time.

P–00265

Place the valve assembly on a flat surface with the mounting feet flat on the surface. Make sure that the mounting feet protrude below the hex plugs on the bottom of the sections. Finish tightening the nuts [C].

Tighten the nut to 12–15 ft.–lbs. (16–20 Nm) torque. Recheck the mounting feet for level settings and the center section for proper clearance.

P–00262

Revised June 98 –2–36–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Build–Up Valve Remove the build–up valve from the valve [A]. Installation: Tighten the build–up valve to 20–25 ft.–lbs. (27–34 Nm) torque. NOTE: If the control valve assembly is not being disassembled, plug the build–up port to avoid contamination. P–00272

Remove the end plug (Item 1) [B], spring (Item 2) [B], piston (Item 3) [B] and the snap ring (Item 4) [B] from the build–up housing (Item 5) [B].

5 1

Remove and discard the O–rings. NOTE: The build–up piston (Item 3) [B] should not be disassembled as it is factory set and cannot be reset.

2 3

Clean all parts in solvent and dry.

Inspect all parts for wear or damage, if damage is found order a new build–up valve assembly from Melroe Parts.

P–00283

Assembly

Reassemble parts in reverse order. Apply oil to the new O–ring before installing. Testing Procedure: Install a gauge (5000 PSI minimum) into the pressure circuit at the valve [C]. Start excavator and run engine at idle. The build–up valve must develop 200 PSI (271 Nm) back pressure to charge the accumulator. The build–up valve is not field adjustable, if back pressure is wrong, order a new build–up valve from Melroe Parts.

P–00303

Revised June 98 –2–37–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511720001–511721411) (Cont’d)

Main Relief Valve Main relief valves set at 2350–2400 PSI (16207–16552 kPa)

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

1 P–00267

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.

B 5

W–2019–1285

Disassembly

Remove the main relief valve (Item 1) [A] from the valve assembly (Item 2) [A]. If the valve assembly is not being disassembled, plug the main relief cavity to avoid contamination.

6 P–00279

P–00288

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above)

The Husco six spool control valve has eight different sections:

4 5

The inlet section (Item 1) [A].

The right hand travel section (Item 2) [A].

The boom section (Item 3) [A].

The bucket section (Item 4) [A]. The auxiliary section (Item 5) [A].

P–06039

The arm section (Item 6) [A]. The left hand travel section (Item 7) [A]. Each of the two inlet sections on the valve have a main relief valve. The boom, bucket and arm sections have 5 work port relief valves. Parts Identification 4 2

1 7

2 9 10

8 CONTROL VALVE ASSEMBLY (6–Spool) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Main Relief Valve 2350 PSI (16203 kPa) Port Relief Valve 2950 PSI (20345 kPa) Port Relief Valve 3400 PSI (23449 kPa) Inlet/Outlet Section R.H Travel Boom Bucket Auxiliary Arm L.H. Travel

1 D–02266

Revised June 98 –2–39–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

P–06040

Clean the control valve assembly with a solvent. Disassembly Remove all the fittings from the control valve before disassembling the valve. Install new O–rings onto the fittings before reusing them. Mark the section for ease of assembly. Remove the nuts from the three tie rods [A]. Remove the inlet valve section from the valve assembly [B].

P–06041

Continue to remove all the valve sections [C]. Keep the valve sections in the correct order for ease of assembly.

P–06042

Remove the O–ring (Item 1) [D], spring (Item 2) [D] and the load check valve (Item 3) [D] from the valve body.

NOTE: There is no spring and load check valve in the auxiliary valve section or the inlet valve sections. If only the valve section O–rings need replacing, clean and dry the side faces of the sections and the O–ring glands. Install new O–rings and reassemble the valve.

See Page 2–51 for tightening torque.

3 P–06031

Revised June 98 –2–40–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Inlet Section Disassembly And Assembly Put the valve section in a vise with protective jaws. Remove the main relief valve from the inlet section [A]. Clean the valve section in solvent and dry. Install the main pressure relief valve into the valve section. Tighten to 43–53 ft.–lbs. (57–71 Nm) of torque. NOTE: If the main pressure relief valve is disassembled the relief pressure setting must be reset. See Page 2–55 for main relief valve repair.

P–06043

Revised June 98 –2–41–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Right Hand & Left Hand Travel Section Disassembly Put the valve section in a vise with protective jaws. Remove the two screws from the retaining plate on the actuating end of the spool [A].

P–06044

Remove the two screws from the end cap [B].

P–06045

Insert a pin into the hole in the actuating end of the spool to prevent the spool from turning. Loosen the spring retaining screw from the end of the spool [C]. Do not use any type of tool to grip the finished surface of the spool; the spool will be damaged. NOTE: The spring is under pressure, use care when removing the spring retaining screw. The spool and housing are not serviced separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and do not intermix the spool and the housings.

P–06046

The spool can be removed from either direction of the valve after the seals have been removed.

Remove the spring retaining bolt (Item 1) [D], spring retainer (Item 2) [D], spring stop (Item 3) [D], spring (Item 4) [D], spring retainer (Item 2) [D] and the plate (Item 5) [D].

2 P–06022

Revised June 98 –2–42–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Right Hand & Left Hand Travel Section (Cont’d) Disassembly (Cont’d) Remove the wiper from the spool (both ends) [A].

P–06047

Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [B].

Use a brass tool to remove the O–ring. Do not scratch the bore of the valve section while removing the O–ring or leakage may occur. Push the other end of the spool into the housing and remove the O–ring from the opposite end. Check the O–ring glands for contamination and clean as necessary.

P–06048

Assembly Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [C]. Use a brass tool and position the O–ring firmly into the O–ring gland. Apply oil to the O–ring. Slowly rotate the spool and push it through the O–ring. Then pull the spool through the valve section far enough to gain access to the spool O–ring gland on the opposite end of the valve.

P–06023

Repeat the steps for installing the spool O–rings.

Install the wiper on both ends of the spool [D]. Use finger pressure to seat the wiper into the bore of the valve.

P–06047

Revised June 98 –2–43–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Right Hand & Left Hand Travel Section (Cont’d)

Assembly (Cont’d)

Install the plate (Item 1) [A] over the spool. Install the spring seat (Item 2) [A], spring (Item 3) [A], spring stop (Item 4) [A] and outer spring seat (Item 2) [A] on the spool.

Apply thread adhesive (LOCTITE 271) to the spring retainer bolt (Item 5) [A] threads.

2 P–06022

Insert a pin through the hole in the spool and tighten the spring retaining bolt [B]. Tighten the spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) of torque.

P–06046

Install the end cap over the spring and install the two screws [C].

Tighten the screws to 6–8 ft.–lbs. (8–10 Nm) of torque.

P–06045

Install the retainer plate and the two screws [D]. Tighten the screws to 3–5 ft.–lbs. (4–6 Nm) torque.

P–06044

Revised June 98 –2–44–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Boom, Bucket & Arm Section Disassembly Put the valve section in a vise with protective jaws. Remove the work port relief valve from the valve section [A]. Installation: Tighten the port relief valve to 30–36 ft.–lbs. (40–48 Nm) of torque. P–06049

NOTE: If the relief valve is disassembled the relief pressure setting must be reset. See Page 2–52 for port relief valve repair.

Loosen the four screws from the spool covers (Item 1) [B].

1 P–06050

Remove the screws and retaining plates from both end covers. Remove the end cover from the actuating end of the valve. Remove the O–ring [C].

P–06033

Insert a pin through the hole in the actuating end of the spool to prevent the spool from turning. Loosen the spring retaining screw from the end of the spool [D].

Do not use any type of tool to grip the finished surface of the spool; the spool will be damaged. NOTE: The spring is under pressure, use care when removing the spring retaining screw.

P–06770

Revised June 98 –2–45–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Boom, Bucket & Arm Section (Cont’d) Disassembly (Cont’d) Remove the retainer from the end cover by pushing on the bolt head with the hex wrench [A].

P–06034

Remove the O–rings (Item 1) [B] and the back–up rings (Item 2) [B] from the retainer (Item 7) [B].

Remove the spring seat (Item 3) [B], the inner spring (Item 4) [B], the outer spring (Item 5) [B] and the second spring seat (Item 3) [B].

The spool and housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and do not intermix the spool and the housings.

Assembly P–06035

Clean parts in solvent and dry.

Install new O–rings (Item 1) [B] and back–up ring (Item 2) [B] on the retainer (Item 7) [B]. Put oil on the new O–rings and back–up rings. Apply thread adhesive (LOCTITE 271) to the spring retaining bolt (Item 6) [B]. Install the spring seat (Item 3) [B], the outer spring (Item 5) [B], the inner spring (Item 4) [B], inner spring seat (Item 3) [B], the bolt (Item 6) [B] and the retainer (Item 7) [B] into end cover. Insert a pin into the hole in the actuating end of the spool to prevent the spool from turning.

P–06770

Install the end cover on the valve section [C]. Tighten spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) torque.

D Install the end cover retaining plate and screws on the end cover [D]. Tighten the screws to 6–9 ft.–lbs. (8–10 Nm) torque.

P–06050

Revised June 98 –2–46–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Boom, Bucket & Arm Section (Cont’d) Assembly (Cont’d) Apply oil to and install a new O–ring on the end cover for the actuating end of the valve section [A].

P–06033

Install the end cover, the end cover retaining plate and the screws [B].

Tighten the screws to 6–9 ft.–lbs. (8–10 Nm) torque.

P–06032

Revised June 98 –2–47–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Auxiliary Section Disassembly Use a vise with protective jaws and clamp the valve section. Remove the two screws and the end cap from the valve section [A]. Insert a pin into the hole in the actuating end of the spool to retain the spool from turning. P–06045

Remove the spring retaining screw from the end of the spool [B].

NOTE: The spring is under pressure, use care when removing the spring retaining screw.

P–06046

Remove the spring retaining screw (Item 5) [C], the spring retainer (Item 2) [C], the spring stop (Item 4) [C], the spring (Item 3) [C], the spring retainer (Item 2) [C] and the plate (Item 1) [C].

C 1

2 P–06022

Remove the wiper from both ends of the spool [D].

P–06047

Revised June 98 –2–48–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Auxiliary Section (Cont’d) Assembly Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section. Use a brass tool to remove the O–ring [A]. Do not scratch the bore of the valve section while removing the O–ring; leakage may occur. Put the other end of the spool into the housing and remove the opposite end O–ring.

P–06048

Check the O–ring gland for contamination and clean as necessary.

Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [B].

P–06023

Use a brass tool to position the O–ring firmly into the O–ring gland.

Apply oil to the O–ring. Slowly rotate the spool and push it through the O–ring. Then pull the spool through the valve section far enough to gain access to the spool O–ring on the opposite end of the valve section. Repeat the O–ring installation instructions for the opposite end. Install the wiper on both ends of the spool [C]. Seat the wiper into the bore of the valve with finger pressure.

P–06047

Install the retaining plate and screws on the actuating end of the valve. Tighten the screws to 3–5 ft.–lbs. (4–7 Nm) of torque [D].

P–06044

Revised June 98 –2–49–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–HydraulicSectionPart2of4

Auxiliary Section (Cont’d)

Assembly (Cont’d)

Install the retaining plate (Item 5) [A], the spring seat (Item 2) [A], the spring (Item 4) [A], the spring stop (Item 3) [A] and the outer spring seat (Item 2) [A] on the end of the spool. Apply thread adhesive (LOCTITE 271) to the threads of the retaining bolt (Item 1) [A].

2 P–06022

Insert a pin through the hole in the spool and tighten the spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) of torque [B].

Install the end cover and the end cover screws. Tighten the screws to 6–8 ft.–lbs. (8–10 Nm) of torque.

P–06046

Assembly

Put grease on the new O–rings and install the O–rings on the face of the valve sections (Item 1) [C]. Install the poppet into the bore on the face of the valve section (Item 2) [C].

P–06015

Install the spring into the poppet [D].

P–06016

Revised June 98 –2–50–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) (Cont’d)

Assembly (Cont’d) Install the nuts onto the short threaded end of the tie rods with at least two threads extending past the nut. Install the tie rods through the inlet section. Check each valve section for location marks. Make sure that the valve sections are installed in the correct order. Install the valve sections on the tie rods [A]. Install the three nuts on the tie rods, finger tighten only at this time.

P–06042

Be sure the valve is flat on the bench by pressing down on the inlet sections so the mounting feet of the the end sections are aligned.

Tighten the tie rod nuts to 10 ft.–lbs (13 Nm) of torque in a crisscross pattern [B]. Tighten the two 0.3125 inch dia. tie rods to 14 ft.–lbs. (19 Nm). Tighten the one 0.375 inch dia. tie rod nut to 33 ft.–lbs. (45 Nm). The valve must not have any spacing between the valve sections and the spools must be free when pushed in and released. The spools must not stick, if the spools do stick, loosen the tie rod nuts and tighten per above information.

P–06040

Recheck the mounting feet for level settings.

Revised June 98 –2–51–

320 (S/N 511720001 & Above) Excavator Service Manual

PORT RELIEF VALVES HUSCO VALVE Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Nut O–ring Nut Screw Spring Poppet Housing O–ring Spring Back–up Ring O–ring Spring Poppet Poppet Sleeve O–ring Back–up Ring Housing O–ring

13 9 8 10

6 5

4 3

18 15 12 14

16 17

C–03361

Revised June 98 –2–52–

320 (S/N 511720001 & Above) Excavator Service Manual

PORT RELIEF VALVES HUSCO VALVE (Cont’d)

Port Relief Valve Pressure Setting Boom relief set at: (Rod End) Front . . . . . . . . . . . 2950 PSI (20345 kPa) (Base End) Rear . . . . . . . . . . . 2950 PSI (20345 kPa) Arm Relief set at: (Rod End) Rear . . . . . . . . . . . . 2950 PSI (20345 kPa) (Base End) Front . . . . . . . . . . 2950 PSI (20345 kPa) Bucket Relief set at: (Rod End) Rear . . . . . . . . . . . . 3400 PSI (24357 kPa) (Base End) Front . . . . . . . . . . . . . . . . . . . . . . . . . None

P–06051

1 11 2

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

12 3

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.

W–2019–1285

Disassembly

Remove the end cap (Item 1) [B] and the O–ring (Item 2) [B] from the adjusting screw (Item 5) [B]. Remove the jam nut (Item 3) [B] and the O–ring (Item 4) [B] from the adjusting screw (Item 5) [B].

Remove the adjusting screw (Item 5) [B], spring (Item 6) [B] and poppet (Item 7) [B] from the housing (Item 8) [B].

Remove the housing (Item 8) [B]. Remove the O–rings (Item 9) [B] and back–up ring (Item 10) [B] from the housing.

9 10

Remove the spring (Item 11) [B], poppet (Item 12) [B], pilot pressure poppet (Item 13) [B]. Remove the O–ring (Item 14) [B] and back–up ring (Item 15) [B] from the poppet.

9 19

P–06052

Remove the spring (Item 16) [B] and sleeve (Item 17) [B] from the housing (Item 18) [B]. Remove the O–ring (Item 19) [B] from the housing (Item 18) [B]. Clean all parts in solvent and dry. Inspect the poppet for scratches or wear at the pilot point. If damage is found, order a new port relief valve assembly from Melroe Parts.

Revised June 98 –2–53–

320 (S/N 511720001 & Above) Excavator Service Manual

PORT RELIEF VALVE HUSCO VALVE (Cont’d)

Assembly

11 2

Put oil on the O–rings and the back–up rings and install. Be careful not to over stretch these parts during installation.

12 3

Put oil on the sleeve (Item 17) [A] and insert it into the housing (Item 18) [A].

Install the spring (Item 16) [A] into the housing (Item 18) [A] and on the sleeve (Item 17) [A].

Install the poppet (Item 13) [A].

15 6

Install the pilot pressure poppet (Item 12) [A] into the poppet (Item 13) [A]. Install the spring (Item 11) [A] on the pilot pressure poppet (Item 12) [A].

Install the housing (Item 8) [A] on the housing (Item 18) [A]. Tighten to 30–36 ft.–lbs. (40 – 48 Nm) of torque.

Insert the poppet (Item 7) [A] and the spring (Item 6) [A] into the housing (Item 8) [A].

Install the adjusting screw (Item 5) [A] into the housing (Item 8) [A].

Install the lock nut (Item 3) [A] on the adjusting screw (Item 5) [A]. Tighten to 6–8 ft.–lbs. (8–10 Nm) of torque.

9 19

Install the end cap (Item 1) [A] on the adjusting screw (Item 5) [A]. Tighten to 6–8 ft.–lbs. (8–10 Nm) of torque.

P–06052

Adjustment A portable hydraulic hand pump will be used to test the work port relief valves. The hand pump must have clean hydraulic fluid that is compatible with the Melroe hydraulic fluid or use SAE 10W–30 motor oil. Install the hand pump hose and a pressure gauge (minimum of 5000 PSI) into the valve section work port in which the port relief valve is located. Pressurize this section with the hand pump until the port relief valve opens and make a note of the pressure reading. If the port relief pressure setting needs to be adjusted, release the hand pump pressure valve. Remove the end cap nut. Loosen the lock nut. Turn the adjusting screw clockwise to increase the pressure and counterclockwise to reduce the pressure. Tighten the jam nut and retest. Adjust the port relief valve until the correct setting is obtained. (See previous page for the port relief pressures.) Install the end cap.

Revised June 98 –2–54–

320 (S/N 511720001 & Above) Excavator Service Manual

MAIN RELIEF VALVES HUSCO VALVE Parts Identification RELIEF VALVE ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

12 10

Nut O–ring Nut Screw Shim Spring Stop Poppet Housing Nut O–ring O–ring

11 9 8 7 6 5 4 2 3 1

C–03361

Revised June 98 –2–55–

320 (S/N 511720001 & Above) Excavator Service Manual

MAIN RELIEF VALVES HUSCO VALVE (Cont’d)

Main Relief Valves are set at 2350 PSI (16203 kPa).

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.

P–06053

W–2019–1285

Disassembly

Remove the main relief valve from the valve assembly [A]. If valve assembly is not being disassembled, plug the main relief cavity to avoid contamination.

2 5

Remove the end cap (Item 1) [B], O–ring (Item 2) [B], locknut (Item 3) [B] and O–ring (Item 4) [B] from the adjusting screw (Item 5) [B].

Remove the adjusting screw (Item 5) [B], shim (Item 6) [B], spring (Item 7) [B], spring stop (Item 8) [B] and poppet (Item 9) [B] from the housing (Item 10) [B].

3 4

Remove the nut (Item 11) [B] and the O–ring (Item 12) [B] from the housing.

Remove the O–ring (Item 13) [B] from the nut.

Assembly

Put oil on the O–rings and install. Be careful not to over stretch these parts during installation.

Install the nut (Item 11) [B] on the housing (Item 10) [B].

Install the poppet (Item 9) [B], spring stop (Item 8) [B], spring (Item 7) [B] and shim (Item 6) [B] into the housing. Install the adjusting screw (Item 5) [B] into the housing (Item 10) [B].

P–06054

Install the lock nut (Item 3) [B] and end cap (Item 1) [B] on the adjusting screw (Item 5) [B]. Tighten to 16–20 ft.–lbs. (21–26 Nm) of torque. Install the main relief valve in the inlet valve assembly. Tighten to 43–53 ft.–lbs (57–71 Nm) of torque. The relief pressure setting must be reset.

Revised June 98 –2–56–

320 (S/N 511720001 & Above) Excavator Service Manual

MAIN RELIEF VALVES HUSCO VALVE (Cont’d)

Adjusting The Main Relief Valves Install the control valve into the excavator. Install all hoses and tubelines. Install all the control linkages. Test the relief valve pressure setting per information on Page 2–6. If the relief valves need to be adjusted do the following: Remove the end cap.

P–06055

Loosen the lock nut on the relief valve adjusting screw. Turn the adjusting screw clockwise to increase the pressure, counterclockwise to decrease the pressure. When the correct pressure setting is obtained, tighten the lock nut while holding the adjusting screw from turning. Recheck the gauge reading after tightening the lock nut to assure that the correct setting has been maintained. Tighten the lock nut to 16–20 ft.–lbs. (21–26 Nm) of torque. Install and tighten end cap to 16–20 ft.–lbs. (21–26 Nm) of torque.

Revised June 98 –2–57–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Parts Identification

The Husco 3–Spool valve has five sections [A]. The inlet (Item 1) [A], the boom swing (Item 2) [A], the blade (Item 3) [A], the swing motor section (Item 4) [A] and outlet section (Item 5) [A].

1 2

The 3–Spool valve has one main pressure relief valve on the Inlet Section. Lockout valves are located in the Blade and Boom Swing Sections (two each), and an accumulator pressure build–up valve is located in the inlet section.

P–06011

CONTROL VALVE ASSEMBLY (3–Spool) 1. 2. 3. 4. 5. 6. 7. 8.

Pressure Build–up Valve 200 PSI (1379 kPa) Main Relief Valve 2350 PSI (16207 kPa) Lockout Valve Inlet Section Swing Motor Blade Boom Swing Outlet Section

5 3 6 3 2

8 3

D–02267

Revised June 98 –2–58–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

When making repairs on hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P–06012

I–2003–0284

Disassembly Clean the control valve assembly with solvent. Remove all the fittings from the control valve before disassembling the valve. Install new O–rings onto the fittings before reusing them. Mark the sections for ease of assembly. Remove the nuts from the three tie rods [A]. Set the valve assembly on its end and remove the valve sections from the valve assembly [B].

P–06013

Remove the O–ring from the face of the valve section [C]. Do not scratch the face of the valve section. NOTE: If only the O–rings need replacing, clean and dry the faces of the sections and O–ring glands. Install new O–rings and reassemble the valve. See Page 2–68 for tightening torque.

P–06014

Remove the spring and the load check valve from the face of the swing motor section [D].

P–06015

Revised June 98 –2–59–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Blade And Boom Swing Section Disassembly Put the valve section in a vise with protective jaws. Remove the two screws holding the plate to the valve section [A]. Remove the plate.

P–06024

Remove the two screws holding the end cover to the valve section [B].

Remove end cover.

P–06017

Insert a pin into the hole in the actuating end of the spool to prevent the spool from turning. Remove the spring retaining screw from the spool [C].

NOTE: The spring is under pressure, use care when removing the spring retaining screw. Do not use any type of tool to grip the finished surface of the spool; the spool will be damaged.

P–06018

Remove the spring retainer screw (Item 1) [D], outer spring seat (Item 2) [D], spring (Item 4) [D], spring stop (Item 3) [D] and the inner spring seat (Item 2) [D] from the spool. Remove the plate (Item 5) [D] from the valve section.

D 5

2 P–06022

Revised June 98 –2–60–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Blade and Boom Swing Section (Cont’d) Disassembly (Cont’d) Remove the wiper from both ends of the spool [A].

P–06020

Pull the spool into the housing far enough to remove the O–ring from the spool bore in the valve section. Use a brass tool to remove the O–ring [B]. Do not scratch the bore of the valve section while removing the O–ring; leakage may occur.

Repeat this procedure for the opposite side of the spool. Check the O–ring gland for contamination and clean as necessary. The spool and the housing are not serviceable separately. The spool does not need to be removed from the housing except to clean the oil passages if contamination is found. If the spool is removed use care not to scratch the spool surface and do not intermix the spool and housings. P–06021

Revised June 98 –2–61–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Blade And Boom Swing Section (Cont’d) Assembly Clean all parts with solvent and dry. Install new O–rings by pinching the O–ring and inserting it into the O–ring gland. Use a brass tool to position the O–ring firmly into the O–ring gland [A]. Put oil on the O–ring and slowly rotate the spool while pushing it through the valve section. Pull the spool far enough into the housing to install a new O–ring on the opposite end of the spool. Repeat the above steps for installing the spool O–ring.

P–06023

Install the wiper on both ends of the spool [B]. Use finger pressure to seat the wiper into the bore of the valve.

P–06020

Install the plate and the two screws on the actuating end of the spool [C]. Tighten the screws to 3–5 ft.–lbs. (4–6 Nm) torque.

P–06024

Apply thread adhesive (LOCTITE 271) to the spring retaining screw (Item 5) [D]. Slide the plate (Item 1) [D] over the spool, install the inner spring seat (Item 2) [D] on the end of the spool.

Install the spring (Item 3) [D] on the spool. Install the spring stop (Item 4) [D], outer spring seat (Item 2) [D] and the retaining screw (Item 5) [D].

2 P–06022

Revised June 98 –2–62–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Blade And Boom Swing Section (Cont’d) Assembly (Cont’d) Insert a pin in the hole in the actuating end of the spool to prevent the spool from turning [A]. Tighten the retainer screw to 6–8 ft.–lbs. (8–10 Nm) torque. Install the end cover over the spring and install the two screws. P–06018

Tighten the screws to 6–8 ft.–lbs. (8–10 Nm) torque.

Lockout Valve Assembly Disassembly Remove the plug (Item 1) [B], spring (Item 2) [B] and poppet (Item 3) [B] from the valve section.

3 2 1 P–06026

Remove the housing (Item 1) [C] and pin (Item 2) [C] from valve section.

1 2

P–06027

Remove the plug from the opposite end of the valve [D].

P–06025

Revised June 98 –2–63–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Lockout Valve Disassembly (Cont’d) Remove the housing (Item 1) [A] and the spool (Item 2) [A].

2 1

P–06028

Remove the O–rings and the back–up rings from the housing and plug [B] & [C].

Lockout Valve Assembly Clean all parts in solvent and dry.

Install the new O–rings and back–up rings on both of the housings and on both of the plugs. Apply oil to the O–rings. Install the spool (Item 1) [B] and the housing (Item 2) [B] into the actuating end of the valve.

Install the poppet (Item 3) [B], the spring (Item 4) [B] and the plug (Item 5) [B].

3 P–06030

Tighten the housing (Item 2) [B] to 43–53 ft.–lbs. (58–71 Nm) of torque.

Tighten the plug (Item 5) [B] to 15 ft.–lbs. (20 Nm) of torque.

Install the pin (Item 1) [C] and the housing (Item 2) [C] in the valve. Tighten the housings to 43–53 ft.–lbs. (58–71 Nm) of torque. Install the poppet (Item 3) [C], spring (Item 4) [C] and the plug (Item 5) [C].

Tighten the plug (Item 5) [C] to 15 ft.–lbs. (20 Nm) of torque. P–06029

Revised June 98 –2–64–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Swing Motor Valve Section Disassembly Remove the O–ring (Item1) [A], spring (Item 2) [A] and poppet (Item 3) [A] from the valve face.

1 3 P–06031

Remove the four screws from the end covers [B].

P–06032

Remove the end cover from the actuating end of the valve. Remove the O–ring from the end cover [C].

P–06033

Insert a pin into the hole in the actuating end of the spool to prevent the spool from turning. Loosen the spring retaining screw from the end of the spool [D]

Do not use any type of tool to grip the finished surface of the spool; the spool will be damaged. NOTE: The spring is under pressure, use care when removing the spring retaining screw.

P–06770

Revised June 98 –2–65–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Swing Motor Valve Section (Cont’d) Disassembly (Cont’d) Once the end cover is removed, use the hex wrench to push on the bolt head to separate the retainer from the end cover [A].

P–06034

Remove the retainer (Item 1) [B].

Remove the spring seat (Item 2) [B], the inner spring (Item 3) [B] and outer springs (Item 4) [B], a second spring seat (Item 2) [B] and the bolt (Item 5) [B].

Remove the backup ring (Item 6) [B] and O–rings (Items 7 & 8) [B] from the retainer (Item 1) [B]. Assembly Clean all parts in solvent and dry.

Install new O–rings (Items 7 & 8) [B] and the back–up ring (Item 6) [B] on the retainer and the end cover. P–06035

Oil the O–rings and the back–up ring.

Install the bolt (Item 5) [B], spring seat (Item 2) [B], the outer spring (Item 4) [B] and inner spring (Item 3) [B] and the second spring seat (Item 2) [B]. Install the retainer (Item 1) [B]. Apply thread adhesive (LOCTITE 271) to the bolt (Item 5) [B] threads. Insert a pin through the hole in the spool and tighten the spring retaining bolt. Tighten the spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) of torque [C]. Install the plate and two screws. Tighten the screws to 6–8 ft.–lbs. (8–11 Nm) torque.

P–06770

Install a new O–ring on the end cover [D].

P–06033

Revised June 98 –2–66–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Swing Motor Valve Section (Cont’d) Assembly (Cont’d) Install the end cover and plate. Install the two screws [A]. Tighten screws to 6–8 ft.–lbs. (8–11 Nm) of torque.

P–06032

Assembly

Put oil on the new O–rings and install the O–rings on to the face of each valve section [B].

P–06014

Install the load check valve into the swing motor valve section [C]. NOTE: The open end of the poppet faces up.

P–06015

Install the spring into the poppet [D].

P–06016

Revised June 98 –2–67–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Assembly (Cont’d) Install the three nuts on the short thread end of the tie rods. Turn the nuts on until they stop. Install the three tie rods through the inlet section and put the inlet section on a bench with the O–rings facing up. Check each valve section for location marks. Make sure the valve sections are installed in the correct order. Install the three nuts on the tie rod ends, finger tight. P–06011

Place the valve assembly onto the mounting pads of valve [A].

Be sure the valve is flat on the bench by pressing down on the inlet section and the end cap section so the mounting feet are aligned. Tighten the tie rod nuts to 10 ft.–lbs. (13 Nm) of torque in a crisscross manner [B]. Tighten the two 0.3125 inch dia. tie rods to 14 ft.–lbs. (19 Nm). Tighten the one 0.375 inch dia. tie rod to 33 ft.–lbs. (45 Nm). The valve must not have any space between valve sections. The spools must be free when pushed in and released.

P–06012

The spools must not stick. If the spools do stick, loosen the tie rod nuts and retighten per the above information. Recheck the mounting feet for level settings.

Revised June 98 –2–68–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) (Cont’d)

Build–Up Valve Disassembly

Remove build–up valve from the valve section. Installation: Tighten the valve to 30–36 ft.–lbs. (40–48 Nm) torque. Remove the housing (Item 1) [A], spring (Item 2) [A] and poppet (Item 3) [A]. Remove the O–rings (Item 4) [A] from the poppet (Item 3) [A] and the O–ring (Item 5) [A] from the housing (Item 1) [A].

Inspect all parts for wear or damage, if damage is found order a new build–up valve assembly from Melroe Parts.

1 P–06036

Build Up Valve Assembly Clean all parts in solvent and dry. Lubricate the new O–rings and install on the poppet and housing. Install the poppet (Item 3) [A], spring (Item 2) [A] and the housing (Item 1) [A] into the valve section. Tighten the housing to 30–36 ft.–lbs. (40–48 Nm) of torque. Build Up Valve Test Procedure Install a gauge (5000 PSI minimum) into the pressure circuit at the valve. Start the excavator and run the engine at idle speed. The build–up valve must develop 200 PSI (271 Nm) back pressure to charge the accumulator. The build–up valve is not field adjustable, if back pressure is wrong after installing a new spring and new O–rings, order a new build–up valve from Melroe Parts.

Revised June 98 –2–69–

320 (S/N 511720001 & Above) Excavator Service Manual

BOOM CYLINDER

Removal And Installation NOTE: Refer to the Page 2–75 – 2–83 for servicing the cylinder. Lower the bucket to the floor. Stop the engine. Support the boom using a chain hoist [A]. Move the hydraulic controls to release the hydraulic pressure.

P–00887

I–2003–0888

Boom Shield Remove the boom shield mounting bolt [A]. Remove the spacer (Item 1) [B] and slide the shield down until the shield can be removed from boom cylinder shield mounting stud (Item 2) [B].

P–00886

Boom Cylinder Disconnect the two hoses from the boom cylinder. Remove the retainer bolt and nut from the boom cylinder base end pin [C].

P–00888

Remove the cylinder base end pin [D].

Lower the base end of the cylinder to the floor. Remove the retainer bolt and nut from the cylinder rod end pin. Remove the cylinder rod end pin. Remove the boom cylinder from the boom. Installation: Tighten the nut to allow NO endplay of the bolt (Item 1) [C].

P–00889

Revised June 98 –2–70–

320 (S/N 511720001 & Above) Excavator Service Manual

ARM CYLINDER

Removal And Installation NOTE: Refer to the Page 2–75 – 2–83 for servicing the cylinder. Lower the boom/bucket to the floor. Stop the engine. Support the arm using a chain hoist [A]. Move the hydraulic controls to release the hydraulic pressure.

P–00876

B When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

Disconnect the two hoses from the arm cylinder [A]. Remove the retainer bolt (Item 1) [B] and nut from the boom cylinder base end pin. P–00879

Remove the retainer bolt (Item 1) [C] and nut from the cylinder rod end pin.

P–00880

Remove the cylinder rod end pin [D].

Remove the cylinder from the arm. Installation: Tighten the bolt to allow NO endplay of the bolt (Item 1) [B] & [C].

P–00878

Revised June 98 –2–71–

320 (S/N 511720001 & Above) Excavator Service Manual

BUCKET CYLINDER

Removal And Installation NOTE: Refer to the Page 2–75 – 2–83 for servicing the cylinder.

Lower the bucket to the floor. Stop the engine. Support the arm using a chain hoist [A]. Move the hydraulic controls to release the hydraulic pressure.

P–00877

1 Disconnect the two hoses (Item 1) [A] from the bucket cylinder. Remove the retainer bolt (Item 1) [B] and nut from the cylinder rod end pin.

P–00872

Remove the retainer bolt (Item 2) [A] and nut from the cylinder base end pin. Remove the cylinder base end pin [C]. Installation: Tighten the bolt to allow NO endplay of the bolt (Item 1) [B]. Remove the bucket cylinder.

P–00873

Revised June 98 –2–72–

320 (S/N 511720001 & Above) Excavator Service Manual

BLADE CYLINDER

Removal And Installation NOTE: Refer to the Page 2–75 – 2–83 for servicing the cylinder. Lower the blade to the floor. Stop the engine. Move the blade control to release the hydraulic pressure. Remove the four nuts from the blade cylinder shield [A].

CD–10117

Remove the blade cylinder shields [B].

Remove the blade cylinder hoses (Item 1) [C].

Remove the rod end bolt (Item 2) [C] and pin.

Remove the base end bolt (Item 3) [C] and pin. Installation: Tighten the nut to allow NO endplay of the bolt (Items 2 & 3) [C].

Remove the blade cylinder.

1 3 CD–10119

Revised June 98 –2–73–

320 (S/N 511720001 & Above) Excavator Service Manual

BOOM SWING CYLINDER

Removal And Installation NOTE: Refer to the Page 2–75 – 2–83 for servicing the cylinder.

P–02216

I–2003–0888

Lower the bucket and blade to the floor. Stop the engine. Remove the bolt from the rod end pin [A]. Remove the rod end pin [B]. Start the excavator and carefully retract the cylinder fully. Stop the engine.

P–02416

Remove the base end pin retainer bolt (Item 1) [C] from under the upperstructure.

With a second person holding the rod end of the cylinder, pry the base end pin down [C].

P–02227

Slide the cylinder forward to remove the base end from the cylinder mount. Set the cylinder down onto the top of the track. Mark the two hoses for ease of assembly. Remove the two hoses [D]. Remove the cylinder. Installation: Tighten the bolts to 29–37 ft.–lbs. (4–50 Nm) torque.

P–03299

Revised June 98 –2–74–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER

320ServiceManual(S/N511720001&Above)#6722642–HydraulicSectionPart3of4

Disassembly NOTE: The drawings may not show the cylinder exactly as it appears, but the procedure is correct for all cylinders. Put the base end of the hydraulic cylinder in a drain pan. Move the rod in and out to remove the fluid from the cylinder. Move the rod slowly so the fluid will go directly into the drain pan. Put the base end of the cylinder in a vise. Use the adjustable gland nut wrench (MEL1075) to loosen the head [A].

B–07000

Remove the rod assembly from the cylinder case [B]. Remove the cylinder case from the vise. Put the rod end in the vise.

B–07001

For Cylinders Using Piston Retaining Bolts Loosen the bolt from the piston end of the rod [C].

B–13745

For Cylinders Using Piston Retaining Lock Nut Loosen the nut from the piston end of the rod [D].

B–07002

Revised June 98 –2–75–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Disassembly (Cont’d)

Remove the bolt or the lock nut (Item 1) [A] from the rod. Pull the piston off the rod (Item 2) [A]. Pull the head (Item 3) [A] off the rod.

CD–12673

Remove the O–ring (Item 1) [B] and back–up washer (Item 2) [B] from the head with seal hook (MEL1074). Remove the O–Ring (Item 3) [B] from the head.

1 2 3

B–13743

Remove the wiper seal [C].

B–07005

Remove the oil seal from the head [D].

B–07006

Added June 98 –2–76–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Disassembly (Cont’d) For Piston With Single Ring Groove Cut the old teflon seal and remove the seal from the piston [A].

B–03689

Remove the O–ring from the piston [B]. Wash the cylinder parts in solvent and air dry them. While servicing the cylinder do not damage the parts. Inspect for nicks, scratches or otherwise damaged or bent parts before assembling the cylinder. Replace parts that appear damaged in any way. The cylinder may not function correctly if there is damage to any of the parts. Destroy all the O–rings and seals and replace them with NEW O–rings and seals.

B–03703

Assembly Install the O–ring on the piston [C].

B–12812

NOTE: Do not overstretch the seal.

Install the seal on the tool (MEL1396) and stretch it until it fits the piston [D]. Allow the O–ring to stretch for 30 seconds before removing it from the tool.

B–12809

Added June 98 –2–77–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Assembly (Cont’d) Install the seal on the piston [A].

B–12813

Use a ring compressor to compress the seal to the correct size [B]. Leave the piston in the ring compressor for three minutes.

B–12811

Disassembly

For Pistons With Three Ring Grooves Remove the two split rings (Item 1) [C] from the piston.

1 B–13736

Cut the old teflon seal and remove the seal from the piston [D].

B–13738

Added June 98 –2–78–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Disassembly (Cont’d) Remove the O–ring from the piston [A]. Wash the cylinder parts in solvent and air dry them. While servicing the cylinder do not damage the parts. Inspect for nicks, scratches or otherwise damaged or bent parts before assembling the cylinder. Replace parts that appear damaged in any way. The cylinder may not function correctly if there is damage to any of the parts. Destroy all the O–rings and seals and replace them with new O–rings and seals.

B–13737

Assembly Install the O–ring on the pistons center groove [B].

B–13739

NOTE: Do not overstretch the seal.

Install the seal on the tool (MEL1396) and stretch it until it fits the piston [C].

B–12809

Install the seal on the pistons center groove [D].

B–13742

Added June 98 –2–79–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Assembly (Cont’d) Use a ring compressor to compress the seal to the correct size [A]. Leave the piston in the ring compressor for three minutes.

B–13740

Install the two outer split rings onto the piston [B].

NOTE: Position the gaps of the piston rings so that they are at 180° from each other.

B–13741

Install the oil seal on the rod seal tool (MEL1033) [C].

NOTE: The O–ring side of the oil seal goes toward the inside of the cylinder.

O–ring Side B–03702

Install the oil seal in the head [D].

B–03671

Added June 98 –2–80–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Assembly (Cont’d) Install the wiper seal with the lip toward the outside of the head [A].

B–03682

Install the O–ring (Item 1) [B] onto the head.

CD–12674

Install the back–up washer (Item 1) [C] and O–ring (Item 2) [C] onto the head.

CD–12675

Apply grease to the inside of the head and to the lips of the seals.

Inspect the beveled edge of the rod for nicks or sharp edges [D]. Remove these with a file prior to installing the gland on the rod or damage to the seals may occur. Install the head on the rod [D].

CD–12676

Added June 98 –2–81–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Assembly (Cont’d) For Cylinders Using Piston Retaining Bolts Install the piston on the rod with the recessed end of the piston toward the head [A]. Lubricate the retainer bolt with oil and install the retainer bolt thru the piston and into the rod. Tighten the bolt to 185–215 ft.–lbs. (250–291 Nm) torque.

CD–12677

For Cylinders Using Piston Retaining Lock Nuts

Install the piston on the rod with the tapered end of the piston towards the head [B]. Lubricate the threads and install the nut [B]. Tighten the nut to 315–385 ft.–lbs. (427–522 Nm) torque.

B–07002

Inspect the inside of the cylinder case for nicks and scratches. If the cylinder case has minor scuffing the cylinder case can be honed [C]. Use a flexible hone and lubricate with oil during the honing process. Thoroughly wash the inside of the cylinder case after honing process.

CD–12678

Put oil on the seal surface of the cylinder case [D].

B–07013

Added June 98 –2–82–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

Assembly (Cont’d) Put oil on the teflon seal on the piston [A].

B–07012

Install the rod assembly in the cylinder base [B].

B–07001

Put oil on the seals on the head [C]. Put oil on the threads of the head.

B–07014

Use the adjustable gland nut wrench (MEL1075) to tighten the head [D].

NOTE: Gland to be tightened until it is flush with the end of the cylinder case. Move rod in and out of cylinder case and make sure that it moves freely.

B–07000

Added June 98 –2–83–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC FILTER ASSEMBLY

Removal And Installation

P–02218

I–2003–0888

Raise the engine cover [A]. Loosen the hose clamp (Item 1) [B] from the hose. Remove the hoses (Item 2) [B] from the filter assembly.

NOTE: Support the two hoses in approximately the same position as when attached to the filter head to avoid any hydraulic fluid from draining out of the hydraulic reservoir.

Remove the two filter head mounting bolts (Item 3) [B]. Remove the filter assembly. P–02357

Installation: Tighten the two bolts to 28 ft.–lbs. (38 Nm) torque.

AUXILIARY COUPLERS Removal And Installation

1 2

P–00884

I–2003–0888

Remove the couplers from the bulkhead fittings [C]. Male coupler (Item 1) [C] and female coupler (Item 2) [C].

Added June 98 –2–84–

320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK MANIFOLD WITH ACCUMULATOR

The joystick manifold valve body contains two valves (pressure reducing valve and electrically activated solenoid valve) and three check valves. The valve body is connected to the accumulator. The pressure reducing valve maintains approximately 365 PSI for oil supply pressure to the joystick control levers. The accumulator provides short term reserve pressure for joystick functions when the engine is not running. NOTE: The ignition switch must be in the ON position and the control consoles must be in the locked position, for the solenoid valve to be electrically activated for the accumulator to supply reserve pressure for the joystick functions. The accumulator has approximately 200 PSI reserve pressure that is maintained by the pressure build–up valve in the three spool valve (See Page 2–38).

CD–12998

B Remove These Hoses

The check valves allow the flow of pressurized oil into the P1 and P2 ports of the valve body but block the flow of oil out of the P1 or P2 ports. The third check valve allows the accumulator to be charged by the build–up valve, but blocks the pressurized oil from flowing back out of the accumulator to the pressure lines or to the pressure reducing valve drain port. If the T port )drain) hose is removed prior to draining the hydraulic draining reservoir, the hydraulic oil will gravity flow out of the reservoir.

P–05308

C When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I–2003–0888

Removal And Installation Drain the hydraulic tank. (See Page 3–23.) Remove the seat. (See Page 5–2.)

CD–13000

Remove the seat mount. (See Page 5–3.) Remove the lock lever/speed control lever mount. (See Page 5–3.) Mark the hoses for correct installation. Disconnect the solenoid harness. Remove the hoses and tubelines from the valve [A]. Remove the two mounting bolts from under the swing frame [B]. Remove the joystick manifold [C]. Installation: Tighten the bolt to 15–18 ft.–lbs. (20–25 Nm) torque. Added June 98 –2–85–

320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

MANIFOLD

WITH

ACCUMULATOR

Removal And Installation (Cont’d) The joystick manifolds pressure reducing valve and solenoid valve can be removed from the valve body without removing the joystick manifold from the excavator. Remove the nut from the solenoid coil [A].

P–00928

Remove the solenoid coil [B].

P–00926

Remove the solenoid [C].

P–00925

Remove the pressure reducing valve [D].

NOTE: Before removing the pressure reducing valve, remove the solenoid coil. If the wrench being used to remove the build–up valve slips off, the coil can be damaged.

P–00923

Added June 98 –2–86–

320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

MANIFOLD

WITH

ACCUMULATOR

Disassembly And Assembly Remove the solenoid coil nut (Item 1) [A].

Remove the solenoid coil (Item 2) [A].

4 2

Remove the solenoid (Item 3) [A].

Installation: Tighten solenoid to 10–12.ft.–lbs. (13–16 Nm) torque.

8 9

Remove the pressure reducing valve (Item 4) [A]. Installation: Tighten pressure reducing valve to 10–12 ft.–lbs. (13–16 Nm) torque.

Remove the accumulator (Item 5) [A]. Remove the adapter (Item 6) [A]. 6

Remove the check valve plugs (Item 7) [A]. Remove the check valve springs (Item 8) [A]. Remove the check balls (Item 9) [A]. Clean all parts in solvent and dry. Inspect the check balls for wear and replace as necessary.

B–13776

Remove O–rings and back–up ring and replace with new.

Added June 98 –2–87–

320 (S/N 511720001 & Above) Excavator Service Manual

DRAIN BLOCK

Filter Screen

CD–13001

I–2003–0888

B Drain the hydraulic reservoir (See Page 3–23). Remove the rear hose and the rear fitting from the drain block [A]. Screen

Remove the 100 mesh screen filter from the drain block [B]. Wash the screen in solvent and dry with compressed air. Replace screen with washer surface toward the fitting.

CD–13002

Removal And Installation

CD–13003

Drain the hydraulic reservoir. (See Page 3–23.)

Mark the hoses for correct installation. Remove the hoses from the drain block [C] & [D]. Remove the two mounting bolts from the drain block [D]. Remove the drain block.

CD–13001

Added June 98 –2–88–

320 (S/N 511720001 & Above) Excavator Service Manual

OIL COOLER

Removal And Installation Drain the hydraulic reservoir. (See Page 3–23.) Open the engine cover. Remove the left hand side cover. (See Page 3–11.)

Remove the left hand rear corner post. (See Page 5–1.)

4 P–02233

I–2003–0888

Remove the tubeline (Item 1) [A] from the elbow (Item 2) [A] on the bottom of the oil cooler.

Remove the two hoses (Item 3) [A] from the tee (Item 4) [A] on the bottom of the oil cooler. Remove the tee (Item 4) [A] from the oil cooler. P–02374

NOTE: The elbow (Item 2) [A] cannot be removed from the oil cooler at this point.

Remove the two oil cooler mounting bolts (Item 1) [B]. Lower the oil cooler downwards until the elbow (Item 1) [C] is accessible from under the upperstructure. Remove the elbow from the oil cooler [C].

P–02360

Lift the oil cooler up and slide to the rear and remove [D].

P–02376

Added June 98 –2–89–

320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK CONTROL CHANGE

320ServiceManual(S/N511720001&Above)#6722642–HydraulicSectionPart4of4

To change from ISO to STANDARD joystick controls, do the following procedure:

3 4

1 2

Open the tool box door. Remove the hose cover plate. (See Page 3–9.) Remove the bottom plate from the tool box. (See Page 3–10.) Mark and remove hoses (Items 1–4) [A] from the bulkhead elbows. P–02348

Install the hoses onto the new locations as shown [B]. 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).

4 3

2 1

P–02348

To change from STANDARD to ISO joystick controls, do the following procedure:

1 2

Open the tool box door.

3 4

Remove the hose cover plate. (See Page 3–9.) Remove the bottom plate from the tool box. (See Page 3–10.) Mark and remove hose (Items 1–4) [C] from the bulkhead elbows.

P–02348

Install the hoses onto the new locations as shown [D].

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).

2 1

4 3

P–02348

Added June 98 –2–90–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE SECTION Page Number BLADE LEVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37 DRIVE MOTOR (SOM) (S/N 23975 & Above) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Oil Level (S/N 23975 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining Final Drive Chain (S/N 23975 & Above) . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–72 3–81 3–65 3–81 3–64

DRIVE MOTOR ASSEMBLY (Kayaba) (S/N 511720001–23974) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining Final Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–70 3–79 3–42 3–61 3–62

FINAL DRIVE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41 FLOORMAT AND FLOOR PANELS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 FUEL TANK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12 GAS SPRING Left Hand Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 JOYSTICK Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–81 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–80 LATCH HOOK Left Hand Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 LEFT CONTROL CONSOLE Console Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lockout Microswitch Removal and Installation . . . . . . . . . . . . . . . . . . . . Microswitch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–5 3–10 3–6 3–5 3–11

LEFT HAND PEDAL (Auxiliary) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34 LOCK LEVER Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 Left Hand Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 LINKAGE RODS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38

DRIVE SECTION

DRIVE SECTION (CONT’D) Page Number RIGHT HAND PEDAL (Boom Swing) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32 RIGHT CONTROL CONSOLE Cab Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Console Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . Console Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . Joystick Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rops Canopy Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–21 3–25 3–22 3–29 3–24 3–21

ROCKERSHAFT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36 TRAVEL LEVERS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30 UPPER CONSOLE Left Hand Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20

Revised Dec. 96

–3–0–

320 (S/N 511720001 & Above) Excavator Service Manual

FLOORMAT AND FLOOR PANELS

Removal and Installation Remove the two bolts in each floormat retaining plate [A].

P–02234

Remove the plate (Item 1) [B] and the two spacers (Item 2) [B] from both sides of the floormat.

NOTE: Excavators that are equipped with a cab have a floormat retainer plate only on the door side.

2 2 P–02236

Remove the two bolts from the control cover plate [C].

P–02244

Remove the control cover plate [D].

P–02238

Revised Dec. 96

–3–1–

320 (S/N 511720001 & Above) Excavator Service Manual

FLOORMAT AND FLOOR PANELS (Cont’d)

Removal and Installation (Cont’d) Remove the floormat [A].

P–02242

Remove the three bolts from the rear floor panel [B].

P–02243

Remove the rear floor panel [C].

P–02237

Remove the bolt from the front floor panel and remove the panel [D].

P–02245

Revised Dec. 96

–3–2–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE

Microswitch Adjustment Procedure Adjust the console latch. (See Page 3–15.) NOTE: Make sure that the microswitch is at the top of the adjustment slots prior to adjusting the console latch or switch damage may occur. Close the console to the latched position. Use feeler gauges and measure the distance between the two latch mounting plates [A] & [C].

CD–12886

Open the console.

Adjust the microswitch downwards (with the actuator roller and the feeler gauge flush) until the gap between the actuator and the microswitch is .050’’ (1,25 mm) [B] & [C]. Tighten the microswitch mounting hardware while holding the microswitch at the proper adjustment. Recheck the microswitch for correct adjustment after tightening the mounting hardware.

CD–18887

Adjust Microswitch gap To This Dimension. 0.050’’ (1,325 mm)

Measure This Distance With Feeler Gauge. MC–01733

Revised Dec. 96

–3–3–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE

Lockout Microswitch Removal and Installation Raise the control console. Remove the access plate. (See Page 3–5.) Unplug the microswitch harness from the console harness [A].

CD–12888

Use a continuity tester to check the microswitch prior to removal [B].

The microswitch is normally open. With the console raised the gauge reading should show no through current. By pushing the actuator on the microswitch, the gauge reading should show a completed circuit. If not, the microswitch is faulty and must be replaced.

CD–12889

Remove the two nuts, lockwashers and screws holding the microswitch [C].

CD–13004

Remove the microswitch [D].

NOTE: See microswitch adjustment procedure on Page 3–3. This procedure must be performed after a new microswitch has been installed.

CD–13005

Revised Dec. 96

–3–4–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Console Cover Removal and Installation Lower the blade and the boom to the ground. Disconnect the battery negative (–) cable. (See Page 6–3.) Remove the latch knob [A].

CD–12892

Remove the eight screws from the console cover [B].

CD–12893

Tilt the console up.

Remove the two bolts holding the access plate [C].

CD–12894

Remove the access plate [D].

CD–12895

Revised Dec. 96

–3–5–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Console Cover Removal and Installation (Cont’d) Remove the harness clamp [A].

CD–12896

Mark the electrical connections for ease of assembly. Remove the wires from the low fuel indicator lamp and from the fuel gauge [B].

CD–12897

Remove the console cover [C].

P–02406

Remove the nuts from the fuel gauge mounting bracket and remove the fuel gauge [D].

CD–12899

Revised Dec. 96

–3–6–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Console Cover Removal and Installation (Cont’d) Remove the indicator lamp [A].

CD–12900

Remove the two bolts and the retainer plate from the arm rest [B]. Remove the arm rest [B].

CD–12901

Revised Dec. 96

–3–7–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Joystick Removal and Installation Lower the boom and blade to the ground. Remove console cover. (See Page 3–5.) Mark the hoses for ease of assembly. Loosen the hose connections while the joystick is bolted to the console [A].

CD–12902

Remove the four bolts (Item 1) [B] from the joystick mounting plate.

1 CD–12903

Lift the joystick upwards and remove the hoses from the joystick [C].

C 1

Remove the four bolts (Item 1) [B] and nuts holding the mounting plate to the joystick.

N–12904

Revised Dec. 96

–3–8–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Removal and Installation Turn the upperstructure to have access to the hydraulic tank drain plug and tot he fuel tank drain valve. Lower the boom/bucket and the blade to the ground.

Remove the floorboards. (See Page 3–1.) Remove the seat. (See Page 5–2.) Remove the seat mount. (See Page 5–3.) Remove the lock lever/speed control lever mount. (See Page 5–3.)

P–02232

Remove the console cover. (See Page 3–5.)

Remove the battery negative (–) cable. (See Page 6–3.) Drain the fuel tank by turning the drain valve (Item 1) [A]. Drain the fuel into a clean container. Drain the hydraulic fluid (approximately 3.5 gal. [13.8 L.]) by removing the drain plug (Item 1) [B] from the elbow on the bottom of the hydraulic reservoir. Drain the fluid into a clean container.

P–02226

Open the tool box door. Remove the two bolts from the hose cover plate [C].

CD–12906

Remove the cover plate [D].

CD–12907

Revised Dec. 96

–3–9–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Removal and Installation (Cont’d) Remove the two bolts and the nut holding the tool box bottom plate and remove the plate [A]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Mark the hose for ease of assembly as shown [A] & [B].

CD–12908

For I.S.O Control Pattern

Remove the hoses (Items 1, 4, 5 & 8) [B] from the elbows.

1 6

For Standard Control Pattern

Remove the hoses (Items 2, 4, 6 & 8) [B] from the elbows.

7 8

P–02348

Remove the hose from the joystick port block [C].

CD–13007

Remove the hose from the drain block [D].

N–12909

Revised Dec. 96

–3–10–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Removal and Installation (Cont’d) Remove the left hand side cover by opening the fuel fill door and removing the four bolts [A]. Slide the cover out from the frame and remove. Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

P–03426

Remove the three bolts holding the control console to the frame and the front engine cover [B]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Tilt the top of the console out from the excavator.

P–02337

Remove the two fuel hoses from the bottom of the fuel tank [C].

CD–12911

Disconnect the two wire harnesses that go to the left hand control console [D].

CD–12912

Revised Dec. 96

–3–11–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT CONTROL CONSOLE (Cont’d)

Removal and Installation (Cont’d) Install a chain hoist to the top sides of the control console and lift the console from the excavator [A].

P–02402

FUEL TANK Removal and Installation Remove the left control console. (See Page 3–9.) Remove the gas spring. (See Page 3–17.) Remove the screw from the cover [B].

P–02338

Disconnect the microswitch harness from the console wire harness [C].

CD–12888

Disconnect the wire harness from the fuel sender [D].

CD–12008

Revised Dec. 96

–3–12–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL TANK (Cont’d)

Removal and Installation (Cont’d) Remove the four bolts holding the joystick mounting plate to the console [A].

CD–12903

Lift the joystick (with the hoses attached) and slide the hoses and the harnesses out of the console.

Remove the two elbows, the drain valve and grommets from the bottom of the fuel tank [B].

CD–12916

Slide the fuel tank out of the back of the control console [C].

CD–12917

Revised Dec. 96

–3–13–

320 (S/N 511720001 & Above) Excavator Service Manual

LOCK LEVER

Left Hand Removal and Installation Remove the console cover. (See Page 3–5.) Remove the gas spring. (See Page 3–17.) Remove the return spring from the lock lever [A].

CD–12918

Remove the two nuts and bolts from the lock levers [B].

NOTE: When installing nuts and bolts, the nuts must be to the top side of the lock levers so that the bolt threads do not rub against the hoses.

CD–12919

Remove the two levers [C].

Installation: Insert the release rod through the lever. Position the levers over the lever mounts and spread them so that there is no play between the mount and the lever but loose enough so that the levers do not bind against mounts and that the spring will return levers to the latched position without interference.

CD–12920

Disconnect the microswitch harness from the console harness [D].

CD–12888

Revised Dec. 96

–3–14–

320 (S/N 511720001 & Above) Excavator Service Manual

LOCK LEVER (Cont’d)

Left Hand Removal and Installation (Cont’d) Push down on the console to remove the gas spring pressure on the latch. Pull the actuating rod forward to release the console latch and tilt the console up. Remove the two bolts holding the console lock latch [A]. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

N–12921

Remove the actuating rod and the lock latch with the microswitch [B].

NOTE: See Page 3–3 for microswitch removal and testing.

Adjustment Procedure NOTE: Before the lock lever adjustments can be made, the microswitch must be moved to the top of the adjustment slots. Switch damage may occur if this is not done prior to lock lever adjustment. Loosen the two bolts that hold the lock latch to the console [A]. (These bolts should be loosened so that the lock latch will not move when the control console is closed but loose enough so that the bolt heads can be tapped with a punch to move the latch fore and aft for proper adjustment.)

CD–12922

Move the Microswitch to the top of adjustment slots

Close the control console to latched position. Push down on the console to remove the gas spring pressure. Flush contact between latch and hook.

Adjust the latch until the spring loaded hook will just make contact with the lock latch when the console is closed [C].

Loosen these two bolts. MC–01733

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

LATCH HOOK

Left Hand Removal and Installation Tilt the console up. Remove the four bolts from the mounting plate [A]. Installation: Tighten the bolts to 6–7 ft.–lbs. (8–10 Nm) torque.

CD–12923

Remove the mounting plate [B].

CD–12924

Remove the bolt and the locknut from the latch pivot [C]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

Disassemble the latch pivot [D]. Bolt (Item 1) [D], washer (Item 2) [D], shim (Item 3) [D], wave washer (Item 4) [D], O–rings (Item 5) [D], sleeve (Item 6) [D], bushing (Item 7) [D], pivot (Item 8) [D], latch hook (Item 9) [D], spacer (Item 10) [D], spring (Item 11) [D], washer (Item 12) [D], nut (Item 13) [D] and the mounting plate (Item 14) [D].

CD–12925

Installation: Tighten the nut to 29–37 ft.–lbs. (40–50 Nm) torque.

D 4

NOTE: When installing new bushings (Item 7) [D], lightly tap them into the pivot (Item 8) [D] or distortion of the bushing may occur. Apply oil to the O–rings (Item 5) [D] before installing the sleeve (Item 6) [D] into the pivot (Item 8) [D].

Make sure that the shim (Item 3) [D] is properly positioned over the sleeve and after tightening the nut, the hook (Item 9) [D] pivots freely.

14 CD–13029

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

GAS SPRING

Left Hand Removal and Installation

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288 CD–12927

Tilt the control console up. Remove the cotter pin and the washer from the mount [A].

NOTE: Hold the console up to remove gas spring. Remove the two bolts from the bottom side of the console [B]. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

P–02337

Remove the top of the gas spring from the mount and remove the gas spring and the lower mount from the console [C].

Remove the cotter pin and washer from the lower mount and remove the mount.

CD–12929

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

UPPER CONSOLE

Left Hand Removal and Installation NOTE: The upper console can be removed with or without the joystick attached to the upper console and with or without the control console removed from the excavator. The photos used show the control console removed from the excavator with the joystick attached. Remove the console cover. (See Page 3–5.)

N–12930

B Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288

Remove the cotter pin and the washer from the gas spring [A]. Remove the gas spring from the mount [A]. Remove the roll pin using a punch [B]. CD–13028

Remove the pivot shaft using a punch [C].

N–12931

Lift the upper console off of the console base and remove the two bushings [D].

Installation: Lightly tap the bushings into the upper console or distortion of the bushings may occur. NOTE: If the upper console is to be completely removed from the console mount, unplug the microswitch harness from the console harness. If the console mount is still bolted to the excavator, the joystick hoses will need to be marked and removed from the joystick. If the console has been removed from the excavator, the hoses can be left attached to the joystick and the hoses and harnesses lift out through the center of the console. Revised Dec. 96

CD–12932

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320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE

ROPS Canopy Models The following right hand control console components removal and installation and the adjustment procedure are the same as the left hand control console. See the corresponding left hand control pages as listed below: MICROSWITCH – Adjustment Procedure. (See Page 3–3.) LOCK OUT MICROSWITCH – Removal and Installation. (See Page 3–4.) LOCK LEVER – Adjustment Procedure. (See Page 3–15.) LOCK LEVER – Removal and Installation. (See Page 3–14.) LATCH HOOK – Removal and Installation. (See Page 3–16.) GAS SPRING – Removal and Installation. (See Page 3–17.)

CD–12933

Cab Models On Excavators equipped with a CAB, the right hand control console is stationary (will not raise and lower with a release lever). The cab models do not use the above components. To tilt the console up, remove the two bolts from the console [A]. Remove the two bolts from the console plate [B].

CD–12934

Remove the console cover plate [C].

CD–12894

The right hand console harness uses a jumper harness (Item 1) [D] in place of the microswitch so that the joystick manifold/accumulator will function properly.

CD–13009

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Console Cover Removal and Installation Lower the boom and blade to the ground. Disconnect the battery negative (–) cable. (See Page 6–3.) Remove the latch lever knob [A].

CD–12935

Remove the ignition key.

Remove the nut and the decal plate from the ignition switch [B]. Push the ignition switch inside the console cover.

CD–12936

Remove the eight screws from the console cover [C].

Tilt the console up.

N–12937

Remove the two bolts from the access plate [D].

Remove the access plate. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

CD–12894

Revised Dec. 96

–3–20–

320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Console Cover Removal and Installation (Cont’d) Mark the electrical wires for ease of assembly. Remove the wires from the auxiliary power plug [A]. Turn the inner auxiliary power plug housing and remove it from the outer hosing. Remove the outer auxiliary power plug [A].

P–02345

Lift the console cover over the joystick handle [B].

P–02405

Remove the wires from the indicator lamps [C].

CD–12939

Remove the indicator lights by squeezing together the mounting tabs on the indicator light and pushing it out of the panel [D].

CD–13010

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Console Cover Removal and Installation (Cont’d) Remove the two bolts and retainer plate from the console cover and remove the armrest [D].

CD–12901

Joystick Removal and Installation

Lower the boom/bucket and blade to the ground. Remove the console cover. (See Page 3–20.) Mark the hoses for ease of assembly. Loosen the hose connections while the joystick is bolted to the console [B].

CD–12949

Remove the horn wires from the joystick [C]. NOTE: The wires going to the horn switch are non specific and can be interchanged without affecting the horns operation.

CD–12950

Remove the four bolts from the joystick mounting plate [D].

Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque. Lift the joystick upwards and remove the hoses from the joystick.

Remove the four bolts (Item 1) [C] and nuts holding the mounting plate to the joystick. Installation: Tighten the bolts to 6–7 ft.–lbs. (8–10 Nm) torque. CD–12951

Revised Dec. 96

–3–22–

320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Control Console Removal and Installation

Turn the upperstructure to have access to the hydraulic reservoir drain plug. Lower the boom/bucket and blade to the ground. Remove the floorboards. (See Page 3–1.)

Remove the seat. (See Page 5–2.) Remove the seat mount. (See Page 5–2.) Remove the speed control lever/lockout lever mount. (See Page 5–3.)

P–02226

Remove the console cover. (See Page 3–20.)

Disconnect the battery negative (–) terminal. (See Page 6–3.) Drain the hydraulic fluid (approximately 3.5 ga. [13.8 L.]) by removing the drain plug (Item 1) [A] from the elbow on the bottom of the hydraulic reservoir.

Remove the three hose clamps (Item 2) [A] and hoses from the elbow.

2 1

Remove the hose (Item 1) [B] from the back of the hydraulic reservoir. Remove the elbow (Item 2) [B] and the straight fitting (Item 3) [B] from the back of the hydraulic reservoir.

P–02388

Open the tool box door. Remove the two bolts from the hose cover plate [C].

CD–12906

Remove the cover plate [D].

CD–12907

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Control Console Removal and Installation (Cont’d) Remove the two bolts and the nut holding the tool box bottom plate and remove the plate [A]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–12908

Mark the hoses for ease of assembly as shown [B].

For I.S.O. Control Pattern Remove the hoses (Items 1, 3, 6 & 7) [B] from the elbows.

1 6

2 3

For Standard Control Pattern

Remove the hoses (Items 1, 3, 5 and 7) from the elbows [B].

P–02348

Remove the hose from the joystick pressure block [C].

CD–13007

Remove the hose from the drain block [D].

CD–12955

Revised Dec. 96

–3–24–

320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–DriveSectionPart1of4

Control Console Removal and Installation (Cont’d) Remove the right hand side cover by opening the hydraulic fill door and removing the four bolts [A]. Slide the cover out from the frame and remove. Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

P–02210

Remove the screw from the right hand cover [B].

P–02352

Lift the right hand cover and remove the light switch harness [C].

P–02349

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Control Console Removal and Installation (Cont’d) Loosen the jam nut on the engine shut off cable [A]. Remove the cable from the control console.

P–02349

Disconnect the wire harnesses going to the right console [B].

CD–12912

Remove the three bolts holding the control console to the frame and the engine cover [C].

P–02334

Install a chain hoist to the top sides of the control console and lift the console from the excavator [D].

P–02401

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT CONTROL CONSOLE (Cont’d)

Hydraulic Tank Removal and Installation Remove the right control console. (See Page 3–22.) Disconnect the microswitch harness from the console wire harness [A].

CD–12888

Remove the four bolts holding the joystick mounting plate to the console [B].

Lift the joystick (with the hoses attached) and slide the hoses and the harnesses out of the center of the console.

CD–12951

Remove the sight gauge (Item 1) [C] from the side of the hydraulic reservoir. The sight gauge is threaded into the reservoir.

Remove the elbow from the bottom of the hydraulic reservoir.

P–02408

Remove the reservoir from the control console [D].

CD–12944

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

TRAVEL LEVERS

Removal and Installation Remove the floor mat and the floorboards. (See Page 3–1.) Remove the nuts from the two ball joints that attach to the travel levers [A].

CD–12945

Remove the four nuts from the sides of the travel lever mounting plate [B].

CD–13011

Remove the travel levers and the mounting plate [C].

CD–13012

Remove the three bolts holding the travel lever pivots to the mounting plate [D].

Installation: Tighten the nuts to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–13013

Revised Dec. 96

–3–28–

320 (S/N 511720001 & Above) Excavator Service Manual

TRAVEL LEVERS (Cont’d)

Removal and Installation (Cont’d) Lift off the two travel levers and the three pivot mounts [A]. NOTE: The center pivot mount is not bolted to the levers, when the levers are lifted, the center pivot can be removed.

CD–13014

Remove the nut and bolt holding the pivot mount to the travel lever [B].

Installation: Tighten the bolt to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–12946

Disassemble the pivot mount [C]. Bolt (Item 1) [C], washer (Item 2) [C], shim (Item 3) [C], bushing (Item 4) [C], pivot (Item 5) [C], O–ring (Item 6) [C], sleeve (Item 7) [C] and nut (Item 8) [C].

C 8

Installation: Lightly tap the new bushings (Item 4) [C] into the pivot (Item 5) [C] or distortion of the bushings may occur. Apply oil to the O–rings (Item 6) [C] before installing he sleeve (Item 7) [C] into the pivot (Item 5) [C].

NOTE: The center pivot mount uses only the two bushings (Item 7) [C] with the pivot (Item 8) [C].

5 CD–12947

Remove the four bolts from the support and remove the support [D]. Installation: Tighten the nuts to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–12948

Revised Dec. 96

–3–29–

320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT HAND PEDAL (Boom Swing)

Removal and Installation Remove the floorboards. (See Page 3–1.) Remove the nut from the ball joint [A].

CD–12958

Remove the three bolts from the pedal mounting plate [B].

Installation: Tighten the bolt to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–12959

Remove the pedal and pedal mounting plate [C].

CD–12960

Remove the nut and bolt holding the pedal to the mounting plate [D].

Installation: Tighten the nuts to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–12961

Revised Dec. 96

–3–30–

320 (S/N 511720001 & Above) Excavator Service Manual

RIGHT HAND PEDAL (Boom Swing) (Cont’d)

Removal and Installation (Cont’d)

Disassemble the pedal mounting plate [A]. Bolt (Item 1) [A], washer (Item 2) [A], shim (Item 3) [A], O–ring (Item 4) [A], sleeve (Item 5) [A], bushing (Item 6) [A], mounting plate (Item 7) [A], pedal (Item 8) [A] and nut (Item 9) [A].

NOTE: When installing new bushings (Item 6) [A] into the mounting plate (Item 7) [A], lightly tap the new bushing or distortion of the bushing may occur.

4 7

Revised Dec. 96

–3–31–

CD–12962

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT HAND PEDAL (Auxiliary)

Removal and Installation Remove the floorboards. (See Page 3–1.) Remove the nut from the ball joint [A].

CD–12963

Remove the bolt from the pedal mount [B].

CD–12964

Remove the pedal and pivot mount [C].

CD–12965

Remove the nut and bolt from the pedal and pivot mount [D].

Installation: Tighten the nut to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–12966

Revised Dec. 96

–3–32–

320 (S/N 511720001 & Above) Excavator Service Manual

LEFT HAND PEDAL (Auxiliary) (Cont’d)

Removal and Installation (Cont’d) Disassemble the pedal mounting plate [A]. Bolt (Item 1) [A], washer (Item 2) [A], shim (Item 3) [A], bushing (Item 4) [A], pivot (Item 5) [A], O–ring (Item 6) [A], sleeve (Item 7) [A] and nut (Item 8) [A].

Installation: Lightly tap the new bushings (Item 4) [A] into the pivot (Item 5) [A] or distortion of the bushing may occur.

Apply oil to the O–rings (Item 6) before installing the sleeve (Item 7) [A] into the pivot (Item 5) [A].

Revised Dec. 96

–3–33–

1 CD–12947

320 (S/N 511720001 & Above) Excavator Service Manual

ROCKERSHAFT

Removal and Installation Remove the floorboards. (See Page 3–1.) Remove the travel levers. (See Page 3–28.) Remove the nut from the ball joint at the left hand pedal (shown) and the right hand pedal [A].

CD–12967

Remove the four cotter pins and clevis pins from the clevis at the control valve [B].

CD–12876

Remove the two bolts from the rockershaft mounting [C]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–13015

Lift the rockershaft assembly from the excavator [D].

CD–12968

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

ROCKERSHAFT (Cont’d)

Removal and Installation (Cont’d) Mark the linkage rods and their orientation in the bellcranks for ease of assembly. Remove the nuts from the linkage ball joints and remove the linkages [A].

CD–12969

Remove the four roll pins from the rockershaft [B].

CD–12970

Remove the four bolts and nuts from the bearings [C]. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

CD–12971

Disassemble the rockershaft [D]. Roll pin (Item 1), washers (Item 2), bellcrank (Item 3), wave washer (Item 4), spacer (Item 5), bearing (Item 6), spacer (Item 7), bellcrank (Item 8), spacer (Item 9), bellcrank (Item 10), nut (Item 11), bolt (Item 12), mounting plate (Item 13) and rockershaft (Item 14).

11 NOTE: Bellcranks (Item 8) [D] have replaceable bushings pressed into each end.

12 11

13 14

–3–35–

3 1

NOTE: The wave washers (Item 4) [D] are used in quantities as required. Replace the wave washers in the same locations as originally removed. Test the rockershaft after assembling to make sure the shaft rotates smoothly and without excessive side play.

Revised Dec. 96

CD–12972

320 (S/N 511720001 & Above) Excavator Service Manual

LINKAGE RODS

Removal and Installation Remove the nuts from the end of the ball joint(s) [A].

CD–12963

Remove the opposite end ball joint [B] or cotter pin and clevis pin [C]. NOTE: Before disassembling the linkages, measure the distance between the center lines of the linkage end and their orientation for ease of assembly.

CD–12967

CD–12876

Loosen the jam nut on the end of the ball joint and or clevis [D]

NOTE: Clevis ends are left hand thread for ease of linkage adjustment.

CD–12973

Revised Dec. 96

–3–36–

320 (S/N 511720001 & Above) Excavator Service Manual

BLADE LEVER

Removal and Installation Remove the floor panel. (See Page 3–1.) Remove the nut (Item 1) [A] from the end of the ball joint.

1 Remove the nut from the blade lever to pivot mount bolt (Item 1) [B], but leave the bolt in place at this time.

P–02241

Remove the two bolts and nuts (Item 2) [B] from the pivot mount.

1 2 P–02258

Slide the lever and pivot mount downwards until the ball joint slides out of the blade lever mounting hole. Installation: Make sure that the ball joint is inserted into the blade lever mounting hole before attaching the pivot mount. Remove the blade lever to pivot mount bolt and remove the blade lever and the pivot mount [C].

P–02252

Revised Dec. 96

–3–37–

320 (S/N 511720001 & Above) Excavator Service Manual

BLADE LEVER (Cont;d)

Removal and Installation (Cont’d) Disassemble the pivot mount [A]. Bushing (Item 1) [A], pivot mount (Item 2) [A], O–ring (Item 3) [A] and the sleeve (Item 4) [A].

3 P–2248

Remove the two cotter pins and clevis pins [B].

CD–12978

Remove the two connecting links [C].

N–12979

Remove the bolt from the bellcrank pivot mount [D].

CD–12980

Revised Dec. 96

–3–38–

320 (S/N 511720001 & Above) Excavator Service Manual

BLADE LEVER (Cont’d)

Removal and Installation (Cont’d) Remove the bellcrank, pivot mount and linkage [A].

CD–12981

Remove the nut from the linkage ball joint [B].

CD–12982

Remove the bolt and nut from the bellcrank and pivot mount [C].

CD–12983

Disassemble the pivot mount (Item 8) [D]. Bolt (Item 1) [D], washer (Item 2) [D], shim (Item 3) [D], bushing (Item 4) [D], O–ring (Item 5) [D], sleeve (Item 6) [D] and nut (Item 7) [D].

3 8

Revised Dec. 96

–3–39–

1 CD–12947

320 (S/N 511720001 & Above) Excavator Service Manual

FINAL DRIVE

Removal and Installation

CD–10173

I–2003–0284

Remove the bolts from the track frame cover [A]. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque. Remove the cover [B].

CD–7595

Mark the hoses for correct installation

Disconnect the pressure hoses from the drive motor [C].

CD–13006

Revised Dec. 96

–3–40–

320 (S/N 511720001 & Above) Excavator Service Manual

FINAL DRIVE (Cont’d)

Removal and Installation (Cont’d) Loosen and remove the drive motor mounting bolts [A]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Remove the drive motor.

CD–08567

Put the drive motor in a vise to remove the drive sprocket [B]. Installation: Tighten the cap screws to 48–55 ft.–lbs. (66–75 Nm) torque.

DRIVE MOTOR ASSEMBLY (Kayaba) (S/N 511720001 – 23974) CD–10178

Parts Identification 1. 2. 3. 4. 5.

HOUSING PLUG SPRING POPPET SPOOL

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

3 4 5

HOUSING BEARING SPRING PISTON HOUSING PISTON SHAFT SEAL NUT GEAR RETAINER COVER O–RING 1

2 3

2 9

5 7 2 8

4 3 9

1 10

12 11

3 1 2 B–12777

Revised Dec. 96

D–01922

–3–41–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974)

The following tool will need to be fabricated by a local machine shop for reassembly purposes:

Floating Seal installation tool. (See Page 3–53.) Disassembly Remove the drain plugs from the end cover of the drive motor [A]. Drain the oil into a container. Remove the two spool caps from the valve end cover [B].

P–00336

Remove the spring and washer from each end of the housing and remove the spool [C].

Spool

Washer

Spring

P–00337

To disassemble the spool, insert a hardened pin through the hole in the spool gland and use a vise with protective jaws to hold the spool [D].

D Hardened Pin

Remove the two end plugs from the ends of the spool. NOTE: DO NOT use any type of clamp tool on the spool. Any marring or scratches in the spool and the spool must be replaced.

P–00338

Revised Dec. 96

–3–42–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d)

Remove the spring (Item 1) [A] and the poppet (Item 2) [A] from the ends of the spool.

Use solvent and clean and dry all spool components.

P–00340

Remove the six bolts holding the valve end plate onto the housing [B].

P–00341

Lift off the valve end plate and remove the two dowel pins (Item 1) [C] and the O–ring (Item 2) [C].

3 NOTE: The dowel pin (Item 3) [C] is staked into the valve plate end cover, do not remove unless damaged.

P–00342

Remove the bearing from the valve end plate [D].

Use a slide hammer bearing puller.

P–00344

Revised Dec. 96

–3–43–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Bronze Side

Disassembly (Cont’d) Remove the valve plate [A]. NOTE: The bronze side of the valve plate goes towards the rotating group.

P–00343

Remove the rotating group from the motor housing [B].

P–00345

Disassemble the pistons (Item 1) [C], retainer plate (Item 2) [C], conical spacer (Item 3) [C], the three pins (Item 4) [C] from the piston housing (Item 5) [C].

5 3

2 4 P–00348

Turn the piston housing over and remove the snap ring from the housing [D].

Install a bolt and flat washer through the center of the piston housing. The outer diameter of the washer should be smaller than the snap ring but large enough to make good contact with the spring spacer top face. Install a nut on the bolt and tighten until the spring is compressed. Remove the snap ring and loosen the nut to remove the spring. NOTE: The spring inside the piston housing is under pressure, use care when removing the snap ring from the piston housing. P–00350

Revised Dec. 96

–3–44–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d) Remove the snap ring (Item 1) [A], collar (Item 2) [A], spring (Item 3) [A] and the collar (Item 4) [A] from the piston housing.

3 1

P–00354

Turn the motor over and remove the end cap retaining plug from the side of the housing [B].

P–00355

Install two 3/8 PT metric bolts (or eye bolts) into the drain plug holes. Use a bar between the bolts (or through the eyebolts) and turn the cover counterclockwise and remove the cover [C].

P–00357

Remove the O–ring from the end cover [D].

P–00346

Revised Dec. 96

–3–45–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d) Remove the thrust plate from the planetary assembly [A].

P–00347

Lift the planetary assembly from the motor housing [B].

P–00349

Remove the planetary pin by driving the spring pin into the center of the planetary pin.

P–00353

Remove the pin (Item 1) [D], bearing (Item 2) [D], and gear (Item 3) [D] from the planetary assembly.

NOTE: The spring pin (Item 4) [D] that was driven into the center of the planetary pin (Item 1) [D], will now have to be driven out of the planetary pin.

2 P–00359

Revised Dec. 96

–3–46–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d) Remove the planetary thrust washer from the housing [A].

P–00352

Remove the center driveshaft from the housing [B].

P–00356

Remove the gear hub from the housing [C].

Snap Ring

NOTE: The snap ring does not need to be removed unless damaged.

P–00358

Remove the plug from the housing (closest to the flange) [D].

NOTE: The second plug does not need to be removed unless there is leakage or damage.

P–00362

Revised Dec. 96

–3–47–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d) Steel Balls

Remove the 109 or 110 steel balls that are used to retain the motor housing to the hub bearing [A] & [B]. The balls must be removed through the plug hole. Use solvent and flush oil off of the steel balls and the mating surfaces of the bearing and motor housing. Use a magnet and remove the exposed steel balls from the plug hole. Use short burst of compressed air to force the first few steel balls to the plug hole and remove these with the magnet. Continue this process until no more balls will appear at the plug hole.

P–00363

Clamp the hub and housing in vise, with the plug hole facing downwards. (Be careful not to loose any balls.) Slowly tighten the vise to compress the hub and housing together. Tap housing with a hammer to loosen the balls.

Wire

NOTE: Use care with the following process not to allow the wire to become lodged or to break off inside the motor. Use a length of 16 gauge mechanics wire and bend a tight, close loop at one end of the wire. Insert the wire into the plug hole and carefully feed the wire around the diameter of the bearing and force the steel balls to the hole. Remove the exposed balls with a magnet and continue this process until all 109 balls are removed and the end of the wire is visible thru the hole. Carefully remove the wire, DO NOT break the wire off inside the housing when removing the wire.

MC–01678

Use a three jaw puller and remove the motor housing [C].

P–00364

Drive the three spring pins into the planetary pins on the internal planetary assembly [D].

P–00311

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d) Bend a hook onto a piece of stiff wire and use this wire to hook the spring pin the center of the planetary pins and pull the planetary pins out of the housing [A].

P–00314

Remove the thrust washer (Item 1) [B], gear (Item 2) [B], spacer (Item 3) [B], bearing (Item 4) [B] and the planetary pin (Item 5) [B] from the housing. With the planetary pins (Item 5) [B] removed, the spring pins (Item 6) [B] will now have to be driven out of the center of the planetary pins.

5 6

P–00317

Remove the three set screws from the housing [C]. These set screws retain the bearing nut from loosening from the housing.

P–00315

If a bearing nut tool of the correct size is available, use it to remove the bearing nut. If a tool is not available, use a punch and hammer and tap the outer diameter of the bearing nut to remove it from the motor hub [D].

P–00316

Revised Dec. 96

–3–49–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–DriveSectionPart2of4

Disassembly (Cont’d) Carefully remove the double race bearing from the hub [A]. NOTE: The inner and outer races of this bearing are not permanently retained to each other. If not lifted off as an assembly, the races will separate and the steel balls will come loose.

P–00313

Remove the top half of the floating seal from the hub [B].

P–00321

Use a screw driver and pry the lower half of the floating seal from the hub and remove [C].

P–00320

Use a punch and tap the swash plate and drive shaft out of the center of the hub [D].

P–00322

Revised Dec. 96

–3–50–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Disassembly (Cont’d) Remove the seal from the hub [A].

P–00318

Press the drive shaft and bearing out of the swash plate [B]. NOTE: The dowel pin in the swash plate is removable, but do not remove it unless it is damaged.

P–00325

Press the bearing off of the drive shaft [C].

Inspect all parts for damage and replace parts as necessary. Use new seal and O–rings when assembling the drive motor.

P–00326

Revised Dec. 96

–3–51–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly Press a new bearing onto the driveshaft [A]. Press only on the internal bearing race surface.

P–00328

Press the bearing and driveshaft into the swash plate [B]. Use a press tube that only contacts the outer bearing race and use a tapered fixture to hold the swash plate square to the press.

P–00330

Install the seal into the hub [C]. NOTE: The lipside of the seal faces upwards as viewed in [C].

P–00329

Align the dowel pin on the swash plate with the hole in the hub [D].

NOTE: Use a plastic or wood dowel and tap the face of the swash plate to seat the swash plate to the hub.

Dowel Pin

NOTE: DO NOT mar or scratch the face of the swash plate or it will have to be replaced.

P–00323

Revised Dec. 96

–3–52–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

170 mm 160 mm

Assembly (Cont’d) 6.9 mm 7.3

Floating seal installation tool [A]. This tool can be made by a local machine shop or use tool MEL1414.

5 mm

142.8/143 mm 141.5/141.8 mm 7.9/8.1 mm 20.1 mm 142.8 mm 143.0 R 0.3 mm

132/133 mm

15° R 0.2 mm

MC–1678

Apply petroleum jelly to the O–ring of the floating seal [B]. Install the floating seal into the installation tool [B]. NOTE: The O–ring side of the floating seal is upwards in the installation tool as viewed in [B].

P–0333

Apply petroleum jelly to the floating seal surface of the hub. Turn the floating seal and installation tool over and set in place in the hub [C]. Using both hands, evenly press down on the installation tool to insert the floating seal into the hub [C].

P–0327

Install the other half of the floating seal onto the hub [D]. Apply petroleum jelly to the O–ring of the floating seal. NOTE: The O–ring of the floating seal faces upwards.

P–0321

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Carefully install the double roller bearing onto the hub [A].

P–00313

Install the bearing nut onto the hub [B]. Tighten the bearing nut to 45–48 ft.–lbs. (61–65 Nm) torque.

P–00319

Install the three retaining set screws [C]. Tighten the set screws to 22–29 ft.–lbs. (30–39 Nm) torque. After set screws are torqued, use a center punch and stake the hub to the set screws.

P–00315

Apply oil to the inner planetary bearings. Install the spacer, bearing and the thrust washers into the hub planetary. Insert the planetary pins and drive the spring pin through the hub and into the planetary pin.

Use a center punch and stake the hub to the spring pin [D].

P–00306

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install the housing onto the hub and press into position [A]. The housing must be pressed onto the hub until the groove in the bearing is centered in the hub plug hole. NOTE: Make sure that the housing is pressed squarely onto the hub so that the planetary gears do not shave metal off of the housing splines. If this happens the housing and the planetary gears will be damaged. P–00334

Clamp the hub and housing in a vise with the hole plug facing up. Tighten the vise until the ball groove is in the center of the plug hole and insert the 109 steel balls into the hole in the side of the hub [B].

B Steel Balls

P–00363

Install the plug into the hub [C].

Tighten the plug to 5–6 ft.–lbs. (7–9 Nm) torque.

P–00362

Install the snap ring onto the gear hub (if previously removed) and install the gear hub into the planetary gear assembly [D].

Snap Ring

NOTE: The gear hub must be installed with the narrow section of the gear upwards (when viewed using the snap ring as the dividing line).

P–00358

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install the center driveshaft through the center of the gear hub [A].

P–00356

Install the planetary thrust washer onto the planetary hub [B].

P–00352

Assemble the planetary assembly by installing the bearing (Item 2) [C] in the gear (Item 3) [C]. Install the gear (Item 3) [C] into the planetary housing and insert the planetary pin (Item 1) [C] through the gear. Align the hole in the planetary pin and the planetary housing and install the spring pin (Item 4) [C].

2 P–00359

Use a center punch and stake the planetary hub to the spring pin [D]. This will prevent the spring pin from working out of the planetary hub.

P–00360

Revised Dec. 96

–3–56–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install the planetary gear assembly into the motor housing [A]. The planetary hubs internally splined collar will face downwards into the housing. The external surface of the collar must fit over the previously installed thrust washer and the splines must match up with the gear hub. Rotate the motor housing to align the gears and the splines.

P–00349

Install the thrust plate onto the planetary gear assembly [B]. The cogs of the thrust plate must align with the notches in the planetary hub.

P–00347

Install a new O–ring onto the end cover [C]. Apply oil to the O–ring.

P–00346

Install the two 3/8 PT metric bolts (or eyebolts) into the drain plug holes in the end cover [D].

Install the end cover into the housing and use a bar to tighten the end cover into the housing. Tighten the end cover until the hole in the side face on the cover is centered into the hole in the side of the housing.

P–00357

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install the dog point set screw into the side of the housing [A]. The point of the set screw must seat freely into the hole in the end cover. Adjust the end cover until the hole in the housing and the hole in the cover align properly. Tighten the set screw to 13–18 ft.–lbs. (18–24 Nm) torque.

P–00355

Install the collar (Item 1) [B], spring (Item 2) [B], collar (Item 3) [B] and snap ring (Item 4) [B] into the piston housing. Install a bolt and flat washer through the spacers and the spring. Insert these parts through the piston housing and install a nut. The outer diameter of the washer should be smaller than the inner diameter of the snap ring but large enough to make good contact with the spring spacer top face. Tighten the nut to compress the spring and install the snap ring. Loosen the nut and remove the bolt and washer.

2 4

P–00254

Assemble the rotating group by applying petroleum jelly to the three pins (Item 4) [C]. Insert the pins (Item 4) [C] into the notches in the splined inner diameter of the piston housing (Item 5) [C]. Set the conical spacer (Item 3) [C] over the pins (Item 4) [C] and on top of the piston housing (Item 5) [C]. Insert the pistons (Item 1) [C] into the retainer plate (Item 2) [C]. Apply clean hydraulic fluid to the outer diameter of the piston (Item 1) [C] and insert the pistons into the piston housing (Item 5) [C].

5 3

2 4 P–00348

Turn the drive motor on its side and apply oil to the face of the swash plate. Install the rotating group into the drive motor hub and onto the piston driveshaft [D].

P–00345

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install a new O–ring into the groove in the motor [A].

P–00305

Press the bearing into the valve end plate [B]. If a new valve end plate is being used, or if the locating dowel pin was removed from the valve end plate, press the dowel pin into the valve end plate [B].

Dowel Pin

P–00332

Apply a film of petroleum jelly to the steel face of the valve plate. Install the valve plate (bronze side faces upwards) onto valve end plate [C]. The notch in the valve plate must align with the dowel pin in the valve end plate.

Dowel Pin

P–00309

Insert the two dowel pins into the drive motor hub and install the valve end plate onto the drive motor [D].

Dowel Pin

P–00310

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install the six bolts into the valve end plate [A]. Inset a pin through the holes in the hub and the housing to keep the hub from rotating and tighten the six (6) bolts. Tighten the bolts to 21–26 ft.–lbs. (29–35 Nm) torque. Remove the pin that was installed to keep the hub and housing from rotating.

P–00341

Apply oil to the outer diameter of the poppets and install the poppets (tapered end in first) into the spool [B]. Insert the spring into the cavity of the poppets. Install a new O–ring onto the end plugs and install the plug [B].

P–00340

Insert a hardened dowel pin through the hole in the spool gland and use a vise with protective jaws to hold the spool from turning. Tighten the end plugs [C].

Hardened Pin

Tighten the plugs to 18–21 ft.–lbs. (24–29 Nm) torque.

P–00338

Apply oil to the spool and install the spool into the valve end plate [D].

Spool

Washer

Install the washer over the end of the spool and the spring [D].

Spring

P–00337

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (Kayaba) (S/N 511720001 – 23974) (Cont’d)

Assembly (Cont’d) Install a new O–ring onto the end plugs. Apply oil to the O–rings and install the plugs. Tighten the plugs to 86–101 ft.–lbs. (117–137 Nm) torque [A].

P–00336

NOTE: Before the drive motor can be put into service, gear lube 90 will need to be added to the drive motor. See information below for oil installation and checking procedure. Install the three end plugs into the end cover [B]. Tighten the two outer plugs (M8) to 21–29 ft.–lbs. (29–39 Nm) torque.

Checking Oil Level P–00335

1. Put the machine on a flat level surface.

2. Position the plugs (Item 1) [C] parallel to the ground. 3. Remove one of the plugs (Item 1) [C]. 4. Add gear lube 90 through the hole if the gear lube level is below the hole.

5. Install and tighten the plug. 6. Repeat the procedure for the other side. Draining Final Drive Case See the SERVICE SCHEDULE Page 1–1 for correct service interval.

CD–07405

1. Put machine on a flat level surface with the plugs position as shown in figure [D].

2. Remove the bottom plug (Item 1) [D] and the top plug (Item 2) [D]. 3. After all the gear lube is removed, install and tighten the bottom plug.

4. Add .3 quarts (0,3 L) of gear lube 90 to the top plug hole. Install the plug.

5. Use the same procedure for Checking Oil Level, add oil as needed. 6. Repeat the procedure for the other side. Revised Dec. 96

CD–07406

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) Parts Identification

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.

Snap Ring Plug 42 Cover O–ring Bushing Sun Gear 39 40 Snap Ring Sun Gear Planetary Carrier Snap Ring 38 Anti–rotation Washers 37 Bearings Planetary Gear Thrust Washer Planetary Carrier Ring Gear Snap Ring Bearing Snap Ring O–ring Seal Ring Snap Ring Snap Ring Bearing Drive Shaft Hub Seal Alignment Pin Swash Plate Rotating Block Motor Plate Alignment Pin Alignment Pin Bearing O–ring Motor Cover Plug O–ring Spring Washer Spool Bolt

39 37

38 40 35 34

31 30

23 23

24 21 18 20 19 18 17

13 11 10

12 14

13 11 10 15

12 7 9

4 3 1

8 5

B–14478

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

I–2003–0888 B–14497

The following tool will need to be ordered from OTC tool to reassemble the drive motor:

MEL1468 for torque ring and seal ring assembly. Disassembly Remove the drain plugs (Item 1) [A] from the end cover. Drain the oil into a container. Remove the internal snap ring from the drive motor case [B].

B–14650

To remove the cover, install two threaded pins in the drain holes and lift the cover off [C].

B–14649

Air pressure may also be used to remove the cover, screw the adapter in a drain hole and apply 8–11 PSI [D].

NOTE: Do not use excess pressure or seal damage may result.

B–14648

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Disassembly (Cont’d)

Remove the outer sun gear (Item 1) [A] by using two levers and prying on the bottom of the gear.

B–14647

Remove the planetary carrier [B].

B–14646

Remove the snap rings (Item 1) [C] anti–rotation washers (Item 2) [C], gears (Item 3) [C], bearings (Item 4) [C] and the bottom thrust washers (Item 5) [C] from the planetary carrier assembly.

1 2 4 3 5

B–14645

Remove the inner sun gear (Item 1) [D], from the first stage planetary carrier.

Removal of the sun gear snap ring (Item 2) [D] is not necessary.

2 1

B–14644

Revised Dec. 96

–3–64–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Disassembly (Cont’d) Remove the planetary carrier [A].

B–14643

Remove the snap rings (Item 1) [B], anti–rotation washers (Item 2) [B], gears (Item 3) [B], bearings (Item 4) [B] and bottom thrust washers (Item 5) [B] from the planetary carrier assembly.

1 2 4 3 5

B–14642

Remove the external snap ring from the hub to free the two bearings, ring gear and motor [C].

B–14641

Install three 10 mm bolts thru the hub mounts, and tighten to separate the hub and ring gear assembly. NOTE: Place a piece of scrap metal (Item 1) [D] in between the bolt and ring gear flange to prevent damage to the flange when tightening the bolts.

1 B–14640

Revised Dec. 96

–3–65–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Disassembly (Cont’d)

Remove the O–ring (Item 1) [A] and internal snap ring (Item 2) [A] from the ring gear.

B–14639

Remove the bearing from the carrier by pressing it out the flanged side of the carrier [B].

B–14638

Install a support cap [C], over the drive shaft and gear, to protect the splines from damage.

1.97’’ (50 mm)

Obtain the support cap locally. The dimensions of the support cap are as follows: Height . 2.56’’ (65 mm) I.D. . . . . 1.38’’ (35 mm) O.D. . . . 1.97’’ (50 mm)

2.56’’ (65 mm)

1.38’’ (35 mm)

B–14637

Press the bearing off the motor hub [D]. NOTE: Do not damage the bottom surface of the bearing as it is lapped (polished) to mate with the front seal ring.

B–14595

Revised Dec. 96

–3–66–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Disassembly (Cont’d) Remove the front seal ring from the motor hub [A].

B–14636

Remove the two plugs (Item 1) [B], springs (Item 2) [B], and washers (Item 3) [B] from each end of the housing.

Remove the spool (Item 4) [B].

3 1

2 3 2

B–14635

To disassemble the spool, insert a hardened pin through the hole in the spool and use a vise with protective jaws to hold the spool [C].

NOTE: Do not use any type of tool to grip the spool or damage to the spool will result. Remove the two end plugs from the end of the spool [C].

B–14492

Remove the spring (Item 1) [D] poppet (Item 2) [D] and check ball (Item 3) [D] from the ends of the spool.

1 2

3 1 B–14491

Revised Dec. 96

–3–67–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Disassembly (Cont’d) Remove the six screws and remove the motor cover [A].

B–14634

Remove the bronze motor plate (Item 1) [B] and dowel pin (Item 2) [B].

B–14677

Remove the O–ring (Item 1) [C] bearing (Item 2) [C] and the two alignment pins (Item 3) [C]. Remove the bearing (Item 2) [C] with a bearing puller.

3 3

B–14633

Invert the hub and the rotating block will slide out [D].

B–14631

Revised Dec. 96

–3–68–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Disassembly (Cont’d)

Remove the internal snap ring (Item 1) [A] retaining the bearing/drive shaft to the hub and press the drive shaft (Item 2) [A] out of the hub.

B–14630

Remove the swash plate (Item 1) [B], seal (Item 2) [B] and alignment pin (Item 3) [B].

2 1

B–14629

Remove the snap ring (Item 1) [C], bearing (Item 2) [C] and second snap ring (Item 3) [C] from the drive shaft.

1 2 3

B–14628

Revised Dec. 96

–3–69–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Assembly

Clean all parts in solvent and dry with compressed air. Inspect all parts and replace any that are damaged. If any of the planetary gears are damaged, replace all the planetary gears and sun gear from the stage (first or second) that the damaged gear is from. One damaged gear can cause microscopic fatigue crack in mating teeth and cause premature failure after servicing. Apply oil to all O–rings (do not oil the rubber torque ring) and light grease to the ball and roller bearings before installation.

Press the bearing (Item 1) [A] in the motor hub. B–14626

Install the internal snap ring (Item 2) [A] in the motor hub.

Wrap glossy paper around the snap ring grooves to prevent damage to the seal. Lubricate with oil, and install the seal (Item 1) [B] on the drive shaft.

Install the snap ring (Item 2) [B] on the drive shaft in the second groove (Item3) [B].

1 2 B–14675

Invert the hub and press the drive shaft into the hub and bearing assembly.

B–14625

Install the new seal into the seal seat in the motor hub using the seal seating tool [D]. Obtain the seal seating tool locally. The dimensions of the seal seating tool are as follows:

Height . 2.75’’ (70 mm) I.D. . . . . .677’’ (17,2 mm) O.D. . . . .708’’ (18 mm)

B–14624

Revised Dec. 96

–3–70–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Assembly (Cont’d)

Invert the motor hub and install the external snap ring (Item 1) [A].

B–14672

Install the swash plate (Item 1) [B] and alignment pin (Item 2) [B] in the motor hub.

Install the two alignment pins (Item 3) [B] in the motor hub.

2 3

B–14651

Lubricate with oil, and install the rotating block in the motor hub [C].

B–14652

Press the bearing (Item 1) [D] into the motor cover.

Apply oil and install the O–ring (Item 2) [D].

B–14654

Revised Dec. 96

–3–71–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Assembly (Cont’d) The bearing (Item 1) [A] must extend from the face of the cover .098–.110’’ (2,5–2,8 mm). .098–.110’’ (2,5–2,8 mm)

B–14777

Install the alignment pin (Item 1) [B] on the motor cover.

Install the valve plate (Item 2) [B] on the motor cover, with the alignment notch, in the valve plate (Item 2) [B] sliding over the alignment pin (Item 1) [B].

B–14677

Lubricate the bearing with oil and install the motor cover onto the hub with six screws [C].

Tighten the screws in a crisscross manner to 18–22 ft. lbs. (25–30 Nm) torque.

B–14655

Install the check ball (Item 1) [D], poppet (Item 2) [D] and spring (Item 3) [D] into both ends of the spool.

4 2

Apply oil and install the new O–rings (Item 4) [D] on the plugs (Item 5) [C].

5 4

5 1 3 B–14491

Revised Dec. 96

–3–72–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Assembly (Cont’d) To assemble the spool, insert a hardened pin through the hole in the spool and use a vise with protective jaws to hold the spool [A]. NOTE: Do not use any type of tool to grip the spool or damage to the spool will result. Install the two plugs in both ends of the spool [A]. Tighten the plugs to 18–22 ft. lbs. (25–30 Nm) torque.

B–14492

Apply oil to the spool and install the spool (Item 1) [B] in the motor cover.

1 2

Install the washer (Item 2) [B] and spring (Item 3) [B] in the motor cover.

Apply oil to the O–rings and install the new O–rings on the plugs (Item 4) [B]. Install the plugs (Item 4) [B] in the motor cover.

3 2 3

B–14656

Apply oil to the outer edge of the bearing and press the bearing (Item 1) [C] in the housing, using the bearing installation tool.

B–14657

Obtain the bearing installation tool locally.

The dimensions of the bearing installation tool [D] are as follows: Height . 4.27” (108,4 mm) I.D. . . . . 3.78” (96 mm) O.D. . . . 5.69” (144,5 mm)

3.78” (96 mm)

4.27” (108,4 mm)

5.69” (144,5 mm) Revised Dec. 96

–3–73–

B–14593

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

Assembly (Cont’d)

Install the internal snap ring (Item 1) [A] in the housing.

Apply oil on the O–ring and install the O–ring (Item 2) [A] in the housing.

B–14658

Apply oil to the outer edge of the second bearing and press the bearing in the housing [B].

NOTE: Make sure the O–ring is correctly installed in the housing so it is not damaged when the second bearing is installed.

B–14659

Install the O–ring (Item 1) [C] on the seal ring (Item 2) [C].

NOTE: Inspect the seal ring for burrs before installing the O–ring. Install the seal ring making sure it is not twisted. To remove any twists, gently pull a section of the O–ring and let it snap back.

2 1

The O–ring, seal ring and motor assembly must be clean and free of any dust, oil film or foreign matter.

B–14496

Install the seal seating tool (MEL1468) on the seal ring [D].

B–14594

Revised Dec. 96

–3–74–

320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–DriveSectionPart3of4

Assembly (Cont’d) The seal ring assembly must be lubricated with alcohol, so the O–ring will slip past the housing retaining ring and seal uniform in the motor housing radius [A]. The O–ring on the seal ring assembly must be lubricated with alcohol. This will allow the O–ring to slide on the motor housing sealing surface without twisting [A].

B–14495

Dip the O–ring and seal ring assembly in a pan of alcohol.

Shake off the excess alcohol and install the seal ring assembly on the motor [B]. Use firm even pressure on the installation tool (MEL1468) to pop the O–ring into the motor housing.

B–14493

After the seal ring is installed, check the stand out height [C] in four places, 90° apart.

The stand out height is .30 ± .02’’ (7.7 ± 6 mm). NOTE: If the seal ring does not meet the height specifications inspect the torque ring for twists or obvious bulges.

B–14494

Apply a light film of oil to the seal ring and lapped face of the bearing.

NOTE: Do not get any oil on the O–ring. Press the reduction unit and motor assembly into the seat of the bearings [D]. The inner bearing may move deeper into the housing as the motor assembly is pressed into the housing. If this happens, press the inner bearing down to its original position.

B–14661

Revised Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d) Assembly (Cont’d)

Install the external snap ring (Item 1) [A] in the motor reduction unit.

B–14662

Install the thrust washers (Item 1) [B], planetary gears (Item 2) [B], bearing (Item 3) [B] anti–rotation washers (Item 4) [B] and external snap rings (Item 5) [B].

5 4

Install the snap rings so the opening of the snap ring is towards the outside.

3 2 1 B–14663

Install the planetary assembly in the hub [C].

B–14664

Install the sun gear into the outer planetary carrier [D].

B–14665

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d) Assembly (Cont’d)

5 4

Install the thrust washers (Item 1) [A] planetary gears (Item 2) [A] bearings (Item 3) [A] anti–rotation washers (Item 4) [A] and external snap rings (Item 5) [A].

Install the snap rings so the opening of the snap ring is towards the outside.

2 1

B–14666

Install the outer planetary assembly in the hub [B].

B–14667

Inspect the cover bushing (Item 1) [C] for wear. If the bushing (Item 1) [C] needs to be replaced, drill a hole in the center of the bushing.

C 2

Using a number 3 drill bit, thread the hole with a 1/4 X 28 inch NF tap.

Install a 1/4 X 28 inch bolt (Item 2) [C] in the bushing and pull the bushing out of the cover. Install the new bushing in the cover with the bevel down. The clearance between the cover bushing and the sun gear must be .008–.031’’ (0,2–0,8 mm).

B–14676

Place a 1/2 inch (13 mm) long piece of 1/16 inch (1,5 mm) solder on the sun gear (Item 1) [D]. Seat the cover in the hub.

Remove the cover and measure the solder.

B–14771

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d) Assembly (Cont’d)

If the clearance between the sun gear and cover bushing does not meet specifications, order the bushing shim kit from Melroe Sales. Shim Thickness

MEL Part Number

0.020’’ (0,5 mm) . . . . . . . . . 6669597 0.030’’ (0,76 mm) . . . . . . . . 6669598 0.050’’ (1,27 mm) . . . . . . . . 6669599 Remove the bushing. B–14670

Install the correct shim under the bushing and install the bushing. NOTE: Make sure there are no burrs on the bushing face from bushing removal.

Repeat the procedure for checking clearance between the sun gear and cover bushing. Lubricate and install the O–ring (Item 1) [A] on the cover. Install the cover (Item 2) [A] on the hub. Install the internal snap ring (Item 1) [B] securing the cover to the drive motor. B–14671

Add .42 qts. (0,4 liters) of gear lube 90W to the top plug hole (Item 1) [C] until the gear lube is at the bottom of the plug hole (Item 2) [C].

Install and tighten the two plugs.

B–14498

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

DRIVE MOTOR (SOM) (S/N 23975 & Above) (Cont’d) Checking Oil Level (S/N 23975 & Above)

Put the machine on a level surface. Position the plugs (Items 1 & 2) [A]. Remove the plug (Item 2) [A]. The oil level should be at the bottom edge of the hole. Add gear lube through hole (Item 1) [A] if the level is below the hole.

Install and tighten the plug(s).

B–14498

Repeat the procedure for the other side.

Draining Final Drive Case Oil (S/N 23975 & Above)

Put the machine a level surface with the plugs (Items 1& 2) [B] positioned as shown.

Remove the bottom plug (Item 1) [B]. After all gear lube is removed, rotate the drive motor so the plugs are in the position as shown in [A]. Add .42 quarts (0,4 L) of gear lube to the top hole (Item 1) [A] and till until oil is level with the bottom of hole (Item 2) [A].

Install the plugs.

B–14497

Repeat the procedure for the other side.

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK Parts Identification NOTE: Left Joystick parts identification and assembly is the same without horn button and wires. RIGHT JOYSTICK SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Plug Rod Seat Spring Bellows Nut Actuator Joint Plate Bolt Handle Assembly

5 11 6

7 1

2 9

3 4

10 D–01972

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Disassembly and Assembly

RIGHT JOYSTICK SHOWN

NOTE: The right joystick is equipped with a horn button. The valve body disassembly and assembly procedure is the same for both joysticks. Remove the cap from the joystick [A]. Right Joystick Only: Remove the horn wires from the cap [A]. NOTE: Mark the wires for correct installation. CD–11679

Remove the screws from the handle [B]. Remove the handle.

CD–08509

Remove the rubber boot from the joystick [C].

RIGHT JOYSTICK SHOWN

CD–11680

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK (Cont’d Disassembly and Assembly (Cont’d)

Remove the joystick lever and the lock nut (Item 1) [A].

Remove the adjustment nut (Item 2) [A] and the horn wires.

Remove the push rod disc (Item 3) [A].

NOTE: To test the joystick for correct rod disc adjustment. Blow air at 10 PSI (69 kPa) into the P port of the joystick and adjust the disc downward until air starts to flow out of the 1, 2, 3 & 4 ports. Adjust the rod disc upward until the air flow stops. Tighten the adjustment nut to 43 in.–lbs. (5 Nm) torque. Remove the joint [B].

CD–11681

Installation: Tighten the joint to 30 in.–lbs. (3,4 Nm) torque.

CD–11682

Remove the plate [C]. Installation: Align the hole in the plate with the valve body hole.

CD–11683

Use screwdrivers to remove the plugs [D].

CD–11684

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Disassembly and Assembly (Cont’d) Remove the push rod from the plug [A]. Check the push rod crown for wear.

CD–11685

Remove the O–ring (Item 1) and seal (Item 2) from the plug [B].

B 2 1

CD–11686

Installation: Be sure the seal lip is toward the valve body [C].

Seal Lip

O–Ring

B–13517

Remove the spool assembly from the valve body [D].

D NOTE: Install the spool assemblies in the same location from which they are removed.

CD–11687

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

JOYSTICK (Cont’d) 320ServiceManual(S/N511720001&Above)#6722642–DriveSectionPart4of4

Disassembly and Assembly (Cont’d)

Push the spring seat down to remove the washers (Item 1) [A].

CD–11688

Remove spring seat, spring and washers from the spool [B].

CD–11689

Remove the two bolts from the port plate [C]. Installation: Tighten the bolts to 26 in.–lbs. (3 Nm) torque.

CD–11690

Remove the port plate (Item 1), and O–ring (Item 2) from the valve body [D].

Use a new O–ring during assembly.

Installation: Align the dowel pin (Item 3) with the dowel pin hole in the valve body [D].

Dowel Pin Hole

CD–11691

Added Dec. 96

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320 (S/N 511720001 & Above) Excavator Service Manual

UPPER WORKS AND SWING SECTION Page Number AIR BAFFLE (Cab Models Only) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 BELLY PAN (Field Installed) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 CAB Door (Removal And Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Glass (Removal And Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Lower Glass (Removal And Installation) . . . . . . . . . . . . . . . . . . . . Front Upper Plexiglass (Removal And Installation) . . . . . . . . . . . . . . . . . Front Window (Removal And Installation) . . . . . . . . . . . . . . . . . . . . . . . . Left Hand Side Glass (Removal And Installation) . . . . . . . . . . . . . . . . . . Rear Glass (Removal And Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Hand Side Glass (Removal And Installation) . . . . . . . . . . . . . . . . .

4–17 4–21 4–20 4–20 4–18 4–21 4–22 4–14 4–22

CAB/CANOPY REAR COVER Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23 CENTER SWIVEL JOINT Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 CROSS PORT RELIEF VALVE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 ROPS CANOPY Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 SWING CIRCLE GEAR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11 SWING MOTOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing The Cross Port Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing The Cross Ports Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–3 4–2 4–4 4–2 4–1 4–1 4–1

UPPERSTRUCTURE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

–4––1–

UPPER WORKS & SWING SECTION

–4–0–

320 (S/N 511720001 & Above) Excavator Service Manual

SWING MOTOR

Testing the Cross Ports Reliefs Tools needed: MEL1355 – Test Kit MEL1355–3 – 500 PSI Gauge MEL1355–12 – Coupler MEL1355–4 – Hose Connect the coupler and the gauge from the tool kit to the hose.

Stop the engine and install the coupler onto the third pump (Item 1) [A] (furthest from the engine). P–2351

Start the Engine

Center the upperstructure with the track frame and lower the swing lock handle into the engaged, locked, position [B]. Move the left hand joystick control lever to the right and record the pressure gauge reading when the relief valve opens. Repeat this test procedure to get an accurate reading. Test the second relief valve by moving the left hand joystick control lever to the left. Record the pressure gauge reading when the relief valve opens. Repeat this test procedure to get an accurate reading. The correct relief valve setting for the two swing motor relief valves is: 1275 PSI (8971 kPa).

P–2176

NOTE: These relief valves cannot be reset. If the pressure setting is out of specification, order a new relief valve from Melroe Parts.

Removing the Cross Port Reliefs Remove the seat. (See Page 5–2.) Remove the seat mount. (See Page 5–2.) Remove the speed control lever/swing lock mount. (See Page 5–3.) Loosen the two cross port reliefs (Item 1) [C]. P–0931

Remove the relief valves [D].

P–0929

–4–1–

320 (S/N 511720001 & Above) Excavator Service Manual

SWING MOTOR (Cont’d)

Removal and Installation

1 2

I–2003–0284

P–0935

Remove the seat. (See Page 5–2.)

Remove the seat mount. (See Page 5–2.)

4 Quad Seal

Remove the speed control lever/swing lock mount. (See Page 5–3.)

Cap Screw (8)

Remove the two (2) pressure hoses (Item 1) [A].

Seal Retainer

Square Cut Seal

Remove the drain hose (Item 2) [A] from the tee. NOTE: The case drain tube that attaches to this tee and goes to the side of the swing motor does not have to be removed from the swing motor. Be careful not to damage the tube when lifting the swing motor from the excavator.

Shaft

Race Seal and O–ring

Shaft and Bearing Housing

Remove the six (6) mounting bolts from the swing motor [A].

Square Cut Seal

Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

Retaining Ring

Shift Face Seal

Remove the swing motor from the excavator.

Wear Plate

Disassembly

Square Cut Seal

Clean the motor and drain the oil from the motor.

Drive

Use a soft jaw vise to hold the motor by the mounting flange.

NOTE: Do not disassemble the geroler (Item 1) [B]. The geroler has machined close tolerances. Damage may occur during reassembly.

Geroler Square Cut Seal

Mark the bearing housing by the alignment groove for assembly. The alignment groove aligns the case drain hole in the valve housing.

Valve Drive Valve Plate

Square Cut Seal

Disassemble the motor. NOTE: The cap screws (Item 2) [B] are held by thread bonding adhesive. DO NOT exceed 70 in–lbs. to remove screws. Use a propane torch to heat the screw heads. This will melt the adhesive on the screws. Discard the screws and remove the seal retainer (Item 3) [B].

Valve Balance Ring

Inner and Outer Face Seals Plug

Pin and Spring

O–ring Remove the quad seal (Item 4) [B] and the square cut seal (Item 5) [B] from the retainer. NOTE: Check the seal retainer for cracks. Order a new retainer from Melroe Parts, if needed.

Valve Housing Bolt (4)

–4–2–

B–13496

320 (S/N 511720001 & Above) Excavator Service Manual

SWING MOTOR (Cont’d)

Assembly

1 4

I–2003–0284

3 B–13401

NOTE: Order a swing motor repair kit from Melroe Parts. Clean the seal surfaces on the retainer (Item 1) [A] and install a new quad seal (Item 2) [A] and the square cut seal (Item 3) [A] in the retainer. Lubricate the inner edge of the quad seal and the square cut seal with petroleum jelly. Install the retainer on the motor using two cap screws (Item 4) 180° from one another [A]. Tighten the cap screws to 60 in–lbs (6,7 Nm) torque. Screw the tap (from the kit) in and out of the six remaining holes. Use compressed air to blow loose particles from the holes. Apply clean solvent to each hole and blow them dry. Wash the new cap screws in solvent, blow them dry and apply two or three drops of LOCTITE 609 to the threads. Install the new cap screws in the six holes and tighten to 60 in–lbs. (6,7 Nm) torque. Remove the two cap screws installed earlier. Repeat the hole cleaning procedure, apply two or three drops of LOCTITE 609 to the threads. Install the screws and tighten to 60 in.–lbs. (6,7 Nm) torque.

–4–3–

320 (S/N 511720001 & Above) Excavator Service Manual

SWING MOTOR (Cont’d)

Assembly (Cont’d)

Shaft Face Seal

Wear Plate

Clamp the shaft and bearing housing so the output shaft is down. Pour a small amount of clean hydraulic fluid into the shaft and bearing housing for start–up lubrication. Shaft

Install the shaft face seal and wear plate as shown [A]. Install the drive, Geroler and valve drive.

Shaft and Bearing Housing Motor Timing

B–13495

Rotate Valve Clockwise Until Spline Teeth Mesh

The direction that the output shaft rotates is determined by timing. Time the motor as follows: Valve

Locate the largest open pocket in the Geroler (Item 1) [B].

Align One of the Valve Side Opening With the Largest Open Geroler Pocket

Install the valve plate (Item 2) [B] and locate the open slot that is over the largest open Geroler pocket [B]. Valve Plate

Align one of the side openings in the valve with the valve plate slot that is over the largest open Geroler pocket.

Engage the valve with the valve drive (Item 3) [B] by rotating it clockwise until the spline teeth mesh (1/2 tooth) [B].

3 Valve Drive

Alignment Groove

Geroler

1 Largest Open Pocket B–13495

Install the inner and outer face seals on the balance ring as shown [C].

Install the springs, pins and balance ring in the valve housing. Hold the balance ring in place, through the forward port in the valve housing, while installing the valve housing over the valve.

Inner Face Seal

Pin Notch Outer Face Seal

Install and tighten the four bolts in a criss–cross pattern. Tighten the bolts to 37 ft.–lbs. (50 Nm) torque. Tighten the case drain plug to 50 in.–lbs. 95,5 Nm) torque. Balance Ring B–13495

–4–4–

320 (S/N 511720001 & Above) Excavator Service Manual

CROSS PORT RELIEF VALVE

Disassembly Mark the assembly for ease of installation. Remove the three bolts (Item 1) [A] and remove the cross port relief valve (Item 2) [A] from the swing motor.

1 1 2 P–08396

Remove the two O–rings (Item 1) [B] from the cross port relief valve (Item 2) [B].

B 1

P–08424

Remove the two relief valves (Item 1) [C] from the cross port relief valve.

C 1 1

P–08358

Remove the large O–ring (Item 1) [D], the small O–ring (Item 2) [D] and the back–up washer (Item 3) [D] from the relief valve.

D 1

3 P–08359

Revised June 98

–4–5–

320 (S/N 511720001 & Above) Excavator Service Manual

CROSS PORT RELIEF VALVE (Cont’d)

Disassembly (Cont’d) Remove the two plugs (Item 1) [A] from the cross port relief valve.

P–08360

Remove the plunger (Item 1) [B], the spring (Item 2) [B] and the O–ring (Item 3) [B] from the plug (Item 4) [B].

Assembly

Clean all parts with solvent and dry with compressed air.

Put grease on O–rings. Install a new O–ring (Item 3) [B] on the plug (Item 4) [B] and install the spring (Item 2) [B] and plunger (Item 1) [B]. Install the two plugs (Item 1) [A] in the cross port relief valve and tighten.

4 P–08361

Install a new O–ring (Item 1) [C], backup washer (Item 2) [C] and O–ring (Item 3) [C] on the relief valve.

C 3

2 P–08359

Install the two relief valves (Item 1) [D] into the cross port relief valve and tighten.

D 1 1

P–08358

Revised June 98

–4–6–

320 (S/N 511720001 & Above) Excavator Service Manual

CROSS PORT RELIEF VALVE (Cont’d)

Assembly (Cont’d)

Install new O–rings (Item 1) [A] on the cross port relief valve (Item 2) [A].

2 P–08359

Align the marks on the swing motor and cross port relief valve assembly and install the three bolts (Item 1) [B] through the cross port relief valve (Item 2) [B] and the swing motor (Item 3) [B] and tighten the bolts to 17 ft.–lbs. (23 Nm) of torque.

B 2

Description

The cross port relief valve used on the swing motor has two relief valves mounted on either side of the valve body. These valves work with the accumulator hoses to dampen the swing stop, preventing damage to the swing motor. The relief valves also prevent the upperstructure from independent movement, or creeping, until the swing circuit is engaged.

3 1 P–08396

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

UPPERSTRUCTURE

Removal With cab (ROPS) structure and engine not removed from upperstructure. Disconnect the battery negative (–) cable. (See Page 6–3.) Drain the hydraulic tank. (See Page 3–23.) Remove the boom and arm. (See Page 5–5 & 5–7.) Remove the floorboards. (See Page 3–1.)

MC–01903

Remove the seat. (See Page 5–2.) Remove the seat mount. (See Page 5–3.)

Remove the speed control lever/swing lock mount. (See Page 5–3.) Remove the 6 spool control valve. (See Page 2–10.) Remove the 3 spool control valve. (See Page 2–23.) Remove the swing motor. (See Page 4–2.) If removal of cab (ROPS) structure and engine is also required, remove these additional components: Remove the engine cover. (See Page 5–1.) Remove the canopy (ROPS) structure. (See Page 4–12.) Or cab (ROPS) structure. (See Page 4–14.)

CD–13017

Remove the left control console. (See Page 3–9.) Remove the right control console. (See Page 3–23.) Remove the steering levers. (See Page 3–28.) Remove the engine. (See Page 7–11.) With cab (ROPS) structure and engine not removed from upperstructure, install a lifting sling as shown [A] and apply a slight amount of lifting pressure with a lifting device of sufficient capacity. With cab (ROPS) structure and engine removed from the upperstructure, attach a hoist to the frame and apply a slight amount of lifting pressure [B].

N–13018

Remove the 16 bolts from the frame to swing bearing [C]. Lift upperstructure from the undercarriage.

Revised June 98

–4–8–

320 (S/N 511720001 & Above) Excavator Service Manual

UPPERSTRUCTURE (Cont’d)

Installation Attach a lifting hoist to the upperstructure per the information on the previous page. Lower the frame onto the swing bearing. Maintain a slight amount of frame weight on the hoist. Remove any paint from the three alignment pin holes in the frame. Apply LOCTITE 242 to the threads of the mounting bolts. Install the sixteen bolts and washers through the frame and into the swing bearing [A].

CD–12984

DO NOT tighten the bolts at this time.

Alignment pin P/N 6539805

B–13728

Insert the three alignment pins (P/N 639805) into the alignment holes [C].

Reposition the frame as necessary until the alignment pins will slide through the frame and into the teeth of the swing bearing. With the pins installed, lower the frame onto the swing bearing and remove the hoist. Tighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque. Remove the alignment pins. Do the following procedure to check for proper swing motor gear to swing bearing gear back lash. CD–12985

Install the swing motor (Item 1) [D] into the frame.

Apply LOCTITE 242 to the threads of the six bolts (Item 2) [D] and install.

1 2

Tighten these bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

Remove the caps and/or plugs from the swing motor but do not install any hoses. The swing motor gear to the swing bearing gear engagement must be checked to insure that there is back lash between the gears through 360° of frame rotation. Check for back lash by moving the frame back and forth at several points throughout the frames rotation. There must be some backlash present.

Revised June 98

CD–12986

–4–9–

320 (S/N 511720001 & Above) Excavator Service Manual

CENTER SWIVEL JOINT

Removal And Installation Raise the blade. Raise the machine and use jackstands under the corners of the blade and the rear corners of the frame. Lower the boom/bucket to the ground. Remove the floorboards. (See Page 3–1.)

CD–12987

I–2003–0888

Mark the seven hoses on the top side of the swivel joint for ease of assembly. Remove the seven hoses from the top of the swivel joint [A]. Remove the four bolts from the bottom access plate [B]. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

CD–10481

Remove the plate.

Mark the eight hoses for ease of assembly.

Remove the eight hoses from the swivel joint [C]. Remove the four mounting bolts (Item 1) [C] and nuts. NOTE: Remove the four nuts first. The bolt goes into a threaded plate and the nuts lock the bolts securely into the plate. Installation: Add LOCTITE 242 and tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque, then install the nuts and tighten to 15–18 ft.–lbs. (20–25 Nm) torque.

Remove the swivel joint from the frame. Disassembly and Assembly

CD–12988

Remove the bolts (Item 1) [D].

Remove the end plate (Item 2) [D]. Remove the snap ring (Item 3) [D] from the end of the rotor.

Remove the rotor (Item 4) [D] from the housing. NOTE: Tap the rotor lightly with a rubber hammer if needed for removal.

Check the condition of the O–rings and seal. Check the rotor and housing for scratches or wear marks.

Use grease or hydraulic oil on the O–rings and seal during assembly.

1 B–12744

Assemble the swivel joint in reverse order. Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

SWING CIRCLE GEAR

Removal And Installation Remove the upperstructure from the swing circle gear. (See Page 4–8.) There is an S (Item 1) [A] stamped on the swing gear, make sure this mark is located to either side of the center line of the machine.

1 CD–12989

Remove the bolts from the swing circle gear [B]. Installation: Add LOCTITE 242 and tighten the bolts to 44–48 ft.–lbs. (60–65 Nm) torque. Use a chain hoist to remove the swing circle gear. Always replace the seal when installing the swing circle gear.

CD–12990

Position the outer ring soft zone to either side of the center line of the machine when installing the swing frame on the track frame [C] & [D].

Outer Ring

Inner Ring S

Soft Zone

Tracks MC–01415

NOTE: The soft zone can be located by the filler plug in the outer ring [D].

Soft Zone Revised June 98

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D–02029

320 (S/N 511720001 & Above) Excavator Service Manual

ROPS CANOPY

Removal And Installation Disconnect the battery negative (–) cable. (See Page 6–3.) Open the tool box door. Disconnect the canopy harness from the main harness [A]. The harness connectors are located under the right hand upperstructure, next to the boom swing cylinder.

P–02274

Remove the bolt (Item 1) [B], the nut and the three spacers from both front corners of the canopy. NOTE: One of the plates goes between the canopy mount and the top of the upperstructure. Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque.

P–02391

Remove the bolt and the spacer from both the rear corners of the canopy [C]. Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque.

P–02384

Install a lifting sling to the canopy and use a lifting device of sufficient capacity and lift the canopy up a few inches [D].

P–02386

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

ROPS CANOPY (Cont’d)

Removal And Installation (Cont’d) With canopy lifted up a few inches, pull the canopy harness (Item 1) [A] up and out of right hand front upperstructure access hole. Remove the third plate (Item 2) [A] that is located between the bottom of the canopy mount and the top of the upperstructure.

Remove canopy from the excavator.

P–02390

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB

Removal And Installation Disconnect the battery negative (–) cable. (See Page 6–3.)

Drain the radiator. Loosen the set screw on the heat control knob and remove the knob [A]. Pull the fan control knob (Item 1) [A] off the fan switch.

P–02254

Remove the six screws from the top half of the heater cover plate [B].

P–02256

Remove the front cover and mark the electrical wires going to the heater switch [C]. Remove the wires from the heater switch.

P–02261

Remove the five screws (Item 1) [D] and the bolt (Item 2) [D] from the lower half of the heater cover plate.

1 1

P–02263

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Removal And Installation (Cont’d) Mark the locations of the two heater hoses for ease of assembly. Loosen the two heater hose clamps and remove the heater hoses from the heater core [A].

P–02259

Remove the two bolts from the base of the heater and remove the heater [B].

P–02262

Remove the bolt, the washer, the plate and the nut from both front cab mount [C]. Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque.

P–02266

Remove the bolt and the washer from both rear cab mounts [D].

Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque.

P–02265

Revised June 98

–4–15–

320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Removal And Installation (Cont’d) Disconnect the cab harness from the main harness [A]. The harness connectors are located under the right hand upperstructure, next to the boom swing cylinder.

P–02274

Open the right hand windows so that one lifting strap can be installed to the front of the window opening and a second lifting strap can be installed to the rear of the window opening [B]. Install a 2.0 inch x 8.0 inch board (Item 1) [B] of sufficient length to spread the lifting straps so that they do not contact the right window glass.

P–02264

Install a chain hoist of sufficient lifting capacity to the lifting straps and lift the cab off of the excavator [C].

P–02269

With the cab lifted off of the upperstructure a few inches, the cab mounts (Item 1) [D] can be removed from the four cab corners.

Remove the cab wire harness through the access hole in the right hand front corner of the upperstructure.

P–02273

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Door (Removal And Installation) The door can be removed from the cab by slowly swinging the door back and forth while lifting up on the door [A]. NOTE: When installing the door; the top hinge is bolted to the door. Align the top hinge first and then position the bottom hinge. Hold up on the door and slowly rock the door back and forth until the hinges are engaged about 0.750 inch (19 mm). Then rock the door back and forth until the door weight settles the door hinges to full engagement.

P–02260

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Front Window (Removal And Installation)

When handling glass: • Wear safety glasses. • Wear protective clothing. • Wear leather gloves.

W–2172–0195

P–02255

Unlatch the window and move it into the open, locked position [A].

AVOID INJURY OR DEATH

The front window assist cylinders must be removed from the window pivot assembly before removing the window. The cylinders are under pressure and can cause the pivot arms to spring up rapidly and cause injury or death. W–2171–0195

P–02457

Remove the retainer clip (Item 1) [B] from the base end of the gas cylinder. Remove the base end of the gas cylinder from the ball joint.

P–02460

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288 P–02459

Lower the window to the closed position and engage the latches.

Remove the wiper arm by prying the arm from the wiper motor shaft [C]. Remove the second wiper arm from the pivot ball joint by lifting upwards on arm until it separates from the ball joint.

Remove the nut (Item 1) [D], washer (Item 2) [D] and the screw from the wiper motor. Remove the plastic cover from the wiper motor.

2 1

Installation: Make sure that the ground wire is installed onto the mounting bolt and tighten the bolt to 30 in–lbs. (3.4 Nm) torque. Remove the nut (Item 3) [D] and washer (Item 4) [D] from the wiper motor. Revised June 98

P–02464

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Front Window (Removal And Installation) (Cont’d) Remove the wiper motor from the window. Mark the wires for ease of assembly and remove the wires from the wiper motor [A].

P–02467

Remove the mounting screws (Item 1) [B], washers (Item 2) [B] and the grommet (Item 3) [B] from the four (4) latches.

Installation: Tighten the mounting screws to 10 in–lbs. (1,1 Nm) torque.

With the help of a second person, use the window handles to hold the window in position and remove the mounting screws (Item 4) [B], washers (Item 5) [B], grommets (Item 6) [B] and the nuts form the window pivot mounts.

4 5

Installation: Tighten the mounting screws to 30 in–lbs. (3,4 Nm) torque.

Remove the glass.

P–02461

Remove the window seal from the outer edge of the glass.

C 3

Remove the mounting screws (Item 1) [C], washers (Item 2) [C], grommets (Item 3) [C] and the nuts from the two (2) window handles.

Installation: Tighten the mounting screws to 30 in.–lbs. (3,4 Nm) torque.

P–02462

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Front Lower Glass (Removal And Installation) Remove the mounting screws (Item 1) [A], washers (Item 2) [A], grommets (Item 3) [A] and the nuts from the lower glass. Installation: Tighten the mounting screws to 30 in–lbs. (3,4 Nm) torque.

Remove the glass.

Remove the gasket from the cab frame.

3 P–02465

Front Upper Plexiglass (Removal And Installation)

Remove the four mounting screws (Item 1) [B] from the upper cab console to access the window mounting nuts.

P–02458

Remove the mounting screws, retainer strap and nuts [C]. Installation: Tighten the mounting screws to 30 in–lbs. (3,4 Nm) torque. Remove the plexiglass. Remove the gasket from the cab frame.

P–02466

Revised June 98

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320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Door Glass (Removal And Installation) The glass is held in position with mounting screws (Item 1) [A], washers (Item 2) [A], grommets (Item 3) [A] and nuts.

Open the door and remove the glass edge seal. Close the door. Use a knife and cut the glass sealer at the center of the door [A]. P–02332

NOTE: When removing the top door glass, the top door hinge is bolted to the glass. Make sure that the door is closed so when the hinge is removed, the door is held in its proper position.

Hold the glass in position and remove the mounting screws from the glass [B]. Remove the glass. Installation: Tighten the mounting screws to 30 in–lbs. (3,4 Nm) torque.

P–02333

Left Hand Side Glass (Removal And Installation) The glass is held in position with mounting screws (Item 1) [C], washer (Item 2) [C], grommets (Item 3) [C] and nuts.

Hold the glass in position and remove the mounting screws (Item 1) [C].

1 Remove the glass. Installation: Tighten the mounting screws to 30 in–lbs. (3,4 Nm) torque. Remove the glass edge seal. P–02332

Revised June 98

–4–21–

320 (S/N 511720001 & Above) Excavator Service Manual

CAB (Cont’d)

Rear Glass (Removal And Installation) The rear glass is held in position with adhesive. Hold the window in position while cutting the adhesive. Insert the cut wire through the adhesive at the corner of the window. Pull the wire around the window diameter to cut the adhesive [A]. Clean the window frame of any adhesive. Installation: Install the adhesive tape to the outer diameter of the window. Position the window to the window opening and press the window into position.

P–02331

Right Hand Side Glass (Removal And Installation) To remove the right hand side glass, the lower window felt channel and the rubber bumper strip must be removed. Unlatch the outer window and open the window slightly. Lift upwards on the felt channel and the rubber bumper strip until they contact the edge of the glass [B]. Slide the glass open while pulling the felt channel and the rubber bumper strip in the same direction as the glass in being opened. Slide the glass open fully. Grasp the glass and slide it backwards to the slightly open position.

P–01168

While holding the glass up, pull the felt channel and the rubber bumper out of the window channel.

Lower the glass down into the channel and tilt the top edge of the glass outwards and lift the glass up and out [C]. Installation: Set the glass into the lower channel and tilt the top of the glass inwards. Lift up on the glass until it is seated in the upper window channel. Hold the glass up and insert the rubber bumper strip into the window channel. With the help of a blunt tool, slide the rubber channel under the glass. Insert the felt channel into the window channel. With the edge of the felt channel flush with the edge of the glass. Lift the glass upwards and slide the glass into the felt channel. With the help of the blunt tool, slide the glass and the felt channel back to the closed window position. Continue this process until the felt channel is fully engaged into the window channel.

P–02276

NOTE: The outer glass must be removed before inner glass can be removed. Use the same procedure to remove the inner glass.

Added June 98

–4–22–

320 (S/N 511720001 & Above) Excavator Service Manual

CAB/CANOPY REAR COVER

Removal The plastic cover is attached to the cab and canopy with an adhesive. To remove the cover, start at one end of the cover and use two putty knives and slowly pry out on the cover to separate the adhesive from the cover and the cab. Remove the three bolts that hold the support to the cab/canopy [A]. Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

P–02419

Installation Clean the back surface of the plastic cover. Install the adhesive tape to the back, top surface of the cover [B]. Leave approximately a 0.125 inch (3 mm) gap between the adhesive tape and the outer edges of the cover. NOTE: Leave the protective film on the one side of the adhesive tape at this time.

P–02421

With the engine cover closed, tip the plastic cover so that the drip rail will slide under the top lip of the engine cover.

Roll the cover towards the cab/canopy until the drip rail is fully engaged [C]. Test fit the cover to the cab and determine the best fit.

P–02420

Tip the cover back and remove the protective film from the tape and install the cover to the cab/canopy [D].

Firmly press the top edge of the cover to the cab/canopy so that the adhesive has a complete bond [D].

P–02422

Added June 98

–4–23–

320 (S/N 511720001 & Above) Excavator Service Manual

AIR BAFFLE (Cab Models Only)

320ServiceManual(S/N511720001&Above)#6722642–UpperWorksandSwingSection

Removal And Installation The air baffle is used on the cab models to direct the air flow through the radiator. Remove the four bolts (Item 1) [A] from the air baffle.

Remove the baffle. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

P–02335

BELLY PAN (Field Installed) Removal And Installation Remove the nine bolts from the belly pan [B]. Remove the belly pan. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

P–02336

Added June 98

–4–24–

320 (S/N 511720001 & Above) Excavator Service Manual

MAIN FRAME AND TRACKS Page Number ARM Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5.. BOOM Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 BUCKET Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 ENGINE COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 REAR CORNER POSTS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 SEAT AND SEAT MOUNT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 SWING POST Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 TRACK Damage Identification and Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11 Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 TRACK FRAME Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 TRACK Damage Identification and Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27 TRACK IDLER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 TRACK ROLLER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20

MAIN FRAME & TRACKS

–5–0–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE COVER

Removal and Installation Open the engine cover [A]. Hold the engine cover open.

P–2218

Remove the bolt (Item 1) [B], washer spacer and nut from the rod end of the gas cylinder.

Remove the bolt (Item 2) [B], washer and nut from the base end of the gas cylinder.

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288 P–2418

Remove the bolts (Item 3) [B] from the hinge (both sides).

Remove the engine cover from the machine. REAR CORNER POSTS

Removal and Installation Remove the left hand side cover, and/or the right hand side cover. (See Page 3–1.) Open the engine cover. Remove the bolt (Item 1) [C] from the back side of the corner post.

P–2370

Installation: Tighten the bolt to 125–140 ft.–lbs. (65–75 Nm) torque.

D 1

Remove the top inner bolt (Item 1) [D] from the corner post. Installation: Tighten the bolt to 48–55 ft.–lbs. (65–75 Nm) torque. NOTE: Left hand corner post removal is shown, right hand corner post removal is identical except as noted.

P–2367

–5–1–

320 (S/N 511720001 & Above) Excavator Service Manual

REAR CORNER POSTS (Cont’d)

Removal and Installation (Cont’d) Remove the bottom front bolt (Item 1) [A] from the corner post.

Installation: Tighten the bolt to 125–140 ft.–lbs. (170–190 Nm) torque.

P–2368

NOTE: When removing the right hand corner post, remove the two (2) bolts (Item 1) [B] and nuts (Item 2) [B] from the hydraulic filter.

1 2

Remove the filter assembly from the corner post and position out of the way. Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

P–2357

SEAT AND SEAT MOUNT Removal and Installation Pull the slide handle (Item 1) [C] out and slide the seat forward until the seat slide rails separate. NOTE: On cab equipped models, open the front window for easier access to remove the seat.

1 Remove the four (4) bolts (Item 1) [D] from the seat mounting plate.

P–2413

D 1

NOTE: If the lower seat slide rails (Item 2) [D] are removed from the seat mount, the lower rails must be realigned with the seat rails for proper fit. With the seat and the mount removed from the excavator, install the lower seat rails onto the main seat rails. Install the seat to the seat mount and tighten the bolts.

2 1

P–2339

–5–2–

320 (S/N 511720001 & Above) Excavator Service Manual

SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING

Removal and Installation

Remove the seat. (See Page 5–2.)

Remove the seat mount. (See Page 5–2.) Disconnect the speed control cable (Item 1) [A] from the ball joint. Loosen the jam nut (Item 2) [A] on the speed cable at the engine cover. Push the cable through the engine cover hole and out of the way.

P–2342

Remove the two (2) nuts (Item 1) [B], the washer (Item 2) [B], the friction washer (Item 3) [B], the two wave washers (Item 4) [B], the nylon spacer (Item 5) [B], the lever (Item 6) [B] and the two (2) bolts (Item 7) [B].

Installation: Tighten the locknuts (Item 1) [B] until approximately 15 lbs. (66 N) of force is needed to move the speed control lever.

1 7

P–2340

Remove the three (3) bolts from the seat mount [C]. Installation: Tighten the bolts to 28–37 ft.–lbs. (40–50 Nm) torque. Remove the mounting plate. NOTE: The speed control lever does not need to be removed to remove the mounting plate.

P–2344

Remove the nut (Item 1) [D] and washer (Item 2) [D].

Installation: Tighten the locknut until it contacts the end of threads.

1 7

Remove the roll pin (Item 3) [D], lock pin (Item 4) [D] and the rod (Item 5) [D].

2 6

Remove the bolt (Item 6) [D] and nut from the lever (Item 7) [D]. Installation: Tighten the bolt and nut until there is very little free play but the lever must not bind against the mounting plate.

5 3 4 –5–3–

P–2347

320 (S/N 511720001 & Above) Excavator Service Manual

BUCKET

Removal and Installation

AVOID INJURY OR DEATH

Stop the machine on a firm flat surface. When removing or installing attachments (such as a bucket), always have a second person in the operator’s seat, give clear signals and work carefully.

P–0817

W–2140–0189

Park the excavator on a flat level surface. Put the bucket on the ground.

Remove the pin retainer clips (Item 1 & 2) [A].

Remove the pivot pins (Item 1 & 2) [B]. Keep the pins clean. Do not damage the dust seals in the arm when removing the bucket. Installation

Install the arm into the bucket and align the hole. P–0871

Install the pivot pin (Item 2) [B] and install the pin retainer clip. Extend the bucket cylinder until the connecting link aligns with the other bucket pin hole. Install the pivot pin (Item 1) [B] and install the pin retainer clip.

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

W–2052–1285

–5–4–

320 (S/N 511720001 & Above) Excavator Service Manual

ARM

Removal and Installation Remove the bucket. (See Page 5–5.) Install a chain hoist to the top of the arm. Remove the nut and bolt from the rod end pin of the arm cylinder [A]. Installation: Tighten the nut and bolt until no end play exists.

P–0879

Remove the retaining pin from the rod end of the arm cylinder [B].

P–0878

Remove the two (2) hoses from the bucket cylinder [C].

P–0877

Remove the nut from the boom/arm pivot pin [D].

Installation: Tighten the lock nut until it is seated firmly against the boom but do not overtighten and deflect the boom mounting plate. The arm must pivot freely.

P–0875

–5–5–

320 (S/N 511720001 & Above) Excavator Service Manual

ARM (Cont’d)

Removal and Installation (Cont’d) Remove the pivot pin [A]. Remove the arm from the boom.

P–0881

–5–6–

320 (S/N 511720001 & Above) Excavator Service Manual

BOOM

Removal and Installation

Remove the bucket. (See Page 5–4.) Remove the arm. (See Page 5–5.) Remove the boom cylinder. (See Page 2–35.) Remove the two (2) tube retainer bolts (Item 1) [A] and the retainer plates. This will allow easier access to remove the hoses from the tubes. Mark the hoses for ease of assembly. P–2407

Remove the six (6) hoses from the tubes [A].

Remove the bolt (Item 1) [B] from the boom pivot pin. Installation: Tighten the bolt to 29–37 ft.–lbs. (40–50 Nm) torque.

P–2222

Remove the boom pivot pin [C].

P–2409

Lift the boom from the swing post [D].

NOTE: If shims are present between the boom and the swing post, be sure to install the shims in the same locations. Side play of the boom should not exceed .03 inch (0,7 mm). Add shims equally to both sides of boom.

P–0899

–5–7–

320 (S/N 511720001 & Above) Excavator Service Manual

SWING POST

Removal And Installation Remove the bucket. (See Page 5–7.) Remove the arm. (See Page 5–8.) Remove the boom. (See Page 5–10.) Remove the snap ring (Item 1) [A] and washer from the boom swing cylinder pivot pin. NOTE: S/N 511720001–511721115 excavators use a bolt to retain the boom swing cylinder pivot pin.

1 P–11128

Remove the swing cylinder pivot pin.

Remove the snap ring from the swing post pivot pin (Item 1) [B]. Remove the washer that is under the snap ring. Install a chain hoist to the swing post.

Support the bottom of the swing bracket when removing the pins. Excess pressure can cause the swing bracket casting to crack.

P–06103

I–2093–1195

Install a jack and spacer tube under the upperstructure swing post to support the casting [C]. The spacer tube must be large enough to allow the pin to be driven into the center of the spacer for pin removal. Use a large punch and drive the swing post pin out.

P–06104

Remove the swing post from the excavator [D].

P–00903

Revised June 98 –5–8–

320 (S/N 511720001 & Above) Excavator Service Manual

SWING POST (Cont’d)

Bushing Replacement Insert the bushing driver through the top bushing and against the bottom bushing [A]. Drive the bottom bushing out of the upperstructure [B]. To remove the top bushing, install the bushing driver from the bottom and drive bushing out. To install new bushings, use a bushing driver of the correct size and install the new bushings into the upperstructure. Swing Post Bushing Removal

P–02414

B Do Not point (hammer) on the boom swing bracket. Excess pressure can cause the casting to crack. I–2095–1195 The following parts will be needed for removal and installation of the swing post bushings: 1. Bolt – 0.625 x 4.5 inch long 2. Nut – 0.625 inch 3. Washer – 0.625 inch I.D. x 2.312 inch O.D. x 0.25 inch thick 4. Washer – 0.625 inch I.D. x 3.5 inch O.D. x 0.25 inch thick 5. Spacer – 2.875 inch I.D. x 3.375 inch O.D. x 1.5 inch thick

P–02417

Install the spacer (Item 5) [C] and washer (Item 6) [C] over the flanged end of the bushing.

The spacer (Item 5) [C] must be centered over the bushing to avoid contact between the bushing and the spacer during removal.

5 6

Install the washer (Item 3) [C] onto the opposite end of the bushing. This washer must be centered on the bushing and must not contact the casting.

Install the bolt (Item 1) [C] and the nut (Item 2) [C] through the washers and spacer. Tighten the bolt and nut to remove the bushing from the casting.

P–06105

Bushing Installation

Apply a film of grease to the outer diameter of the bushing and the inner diameter of the casting.

1 4

Center the bushing on the casting hole. NOTE: Make sure the bushing is centered into the casting hole and that it starts into the hole evenly and square.

Put the washer (Item 3) [D] over the flanged end of the bushing. Put the washer (Item 4) [D] over the bushing hole casting, center the washer over the bushing hole.

Install the bolt (Item 1) [D] through the washers and the bushing and install the nut (Item 2) [D]. Tighten the bolt and nut until the bushing is seated in the casting.

P–06106

Revised June 98 –5–9–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK

Track Tension Adjustment NOTE: The wear of the pins and bushings on the undercarriage vary with the work conditions and different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. (See Service Schedule Page 1–1 for the correct service interval.) Raise one side of the machine (approximately 4’’ [101 mm]) using the boom and arm as shown in [A]. Raise the blade completely and install jackstands under the blade and the track frame. Stop the engine.

P–2239

B 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 2.25–2.50’’ (57–63 mm), the track tension is correct [B]. P–0854

If not, loosen one bolt and remove the other bolt from the cover [C].

Add grease to the fitting (Item 1) [D] until the track tension is correct. If track tension is to tight, decrease the track tension pressure by loosening the bleed screw (maximum of 1 turn) and allow the grease to flow out of the bleed screw 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–0845

Add Grease Here

Bleed Here

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.

W–2143–0189

B–13134

–5–10–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Removal and Installation

Bleed Here

Add Grease Here

Lift and block the side of the machine where the track will be removed. Slowly loosen the bleed screw fitting (one (1) turn maximum) to remove track tension [A]. NOTE: Apply additional pressure to the track by standing on the lower track span so all the tension is released from the grease cylinder for easier removal of the track. B–13134

Remove the track from the front track idler [B].

Remove the track from the frame and rear drive sprocket. Damage Identification and Causes See pages (5–16 – 5–23) which includes information detailing the identification of track wear and failure and the possible causes. The photos will show actual examples of different types of damage. We will describe the causes and recommend prevention to extend the service life of the rubber tracks. CD–7625

–5–11–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK FRAME

320ServiceManual(S/N511720001&Above)#6722642–MainFrameandTracksSectionPages1–12

Disassembly and Assembly Use the following procedure to remove the different parts from the track frame: Remove the track. (See Page 5–11.) Slide the front track idler out of the track frame to remove it [A].

CD–7626

Remove the sliding plate [B].

CD–7627

Slide the recoil spring cylinder forward and remove it from the track frame [C].

N–07628

Whenever the recoil spring is removed from the track frame, check and adjust the grease spring [D].

Tighten or loosen the nut (Item 1) [D] to adjust the spring to the dimensions shown.

Grease Fitting

When reinstalling the recoil spring make sure the grease fitting faces to the outside of the track frame.

8.62’’ (219 mm) 8.50’’ (215 mm)

B–14089

–5–12–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER Parts Identification

3 4 5 6 7

7 6 2

C–3127

FRONT IDLER Ref. 1. 2. 3. 4.

Description

Ref.

Shaft Pin Block Snap Ring

5. 6. 7. 8.

–5–12a–

Description Seal Snap Ring Bearing Idler

TRACK IDLER (Cont’d) The following tools must be fabricated for this procedure:

1. Driver Tool – See [A]. 2. Support Fixture – Tube, 3’’ ID x 1/4’’ wall x 6 inches long.

3.50’’ (90 mm) 2.75’’ (70 mm)

0.03’’ (0,75 m) Chamfer 3 Places

1.35’’ (35 mm) Dia. B–14204

Disassembly Remove the roll pin and block from each end of the shaft [B].

CD–0289

Remove the snap ring from each side of the idler [C].

CD–0288

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [D].

CD–0290

–5–12b–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

Disassembly (Cont’d) Apply penetrating oil to both ends of the exposed shaft to ease removal of the inner part of the seal. Remove the inner part of the seal using two screwdrivers [A].

CD–0287

Remove the outer part of the seal from the idler using two screwdrivers [B].

Pour the oil out of the idler. Discard the oil in an appropriate manner. Turn the idler assembly over and remove the other seal.

CD–0285

Remove the snap ring from each side of the idler [C].

CD–0278

Using the fabricated driver tool and support fixture, press or drive the shaft and bearing assembly out of the idler [D].

D Driver Tool

Support Fixture CD–0277

–5–12c–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

Disassembly (Cont’d) Inspect the bearings for rust or for rough spots. The bearings must turn freely. If any damage is found, replace the bearings. If replacement of the bearings is necessary, use a two (2) or three (3) jaw puller, remove the two bearings from the shaft [A].

CD–0273

Assembly Remove all paint and corrosion from the seal surface on both sides of the idler [B]. Be sure all parts are clean before assembly.

CD–0271

Using the driver tool, install a new bearing, with the numbered side upward, onto the shaft [C]. Press only on the inner diameter of the bearing.

CD–0272

Using the driver tool, install the shaft and bearing assembly into the idler [D].

CD–0274

–5–12d–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

Assembly (Cont’d) Install the snap ring [A].

CD–0275

Turn the idler assembly over. Using the driver tool, install the other bearing, with the numbered side upward, into the roller [B].

CD–0276

Install the snap ring [C].

CD–0278

Using a dial indicator, check the endplay of the shaft [D]. If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed. Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14276

CD–0280

–5–12e–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

Assembly (Cont’d) Separate the inner and outer halves of the seal. Apply grease to the grooves on the outer part of a new seal [A].

CD–0281

Apply a small bead of high temperature silicone sealant around the flange surface of the seal [B].

CD–0282

Using the driver tool, install the outer part of the new seal into the idler [C].

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–0284

Using the driver tool, install the inner part of the new seal over the shaft [D].

NOTE: The inner part of the seal must be pressed down level with the outer part of the seal to seal properly.

CD–0286

–5–12f–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

Assembly (Cont’d) Turn the roller assembly over. Using a syringe add 35 cc of SAE 10W/30 oil to the assembly [A]. Repeat Page 5–19 Step A thru Page 5–20 Step D to install the remain seal. Check for leaks.

CD–0283

Install the snap ring on each side of the idler [B].

CD–0288

Install the roll pin and block on each end of the shaft [C].

The two blocks must point the same direction.

CD–0289

–5–12g–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

Assembly (Cont’d) Loosen the nuts from the track roller on both sides of the track frame [A]. Installation: Tighten the nuts to 125–140 ft.–lbs. (170–190 Nm) torque.

CD–7631

Remove the track roller [B].

TRACK ROLLER Parts Identification

CD–7632

2 1

5 6 7 8 9 10 8 7 6

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Washer Nut Washer Spacer Snap Ring Seal Snap Ring Bearing Shaft Roller

4 3

–5–13–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d) The following tools must be fabricated for this procedure:

1. Driver Tool – See [A]. 2. Support Fixture – Tube, 3’’ ID x 1/4’’ wall x 6 inches long.

3.50’’ (90 mm) 0.03’’ (0,75 mm) Chamfer 3 places

2.25’’ (60 mm) 1.20’’ (20 mm) Dia. 2.00’’ (50 mm) Dia.

B–14203

Disassembly Remove the snap ring from each end of the shaft [B].

CD–0331

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [C].

CD–0330

Apply penetrating oil to both ends of the exposed shaft to ease removal of the inner part of the seal.

Remove the inner part of the seal using two screwdrivers [D].

CD–0328

–5–13a–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

Disassembly (Cont’d) Remove the outer part of the seal from the roller using two screwdrivers [A]. Pour the oil out of the roller. Discard the oil in an appropriate manner. Turn the roller assembly over and remove the other seal.

CD–0324

Remove the snap ring from each side of the roller [B].

CD–0320

Using the fabricated driver tool and support fixture, press or drive the shaft and bearing assembly out of the roller [C].

C Driver Tool

Support Fixture CD–0318

Inspect the bearings for rust or for rough spots. The bearings must turn freely. If any damage is found, replace the bearings. If replacement of the bearings is necessary, use a two (2) or three (3) jaw puller, remove the two bearings from the shaft [D].

CD–0312

–5–13b–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

Assembly Remove all paint and corrosion from the seal surface on both sides of the roller [A]. Be sure all parts are clean before assembly.

Cd–0310

Using the driver tool, install a new bearing, with the numbered side upward, onto the shaft [B]. Press only on the inner diameter of the bearing.

CD–0311

Using the driver tool, install the shaft and bearing assembly into the roller [C].

CD–0313

Install the snap ring [D].

CD–0314

–5–13c–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

Assembly (Cont’d) Turn the roller assembly over. Using the driver tool, install the other bearing, with the numbered side upward, into the roller [A].

CD–0316

Install the snap ring [B].

CD–0320

Using a dial indicator, check the endplay of the shaft [C]

If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed. Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14276

P–0322

Separate the inner and outer halves of the seals.

Apply grease to the grooves on the outer part of a new seal [D].

CD–0325

–5–13d–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

Assembly (Cont’d) Apply a small bead of high temperature silicone sealant around the flange surface of the seal [A].

CD–0326

Using the driver tool, install the outer part of the new seal into the roller [B].

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–0323

Using the driver tool, install the inner part of the new seal over the shaft [C].

NOTE: The inner part of the seal must be pressed down level with the outer part of the seal to seal properly.

CD–0327

Turn the roller assembly over. Using a syringe add 25 cc of SAE 10W/30 oil to the assembly [D].

Repeat Page 5–26 thru Page 5–27 Step C to install the remaining seal. Check for leaks.

CD–0321

–5–13e–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–MainFrameandTracksSectionPages12a–13f

Assembly (Cont’d) Install the snap ring on each end of the shaft [A].

CD–0331

–5–13f–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK

Damage Identification and Causes Cutting of Steel Cords: Damage Embedded steel cords are cut off [A] & [B]. Replacement: Replacement is required [A] & [B].

P–3864

Steel Cords

Causes of the damage

PI–13034

When applied to rubber tracks under the following circumstances, tension in excess of the breaking strength of the embedded steel cords causes steel cords to be cut:

When the rubber track is detracking, the idler or sprocket rides on the projections of the embedded metal [C]. When the rubber track is detracted, projections of rubber tracks get stuck between the frame of the undercarriage. The rubber track is clogged with stones or foreign obstacles. Furthermore, when moisture invades through a cut on the lug side rubber surface, the embedded steel cords will corrode. The deterioration of the design strength may lead to the breaking off of the steel cords.

PI–13035

Prevention The following preventions should be taken to minimize the risk of this damage: Periodical checking on site of the recommended track tension (See Page 5–4). Avoiding quick turns on bumpy and rocky fields. Drive carefully to avoid having stones and other articles clog the rubber tracks. Driving over sharp objects should be avoided. If this is impossible, do not make turns while driving over sharp objects.

–5–14–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Abrasion of Embedded Metals Damage In proportion to the service time, embedded metals will gradually wear away by friction [A].

P–3865

Replacement Replacement is required when the width of the embedded metals (D1) becomes 67% of their original width (D) [B].

Abrasion

Causes of the damage When the track rollers, sprockets and idler gears roll over the embedded metals, abrasion of embedded metals is inevitable. The following cases sometimes accelerate their abrasion: Rubber tracks are driven with an extraordinary heavy load on them.

D1 = 0.67D PI–13037

Rubber tracks are used on sandy fields. Prevention As long as rubber tracks are used under normal operating conditions, abnormal abrasion is unlikely to occur. The level of abrasion should be carefully checked when the machines are used for dozing which generate a heavy load for rubber tracks, and when they are operated under a sandy field condition for a long time.

–5–15–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Separation of Embedded Metals Damage: Extraordinary outer forces applied to embedded metals cause their separation from the rubber track’s body [A]. Replacement: Even a partial separation of embedded metals requires replacement of the track.

P–4379

Causes of the damage: Embedded metals are adhered between the steel cords and the rubber body. The following cases generate external forces greater than the adhesion strength, causing separation of the embedded metals:

Idler

When the idler continually rides on the projections of embedded metals, the embedded metals will eventually peel off [B].

Rubber track

PI–13039

When a rubber track is detracted, it becomes stuck between the guide or the undercarriage frame, causing the separation of embedded metals [C].

Guide

PI–13040

Abnormally worn sprockets as shown will pull embedded metals out [D].

Prevention: Similar to the prevention against the cutting of the steel cords: Abrasion

Recommended track tension should be periodically checked (Page 5–12). Quick turns on bumpy and rocky fields should be avoided. If abnormal wear of sprockets is observed, they should be immediately replaced.

PI–13041

–5–16–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Separation of Embedded Metals Due To Corrosion Damage: Due to corrosion of embedded metals, the adhesion to the rubber body deteriorates, resulting in complete separation [A]. Replacement: Even a partial separation of embedded metals requires a rubber track replacement.

P–4378

Causes of the damage

Embedded metals are bonded to the rubber body. The following operating conditions cause embedded metals to corrode, causing deterioration of the bonding, and finally resulting in separation of the embedded metals from the rubber body [B].

Embedded metal

Good

Excessively salty fields, like the sea shore. Strong acidic or alkali soil conditions Compost spread grounds

Separation of bonded rubber cover

On tracks that are out of adjustment, the track rollers, idlers and sprockets will gradually wear the rubber surface at track roller side, causing exposure of the embedded metals. Consequently the embedded metals will corrode resulting in their separation from the rubber body.

PI–13043

Prevention: If rubber tracks are used under such field conditions as described under (Causes of the damage), they should be washed with plenty of water. After being completely dried, they should be stored correctly. When the bonded rubber cover is separated from the embedded metal projections and the metals in the rubber body become loose, it is time to consider replacement of the rubber track.

–5–17–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Cuts On The Lug Side Rubber Damage: Cuts on the lug side rubber often occurs as one of the most typical failure modes [A] Replacement: When a cut on the lug side rubber reaches the embedded steel cords, it should be immediately repaired with cold vulcanization rubber.

P–4377

Causes of the damage:

When rubber tracks drive over projections or sharp stones in the fields, the concentrated forces applied cause cuts on the lug side rubber surface. In case of making turns on projections, the lug side rubber surface will have an even higher chance to be cut. If the cuts run through the embedded steel cords, it might result in the steel cords’ breakage due to their corrosion. It is highly recommended to repair the cuts with cold vulcanization rubber as soon as they are observed [B].

Cuts

Prevention: Machine operators are requested to drive with great attention to the ground’s surface especially in terrains of the following type:

PI–13045

Construction sites Demolition sites Paths covered with rocks and wood Concrete ridges Stumpy fields When operating on terrains as mentioned above, high speed, quick turns and overloading should be avoided.

–5–18–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Cracks Of The Lug Side Rubber Due To Fatigue Damage: Small racks around the root of the lug as a result from operation fatigue [A] & [B]. Replacement; When the cracks reach so deep that they expose the steel cords, track replacement is required.

P–4382

Causes of the damage: Because of wound stress applied to rubber tracks around the undercarriage parts during operation, the fatigue especially causes cracks on the lug side rubber surface. Once the cracks occur, they gradually deteriorate with even small external cracks. Also when operating near seashores or under cold temperatures, rubber tracks are more likely to suffer from ozone cracks. Prevention: Rubber tracks are designed with special rubber compounds to prevent cracks due to fatigue. However, external injuries on the lug side rubber sometimes cause more chance of cracking. Machine operators should observe soil conditions when driving, so as not to cause external injuries to the lug side rubber. In order to minimize the occurrence of ozone cracks, attention should be paid to the following instructions for maintenance:

P–4380

Avoid exposing stored tracks to direct sun light Avoid exposing stored tracks to direct rain and snow fall Store tracks in well ventilated warehouses Use the tracks at least once a month

–5–19–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Lug Abrasion Damage: As its service time proceeds, the lug side inevitably undergoes abrasion [A] & [B]. Replacement: No replacement is required.

P–4381

Causes of the damage:

Lug abrasion is more or less inevitable. Even if lug abrasion is proceeding, the rubber track can be used. However, as the traction performance deteriorates accordingly, it is highly recommended to replace the abraded tracks with new ones when the lug height becomes less than 5 mm.

Lug abrasion t

Prevention: In order to prevent the rubber track from abnormal or premature abrasion, following operating conditions should be avoided: Making quick and repeated turns on concrete and asphalt roads

PI–13049

Driving up and down hilly paths with slippage

Making frequent turns on paths covered with rocks and wood Cracks and cuts on the lugs side rubber at the edges of the embedded metals Damage: Sometimes cracks and cuts on the lug side rubber at the edges of the embedded metals can be observed [C]. Replacement: Basically, no replacement is required unless the cuts on the lug side rubber are discovered all around the edges of the embedded metals, as this will result in a complete cut off.

CD–13050

Causes of the damage: When rubber tracks drive over sharp projections, intensive stress is applied to the lug side rubber surface, especially at the edges of embedded metals, causing cracks and cuts in the area around the embedded metals [D].

Crack at the edge of embedded metal

Cut on lug side rubber

Prevention: To avoid extensive stress applied to the lug root where metals are embedded, machine operators are requested to avoid driving over stumps and ridges. PI–13051

–5–20–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

Damage Identification and Causes (Cont’d) Abrasion Of The Track Roller Side Damage: The rubber surface on which track rollers run is gradually abraded. It will end in the exposure of the embedded metals [A]. Replacement: It is recommended to replace the rubber track when more than half of the embedded metals are completely exposed.

P–4383

Causes of the damage:

The abrasion of the track roller side rubber surface occurs because of sand and gravel being clogged between the rubber and the outside surface of the track rollers. The stress pushes the sand and gravel against the side of the rubber track to cause the abrasion [B].

Track roller Abrasion

The level of abrasion is highly dependent on terrain conditions. A higher level of abrasion will occur when the rubber tracks are operated in fields covered with many stones and gravel. Small stones hardened with mud, stuck to the track rollers increase the abrasion level. After an extended period of abrasion, it will be more likely for exposed embedded metals to catch moisture through the inside steel cords, which can cause breakage of steel cords and separation of the metals from the rubber body.

PI–13053

Prevention: After operation in wet fields containing many small stones, wash off the mud that is stuck to the track rollers completely. When operating on gravel paths and stony grounds, machines should be driven slowly and the turning radius should be big enough to prevent stones and gravel from getting stuck to the track roller side rubber.

–5–21–

320 (S/N 511720001 & Above) Excavator Service Manual

TRACK (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–MainFrameandTracksSectionPages14–22

Damage Identification and Causes (Cont’d) Cuts On The Edges Of Track Roller Side Damage: Both edges of a rubber track have no special reinforcements. It sometimes occurs during operation that they are cut or torn off [A] & [B]. Replacement: In such case, the rubber track does not have to be replaced.

P–4384

Causes of the damage:

This damage is caused by objects on the field or by interference with the machine frame.

Edge

In case of damage by objects on the operating ground:

Edge

The edges of rubber track are often deformed largely due to a bumpy ground surface, stones and other objects, which cause extensive stress on the edges resulting in the damage. Especially, when a machine drives over concrete ridges, this type of damage easily occurs. In case of damage by interference with the machine frame PI–13055

If a machine continues operating with rubber tracks being detracted, the rubber tracks may get caught up in the machine frame or undercarriage parts resulting in damage. Furthermore, when a machine travels along side slopes, the rubber tracks are deformed so much that they come into contact with the machine frame and undercarriage parts, which causes cutting, gouging and rubbing of rubber tracks in the end.

Prevention: When traveling, a machine operator should be careful not to drive over any projections on the ground. He should also prevent rubber tracks from coming into contact with concrete walls, ditches and ridges. If rubber tracks are detracked, the machine should be stopped immediately for retracking.

PI–13056

D Cut

Tear

PI–13057

–5–22–

320 (S/N 511720001 & Above) Excavator Service Manual

ELECTRICAL SYSTEM Page Number ALTERNATOR Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 Checking Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 Disassembly and Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 BATTERY Check the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 BATTERY BOX Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 CAB ELECTRICAL (Cab Option) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 ELECTRICAL SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 FUEL LEVEL SENDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14 HORN Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14 STARTER Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

–6–0–

320 (S/N 511720001 & Above) Excavator Service Manual

TROUBLESHOOTING The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, 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 [A].

W–2003–1289

PROBLEM

CAUSE

Battery will not take a charge.

1, 2, 3, 4, 5

Alternator will not charge.

1, 2, 5

Starter will not turn the engine.

2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE 1. Alternator belt is loose or damaged. 2. Battery connections are dirty or loose. 3. Battery is damaged. 4. The ground connection is not making a good contact. 5. The alternator is damaged. 6. The engine is locked. 7. The starter is damaged. 8. The wiring or the solenoid is damaged. 9. Check the fuses ELECTRICAL SYSTEM Description The excavator has a 12 volt, negative ground electrical system. There are two main circuits. 1. The charging circuit has an alternator (with integral regulator) and a battery. 2. The starting circuit has a starter motor, solenoid and starter switch for starting the engine. The electrical system is protected by fuses, installed in the hourmeter panel inside the engine compartment. Fuses protect the electrical system from an overload. The reason for the overload must be found before starting the engine.

–6–1–

320 (S/N 511720001 & Above) Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

Fuses The excavator has a 12 volt, negative ground charging system. The following fuses protect these circuits from overload: 1. 25 amp: This fuse protects the light switch circuit and it supplies power to the cab (if equipped) [A]. 2. 25 amp: This fuse protects the ignition circuit, the auxiliary power outlet and the hourmeter [A]. 3. 25 amp: This fuse protects the heater circuit (if equipped) and the rear accessory wire [A].

P–0834

4. 5 amp: This fuse protects the cab electrical circuit; wipers, washer and interior light (if equipped) [B].

Replace the fuse with the same type and capacity. NOTE: Before replacing any fuse, find the problem that caused the fuse to blow. Make sure the key switch is in the OFF position before replacing the fuse.

P–2267

Electrical System Service

Use the following procedure to service the electrical system: 1. Open the engine cover. The battery cable ends must be clean and tight [C]. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution [D]. Cover the battery terminals and cable ends with battery saver grease. 2. Check for broken or loose connections. 3. With factory equipped battery, no maintenance is need as this is a maintenance free battery. If the machine has had a Melroe parts replacement battery install, check the electrolyte level in the battery. If it is lower than 1/2’’ (13 mm) above the plates, add distilled water only. (See Battery Manual P/N 6566047 for additional information.)

P–2212

4. Check the alternator belt for wear and correct tension. 5. Check that all wire connections are secure. NOTE: 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.

A–2741

–6–2–

320 (S/N 511720001 & Above) Excavator Service Manual

BATTERY

Checking the Battery The tool listed will be needed to do the following procedure: MEL10004A – Battery Tester

To make a safe and complete check of the battery, see the Melroe Battery Manual (P/N 6566047). The battery manual has all the information needed for checking and servicing the battery.

Removal and Installation P–2212

Open the engine cover. Disconnect the negative (–) cable (Item 1) [A] first.

Disconnect the positive (+) cable (Item 2) [A].

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves 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.

P–2210

W–2065–1286

C Open the hydraulic tank access door [B].

Remove the four (4) bolts from the side cover [B]. Remove the side cover.

Remove the two (2) nuts (Item 1) [C] and remove the hold down clamp (Item 2) [C].

P–2219

Remove the battery from the compartment [D].

NOTE: Do Not touch any metal to the battery terminals. NOTE: When installing the battery, always make the last connection the negative (–) cable to the battery. NOTE: When installing a new battery, check the locations of the positive (+) and negative (–) post between the factory installed battery and the replacement battery. Make sure to install the cables to the correct battery posts. P–2211

–6–3–

320 (S/N 511720001 & Above) Excavator Service Manual

BATTERY BOX

Removal and Installation Remove the battery. (See Page 6–3.) Remove the four (4) bolts (Item 1) [A], the lockwashers and nuts.

Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

Remove the battery box.

P–2369

CAB ELECTRICAL (Cab Option) Remove the negative cable from the batter. (See Page 6–3.) Remove the four (4) screws from the cab overhead console [B].

P–2458

Lower the console down. Mark the wires for ease of assembly. Remove the wires from the wiper/washer switch and remove the switch [C]. Remove the wires from the fuse holder and remove the fuse holder [C].

P–2463

–6–4–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR

Checking the Alternator Output Use OEM–1428 MULTIMETER to check the alternator output. Start the engine. Set the multimeter to DC Volts and check the output as follows: Touch one probe to the battery lead on the alternator and the other probe to the body of the alternator [A]. The output reading should be 14.2 volts.

P–2371

(See Pages 6–7 thru 6–11 for additional testing and repair.)

Belt Adjustment Stop the engine. Open the engine cover. The belt should deflect about 5/8’’ (16 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 22 lbs. (98 N) force [B].

P–2197

If the tension is not correct, loosen the alternator mounting bolt and the adjustment bolt [C]. Move the alternator until the belt tension is correct. 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 pulley.

P–2200

Electrical Connection

If a Melroe Parts replacement alternator is to be installed on the excavator, check the electrical connections on the back of the alternator. Replacement alternators will have the purple wire installed on the EXC terminal. Remove the wire from the EXC terminal and install it on the L2 terminal. If this is not done the alternator indicator lamp will not function [D].

(Ind Light Terminal)

Ignition Switch Term PURPLE

RED

B–13775

–6–5–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR (Cont’d)

Removal and Installation Disconnect the negative (–) cable from the batter. (See Page 6–3.)

Disconnect the wire from the alternator (Item 1) [A].

Disconnect the alternator plug in harness (Item 2) [A] from the engine harness.

P–0866

Remove the adjustment bolt [B]. Remove the alternator belt. Remove the mounting bolt. Remove the alternator from the bracket.

P–2200

–6–6–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR (Cont’d)

Check the Alternator Output

REAR VIEW OF ALTERNATOR NEW 6661611

Test the New Style alternator as follows: a. Alternator Output Test b. Rectifier (Diode) Test c. Alternator Regulator Test Alternator Output Test

B–13775

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

1 Open the engine cover. Disconnect the negative (–) cable from the battery. Disconnect the red wire (Item 1) [B] (S terminal) from the alternator. Connect the wire to the negative (–) side of the ammeter. Connect the positive (+) side of the ammeter to the output terminal on the alternator (Item 2) [B] (B terminal). P–1360

Connect the negative (–) cable to the battery.

Make sure the shut–off control cable is raised (OFF) position [C]. Crank the engine for 30 seconds to discharge the battery. Push the shut–off control cable down (RUN), start the engine and run at maximum RPM.

Shut Off Knob OFF

Stop the engine. If the reading is low, remove the screws and pull the regulator cover away from the alternator. Rectifier (Diode) Test The alternator is removed from the excavator for clarity purposes [D].

P–2178

Disconnect the negative (–) cable from the battery.

Install the wires in the original location on the back of the alternator. Connect a jumper wire (Item 1) [D] to the alternator output (B) terminal and the regulator terminal.

Output B Terminal

Connect the battery negative (–) cable. Start the engine and run at maximum RPM.

If the reading is within 45–55 AMPs at Maximum RPM, replace the rectifier (diode) assembly or replace the alternator.

Regulator Terminal

Stop the engine. If the reading is low, do the Alternator Regulator Test.

P–1304

–6–7–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR (Cont’d)

Alternator Regulator Test

Negative Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

Positive

W–2017–0286

P–2212

Connect the positive (+) voltmeter lead to the positive (+) battery terminal [A].

Ground Stud

Connect the negative (–) voltmeter lead to the negative (–) battery terminal [A]. Start the engine and run at 1500–2000 RPM. The voltmeter should read between 13.9 – 14.7 volts. If the reading is low, stop the engine and disconnect the battery negative (–) cable.

Brush Terminal

The alternator is removed from the loader for clarity purposes [B].

1 P–1364

Remove the wires from the back of the alternator. Remove the regulator cover from the back of the alternator. Install the wires on the back of the alternator. Connect a jumper wire (Item 1) [B] from the brush terminal to the ground stud. Connect the negative (–) battery cable and start the engine. Run at 1500 RPM. Connect the voltmeter to the battery as described above. If the voltmeter reading is 14.5 or above replace the regulator. If the voltmeter reading is below 14.5, repair or replace the alternator.

–6–8–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR (Cont’d)

Disassembly and Assembly Disassemble the alternator as shown. Remove the regulator cover and regulator.

Remove the four bolts holding halves together.

1 5

Pry the halves apart (use a press if needed). 7

Use a soft jaw vise to hold rotor while removing pulley nut.

Remove front case half from the rotor using a plastic hammer or press. Unsolder the stator leads from the rectifier. Remove the stator.

12 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Nut Pulley Fan Bolt Case Half (Front) Bearing Rotor Stator Rectifier (Diode) Case Half (Rear)

14 11. 12. 13. 14. 15.

Condenser Assy. Strap Regulator Brush Cover

D–1760

Stator Continuity Test Use an ohmmeter to test the stator. Touch the probes to two of the bare stator wires [B]. Move one of the probes to the third wire. The readings should be the same. If there is no continuity, replace the stator.

P–1369

Stator Ground Test

Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [C]. There should be no continuity. Replace the stator if there is continuity.

P–1365

–6–9–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR (Cont’d)

Rotor Continuity Test Use an ohmmeter to test the rotor. Touch the probes to the slip rings [A]. The ohmmeter should read between 3.065–3.385 ohms. If there is no continuity replace the rotor.

P–1365

Rotor Ground Test Touch one probe to one of the slip rings and the other probe to the rotor shaft [B]. There should be no continuity. Replace the rotor if there is continuity.

P–1378

Rectifier Continuity (Diode) Test NOTE: In the diode test there should be continuity in one direction only. If the diode being tested shows no continuity or continuity in both directions, replace the rectifier assembly. Touch the probes to the terminals of each diode and read the meter [C]. Reverse the probes to check the diode in the other direction. There should be continuity in one direction only.

P–1373

Touch one probe to the diode and the other probe to the connected heatsink and read the meter [D].

Reverse the probes to check the diode in the other direction. There should be continuity in one direction only.

Touch on Bottom Heat Sink P–1370

–6–10–

320 (S/N 511720001 & Above) Excavator Service Manual

ALTERNATOR (Cont’d)

Disassembly and Assembly (New Style) Touch one probe to the diode and the other probe to the connected heatsink and read the meter [A]. Reverse the probes to check the diode in the other direction. There should be continuity in one direction only.

P–1390

Reverse the order of disassembly. Do not assemble the rear case half. Place the rotor in soft jaws when tightening the shaft nut. Tighten to 50 ft.–lbs. (68 Nm) torque [B]. Install the rear case half and the remaining parts.

P–1808

–6–11–

320 (S/N 511720001 & Above) Excavator Service Manual

STARTER

Removal and Installation Open the engine cover. Disconnect the negative (–) cable from the battery [A]. Mark the starter wires for ease of assembly.

Negative

Positive P–2212

Disconnect the wires from the starter [B].

P–2361

Remove the mounting bolts from the starter [C]. Remove the starter from the bell housing.

P–2359

–6–12–

320 (S/N 511720001 & Above) Excavator Service Manual

STARTER (Cont’d)

Disassembly and Assembly

Disassemble the stator as shown [A]. Cleaning and Inspection

6 3 8

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

1 7

9 10

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used. W–2019–1285

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Use a brush and air pressure to clean the drive, field coils, armature and starter housing. NOTE: Do not use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip. Check the following items:

Frame Washer Brush Holder Solenoid Lever Fields Armature Drive Housing Bushing

B–1192

Armature Broken or burned insulation. Loose connections at commutator. Open or grounded circuits. Worn shaft or bearings. Rough commutator. Field Coils Broken or burned insulation. Electrical continuity. Brush connections. Drive Gear Worn teeth. Tooth engagement (drive gear must engage ring gear by 1/2 the depth of the ring gear tooth). Brush Holders Broken springs. Broken insulation. Spring tension.

–6–13–

320 (S/N 511720001 & Above) Excavator Service Manual

HORN

320ServiceManual(S/N511720001&Above)#6722642–EletricalSystemSection

Removal and Installation Remove the floor panel. (See Page 3–1.) Remove the wire from the horn [A]. Remove the horn mounting bolt.

CD–12863

FUEL LEVEL SENDER

Removal and Installation Remove the screw (Item 1) [B] from the cover.

P–2338

Remove the four (4) bolts (Item 1) [C] from the left side cover. Remove the top cover and the side cover. Disconnect the fuel level sender harness from the fuel level sender.

1 1 1

1 P–2346

Install a socket onto the sender and remove the sender from the fuel reservoir [D].

CD–12864

–6–14–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE SERVICE Page Number CRANKSHAFT AND PISTONS Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34 Servicing the Connecting Rods & Pistons . . . . . . . . . . . . . . . . . . . . . . . . 7–37 CYLINDER HEAD Assembling the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Rocker Arm & Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . .

7–25 7–25 7–24 7–22 7–25 7–21 7–23

CYLINDER LINERS Checking the Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 ENGINE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 ENGINE FLYWHEEL Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20 Hydraulic Pump Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20 FUEL FILTER Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 FUEL INJECTOR NOZZLES Checking the Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 FUEL INJECTION PUMP Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 GLOW PLUGS Checking the Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 RADIATOR Checking the Radiator and Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16

ENGINE SERVICE

ENGINE SERVICE (Cont’d) Page Number SPARK ARRESTOR MUFFLER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15 TIMING GEAR, CAMSHAFT AND OIL PUMP Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–29 Servicing the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32 TIMING GEAR COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE CLEARANCE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 WATER PUMP Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40

–7–0–

320 (S/N 511720001 & Above) Excavator Service Manual

PROBLEM

CAUSE

Slow cranking speed. Engine will not start. Difficult to start. No power from engine.

1, 2, 3, 4 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29

Engine is mis–firing. Too much fuel consumption. Black exhaust. Blue/white exhaust.

8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28 10, 12, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 10, 12, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50

Low oil pressure. Engine knocking. Engine running rough.

4, 31, 32, 33, 34, 35, 37, 38, 39, 52 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53

Vibration. High oil pressure. Overheating. Too much crankcase pressure.

12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43 4, 33, 36 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51 22, 27, 29, 30, 40, 49

Poor compression. Start and stop

10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53 9, 10, 11

KEY TO CORRECT THE CAUSE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.

Battery capacity low. Bad electrical connections. Faulty starter motor. Incorrect grade of oil. Low cranking speed. Fuel tank empty. Faulty stop control operation. Plugged fuel line. Plugged fuel filter. Restriction in the air cleaner. Air in the fuel system. Faulty fuel injection pump. Faulty fuel injectors. Broken injection pump drive. Incorrect injection pump timing. Incorrect valve timing. Poor compression. Plugged fuel tank vent. Incorrect grade of fuel. Exhaust pipe restriction. Cylinder head gasket leaking. Overheating. Cold running. Incorrect tappet adjustment. Sticking valves. Incorrect high pressure fuel lines. Worn cylinder bores.

–7–1–

Worn valves and seat. Broken or worn piston rings. Worn valve stems or guides. Worn or damaged bearings. Not enough oil in the oil pan. Switch is defective. Oil pump worn. Relief valve is stuck open. Relief valve is stuck closed. Broken relief valve spring. Faulty suction pipe. Plugged oil filter. Piston seizure. Incorrect piston height. Faulty engine mounting. Incorrect alignment of flywheel. Faulty thermostat. Restriction in water jacket. Loose alternator belt. Plugged radiator. Plugged breather pipe. Plugged breather pipe. Damaged valve stem oil deflectors. Coolant level too low. Plugged oil pump pipe strainer. Broken valve spring.

320 (S/N 511720001 & Above) Excavator Service Manual

VALVE CLEARANCE

Adjustment

0.006’’–0.007’’ (0,15–0,18 mm)

Adjust the valve clearance with the engine stopped and cold. The correct valve clearance is 0.006–0.007 inch (0,15–0,18 mm) [A]. Make sure the piston is at T.D.C. when making the adjustment for the valves of the particular cylinder.

A–2730

Put the correct size feeler gauge between the rocker arm and valve stem. Turn the adjustment bolt until the clearance is correct [B].

B–5893

ENGINE COMPRESSION Checking The tools listed will be needed to do the following procedure: OEM–1074 – Engine Compression Kit The engine must be at operating temperature. Remove the fuel injector nozzles from the engine. (See Page 7–7). Install the correct compression adapter into the cylinder head [C].

B–12827

Connect the compression gauge [D].

Turn the engine with the starter (must turn at least 175 RPM). Run the test for each cylinder two times for 5–10 seconds. The compression must be a least 337 PSI (2234 kPa) with no more than 50 PSI (345 kPa) difference between the cylinders.

B–12828

–7–2–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL FILTER

Element See the Service Schedule page 1–1 for the correct service interval for the fuel filter. Use a filter wrench to remove the fuel filter [A]. Put some oil on the new filter gasket. Install the new filter element and hand tighten only. To remove water from the filter, open the drain valve (Item 1) [A] on the bottom of the filter element.

1 P–2217

Removing Air from the Fuel System After replacing the fuel filter or after running out of fuel, air must be removed from the fuel system.

Open the vent valve on the injection pump [B]. Open the bleed screw (Item 3) [D] on the top of the fuel filter housing. Squeeze the priming bulb to fill the filter with fuel [C]. When fuel, free of air bubbles emerges from the filter housing, close the bleed screw. Leave the vent screw on the injection pump open slightly [B]. Start the engine. When the engine runs smoothly, close the vent screw on the injection pump.

P–0727

NOTE: If the engine fails to start after the above procedure is performed, it will be necessary to bleed the injection lines, do the following: 1. Loosen the three (3) injector lines lock nuts, one turn. 2. While cranking the engine, as fuel emerges from the injector lines, slowly tighten the injector line lock nuts.

P–2184

Removal and Installation

(Filter Element and Filter Head) Remove the fuel lines (Item 1) [D] from the filter head.

Remove the bolts (Item 2) [D] from the filter head. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

2 1

P–2350

–7–3–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL INJECTION PUMP

Checking the Injection Pump The injection pump contains parts which have a very close tolerance and its operation has a direct effect on the performance of the engine.

Do not attempt to maintain or adjust unless you are trained and have the correct equipment.

B–5959

I–2028–0289

The tools listed will be needed to do the following procedure: MEL1237 – Adapter Fuel Line MEL1173–1 – Pressure Gauge To check the discharge pressure at the fuel injection pump, use the following procedure:

Disconnect one of the high pressure fuel lines at the pump [A]. Loosen the other end of the same high pressure line so it can be turned away from the fitting.

Connect the adapter fuel line (Item 1) [B].

B–8235

Connect the pressure gauge (Item 2) [B].

Rotate the flywheel by hand, to increase the pressure to 5689 PSI (39225 kPa) to 4978 PSI (34323 kPa). A new pump should require 60 seconds or more for the pressure to drop. The minimum allowable time is 30 seconds. Removal and Installation NOTE: The fuel injection pump should be serviced only by an OEM authorized service center. NOTE: To remove the fuel injection pump, either remove the engine from the machine (page 7–10) or remove the seat, seat mount the speed control lever mount (page 5–2 & 5–3). This will allow access through the front engine cover.

B–5960

Clean the area around the fuel injection pump. Remove the high pressure fuel lines. Disconnect the glow plug wires [C].

–7–4–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL INJECTION PUMP (Cont’d)

Removal and Installation (Cont’d) Disconnect the throttle linkage cable from the injection pump. Remove the bolts from the intake manifold. Remove the intake manifold [A].

B–6567

Disconnect the fuel inlet hose (Item 1) [B] and return hose (Item 2) [B].

B 2 1

B–5964

Remove the engine lift hook (Item 1) [C]. Remove the four nuts from the injection pump [C]. Installation: Tighten the nuts to 17–20 ft.–lbs. (23–27 Nm) torque.

B–5965

Align the pin (Item 1) [D] in the control rack with the slot in the engine block.

Remove the injection pump. Installation: When the injection pump is installed, make sure the pin (Item 1) [D] on the control rack is correctly installed on the fork lever. If the slot is not installed correctly, the engine will run over maximum speed and serious damage can result. NOTE: Make sure the same number shims are installed under the injection pump. The shims are used for engine timing.

1 B–5966

–7–5–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL INJECTION PUMP (Cont’d)

Timing the Injection Pump NOTE: The engine timing marks are located on the front pulley of the engine. Timing the fuel injection pump is done by changing the number of shims (Item 1) [A] between the injection pump and engine block.

Each shim will change the timing 1.5 degrees. The timing of the pump will be later when a shim is added, and earlier when a shim is removed. Use the following procedure to time the injection pump:

B–10007

1. Remove the number 1 cylinder high pressure line from the injection pump.

2. Install a short pipe in the number 1 outlet of the pump. Point the pipe up (vertical). 3. Push the speed control lever fully forward (Max. RPM). 4. Turn the engine over by hand, in a clockwise direction (viewed from the water pump end of the engine) until fuel flows out of the short pipe installed in step 2. 5. With fuel supply to the short pipe, rotate the engine by hand in a clockwise direction (viewed from the water pump end of the engine). Fuel must flow from the pipe as the mark F–1 on the crankshaft pulley and the pointer are in alignment [B].

CD–10226

6. The correct timing for the engine is 23–25 degrees B.T.D.C. Add or subtract shim(s) as needed to adjust the delivery time of the fuel injection pump. 7. Repeat Step 5 server times for correct timing mark alignment before adding or removing shim(s).

–7–6–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL INJECTOR NOZZLES

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention. W–2074–1285 B–5958

Some problems caused by faulty injector nozzles:

* The engine is hard to start or will not start. * Rough engine operation at idle. * The engine will not have full power. * The engine exhaust smoke is black, white or blue.

Removal and Installation

B–5969

Do not bend the high pressure fuel injection tubes when removing or installing them. I–2029–0289

The tool listed will be needed to do the following procedure: MEL1181 – Nozzle Socket Disconnect the high pressure fuel lines from the fuel injectors [A]. Disconnect the other end of the fuel lines from the injection pump. Remove the high pressure fuel lines. B–5970

Disconnect the return fuel hoses (Item 1) [B].

Remove the banjo fitting from the fuel injector [B]. Use the special socket and loosen the injector nozzle [C]. Installation: Tighten the injector nozzle to 22–36 ft.–lbs. (29–49 Nm) torque. Remove the injector nozzle from the cylinder head [D].

B–5971

–7–7–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL INJECTOR NOZZLES (Cont’d)

Checking the Injector Nozzle

Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.

I–2027–0284

1 B–4103

The tool listed will be needed to do the following procedure:

MEL10018 – Injector Nozzle Tester You can adjust the release pressure of the injector nozzle by adding or removing spacer(s) (Item 1) [A] from the top of the nozzle spring (Item 2) [A]. Each spacer is 0.004’’ (0,10 mm) thick and will change the release pressure by about 142 PSI (980 kPa). The release pressure should be 1990–2133 PSI (13721–14707 kPa). Connect the injector nozzle to the tester with the nozzle down [B].

A–2513

Operate the hand lever slowly and note the opening pressure. If the pressure is not correct, disassemble the injector nozzle and add or remove spacer(s) (Item 1) [A] as needed.

Assemble the nozzle and check the pressure again. Tighten the nozzle body (Item 3) [A] to 43–58 ft.–lbs. (59–79 Nm) torque.

Spring CORRECT

WRONG

Pressure Pin Holder Nozzle Body

NOTE: Do not over–tighten, or slow action of the valve will occur. Check for internal leakage. Operate the hand lever until the pressure is almost enough to open the injector valve.

Needle Valve

Record the pressure. Release the hand lever. Check the pressure drop for 10 seconds. If the pressure drop is more than 740 PSI (5102 kPa), the nozzle is damaged.

A–2621

Check that the spray pattern is correct [C]: * Fuel does not come out the side of the nozzle. * Drops of fuel are not present at the nozzle. * The nozzle has an even flow coming from the nozzle.

–7–8–

320 (S/N 511720001 & Above) Excavator Service Manual

GLOW PLUGS

Removal and Installation Remove the three (3) high pressure fuel lines from the injector nozzles and injection pump.

Do not bend the high pressure fuel injection tubes when removing or installing them. I–2029–0289

B–5960

Disconnect the glow plug wires [A].

Remove the intake manifold [B].

B–6567

Remove the glow plugs from the cylinder head [C].

B–5972

Checking the Glow Plug Connect an ohmmeter to the terminal end of the glow plug, touch the other lead from the ohmmeter to the heating end of the glow plug [D].

The reading must be approximately 1.5 OHMS. If the resistance is zero OHMS, the glow plug has a short circuit. If the resistance is infinite, the coil of the glow plug is broken.

B–11571

–7–9–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE

Removal and Installation Disconnect battery. (See Page 6–3.) Lower the attachments. Stop the engine. Drain the hydraulic tank. (See Page 3–23.) Remove the battery. (See Page 6–3.) Remove the battery box. (See Page 6–4.)

P–2377

Remove the seat mount. (See Page 5–2.) Remove the left hand side cover. (See Page 3–11.)

Remove the engine cover. (See Page 5–1.) Remove the left and right hand corner posts. (See Page 5–1.)

Remove the muffler. (See Page 7–16.) Drain the cooling system. Remove the three (3) bolts from the fan guard and remove the fan guard [A]. Remove the top radiator hose clamps (Item 1) [B] and remove the hose.

P–2379

Remove the lower radiator hose clamps and remove hose.

Mark the starter wires for ease of assembly. Remove the wires from the starter [C].

P–2361

Remove the bolt (Item 1) [D] and the nut from the engine ground strap.

D 1

P–2231

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320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d)

Loosen the air cleaner hose clamp (Item 1) [A] and remove the hose from the intake manifold. NOTE: Plug the intake manifold hole after removing the hose.

P–2364

Remove the two (2) air cleaner mounting bolts (Item 1) [B] and nuts. Remove the air cleaner and the air cleaner hose.

Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

P–2363

Remove the drain hose (Item 1) [C], elbow (Item 2) [C] and the straight connector (Item 3) [C] from the back of the hydraulic tank.

C 2

1 P–2388

Remove the three (3) nuts from the top radiator support [D].

Installation: Tighten the nuts to 14–18 ft.–lbs. (20–25 Nm) torque.

P–2380

–7–11–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d) Remove the speed control cable from the ball joint [A]. Loosen the speed control cable mounting nut and push the cable through the engine cover and into the engine compartment [A]. Remove the four (4) bolts from the left and right side of the control consoles and the speed control lever mount [A]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

P–2342

Remove the right hand console plate mounting screw (Item 1) [B].

P–2352

Tilt the cover up and loosen the shut off cable mounting nut (Item 1) [C]. Push the shut off cable through the engine cover and into the engine compartment.

P–2349

Mark the fuse and hourmeter wires for ease of assembly.

Remove the fuse and the hourmeter wires [D].

P–2389

–7–12–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation

Remove the four bolts (Item 1) [A] from the left and right side of the front engine cover.

Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque. NOTE: The photo shows the radiator removed, the radiator does not need to be removed to the remove the engine.

P–2392

Remove the two (2) bolts (Item 1) [B] from the front lip of the front engine cover.

Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque. Lift the front engine cover up and off of the upperstructure.

NOTE: The left and the right consoles and the speed control lever mount may need to be tilted forward slightly to allow for additional clearance to remove the engine cover. Mark the electrical wires going to sending units and to the alternator for ease of assembly. Remove the water temperature sender wire and the oil pressure sender wire [C].

P–2395

P–2393

Remove the alternator wire (Item 1) [D] and disconnect the alternator harness. NOTE: Make sure that harnesses are not cable tied to engine.

D 1

P–2398

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320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d) Remove the glow plug wire (Item 1) [A] and the fuel return hose.

P–2399

Remove the fuel supply hose (Item 1) [B].

Remove the fuel shut off cable (Item 2) [B] and the speed control cable (Item 3) [B] from the engine. NOTE: The fuel shut off cable and the speed control cable can be removed with the engine, but be careful not to catch and damage the cables while removing the engine.

P–2400

Remove the four (4) nuts (Item 1) [C] from the engine mounts, front and rear.

1 P–2397

Install a chain and a hoist to the engine lift eyes [D].

Lift the engine up until the engine mounts clear the rubber mounts, then slide the engine to the right until the fan blade clears the radiator shroud. Lift the engine out of the upperstructure.

P–2404

–7–14–

320 (S/N 511720001 & Above) Excavator Service Manual

SPARK ARRESTOR MUFFLER

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.

W–2011–1285

Stop the engine. Allow the muffler to cool.

P–2387

Remove the clean out plug on the bottom of the muffler [A]. Start the engine and run at full RPM for about 10 seconds to clean out the muffler.

Stop the engine and install the plug.

1 Removal and Installation Remove the two (2) nuts (Item 1) [B] from the muffler mounting bracket. Loosen the nut (Item 2) [B] on the engine lift bracket.

2 P–2385

Remove the muffler. NOTE: Plug the exhaust manifold hole after muffler removal.

–7–15–

320 (S/N 511720001 & Above) Excavator Service Manual

RADIATOR

Checking the Radiator and Radiator Cap

Do not remove radiator cap when the engine is hot. You can be seriously burned. W–2070–1285

NOTE: Allow the engine to cool before removing the radiator cap.

CD–10241

Remove the radiator cap and install it on the tester. Increase the pressure to 7 PSI (3.18 kg). The pressure should not drop more than 4.3 PSI (1.95 kg) in 10 seconds. Replace the radiator cap if pressure does not hold. Install the tester on the radiator as shown [B]. Increase the pressure to 7 PSI (3.18 kg) and check for leaks.

P–2362

Removal and Installation

Turn the upperstructure so that there is access to the area under the radiator. The radiator will be removed from the bottom side of the upperstructure.

1 NOTE: The oil cooler can be removed, see page 2–1, before radiator is removed or it can be removed with the radiator. Drain the hydraulic tank. (See Page 3–27.) Drain the coolant. Remove the floor boards. (See Page 3–1.)

P–2379

Remove the top radiator hose clamp (Item 1) [C] and remove the hose from the radiator.

Remove the bottom radiator hose clamp and remove the hose from the radiator. Remove the three (3) bolts from the fan guard [D]. Remove the fan guard.

P–2377

–7–16–

320 (S/N 511720001 & Above) Excavator Service Manual

RADIATOR (Cont’d)

Removal and Installation (Cont’d)

Remove the three (3) nuts (Item 1) [A] from the top radiator support bracket.

Remove the four (4) bolts (Item 2) [A] from the sides of the radiator shroud. Move the shroud over the fan blades and leave in this position.

2 P–2380

If the oil cooler has not been removed; Remove the tubeline (Item 1) [B] from the elbow (Item 2) [B]. Remove the two (2) hoses (Item 3) [B] from the tee (Item 4) [B].

Remove the tee (Item 4) [B] from the bottom of the oil cooler. NOTE: The elbow (Item 2) [B] can not be removed at this point.

Remove the tubeline (Item 1) [C] from the control valve.

P–2233

The tubeline will need to be repositioned under the frame so clearance will be available for radiator removal.

Remove the counterweight mounting bolt (Item 1) [D]. Installation: Tighten the bolt to 125–140 ft.–lbs. (170–190 Nm) torque.

Remove the two (2) bolts (Item 2) [D] from the lower mount. Installation: Tighten the bolts to 29–32 ft.–lbs. (40–50 Nm) torque.

P–2375

2 1

I–2003–0284 P–2378

–7–17–

320 (S/N 511720001 & Above) Excavator Service Manual

RADIATOR (Cont’d)

Removal and Installation (Cont’d) With a second person holding the radiator up, remove the nut (Item 1) [A] and bolt from the center of the lower radiator mount.

P–2381

Lower the radiator downwards. Remove the two (2) bolts (Item 1) [B] and nuts that mount the radiator to the lower radiator mount. Installation: Tighten the bolts to 14–18 ft.–lbs. (20–35 Nm) torque. Remove the lower radiator mount and the rubber radiator mounts.

Lower the radiator down and remove from the upperstructure.

NOTE: The radiator shroud can now be removed from the fan blades. Be sure to position the radiator shroud over the fan blades before the radiator is installed.

P–2383

–7–18–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE FLYWHEEL

Removal and Installation NOTE: The flywheel can be removed with the engine installed in the machine. The following photo’s show the engine removed from the machine for photo clarity. Remove the hydraulic pump. (See Page 2–8.) Support the rear of the engine to remove the flywheel housing. Remove the flywheel housing bolts [A].

CD–10251

Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

Remove the flywheel housing. NOTE: Check that the alignment dowels are installed in the flywheel housing for assembly. Remove the bolts from the hydraulic pump coupler [B]. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Remove the hydraulic pump coupler.

CD–10252

–7–19–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE FLYWHEEL (Cont’d)

Hydraulic Pump Coupler Put the pump coupler in a vise and remove the coupler bolts [A]. Installation: Tighten the bolts evenly until the rubber contacts the coupling, then tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. NOTE: The coupler splined bushing must extend from the coupler away from the flywheel as shown [A]. Remove the bolts from the flywheel [B].

CD–10253

Installation: Tighten the bolts to 40–43 ft.–lbs. (54–59 Nm) torque.

Remove the flywheel. Flywheel Ring Gear

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

CD–10254

When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used. W–2019–1285

The ring gear on the flywheel is an interference fit. Heat the ring gear enough to expand it and hit it with a hammer, evenly to remove it. Clean the outer surface of the flywheel to give a smooth fit. Clean the new ring gear and heat it to a temperature of 450–500°F (232–260°C). Fit the ring gear over the flywheel. Make sure the gear is seated correctly.

–7–20–

320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER HEAD

Removal of the Cylinder Head Drain the cooling system. Remove the nuts from the valve cover. Remove the valve cover and gasket [A].

B–5094

Disconnect and remove the high pressure fuel lines [B].

Remove the fuel injector nozzles. (See Page 7–8.)

B–5882

Remove the nuts from the rocker arm supports. Remove the rocker arm assembly [C].

B–5093

Remove the push rods [D].

Mark the push rods so they will be returned to their original position.

B–5881

–7–21–

320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

Removal of the Cylinder Head (Cont’d) Remove the cylinder head from the engine block [A].

B–5101

Remove the head gasket and O–ring from the engine block [B]. NOTE: Some engines may use a shim and some do not. If a shim is present it must be used during reassembly. The shim (if used) must be installed between the cylinder head and gasket.

B–5886

Disassembly of the Cylinder Head

The tool listed will be needed to do the following procedure: MEL10121 – Valve Tool Use a valve spring compression tool to remove the valves [C].

B–5889

Remove the valve cap (Item 1) [D] and valve spring collet (Item 2) [D].

5 2

Remove the valve spring retainer (Item 3) [D] and spring (Item 4) [D].

Remove the seal (Item 5) [D] and the valve (Item 6) [D].

Seal

Collets

Cap

Valve Spring Retainer B–4122

–7–22–

320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

Disassembly of the Cylinder Head (Cont’d) Remove the thermostat housing and thermostat [A].

B–3643

Servicing the Cylinder Head and Valves

Clean the surface of the cylinder head.

Put a straight edge (Item 1) [B] on the cylinder head. NOTE: Do not put the straight edge across the combustion chambers. Put a feeler gauge (Item 2) [B] between the straight edge and the surface of the cylinder head.

The maximum distortion of the head surface ± 0.002’’ (± 0.0512 mm) in 4’’ (102 mm) of the length of the cylinder head surface. If the measurement is more than the specifications, the cylinder head must be replaced. If the measurement is more than the specifications, the cylinder head must be replaced.

A–2735

Clean the valve seat and combustion chamber. Measure the width of the valve seat [C].

B–3632

The correct width of the seat is 0.083’’ (21 mm). The correct angle of the valve and seat is 45 degrees [D].

Valve Contacting Width

Grind the valve seats as follows: 1. Use a 45° cutter to grind the surface of the valve seat. 2. Use a 15° cutter to grind the top surface of the valve seat. 3. Use a 65 or 70° cutter to grind the bottom surface of the valve seat to finish the valve seat to a 0.083’’ (2,1 mm) width. 4. Grind the valve surface to 45°.

–7–23–

Corrected Surface of Valve Seat

Uncorrected Surface of Valve Seat A – 45° cutter B – 15° cutter C – 65° or 70° cutter

A–2729

320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

Servicing the Cylinder Head and Valves (Cont’d) Install the valve in the seat and check the depth [A]. The specifications for the depth of the valves is 0.043–0.051’’ (1,09–1,30 mm). If the measurement is more than specifications, add the correct thickness of washer under the valve spring to keep the correct spring tension.

B–3634

Clean the valve guide. Install the valve in the cylinder head. Install a dial indicator [B]. Measure the clearance of the valve guide and the valve. The measurement must be 0.0014–0.0026’’ (0,04–0,07 mm). Replace the valve guide and valves as needed. Make sure to ream the inside diameter of the new guide to the correct dimension of 0.076–0.077’’ (7,01–7,04 mm).

B–3698

Checking Valve Springs Measure the valve spring. The length of the spring must be 1.382–1.402’’ (35,1–35,6 mm). Check the valve spring with a square to make sure it is straight [C].

B–3680

Put the valve spring in a tester [D].

Push down on the spring 1.22’’ (31 mm), the compression load must be 16.5 lbs. (7,5 kg.) Replace the valve spring if it does not meet these specifications.

A–2759

–7–24–

320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

320ServiceManual(S/N511720001&Above)#6722642–EngineServiceSectionPart1of2

Checking Rocker Arm and Shaft Measure the inside diameter of the rocker arm bushing and the shaft diameter [A]. The inside diameter of the rocker arm bushing is 0.433–0.435’’ (11,0–11,05 mm). If the measurements are not within specification, replace the parts. Assembling the Cylinder Head Install the valves. Put oil on the valve seal and install the seal on the valve stem. Install the valve spring and retainer. Install the spring collet and valve cap.

B–3697

Install the thermostat. Install the thermostat housing and a new gasket. Installing the Cylinder Head Install the O–ring in the cylinder block [B].

B–5890

Install the new head gasket [C]. Install the shim (if present during disassembly). The shim goes between the cylinder head and gasket. NOTE: Use the shim over again or replace it with a shim of the same thickness.

B–5886

Install the cylinder head. Put oil on the cylinder head bolts.

Tighten the bolts and nuts to 29–33 ft.–lbs. (40–45 Nm) torque. Use the tighten sequence as shown in figure [D].

A–2773

–7–25–

320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

Installing the Cylinder Head (Cont’d) Lower the piston to be measured for the clearance. Put a piece of solder in the injector port [A]. Make sure the solder does not touch the valve. Turn the engine crankshaft (manually) until the piston goes over T.D.C. Remove the solder and measure it. The thickness must be 0.04–0.031’’ (0,6–0,8 mm). If the measurement is not within this specification, remove the cylinder head. Install the correct shim between the cylinder head and gasket.

B–4068

Install the cylinder head. Tighten the bolts and nuts to 19–33 ft.–lbs. (40–45 Nm) torque. Use the tightening sequence on page 7–27, figure [D].

Install the push rods [B].

B–5881

Install the rocker arms [C]. Install the injector nozzles. (See Page 7–8.) Install the high pressure fuel lines. Adjust the valve clearance. (See Page 7–2.)

B–5093

Install the valve cover with a new gasket [D].

Connect the radiator hose. Add coolant to the cooling system. NOTE: Make sure to tighten the cylinder head bolts and nuts to the correct torque after the engine has been operated for 30 minutes. Readjust the valve clearance.

B–5094

–7–26–

320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR COVER

Removal and Installation NOTE: It may be easier to remove and install the timing gear cover with the engine removed from the machine. Remove the fuel injection pump. (See Page 7–5.) Remove the side plate from the governor housing. Disconnect the governor spring from the governor fork [A].

B–3676

Remove the plate for the speed control and governor spring [B].

B–3647

Remove the start spring from the gear case [C].

B–3678

Straighten the washer on the crankshaft pulley. Remove the nut and washer.

Installation: Tighten the nut to 101–116 ft.–lbs. (137–157 Nm) torque. Use a puller and remove the pulley [D]. Remove the crankshaft key.

B–5896

–7–27–

320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR COVER (Cont’d)

Removal and Installation (Cont’d) Remove the bolts from the gearcase. Installation: Tighten the bolts to 13–15 ft.–lbs. (18–21 Nm) torque. Remove the gear case and O–rings [A].

B–5895

Installation: Install new crankshaft seal. Install the three O–rings. Put non–drying adhesive on the edge of the gearcase cover [B].

Oil Seal B–3617

–7–28–

320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP

Removal and Installation

3 2

Remove the cylinder head. (See Page 7–21.)

Remove the tappets. Remove the timing gearcase cover. (See Page 7–27.) Remove the crankshaft collar (Item 1) [A], O–ring (Item 2) [A] and oil slinger (Item 3) [A].

B–3637

Remove the snap ring and washer from the idler gear [B].

B–5918

Remove the idler gear (Item 1) [C]. Remove the idler gear collar from the shaft [C].

B–3699

Align the holes in the camshaft gear with the stop plate bolts.

Remove the bolts from the camshaft stop plate [D]. Installation: Tighten the bolts to 14–15 ft.–lbs. (18–21 Nm) torque.

B–5930

–7–29–

320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

Removal and Installation (Cont’d) Remove the camshaft [A].

B–3655

Remove the two bolts that hold the fork lever on the fuel camshaft. Installation: Tighten the fork lever bolts to 60–72 in.–lbs. (6,8–8,1 Nm) torque. Remove the fork lever [B].

B–5919

Remove the stop (Item 1) [C] from the fuel camshaft.

Remove the fuel camshaft [C].

B–5922

Installation: Make sure the timing marks on the gears are aligned when installing the gears [D].

Gear backlash is 0.0017–0.0045’’ (0,043–0,114 mm). The limit permitted is 0.0079’’ (0,2 mm).

Injection Pump Gear

Camshaft Gear

Idler Gear Crankshaft Gear

B–5927

–7–30–

320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

Removal and Installation (Cont’d) Remove the crankshaft gear with a puller [A]. Remove the crankshaft key.

B–3686

Oil Pump Service Straighten the washer on the gear of the oil pump. Remove the bolt from the oil pump gear. Installation: Tighten the bolt to 60–72 in–lbs. (6,8–8,1 Nm) torque. Remove the oil pump gear [B].

B–5923

Remove the oil pump bolts and oil pump [C]. Installation: Tighten the oil pump bolts to 60–72 in.–lbs. (6,8–8,1 Nm) torque.

B–5925

Check the clearance between the inner and outer rotor [D].

The clearance for the inner rotor is 0.004–0.006’’ (0,10–0,15 mm). The wear limit is 0.008’’ (0,20 mm).

B–3616

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320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

Oil Pump Service (Cont’d) Check the clearance between the outer rotor and the body of the oil pump [A]. The clearance for the outer rotor is 0.004–0.008’’ (0,10–0,20 mm). At rated engine speed, the normal oil pressure is 28–64 PSI (193–441 kPa). It must not be lower than 28 PSI (196 kPa).

A–2732

Servicing the Camshaft Measure the camshaft bearing in the engine block [B]. The specification is 1.299–1.300’’ (32,99–33,02 mm). The wear limit is 0.002–0.0036’’ (0,051–0,091 mm).

B–3620

Measure the camshaft journal [C]. The specification is 1.296–1.297’’ (32,91–32,94 mm). If the measurements are not within limits, replace the parts as needed.

B–2761

Put the camshaft in V–blocks. Install a dial indicator on the journals [D].

Turn the camshaft slowly. The wear limit is 0.002’’ (0,05 mm). If the camshaft measurements are not within the specifications, replace the part as needed.

A–2760

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320 (S/N 511720001 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d) Servicing the Camshaft (Cont’d)

The specification is 1.058’’ (26,87 mm). The wear limit it 1.056’’ (26,82 mm).

B–5001

Installation: After the crankshaft is installed, check the clearance for the camshaft gear. Mount a dial indicator [B].

Hold one gear while turning the other gear. The specification is 0.0017–0.0045’’ (0,43–0,114 mm). The wear limit is 0.0079’’ (0,2 mm).

B–3672

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320 (S/N 511720001 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS

Removal and Installation The tools listed will be needed to do the following procedure: MEL1063 – Ring Compressor ME1064 – Piston Ring Expander Remove the cylinder head. (See Page 7–21.) Remove the gear case cover. (See Page 7–27.) Remove the timing gears. (See Page 7–29.)

B–5924

Remove the flywheel. Remove the oil pan [A].

Remove the oil pump tube and screen [B]. Do not change the O–ring on the tube. Straighten the washer on the connecting rod bolts. Remove the connecting rod nuts and bolts.

B–5920

Remove the cap and bearing from the connecting rod [C]. NOTE: Make sure the marks on the connecting rod and bearing cap are in aligned when installing the bearing cap [C]. Installation: Put oil on the bolts and tighten to 26–30 ft.–lbs. (35–41 Nm) torque.

A–2731

B–3688

Remove the piston and connecting rod assembly from the engine block [D]. NOTE: Make sure the pistons are marked so they will be returned to the same cylinder bore.

B–3625

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320 (S/N 511720001 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

Removal and Installation (Cont’d) Straighten the washer on the bolts that hold the main bearings in position. Remove the main bearing bolts from the engine block [A]. Installation: Tighten the bolts to 40–50 ft.–lbs. (64–68 Nm) torque.

B–3644

Straighten the washer on the bolts that hold the rear cover in position. Remove the bolts.

Install two bolts in the rear cover and pull the cover out [B]. Installation: Install a new seal in the rear cover. Tighten the bolts to 22–25 ft.–lbs. (29–34 Nm) torque.

B–3648

Installation: Check the crankshaft end play with a dial indicator [C]. The normal end play is 0.006–0.012’’ (0,15–0,30 mm). Replace the thrust bearing if the end play exceeds 0.020’’ (0,5 mm).

B–10072

Remove the crankshaft from the rear of the engine block [D]. NOTE: Do not damage the crankshaft removing it from the engine block.

when

B–4126

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320 (S/N 511720001 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

Crankshaft Service Straighten the washers on the main bearing bolts. Remove the bolts from the bearing cap halves [A]. Remove the halves of the main bearings. NOTE: When installing the bearing cap halves, make sure to position the markings on the bearing caps toward the flywheel. Thrust washers must be installed with oil grooves facing outward.

B–4092

Put the crankshaft on V–blocks. Put a dial indicator on the center journal [B]. Turn the crankshaft slowly. The specifications is 0.008’’ (0,02 mm). The wear limit is 0.003’’ (0,08 mm).

A–2763

Check the inside diameter of the crankshaft bearing in the engine block [C].

The specification is 1.732–1.734’’ (43,88–44,04 mm). The wear limit is 0.008’’ (0,20 mm).

B–3631

Check the outside diameter of the #1 crankshaft journal [D]. The specification is 1.730–1.7303’’ (43,94–43,95 mm). The wear limit is 0.008’’ (0,20 mm).

B–3618

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320 (S/N 511720001 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

Servicing the Connecting Rods and Pistons Remove the piston rings (Item 1) [A] and the piston pin (Item 2) [A].

B–3621

Installation: Position the top ring so the gap is not lined up with the piston pin. Position the other rings so there is a gap every 90° [B]. Use a ring compressor to install the pistons in the engine block with the marks away from the camshaft.

Alignment Marks B–3614

Put the piston ring on the bottom of the cylinder bore [C]. Check the clearance of the ring gap. The specifications are:

Top & 2nd Ring . . . . . . 0.010–0.0158’’ (0,25–0,40 mm) Oil Ring . . . . . . . . . . . . . 0.008–0.0158’’ (0,20–0,40 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . 0.05’’ (1,27 mm)

B–3622

Measure the piston pin hole [D].

The specifications are 0.787–0.788’’ (19,98–20,02 mm). The wear limit is 0.0789’’ (20,04 mm).

A–2733

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320 (S/N 511720001 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

Servicing the Connecting Rods and Pistons (Cont’d) Measure the piston pin (Item 1) [A] and the connecting rod bushing (Item 2) [A]. The specifications are 0.788–0.789’’ (20,03–20,04 mm). Clearance between piston pin and bushing is 0.0006–0.0015’’ (0,015–0,04 mm). The wear limit is 0.006’’ (0,15 mm).

NOTE: Replacement bushing specifications are .0006–.0026’’ (0,015–0,066 mm).

1 B–3633

Install the connecting rod on the tool for checking connecting rod alignment [B].

Check the clearance in the piston pin area. The specification is 0.0008’’ (0,020 mm). The wear limit is 0.002’’ (0,05 mm). NOTE: Be sure the bushing diameter of the connecting rod is within specifications.

B–4067

Check the connecting rod bearings [C].

The specifications are 1.457–1.459’’ (37,00–37,06 mm). The wear limit is 0.008’’ (0,20 mm).

120°

A–2727

Check the connecting rod journals [D].

The specifications are 1.455–1.456’’ (36,96–36,98 mm). The wear limit is 0.008’’ (0,20 mm).

If the connecting rod journals are not within specifications, grind the journals as follows [D]:

2 1. Crankshaft corner radius must be 0.138’’ R ± 0.008’’ (3,5 mmR ± 0,20 mm). 2. The oil hole must be chamfered to 0.039–0.059’’R (0,99–1,5 mmR).

1 A–2716

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320 (S/N 511720001 & Above) Excavator Service Manual

CYLINDER LINERS

Checking the Cylinder Liners The tools listed will be needed to do the following procedure: MEL1060 – Ridge Reamer MEL1180 – Dry Liner Puller Check the inside diameter of the cylinder line [A].

B–10073

To find the maximum wear check the inside diameter in three different locations [B].

The specifications are 2.677–2.678’’ (67,99–68,02 mm). The wear limit is +0.006’’ (+0,15 mm). When the cylinder liner has more wear than specifications, bore and hone the cylinder to 2.697–2.698’’ (68,5–68,53 mm). NOTE: Make sure you use the correct oversize pistons and rings. If the cylinder liner is not within the specifications, replace the cylinder liner. These are dry cylinder liners. Cylinder Liner Installation Clean and rub oil on the bores of the engine block. Clean and put oil on the outside of the cylinder liners. Install the cylinder liners into the engine block with the chamfered end down. The top of the liner must be even with the top of the engine block machined surface. After installation, bore and/or hone the cylinder liner to 2.677–2.678’’ (67,99–68,02 mm).

A–2717

–7–39–

320 (S/N 511720001 & Above) Excavator Service Manual

WATER PUMP

320ServiceManual(S/N511720001&Above)#6722642–EngineServiceSectionPart2of2

Removal and Installation Drain the cooling system. Remove the radiator. (See Page 7–17.) Remove the alternator belt. Remove the fan. Remove the water pump bolts. Remove the water pump [A].

B–5926

Installation: Always use a new gasket when installing the water pump.

1. Water Pump Impeller 2. Seals 3. Water Pump Body 4. Bearing

Disassembly and Assembly Put the water pump in a vise. Remove the pulley. Press the shaft out of the impeller side of the water pump [B].

(4)

Remove the seal.

(2) (3)

(1)

Install a new seal when assembling the water pump. B–5929

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320 (S/N 511720001 & Above) Excavator Service Manual

SPECIFICATIONS Page Number BUCKET SPECIFICATIONS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 ENGINE SPECIFICATIONS Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re–Grinding the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–5 8–5 8–5 8–4 8–4 8–7 8–4 8–4 8–6 8–5 8–5 8–8 8–4 8–6 8–4 8–4

FUEL, COOLANT AND LUBRICANTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 HYDRAULIC EXCAVATOR SPECIFICATIONS Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–3 8–3 8–2 8–3 8–3 8–2 8–2 8–3 8–3 8–2 8–1 8–2 8–3 8–3 8–3

OIL SPECIFICATIONS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9

SPECIFICATIONS

–8–0–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS

Machine Dimensions

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

88.34 (2243.9)

48.18 (1223.9)

9.8 (250) 28.7 (730)

17.5 (443)

38.6 (980)

1 (26)

MC–1862

10.3 (262)

43.8 (1112) 36 (914)

109.5 (2781.3) 58.2 (1480) 74 (1883)

151.59 (3850) 23.6 (600)

MC–1859

20.1 (510)

54.2 (1377)

153.2 (3892) 149.5 (3799) 67.8 (1722)

194°

107.9 (2542)

135.43 (3440)

96.55 (2452)

MC–1888

7.3 (185.5)

4.88 (124)

61.3 (1557) 86.57 (2199)

90 (2294)

MC–1884

–8–1–

320 (S/N 511720001 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS Lifting Capacity

320

SPECIFICATIONS WEIGHTS Operating Weight (Includes 20” Bucket)

ROPS Canopy – 3180 Lbs. (1442 kg) ROPS Cab – 3440 Lbs. (1560 kg)

Travel Speed Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excavator . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 MPH (1,83 km/hr.) 1.1 MPH (1,83 km/hr.) Two Hand or Foot Levers Two pilot–operated joysticks control boom, bucket, dipperstick and cab swing A foot pedal controls boom swing and the blade is controlled by a separate lever.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horsepower . . . . . . . . . . . . . . . . . . . . . . . Maximum Governed RPM (Full Load) . . . . . . . . . . . . . . . . . . . . . . Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of Cylinders . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . .

Kubota D750–BW–Clark 2 Diesel 13.5 HP (10,1 Kw) @ 2500 RPM 2500 RPM 31 ft.–lbs. (42Nm) @ 1800 RPM Three 46.5 cu.–in. (0,76L) 2.68” x 2.76” (68mm x 70mm) Forced Cartridge Type – Full Flow Dry replaceable paper cartridge

ELECTRICAL Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Volt, Reduction Drive 12 Volt, 50 Amps. 12 Volt, 425 Cold Crank Amps –8–2–

320 (S/N 511720001 & Above) Excavator Service Manual

SPECIFICATIONS (Cont’d) HYDRAULIC SYSTEM Number of Pumps . . . . . . . . . . . . . . . . . . Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . System Relief Setting Implement Circuits . . . . . . . . . . . . . . . . Travel Circuits . . . . . . . . . . . . . . . . . . . . Swing Circuits . . . . . . . . . . . . . . . . . . . . Auxiliary Flow . . . . . . . . . . . . . . . . . . . . . . Control Valve(s) . . . . . . . . . . . . . . . . . . . Drive Motors . . . . . . . . . . . . . . . . . . . . . . . Swing Motor . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Function Time Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Swing . . . . . . . . . . . . . . . . . . . . . . Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING SYSTEM Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CYLINDERS Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Swing . . . . . . . . . . . . . . . . . . . . . . . Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SYSTEM Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . Type of Reduction . . . . . . . . . . . . . . . . . . Max. Drawbar Pull . . . . . . . . . . . . . . . . . Gradability Traveling Down or Backing Up Slopes Traveling on Side Slopes . . . . . . . . . . Traveling Up Slopes Forward . . . . . . BRAKES Travel Service Parking Swing Service Holding

320 Three Triple Section Gear Pump 3 x 4 GPM (15.2 L/min.) 2400 PSI (16664 kPa) 2400 PSI (16664 kPa) 1275 PSI (8793 kPa) 8.0 GPM (30 L/min.) 6 Spool & 3 Spool Two Axial Piston Motors Orbit Motor Curl 3.86 Sec. Retract 4.70 Sec. Raise 3.90 Sec. Left 4.10 Sec. Raise 2.67 Sec.

Dump,2.37 Sec. Extend 3.20 Sec. Lower 2.60 Sec. Right 2.90 Sec. Lower 3.11 Sec.

Motor Connected to a Pinion Single Row Shear Type Ball Bearings with an Internal Gear Built into Swing Circle 10 RPM Bore Dia. in. (mm) 2.38 (60) 2.38 (60) 2.25 (57) 2.38 (60) 2.38 (60)

Rod Dia. in. (mm) 1.38 (35) 1.38 (35) 1.5 (38) 1.38 (35) 1.38 (35)

Each Track is Independently Driven by an Axial Piston Motor Planetary Gear Reduction 3514 (1594 kg) 25_ 15_ 15_

.......................... ..........................

Hydraulic Lock on Motor Hydraulic Lock on Motor

.......................... ..........................

Hydraulic Lock on Motor Pin Lock

UNDERCARRIAGE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke in. (mm) 13.46 (342) 16.57 (421) 15.16 (385) 13.62 (246) 2.75 (70)

Crawler–Tractor Design Undercarriage. Sealed Track Rollers with Reinforced Box–Section Track Roller Frame. Grease Type Track Adjusters with Shock Absorbing Recoil Springs.

STD TRACK SHOES Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. of Shoes . . . . . . . . . . . . . . . . . . . . . . . No of Track Rollers . . . . . . . . . . . . . . . . . Ground Pressure . . . . . . . . . . . . . . . . . . .

Rubber 9.84” (250 mm) Single Assembly Three Each Side 3.38 PSI (23,3 kPa)

CAPACITIES Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil & Filter . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . .

6.5 gal. (24.6 L) 1.5 gal. (5,7 L) 4.5 qts. (4,3 L) 3.65 gal. (13,8 L)

DIGGING FORCE Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1892 lbs. (858 kg) 3272 lbs (1484 kg) –8–3–

320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Engine Compression (Operating Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 PSI (3103 kPa) @ 200–300 RPM Fuel Injector Nozzles Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2133 PSI (13719–14705 kPa) Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 1848 PSI (12740 kPa) Fuel Injection Pump Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . . 8 Seconds: Initial pressure drop from 1237–1031 PSI (9805–7109 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 seconds or less Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . . 10 Seconds: Initial pressure drop from 1422–71 PSI (9805–490 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seconds or Less Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23–25 degrees B.T.D.C. Cylinder Head Cylinder Distortion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) in 3.9 (100) of the length of the cylinder head Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0413–0.0453’’ (1,05–1,15 mm) Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02–0.03 (0,51–0,8 Valves Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (2,1) O.D. of Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.274–0.275 (6,96–6,99) I.D. of Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.276–0.277 (7,01–7,04) Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0014–0.0026 (0,035–0,065) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1) Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035–0.043 (0,09–1,1) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,3) Valve Clearance (Cold) (Intake & Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–0.007 (0,15–0,18) Valve Springs Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.382–1.402 (35,1–35,6) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37 (34,8) Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.220 (31) Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 lbs. (7,5 kg) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 lbs. (6,4 N) Limit Permitted for Spring being Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,3) Rocker Arms O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5501–0.5506 (13,97–13,99) I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5512–0.5528 (14,0–14,04) Clearance Between Rocker Arm & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.0024 (0,02–0,06) Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)

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320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Camshaft O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2966–1.2972 (32,93–32,95) I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2992–1.3002 (32,99–33,025) Clearance between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0017–0.0045 (0,042–0,115) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0583 (22,88) Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002–0.003 (0,051–0,08) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Cylinders I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.677–2.678 (67,99–68,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0059 (+0,15) Piston Rings Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.016 (0,25–0,41) Ring Gap, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078–0.0158 (0,20–0,40) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.049 (1,24) Side Clearance of Ring Groove: Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 (0,0) Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.004 (0,08–0,10) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.002 (0,02–0,051) Oversize of Piston & Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,51) Pistons I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.788 (19,98–20,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.789 (20,04) O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.788 (19,98–20,04) I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.788–0.790 (20,02–20,07) Clearance between Piston Pin & Bushing (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015 (0,015–0,04) (Service Replacement Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–.0026 (0,015–0,066) Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Crankshaft Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08) O.D. of Crankshaft Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7297–1.7303 (43,93–43,95) I.D. of Crankshaft Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7317–1.7339 (43,984–44,040) Clearance between Crankshaft Journals & Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0042 (0,03–0,106) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Clearance between Crankshaft Journals & Bearing No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0036 (0,034–0,092) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,2) O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4551–1.4557 (36,96–36,98) I.D. of Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4568–1.4587 (37,003–37,051) Clearance between Connecting Rod Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011–0.0036 (0,028–0,091) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–0.012 (0,15–0,30) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)

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320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Oil Pump Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–64 PSI (193–441 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PSI (193 kPa) Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PSI (69 kPa) Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004–0.006 (0,10–0,15) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Clearance Between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.006 (0,08–0,015) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25) End Clearance between Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.0205(0,08–0,13) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Thermostat Opening Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177–182°F (81–84°C) Full Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203°F (95°C) Distance of Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 (8)

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320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (KUBOTA) (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Engine Torque Ft.–Lbs.

*Cylinder Head Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29–33 *Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–17 *Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–25 *Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–43 *Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 *Rocker Arm Bracket Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 *Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–36 Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–36 Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15 Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19 Crankshaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101–116 Injection Pump Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13

39–44 20–24 29–34 54–59 27–30 17–21 9–11 20–25 39–49 29–49 15–20 13–26 137–157 14–18

*Lightly Oil Threads

PUNCHED NUMBER None

BOLT MATERIAL GRADE Standard Bolts

SS41, S20C

Special Bolts

S43C, 248C (Refined)

Special Bolts

SCM3, SCR3 (Refined)

BOLT TORQUES MATERIAL GRADE

STANDARD BOLT

NOMINAL DIAMETER

SS42, S20C

S43C, S48C (Refined)

SCR3, SCM3 (Refined)

6–7 ft.–lbs. (8–9 Nm)

7–8 ft.–lbs. (9–11 Nm)

9–11 ft.–lbs. (12–15 Nm)

13–15 ft.–lbs. (18–20 Nm)

17–20 ft.–lbs. (23–27 Nm)

22–25 ft.–lbs. (30–34 Nm)

M10

29–33 ft.–lbs. (39–45 Nm)

35–41 ft.–lbs. (47–56 Nm)

45–52 ft.–lbs. (61–71 Nm)

M12

46–54 ft.–lbs. (62–73 Nm)

57–67 ft.–lbs. (77–91 Nm)

76–87 ft.–lbs. (103–118 Nm)

M14

80–93 ft.–lbs. (108–126 Nm)

91–109 ft.–lbs. (123–148 Nm)

123–145 ft.–lbs. (167–197 Nm)

M16

123–141 ft.–lbs. (167–191 Nm)

145–166 ft.–lbs. (197–225 Nm)

192–224 ft.–lbs. (260–304 Nm)

M18

181–210 ft.–lbs. (245–285 ft.–lbs.

203–235 ft.–lbs. (275–319 Nm)

253–297 ft.–lbs. (343–403 Nm)

M20

246–189 ft.–lbs. (334–392 Nm)

271–318 ft.–lbs. (367–431 Nm)

362–420 ft.–lbs. (491–578 Nm)

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320 (S/N 511720001 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (KUBOTA) (Cont’d) Crankshaft Re–Grind Data If the standard size bearing cannot be used due to excessive wear of the crankpin and crankshaft journals, use undersize or oversize bearings.

D 3

C 2 2

B 1

1 B–5928

REF.

SIZE

CODE NUMBER

DESCRIPTION

DIMENSION

MARK

0.008 in. (0,2 mm) U/S

15261–2391–1

Crankshaft Bearing #1

1.7218–17224 in. (43,743–43,750 mm)

020US

0.016 in. (0,4 mm) U/S

15261–2392–1

Crankshaft Bearing #1

1.7139–1.7146 in. (43,534–43,550 mm)

040US

0.008 in. (0,2 mm) U/S

15261–2393–1

Crankshaft Bearing #1

1.7218–1.7224 in. (43,734–43,750 mm)

020US

0.016 in. (0,4 mm) U/S

15261–2394–1

Crankshaft Bearing #1

1.7139–1.7146 in. (43,534–43,550 mm)

040US

0.008 in. (0,2 mm) U/S

15531–2297–1

Crankpin Bearing

1.4472–1.4478 in. (36,759–36,775 mm)

020US

0.016 in. (0,4 mm) U/S

15531–2298–1

Crankpin Bearing

1.4393–1.4400 in. (36,559–36,575 mm)

040US

0,008 in. (0,2 mm) O/S

15261–2397–1 15261–2395–1

Crankshaft Thrust Bearing

0.9528–0.9547 in. (24,20–24,25 mm)

0.20 OS

0.016 in. (0,4 mm) O/S

15261–2398–1 15261–2396–1

Crankshaft Thrust Bearing

0.9606–0.9626 in. (24,40–24,45 mm)

0.40 OS

Radius – 0.13–.146 in (3,3–3,7 mm)

0.1300–0.1457 in. (3,3–3,7 mm)

Radius – 0.11–0.126 in. (2,8–3,2 mm)

0.1102–0.1260 in. (2,8–3,2 mm)

IMPORTANT: Oil hoses must have a 0.04–0.06 in. (1–1,5 mm) chamfer. Use on oil stone to chamfer the oil hole.

–8–8–

320 (S/N 511720001 & Above) Excavator Service Manual

FUEL, COOLANT AND LUBRICANTS Use the following chart for correct selection of Fuel, Coolant and Lubricants. AMBIENT TEMPERATURE RESERVOIR

KIND OF FLUID

Engine oil pan

Use SAE Viscosity Number as Listed With API Classification CC, CD or CE

F° –30 –20 –10 0 +10 +20+30 +40 +50 +60 +70 +80 +90 +100 C° –34 –29 –23 –18–13 –7 –1 +4 +10 +15 +21 +27 +32 +38

CAPACITY Refill 4.5 qts. (4,3 L)

SAE 10W–30 SAE 15W–40 SAE 5W–30 SAE 30 SAE 20W/20 SAE 10W

Fuel Tank

Diesel Fuel

6.5 gals (24,6 L)

No. 1 No. 2

Cooling System

50/50 Water & Anti–Freeze

Hydraulic Tank

Bobcat Fluid 6563328*

Tank Cap. 3.65 gals (13,8 L) System Capacity 7.15 gals. (27,1 L)

90W Gear

0.3 qts. (0,3 L)

Final Drive Case (each)

50/50 Water & Anti–Freeze

6.0 qts. (5,7 L)

*If Bobcat fluid (P/N 6563328 is not available use Engine Oil SAE 10W–30/10W–40, Class SE. OIL SPECIFICATIONS When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule page 27. Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%. Fuel Sulphur Change Interval Of Content Engine & Oil Filter 0.5 to 1.0% 1/2 of Regular Interval Above 1.0% 1/4 of Regular Interval * Ethylene Glycol Add premixed coolant, 50% water and 50% ethylene glycol to the recovery tank if the coolant level is low. Propylene Glycol Add premixed coolant 43% water and 57% propylene glycol to the recovery tank if the coolant level is low. One gallon and one pint of propylene glycol mixed with one 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. –8–9–

320 (S/N 511720001 & Above) Excavator Service Manual

BUCKET SPECIFICATIONS 320ServiceManual(S/N511720001&Above)#6722642–SpecificationsSection

MC–1411

Bucket Size

Capacity SAE Heaped

Shipped Weight

10.5 in. (268 mm) 12.5 in. (318 mm) 16.5 in. (418 mm) 20.4 in. (518 mm)

.65 cu. ft. (0,018 cu.m.) .81 cu. ft. (0,023 cu.m.) 1.21 cu. ft. (0,034 cu.m.) 1.55 cu. ft. (0,044 cu.m.)

54.7 lbs. (24,8 kg) 63.6 lbs. (28,8 kg) 72.9 lbs. (33,1 kg) 85.6 lbs. (38.8 kg)

–8–10–

320 (S/N 511720001 & Above) Excavator Service Manual

320–1 ®

Revision Number

18 February 1995

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

320 (S/N 20001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6722642 (4–94)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 320 Excavator Service Manual P/N 6722642 (4–94). Put in the added pages as follows: TAKE OUT

PUT IN

Section 5 – Content Page

Section 5 – Content Page (Revised Feb. 95) 5–12a thru 5–12g (Added Feb. 95) 5–13 thru 5–13f (Added Feb. 95)

5–13

320–2 ®

Revision Number

9 March 1995

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

320 (S/N 20001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6722642 (4–94)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 320 Excavator Service Manual P/N 6722642 (4–94). Put in the added pages as follows: TAKE OUT

PUT IN

5–13f

5–13f, 5–14

320–3 ®

Revision Number

10 December 1996

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

320 (S/N 20001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6722642 (4–94)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 320 Excavator Service Manual P/N 6722642 (4–94). Put in the added pages as follows: TAKE OUT

PUT IN

Section 3

Section 3 (Revised Dec. 96)

320–4 ®

Revision Number

9 June 1998

SERVICE MANUAL REVISION AFFECTING: Product EXCAVATOR Model

320 (S/N 511720001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6722642 (4–94)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The folowing pages are a revision to the Above Service Manual. Take out the pages shown and put in the new pages as listed below: TAKE OUT

PUT IN

Section 2 Contents Page Section 2 DO NOT REMOVE the Hydraulic Schematics in Section 2

Section 2 Contents Page Section 2

Section 4 Contents Page Section 4

5–7 through 5–10