Bobcat X320 Excavator Sn 562313001 Above Service Repair by www.heydownloads.com

X 320/322 Excavator Service Manual (S/N 562313001 & Above) (S/N 517811001 & Above)

6724910 (1–97)

Printed in U.S.A.

MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine, Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0199

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

CORRECT

B–10731

B–14148

B–14142

Never service the Hydraulic Excavator instructions.

Bobcat without

WRONG

B–14147

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

Cleaning and maintenance are required daily.

WRONG

B–14141

B–14145

Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust fumes can kill without warning.

Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

B–14146

B–14143

B–6589

Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the excavator.

Lead–acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

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

Stop, cool and clean engine of flammable materials before checking fluid. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in this manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

MSW20–0500

ALPHABETICAL INDEX ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR BAFFLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUXILIARY FLUSH FACE COUPLERS . . . . . . . . . . .

2–1 4–1 7–1 1–1 6–1 1–1 5–1 5–1 2–1 2–1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELLY PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

6–1 6–1 4–1 7–1 2–1 3–1 5–1 5–1 2–1 2–1 5–1 2–1 8–1

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB/CANOPY REAR COVER . . . . . . . . . . . . . . . . . . . CAB ELECTRICAL (Cab Option) . . . . . . . . . . . . . . . . . CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . CONTROL CONSOLE LEFT HAND . . . . . . . . . . . . . . CONTROL CONSOLE RIGHT HAND . . . . . . . . . . . . . CONSOLE COVER LEFT HAND . . . . . . . . . . . . . . . . . CONSOLE COVER RIGHT HAND . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . CORNER POSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COUNTER WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . . . CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–1 4–1 6–1 4–1 3–1 3–1 3–1 3–1 1–1 5–1 5–1 7–1 7–1 7–1 7–1

DRAIN BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . 1–1, 6–1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . 1–1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8–1 FAN GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOOR MAT AND FLOOR PANELS . . . . . . . . . . . . . . FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . .

7–1 1–1 3–1 7–1 8–1 7–1

FUEL FUEL FUEL FUEL FUEL

INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . SHUTOFF SOLENOID . . . . . . . . . . . . . . . . . . . . SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 6–1 7–1 1–1 3–1

GAS SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HEATER AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . . HYDRAULIC FILTER ASSEMBLY . . . . . . . . . . . . . . . . HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SERVICE INFORMATION . . . . . . . . . . . HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .

1–1 6–1 2–1 2–1 8–1 2–1 2–1 3–1 2–1 1–1

IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . . 7–1 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 JOYSTICK CONTROL CHANGE . . . . . . . . . . . . 1–1, 2–1 LATCH HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINKAGE RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION OF THE HYDRAULIC EXCAVATOR

3–1 6–1 3–1 3–1 1–1

MAIN RELIEF VALVES (Adjustable) . . . . . . . . . . . . . . 2–1 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . 1–1 MICROSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 PEDAL LEFT HAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . PEDAL RIGHT HAND . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . .

3–1 3–1 7–1 2–1

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . ROCKERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 7–1 3–1 4–1

SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . 5–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . 1–1, 7–1 SPEED CONTROL LEVER/SWING LOCK LEVER . 5–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 SWING POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

Continued On Next Page

Revised July 05

320/322 Excavator Service Manual

ALPHABETICAL INDEX (CONT’D) TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIMING GEARCASE COVER . . . . . . . . . . . . . . . . . . . . 7–1 TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TRACK DAMAGE IDENTIFICATION . . . . . . . . . . . . . . 5–1 TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TRACK FRAME EXPANSION CYLINDER (322 (S/N 517811001 & Above) . . . . . . . . . . . . . . . . . . 2–1 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TRAVEL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . 2–1, 6–1, 7–1 TWO SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 UPPER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . 7–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

Revised July 05

320/322 Excavator Service Manual

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . ix PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

DRIVE SYSTEM

UPPER WORKS & SWING SYSTEM

MAIN FRAME & TRACKS

ELECTRICAL SYSTEM

ENGINE SERVICE

TECHNICAL DATA

Revised July 05

320/322 Excavator Service Manual

Revised July 05

320/322 Excavator Service Manual

FOREWORD This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing and adjustment procedures for the hydraulic excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc. A general inspection of the following items must be made after the hydraulic excavator has had service or repair: 1. Check that the ROPS/TOPS/ FOGS is in good condition and is not modified.

9. Safety treads must in good condition.

2. Check that ROPS/TOPS mounting hardware is tightened and is Melroe approved.

10. Check for correct function of indicator lamps (Optional on some models).

3. The seat belt must be correctly installed, functional and in good condition.

11. Check hydraulic fluid level, engine oil level and fuel supply.

4. Inspect for loose or broken parts or connections.

12. Inspect for fuel, oil or hydraulic fluid leaks.

5. Machine signs must be legible and in the correct location.

13. Lubricate the excavator.

6. Steering levers, control levers and foot pedals must return to neutral. Check that foot pedals lock and control lever locks are in working condition.

14. Check the condition of the battery and cables.

7. Inspect the air cleaner for damage or leaks. Check the condition of the element.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

8. Check the electrical charging system.

Revisedy July 05

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are know to the state of California to cause cancer, birth defects and other reproductive harm. iii

320/322 Excavator Service Manual

Revised July 05

320/322 Excavator Service Manual

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

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0903

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine. I–2019–0284

W–2044–1285

The following publications provide information on the safe use and maintenance of the BobcatR machine and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as

well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your BobcatR dealer.

• Machine signs (decals) instruct on the safe operation and care of your BobcatR machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your BobcatR dealer.

• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The hand-

book is available from your dealer in an English edition or one of many other languages. See your BobcatR dealer for more information on translated versions.

• The AEM Safety Manual delivered with the machine gives general safety information. • The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

• The Compact Excavator Operator Training Course is available through your local dealer or at www.bobcat.com. This course is intended to provide rules and practices of correct operation of the BobcatR Excavator. The course is available in English and Spanish versions.

• Service Safety Training Courses are available from your BobcatR dealer or at www.bobcat.com. They provide information for safe and correct service procedures.

• The BobcatR Compact Excavator Safety Video is available from your BobcatR dealer or at www.bobcat.com. SI EXC–0705

Revised July 05

320/322 Excavator Service Manual

SAFETY INSTRUCTIONS (Cont’d) The dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.

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

SI EXC–0705

Revised July 05

320/322 Excavator Service Manual

SAFETY INSTRUCTIONS (Cont’d) FIRE PREVENTION The machine and attachments have components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks. Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential hazard. The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The operator cab, engine compartment, and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.

• Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. NO SMOKING! • Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting. • Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped). • Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your BobcatR dealer [A].

SI EXC–0705

Revised July 05

vii

320/322 Excavator Service Manual

SERIAL NUMBER LOCATIONS

Always use the FULL serial number (including the first four digits) when requesting service or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. HYDRAULIC EXCAVATOR SERIAL NUMBER The excavator serial number is on the right front side of the machine frame [A].

Nâ&#x20AC;&#x201C;00806

ENGINE SERIAL NUMBER

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

Pâ&#x20AC;&#x201C;11102

DELIVERY REPORT The Delivery Report items must be explained to the owner/operator by the dealer. The dealer is to fill out the form and the owner/operator signs the form to indicate his understanding [C].

Revised July 05

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320/322 Excavator Service Manual

HYDRAULIC EXCAVATOR IDENTIFICATION

320ServiceManual#6724910S/N562313001&Above–ContentsSection

GRAB HANDLES CONTROL LEVERS (JOYSTICK) CANOPY (ROPS)

ENGINE COVER UPPERSTRUCTURE TRACK FRAME TRACK

OPERATORS HANDBOOK

GRAB HANDLES

ARM CYLINDER

OPERATOR SEAT AUXILIARY LINES BUCKET CYLINDER

SEAT BELT

ARM

TOOL BOX (Operator’s Manual Location)

BUCKET LINK

BLADE CYLINDER BUCKET BOOM BLADE BOOM CYLINDER Added July 05

B–14408 B–14407

320/322 Excavator Service Manual

Added July 05

320/322 Excavator Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Propylene Glycol (Factory Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 ELECTRICAL SYSTEM Electrical Relays and Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Solenoid (Engine Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . Service the Electrical System (and Battery) . . . . . . . . . . . . . . . . . . . . . . .

1–11 1–13 1–12 1–13 1–12

ENGINE COVER Adjustment of the Engine Cover Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 FINAL DRIVE CASE Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 FUEL SYSTEM Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–7 1–7 1–8 1–8 1–8

HEATER AIR FILTER (With Cab Option Only) . . . . . . . . . . . . . . . . . . . . . . 1–23 HYDRAULIC SYSTEM Case Drain Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–15 1–14 1–15 1–15 1–15

JOYSTICK CONTROL CHANGE ISO to Standard Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 Standard to ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . 1–21 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 SPARK ARRESTOR MUFFLER (if equipped) . . . . . . . . . . . . . . . . . . . . . . 1–16 TRACK TENSION Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

Revised July 05

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320/322 Excavator Service Manual

Revised July 05

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320/322 Excavator Service Manual

MAINTENANCE SAFETY

Do not continuously apply more than 200 V.

•

Never service the machine without instructions.

Install the ground cable (from welder) at least 3 ft. (1 m) away from the part being welded.

•

Cleaning and maintenance are required daily.

•

Keep engine cover closed except for service. Close and latch the cover before operating.

When attaching ground cable (from welder) make sure there are no seals or bearings between the ground and the part to be welded.

•

Never fill the fuel tank with the engine running, while smoking or when near open flame.

•

Lead–acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries.

•

Never modify equipment or add attachments not approved by Melroe Company.

•

Do not handle electrical equipment while wearing wet gloves, or in wet places, this can cause an electrical shock.

Stop, cool and clean the engine of flammable materials before checking fluid levels.

•

Do not allow unauthorized personnel near the machine during maintenance.

•

Never service or adjust machine with engine running unless instructed to do so in this manual.

•

Keep body, loose objects and clothing away from moving parts, electrical contracts, hot parts and exhaust. Never wear loose clothing or jewelry around machinery.

When working under the machine, always place signs to that effect on the operator’s seat and around the machine.

•

When maintenance is done with equipment raised, it must be securely blocked.

•

Relieve pressure on work cylinders as follows:

Avoid contact with leaking hydraulic fluid or diesel fuel which is under pressure, it can penetrate the skin and eyes.

Lower work equipment to the ground. Stop the engine.

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

Operate all the control levers through their functions.

•

When fluids are under pressure.

•

Flying debris or loose material is present.

NOTE: Control console must be lowered to the latched position with the key in the run position to activate the joystick function and relieve the accumulator pressure.

•

Engine is running.

Loosen the cap on the hydraulic tank.

•

Tools are being used.

•

Do not check alternator belt tension with engine running. Stop the engine before inspecting any rotating parts.

When working on rocky ground, avoid damage to the under carriage. Check for loose nuts and bolts, cracks and other damage.

•

Before working in water, rain or snow, check that plugs and valves are tightened. When finished, wash the machine, then check for cracks, loose or missing nuts or bolts. Lubricate the machine.

•

Always disconnect the negative (–) cable from the battery before doing electrical maintenance or welding.

•

When tracks are adjusted, do not put your fingers between the track and rollers.

•

Perform only the service procedures shown in this manual; unless you have had special Bobcat Hydraulic Excavator training.

When welding on the machine, do the following: 1.

Disconnect the negative (–) cable at the battery.

Revised July 05

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320/322 Excavator Service Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Hydraulic Excavator. Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death. W–2003–1089

ITEM

SERVICE REQUIRED

Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Cab Seat Belt Safety Signs (Decals) Tracks All Machinery Pivot Points Hyd. Fluid, Hoses & Tubelines Battery

Check and empty dust cap as required. Check the oil level & add oil as needed. Check radiator coolant level. Check for correct operation. Check the fastening bolts, nuts, & condition of cab/canopy. Check the condition & that fasteners are tight. Check for damaged signs (decals) replace as needed. Check & adjust tension. Lubricate 21 grease fittings. Check fluid level & add as needed. Check for damage & leaks. Repair & replace as needed. Check & clean cable ends & check electrolyte level. Add distilled water as needed. Drain water & sediment from fuel tank/fuel filter. Lubricate two grease fittings. Lubricate one grease fitting. Clean spark chamber. Check & adjust tension. Replace oil & filter element. Check fluid level & add oil as needed. Replace filter element. Replace Air Cleaner Element Clean the radiator fins. Check the condition and connections. Replace filter element. Replace filter. Check and adjust as needed Drain, flush & add new coolant to the cooling system. Change the fluid, clean fill neck strainer. Change the oil. Clean the filter.

Fuel Tank/Fuel Filter Swing Circle Swing Pinion Spark Arrestor Muffler Alternator/Fan Belt Engine Oil & Filter Final Drive Case Fuel Filter Air Cleaner Element Cooling System Alternator & Starter Hydraulic Filter Case Drain Hydraulic Filter Engine Valve Clearance Cooling System Hydraulic Tank Final Drive Case Cab Heater Air Filter

8–10

100

250

500 1000

* *

** **

*After the first 50 hours of machine operation do the following: • Replace the engine oil and filter. • Check the condition of the alternator/fan belt. **After the first 100 hours of machine operation do the following procedures: • Change oil in final drive case. • Clean case drain filter. • Replace hydraulic filter. Or Every 12 Months.

Revised July 05

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320/322 Excavator Service Manual

ENGINE 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

Keep the engine cover closed when operating the machine.

P–11057

W–2141–0189

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

Adjustment of the Engine Cover Latch Open the engine cover.

Loosen the nuts and adjust the stop (Item 1) [B]. Tighten the nuts when the stop (Item 1) [B] is in the correct position.

Loosen the two bolts (Item 2) [B] and adjust the striker plate (Item 3) [B] until it is in the correct position. Tighten the two bolts (Item 2) [B].

AIR CLEANER SERVICE

P–11058

See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Service the air cleaner as follows: Daily Check. Loosen the clamp (Item 1) [C] on the air cleaner.

Remove the cover (Item 2) [C].

P–11059

Remove the dust cup (Item 1) [D] from the cover. Remove the left side cover and visually inspect the filter element. Do not remove the element unless it is plugged and replacement is necessary.

1 P–11060

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320/322 Excavator Service Manual

AIR CLEANER SERVICE (Cont’d)

Filter Replacement Remove the wing nut (Item 1) [A] and the filter element (Item 2) [A].

2 1

P–11061

Check the air cleaner housing for damage.

Wipe the canister and the seal surface clean with a clean cloth. Do Not use compressed air. Check the seal (Item 1) [B] for damage. Do not use an air filter element with a damaged seal. Install a new air filter element. Install and tighten the wing nut. Install the dust cup and cover so the arrow points up. Check that all the air cleaner hose clamps are tight.

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P–11062

320/322 Excavator Service Manual

FUEL SYSTEM

Filling the Fuel Tank

2 1

Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W–2063–0887

P–11035

The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the ignition switch is ON.

NOTE: When the fuel level reaches the .8 gals. (3.1 L.) fuel level, the low fuel light (Item 2) [A] will come ON to alert the operator of this condition. Use the key to unlock the left side cover [B]. Turn the fuel cap to remove it [C]. Use a clean, approved safety container to add fuel to the tank. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING! After the tank is full, install and tighten the fuel cap. Close and lock the fuel door.

P–11063

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285

Fuel Filter P–11064

See the SERVICE SCHEDULE Page 1–4 for the service interval when to replace the fuel filter.

The fuel filter is located under the left hand side of the excavator Loosen the drain (Item 1) [D] at the bottom of the filter element to drain any water from the fuel filter. Tighten the drain when all the water has been removed.

Remove the filter element (Item 2) [D].

Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter and hand tighten. Remove the air from the fuel filter.

P–11065

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320/322 Excavator Service Manual

FUEL SYSTEM (Cont’d)

Fuel System Maintenance See the SERVICE SCHEDULE Page 1–4 for the correct service intervals. To remove water and sediment from the fuel tank, turn the upperstructure until the fuel tank is centered between the rear tracks.

Open the drain valve (Item 1) [A] at the bottom of the fuel tank. Drain contaminated fuel into a container.

P–11066

Removing Air From the Fuel System After replacing the fuel filter or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

Open the vent (Item 1) [B] on the fuel filter housing. Operate the hand pump (priming bulb) (Item 1) [C] until the fuel flows from the vent with no air bubbles.

Tighten the vent plug. Start the engine. It may be necessary to open the vent (Item 1) [D] at the fuel injection pump briefly until the engine runs smoothly. Fuel Specification

P–11067

Use only clean, high quality diesel fuel, Grade No. 1 or Grade No.2.

The following is suggested blending guideline which should prevent fuel gelling problems. Temp. F°

No. 2

No. 1

+15°(9°c) Down to –20° (–29°c) Below –20° (–29°c)

100% 50% 0%

0% 50% 100%

For local recommendations, the operator can contact his fuel supplier.

1 P–11065

D Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285

1 P–11068

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320/322 Excavator Service Manual

ENGINE LUBRICATION SYSTEM

Checking Engine Oil Check the engine oil every day. Stop the engine. Open the engine cover. Remove the dipstick (Item 1) [A]. Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets the correct API Service Classification. (See Fuel, Coolant and Lubrication Chart, Page 8–1.) P–11069

Replacement of Oil and Filter

See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Run the engine until it is at operating temperature. Stop the engine.

Open the engine cover. Remove the drain plug (Item 1) [B] from the oil pan. Drain the oil into a container.

P–11070

Remove the oil filter (Item 1) [C], using a filter wrench.

Clean the filter housing surface. Put clean oil on the filter gasket. Install the new filter and hand tighten only. Install and tighten the oil drain plug.

1 Remove the oil fill cap (Item 1) [D]. Put in 3.4 qts. (3,2 L) of oil into the engine. (See Fuel, Coolant and Lubricants Chart, Page 8–1.)

P–11071

Start the engine and let it run for several minutes.Stop the engine. Check for leaks at the oil filter and the oil drain plug. Check the oil level and add oil as needed if it is not at the top mark on the dipstick.

P–11072

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320/322 Excavator Service Manual

COOLING SYSTEM

Coolant Level When the engine is cool, remove the radiator cap (Item 1) [A]. The coolant level must be 3/4 to 1 inch (19 to 25 mm) below the filler neck. If the coolant level is low, add premixed coolant to the radiator. (See type of coolant information below.)

Coolant Replacement Turn the upperstructure so there is access to the engine and radiator from between the tracks. Stop the engine.

P–11073

When the engine is cool, loosen and remove the radiator cap (Item 1) [A].

Open the radiator drain valve (Item 1) [B] at bottom of radiator. Drain the coolant into a container.

1 P–11074

Open the engine block drain valve (Item 1) [C] and drain the coolant into a container. After all the coolant is removed, close both drain valves.

Propylene Glycol (Factory Installed)

Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.

P–11075

1 gallon and 1 pint of propylene glycol mixed with 1 gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection. Use a refractometer to check the condition of propylene glycol in your cooling system. Fill the radiator with the premixed coolant until it is 3/4 to 1 in. (19 to 25 mm) below the filler neck.

Do not remove radiator cap when the engine is hot. You can be seriously burned.

Run the engine at idle speed for about 5 to 10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation).

W–2070–1285

Stop the engine. Check the coolant level and add as needed to bring it up to the radiator filler neck. Install the radiator cap and tighten. –1–10–

320/322 Excavator Service Manual

ALTERNATOR BELT ADJUSTMENT

To adjust the belt tension, use the following procedure: Stop the engine. Open the engine cover. The belt should deflect about 1/2 in. (13 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 13 ft.–lb. (58 NSm) pressure [A].

If the tension is not correct, Loosen the alternator mounting bolt (Item 1) [A].

Loosen the alternator adjustment bolt (Item 2) [A].

P–11076

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 pulleys. ELECTRICAL SYSTEM

Electrical Relays and Diodes

The 3 engine harness electrical relays (Item 1) [B] and the fuel shut off timer (Item 2) [B] are located in the engine compartment to the right of the air cleaner.

P–11036

The 3 relays (Item 1) [B] control the starter, glow plugs and switched power circuits.

The 2 diodes (Item 1) [C], are for alternator feedback protection and the glow plug during start function.

P–11077

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320/322 Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

The excavator has a 12 volt, negative ground electrical system. Fuses The fuses are located in the right side of the engine compartment [A]. 1. FUSE – 10 AMP: This fuse supplies power to the instrument circuit [B]. 2. FUSE – 15 AMP: This fuse supplies power to any accessory that is powered when the key is in the run position [B]. 3. FUSE – 20 AMP: This fuse supplies power to the ignition circuit [B]. 4. FUSE – 15 AMP: This fuse supplies power to the cab wiring (if equipped) [B]. 5. FUSE – 15 AMP: This fuse supplies power to any accessory that has constant power [B]. 6. FUSE – 15 AMP: This fuse supplies power to the timer [B]. 7. FUSE – 15 AMP: This fuse supplies power to the timer when it is powered by the ignition switch [B]. 8. NOT USED

P–11036

B 3

Replace all fuses with the same type and capacity. NOTE: Before replacing any fuse, find and fix the problem that caused the circuit overload. Make sure the key switch is in the OFF position before replacing the fuse.

Service the Electrical System (and Battery)

Remove the left side cover [C], using the ignition key to unlock the cover.

7 B–14855

The battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery saver grease [D]. Check for broken or loose connections. If the battery cables are removed for any reason, disconnect the negative (–) cable first and when installing the battery cables, make the last connection the negative (–) cable to the battery. With factory equipped battery, no maintenance is needed as this is a maintenance free battery. If the machine has a BobcatR parts replacement battery installed, check the electrolyte level in the battery.

P–11063

If it is lower than 1/2 in. (13 mm) above the plates, add distilled water only.

D +

–

Batteries contain acid which burns eyes and skin on contact. Wear goggles and protective clothing to keep acid off body. In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact. W–2201–0595

P–11098

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320/322 Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

Removal and Installation of the Battery Remove the side cover. (See Page 1–12.) Disconnect the negative (–) cable (Item 1) [A] first. Disconnect the positive (+) cable (Item 2) [A].

P–11098

Remove the bolt (Item 1) [B] and remove the hold down clamp (Item 2) [B].

2 1

P–11100

Remove the battery from the compartment [C].

Always clean the terminals and the cable ends, even when installing a new battery. Install the battery. Install the hold down clamp and tighten the bolt. Connect the battery cables. Connect the negative (–) cable (Item 1) [A] last to prevent sparks at the terminal.

P–11101

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact.

W–2065–1286

Electric Solenoid (Engine Stop) The electric solenoid (Item 1) [D] shuts off fuel supply and stops the engine when the key is turned to the OFF position. P–11078

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320/322 Excavator Service Manual

HYDRAULIC SYSTEM

Checking and Adding Fluid To check and add hydraulic fluid to the reservoir, use the following procedure: Put the machine on a flat level surface. Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine. Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [A] located on the side of the hydraulic reservoir.

1 P–11079

If the fluid level is not correct, use the ignition key and open the right side cover [B].

P–11080

Remove oil fill cap [C].

Check the condition of the fill strainer [D]. The screen must be installed in fill neck when adding oil.

Add the correct fluid to the reservoir until it is visible in the sight gauge. (See Fuel, Coolant and Lubricants Chart, Page 8–1.) Install the reservoir cap. Close and lock the access door.

P–11103

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320/322 Excavator Service Manual

HYDRAULIC SYSTEM (Cont’d)

Diagnostic Couplers The diagnostic couplers are located on each hydraulic pump (Item 1) [A]. The couplers can be used to check circuit pressures. (Refer to the Service Manual.) Hydraulic Reservoir See the SERVICE SCHEDULE Page 1–4 for the correct service interval.

1 P–11082

Move the upperstructure so there is clearance for the reservoir drain between the tracks.

Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine. Remove and replace the hydraulic filter (See below). Remove the drain plug from the bottom of the reservoir [B]. Drain the fluid into a container. Install the drain plug. Add approximately 3.65 gals. (13,8 L) of fluid to the reservoir. (See Fuel, Coolant and Lubricants Chart, Page 8–1.)

N–00805

Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed.

Replacement of the Hydraulic Filter See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Open the engine cover. Use a filter wrench and remove the filter element (Item 1) [C]. Clean the housing contact.

where the filter

gasket makes

Put clean hydraulic fluid on the gasket. Install the new filter element and hand tighten only.

P–11083

Start the engine. Run the machine through the hydraulic functions. Stop the engine. Check the fluid level at the reservoir and add as needed. Check around the filter for leaks.

Case Drain Hydraulic Filter See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Open the right side cover. (See Page 1–12.)

Remove the case drain filter (Item 1) [D]. Install a new case drain filter. P–11084

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320/322 Excavator Service Manual

SPARK ARRESTOR MUFFLER (if equipped)

See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Do not operate the excavator with a defective exhaust system.

This excavator is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

P–11085

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

Make reference to local laws and regulations for spark arrestor requirements. I–2061–0195

W–2050–1285

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.

Stop the engine. Open the engine cover.

W–2011–1285

Remove the plug (Item 1) [A] from the bottom of the muffler.

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. (The carbon deposits will be forced out of the muffler plug hole.)

W–2068–1285

Stop the engine. Install and tighten the plug. Close the engine cover.

When the engine is running during service, the steering levers must be in neutral. Failure to do so can cause injury or death. W–2203–0595

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320/322 Excavator Service Manual

TRACK TENSION

NOTE: The wear of the parts on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. (See SERVICE SCHEDULE Page 1–4 for the correct service interval.) Adjustment Raise 1 side of the machine (approximately 4 in. [102 mm]) using the boom and arm as shown in [A]. Raise the blade fully and install jackstands under the blade and the track frame [A]. Operate the boom until all machine weight is on the jackstands.

P–02239

Stop the engine.

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension. W–2142–0189

Measure the distance between the frame and the top of the track. If the distance is between 2.25 to 2.50 in. (57 to 63 mm), the track tension is correct [B].

P–11086

If not, loosen 1 bolt (Item 1) [C] and remove the other bolt (Item 2) [C] from the cover. Add grease to the fitting (Item 1) [D] until the track tension is correct. If track tension is too tight, decrease the track tension pressure by loosening the bleed screw (Item 2) [D] (maximum of 1 turn) and allow grease to flow out of the bleed screw. When the tension is correct, tighten the bleed screw.

1 2

Repeat the procedure for the other side. If the track tension is still loose after adjusting to the above mentioned limit, it indicates the track is worn. See your dealer for repairs.

P–11087

D 2

AVOID INJURY Do not loosen the grease fitting more than one complete rotation. Also, be careful not to loosen any part other than the grease fitting. If the grease fitting or any part is loosened too much, it can fly off under high pressure. If the grease does not ooze smoothly, try moving the machine back and forth for a short distance.

W–2143–0189 P–11088

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320/322 Excavator Service Manual

FINAL DRIVE CASE

Checking Oil Level

Put the machine on a level surface with the plugs positioned as shown in figure [A]. Remove the plug (Item 1) [A]. The oil level should be at the bottom edge of the plug hole.

Add gear lube 90W through the hole (Item 2) [A] if the oil level is below the hole (Item 1) [A]. (See Fuel, Coolant and Lubricant Chart, Page 8–1) Install and tighten both plugs. P–11166

Repeat the procedure for the other side.

Draining Final Drive Case See the SERVICE SCHEDULE Page 1–4 for the correct service interval. Put the machine on a level surface with the plugs positioned as shown in figure [B].

Remove the bottom plug (Item 1) [B] and top plug (Item 2) [B]. After all the gear lube is removed, rotate the drive motor as shown in figure [A].

Add 0.30 quarts (0,3 L) of gear lube to the top plug hole (Item 2) [A] (or until the gear lube level is at the bottom edge of the plug hole (Item 1) [A]). Install and tighten the plug.

P–11090

Repeat the procedure for the other side.

–1–18–

320/322 Excavator Service Manual

JOYSTICK CONTROL CHANGE

ISO to Standard Control Pattern To change from ISO to STANDARD joystick controls, do the following procedure: Open the tool box door. Remove the hose cover plate [A].

P–11091

Remove the bottom plate from the tool box [B].

PI–12908

Mark and remove hoses (Items 1, 2, 3 & 4) [C] from the bulkhead elbows.

1 2

P–02348

Install the hoses onto the new locations as shown (Items 1, 2, 3 & 4) [D].

Install new decals (P/N 6587427) onto the right hand console and (P/N 6587428) onto the left hand console.

4 3

2 1

After exchange of the hoses, the right joystick will now control arm (raise and lower) and the bucket (curl). The left joystick will control the boom (raise and lower) and the upperstructure (swing).

P–02348

–1–19–

320/322 Excavator Service Manual

JOYSTICK CONTROL CHANGE (Cont’d)

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

3 4

Open the tool box door. Remove the hose cover plate. Remove the bottom plate from the tool box. Mark and remove hoses (Items 1, 2, 3 & 4) [A] from the bulkhead elbows. P–02348

Install the hoses onto the new locations as shown (Items 1, 2, 3 & 4) [B]. Install new decals (P/N 6587425) onto the right hand console and (P/N 6587426) onto the left hand console.

2 1

4 3

After exchange of the hoses, the right joystick will now control boom (raise and lower) and the bucket (curl). The left joystick will control the arm (raise and lower) and the upperstructure (swing).

P–02348

–1–20–

320/322 Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

Lubricate the Hydraulic Excavator as specified in the Service Schedule, Page 1–1 for the best performance of the machine. Record the operating hours each time you lubricate the Hydraulic Excavator. Always use a good quality lithium based multi–purpose grease when lubricating the machine. Apply the lubricant until extra grease shows. Ref.

2 3

Description (# of Fittings)

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

P–11089

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

6 4 5 P–11092

7. Boom Swing Bracket Pivot, every 8 to 10 hours (2) [C]. 8. Frame Swing Bracket Pivot, every 8 to 10 hours (1) [C].

7 8

P–11093

D 9. 10. 11. 12. 13.

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

11 12

9 13 P–11094

–1–21–

320/322 Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

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

P–02223

17. Boom Swing Cylinder Base End, every 8 to 10 hours (1) [B].

NOTE: Access to the grease fitting is from under the upperstructure, right side.

P–02227

18. Swing Circle Ball Bearing, every 50 hours (2) [C].

NOTE: Do not over grease the swing circle or damage to the seal could result. Install 4 to 5 pumps of grease from a grease gun into each of the 2 grease fittings. Rotate the upperstructure 90o and install 4 to 5 pumps of grease into each of the 2 grease fittings.

P–11095

19. Swing Circle Pinion, every 50 hours (Item 1) [D]. Install 4 pumps of grease from a grease gun into the grease fitting. Rotate the upperstructure 180° and install 4 more pumps of grease into the grease fitting.

D 19

N–00806

–1–22–

320/322 Excavator Service Manual

HEATER AIR FILTER (With Cab Option Only)

See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

Remove the air filter (Item 1) [A] from the back of the heater by lifting up on the tab on the top of the filter. Clean the filter element with compressed air only. Install the filter element in the back of the heater.

P–09446

–1–23–

320/322 Excavator Service Manual

–1–24–

320/322 Excavator Service Manual

HYDRAULIC SECTION Page Number ACCUMULATOR Assembly (S/N 562313001–562320721 & 517811001–517811977) . . Assembly (S/N 562320722 & Above & 517811978 & Above) . . . . . . . . Disassembly (S/N 562313001–562320721 & 517811001–517811977) Disassembly (S/N 562320722 & Above & 517811978 & Above) . . . . . Parts Identification (S/N 562320722 &Above & 517811978 & Above) . Pressure Reducing Valve (Description) . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–59 2–65 2–57 2–63 2–62 2–56 2–56 2–68

HYDRAULIC SYSTEM

ARM CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–71 AUXILIARY FLUSH FACE COUPLERS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–89 BLADE CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–73 BOOM CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–70 BOOM SWING CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74 BUCKET CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–72 DRAIN BLOCK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–90 HYDRAULIC CONTROL VALVE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom, Bucket, Arm and Swing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Boom, Bucket, Arm and Swing Disassembly . . . . . . . . . . . . . . . . . . . . . . Boom Swing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Swing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Travel, Right Travel, Auxiliary and Blade Assembly . . . . . . . . . . . . Left Travel, Right Travel, Auxiliary and Blade Disassembly . . . . . . . . . Mid Inlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mid Inlet Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outlet Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outlet Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–48 2–34 2–31 2–40 2–38 2–45 2–43 2–22 2–25 2–29 2–27 2–26 2–26 2–26 2–26 2–22 2–37 2–36

Continued On Next Page

Revised July 05

–2–1–

320/322 Excavator Service Manual

HYDRAULIC SECTION (Cont’d) Page Number HYDRAULIC CYLINDER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly – For Cylinder Using Piston Retaining Bolts . . . . . . . . . . . . . Assembly – For Cylinder Using Piston Retaining Lock Nuts . . . . . . . . . Disassembly–For Cylinders Using Piston Retaining Bolts . . . . . . . . . . . Disassembly–For Cylinders Using Piston Retaining Lock Nut . . . . . . . Disassembly–For Pistons with Three Ring Grooves . . . . . . . . . . . . . . . .

2–81 2–86 2–86 2–79 2–79 2–82

HYDRAULIC FILTER ASSEMBLY Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–89 HYDRAULIC PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupler Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–19 2–15 2–17 2–16 2–14

HYDRAULIC SERVICE INFORMATION Checking the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 Checking the Main Relief Valves and Crossport Relief Valves . . . . . . . 2–8 JOYSTICK CONTROL CHANGE ISO to Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–91 Standard to ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–91 MAIN RELIEF VALVES (Adjustable) Adjusting the Main Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–55 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 PORT RELIEF VALVES Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Relief Valve Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–52 2–52 2–51 2–50 2–51

TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Revised July 05

–2–2–

320/322 Excavator Service Manual

TROUBLESHOOTING

TROUBLESHOOTING THE COMMON CIRCUIT PROBLEM No hydraulic operation at one or more circuits.

CAUSE

CORRECTION

PAGE

Hydraulic oil level low.

Refill with correct oil.

1–1

Hydraulic pump drive coupling damaged.

Replace.

7–1

Hydraulic pump defective.

Check, repair or replace.

Main relief valve defective.

Readjust or replace.

2–8

Hydraulic power insufficient to one or more circuits.

Main relief valve pressure setting incorrect.

Readjust or replace.

2–8, 2–53

Hydraulic speed too slow.

Hydraulic oil level or viscosity incorrect.

Refill or replace.

1–1, 8–1

Engine RPM reduced.

Readjust or replace.

7–1

Control valve linkage defective.

Check, repair or replace.

3–1

Hydraulic pump volume low.

Check, repair or replace.

2–13, 2–14

Oil cooler or radiator fins plugged.

Clean oil cooler external surface.

2–17

Hydraulic oil level low.

Refill or replace.

1–1

Non recommended hydraulic oil.

Replace.

8–1

Relief valve activated.

Use proper procedures.

Oil temperature too high.

excessively

One or more relief valves not set correctly.

2–13, 2–14, 2–17

operating

Test, readjust or replace.

2–8, 2–53

Extreme operating conditions. High ambient temperature (IE: Enclosed structure).

–2–3–

320/322 Excavator Service Manual

TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE CYLINDER CIRCUIT PROBLEM Cylinder inoperable.

Cylinder Force insufficient.

Cylinder Speed too slow.

Cylinder drift excessive.

CAUSE

CORRECTION

PAGE

Control console(s) raised.

Lower control console.

Loose fittings or broken hoses.

Repair or replace.

Lever linkage misadjusted.

Readjust.

3–1

Control console lockout switch.

Readjust or replace.

3–1

Cylinder excessive.

Repair or replace.

2–68

Joystick manifold solenoid coil defective.

Test, repair or replace.

2–61

Joystick manifold solenoid valve defective.

Test, repair or replace.

2–61

Joystick manifold pressure reducing valve defective.

Test, repair or replace.

2–56, 2–61

Joystick excessive.

Repair or replace.

3–1

Main relief valve pressure too low.

Readjust or replace.

2–8, 2–53

Work port relief pressure too low.

Readjust or replace.

2–50

Lever linkage misadjusted.

Readjust.

3–1

Cylinder excessive.

leakage

Repair or replace.

2–68

Joystick manifold solenoid valve defective.

Repair or replace.

3–1

Joystick manifold pressure reducing valve defective.

Repair or replace.

3–1

Control valve internal leakage excessive.

Repair or replace.

2–15, 2–28

Joystick excessive.

internal

leakage

Repair or replace.

3–1

Cylinder excessive.

internal

leakage

Repair or replace.

2–68

Work port relief valve seals leaking.

Test, repair or replace.

2–50

Control valve internal leakage excessive.

Repair or replace.

2–22, 2–25

internal

–2–4–

leakage

320/322 Excavator Service Manual

TROUBLESHOOTING (Cont’d)

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

Swing force.

Swing speed too slow.

Swing over run excessive.

CAUSE

CORRECTION

PAGE

Control console(s) raised.

Lower control console(s).

Control console lockout switch defective.

Readjust or replace.

3–1

Swing lock pin engaged.

Disengage lock pin.

5–1

Joystick manifold pressure reducing valve defective.

Repair or replace.

3–1

Joystick manifold solenoid coil defective.

Replace.

3–1

Joystick manifold solenoid valve defective.

Repair or replace.

3–1

Swing motor gear defective.

Repair or replace.

4–1

Joystick excessive.

Repair or replace.

3–1

Swing motor defective.

Repair or replace.

4–1

Main relief valve set too low.

Readjust or replace.

2–8, 2–53

Swing motor relief valve pressure too low.

Readjust or replace.

4–1

Pump flow low.

Check, repair or replace.

Blocked or restricted line to swing motor.

Replace.

Joystick excessive.

leakage

Repair or replace.

3–1

Control valve internal leakage excessive.

Repair or replace.

2–22, 2–25

Swing motor internal leakage excessive.

Repair or replace.

4–1

Control valve spool sticking.

Repair or replace.

2–22, 2–25

Joystick spool sticking.

Repair or replace.

3–1

Swing motor relief valve set too low.

Repair or replace.

4–1

Swing motor internal leakage excessive.

Repair or replace.

4–1

internal

–2–5–

leakage

2–13, 2–17

320/322 Excavator Service Manual

TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE TRAVEL CIRCUIT PROBLEM Travel system inoperable.

CAUSE Lever linkage adjusted.

Speed too slow.

3–1

Track tension too tight.

Readjust.

5–1

Defective pump.

Check, repair or replace.

2–7, 2–8

counterbalance

Repair or replace.

3–1

Travel motor internal leakage excessive.

Repair or replace.

3–1

Travel motor defective.

Repair or replace.

3–1

Travel motor gears defective.

Repair or replace.

3–1

Swivel joint defective.

Repair or replace.

4–1

Main relief valve pressure too low.

Readjust or replace.

2–8, 2–53

Track tension too tight.

Readjust.

5–1

Main relief valve pressure too low.

Readjust or replace.

2–8, 2–53

Travel motor spool sticking.

Repair or replace.

3–1

Readjust.

3–1

leakage

Repair or replace.

4–1

Control valve internal leakage excessive.

Repair or replace.

2–22, 2–25

Low pump pressure.

Check, repair or replace.

2–14, 2–17

Travel motor internal leakage excessive.

Repair or replace.

counterbalance

Lever linkage adjusted. Swivel joint excessive.

incorrectly

PAGE

Readjust.

Travel motor spool sticking.

Travel power.

CORRECTION

incorrectly

internal

–2–6–

3–1

320/322 Excavator Service Manual

TROUBLESHOOTING (Cont’d)

TROUBLESHOOTING THE TRAVEL CIRCUIT (CONT’D) PROBLEM Machine not running straight.

Machine will not hold on slope or while digging.

Blade drops while machine is moving.

CAUSE Lever linkage adjusted.

CORRECTION incorrectly

PAGE

Readjust.

3–1

Track tension not equal.

Readjust.

5–1

Pump output not equal.

Repair or replace.

2–7, 2–8

Travel motor internal leakage not equal.

Repair or replace.

3–1

Travel motor spool sticking.

counterbalance

Repair or replace.

3–1

Main relief valves pressure set too low.

Repair or replace.

2–6, 2–7, 2–39

Swivel joint excessive.

leakage

Repair or replace.

4–1

Control valve internal leakage not equal.

Repair or replace.

2–15, 2–28

Track motor counterbalance valve leakage excessive.

Repair or replace.

3–1

Hose damage.

Replace.

Lever linkage misadjusted.

Readjust.

3–1

Cylinder excessive.

leakage

Repair or replace.

2–46

Control valve internal leakage excessive.

Repair or replace.

3–1

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

Repair or replace.

4–1

internal

–2–7–

320/322 Excavator Service Manual

HYDRAULIC SERVICE INFORMATION

Checking the Main Relief Valves and Cross Port Relief Valve. The hydraulic system has three main relief valves that protect the hydraulic pump from high pressure and two crossport relief valves that protect the swing motor 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 test:

P–11234

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.

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.

The system relief valve pressure for each pump section recorded at the pump, should be as follows: Pump 1: 2500–2550 PSI (17241–17582 kPa) Pump 2: 2500–2550 PSI (17241–17582 kPa) Pump 3: 2500–2500 PSI (17241–17582 kPa)

I–2003–0284

The crossport relief valve pressure should be as follows: Pump 3: 1110–1190 PSI (7653–8205 kPa) Start the engine and run at full RPM. Warm the hydraulic fluid to 140° F (60° C). Stop the engine.

–2–8–

320/322 Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

Checking the Main Relief Valves and Crossport Relief Valves (Cont’d) Install the test coupler on the number one pump section [A]. NOTE: Pump section one is closest to the engine.

P–11236

Start the engine and engage the boom circuit.

Continue engaging the boom circuit until the main relief valve (Item 1) [B] & [C] goes over relief. Record the pressure.

P–11240

NOTE: The main relief adjustment procedure is the same for all three relief valves.

1 P–11195

If adjustment is needed, remove the cap (Item 1) [D].

1 P–11196

–2–9–

320/322 Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

Checking the Main Relief Valves and Crossport Relief Valves (Cont’d) Loosen the locknut (Item 1) [A]. Turn the adjustment screw (Item 2) [A] clockwise to increase the pressure or counterclockwise to decrease the pressure.

Tighten the locknut (Item 1) [A], install the cap and retest the main relief valve.

2 P–11220

Stop the engine.

Move the test coupler to the pump section two [B]. Start the engine and engage the arm circuit.

P–11237

Continue engaging the arm circuit until the main relief valve (Item 1) [C] & [D] goes over relief.

Record the pressure. If adjustment is needed, adjust the main relief valve as shown on Page 2–9. Retest the main relief after adjustment.

P–11239

P–11195

–2–10–

320/322 Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

Checking the Main Relief Valves and Crossport Relief Valves (Cont’d) Stop the engine. Move the test coupler to pump section three [A].

P–11238

Start the engine and engage the boom swing circuit.

Continue engaging the boom swing circuit until the main relief valve (Item 1) [B] & [C] goes over relief. Record the pressure.

If adjustment is needed, adjust the main relief valve as shown on Page 2–9. Retest the main relief after adjustment.

P–11239

–2–11–

P–11195

320/322 Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

Checking the Main Relief Valves and Crossport Relief Valves (Cont’d) Warm the hydraulic oil to 140° F (60° C). Stop the engine. Install the test coupler on pump section three [A]. NOTE: Pump section one is closest to the engine.

P–11238

With the swing lock (Item 1) [B] in the locked position.

Move the left hand joystick to engage the swing circuit in the clockwise direction. Record the pressure.

LOCKED

Move the left hand joystick to engage the swing circuit in the counterclockwise direction. Record the pressure. The correct pressure recorded at pump section three is 1110–1190 PSI (7653–8205 kPa). If the pressure is incorrect, remove the seat Page 5–1, seat mount Page 5–1 and speed control lever/swing lock mount Page 5–1.

1 P–02176

Remove the crossport relief valves (Items 1 & 2) [C].

Clean the valves, reinstall and retest.

If the pressure is still incorrect, replace the crossport relief valves.

1 P–11193

–2–12–

320/322 Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

Checking the Hydraulic Pump The hydraulic pump flow is 4 G.P.M. (16L/min.) for pump sections one and two and 8 G.P.M. (30L/min.) for pump sections three at 3000 RPM. NOTE: Pump section one is closest to the engine. The following tools will be needed for hydraulic pump test: MEL10003 Hydraulic Tester Stop the engine.

P–11244

Raise the engine cover. Remove the outlet hose from the hydraulic pump section being tested [A].

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].

P–11224

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. 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 G.P.M. (L/min.). Close the flow control knob (Item 1) slowly, to approximately 100 PSI below the relief valve setting which is 2500–2550 PSI (17241–17582 kPa). Record the pump high pressure flow G.P.M. (L/min.). NOTE: The high pressure flow must be at least 80% of free flow. HIGH PRESSURE FLOW (GPM) x 100

%= FREE FLOW (GPM)

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.

–2–13–

320/322 Excavator Service Manual

HYDRAULIC PUMP

Removal and Installation Drain the hydraulic reservoir. (See Page 1–1.)

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.

P–11302

I–2003–0888

Remove the battery. (See Page 6–1.) Remove the battery box. (See Page 6–1.) Disconnect the inlet hoses (Item 1) [A] from the hydraulic pump.

1 Disconnect the pressure hoses (Item 1) [B].

P–11244

Remove the number one pump section test port (Item 1) [C].

Remove the fitting (Item 2) [C] from the pump section.

2 1

P–11303

Remove the bolts (Item 1) [D] from the pump flange.

Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Remove the hydraulic pump from the flywheel housing by sliding the pump straight out from the flywheel housing. Pull the pump outwards until the splined shaft is loose from the flywheel coupling.

1 1

P–11304

–2–14–

320/322 Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Coupler Removal and Installation

0.54 ’’ (13,6 mm)

Remove the bolt (Item 1) [A] from the coupler. Slide the coupler off of the pump shaft. When installing the coupler, maintain 0.54 inch (13.6 mm) gap from the pump mount flange to the coupler [A]. Tighten the bolt (Item 1) [A] to 36 ft.–lbs. (48 Nm) torque.

P–11256

–2–15–

320/322 Excavator Service Manual

HYDRAULIC PUMP (Cont’d) Hydraulic Pump Assembly Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9.

PLATE GEAR SHAFT GEAR SEAL PLATE PLATE COVER BOLT

7 3

7 4

6 4

B–14045

–2–16–

320/322 Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Disassembly

4 3

6 5 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. 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 protected 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 pins (Item 1) [C].

C 1

CD–00223

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

Remove the O–ring from the end of the housing

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

CD–00224

–2–17–

320/322 Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Disassembly (Cont’d) Remove the upper bearing [A].

Back–up ring (white) E–seal (Black)

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 2–17, step [C] through Page 2–18, 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

–2–18–

320/322 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 CD–00209

All parts must be clean before assembly. Clean all parts in clean solvent. Use air pressure to dry.

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.

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.

4 1 CD–00192

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

Open side of E–seal must go towards the inlet ports on housings

Install the two dowel pins (Item 1) [C] into the mounting flange (or separating plate).

1 1

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].

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

–2–19–

320/322 Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

Assembly (Cont’d)

Open side of E–seal must go towards the inlet ports on housings

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.

Install O–ring on each side of the 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 [B].

Upper bearing must be slightly lower than housing

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. Install the two dowel pins (Item 1) [B] into the gear housing.

CD–00229

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].

D Oil passages must align to supply oil to section one

P–00207

–2–20–

320/322 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 2–19 step [B] through Page 2–21 step [A] to assemble pump section 2.

Repeat Page 2–19 step [B] through Page 2–20 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 (See note below). 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. NOTE: There have been two different hydraulic pumps used. One pump uses black oxide end cap, mounting flange and plates between the pump sections. The other pump has zinc plated (silver) end cap, mounting flange and plates between the pump sections.

CD–00193

Tighten the pump bolts with black oxide plated parts to 50 – 55 ft. lbs. (68 – 75 Nm.) torque. Tighten the pump bolts with zinc plated parts to 38 – 43 ft. lbs. (52 – 58 Nm.) torque.

–2–21–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE

Description

The hydraulic control valve has three main relief valves that operate at 2500 PSI (17238 kPa). The boom bucket and arm sections have a 2950 PSI (20340 kPa) and a 3400 PSI (23442 kPa) work port reliefs.

Removal and Installation

1 P–11305

I–2003–0888

1 Remove the floormat and floorplate. (See Page 3–1.) Remove the seat and seat mount. (See Page 5–1.) Remove the speed control lever/swing lock lever mount. (See Page 5–1.) P–11306

Disconnect the two speed switch. Remove the travel levers. (See Page 3–1.)

Remove the six crossmember mount bolts (Item 1) [A]. Remove the crossmember. Mark all tubes and hoses for ease of assembly. Remove the tube (Item 1) [B] from the control valve. Loosen the tube at the oil cooler [C]. Reposition the tube to gain clearance. P–11307

Remove the hoses from the control valve [D].

P–11308

–2–22–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Removal and Installation (Cont’d) Remove the bolt (Item 1) [A], nut (Item 2) [A], and clamp (Item 3) [A] from the tube. Remove the tube (Item 4) [A] from the swing motor and hydraulic control valve.

Continue removing the hoses from the control valve.

2 P–11309

Remove the tube (Item 1) [B] from the hydraulic control valve.

Remove the tube (Item 2) [B] from the hydraulic control valve and reposition the tube (Item 2) [B] to provide clearance. Remove the hose guide (Item 3) [B] from the valve.

1 2 3 P–11310

Remove the remaining hoses from the control valve [C].

NOTE: Temporarily install tie wraps (Item 1) [C] & [D] on the hoses for ease of assembly.

1 P–11311

Remove the tubes from the valve [D].

1 P–11312

–2–23–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Removal and Installation (Cont’d) Remove the nine pilot tubes from the control valve [A]. NOTE: There are four pilot tubes on the front of the control valve and five pilot tubes on the rear of the control valve.

P–11313

Remove the five cotter pins and clevis pins (Item 1) [B] from the actuating ends of the control valve.

1 P–11176

Remove the three mount bolts (Item 1) [C] from the control valve.

1 P–11314

Remove the control valve [D].

P–11315

–2–24–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

320ServiceManual#6724910S/N562313001&Above–HydraulicSystemSectionpart1of4

Disassembly Remove the mounts (Item 1) [A]. Mark the valve sections for ease of assembly.

P–11194

Remove the three tie rod nuts (Item 1) [B].

1 P–11196

Remove the inlet section from the valve assembly.

Continue removing the valve sections. Keep the valve sections in order for ease of assembly [C].

P–11197

Remove the O–rings (Item 1) [D], springs (Item 2) [D] and load check valves from the valve sections.

NOTE: There are no springs (Item 2) [D] or load check valves (Item 3) [D] in the inlet, utility, mid–inlet, boom swing or boost 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 assemble the valve. See Page 2–48 for tightening torque.

3 P–06031

–2–25–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Outlet Section Disassembly

Put the valve section in a vise with protective jaws.

Remove the main relief valve (Item 1) [A] from the inlet section. Remove the plug (Item 2) [A] from the inlet section.

P–11198

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

Outlet Section Assembly Oil and install a new O–ring on the plug. Clean the valve section in solvent and dry with compressed air. Install the plugs in the inlet section.

Install the main pressure relief valve into the valve section. Tighten to 43–53 ft.–lbs. (57–71 Nm) torque. NOTE: If the main pressure relief valve is disassembled the relief pressure setting must be reset. See Page 2–9 for main relief valve repair.

P–08461

Mid Inlet Section Disassembly Put the valve section in a vise with protective jaws. Remove the main reliefs from both ends of the section [C].

P–11199

Mid Inlet Section Assembly Clean the valve section in solvent and dry with compressed air. Install the main relief valves on both ends of the valve section. Tighten to 30–36 ft.–lbs. (40–48) Nm) torque. NOTE: If the relief valve is disassembled the relief pressure setting must be reset. See page 2–53 for main relief valve repair.

Revised Sept. 99

–2–26–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Left Travel, Right Travel, Auxiliary and Blade Disassembly

Remove the plug (Item 1) [A] from the rear of the blade section.

P–11208

Remove the plugs (Item 1) [B] from the auxiliary section.

B 1

P–11210

Remove the fittings (Item 1) [C] and plugs (Item 2) [C] from the right travel section.

C 2

NOTE: The left travel section is shown for disassembly and assembly. The auxiliary and right travel sections have the check valve and O–ring on the opposite side of the valve section. The procedure is the same for the left travel, right travel, auxiliary and blade sections.

P–11211

Remove the two screws (Item 1) [D] from the retaining plate on the actuating end of the spool.

Remove the retaining plate (Item 2) [D].

2 1 1

P–08494

Revised Sept. 99

–2–27–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Left Travel, Right Travel, Auxiliary and Blade Disassembly (Cont’d) Remove the two screws (Item 1) [A] from the end cap.

2 Remove the end cap (Item 2) [A].

1 1

P–08495

Insert a pin in the hole in the actuating end of the spool and remove the spring retaining bolt [B].

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 spools and the housings. P–08496

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

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

4 P–08499

Remove the wiper from the spool (both ends) [D].

P–06047

Revised Sept. 99

–2–28–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Left Travel, Right Travel, Auxiliary and Blade 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. 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

Left Travel, Right Travel, Auxiliary and Blade 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 [B]. 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 second spool O–ring. Install the wiper on both ends of the spool [C]. Use finger pressure to seat the wiper into the bore of the valve.

P–06047

Install the plate (Item 1) [D] over the spool.

Install the spring seat (Item 2) [D], spring (Item 3) [D] and outer spring seat (Item 2) [D] on the spool.

Apply thread adhesive (LOCTITE #271) to the spring retainer bolt (Item 4) [D] threads.

1 P–08499

Revised Sept. 99

–2–29–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Left Travel, Right Travel, Auxiliary and Blade Assembly (Cont’d) Insert a pin through the hole in the spool and tighten the spring retaining bolt [A]. Tighten the spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) torque.

P–08496

Install the end cap (Item 1) [B] over the spring and install the two screws (Item 2) [B].

Tighten the screws (Item 2) [B] to 6–8 ft.–lbs. (8–10 Nm) torque.

2 1 1

P–08495

Install the retainer plate (Item 1) [C] and the two screws (Item 2) [C].

Tighten the screws to 3–5 ft.–lbs. (4–6 Nm) torque.

1 2 2

P–08494

Install the fittings (Item 1) [D] and plugs (Item 2) [D] on the right travel section.

D 2

P–11211

Revised Sept. 99

–2–30–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Left Travel, Right Travel, Auxiliary and Blade Assembly (Cont’d)

Install the plugs (Item 1) [A] on the auxiliary section.

P–11210

Install the plug (Item 1) [B] on the rear of the blade section.

Boom, Bucket Arm and Swing Disassembly

P–11208

Remove the fittings (Item 1) [C] from the swing section.

NOTE: The boom section disassembly and assembly is shown. The bucket and arm sections have the check valve and O–ring bore on the opposite side of the valve section. The procedure is the same.

1 1

P–11209

Remove the work port relief valves (Item 1) [D] from both ends of the bucket, arm and boom valve sections.

The 3400 PSI (23443) pressure relief valve is installed in the front ports of the boom and arm sections and the rear ports of the bucket section.

1 1

The 2950 pressure relief valve is installed in the rear ports of the boom and arm sections and the front port of the bucket section.

P–08467

Revised Sept. 99

–2–31–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom, Bucket Arm and Swing Disassembly (Cont’d) Remove the four screws (Item 1) [A] and retaining plates (Item 2) [A] from both end covers.

1 2

1 P–08468

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

P–08469

Remove the end cover and spool from the valve section [C].

P–08470

To remove the end cover from the spool, a holding fixture will have to be made from a 3/4 inch thick x 1–1/2 inch wide x 2 inch long (19 mm thick x 38 mm wide x 50 mm long) piece of hardwood. Drill a 9/16 inch (14 mm) hole in the center of the hardwood block. Cut the block lengthwise [D].

Cut

9/16’’ dia.

2’’

1 1/2’’ 3/4’’

Revised Sept. 99

–2–32–

B–14674

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom, Bucket Arm and Swing Disassembly (Cont’d) Place both halves of the hardwood block around the spool, next to the end cover. Clamp the blocks in a vise [A]. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged.

P–08471

Remove the end cover from the spool [B]. Use care not to scratch the spool, as the spool and housing are not serviceable separately.

P–08472

Remove the retainer from the end cover by pushing on the bolt head [C].

P–06034

Remove the O–rings (Item 1) [D] from the retainer (Item 2) [D].

Remove the spring seat (Item 3) [D], the inner spring (Item 4) [D], the outer spring (Item 5) [D], the second spring seat (Item 3) [D] and the retaining bolt (Item 6) [D] from the end cover (Item 7) [D].

2 P–08473

Revised Sept. 99

–2–33–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom, Bucket, Arm and Swing Assembly Clean parts in solvent and dry.

Oil and install new O–rings (Item 1) [A] on the retainer (Item 2) [A].

Apply thread adhesive (LOCTITE #271) to the spring retaining bolt (Item 6) [A]. Install the spring seat (Item 3) [A], the outer spring (Item 5) [A], the inner spring (Item 4) [A], inner spring seat (Item 3) [A], the bolt (Item 6) [A] and the retainer (Item 2) [A] in the end cover.

2 P–08473

Clamp the spool in a vise using the hardwood fixture used for disassembly [B].

Install the end cover on the spool [B].

P–08471

Tighten the spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) torque [C].

P–08472

Install the end cover retaining plate (Item 1) [D] and screws (Item 2) [D] on the end cover.

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

2 P–08468

Revised Sept. 99

–2–34–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom, Bucket, Arm and Swing Assembly (Cont’d) Oil and install a new O–ring on the end cover of the valve section [A].

P–08469

Install the end cover, the end cover retaining plate (Item 1) [B] and the screws (Item 2) [B].

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

1 2 2 P–08501

Install the port relief valves on the bucket, arm and boom valve sections. Tighten to 30–36 ft.–lbs. (40–48 Nm) torque [C].

P–08467

Install the fittings (Item 1) [D] on the swing valve section.

D 1 1

P–11209

Revised Sept. 99

–2–35–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Utility Block Disassembly Remove the plug (Item 1) [A] from the front of the utility block.

P–11212

Remove the spring (Item 1) [B] and poppet (Item 2) [B].

P–11213

Remove the plug (Item 1) [C] from the rear of the utility block.

1 P–11214

Remove the spring (Item 1) [D] and poppet (Item 2) [D].

Clean all parts in solvent and dry with compressed air.

P–11215

Revised Sept. 99

–2–36–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Utility Block Assembly Oil and install a new O–ring on the front and rear plug. Apply oil to and install the poppet (Item 1) [A] and spring (Item 2) [A] in the rear port of the utility block.

P–11215

Install the rear plug (Item 1) [B].

1 P–11214

Apply oil to and install the poppet (Item 1) [C] and spring (Item 2) [C] in the front of the utility block.

P–11213

Install the front plug (Item 1) [D].

P–11212

Revised Sept. 99

–2–37–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom Swing Disassembly Remove the two screws (Item 1) [A] holding the plate (Item 2) [A] to the valve section. Remove the plate.

2 1 1 P–08474

Remove the two screws (Item 1) [B] holding the end cover (Item 2) [B] to the valve section.

Remove the end cover.

2 1 P–08475

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 3) [D] and the inner spring seat (Item 2) [D] from the spool. Remove the plate (Item 4) [D] from the valve section.

D 4

2 P–08476

Revised Sept. 99

–2–38–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom Swing 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

Remove the plug (Item 1) [C], spring (Item 2) [C] and poppet (Item 3) [C] from both ends of the valve section.

3 2 1 P–06026

Remove the housing (Item 1) [D] and pin (Item 2) [D] from the actuating end of the valve section.

D 1 2

P–08477

Revised Sept. 99

–2–39–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom Swing Disassembly (Cont’d) Remove the housing (Item 1) [A] and the spool (Item 2) [A] from the rear of the valve section.

2 1

P–06028

Remove the O–rings (Item 1) [B] & [C] and the back–up rings (Item 2) [B] & [C] from the housing and plug.

Boom Swing Assembly Clean all parts in solvent and dry.

Install the new O–rings (Item 1) [B] & [C] and back–up rings (Item 2) [B] & [C] on both of the housings and the plugs. Apply oil to the O–rings.

Install the pin (Item 3) [B] and the housing (Item 4) [B] in the actuating end of the valve.

Tighten the housing (Item 4) [B] to 43–53 ft.–lbs. (58–71 Nm) torque.

P–08478

Install the poppet (Item 5) [B], the spring (Item 6) [B], and the plug (Item 7) [B].

Tighten the plug (Item 5) [B] to 15 ft.–lbs. (20 Nm) torque. Install the spool (Item 3) [C] and the housing (Item 4) [C] in the valve.

Tighten the housings (Item 4) [C] to 43–53 ft.–lbs. (58–71 Nm) torque. Install the poppet (Item 5) [C], spring (Item 6) [C] and the plug (Item 7) [C].

Tighten the plug (Item 7) [C] to 15 ft.–lbs. (20 Nm) torque. P–08479

Revised Sept. 99

–2–40–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom Swing Assembly (Cont’d) 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–08480

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 4) [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 outer spring seat (Item 2) [D] and the retaining screw (Item 4) [D].

2 P–08476

Revised Sept. 99

–2–41–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boom Swing 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.

P–06018

Install the end cover over the spring and install the two screws [B].

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

P–06017

Revised Sept. 99

–2–42–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boost Disassembly

Remove the plug (Item 1) [A] and fitting (Item 2) [A].

P–11201

Remove the two screws (Item 1) [B] from the retaining plate.

Remove the retaining plate (Item 2) [B].

2 P–11200

Remove the two screws (Item 1) [C] and retaining plate (Item 2) [C] from the end cover.

2 P–11203

Remove the wiper (Item 1) [D] from the spool.

P–11204

Revised Sept. 99

–2–43–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boost Disassembly (Cont’d) Remove the end cover and spool from the valve section [A].

P–11207

To remove the end cover from the spool, a holding fixture will have to be made from a 3/4 in. thick x 1 1/2 in. wide x 2 in. long (19 mm thick x 38 mm wide x 50 mm long) piece of hardwood. Drill a 9/16 in. (14 mm) hole in the center of the hardwood block. Cut the block lengthwise [B].

Cut

9/16’’ dia.

2’’

1 1/2’’ 3/4’’ Place both halves of the hardwood block around the spool, next to the end cover.

B–14674

Clamp the blocks in a vise [C]. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged.

P–08471

Remove the end cover from the spool [D]. Use care not to scratch the spool, as the spool and housing are not serviceable separately.

P–08472

Revised Sept. 99

–2–44–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boost Disassembly (Cont’d) Remove the retainer from the end cover by pushing on the bolt head [A].

P–06034

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

2 P–08473

Remove the O–ring from the spool bore [C].

P–11205

Boost Assembly

Apply oil to and install the O–ring in the spool bore [D].

P–11206

Revised Sept. 99

–2–45–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boost Assembly (Cont’d) Clean parts in solvent and dry with compressed air.

Oil and install new O–rings (Item 1) [A] on the retainer (Item 2) [A]. Apply thread adhesive (LOCTITE #271) to the spring retaining bolt (Item 6) [A]. Install the spring seat (Item 3) [A], the outer spring (Item 5) [A], the inner spring (Item 4) [A], inner spring seat (Item 3) [A], the bolt (Item 6) [A] and the retainer (Item 2) [A] into the end cover.

2 P–08473

Clamp the spool in a vise using the hardwood fixture used for disassembly.

Install the end cover on the spool [B].

P–08471

Tighten the spring retaining bolt to 6–8 ft.–lbs. (8–10 Nm) torque [C].

P–08472

Install the end cover and spool in the valve section [D].

P–11207

Revised Sept. 99

–2–46–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Boost Assembly (Cont’d) Install the end cover retaining plate (Item 1) [A] and screws (Item 2) [A] on the end cover. Tighten the screws to 6–9 ft.–lbs. (8–10 Nm) torque.

1 P–11203

Install the wiper (Item 1) [B] on the spool. Use finger pressure to seat the wiper into the bore of the valve.

P–11204

Install the retainer plate (Item 1) [C] and two screws (Item 2) [C].

Tighten the screws to 3–5 ft.–lbs. (4–6 Nm) torque.

1 P–11200

Install the plug (Item 1) [D] and fitting (Item 2) [D].

D 1

P–11201

Revised Sept. 99

–2–47–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Assembly

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

P–06015

Install the spring in the poppet [B].

Install the nuts on the short threaded end of the tie rods, with at least two threads extending past the nut. Install the tie rods through the outlet section. Check each valve section for location marks. Make sure that the valve sections are installed in the correct order.

P–06016

Install the valve sections on the tie rods [C].

Install the three nuts on the tie rods, finger tight. Be sure the valve is flat on the bench by pressing down on the inlet sections so the mounting feet on the end sections are aligned.

P–11197

Tighten the tie rod nuts to 10 ft.–lbs. (13 Nm) of torque in a crisscross manner[D].

Tighten the two 5/16 inch diameter tie rod nuts (Item 1) [D] to 14 ft.–lbs. (19 Nm) of torque.

Tighten the one 3/8 inch diameter tie rod nuts (Item 2) [D] to 33 ft.–lbs. (45Nm) of torque. 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.

Recheck the mounting feet for level settings. Revised Sept. 99

P–11196

–2–48–

320/322 Excavator Service Manual

HYDRAULIC CONTROL VALVE (Cont’d)

Assembly (Cont’d) Install the mounts (Item 1) [A] on the control valve.

Revised Sept. 99

–2–49–

P–11194

320/322 Excavator Service Manual

PORT RELIEF VALVES 320ServiceManual#6724910S/N562313001&Above–HydraulicSystemSectionpart2of4

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

2 1

16 17

C–03361

Revised Sept. 99

–2–50–

320/322 Excavator Service Manual

PORT RELIEF VALVES (Cont’d)

Port Relief Valve Pressure Setting Boom Relief set at: (Rod End) Front . . . . . . . . . 2950 PSI (20340 kPa) (Base End) Rear . . . . . . . . 3400 PSI (23443 kPa Bucket Relief set at: (Rod End) Rear . . . . . . . . 3400 PSI (23443 kPar) (Base End) Front . . . . . . . . 2950 PSI (20340 kPa) Arm Relief set at: (Rod End) Front . . . . . . . . . 3400 PSI (23443 kPa (Base End) Rear . . . . . . . . 2950 PSI (20340 kPa)

P–06051

Disassembly

1 11

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].

2 12 3

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.

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.

15 6 7

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 Bobcat Parts.

18 9 19

P–06052

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

• • • •

Revised July 05

–2–51–

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

320/322 Excavator Service Manual

PORT RELIEF VALVES (Cont’d)

Assembly

1 11

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

2 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]. 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].

15 6

Install the housing (Item 8) [A] on the housing (Item 18) [A]. Tighten to 30 to 36 ft.–lb. (40 to 48 NSm) 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 to 8 ft.–lb. (8 to 10 NSm) of torque.

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

9 19

P–6052

Adjustment Procedure

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 Bobcat hydraulic fluid.

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 [B]. 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 (Item 1) [B].

P–11216

Turn the adjusting screw (Item 2) [B] clockwise to increase the pressure and counterclockwise to reduce the pressure. NOTE: 1/8 turn is approximately 100 PSI (690 kPa) and 1/4 turn is approximately 250 PSI (1724 kPa). When the correct pressure setting is obtained, tighten the locknut while holding the adjustment screw from turning. Adjust the port relief valve until the correct setting is obtained. (See previous page for the port relief pressures.) Install the end cap. NOTE: The valve is shown out of the excavator for photo clarity.

Revised July 05

–2–52–

320/322 Excavator Service Manual

MAIN RELIEF VALVES (Adjustable)

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

1 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], spring (Item 6) [B] and poppet (Item 7) [B] from the housing (Item 8) [B].

P–11198

Remove the housing (Item 8) [B].

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

Remove the spring (Item 11) [B], stem (Item 12) [B] and poppet (Item 13) [B].

Remove the O–ring (Item 14) [B] and back–up ring (Item 15) [B] from the poppet.

Remove the inner body (Item 16) [B].

Remove the O–ring (Item 17) [B] from the outer body (Item 18) [B].

14 13

11 12

8 9

9 P–11218

Assembly Apply oil on the O–rings and back–up rings before installing. Use care not to overstretch these parts during installation. Install the O–ring (Item 17) [B] on the outer body (Item 18) [B]. Wear safety glasses to prevent eye injury when any of the following conditions exist:

Install the inner body (Item 16) [B].

• • • •

Install the O–ring (Item 14) [B] and back–up ring (Item 15) [B] on the poppet (Item 13) [B]. Install the poppet (Item 13) [B], stem (Item 12) [B] and spring (Item 11) [B].

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

Install the two O–rings (Item 9) [B] and back–up ring (Item 10) [B] on the housing (Item 8) [B]. Install the housing (Item 8) [B]. Install the poppet (Item 7) [B], spring (Item 6) [B] and adjusting screw (Item 5) [B]. Install the O–ring (Item 4) [B], locknut (Item 3) [B], O–ring (Item 2) [B] and end cap (Item 1) [B]. Tighten to 16–20 ft.–lbs. (21–26 Nm) torque. Install the main relief valve in the inlet valve. Tighten to 43–53 ft.–lbs. (57–71 Nm) torque. The relief pressure setting must be reset.

–2–53–

320/322 Excavator Service Manual

MAIN RELIEF VALVES (Adjustable) (Cont’d)

Assembly (Cont’d)

Main Relief Valve pressure setting at the hydraulic pump: Inlet Section Main Relief Valve (Item 1) [A] 2500–2550 PSI (17241–17582 kPa) Mid Inlet Section Main Relief Valves (Item 2) [A] 2500–2550 PSI (17241–17582 kPa) NOTE: All main relief pressure setting are measured from the hydraulic pump test ports with the valve installed in the excavator.

1 2

–2–54–

P–11195

320/322 Excavator Service Manual

MAIN RELIEF VALVES (Adjustable) (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 2–1.

If the relief valves need to be adjusted do the following: Remove the end cap (Item 1) [A].

P–11219

Loosen the lock nut (Item 1) [B].

Turn the adjustment screw (Item 2) [B] clockwise to increase the pressure and counterclockwise to reduce the pressure. When the correct pressure setting is obtained, tighten the lock nut while holding the adjusting screw from turning. Adjust the main relief valve until the correct setting is obtained. (See Page 2–53 for Main Relief Valve Pressures.)

Install the end cap.

NOTE: The valve is shown out of the excavator for photo clarity.

P–11195

–2–55–

320/322 Excavator Service Manual

ACCUMULATOR

Pressure Reducing Valve (Description)

The Pressure Reducing valve body contains two valves, the pressure reducing valve and a safety relief valve. The body is connected to the accumulator. The pressure reducing valve supplies 365 PSI (2517 kPa) to the joysticks to activate the control valve spools. The accumulator provides short term reserve pressure for joystick function with engine off. P–11279

Removal and Installation

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

Remove the center floor panel. (See Page 4–1.)

P–11280

Mark hoses for correct installation. Remove the hoses and tubelines from the reducing valve [A] & [B]. Disconnect the wire harness (Item 1) [A] from the coils. Remove the two mounting bolts (Item 1) [B] from under the upperstructure. Remove the accumulator/valve.

–2–56–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d) Disassembly (S/N 562313001 517811001 –517811977)

A –

562320721

Use a vise with protective jaws and clamp the valve body. Remove the accumulator (Item 1) [A] from the valve body.

P–08842

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

NOTE: The accumulator is non–rechargeable. If the accumulator pressure is not correct order a new accumulator from Bobcat Parts.

P–08843

Remove the two coil nuts (Item 1) [C] and coils (Item 2) [C] from the spools.

1 2 2

P–08844

Remove the two spools (Item 1) [D] from the valve body.

P–08845

Revised Dec. 00

–2–57–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d)

Disassembly (S/N 562313001 – 562320721 & 517811001 –517811977) (Cont’d)

Remove the O–rings (Item 1) [A] and back–up rings (Item 2) [A] from both spools.

P–08846

Remove the relief valve (Item 1) [B] from the valve body.

B 1

P–08847

Remove the O–rings (Item 1) [C] and back–up rings (Item 2) [C] from the relief valve.

NOTE: The relief valve is not serviceable with the exception of new O–rings and back–up rings.

1 P–08848

Remove the plug (Item 1) [D], spring (Item 2) [D] and check ball (Item 3) [D] from the valve body.

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

3 2 1

4 P–08849

Revised Dec. 00

–2–58–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d) Disassembly (S/N 562313001 – 517811001 –517811977) (Cont’d)

562320721

Remove the plug (Item 1) [A] from the valve body. Remove the O–ring (Item 2) [A] from the plug (Item 1) [A].

Assembly (S/N 562313001 – 562320721 & 517811001 –517811977)

P–08850

Clean all parts in solvent and dry with compressed air.

Install the check ball (Item 1) [B] and spring (Item 2) [B] in the valve body. Apply oil and install the O–ring (Item 3) [B] on the plug (Item 4) [B].

1 2

Install the plug (Item 4) [B] in the valve body.

3 P–08849

Apply oil and install the O–rings (Item 1) [C] and back–up rings (Item 2) [C] on the relief valve.

C 2

Apply oil on the relief valve.

P–08848

Install the valve (Item 1) [D] in the valve body.

D 1

P–08847

Revised Dec. 00

–2–59–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d)

Assembly (S/N 562313001 – 562320721 & 517811001 –517811977) (Cont’d)

Apply oil and install the O–rings (Item 1) [A] and back–up rings (Item 2) [A] on both spools.

1 P–08846

Apply oil on the two spools.

Install the spools (Item 1) [B] in the valve body.

P–08845

Install the two coils (Item 1) [C] and two coil nuts (Item 2) [C].

Tighten the coil nuts (Item 2) [C] to 4–6 ft.lbs. (5–8 Nm) of torque.

2 1

NOTE: Over tightening the coil nut (Item 2) [C] may cause spool or coil failure.

P–08844

Apply oil and install the O–ring (Item 1) [D] on the accumulator.

P–08843

Revised Dec. 00

–2–60–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d)

Assembly (S/N 562313001 – 562320721 & 517811001 –517811977) (Cont’d)

Install the accumulator (Item 1) [A] on the valve body.

P–08842

Revised Dec. 00

–2–61–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d)

Parts Identification (S/N 562320721 & Above & 517811978 & Above).

1. 2. 3. 4. 5. 6.

Accumulator Valve Body Pressure Reducing Valve Check Valve Spool Coil 6

3 5

Revised Dec. 00

–2–62–

320/322 Excavator Service Manual

ACCUMULATOR (Cont)

Disassembly(S/N 562320721 & Above & 517811978 & Above)

Use a vise with protective jaws and clamp the valve body. Remove the accumulator (Item 1) [A] from the valve body.

P–21172

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

NOTE: The accumulator is non–rechargeable. If the accumulator pressure is not correct order a new accumulator from Bobcat Parts.

P–08843

Remove the two nuts (Item 1) [C] and coils (Item 2) [C] from the spools.

2 1

2 P–21173

Remove the two spools (Item 1) [D] from the valve body.

P–21174

Revised Dec. 00

–2–63–

320/322 Excavator Service Manual

ACCUMULATOR (Cont)

Disassembly(S/N 562320721 & Above & 517811978 & Above) (Cont’d)

Remove the O–rings (Item 1) [A] and back–up rings (Item 2) [B] from both spools.

2 P–21175

Remove the relief valve (Item 1) [B] from the valve body.

B 1

P–21176

Remove the O–rings (Item 1) [C] and back–up rings (Item 2) [C] from the relief valve.

C 1

NOTE: The relief valve is not serviceable with the exception of new O–rings and back–up rings.

2 P–21177

Loosen the plug (Item 1) [D].

P–21178

Revised Dec. 00

–2–64–

320/322 Excavator Service Manual

ACCUMULATOR (Cont)

Disassembly (S/N 562320721 & Above & 517811978 & Above) (Cont’d) Remove the plug (Item 1) [A], spring (Item 2) [A] and check ball (Item 3) [A] from the valve body. Remove the O–ring (Item 4) [A] from the plug (Item 1) [A].

3 1 Remove the plug (Item 1) [B] from the valve body.

P–21179

Remove the O–ring from the plug (Item 1) [B]. Assembly (S/N 562320721 & Above & 517811978 & Above) (Cont’d) Clean all parts in solvent and dry with compressed air. Install the O–ring on the plug (Item 1) [B]. Install the plug (Item 1) [B] in the valve body.

Install the check ball (Item 3) [A] and spring (Item 2) [A] in the valve body. P–08850

Put oil on the O–ring (Item 4) [A] and install on the plug (Item 1) [A].

Install the plug (Item 1) [A & C] in the valve body (number 4 port).

P–21178

Put oil on the O–rings (Item 1) [D] and back–up rings (Item 2) [D] and install on the pressure reducing valve.

D 1

2 P–21177

Revised Dec. 00

–2–65–

320/322 Excavator Service Manual

ACCUMULATOR (Cont)

Assembly (S/N 562320721 & Above & 517811978 & Above) (Cont’d) Put oil on the pressure reducing valve.

Install the valve (Item 1) [A] in the valve body.

P–21176

Put oil on the O–rings (Item 1) [B] and back–up rings (Item 2) [B] and install on both spools.

B 1

Put oil on the two spools.

P–21175

Install the spools (Item 1) [C] in the valve body.

P–21174

Install the two solenoid coils (Item 1) [D] and two nuts (Item 2) [D].

Tighten the nuts (Item 2) [D] to 48–96 in.–lbs. (5,4–10,8 Nm) torque.

2 1

NOTE: Over tightening the nut (Item 2) [D] may cause spool or coil failure.

2 P–08844

Revised Dec. 00

–2–66–

320/322 Excavator Service Manual

ACCUMULATOR (Cont)

Assembly (S/N 562320721 & Above & 517811978 & Above) (Cont’d) Put oil on the O–ring (Item 1) [A] and install on the accumulator. Apply Loctite # 545 to the threads of the accumulator. Install the accumulator (Item 1) [B] on the valve body.

Tighten the accumulator to 20 ft.–lbs. (27 Nm) torque.

P–08843

B 1

P–21172

Revised Dec. 00

–2–67–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d)

Testing (All Models)

To test the accumulator for proper operation, start the engine and raise the boom one foot (305 mm). Stop the engine. While the engine is not running, turn the ignition key to the run position. Activate the boom down circuit. The boom must lower when the boom circuit is activated. Turn the ignition key to the off position.

P–11280

The T port (drain to reservoir port) (Item 1) [A] is normally closed when the excavator is running. If a high pressure spike occurs, hydraulic fluid will flow out the T port and to the reservoir. Remove the line (Item 1) [A] from the T port and plug the line. Install a temporary drain line on the T port. Route the drain line in an empty drain pan. Run the excavator for one minute. Measure the amount of oil in the drain pan. The service limit is 1/2 gal. (1,9 liters) per minute.

Revised Dec. 00

–2–68–

320/322 Excavator Service Manual

ACCUMULATOR (Cont’d)

Testing (All Models) (Cont’d)

If the amount of oil from the T port is at or over service limits. It is an indication of worn O–rings and back–up rings on the spools and pressure reducing valve, or a stuck pressure reducing valve.

Replace the O–rings and back–up rings on the spools. (See Page 2–59.) Remove the pressure reducing valve.

Remove the O–rings (Item 1) [A] and back–up rings (Item 2) [A] from the valve.

4 P–08848

Loosen the locknut (Item 3) [A] and turn the adjustment screw (Item 4) [A] counterclockwise until the adjustment screw reaches it’s top limit.

Using a brass or plastic drift, activate the poppet (Item 5) [A] while the valve is in clean solvent. Dry the valve with compressed air.

Install the new O–rings (Item 1) [A] and back–up rings (Item 2) [A]. Install the valve and set to 365 PSI (2517 kPa). (See Below.) Repeat the test for excessive oil from the T port. Remove the cap (Item 1) [B] from the tee fitting.

P–11280

Install a 1000 PSI (6895 kPa) gauge on the tee.

Start the excavator and record the pressure.

The pressure reducing valve is factory set at 365 PSI (2517 kPa). To adjust the pressure, loosen the lock nut (Item 1) [C] and turn the adjustment screw (Item 2) [C] clockwise to increase the pressure and counterclockwise to decrease the pressure.

Tighten the lock nut (Item 1) [C]. Remove and install the cap (Item 1) [B] on the tee. P–11279

Revised Dec. 00

–2–69–

320/322 Excavator Service Manual

BOOM CYLINDER

Removal and Installation NOTE: Refer to the Page 2–72 – 2–81 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.

1 P–11120

I–2003–0888

Remove the boom shield mounting bolt (Item 1) [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].

1 P–11316

Disconnect the two hoses (Item 1) [C] from the boom cylinder.

Remove the snap ring (Item 2) [C] and washers from the boom cylinder base end pin. Remove the cylinder base end pin.

Lower the base end of the cylinder to the floor.

2 P–11317

Remove the snap ring (Item 1) [D] and washer from the cylinder rod end pin.

Remove the cylinder rod end pin. Remove the boom cylinder from the boom.

P–11318

Revised Dec. 00

–2–70–

320/322 Excavator Service Manual

ARM CYLINDER

Removal and Installation NOTE: Refer to the Page 2–72 – 2–81 for servicing the cylinder.

Lower the boom/bucket to the floor. Stop the engine. Support the boom using a chain hoist [A].

3 1

Move the hydraulic controls to release the hydraulic pressure.

P–11319

I–2003–0888

Disconnect the two hoses (Item 1) [A] from the arm cylinder. Remove the hose clamp (Item 2) [A] from the arm cylinder.

P–11121

Remove the snap ring (Item 3) [A] and washer from the boom cylinder base end pin. Remove the cylinder base end pin. Remove the snap ring (Item 1) [B] and washer from the cylinder rod end pin. Remove the cylinder rod end pin. Remove the cylinder from the arm.

Revised Dec. 00

–2–71–

320/322 Excavator Service Manual

BUCKET CYLINDER

Removal and Installation

2 NOTE: Refer to the Page 2–72 – 2–81 for servicing the cylinder. Lower the bucket to the floor. Stop the engine. Support the boom using a chain hoist. Move the hydraulic controls to release the hydraulic pressure.

P–11122

I–2003–0888

Disconnect the two hoses (Item 1) [A] from the bucket cylinder.

Remove the snap ring (Item 2) [A] and washer from the cylinder base end pin.

P–11320

Remove the base end pin and lower the base end to the floor.

Remove the two snap rings (Item 1) [B].

Remove the bucket link (Item 2) [B]. Remove the bucket link pins (Item 1) [C]. Remove the bucket cylinder.

P–11321

Revised Dec. 00

–2–72–

320/322 Excavator Service Manual

BLADE CYLINDER

Removal and Installation NOTE: Refer to the Page 2–72 – 2–81 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 (Item 1) [A] from the blade cylinder shield.

P–11322

Remove the blade cylinder shields (Item 1) [B].

B 1

I–2003–0888 P–11323

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

C 1

P–11324

NOTE: Use care not to lose the orifice (Item 1) [D] located in the cylinder base end hose.

P–11325

Revised Dec. 00

–2–73–

320/322 Excavator Service Manual

BLADE CYLINDER (Cont’d)

Removal and Installation Remove the snap rings (Item 1) [A] and washers from the cylinder base and rod ends.

1 2

Remove the cylinder retaining pins (Item 2) [A]. Remove the blade cylinder.

NOTE: Install the cylinder base end shims (Item 3) [A] on both sides of the cylinder base.

P–11326

BOOM SWING CYLINDER

Removal and Installation NOTE: Refer to the Page 2–72 – 2–81 for servicing the cylinder.

1 N–00806

I–2003–0888

Lower the bucket and blade to the floor. Stop the engine. Remove the snap ring (Item 1) [B] and washer from the rod end pin .

Remove the rod end pin (Item 2) [B]. Start the excavator and carefully retract the cylinder fully. Stop the engine. P–02227

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]. Slide the cylinder forward to remove the base end from the cylinder mount. Set the cylinder down on 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. (40–50 Nm) torque. Revised Dec. 00

P–03299

–2–74–

320/322 Excavator Service Manual

TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above)

NOTE: Refer to Page 2–72 – 2–81 for servicing the cylinder. Expand the track frame fully. Place blocks under the excavator tracks [A].

P–15286

Remove the four bolts (Item 1) [B].

Remove the access plate (Item 2) [B].

P–15316

Remove the hose (Item 1) [C] from the cylinder rod end.

1 P–15311

Install a hose (Item 1) [D] on the cylinder rod end. Place the other end of the hose in a drain pan.

P–15310

Revised Dec. 00

–2–75–

320/322 Excavator Service Manual

TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d) Remove the hose (Item 1) [D] from the cylinder base end.

P–15313

Install a hose (Item 1) [B] on the cylinder base end. Place the other end of the hose in a drain pan.

B 1

P–15312

Remove the three nuts (Item 1) [C] from the rod end of the cylinder.

Installation: Tighten the nuts to 32–35 ft. lbs. (43–47 Nm) torque.

1 P–15309

Slightly compress the cylinder. Remove the two plates (Item 1) [D] from the rod end of the cylinder.

D 1

P–15308

Revised Dec. 00

–2–76–

320/322 Excavator Service Manual

TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above)

Remove the mount plate (Item 1) [A] from the track frame.

1 P–15307

Remove the three bolts (Item 1) [B] from the track frame.

B 1

P–15306

Remove the three nuts (Item 1) [C] from the base end of the cylinder installation: Tighten the nuts to 32–35 ft.–lbs. (43–47 Nm) torque.

1 P–15305

Pull the cylinder out of the mount. Remove the two plates (Item 1) [D] from the base end of the cylinder.

1 P–15304

Revised Dec. 00

–2–77–

320/322 Excavator Service Manual

TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d) Remove the mount plate (Item 1) [A] from the track frame.

1 P–15303

Remove the three bolts (Item 1) [B] from the track frame.

Compress the cylinder. Rotate the cylinder until the hose clamp is accessible.

P–15302

Remove the bolt (Item 1) [C].

Remove the cylinder.

P–15301

Revised Dec. 00

–2–78–

320/322 Excavator Service Manual

HYDRAULIC CYLINDER

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 Dec. 00

–2–79–

320/322 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 (Item 2) [A] off the rod. 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

Revised Dec. 00

–2–80–

320/322 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

Revised Dec. 00

–2–81–

320/322 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

Revised Dec. 00

–2–82–

320/322 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.

B–12809

B–13742

Revised Dec. 00

–2–83–

320/322 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–3702

B–3671

Revised Dec. 00

–2–84–

320/322 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 Dec. 00

–2–85–

320/322 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]. Boom, Arm, Blade Bucket and Swing Cylinder; Tighten the nut to 315–385 ft.–lbs. (427–522 Nm) torque. Track Expansion Cylinder; Tighten the nut to 90 ft.–lbs (122 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 Dec. 00

–2–86–

320/322 Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

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

B–13744

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: Tighten the gland nut until it is flush with the end of the cylinder case.

B–07000

Added Dec. 00

–2–87–

320/322 Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d

Assembly (Cont’d) Remove the seals (Item 1) [A].

Remove the bushing (Item 2) [A] (if equipped). NOTE: Cylinders that have the wear bushing and seals installed in the rod end are painted black for identification. When installing the bushing (Item 2) [A] make sure the bushing is aligned with the grease channel in the cylinder.

2 1

Install the seals (Item 1) [A]. N–16436

Added Dec. 00

–2–88–

320/322 Excavator Service Manual

HYDRAULIC FILTER ASSEMBLY

Removal and Installation

P–11057

I–2003–0284

Raise the engine cover [A]. Loosen the hose clamp (Item 1) [B] from the hose.

Remove the hose from the filter assembly. Remove the tube (Item 2) [B].

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–11083

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

AUXILIARY FLUSH FACE COUPLERS Removal and Installation

Excavators are equipped with flush faced couplers. Wipe the mating surfaces clean (including the outside diameter of the male coupler). To engage, align the ends of the couplers and push straight in. When the couplers are engaged, the locking collar can be turned to prevent unwanted disengagement. To disengage, align the ball and slot on the female coupler then slide the locking collar back.

2 P–11094

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

Added Dec. 00

–2–89–

320/322 Excavator Service Manual

DRAIN BLOCK

Removal and Installation

1 P–11280

I–2003–0888

Drain the hydraulic reservoir. (See Page 1–1.) Mark the hoses for ease of assembly. Remove the hoses from the drain block [A].

Remove the two bolts (Item 1) [A] from the drain block. Remove the block. OIL COOLER Removal and Installation For ease of removal, remove the oil cooler with the radiator. (See Page 7–1.)

P–11282

Remove the two bolts (Item 1) [B] from the oil cooler and remove the cooler from the radiator.

Added Dec. 00

–2–90–

320/322 Excavator Service Manual

JOYSTICK CONTROL CHANGE

ISO To Standard

3 4

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

1 2

Open the tool box door. Remove the hose cover plate. (See Page 3–1.) Remove the bottom plate from the tool box. (See Page 3–1.) Mark and remove hoses (Item 1) [A], (Item 2) [A], (Item 3) [A] and (Item 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

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

1 2

3 4

Open the tool box door. Remove the hose cover plate. (See Page 3–1.) Remove the bottom plate from the tool box. (See Page 3–1.) Mark and remove hose (Item 1) [C], (Item 2) [C], (Item 3) [C] and (Item 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 Dec. 00

–2–91–

320/322 Excavator Service Manual

–2–92–

320/322 Excavator Service Manual

DRIVE SECTION Page Number BLADE LEVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–39 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41 CONTROL CONSOLE LEFT HAND Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 CONTROL CONSOLE RIGHT HAND Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23

DRIVE SECTION

CONSOLE COVER LEFT HAND Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 CONSOLE COVER RIGHT HAND Cab Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 Rops Canopy Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20 DRIVE MOTOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–51 3–44 3–43 3–42

FLOORMAT AND FLOOR PANELS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 FUEL TANK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 GAS SPRING Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18 HYDRAULIC RESERVOIR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 JOYSTICK Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–64 3–61 3–60 3–9 3–69

LATCH HOOK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 LINKAGE RODS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38 LOCK LEVER Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15

–3–1–

320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE SECTION (Cont’d) Page Number MICROSWITCH Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 PEDAL LEFT HAND Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34 PEDAL RIGHT HAND Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32 ROCKERSHAFT Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36 TRAVEL LEVERS Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29 UPPER CONSOLE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19

–3–2–

320 (S/N 562313001 & Above) Excavator Service Manual

FLOORMAT AND FLOOR PANELS

Removal and Installation Remove the two bolts (Item 1) [A] in each floormat retaining plate. Remove the floormat retaining plate (Item 2) [A] from both sides.

1 2 P–11097

Remove the two spacers (Item 1) [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.

P–11167

Remove the floormat [C].

P–11168

Remove the two bolts (Item 1) [D] from the control cover plate.

1 P–11169

–3–3–

320 (S/N 562313001 & Above) Excavator Service Manual

FLOORMAT AND FLOOR PANELS (Cont’d)

Removal and Installation (Cont’d) Remove the three bolts from the rear floor panel.

P–11170

Remove the rear floor panel [B].

P–11171

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

P–11172

–3–4–

320 (S/N 562313001 & Above) Excavator Service Manual

MICROSWITCH

Adjustment Adjust the console latch. (See Page 3–16.) 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 inch (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–12887

Move the Microswitch to the top of adjustment slots.

MC–01733

–3–5–

320 (S/N 562313001 & Above) Excavator Service Manual

MICROSWITCH (Cont’d)

Removal and Installation Raise the control console. Remove the access plate. (See Page 3–7.) Unplug the microswitch harness from the console harness [A].

CD–12888

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

The microswitch is normally open. With the console raised the gauge reading should show no thru 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, lock washers and screws holding the microswitch [C].

CD–13004

Remove the microswitch [D].

NOTE: See microswitch adjustment procedure on Page 3–5. This procedure must be performed after a new microswitch has been installed.

CD–13005

–3–6–

320 (S/N 562313001 & Above) Excavator Service Manual

CONSOLE COVER LEFT HAND

Removal and Installation Lower the blade and the boom to the ground. Disconnect the battery negative (–) cable. (See Page 6–1.)

Remove the latch knob (Item 1) [A].

Remove the eight screws (Item 2) [A] from the console cover.

P–11292

Tilt the console up.

Remove the two bolts (Item 1) [B] from the access plate. Remove the access plate.

P–11222

Remove the harness clamp (Item 1) [C]. Mark the wires for ease of assembly.

1 P–11223

Remove the wires from the fuel gauge (Item 1) [D] and low fuel indicator lamp (Item 2) [D].

CD–12897

–3–7–

320 (S/N 562313001 & Above) Excavator Service Manual

CONSOLE COVER LEFT HAND (Cont’d)

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

P–02406

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

CD–12899

Remove the indicator lamp [C].

CD–12900

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

Remove the arm rest [D].

CD–12901

–3–8–

320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK

Removal and Installation Lower the boom and blade to the ground. Remove the console cover. (See Page 3–7.) 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 from the joystick mounting plate [B].

CD–12903

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

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

N–12904

–3–9–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE LEFT HAND

Removal and Installation Turn the upperstructure to have access to the hydraulic tank drain plug and to the fuel tank drain valve. Lower the boom/bucket and the blade to the ground. Remove the floorboards. (See Page 3–3.)

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

P–11066

Remove the console cover. (See Page 3–7.)

Remove the battery negative (–) cable. (See Page 6–1.) 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.

N–00805

Open the tool box door.

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

P–11091

Remove the cover plate [D].

CD–12907

–3–10–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE LEFT HAND (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 (Item 1) [B], (Item 4) [B], (Item 5) [B], and (Item 8) [B] from the fittings.

5 6

2 3

For Standard Control Pattern

Remove the hoses (Item 2) [B], (Item 4) [B], (Item 6) [B], and (Item 8) [B] from the fittings.

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

–3–11–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE LEFT HAND (Cont’d)

Removal and Installation (Cont’d) Remove the left hand side cover by using the ignition key and unlocking the side cover [A]. Tilt the cover back and remove it from the frame.

P–11063

Remove the three bolts holding the control console to the frame and the front engine cover [B] & [C].

Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Tilt the top of the console out from the excavator.

P–11263

P–11289

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

CD–12911

–3–12–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE LEFT HAND (Cont’d)

Removal and Installation (Cont’d) Disconnect the two wire harnesses that go to the left hand control console [A].

CD–12912

Install a chain hoist to the top sides of the control console and lift the console from the excavator [B].

P–02402

FUEL TANK Removal and Installation

Remove the left control console. (See Page 3–10.)

Remove the gas spring. (See Page 3–18.) Remove the screw (Item 1) [C] from the cover. Remove the three bolts (Item 2) [C] from the cover. Remove the cover.

P–11291

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

CD–12888

–3–13–

320 (S/N 562313001 & Above) Excavator Service Manual

FUEL TANK (Cont’d)

Removal and Installation (Cont’d) Disconnect the wire harness from the fuel sender [A].

CD–13008

Remove the four bolts holding the joystick mounting plate to the console [B].

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 [C].

CD–12916

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

CD–12917

–3–14–

320 (S/N 562313001 & Above) Excavator Service Manual

LOCK LEVER

Removal and Installation Remove the console cover. (See Page 3–7.) Remove the gas spring. (See Page 3–18.) 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 thru 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

–3–15–

320 (S/N 562313001 & Above) Excavator Service Manual

LOCK LEVER (Cont’d)

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 3–5 for microswitch removal and testing.

Adjustment 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 the lock lever adjustments. CD–12922

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 before and after for proper adjustment.)

C Flush contact between latch and hook.

Close the control console to latched position. Push down on the console to remove the gas spring pressure. Loosen these two bolts.

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

MC–1733

–3–16–

320 (S/N 562313001 & Above) Excavator Service Manual

LATCH HOOK

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. 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 mounting plate (Item 14) [D].

CD–12925

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

CD–13029

–3–17–

320 (S/N 562313001 & Above) Excavator Service Manual

GAS SPRING

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 (Item 1) [B] from the bottom side of the console.

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

–3–18–

320 (S/N 562313001 & Above) Excavator Service Manual

UPPER CONSOLE

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 3–7.)

CD–12980

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].

CD–12981

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.

PI–12932

–3–19–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE RIGHT HAND

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 console pages as listed below: MICROSWITCH – Adjustment Procedure (See Page 3–5.) LOCK OUT MICROSWITCH – Removal and Installation (See Page 3–6.)

CD–12933

LOCK LEVER – Adjustment Procedure (See Page 3–16.) LOCK LEVER – Removal and Installation (See Page 3–15.)

LATCH HOOK – Removal and Installation (See Page 3–17.) GAS SPRING – Removal and Installation (See Page 3–18.) 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. CD–12934

To tilt the console up, remove the two bolts from the console [A].

C Remove the two bolts from the console plate [B]. Remove the console cover plate [C].

CD–12894

The right hand console harness uses a jumper harness (Item1) [D] in place of the microswitch so that the joystick manifold/accumulator will function properly.

CD–13009

–3–20–

320 (S/N 562313001 & Above) Excavator Service Manual

CONSOLE COVER RIGHT HAND

Removal and Installation Lower the boom and blade to the ground. Disconnect the battery negative (–) cable. (See Page 6–1.) Remove the ignition key. Remove the nut and the decal plate from the ignition switch [A]. Push the ignition switch inside the console cover.

CD–12936

Remove the latch lever knob (Item 1) [B]. Remove the eight screws (Item 2) [B] from the console cover. Tilt the console up.

1 P–11288

Remove the two bolts (Item 1) [C] from the access plate. Remove the access plate. Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

P–11287

–3–21–

320 (S/N 562313001 & Above) Excavator Service Manual

CONSOLE COVER RIGHT HAND (Cont’d)

Removal and Installation (Cont’d) Mark the electrical wires for ease of assembly.

Remove the wires from the auxiliary power plug (Item 1) [A]. Turn the inner auxiliary power plug housing and remove it from the outer housing. Remove the outer auxiliary power plug [A].

P–11286

Lift the console cover over the joystick handle.

Mark and remove the wires from the indicator lamps [B].

CD–12939

Remove the indicator lights by squeezing together the mounting tabs on the indicator light and pushing it out of the panel [C].

CD–13010

Remove the two bolts and retainer plate from the console cover and remove the armrest [D].

CD–12901

–3–22–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE RIGHT HAND

Removal and Installation Lower the boom/bucket and blade to the ground. Remove the console cover. (See Page 3–21.) Mark the hoses for ease of assembly. Loosen the hose connections while the joystick is bolted to the console [A].

CD–12949

Remove the horn wires from the joystick [B].

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 [C].

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

–3–23–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE RIGHT HAND (Cont’d)

Removal and Installation (Cont’d)

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 3–3.) Remove the seat. (See Page 5–1.)

Remove the seat mount. (See Page 5–1.) Remove the speed control lever/lockout lever mount. (See Page 5–1.)

N–00805

Remove the console cover. (See Page 3–21.)

Disconnect the battery negative (–) terminal. (See Page 6–1.) Drain the hydraulic fluid (approximately 3.5 gal. [13.8 L.]) by removing the drain plug (Item 1) [A] from the elbow on the bottom of the hydraulic reservoir. Remove the hose clamp (Item 2) [A] and hose from the elbow.

2 Remove the hose (Item 1) [B] and case drain filter (Item 2) [B] from the hydraulic reservoir.

1 P–11084

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

CD–12906

Remove the cover plate [D].

CD–12907

–3–24–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE RIGHT HAND (Cont’d)

320ServiceManual#6724910S/N562313001&Above–DriveSectionpart1of3

CD–12908

Mark the hoses for ease of assembly as shown [B].

For I.S.O. Control Pattern

5 6

Remove the hoses (Item 2) [B], (Item 3) [B], (Item 6) [B], and (Item 7) [B] from the elbows.

For Standard Control Pattern Remove the hoses (Item 1) [B], (Item 3) [B], (Item 5) [B], and (Item 7) [B] from the elbows.

7 8

P–02348

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

CD–13007

Remove the hose from the drain block [D].

CD–12955

–3–25–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE RIGHT HAND (Cont’d)

Removal and Installation (Cont’d) Remove the right hand side cover by using the ignition key and unlocking the side cover [A]. Tilt the cover back and remove it from the frame.

P–11080

Remove the light switch harness (Item 1) [B] from the light switch.

B 1

P–11241

Remove the screw (Item 1) [C] from the cover.

P–11242

Remove the three bolts (Item 1) [D] from the right cover. Remove the cover.

D 1

P–11284

–3–26–

320 (S/N 562313001 & Above) Excavator Service Manual

CONTROL CONSOLE RIGHT HAND (Cont’d)

Removal and Installation (Cont’d) Disconnect the wire harnesses going to the right console [A].

P–11290

Remove the bolt (Item 1) [B] holding the control console to the frame.

B 1

P–11305

Remove the two bolts (Item 1) [C] from the console.

P–11285

Install a chain hoist to the top sides of the control console and lift the console from the excavator [D].

P–02401

–3–27–

320 (S/N 562313001 & Above) Excavator Service Manual

HYDRAULIC RESERVOIR

Removal and Installation Remove the right control console. (See Page 3–24.) Disconnect the microswitch harness from the console wire harness [A].

PI–12888

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

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

–3–28–

320 (S/N 562313001 & Above) Excavator Service Manual

TRAVEL LEVERS

Removal and Installation Remove the floormat and floorboards. (See Page 3–3.) Remove the cover plate [A].

P–11173

Remove the boom swing pedal guard mount bolt (Item 1) [B].

Remove the pedal guard.

P–11258

Remove the three bolts (Item 1) [C] & [D] from the boom swing pedal.

Reposition the pedal out of the way to provide clearance for removing the travel levers.

P–11257

D 1

P–11259

–3–29–

320 (S/N 562313001 & Above) Excavator Service Manual

TRAVEL LEVERS (Cont’d)

Removal and Installation (Cont’d) Remove the nuts from the two ball joints (Item 1) [A] that attach to the travel levers.

P–11174

Loosen the four bolts (Item 1) [B] (two per side) from the sides of the travel lever mounting plate.

Remove the travel levers and mounting plate.

P–11175

Disassembly and Assembly Remove the three bolts (Item 1) [C] holding the travel lever pivots to the mounting plate. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

CD–13013

–3–30–

320 (S/N 562313001 & Above) Excavator Service Manual

TRAVEL LEVERS (Cont’d)

Disassembly and Assembly (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. 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 the 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

–3–31–

320 (S/N 562313001 & Above) Excavator Service Manual

PEDAL RIGHT HAND

Removal and Installation Remove the floorboards. (See Page 3–3.) 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

Disassembly and Assembly 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

–3–32–

320 (S/N 562313001 & Above) Excavator Service Manual

PEDAL RIGHT HAND (Cont’d)

Disassembly and Assembly (Cont’d)

Disassemble the pedal mounting plate. 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

–3–33–

CD–12962

320 (S/N 562313001 & Above) Excavator Service Manual

PEDAL LEFT HAND

Removal and Installation Remove the floorboards. (See Page 3–3.) 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

Disassembly and Assembly

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

–3–34–

320 (S/N 562313001 & Above) Excavator Service Manual

PEDAL LEFT HAND (Cont’d)

Disassembly and Assembly (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) [A] before installing the sleeve (Item 7) [A] into the pivot (Item 5) [A].

–3–35–

1 CD–12947

320 (S/N 562313001 & Above) Excavator Service Manual

ROCKERSHAFT

Removal and Installation Remove the floorboards. (See Page 3–3.) Remove the travel levers. (See Page 3–29.) Remove the nut from the ball joint at the left hand pedal (shown) and the right hand pedal [A].

CD–12967

Remove the cotter pins and clevis pins from the clevis at the control valve [B].

P–11176

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

–3–36–

320 (S/N 562313001 & Above) Excavator Service Manual

ROCKERSHAFT (Cont’d)

Disassembly and Assembly Mark the linkage rods and their orientation in the bellcranks for ease of assembly. Mark the bellcrank locations and orientation. 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) [D], washers (Item 2) [D], bellcrank (Item 3) [D], wave washer (Item 4) [D], spacer (Item 5) [D], bearing (Item 6) [D], spacer (Item 7) [D], bellcrank (Item 8) [D], spacer (Item 9) [D], bellcrank (Item 10) [D], nut (Item 11) [D], bolt (Item 12) [D], mounting plate (Item 13) [D] and rockershaft (Item 14) [D].

10 1

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.

NOTE: Bellcranks (Item 8) [D] have replaceable bushings pressed into each end.

12 11

13 14

–3–37–

CD–12972

320 (S/N 562313001 & 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

P–11176

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

–3–38–

320 (S/N 562313001 & Above) Excavator Service Manual

BLADE LEVER

Removal and Installation Remove the floor panel. (See Page 3–3.) 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

–3–39–

320 (S/N 562313001 & Above) Excavator Service Manual

BLADE LEVER (Cont’d)

Removal and Installation (Cont’d) Disassemble the pivot mount. Bushing (Item 1) [A], pivot mount (Item 2) [A], O–ring (Item 3) [A] and the sleeve (Item 4) [A].

3 P–02248

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

–3–40–

320 (S/N 562313001 & Above) Excavator Service Manual

BLADE LEVER (Cont’d)

Removal and Installation (Cont’d) Remove the bellcrank, pivot mount and linkage [A].

CD–12981

Disassembly and Assembly 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

–3–41–

1 CD–12947

320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR

Removal and Installation Remove the track. (See Page 5–1.)

P–11248

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. Mark the hoses for correct installation

Disconnect the hoses (Item 1) [B] from the drive motor. Remove the drive motor mounting bolts (Item 2) [B]. P–11249

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

Remove the drive motor. Put the drive motor in a vise to remove the drive sprocket [C]. Installation: Tighten the cap screws to 48–55 ft.–lbs. (66–75 Nm) torque.

PI–10178

–3–42–

320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d) Parts Identification 39 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 42 Plug Cover O–ring 39 40 Bushing Sun Gear Snap Ring Sun Gear 38 Planetary Carrier 37 Snap Ring Anti–rotation Washers 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

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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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 I.D. O.D.

2.56 inch (65 mm) 1.38 inch (35 mm) 1.97 inch (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

320ServiceManual#6724910S/N562313001&Above–DriveSectionpart2of3

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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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 I.D. O.D.

2.75 inch (70 mm) .677 inch (17,2 mm) .708 inch (18 mm)

B–14624

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

Assembly (Cont’d) The bearing (Item 1) [A] must extend from the face of the cover 0.098–0.110 inch (2,5–2,8 mm). 0.098–0.110’’ (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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 in the housing, using the bearing installation tool [C].

B–14657

Obtain the bearing installation tool locally.

The dimensions of the bearing installation tool [D] are as follows: Height I.D. O.D.

4.27 inch (108,4 mm) 3.78 inch (96 mm) 5.69 inch (144,5 mm)

3.78’’ (96 mm)

4.27’’ (108,4 mm)

5.69’’ (144,5 mm)

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B–14593

320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

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 0.30 ± 0.02 inches (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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.

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 0.008–0.031 inch (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 [D].

Seat the cover in the hub. Remove the cover and measure the solder.

B–14771

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320 (S/N 562313001 & Above) Excavator Service Manual

DRIVE MOTOR (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 inch (0,5 mm) . . . . . . 6669597 0.030 inch (0,76 mm) . . . . . 6669598 0.050 inch (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 1.06 qts. (1,0 L) 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

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320 (S/N 562313001 & 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.

Plug Rod Seat Spring Rod Boot Nut Selector Ring Joint Handle Assembly 10

6 1 7 2

3 4 8

9 5

B–14600

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Disassembly

2 1

Clamp the joystick in a vise with padded jaws. Loosen the handle locknut (Item 1) [A] and remove the handle (Item 2) [A].

P–08531

Remove the dust boot from the groove on the joystick valve [B].

P–08532

Pull the dust boot up and remove the boot lip from the top groove [C]. Remove the dust boot.

P–08533

Loosen the lever locknut locknut (Item 1) [D] and remove the lever (Item 2) [D].

2 1

P–08534

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Disassembly (Cont’d) Insert a drift in the selector ring hole (Item 1) [A] and loosen the coupler (Item 2) [A].

Remove the coupler.

P–08535

Remove the selector ring (Item 1) [B].

B 1

P–08536

Remove the swivel joint (Item 1) [C].

C 1

P–08537

Remove the plunger snap ring (Item 1) [D].

P–08538

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Disassembly (Cont’d) Remove the plunger by prying on the edges with two small flat blade screwdrivers [A]. NOTE: Install the plungers in the same bore from which they are removed.

P–08539

Remove the push rod (Item 1) [B] from the plug (Item 2) [B]. Remove the O–ring (Item 3) [B] from the outside of the plug (Item 2) [B] and the seal (Item 4) [B] from the inside of the plug (Item 2) [B].

B 3

4 P–08542

Remove the spool assembly (Item 1) [C].

NOTE: Install the spool assembly in the same bore from which they are removed.

P–08541

Remove the centering spring (Item 1) [D] from the joystick body.

P–08540

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Disassembly (Cont’d) Remove the two shims (Item 1) [A] from the end of the spool (Item 2) [A].

2 P–08543

Compress the spring (Item 1) [B] and remove the C–clip (Item 2) [B] and washer (Item 3) [B] from the end of the spool (Item 4) [B].

B 1

P–08544

Remove the spring seat (Item 1) [C], the spring (Item 2) [C] and washer (Item 3) [C] from the spool (Item 4) [C].

Repeat steps 62–[D] through 64–[C] for the remaining three plunger/spool assembly.

P–08545

Assembly

Clean all parts in solvent and dry with compressed air. Inspect the push rod crown for wear. Replace all components showing excessive wear.

Oil and Install a new seal (Item 1) [D] in the plug. Be sure the seal lip is toward the valve body. Oil and install a new O–ring (Item 2) [D] on the plug.

2 B–14599

Revised Dec. 00

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Assembly (Cont’d) Install the push rod (Item 1) [A] in the plug (Item 2) [A].

P–08542

Install the washer (Item 1) [B], spring (Item 2) [B] and the spring seat (Item 3) [B] on the spool (Item 4) [B].

P–08545

Compress the spring (Item 1) [C] and install the washer (Item 2) [C] and C–clip (Item 3) [C] on the end of the spool (Item 4) [C].

C 1

P–08544

Install the two shims (Item 1) [D] on the end of the spool (Item 2) [D]. Slide the spring seat (Item 3) [D] to the end of the spool (Item 2) [D] to retain the shims (Item 1) [D] in place.

D 3

2 P–08543

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Assembly (Cont’d) Install the centering spring (Item 1) [A] in the joystick body.

P–08540

Dip the spool assembly (Item 1) [B] in clean hydraulic oil and install the spool assembly (Item 1) [B] in the port which it was previously removed.

B 1

P–08541

Install the plunger (Item 1) [C] in the valve body. Install the plunger snap ring (Item 2) [C] in the snap ring groove.

Repeat steps 3–64 [D] through 3–66 [C] for the remaining three plunger/spool assembly.

2 1 P–08538

Revised Dec. 00

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Assembly (Cont’d) Apply thread lock (LOCTITE #542) to the swivel joint threads, and install the swivel joint (Item 1) [A] in the joystick valve body. Tighten to 5 ft.–lbs. (7 Nm) of torque. Lubricate the swivel joint after installation.

P–08537

Grease the bottom plate of the selector ring [B].

P–08546

Install the selector ring (Item 1) [C].

Tighten the selector ring until it makes slight contact with all four push rods.

P–08536

Install the coupler (Item 1) [D] on the end of the swivel joint. Insert a drift in the hole in the selector ring (Item 2) [D] and tighten the coupler to 5 ft.–lbs. (7 Nm) of torque.

D 1

P–08535

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Assembly (Cont’d)

Install the lever (Item 1) [A], in the coupler (Item 2) [A].

3 Tighten the locknut (Item 3) [A] making sure the lever (Item 1) [A] is orientated toward port number two.

P–08534

Install the dust boot over the lever until the top lip on the dust boot engages the top groove on the coupler [B].

P–08533

Install the bottom lip of the dust boot in the groove on the joystick valve body [C].

P–08532

Install the handle (Item 1) [D] on the lever (Item 2) [D].

Tighten the handle locknut (Item 3) [D].

1 3 2

P–08531

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320 (S/N 562313001 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

Troubleshooting To test a joystick that has a circuit that sticks, remove the cap (Item 1) [A] from the tee fitting.

Install a 500 PSI (3448 kPa) gauge on the tee fitting. Start the excavator, and warm the hydraulic oil to operating temperature. Engage the circuit to be tested and record the operating pressure. The operating pressure should be approximately 300 PSI (2482 kPa).

P–11280

If the pressure is low, check the other joystick pilot lines for correct operating pressure. If the operating pressure is correct, check the valve section spool for proper operation. If the operating pressure is incorrect, remove the pressure reducing valve, clean, install and retest. If the pressure is still incorrect replace the pressure reducing valve. (See Page 2–1.)

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320 (S/N 562313001 & Above) Excavator Service Manual

320ServiceManual#6724910S/N562313001&Above–DriveSectionpart3of3

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320 (S/N 562313001 & Above) Excavator Service Manual

UPPER WORKS AND SWING SECTION Page Number AIR BAFFLE (Cab Models Only) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–41 BELLY PAN (Field Installed) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–41 CAB Door (Removal and Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33 Front Lower Window (Removal and Installation) . . . . . . . . . . . . . . . . . . . 4–35 Front Upper Window (Removal and Installation) . . . . . . . . . . . . . . . . . . . 4–35 Front Window (Removal and Installation) . . . . . . . . . . . . . . . . . . . . . . . . . 4–34 Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–38 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30 Right Hand Side Window (Removal and Installation) . . . . . . . . . . . . . . . 4–36 Right Side Front And Rear Sliding Window Weather Strip Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–37 Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–37

UPPER WORKS & SWING SYSTEM

CAB/CANOPY REAR COVER Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–40 CENTER SWIVEL JOINT (S/N 562313001 – 562319999) Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–19 4–15 4–14 4–8

ROPS CANOPY Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28 SWING CIRCLE GEAR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27 SWING MOTOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–5 4–4 4–6 4–3

UPPERSTRUCTURE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23

Revised July 05

–4–1–

320/322 Excavator Service Manual

Revised July 05

–4–2–

320/322 Excavator Service Manual

SWING MOTOR

Removal and Installation

P–11276

I–2003–0888

B Remove the seat and seat mount. (See Page 5–1.) Remove the speed control lever/swing lock mount. (See Page 5–1.)

Remove the tubelines (Item 1) [A] from the swing motor. Remove the hose (Item 1) [B] from the swing motor.

P–11278

Remove the six bolts (Item 1) [C] from the swing motor. Installation: Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Remove the swing motor from the excavator.

P–11277

Revised Sept. 99

–4–3–

320/322 Excavator Service Manual

SWING MOTOR (Cont’d)

Disassembly

4 Quad Seal

Cap Screw (8)

Clean the motor and drain the oil from the motor.

Use a soft jaw vise to hold the motor by the mounting flange.

Seal Retainer

Square Cut Seal

NOTE: Do not disassemble the geroler (Item 1) [A]. The geroler has machined close tolerances. Damage may occur during reassembly.

Shaft

Race Seal and O–ring

Mark the bearing housing by the alignment groove for assembly. The alignment groove aligns the case drain hole in the valve housing.

Shaft and Bearing Housing

Disassemble the motor. NOTE: The cap screws (Item 2) [A] are held by thread bonding adhesive. DO NOT exceed 70 in–lbs. to remove the 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) [A].

Square Cut Seal

Retaining Ring

Shift Face Seal Wear Plate Square Cut Seal

Remove the quad seal (Item 4) [A] and the square cut seal (Item 5) [A] from the retainer. NOTE: Check the seal retainer for cracks. Order a new retainer from Melroe Parts, if needed.

Drive

1 Geroler Square Cut Seal

Valve Drive Valve Plate

Square Cut Seal

Valve Balance Ring

Inner and Outer Face Seals Plug

Pin and Spring

O–ring

Valve Housing Bolt (4)

Revised Sept. 99

–4–4–

B–13496

320/322 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) [A] 180° from one another. 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 thread adhesive (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 thread adhesive (LOCTITE 609) to the threads. Install the screws and tighten to 60 in.–lbs. (6,7 Nm) torque.

Revised Sept. 99

–4–5–

320/322 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. 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).

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 crisscross 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

Revised Sept. 99

–4–6–

320/322 Excavator Service Manual

CENTER SWIVEL 562319999)

JOINT

(S/N

562313001

–

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 seat and seat mount. (See Page 5–1.) Remove the floorboards. (See Page 3–1.)

CD–12987

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]. CD–10481

Installation: Tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

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: Apply thread adhesive (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. CD–12988

Disassembly and Assembly 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.

Assemble the swivel joint in reverse order. Revised Sept. 99

B–12744

–4–7–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)

Removal And Installation Expand the track frame fully. Place blocks under the excavator tracks [A]. Lower the boom/bucket to the ground Remove the seat and seat mount. (See page 5–1.) Remove the floormat and floor plate. (See page 3–1.) Remove the left and right side covers. (See page 1–1.) Drain the hydraulic reservoir. (See page 1–1.)

P–15286

I–2003–0888

Remove the tube line (Item 1) [B] from the hydraulic cooler.

P–15289

Remove the tube line (Item 1) [C] from the hydraulic control valve. Rotate the tube up away from the valve. Open the tool box door.

P–15287

Remove the hose cover plate (Item 1) [D].

P–11091

Revised Sept. 99

–4–8–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d) Remove the bottom plate from the tool box [A].

P–15040

Remove the three bolts (Item 1) [B] from the left console.

1 1

P–15283

Remove the bolt (Item 1) [C] from the left console.

1 P–15281

Revised Sept. 99

–4–9–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d) Remove the three bolts (Item 1) [A] from the right console.

1 1

P–15285

Remove the bolt (Item 1) [B] from the right console.

P–15288

Disconnect the two speed switch (Item 1) [C]. Remove the four bolts (Item 2) [C].

Reposition the consoles and remove the crossmember (Item 3) [C].

1 P–15284

Remove the three hoses (Item 1) [D] from the front of the valve.

P–15280

Revised Sept. 99

–4–10–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d)

Remove the three hoses (Item 1) [A] from the rear of the valve.

P–15279

Remove the tubeline (Item 1) [B] from the valve and swivel joint.

P–15278

Remove the fitting (Item 1) [C] from the valve.

Remove the tubeline (Item 2) [C] from the valve and swivel joint. Loosen and reposition the tubeline (Item 3) [C] from the valve.

2 3

1 P–15277

Loosen the tubelines (Item 1) [D] from the valve and remove the tubelines from the swivel joint.

1 1

P–15276

Revised Sept. 99

–4–11–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 56230000 & Above) and 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d)

4 3

Loosen the clamp (Item 1) [A]. Loosen both ends of the tubeline (Item 2) [A].

Remove the tubeline (Item 3) [A] from the valve and the swivel joint.

Loosen the tubeline (Item 4) [A] from the control valve and remove the tubeline from the swivel joint.

Remove the pilot tubelines (Item 5) [A] from the valve. P–15275

Disconnect the solenoid wire harness (Item 1) [B].

P–15268

Remove the nut (Item 1) [C] from the spool. Installation: Tighten the nut until snug. Do not use any type of tool to tighten the nut or change to the coil or spool could occur.

P–15269

Remove the coil (Item 1) [D].

P–15272

Revised Sept. 99

–4–12–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) (Cont’d)

Removal And Installation (Cont’d)

Remove the spring (Item 1) [A] from the spool.

P–15273

Remove the five hoses (Item 1) [B] from the right side of the swivel joint.

B 1

1 1

P–15250

Remove the five hoses (Item 1) [C] from the left side of the swivel joint.

1 1

P–15251

Remove the remaining three nuts (Item 1) [D] and lower the swivel joint out the bottom of the excavator. Installation: Tighten the nuts to 32–25 ft. lbs. (43–47 Nm) torque.

P–15274

Revised Sept. 99

–4–13–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (s/n 562320000 & above) and 322 (S/N 517811001 & Above) (Cont’d) Parts Identification

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Plug O–Ring Housing Stud Washer Plug O–Ring Rotor Seal Seal Washer Snap Ring

NOTE: 320 excavators have seven seals (Item 10) installed on the rotor. 322 excavators have eight seals (Item 10) installed on the rotor.

8 10

7 6

5 5 11

4 3

2 1

Revised Sept. 99

–4–14–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) (Cont’d)

Disassembly Remove the two fittings (Item 1) [A].

1 1

P–15252

Remove the spool (Item 1) [B] and fitting (Item 2) [B].

B 2

P–15253

Remove the O–ring (Item 1) [C] back up ring (Item 2) [C] and seals (Item 3) [C].

P–15255

Remove the three bolts (Item 1) [D]. Remove the mount (Item 2) [D].

1 1

P–15254

Revised Sept. 99

–4–15–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

Disassembly (Cont’d)

Remove the snap ring (Item 1) [A] from the bottom of the swivel joint.

P–15256

Remove the washer (Item 1) [B].

P–15257

Remove the nylon washer (Item 1) [C].

P–15258

Tap the end of the rotor (Item 1) [D] to drive the rotor out of the housing.

1 P–15259

Revised Sept. 99

–4–16–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

A 1

Disassembly (Cont’d) Remove the seal (Item 1) [A].

P–15260

Remove the O–ring (Item 1) [B].

P–15261

Remove the seals (Item 1) [C]. NOTE: The 320 swivel joint is equipped with 7 seals and the 322 swivel joint is equipped with 8 seals.

P–15262

Remove the O–rings (Item 1) [D].

P–15263

Revised July 05

–4–17–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

Disassembly (Cont’d) Remove the seal (Item 1) [A].

P–15264

Remove the O–ring (Item 1) [B].

Remove the nylon washer (Item 2) [B].

2 P–15265

Revised July 05

–4–18–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

Assembly

Clean all parts in solvent and dry with compressed air. Inspect the rotor and housing for scratches or wear that could cause internal leakage. Always install new O–rings and seals. Install the nylon washer (Item 1) [A]. Apply oil to and install the O–ring (Item 2) [A]. Heat the seal in hydraulic oil for 3 minutes at 130°F (54°C).

1 P–15265

Install the seal (Item 1) [B] on the O–ring.

P–15264

Apply oil to and install the O–rings (Item 1) [C].

C 1

P–15263

Heat the seals in hydraulic oil for 3 minutes at 130°F (54°C) Install the seals (Item 1) [D].

D 1

P–15262

Revised July 05

–4–19–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

Assembly (Cont’d)

Apply oil to and install the O–ring (Item 1) [A].

P–15261

Heat the seal in hydraulic oil for 3 minutes at 130°F (54°C).

Install the seal (Item 1) [B].

P–15260

NOTE: A ring compresses (Item 1) [C] may be used to fit the seals into the seal grove [C].

C 1

P–15266

Apply hydraulic oil to the rotor. Install the rotor (Item 1) [D] in the housing [D].

D 1

P–15267

Revised July 05

–4–20–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

Assembly (Cont’d) Install the nylon washer (Item 1) [A].

P–15258

Install the washer (Item 1) [B].

B 1

P–15257

Install the snap ring (Item 1) [C].

P–15256

Install the mount on the swivel joint. Install the three bolts (Item 1) [D]. Tighten the bolts to 32–35 ft.–lbs. (43–47 Nm) torque.

1 1

P–15254

Revised Sept. 99

–4–21–

320/322 Excavator Service Manual

CENTER SWIVEL JOINT 320 (S/N 562320000 & Above) and 320 (517811001 & Above) (Cont’d)

Assembly (Cont’d)

Apply oil to and install the O–ring (Item 1) [A] back–up ring (Item 2) [A] and seals (Item 3) [A].

3 P–15255

Install the spool (Item 1) [B] in the swivel joint. Tighten to 35 ft.–lbs. (47 Nm) torque.

Install the fitting (Item 2) [B].

2 1

P–15253

Install the two fittings (Item 1) [C].

P–15252

Revised Sept. 99

–4–22–

320/322 Excavator Service Manual

UPPERSTRUCTURE

Removal Disconnect the battery negative (–) cable. (See Page 6–1.) Drain the hydraulic tank (See Page 3–1.) Remove the seat and seat mount. (See Page 5–1.) Remove the speed control lever/swing lock mount. (See Page 5–1.) Remove the hydraulic control valve. (See Page 2–1.)

P–11056

Remove the swing motor. (See Page 4–3.) Connect a lifting sling to the excavator at the rear of the swing frame [A].

Connect a lifting sling to the excavator at the rear of the swing frame and the front of the swing frame [A] & [B].

AVOID INJURY OR DEATH

• Use a lifting fixture with sufficient capacity • • •

for the weight of the excavator plus any added attachments. Maintain center of gravity and balance when lifting. Do not swing boom or upperstructure. Engage the swing locking lever. Never lift with operator on machine.

MC–1857A

W–2202–0595

Mark the upperstructure to the swing bearing and to the track frame for assembly [C].

N–00853

Mark and remove the hoses from the swivel joint [D].

D 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–11189

Revised Sept. 99

–4–23–

320/322 Excavator Service Manual

UPPERSTRUCTURE (Cont’d)

Removal (Cont’d)

Remove the swivel joint bracket mount bolts (Item 1) [A]. Remove the bracket (Item 2) [A].

N–00852

Apply a small amount of the lifting pressure to the upperstructure with the lift sling.

Remove the sixteen bolts from the upperstructure [B]. Lift the upperstructure off the swing bearing. Position the upperstructure onto suitable supporting stands or blocks.

P–11190

Revised Sept. 99

–4–24–

320/322 Excavator Service Manual

UPPERSTRUCTURE (Cont’d)

Installation Attach a lifting hoist to the upperstructure. (See Page 4–23). 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 thread adhesive (LOCTITE #242) to the threads of the mounting bolts.

N–00849

Install the sixteen bolts and washers through the frame and into the swing bearing [A].

DO NOT tighten the bolts at this time.

Alignment pin P/N 6539805

Insert the three alignment pins (P/N 639805) [B] & (Item 1) [C] into the alignment holes. 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. B–13728

Remove the alignment pins.

Do the following procedure to check for proper swing motor gear to swing bearing gear back lash.

N–00848

Install the swing motor (Item 1) [D] in the frame.

Apply thread adhesive (LOCTITE #242) to the threads of the six bolts (Item 2) [D] and install. Tighten the 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 Sept. 99

N–00850

–4–25–

320/322 Excavator Service Manual

UPPERSTRUCTURE (Cont’d)

Installation (Cont’d)

Install the swivel joint bracket (Item 1) [A]. Install the swivel joint bracket mount bolts (Item 2) [A].

N–00851

Install the hoses on the swivel joint [B].

P–11192

Install the tubes and hoses on the swing motor [C].

Install the hydraulic control valve. (See Page 2–1.) Install the speed control lever/swing lock mount. (See Page 5–1.) Install the seat and seat mount. (See Page 5–1.) Fill the hydraulic tank. (See Page 3–1.) Connect the negative (–) battery cable. (See Page 6–1.)

P–11193

Revised Sept. 99

–4–26–

320/322 Excavator Service Manual

SWING CIRCLE GEAR

Removal and Installation Remove the upperstructure from the swing circle gear. (See Page 4–23.) The swing gear and outer ring both have a soft zone. The swing gear soft zone is identified with an S (Item 1) [A] & [B] stamped in the swing gear. The outer ring soft zone is identified by a filler plug (Item 2) [A] & [B] pressed into the outer ring.

The soft zones of both the swing gear and outer ring must be positioned to the right side of the center line of the excavator.

MC–1415

B 2

N–00854

Remove the bolts from the swing circle gear [C].

Installation: Apply thread lock (LOCTITE #242) to the bolt threads. Early models with 10 mm diameter bolts – tighten to 44–48 ft.–lbs. (60–65 Nm) torque. Later models with 12 mm diameter bolts – tighten to 74–81 ft.–lbs. (100–110 Nm) torque.

N–00855

Using a 10 X 1.5 mm (or on later models, 12 X 1,75 mm) tap, clean the track frame bolt holes to remove the old thread locking compound.

N–00856

Revised Dec. 00

–4–27–

320/322 Excavator Service Manual

ROPS CANOPY

Removal and Installation Disconnect the battery negative (–) cable. (See Page 6–1.) 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

Added Sept. 99

–4–28–

320/322 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

Added Sept. 99

–4–29–

320/322 Excavator Service Manual

CAB

Removal and Installation Disconnect the battery negative (–) cable. (See Page 6–1.)

Drain the radiator. (See Page 7–1.) 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

Added Sept. 99

–4–30–

320/322 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

Added Sept. 99

–4–31–

320/322 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

Install the lifting eyes on the cab [B].

P–06397

Install a lifting device of sufficient capacity to the lifting eyes and lift the cab up a few inches [C].

P–06398

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

Added Sept. 99

–4–32–

320/322 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 3/4 inch (19 mm). Then rock the door back and forth until the door weight settles the door hinges to full engagement.

P–06399

Added Sept. 99

–4–33–

320/322 Excavator Service Manual

CAB (Cont’d)

Front Window Removal and Installation Remove the wiper motor from the window. Mark the wires for ease of assembly, and remove the wires from the wiper motor [A].

P–06402

Remove the mounting screw (Item 1) [B], bushing (Item 2) [B] and nut (Item 3) [B] from the two window pivots.

2 P–06403

With the help of a second person, use the window handles to hold the window in position and remove the two lower latches by removing the two screws and washers on each side of the window frame [C]

P–06404

Remove the latch (Item 1) [D], spacer (Item 2) [D] and the roller (Item 3) [D] from both sides.

D 2

Remove the front window and frame assembly.

1 3 P–06405

Added Sept. 99

–4–34–

320/322 Excavator Service Manual

CAB (Cont’d)

Front Lower Window 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 mountings screws to 30 in.–lbs. (3,4 Nm) torque. Remove the glass. Remove the gasket from the cab frame.

When installing the window, use a new window gasket seal.

P–02465

Front Upper Window Removal and Installation Remove the mounting screws (Item 1) [B] from the upper cab console to access the window mounting nuts.

1 P–02458

Remove the mounting screws, retainer straps and nuts [C].

Installation: Tighten the mounting screws to 30 in.–lbs. (3,4 Nm) torque. Remove the window. Remove the gasket from the cab frame. When installing the window, use a new window gasket seal.

P–02466

Added Sept. 99

–4–35–

320/322 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

Added Sept. 99

–4–36–

320/322 Excavator Service Manual

CAB (Cont’d)

Right Hand Side Window Removal and Installation THREE PIECE SIDE WINDOW. To remove the right hand side glass, the top window felt channel and the rubber bumper strip must be removed. Unlatch the outer window and open the window slightly. Remove the rubber bumper strip [A].

P–06410

Pull down on the felt channel [B].

Slide the glass open while pulling the felt channel 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. Pull the felt channel out of the window channel.

P–06411

Lift the glass up into the window channel and tilt the bottom edge out. Lower the glass from the cab [C].

NOTE: The outer glass must be removed before inner glass can be removed.

P–06412

Use the same procedure to remove the inner glass.

Installation: Tilt the top of the glass inward and up into the window channel. Lower the glass onto the window track.

With the window in the open position, slide the window felt channel into the window frame and onto the window. Slide the window back and forth while working the window felt into the window frame [D]. Use a blunt tool to fully seat the window channel felt. Install the rubber bumper strip at the front of the window frame. Added Sept. 99

P–06411

–4–37–

320/322 Excavator Service Manual

CAB (Cont’d) Right Hand Installation

Window

Assembly

Removal

and

Right Hand Window Assy.

To remove the right hand window assembly, remove the two pieces of glass. (See Previous Page.) Carefully pry out the window frame from the cab assembly.

Cab Frame

NOTE: If the window frame is to be reused, use care when removing the frame. The window frame is aluminum and can easily be damaged.

Install a bead of urethane window sealer

To install the window frame, clean the cab frame opening of any dust, dirt, grease or existing urethane window sealant. Put a bead of urethane window sealant (P/N 6654148) on the window frame assembly as shown [A].

Install the window assembly into the opening and press into position. Let the sealant set–up (per the recommendation on the sealant instructions on the tube) before moving the excavator. Rear Window Removal and Installation Remove the four clamps [B]. Hold the window in position while cutting the abrasive.

P–06413

Insert the cut wire through the adhesive at the corner of the window. Pull the wire around the window perimeter to cut the adhesive [C].

Installation: Install the adhesive tape to the outer perimeter of the window. Put the window into the window opening and press the window into position. Install the four window retaining clamps.

P–6410

Added Sept. 99

–4–38–

320/322 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 1/8 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 Sept. 99

–4–39–

320/322 Excavator Service Manual

AIR BAFFLE (Cab Models Only)

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 Sept. 99

–4–40–

320/322 Excavator Service Manual

MAIN FRAME AND TRACKS Page Number ARM Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 ARM BUSHINGS Arm To Boom Bushing Removal and Installation . . . . . . . . . . . . . . . . . . 5–9 Arm To Bucket and Bucket Link Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 BOOM Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11 BOOM BUSHING Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 BUCKET Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 CORNER POSTS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

MAIN FRAME & TRACKS

COUNTERWEIGHT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 ENGINE COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 SEAT AND SEAT MOUNT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 SWING POST Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Post Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRACK Adjustment 320 (S/N 562313001–562319999) . . . . . . . . . . . . . . . . . . . . Adjustment 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Track Damage Identification & Causes . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–14 5–14 5–13 5–14 5–15 5–16 5–17 5–17

Continued On Next Page

Revised July 05

–5–1–

320/322 Excavator Service Manual

MAIN FRAME AND TRACKS (CONT’D) Page Number TRACK DAMAGE IDENTIFICATION Abrasion of Embedded Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abrasion of the Track Roller Side Rubber Surface . . . . . . . . . . . . . . . . . Cracks and Cuts on the Lug Side Rubber at the Edges of the Embedded Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cracks on the Lug Side Rubber Due to Fatigue . . . . . . . . . . . . . . . . . . . Cuts on the Edges of the Track Roller Side . . . . . . . . . . . . . . . . . . . . . . . Cuts on the Lug Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting of the Steel Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lug Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separation of Embedded Metals Due to Corrosion . . . . . . . . . . . . . . . . . Separation of Embedded Metals Due to External Forces . . . . . . . . . . . TRACK FRAME Disassembly and Assembly 320 (S/N 562313001–562319999) . . . . . Disassembly and Assembly 320 (S/N 562320000 & Above) And 322 (S/N 517811001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil Spring Cylinder Disassembly And Assembly . . . . . . . . . . . . . . . . Removal and Installation of Expandable Track Frame (322 only) . . . .

Revised July 05

–5–2–

5–25 5–32 5–31 5–29 5–33 5–28 5–24 5–30 5–27 5–26 5–18 5–20 5–22 5–23

MAIN FRAME & TRACKS

320/322 Excavator Service Manual

ENGINE COVER

Removal and Installation Open the engine cover [A]. Hold the engine cover open.

Remove the bolt (Item 1) [B], 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. P–11057

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

W–2113–0288

3 Remove the bolts (Item 3) [B] from the hinge.

Remove the engine cover from the excavator. P–11107

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. Installation: Tighten the bolt to 125–140 ft.–lbs. (170–190 Nm) torque.

Remove the top bolt (Item 1) [D] and nut (Item 2) [D] from the corner post. P–11108

Installation: Tighten the bolt to 48–55 ft.–lbs. (65–75 Nm) torque.

Remove the bottom bolt (Item 3) [D] from the corner post.

Installation: Tighten the bolt to 125–140 ft.–lbs. (170–190 Nm) torque. NOTE: When removing the left hand corner post, remove the two bolts (Item 4) [D] and nuts from the hydraulic filter mount.

Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque. NOTE: Left hand corner post removal is shown, right hand corner post removal is identical except as noted.

3 P–11109

Revised Sept. 99

–5–3–

320/322 Excavator Service Manual

COUNTERWEIGHT

Removal and Installation Remove the left and right corner posts. (See Page 5–3.) Remove the battery box. (See Page 6–1.)

Remove the bolt (Item 1) [A] & [B] from the left and right side to provide clearance for removal of the top counterweight bolts.

P–11114

Attach a chain hoist to the counterweight.

P–11115

Remove the three left counterweight bolts (Item 1) [C].

P–11113

Remove the three right counterweight bolts (Item 1) [D].

Remove the counterweight.

1 P–11112

Revised Sept. 99

–5–4–

320/322 Excavator Service Manual

SEAT AND SEAT MOUNT

Removal and Installation Pull the slide handle (Item 1) [A] out and slide the seat forward. Remove the seat belt brackets (Item 2) [A] from both sides of the seat. Remove the seat. NOTE: On cab equipped models, open the front window for easier access to remove the seat.

2 P–11110

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

B 1

NOTE: If the lower seat slide rails (Item 2) [B] 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.

1 P–11111

Revised Sept. 99

–5–5–

320/322 Excavator Service Manual

SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING

Removal and Installation Remove the seat. (See Page 5–5.) Remove the seat mount. (See Page 5–5.) Disconnect the throttle control cable (Item 1) [A] from the ball joint.

Loosen the U–bolt (Item 2) [A] on the throttle cable. Remove the ball joint from the throttle cable.

P–11116

Remove the three bolts (Item 1) [B] from the seat mount. Installation: Tighten the bolts to 28–37 ft.–lbs. (40–50 Nm) torque. Remove the mounting plate.

P–11118

Remove the two nuts (Item 1) [C], the washer (Item 2) [C], the friction washer (Item 3) [C], the two wave washers (Item 4) [C], the nylon spacer (Item 5) [C], the lever (Item 6) [C] and the two bolts (Item 7) [C].

6 2

Installation: Tighten the locknuts (Item 1) [C] until approximately 15 lbs. (66 N) of force is needed to move the speed control lever.

1 7

4 5

P–11117

Remove the nut (Item 1) [D].

Installation: Tighten the locknut until it contacts the end of threads.

Remove the roll pin (Item 2) [D], lock pin (Item 3) [D] and the rod (Item 4) [D]. Remove the bolt (Item 5) [D] and nut from the lever (Item 6) [D].

6 4

Installation: Tighten the bolt (Item 5) [D] and nut until there is very little free play. The lever must not bind against the mounting plate.

2 3 P–11119

Revised Sept. 99

–5–6–

320/322 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.

1 P–11050

W–2140–0189

Park the excavator on a flat level surface. Put the bucket on the ground.

Remove the pin retainer clips (Item 1) [A]. Remove the washers (Item 1) [B]

Remove the pivot pins (Item 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–11051

Install the pivot pin. Extend the bucket cylinder until the connecting link aligns with the other bucket pin hole. Install the washers (Item 1) [B]. Install the pin retainer clips (Item 1) [A]. Add grease to the pivot pins before operation.

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

Revised Sept. 99

–5–7–

320/322 Excavator Service Manual

ARM

Removal and Installation Remove the bucket. (See Page 5–7.) Support the boom with a chain hoist [A].

P–11120

Remove the snap ring (Item 1) [B] and washer from the rod end pin of the arm cylinder.

Remove the retaining pin from the rod end of the arm cylinder. Remove the rod end of the arm cylinder from the arm.

P–11121

Remove the two hoses (Item 1) [C] from the bucket cylinder.

1 P–11122

Reinstall the rod end retaining pin (Item 1) [D] and attach a chain hoist.

Remove the nut (Item 2) [D] from the boom/arm pivot pin. Installation: Tighten the lock nut until it is seated firmly against the boom. Do not overtighten and deflect the boom mounting plate. The arm must pivot freely.

2 P–11123

Revised Sept. 99

–5–8–

320/322 Excavator Service Manual

ARM (Cont’d)

Removal and Installation (Cont’d) Remove the pivot pin (Item 1) [A]. Remove the arm from the boom.

P–11124

ARM BUSHINGS

Arm To Boom Bushing Removal And Installation Remove the dust seal (if equipped) from both sides of the arm. NOTE: If the bushing has a dust seal it has a through bore. If it is not equipped with the dust seal it has a stepped bore. Remove the bushings (Item 1) [B] from both sides of the arm.

1 N–16505

Install the new bushings in the arm. If the arm is not equipped with the dust seal, install the bushings until they are flush with the pin boss [C].

Flush Bushings

Through Bore

If the arm is equipped with the dust seal, install the bushings until they are seated 0.197 inches (5 mm) in the pin boss [C].

Stepped Bore

Install new dust seals (if equipped).

0.197” (5 mm) TS–01614

Revised Sept. 99

–5–9–

320/322 Excavator Service Manual

ARM BUSHINGS (Cont’d)

Arm To Bucket and Bucket Link Bushing Removal and Installation Remove the dust seals (Item 1) [A] from both sides of the arm.

1 1

N–16507

Remove the bushings (Item 1) [B] from both sides of the arm.

N–16506

Install the new bushings in the arm. If the arm has the stepped bore, install the bushings until they are seated 0.190 inches (4,83 mm) in the pin boss [C].

Stepped Bore

0.190” (4,83 mm) TS–01614

If the arm has the through bore install the bushings until they are seated 0.197 inches (5 mm) in the pin boss [D].

Through Bore

Install the dust seals (Item 1) [A] on both sides of the arm.

0.197” (5 mm) Revised Sept. 99

–5–10–

TS–01614

320/322 Excavator Service Manual

BOOM

Removal and Installation Remove the bucket. (See Page 5–7.) Remove the arm. (See Page 5–8.) Install a chain hoist onto the boom [A]. Remove the boom cylinder. (See Page 2–1.)

P–11120

Remove the two tube retainer bolts (Item 1) [B] and the retainer plates. This will allow easier access to remove the hoses from the tubes.

B 1

Mark the hoses for ease of assembly. Remove the six hoses from the tubes [B]. Remove the snap ring (Item 2) [B] and washer from the boom pivot pin.

P–11125

Remove the boom pivot pin (Item 1) [C].

P–11126

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 0.03 inch (0,7 mm). Add shims equally to both sides of boom.

P–11127

Revised Sept. 99

–5–11–

320/322 Excavator Service Manual

BOOM BUSHING

Flush Bushings

Removal And Installation Remove the boom. (See Page 5–11.) Remove the dust seals from both sides of the boom. Remove the bushings from both sides of the boom. Install the new bushings in the boom.

Stepped Bore

If the boom has the stepped bore, install the bushings they are flush with the pin boss [A].

TS–01614

If the boom has the through bore, install the bushings until they are seated 0.197 inch (5 mm) in the pin boss [B].

Through Bore

0.197” (5 mm)

Revised Sept. 99

–5–12–

TS–01614

320/322 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 5–11.) Remove the snap ring (Item 1) [A] and washer from 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 Sept. 99

–5–13–

320/322 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 hammer on the swing post bracket. Excess pressure can cause the casting to crack. 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.

3 2

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.

Revised Sept. 99

P–06106

–5–14–

320/322 Excavator Service Manual

TRACK

NOTE: The wear of the parts on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. (See SERVICE SCHEDULE Page 1–4 for the correct service interval.) Adjustment 320 (S/N 562313001–562319999) Raise one side of the machine (approximately 4 inches) using the boom and arm as shown in [A]. Raise the blade fully and install jackstands under the blade and the track frame [A]. Operate the boom until all machine weight is on the jackstands.

P–02239

Stop the engine.

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension. W–2142–0189

Measure the distance between the frame and the top of the track. If the distance is between 2.25–2.50 inch (57–63 mm), the track tension is correct [B].

P–11086

If not, loosen one bolt (Item 1) [C] and remove the other bolt (Item 2) [C] from the cover. Add grease to the fitting (Item 1) [D] until the track tension is correct. If track tension is too tight, decrease the track tension pressure by loosening the bleed screw (Item 2) [D] (maximum of 1 turn) and allow grease to flow out of the bleed screw. When the tension is correct, tighten the bleed screw.

1 2

Repeat the procedure for the other side. P–11087

D 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.

2 1

W–2143–0189

P–11088

Revised Sept. 99

–5–15–

320/322 Excavator Service Manual

TRACK (Cont’d)

NOTE: The wear of the parts on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. (See SERVICE SCHEDULE Page 1–4 for the correct service interval.) Adjustment 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) Raise one side of the machine (approximately 4 inches) using the boom and arm as shown in [A].

P–02239

Raise the blade fully and install jackstands under the blade and the track frame [A]. Operate the boom until all machine weight is on the jackstands.

Stop the engine.

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension. W–2142–0189

Measure the distance between the frame and the top of the track. If the distance is between 2.25–2.50 inch (57–63 mm), the track tension is correct [B].

N–20070

If track tension is not correct, loosen one bolt (Item 1) [C] and remove the other bolt (Item 2) [C] from the cover. Add grease to the fitting (Item 1) [D] until the track tension is correct. If track tension is too tight, decrease the track tension pressure by loosening the bleed screw (Item 2) [D] (maximum of 1 turn) and allow grease to flow out of the bleed screw. When the tension is correct, tighten the bleed screw.

Repeat the procedure for the other side. N–20069

2 1

W–2143–0189

N–20068

Revised Sept. 99

–5–16–

320/322 Excavator Service Manual

TRACK (Cont’d)

Removal and Installation

S/N 562313001–562319999

Lift and block the side of the machine where the track will be removed. (See Page 5–16.) Slowly loosen the bleed screw fitting (Item 1) [A & B] (1 turn maximum) to remove track tension.

1 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. P–11088

S/N 562320001 & Above S/N 517811001 & Above

2 N–20068

Install a round bar (Approximately 1–1/4 in. (30 mm) diameter) between the drive lugs [C].

P–11225

Turn the track until the bar contacts the frame [D].

Pry the track off the idler wheel. Remove the track from the drive sprocket. Track Damage Identification and Causes See pages (5–23 to 5–32) 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.

P–11226

Revised July 05

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320/322 Excavator Service Manual

TRACK FRAME Disassembly and 562313001–562319999

Assembly

320

(S/N

Use the following procedure to remove the different parts from the track frame: Remove the track. (See Page 5–17.) Slide the front track idler out of the track frame to remove it [A].

P–11229

Remove the sliding plate [B].

P–11230

Remove the grease fitting (Item 1) [C] from the recoil spring.

P–11231

D AVOID INJURY OR DEATH SSpring loaded components under pressure can cause serious injury or death. SDo not disassemble the coil spring assembly. W–2617–1004

DO NOT DISASSEMBLE OR REPAIR THE COIL SPRING ASSEMBLY (Item 1) [D].

1 P–11245

Revised July 05

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320/322 Excavator Service Manual

TRACK FRAME (Cont’d) Disassembly and Assembly 562313001–562319999) (Cont’d)

320

(S/N

Loosen the nuts from the track roller on both sides of the track frame [A]. Installation: Tighten the nuts to 125 to 140 ft.–lb. (170 to 190 NSm) torque. Remove the track roller.

P–11227

Remove the 2 bolts (Item 1) [B] from the track guide plate.

P–11228

Revised July 05

–5–19–

320/322 Excavator Service Manual

TRACK FRAME

Disassembly and Assembly 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) Remove the track. (See Page 5–17.) Slide the front track idler out of the track frame to remove it [A].

P–15319

Remove the sliding plate [B].

P–15320

DO NOT DISASSEMBLE OR REPAIR THE COIL SPRING ASSEMBLY (Item 1) [C].

P–15151

AVOID INJURY OR DEATH SSpring loaded components under pressure can cause serious injury or death. SDo not disassemble the coil spring assembly. W–2617–1004

Revised July 05

–5–20–

320/322 Excavator Service Manual

TRACK FRAME (Cont’d)

Disassembly and Assembly 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) (Cont’d) Loosen the nuts fromt he track roller on both sides of the track frame [A]. Installation: Tighten the nuts to 125 to 140 ft.–lb. (170 to 190 NSm) torque. Remove the track roller (Item 1) [A].

1 P–15153

Inspect the track guide (Item 1) [B] for wear or damage.

P–15155

Revised July 05

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320/322 Excavator Service Manual

TRACK FRAME

Recoil Spring Cylinder Disassembly And Assembly

DO NOT DISASSEMBLE OR REPAIR THE COIL SPRING ASSEMBLY (Item 2) [A].

P–15317

B 1

AVOID INJURY OR DEATH SSpring loaded components under pressure can cause serious injury or death. SDo not disassemble the coil spring assembly. W–2617–1004

3 2

Remove the cylinder (Item 1) from the coil spring assembly (Item 2) [A].

P–15318

Remove the seal (Item 1), backup ring (Item 2), and O–ring (Item 3) [B]

Revised July 05

–5–22–

320/322 Excavator Service Manual

TRACK FRAME (Cont’d)

Removal and Installation of Expandible Track Frame (322 only)

Remove the track expansion cylinder. (See page 2–1.) Lift and block the track frame. Remove the track. (See page 5–17.) Remove the travel motor cover. Remove the hoses (Item 1) [A] from the travel motor.

Remove the hose clamp (Item 2) [A] from the track frame. P–15156

Remove the nut (Item 1) [B[ from the track expansion stop rod.

P–15154

Install a chain hoist on the track frame [C]. Lift the frame a small amount while pulling the frame away from the excavator.

P–15157

Revised July 05

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320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION

Cutting of the Steel Cords Damage Embedded steel cords are cut off [A] & [B]. Replacement: Replacement is required [A] & [B].

P–03864

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 5–15.) 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. Revised July 05

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320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

Abrasion of Embedded Metals Damage In proportion to the service time, embedded metals will gradually wear away by friction [A].

P–03865

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.

Rubber tracks are used on sandy fields.

D1 = 0.67D PI–13037

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.

Revised July 05

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320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

Separation of Embedded Metals Due to External Forces 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–04379

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 5–15.) Quick turns on bumpy and rocky fields should be avoided. If abnormal wear of sprockets is observed, they should be immediately replaced. Revised July 05

PI–13041

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320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (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–04378

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].

Excessively salty fields, like the sea shore.

Embedded metal

Good

Strong acidic or alkali soil conditions Compost spread grounds 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.

Separation of bonded rubber cover 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.

Revised July 05

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320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

Cuts On The Lug Side 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–04377

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].

B Cuts

Prevention: Machine operators are requested to drive with great attention to the ground’s surface especially in terrains of the following type: Construction sites

PI–13045

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.

Revised July 05

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320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

Cracks On The Lug Side Rubber Due To Fatigue Damage: Small cracks 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–04382

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–04380

Avoid exposing stored tracks to direct sun light. Avoid exposing stored tracks to direct rain and snowfall. Store tracks in well ventilated warehouses. Use the tracks at least once a month.

Revised July 05

–5–29–

320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

Lug Abrasion Damage: As its service time proceeds, the lug side inevitably undergoes abrasion [A] & [B]. Replacement: No replacement is required.

P–04381

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.

Revised July 05

–5–30–

320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

Cracks and Cuts on the Lug 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

Prevention:

Cut on lug side rubber

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

Revised July 05

–5–31–

320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

320Service Manual #6724910 S/N 562313001 & Above – Main Frame And Tracks Section Part 1 of 2

Abrasion Of The Track Roller Side Rubber Surface 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–04383

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].

B Track roller

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.

Abrasion

Prevention:

PI–13053

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.

Revised July 05

–5–32–

320/322 Excavator Service Manual

TRACK DAMAGE IDENTIFICATION (Cont’d)

320Service Manual #6724910 S/N 562313001 & Above – Main Frame And Tracks Section Part 2 of 2

Cuts On The Edges Of The 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–04384

Causes of the damage: This damage is caused by objects on the field or by interference with the machine frame.

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.

Edge

In case of damage by interference with the machine frame 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.

PI–13055

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

Added July 05

–5–33–

320/322 Excavator Service Manual

Added July 05

–5–34–

320/322 Excavator Service Manual

ELECTRICAL SYSTEM Page Number ALTERNATOR Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 Checking Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 BATTERY Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 Using a Booster Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 BATTERY BOX Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 CAB ELECTRICAL (Cab Option) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 ELECTRICAL SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Relays and Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–3 6–5 6–4 6–4

FUEL LEVEL SENDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12 HORN Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12

ELECTRICAL SYSTEM

LIGHT SWITCH Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13 STARTER Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 Two Speed Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14

–6–1–

320 (S/N 562313001 & Above) Excavator Service Manual

–6–2–

320 (S/N 562313001 & Above) Excavator Service Manual

TROUBLESHOOTING Chart 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.

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 fuse. 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. The fuses are located next to 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.

–6–3–

320 (S/N 562313001 & Above) Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

Fuses

4 3

The excavator has a 12 volt, negative ground charging system. The following fuses protect these circuits from overload: 1.

10 amp: This fuse protects the instrument circuit [A].

2. 15 amp: This fuse protects any accessory that is powered when the key is in the run position [A]. 3.

20 amp: This fuse protects the ignition circuit [A].

7 B–14855

4. 15 amp: This fuse protects the cab wiring circuit (if equipped) [A].

5. 15 amp: This fuse protects any accessory that has constant power [A]. 6.

15 amp: This fuse protects the timer [A].

7. 15 amp: This fuse protects the timer when it is powered by the ignition switch [A]. 8.

Not Used

The wiper motor (if equipped) is protected by a 5 amp fuse (Item 1) [B] Replace the fuse with the same type and capacity. P–02267

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.

Electrical System Service Use the following procedure to service the electrical system: Open the left side 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. Check for broken or loose connections.

P–11098

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 inch (13 mm) above the plates, add distilled water only.

Check the alternator belt for wear and correct tension. 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–02741

–6–4–

320 (S/N 562313001 & Above) Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

Electrical Relays and Diodes The three engine harness electrical relays (Item 1) [A] and the fuel shut off timer (Item 2) [A] are located in the engine compartment to the right of the air cleaner.

The three relays (Item 1) [A] control the starter, glow plugs and switched power circuits.

P–11036

The two diodes (Item 1) [B], are for alternator feedback protection and the glow plug during start function.

P–11077

–6–5–

320 (S/N 562313001 & Above) Excavator Service Manual

BATTERY

Using A Booster Battery (Jump Starting)

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.

P–11063

I–2060–0195

If it is necessary to use a booster battery to start the engine. BE CAREFUL!

Make sure the swing lock is in the engaged position. The key switch must be in the OFF position. The booster battery must be 12 volt. Using the ignition key, unlock the left side cover lock. Tilt the top of the side cover out and lift up on the side cover to remove [A].

P–11099

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 positive (+) terminal (Item 1) [B] of the machine battery. 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 frame (Item 2) [B]. Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Start the engine. After the engine is running, remove the cable (Item 2) [B] connected to the frame first. Disconnect the cable from the machine battery (Item 1) [B].

Do not jump start or charge a frozen or damaged battery. Warm battery to 60° F. (16° C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. Battery gas can explode and cause serious injury.

Damage to the alternator can occur if:

W–2066–1296

• Engine is operated with battery cables 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. I–2023–1285

–6–6–

320 (S/N 562313001 & Above) Excavator Service Manual

BATTERY (Cont’d)

Removal and Installation Open the left side cover [A].

P–11063

Disconnect the negative (–) cable (Item 1) [B] first. Disconnect the positive (+) cable (Item 2) [B].

2 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–11098

W–2065–1286

Open the right side cover. Remove the bolt (Item 1) [C] and remove the hold down clamp (Item 2) [C].

2 1 P–11100

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–11101

–6–7–

320 (S/N 562313001 & Above) Excavator Service Manual

BATTERY BOX

Removal and Installation Remove the battery. (See Page 6–7.) Remove the four bolts (Item 1) [A] and nuts. Installation: Tighten the bolts to 14–18 ft.–lbs. (20–25 Nm) torque.

Remove the battery box.

P–11327

CAB ELECTRICAL (Cab Option) Removal and Installation Remove the negative cable from the battery. (See Page 6–7.) Remove the four screws from the cab overhead console [B].

P–02458

Lower the console down. Mark the wires for ease of assembly. Remove the wires from the wiper/washer switch and remove the switch (Item 1) [C]. Remove the wires from the fuse holder and remove the fuse holder (Item 2) [C].

2 1 P–02463

–6–8–

320 (S/N 562313001 & Above) Excavator Service Manual

ALTERNATOR

Checking the Alternator Output

Use OEM–1428 MULTIMETER to check the alternator output.

Start the engine.

3 Set the multimeter to DC Volts and check the output as follows: Touch one probe to the battery lead (Item 1) [A] on the alternator and the other probe to the body of the alternator.

P–11295

The output reading should be 14.2 volts. Removal and Installation

Disconnect the negative (–) cable from the battery. (See Page 6–7.) Remove the battery lead (Item 1) [A] from the alternator.

Remove the wire harness (Item 2) [A] from the alternator. Remove the belt guard (Item 3) [A]. Remove the adjustment bolt (Item 4) [A]. Remove the alternator belt. Remove the mounting bolt (Item 5) [A].

1 P–11076

Remove the alternator from the bracket. Belt Adjustment To adjust the belt tension, use the following procedure: Stop the engine. Open the engine cover. The belt should deflect about 1/2 inch (13 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 13 lbs. (58 Nm) pressure [B]. If the tension is not correct, Loosen the alternator mounting bolt (Item 1) [B]. Loosen the alternator adjustment bolt (Item 2) [B]. 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 pulleys.

–6–9–

320 (S/N 562313001 & Above) Excavator Service Manual

STARTER

Removal and Installation Remove the left side cover [A], using the ignition key to unlock the cover.

P–11063

Disconnect the negative (–) cable (Item 1) [B] from the battery.

P–11098

Mark the starter wires for ease of assembly. Disconnect the wires (Item 1) [C] from the starter.

Remove the mounting bolts (Item 2) [C] from the starter. Remove the starter from the bell housing.

P–11293

–6–10–

320 (S/N 562313001 & 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–01192

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.

–6–11–

320 (S/N 562313001 & Above) Excavator Service Manual

HORN

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 left side cover [B] using the ignition key to unlock the cover.

P–11063

Remove the screw (Item 1) [C] from the cover.

Remove the three bolts (Item 2) [C] from the cover.

Remove the cover. Disconnect the fuel level sender harness from the fuel level sender.

P–11291

Install a socket onto the sender and remove the sender from the fuel reservoir [D].

CD–12864

–6–12–

320 (S/N 562313001 & Above) Excavator Service Manual

LIGHT SWITCH

Removal and Installation Using the ignition key [A] unlock and remove the right side cover.

P–11080

Remove the wiring harness (Item 1) [B] from the switch.

P–11241

Remove the screw (Item 1) [C] and knob (Item 2) [C] from the switch.

C 1

P–11242

Remove the nut (Item 1) [D] from the switch.

Remove the switch from the bottom of the panel.

P–11243

–6–13–

320 (S/N 562313001 & Above) Excavator Service Manual

TWO SPEED SWITCH

320ServiceManual#6724910S/N562313001&Above–ElectricalSystemSection

Removal and Installation Remove the floormat and floor plate. (See Page 3–1.)

Remove the hose (Item 1) [A] from the control valve.

P–11262

B 1

W–2003–1289

2 Loosen and reposition the rear hose (Item 1) [B] on the control valve. Remove the two bolts (Item 2) [B] and nuts from the switch. Push the switch out the bottom of the cross member. P–11263

Remove the wire harness (Item 1) [C] from the switch.

P–11264

–6–14–

320 (S/N 562313001 & Above) Excavator Service Manual

ENGINE SERVICE Page Number AIR CLEANER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17 BELT GUARD Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12 CRANKSHAFT AND BEARINGS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46 Servicing the Crankshaft and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–47 CRANKSHAFT GEAR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40 CYLINDER BORE Checking the Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50 CYLINDER HEAD Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–29 7–28 7–30 7–30

ENGINE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18 ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 ENGINE FLYWHEEL (EARLY MODELS) Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24 Hydraulic Pump Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23

ENGINE SERVICE

ENGINE FLYWHEEL (LATER MODELS) Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27 Hydraulic Pump Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25 FAN GUARD Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14 FUEL CAMSHAFT Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 FUEL INJECTION PUMP Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 FUEL INJECTOR NOZZLES Checking the Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 Continued On Next Page Revised July 05

–7–1–

320/322 Excavator Service Manual

ENGINE SERVICE (Cont’d) Page Number FUEL SHUTOFF SOLENOID Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 Timer Module Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 GLOW PLUGS Checking the Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 IDLER GEAR AND CAMSHAFT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 Servicing the Idler Gear and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 OIL PUMP Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–41 7–40 7–41 7–40

PISTON AND CONNECTING ROD Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42 Servicing the Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . 7–43 RADIATOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 ROCKER ARM AND SHAFT Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33 SPARK ARRESTOR MUFFLER (If Equipped) Cleaning Spark Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16 TIMING GEARS Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 TIMING GEARCASE COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 VALVE CLEARANCE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 VALVE, VALVE SEAT AND GUIDE Checking the Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31 Reconditioning the Valve and Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . 7–32 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33 WATER PUMP Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51

Revised July 05

–7–2–

320/322 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.

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.

Revised July 05

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.

–7–3–

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.

320/322 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. Remove the valve cover. The correct valve clearance is 0.006 to 0.007 in. (0,145–0,185 mm) [A]. Make sure the piston is at T.D.C. when making the adjustment for the valves of the particular cylinder.

A–02730

Put the correct size feeler gauge between the rocker arm and valve stem. Turn the adjustment bolt until the clearance is correct [B].

B–05893

ENGINE COMPRESSION Checking The tools listed will be needed to do the following procedure: MEL–1594 – Compression Kit The engine must be at operating temperature. Remove the glow plugs from the engine. (See Page 7–9.) Install the compression adapter into the glow plug ports in the cylinder head [C].

P–33289

Connect the compression gauge [D].

Turn the engine with the starter at 200 to 300 RPM. Run the test for each cylinder 2 times for 5 to 10 seconds. The compression of the Kubota D–722–E is 412 to 469 PSI (2840 to 3240 kPa) with the allowable limit of 327 PSI (2260 kPa) and no more than 10% difference between cylinders.

P–33290

Revised July 05

–7–4–

320/322 Excavator Service Manual

FUEL SHUTOFF SOLENOID

Removal and Installation Disconnect the wire from the solenoid (Item 1) [A].

Remove the top alternator mount bolt (Item 2) [A]. Remove the alternator bracket mounting bolts (Item 3) [A].

Remove the solenoid (Item 4) [A].

P–11295

Timer Module Removal and Installation

The timer modules’ function is to provide pull in current to the fuel solenoid for only a short duration. This provides longer fuel solenoid service life and also allows for more starter cranking power.

Disconnect the wire harness from the timer module [B]. Remove the bolt (Item 1) [B] and nut. Remove the timer module.

P–11294

Revised July 05

–7–5–

320/322 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.

1 2 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.

B–8235

W–2074–1285

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 a high pressure fuel line from the injection pump. Loosen the other end of the same fuel line so it can be turned away from the fitting.

P–11300

Connect the adapter fuel line (Item 1) [A] to the fitting and connect the pressure gauge (Item 2) [A].

Turn the flywheel by hand to increase the pressure. If the pressure can not reach the allowable limit, replace the injection pump assembly.

Fuel Tightness of Pump Element Allowable Limit . . . . . . . . . . . . . . 2133 PSI (14707 kPa) Measure the time needed to decrease the pressure from 2133 PSI to 1990 PSI (14707 kPa to 13721 kPa). If the measurement is less than the allowable limit, replace the delivery valve. Fuel Tightness of Delivery Valve Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . 5 seconds

P–11232

Removal and Installation

Clean around the injection pump.

Remove the air intake hose (Item 1) [B].

Remove the fuel line clamps (Item 1) [C].

Disconnect the high pressure lines (Item 1) [D] from the fuel injector and fuel injection pump.

P–11233

Revised July 05

–7–6–

320/322 Excavator Service Manual

FUEL INJECTION PUMP (Cont’d)

Removal and Installation (Cont’d)

1 2 Do not bend the high pressure fuel injection tubes when removing or installing them. I–2029–0289

Disconnect the throttle linkage cable ball joint (Item 1) [A] from the injection pump.

P–11182

Loosen the jam nuts (Item 2) [A] from the bracket to remove the throttle cable.

Disconnect the fuel inlet hose (Item 1) [B] and the return hose (Item 2) [B].

Remove the four injection pump mounting nuts. Installation: Tighten the nuts to 7 to 8 ft.–lb. (10 to 11 NSm) torque.

2 P–11183

Align the pin (Item 1) [C] 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) [C] 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.

B–14423

Revised July 05

–7–7–

320/322 Excavator Service Manual

FUEL INJECTION PUMP (Cont’d)

Timing the Injection Pump

Timing the injection pump is done by changing the number of shims between the injection pump and engine block. Remove the number 1 cylinder high pressure line (Item 1) [A] from the injection pump.

P–11232

Do not bend the high pressure fuel injection tubes when removing or installing them.

I–2029–0289

Turn the fuel supply lever to the ON position. Install a short plastic tube in the fitting of the number 1 cylinder port. Point the tube vertical. Turn the engine by hand counterclockwise until fuel flows out of the injection pumps number 1 cylinder nozzle. (Install a tool on the crankshaft at the front of the engine to turn the engine).

NOTE: The fuel must flow out of the nozzle for 1 firing cycle before timing can be attempted.

P–11255

Continue to turn the engine slowly (for approximately 1–3/4 turns after fuel stops flowing from the injection pump nozzle), until the 20 to 22° B.T.D.C. mark on the side of the flywheel is at the bottom edge of the timing hole (Item 1) [B] in the flywheel housing.

NOTE: The battery box and hydraulic pump are removed for photo clarity.

Slowly turn the engine counterclockwise: as soon as fuel starts to flow at the top of the injection pump nozzle stop turning the engine. The correct engine timing for all Kubota D–722–E engines is 20 to 22° B.T.D.C. . Add or subtract shims (Item 1) [C] to time the engine to 20 to 22° B.T.D.C. The engine is correctly timed when the 20 to 22° B.T.D.C. mark on the flywheel is aligned with the notch in the timing hole [B].

B–14422

NOTE: Adding or reducing the shim thickness by 0.05 mm retards or advances the injection timing by 0.5°.

Revised July 05

–7–8–

320/322 Excavator Service Manual

FUEL INJECTOR NOZZLES

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 P–11299

B 1

Do not bend the high pressure fuel injection tubes when removing or installing them. I–2029–0289

Remove the air intake hose (Item 1) [A]. Remove the high pressure fuel line clamps (Item 1) [B]. Disconnect the high pressure fuel lines from the fuel injectors (Item 1) [C].

P–11232

Disconnect the fuel lines from the injection pump.

Remove the high pressure fuel lines.

Disconnect the inlet fuel hose (Item 2) [C].

Disconnect the return fuel hose (Item 3) [C]. Remove the retainer nut from the top of the fuel injectors. Remove the fuel return pipe (Item 4) [C].

Loosen the injector nozzle. Installation: Tighten the injector nozzle to 36 to 51 ft.–lb. (49 to 69 NSm) torque.

3 P–11233

Remove the injector nozzle from the cylinder head. NOTE: Be sure to replace the copper washer and nozzle cap anytime new or used fuel injectors are installed.

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

Revised July 05

–7–9–

320/322 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

The tool listed will be needed to do the following procedure:

MEL10018 – Injector Nozzle Tester

4 5

The nozzle release pressure can be adjusted by adding or removing washer(s) (Item 2) [A] from the top of the nozzle spring (Item 3) [A].

Each spacer will change the release pressure by about 142 PSI (9,8 bar). 7

Fuel Injection Pressure. . . . . . . . . . . . 1991 to 2133 PSI (13728 to 14707 kPa)

(1) (2) (3) (4) (5) (6) (7)

Nozzle Holder Adjusting Washer Nozzle Spring Push Rod Distance Piece Nozzle Piece Nozzle Retaining Nut PI–09981

Assemble the injector nozzle. Connect the nozzle to the tester with the nozzle down [B].

Operate the hand lever at a slow rate and record the opening pressure. If the pressure is not correct, disassemble the nozzle and add or remove the spacer (Item 2) [A] as needed. When the injector nozzle is assembled, tighten the nozzle body to 25 to 29 ft.–lb. (34 to 39 NSm) torque. Check for inside leakage. Operate the hand lever until the pressure 1850 PSI (12755 kPa). Keep the nozzle under this pressure for 10 seconds, check to see if fuel leaks from the nozzle. If fuel leaks, replace the nozzle. A–02513

Check that the spray pattern is correct [C]:

1. Fuel does not come out the side of the nozzle.

CORRECT WRONG

2. Drops of fuel are not present at the nozzle 3. The injector has an even flow coming from the nozzle.

A–02621

Revised July 05

–7–10–

320/322 Excavator Service Manual

GLOW PLUGS

Removal and Installation

Do not bend the high pressure fuel injection tubes when removing or installing them. I–2029–0289

Disconnect the glow plug wire (Item 1) [A].

P–11297

Remove the glow plug lead (Item 1) [B].

B 1

P–11298

Remove the glow plugs from the cylinder head [C].

Installation: Tighten the glow plugs to 6 to 11 ft.–lb. (8 to 15 N·m) torque.

P–11299

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 will be approximately 0.9 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

Revised July 05

–7–11–

320/322 Excavator Service Manual

BELT GUARD

Removal and Installation Open the engine cover [A].

P–11057

Remove the 2 bolts (Item 1) [B] & [C].

Remove the belt guard.

P–11073

C 1

P–11074

Revised July 05

–7–12–

320/322 Excavator Service Manual

RADIATOR

Removal and Installation Turn the upperstructure to provide room to lower the radiator out the bottom of the excavator upperstructure. Open the engine cover. (See Page 1–1.)

Remove the right rear side cover. Drain the cooling system by opening the radiator drain valve (Item 1) [A]. Remove the belt guard. (See Page 7–12.)

P–11074

Remove the alternator. (See page 6–1.)

Open the engine block drain (Item 1) [B] and drain the coolant into a container. Drain the hydraulic reservoir. (See Page 3–1.)

P–11075

Loosen the top radiator hose clamps (Item 1) [C] and remove the top radiator hose.

P–11131

Loosen the bottom radiator hose clamps (Item 1) [D] and remove the lower radiator hose.

1 P–11130

Revised July 05

–7–13–

320/322 Excavator Service Manual

RADIATOR (Cont’d)

Removal and Installation (Cont’d) Remove the 3 nuts (Item 1) [A] from the top radiator support bracket.

Remove the 4 bolts (Item 2) [A] from the sides of the radiator shroud. Move the shroud over the fan blades and leave in this position.

P–11129

Remove the tubeline (Item 1) [B] from the hydraulic filter and oil cooler.

1 P–11083

Remove the tubeline (Item 1) [C] from the control valve and oil cooler.

The tubeline will need to be repositioned under the frame so clearance will be available for radiator removal.

P–11263

Remove the counterweight mounting bolt (Item 1) [D].

Installation: Tighten the bolt to 125 to 140 ft.–lb. (170 to 190 N·m) torque.

P–11112

Revised July 05

–7–14–

320/322 Excavator Service Manual

RADIATOR (Cont’d)

Removal and Installation (Cont’d) Remove the 2 bolts (Item 1) [A] from the lower radiator mount. Engine removed for photo clarity. Installation: Tighten the bolts to 29 to 32 ft.–lb. (40 to 50 N·m) torque.

1 P–11250

B 1

With a second person holding the radiator up, remove the nut (Item 1) [B] and bolt from the center of the lower radiator mount.

P–11283

Lower the radiator down and out the bottom of the excavator.

Remove the 2 bolts (Item 1) [C] and nuts that mount the radiator to the lower radiator mount. Installation: Tighten the bolts to 14 to 18 ft.–lb. (20 to 25 N·m) torque. Remove the lower radiator mount (Item 2) [C] and the rubber radiator mounts. 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.

1 P–11281

Remove the 2 bolts (Item 1) [D] from the oil cooler.

Remove the oil cooler from the radiator.

P–11282

Revised July 05

–7–15–

320/322 Excavator Service Manual

SPARK ARRESTOR MUFFLER (If Equipped)

Cleaning Spark Chamber

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

1 P–11085

Stop the engine. Allow the muffler to cool.

Remove the clean out plug on the bottom of the muffler (Item 1) [A]. Start the engine and run at full RPM for about 10 seconds while a second person wearing safety glasses, holds a piece of wood over the outlet of the muffler. (The carbon deposits will be forced out the muffler plug hole.)

Stop the engine and install the plug. Removal and Installation Remove the 2 bolts (Item 1) [B] from the muffler mounting bracket. P–11301

Remove the 4 bolts (Item 1) [C] from the muffler mount flange.

Remove the muffler. NOTE: Plug the exhaust manifold hole after muffler removal so no contamination can get into the engine.

P–11059

W–2050–1285

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

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death. W–2068–1285

Revised July 05

–7–16–

320/322 Excavator Service Manual

AIR CLEANER

Removal and Installation Raise the engine cover. Remove the left side cover. Loosen the hose clamp (Item 1) [A] on the air intake hose.

1 Remove the hose. NOTE: Plug the intake manifold hole to prevent any contamination from getting into the engine. P–11177

Remove the bolt (Item 1) [B] and nut from the air cleaner bracket. Remove the air cleaner and intake hose assembly.

1 P–11178

Revised July 05

–7–17–

320/322 Excavator Service Manual

ENGINE

Removal and Installation

Remove the battery. (See Page 6–1.)

Remove the battery box. (See Page 6–1.) Drain the hydraulic tank. (See Page 3–1.) Remove the left hand side cover. Remove the right hand side cover. Remove the engine cover. (See page 5–1.)

P–11129

Remove the left and right hand corner posts. (See Page 5–1.)

Remove the counterweight. (See Page 5–1.) Remove the muffler. (See Page 7–16.) Drain the cooling system. (See Page 7–13.) Remove the starter. (See Page 6–1.) Remove the alternator. (See Page 6–1.)

Remove the hydraulic pump. (See Page 2–1.) Remove the nut (Item 1) [A] and bolt (Item 2) [A] from the fan guard. Remove the fan guard.

P–11131

Loosen the top radiator hose clamps (Item 1) [B] and remove the hose.

Loosen the lower radiator hose clamps (Item 1) [C] and remove the hose.

1 P–11130

Remove the bolt (Item 1) [D] from the engine ground strap.

D 1

P–11132

Revised July 05

–7–18–

320/322 Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d) Remove the air intake hose clamp (Item 1) [A].

P–11177

Remove the bolt (Item 1) [B] and nut (Item 2) [B] from the air cleaner mount. Remove the air cleaner and intake hose assembly. NOTE: Plug the intake manifold to prevent any foreign objects from entering the manifold.

1 P–11178

Mark and remove the wires (Item 1) [C] from the hourmeter.

1 P–11179

Remove the tube (Item 1) [D] from the hydraulic filter and oil cooler.

P–11181

Revised July 05

–7–19–

320/322 Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d) Remove the 3 bolts (Item 1) [A] from the wire harness bracket.

P–11180

Remove the fuel line (Item 1) [B]. Remove the throttle cable (Item 2) [B]. Remove the throttle cable housing (Item 3) [B] from the mount.

1 3 P–11182

Remove the return fuel line (Item 1) [C]. Remove the wire harness from the water temperature sending unit (Item 2) [C] and the glow plugs (Item 3) [C].

Disconnect the wire harness (Item 4) [C] from the fuel shutoff.

2 3 1 P–11183

Disconnect the wire harness (Item 1) [D] from the oil pressure sending unit.

P–11185

Revised July 05

–7–20–

320/322 Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d) Remove the engine ground bolt (Item 1) [A] and position the wire harness to the left side of the engine compartment.

P–11184

Remove the 4 shroud bolts (Item 1) [B] and 2 nuts (Item 2) [B] from the fan shroud. Position the shroud over the fan.

Install a chain hoist to the engine lifting eyes.

P–11129

Remove the nut (Item 1) [C] and bolt from the bell housing motor mount.

1 P–11255

Remove the nut (Item 1) [D] and bolt from the front and rear motor mounts.

P–11187

Revised July 05

–7–21–

320/322 Excavator Service Manual

ENGINE (Cont’d)

Removal and Installation (Cont’d) Lift and turn the engine as shown in [A] to gain enough clearance to remove the engine from the excavator.

P–11251

Revised July 05

–7–22–

320/322 Excavator Service Manual

ENGINE FLYWHEEL (EARLY MODELS)

Removal and Installation Remove the battery and battery box. (See Page 6–1.) Remove the hydraulic pump. (See Page 2–1.) Remove the mount bolt (Item 1) [A] and nut. Install a chain hoist to the engine lifting eye to support the engine.

1 P–11255

Remove the motor mount (Item 1) [B].

1 P–11253

Remove 4 flywheel housing bolts (Item 1) [C]. Installation: Tighten the bolts to 29 to 37 ft.–lb. (40 to 50 NSm) torque. Remove the flywheel housing.

1 NOTE: Check that the alignment dowels are installed in the flywheel housing for assembly.

P–11252

Remove the 5 bolts (Item 1) [D] from the flywheel.

Installation: Tighten the bolts to 40 to 43 ft–lb (54 to 59 NSm) torque. Remove the flywheel.

P–11254

Revised July 05

–7–23–

320/322 Excavator Service Manual

ENGINE FLYWHEEL (EARLY MODELS) (Cont’d)

Hydraulic Pump Coupler Remove the bolts (Item 1) [A] from the hydraulic pump coupler. Installation: Tighten the bolts to 29 to 37 ft.–lb. (40 to 50 NSm) torque. Remove the hydraulic pump coupler.

Flywheel Ring Gear

P–11254

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

The ring gear is installed on the flywheel with an interference fit. Heat the ring gear enough to expand it and hit it with a hammer, (evenly) to remove it. Clean the ring gear mounting surface of the flywheel to give a smooth fit. Clean the new ring gear and heat it to a temperature of 450 to 500° F (232 to 260° C). Fit the ring gear over the flywheel. Make sure the gear is seated correctly.

Revised July 05

–7–24–

320/322 Excavator Service Manual

ENGINE FLYWHEEL (LATER MODELS)

Removal And Installation Remove the battery and battery box. (See Page 6–1.) Remove the hydraulic pump. (See Page 2–1.) Remove the mount bolt (Item 1) [A] and nut. Install a chain hoist to the engine lifting eye to support the engine.

1 P–11255

Remove the motor mount (Item 1) [B].

1 P–11253

Remove 4 flywheel housing bolts (Item 1) [C]. Installation: Tighten the bolts to 29 to 37 ft.–lb. (40 to 50 NSm) torque.

Remove the flywheel housing. NOTE: Check that the alignment dowels are installed in the flywheel housing for assembly.

1 P–11252

Remove the 3 bolts (Item 1) [D] from the hydraulic pump coupler.

Installation: Tighten the bolts to 29 to 37 ft.–lb. (40 to 50 NSm) torque.

P–59314

Revised July 05

–7–25–

320/322 Excavator Service Manual

ENGINE FLYWHEEL (LATER MODELS) (CONT’D)

Removal And Installation (Cont’d)

Each hydraulic pump coupler bolt has a spacer (Item 1) [A] between coupler and flywheel.

1 1

P–59312

Remove the 5 bolts (Item 1) [B] from the flywheel. Installation: Tighten the bolts to 40 to 43 ft.–lb. (54 to 59 NSm) torque.

1 1

Remove the flywheel.

1 1 P–59313

Revised July 05

–7–26–

320/322 Excavator Service Manual

ENGINE FLYWHEEL (LATER MODELS) (CONT’D)

Hydraulic Pump Coupler Remove the 3 bolts (Item 1) [A] from the hydraulic pump coupler.

Installation: Apply Loctitet 242 (Blue) to bolts and tighten the bolts to 29 to 37 ft–lb. (40 to 50 NSm) torque. Remove the hydraulic pump coupler

P–59314

Each hydraulic pump coupler bolt has a spacer (Item 1) [B] between coupler and flywheel.

1 1 1

P–59312

Flywheel Ring Gear

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

Revised July 05

–7–27–

320/322 Excavator Service Manual

CYLINDER HEAD

320ServiceManual#6724910S/N562313001&Above–EngineServiceSectionPart1of2

Removal and Installation

Remove the bolts (Item 1) [A] from the valve cover and remove the valve cover and gasket.

B–14415

Remove the fuel injector nozzles. (See Page 7–9.) Remove the glow plugs. (See Page 7–11.)

Remove the alternator. (See Page 6–1.) Remove the rocker arm and shaft assembly (Item 1) [B]. Installation: Tighten the nuts to 7 to 8 in.–lb. (9,8 to 11,3 NSm) torque. Remove the intake and exhaust manifolds.

B–14416

Remove the water return hose [C].

B–14417

Remove the cylinder head bolts in order of #14 to #1 [D].

Installation: Put oil on the bolt threads. Tighten the bolts in the correct sequence to 29 to 33 ft.–lb. (39 to 44 NSm) torque. NOTE: Re–tighten the cylinder head bolts in the correct sequence after the engine has been run for 30 minutes.

B–14490

Revised July 05

–7–28–

320/322 Excavator Service Manual

CYLINDER HEAD (Cont’d)

Removal and Installation (Cont’d) Remove the cylinder head from the engine block. Installation: Always use a new head gasket and new O–ring. Make sure the O–ring (Item 1) [A] is seated over the dowel.

1 B–14334

Disassembly and Assembly

Use a valve spring compressor to compress the valve spring [B].

1 3 2 5 4

Remove the valve cap (Item 1) [C] and valve spring collet (Item 2) [B] & [C].

B–14418

Remove the valve spring retainer (Item 3) [B] & [C] and the spring (Item 4) [B] & [C]. Remove the valve (Item 5) [B] & [C]. Remove the seal (Item 6) [C].

B–04122

Remove the thermostat from the cylinder head. Remove the thermostat housing (Item 1) [D].

1 B–03643

Revised July 05

–7–29–

320/322 Excavator Service Manual

CYLINDER HEAD (Cont’d)

Servicing the Cylinder Head

Clean the surface of the cylinder head. Put a straight edge (Item 1) [A] on the cylinder head. NOTE: Do not put the straight edge across combustion chambers.

Put a feeler gauge (Item 2) [A] between the straight edge and the surface of the cylinder head.

A–02735

Put the straight edge on the cylinder head’s 4 sides and 2 diagonal as shown in figure [B].

The maximum distortion of the head surface ± 0.002 in. (± 0,05 mm). If the measurement exceeds the specification, replace the cylinder head.

E C

PI–09989

Top Clearance

Install the cylinder head gasket. Put the piston (Item 1) [C] being checked at T.D.C.

Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2) [C] on the top piston. Use grease to hold them in position. NOTE: Put the solder in position so they do not touch the valves. Turn the piston to bottom dead center.

Install the cylinder head and tighten to the correct torque in the correct sequence. (See Page 7–25).

3 PI–09989

Turn the crankshaft until the piston exceeds T.D.C. Remove the cylinder head. Remove the solder wire (Item 3) [C] and measure it. If the measurement exceeds the specifications, check the oil clearance of the crank pin journal or the piston pin. Top clearance .........0.0197 to 0.0256 in. (0,50 to 0,65 mm)

Revised July 05

–7–30–

320/322 Excavator Service Manual

VALVE, VALVE SEAT AND GUIDE

Checking the Valve Guide Remove the valve and spring from the cylinder head. (See Page 7–29.) Clean the valve seat and combustion chamber. Install the valve into the guide. Measure the valve recessing with a depth gauge [A].

B–03634

If the measurement exceeds the allowable limit, replace the valve or cylinder head [B].

Recessing . . . . . . . . . . . . . . . . . . . . . 0.004 in. (0,10 mm) Allowable Limit (Recessing) . . . . . . 0.0118 in. (0,3 mm)

1. Cylinder Head Surface 2. Recessing PI–09990

Remove the carbon from the valve guide.

Measure the valve stem O.D. [C]. Measure the valve guide I.D. [C]. Calculate the clearance. If the clearance exceeds the allowable limit, replace the valve and/or valve guide. Valve Guide I.D. . . . . . . . . . . . . . . . . 0.2366 to 0.2372 in. (6,01 to 6,025 mm) Valve Stem O.D. . . . . . . . . . . . . . . . 0.2350 to 0.2354 in. (5,9168 to 5,980 mm) Clearance Between Valve Stem and guide . . . . . . . . . . . 0.00118 to 0.00224 in. (0,03 to 0,057 mm) Allowable Limit . . . . . . . . . . . . . . . . . 0.0039 in. (0,1 mm)

B–14335 7.87’’ (200 mm)

To remove and replace the valve guide, make the driver tools as shown in figure [D].

0.79” (20 mm)

0.3921–0.3929” (9,96–9,98 mm)

3.15” (80 mm)

1.57’’ (40 mm)

0.2165–0.2244” (5,5–5,7 mm) 0.276” (7 mm)

0.2’’ (5,0 mm)

0.236–0.240” (6,0–6,1 mm)

Revised July 05

–7–31–

0.59” (15,0 mm)

0.417–0.421” (10,6–10,7 mm)

0.71’’ (18,0 mm)

MC–01364

320/322 Excavator Service Manual

VALVE, VALVE SEAT AND GUIDE (Cont’d)

Checking the Valve Guide (Cont’d) Press the used valve guide out of the cylinder head using the special driver tool [A]. (See previous page for tool dimensions.)

Put oil on the outside diameter of the new valve guide. Press the new valve guide into the cylinder head from the top side. Use the special driver tools (Item 1 & 2) [A], press the new guide until the tools contact the cylinder head.

Ream the valve guide to the correct specifications. PI–09992

Reconditioning the Valve and Valve Seat

Grind the valve face to the correct angle using a valve refacer [B] & [D].

PI–09993

Grind the valve surface in the cylinder head to the correct angle [C].

15°

45° (30°)

PI–09994

Check the seat surface and valve face (Item 1) [D].

If the seat surface is too wide, use a 15 degree cutter (Item 2) [D] to get the correct width (Item 3) [D].

15°

Valve Seat Width Intake . . . . . . . . . . . . . . . . . . . . 0.0835 in. (2,12 mm) Exhaust . . . . . . . . . . . . . . . . . . 0.0835 in. (2,12 mm) Valve Seat & Face Angle Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

0.0835” (2,12 mm) Revised July 05

–7–32–

PI–09995

320/322 Excavator Service Manual

VALVE, VALVE SEAT AND GUIDE (Cont’d)

Valve Spring Measure the length of the valve spring. If the measurement is less than the allowable limit, replace the spring [A]. Free Length . . . . . . . . . . . . . . . . . . . 1.244 in. (31,6 mm) Allowable Limit . . . . . . . . . . . . . . . . . 1.118 in. (28,4 mm) Put the spring on a flat surface, place a square on the side of the spring [A]. Rotate the spring and measure the maximum tilt. If the measurement is in excess of the allowable limit, replace the spring.

B–03680

Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 in. (1,2 mm)

Put the spring on a tester and compress to specified length [B]. Read the compressed load on the gauge. If the measurement exceeds allowable limit, replace the spring. Setting Length . . . . . . . . . . . . . . . . . . . 1.063 in. (27 mm) Setting Load . . . . . . . . . . . . . . . . . . . . . . 14.6 lb. (64.1 N) Allowable Limit (setting load) . . . . . . . . 12.3 lb. (54.9 N)

A–02759

ROCKER ARM AND SHAFT Checking Measure the rocker arm I.D. (Item 1) [C] with an inside micrometer.

Measure the rocker shaft O.D. (Item 2) [C] with an outside micrometer. If the clearance exceeds the allowable limit, replace the bushing. If the clearance still exceeds the allowable limit after the bushing is replaced, replace the rocker arm shaft. B–03697

Oil Clearance Between Rocker Arm . . . & Shaft . 0.0006 to 0.0018 in. (0,016 to 0,045 mm) Allowable Limit . . . . . . . . . . . . . . . . 0.0059 in. (0,15 mm) Rocker Arm . . . Shaft O.D.0.4123 to 0.4128 in. (10,47 to 10,48 mm) Rocker Arm I.D.0.4134 to 0.4141 in. (10,5 to 10,52 mm)

Revised July 05

–7–33–

320/322 Excavator Service Manual

TIMING GEARCASE COVER

Removal and Installation

Remove the fuel injection pump. (See Page 7–6.) Remove the cylinder head, rocker arms and push rods. (See page 7–28.)

Remove the screws (Item 1) [A] from the speed control plate (Item 2) [A].

1 B–14868

Separate the speed control plate from the engine and remove the spring (Item 1) [B]. Remove the speed control plate.

B–14869

Remove the bolt (Item 1) [C] and disconnect the shaft spring (Item 2) [C].

2 B–14870

Remove the crankshaft pulley bolt. Installation: Tighten the bolt 72 to 80 ft.–lbs. (98 to 108 N.m) torque. Use a puller and remove the crankshaft pulley [D].

B–14871

Revised July 05

–7–34–

320/322 Excavator Service Manual

TIMING GEARCASE COVER (Cont’d)

Removal and Installation (Cont’d) When installing the crankshaft pulley, make sure the alignment marks are aligned [A].

B–14872

Remove the timing gearcase cover bolts. Installation: Tighten the bolts to 7 to 8 ft.–lb. (10 to 11 NSm) torque. Remove the timing gearcase [B].

B–14873

Installation: Install 3 new O–rings and the oil seal into the timing gear case cover.

Oil Seal

O–rings

B–03617

Revised July 05

–7–35–

320/322 Excavator Service Manual

IDLER GEAR AND CAMSHAFT

Removal and Installation Remove the snap ring (Item 1) [A] and collar (Item 2) [A] from the idler gear shaft (Item 3) [A].

1 2

B–14341

Remove the idler gear (Item 1) [B].

B–03699

Installation: Make sure the timing marks are in correct alignment when installing the timing gears [C]. Align the holes on the camshaft gear with the camshaft retainer plate bolts. Remove the bolts. Installation: Tighten the camshaft retainer bolts to 14 to 15 ft.–lb. (18 to 21 NSm) torque.

B–14874

Remove the camshaft from the engine block [D].

B–03655

Revised July 05

–7–36–

320/322 Excavator Service Manual

IDLER GEAR AND CAMSHAFT (Cont’d)

Removal and Installation (Cont’d) Measure the camshaft bearing in the engine block [A].

B–03620

Measure the camshaft journal [B]. Calculate the oil clearance. If the clearance exceeds the allowable limit, replace the camshaft. Bearing I.D. 1.2992 to 1.3002 in. (32,93 to 32,95 mm) Journal O.D. . 1.2966 to 1.2972 in.(32,93 to 32,95 mm) Clearance of Camshaft Journal . . . . . . 0.002 to 0.004 in.(0,05 to 0,09 mm) Allowable Limit . . . . . . . . . . . . . . . . . . 0.006 in.(0,15 mm)

A–02761

Measure the cam lobes at their highest point [C]. If the measurement is less than the allowable limit, replace the camshaft. Cam Lob Height . . . . . . . . . . . . . . 1.0583 in. (26.88 mm) Allowable Limit . . . . . . . . . . . . . . . . . 1.056 in.(26,83 mm)

B–05001

Put the camshaft in V–blocks. Install a dial indicator [D].

Turn the camshaft at a slow rate. If the misalignment exceeds the allowable limit, replace the camshaft. Camshaft Alignment Allowable Limit . . . . . . . . . . . . . 0.0004 in.(0,01 mm)

A–02760

Revised July 05

–7–37–

320/322 Excavator Service Manual

IDLER GEAR AND CAMSHAFT (Cont’d) Servicing the Idler Gear and Shaft

Measure the O.D. of the idler gear shaft [A]. Measure the I.D. of the idler gear bushing [A]. If the clearance exceeds the allowable limit, replace the bushing. Idler Gear Shaft O.D. . . . . . . . . . . . . . 0.786 to 0.787 in. (19,7 to 19,98 mm) Idler Gear Shaft I.D. . . . . . . . . . . . . . . 0.787 to 0.789 in. (20,00 to 29,05 mm) PI–10003

Oil Clearance between idler shaft & Gear Bushing . . . . . . . . . . . . 0.0008 to 0.0033 in. (0,020 to 0,089 mm) Allowable Limit . . . . . . . . . . . . . . . . . . . 0.004 in.(0,1 mm)

To replace the idler gear bushing, make a driver tool as shown in figure [B].

0.79” (20 mm) 5.91” (150 mm)

0.98” (25 mm)

1.18” (30 mm)

0.862–0.864” (21,9–21,95 mm)

0.784–0.785” (19,9–19,95 mm) MC–01366

Use a press and special driver tool, to remove the old bushing and install the new bushing [C].

TIMING GEARS Checking Backlash When the gears are installed, check the backlash of the gears. Install a dial indicator [D]. Hold one gear while turning the other gear [D]. If the backlash exceeds the allowable limit, check the oil clearance of the shaft and gear. If the oil clearance is correct, replace the gear. Crank Gear & Idler Gear . . . . . . . . . . 0.002 to 0.005 in. (0,043 to 0,124 mm)

PI–10004

Allowable Limit . . . . . . . . . . . . . . . . . 0.006 in. (0,15 mm) Cam Gear & Idler Gear . . . . . . . . . . 0.002 to 0.005 in. (0,047 to 0,12 mm) Allowable Limit . . . . . . . . . . . . . . . . . 0.006 in. (0,15 mm) Injection Pump Gear & Idler Gear 0.002 to 0.005 in. (0,046 to 0,124 mm) Allowable Limit . . . . . . . . . . . . . . . . . 0.006 in. (0,15 mm) Oil Pump Gear & Crankshaft Cover . . . . . . . . . . . . 0.002 to 0.005 in. (0,041 to 0,123 mm) Allowable Limit . . . . . . . . . . . . . . . . . 0.006 in. (0,15 mm) Revised July 05 –7–38–

PI–10005

320/322 Excavator Service Manual

FUEL CAMSHAFT

Removal and Installation

Remove the timing gearcase cover. (See Page 7–34.) Remove the idler gear. (See Page 7–36.) Remove the bolt (Item 1) [A] from the retainer plate (Item 2) [A]. Installation: Tighten the bolt to 56 to 72 in.–lb. (6,8 to 8,1 NSm) torque.

Remove the fuel camshaft retainer plate (Item 2) [A].

B–14342

Remove the fuel camshaft and fork lever assembly at the same time.

Governor

2 The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load.

Disassemble and assemble the governor and fuel camshaft as shown in figure [B]. Check all the parts for wear or damage and replace as needed.

3 11 10 6

9 7

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Start Spring Governor Spring Fork Lever Fork Lever Fork Lever Shaft Governor Sleeve Retainer Plate Bearing Fuel Camshaft Bearing Snap Ring B–14875

Revised July 05

–7–39–

320/322 Excavator Service Manual

CRANKSHAFT GEAR

Removal and Installation Remove the timing gearcase cover. (See page 7–34.) Remove the idler gear. (See Page 7–36.) Remove the crankshaft gear with a puller [A]. Remove the crankshaft key.

OIL PUMP B–03686

Removal and Installation

Remove the timing gearcase cover. (See Page 7–34.) Remove the crankshaft gear.

Remove the nut from the oil pump shaft. Use a puller to remove the oil pump gear (Item 1) [B]. Remove the oil pump mounting bolts. Remove the oil pump (Item 2) [B]. Installation: Tighten the oil pump mounting bolts to 60 to 72 in.–lb. (6,9 to 8,1 NSm) torque.

2 B–03658

Oil Pump Service Measure the clearance between the lobes of the inner rotor and outer rotor [C].

B–03616

Measure the clearance between the outer rotor and pump body [D].

If the clearance exceeds the factory limit, replace the oil pump. Clearance Between Inner & Outer Rotor . 0.012 to 0.0055 in. (0,03 to 0,14 mm) Clearance Between Outer rotor & Body . . . 0.0028 to 0.0059 in. (0,07 to 0,15 mm)

A–02732

Revised July 05

–7–40–

320/322 Excavator Service Manual

OIL PUMP (Cont’d)

Oil Pump Service (Cont’d) Put a piece of press gauge on the rotor face [A]. Install the cover and tighten the bolts. Remove the cover carefully. Measure the width of the press gauge [A]. If the clearance exceeds the factory limit replace the oil pump. End Clearance . . . . . . . . . . . . . 0.0029 to 0.0053 in. (0,75 to 0,135 mm)

PI–10009

Checking Engine Oil Pressure

Remove the oil pressure sensor. Install a pressure gauge [B]. Start the engine and run until it is at operating temperature. If the oil pressure is less than the allowable limit, check the following item: • Engine Oil Level Low • Oil Pump Defective • Oil Galley Plugged • Oil Strainer Plugged • Excessive Clearance at the Rod & Main Bearings • Relief Valve Stuck

B–14876

At Idle Speed Allowable Limit . . . . . . . 14 PSI (98 kPa)

At Rated Speed . . . . . . . 28 to 64 PSI (193 to 441 kPa) Allowable Limit . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa)

Relief Valve The relief valve prevents damage of the lubricating system due to high pressure. This relief valve is a ball type. Remove the valve seat (Item 1) [C], ball (Item 2) [C] and spring (Item 3) [C]. Check the parts for wear or damage and replace as needed.

Revised July 05

PI–10011

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320/322 Excavator Service Manual

PISTON AND CONNECTING ROD

Removal and Installation Remove the cylinder head. (See Page 7–28.) Remove the top edge from the cylinder bore with a ridge reamer.

Remove the oil pan. Remove the oil pump strainer (Item 1) [A]. Turn the flywheel and put a pair of connecting rods at bottom dead center.

B–14344

Remove the connecting rod bolts. Installation: Tighten the connecting rod bolts to 20 to 22 ft.–lb. (27 to 30 NSm) torque.

Remove the rod cap and bearing [B]. Use a hammer handle and push the piston connecting rod assembly out of the cylinder bore [B]. NOTE: Make sure the pistons are marked so they will be returned to the same cylinder bore.

PI–10013

Installation: Make sure the marks (Item 1) [C] on the connecting rod and bearing are aligned when installing the bearing cap [C].

Repeat the procedure to remove the other piston/connecting rod assemblies from the engine block. 828

1 828 A–02903

Remove the first compression ring (Item 1) [D].

Remove the second compression ring (Item 2) [D]. Remove the oil ring (Item 3) [D].

Remove the snap ring (Item 4) [D] and piston pin (Item 5) [D].

Separate the piston (Item 6) [D] from the connecting rod (Item 7) [D].

NOTE: Make sure the piston and rod assembly is marked so as not to change the piston rod assembly with another piston or connecting rod.

B–03621

Revised July 05

–7–42–

320/322 Excavator Service Manual

PISTON AND CONNECTING ROD (Cont’d)

Removal and Installation (Cont’d)

Installation: When installing new rings, assemble the ring so the mark (Item 1) [A] near the gap faces the top of the piston. When installing the oil ring, place the expander joint (Item 2) [A] on the opposite side of the oil ring gap (Item 3) [A].

1 3 PI–10015

Installation: When reassembling, align the marks (Item 1) [B] on the connecting rod and piston (Item 2) [B]. Heat the piston in oil to 176° F (80° C) for 10 to 15 minutes and tap the piston pin into position. Place the piston rings so that there are gaps every 120° (Item 3, 4 & 5) [B] with no gap facing the piston pin in the cylinder.

1 2

5 PI–10014

Servicing the Piston and Connecting Rod Measure the I.D. of the piston pin bore in both horizontal and vertical direction [C]. If the measurement exceeds the allowable limit, replace the piston. Piston Pin Bore I.D. . . . . . . . . . . . . . 0.7874 to 0.7879 in. (20,0 to 20,013 mm) Allowable Limit . . . . . . . . . . . . . . . . 0.789 in. (20,04 mm)

A–02733

Measure the O.D. of the piston pin (Item 1) [D].

Measure the I.D. of the connecting rod small end (Item 2) [D].

Calculate the oil clearance. If the clearance exceeds the allowable limit, replace the bushing. If it still exceeds the specifications, replace the piston pin. Piston Pin O.D. . . . . . . . . . . . . . . . . 0.7875 to 0.7878 in. (20,002 to 20,011 mm) Bushing I.D. . . . . . . . . . . . . . . . . . . . 0.7884 to 0.7890 in. (20,025 to 20,04 mm) Oil Clearance between Piston Pin & Bushing . . . . . . . . . . . . 0.0006 to 0.0015 in. (0,014 to 0,038 mm) Allowable Limit . . . . . . . . . . . . . . . . . 0.004 in. (0,10 mm) Revised July 05

1 B–03633

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320/322 Excavator Service Manual

PISTON AND CONNECTING ROD (Cont’d)

Servicing the Piston and Connecting Rod (Cont’d) To replace the connecting rod small end bushing, make a driver tool as shown in figure [A].

0.79” (20 mm) 5.7” (145 mm)

0.98” (25 mm)

0.8622–0.8642” (21,9–21,96 mm)

0.7835–0.7854” (19,9–19,95 mm) MC–01366

Use a press and special driver tool to remove the small end bushing [B]. Installation: Clean the small end bushing and bore. Put oil on the bushing and press into the connecting rod until it is flush [B].

PI–10016

Install a new piston ring into the lower part of the cylinder bore. Measure the ring gap with a feeler gauge [C]. If the gap exceeds the allowable limit, replace the ring. Top Compression Ring & Oil Ring . 0.006 to 0.012 in. (0,15 to 0,30 mm) Second Compression Ring . . . . . . . . 0.012 to 0.018 in. (0,30 to 0,45 mm) Allowable Limit . . . . . . . . . . . . . . . . . . 0.047 in. (1,2 mm)

B–03622

Remove the carbon from the ring grooves. Measure the clearance between the ring and groove with a feeler gauge [D].

If the clearance exceeds the allowable limit, replace the piston. Second ring Oil ring

0.0035 to 0.0043 in.(0,09 to 0,12 mm) 0.0016 to 0.0031 in. (0,04 to 0,08 mm)

Allowable limit second ring Allowable limit oil ring

0.0059 in. (0,15 mm) 0.0059 in. (0,15 mm)

B–14475

Revised July 05

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320/322 Excavator Service Manual

PISTON AND CONNECTING ROD (Cont’d)

Connecting Rod Alignment NOTE: The small end bushing is the basis of this check, check the bushing for wear before doing this check. Install the piston pin into the connecting rod. Install the connecting rod on an alignment tool. Put the gauge over the piston pin and move it against the face plate. If the gauge does not fit squarely against the face place, measure the space between the gauge and face plate [A].

B–04067

If the measurement exceeds the allowable limit, replace the connecting rod. Rod Alignment Allowable Limit . . . 0.002 in. (0,05 mm)

Revised July 05

–7–45–

320/322 Excavator Service Manual

CRANKSHAFT AND BEARINGS

Removal and Installation Remove the piston and connecting rod assemblies. (See Page 7–39.) Remove the engine flywheel. (See Page 7–23.) Remove the bolts which fasten the bearing case cover to the block. Installation: Tighten the bearing case cover bolts to 7 to 8 f t.–lb. (10 to 11 NSm) torque. Install two bolts into the bearing case cover and pull the cover out [A].

B–03648

Installation: When installing the cover (Item 1) [B], make sure the casting mark (Item 2) [B] is in the up position.

B–14877

Before removing the crankshaft/main bearings, check the end play. Install a dial indicator. Measure the end play by moving the crankshaft back and forth [C]. If the measurement exceeds the allowable limit, replace the thrust washers. End Play . . . . . . . 0.006 to 0.012 in. (0,15 to 0,30 mm) Allowable Limit . . . . . . . . . . . . . . . . . . 0.020 in. (0,5 mm)

B–09565

Remove the main bearing case bolt (Item 1) [D].

Installation: Align the bearing case hole (Item 2) [D] with the hole in the block. Put oil on the bolt threads and tighten to 20 to 22 ft.–lb. (27 to 30 NSm) torque.

1 B–14346

Revised July 05

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320/322 Excavator Service Manual

CRANKSHAFT AND BEARINGS (cont’d)

Removal and Installation (Cont’d) Remove the crankshaft/main bearing assembly from the engine block [A]. Mark the bearing case halves for correct installation.

B–14878

Remove the 2 bearing case bolts [B].

Remove the bearing case and bearing. Installation: Tighten the bearing case bolts to 9 to 12 ft.–lb. (13 to 16 NSm) torque.

B–04092

Installation: When installing the main bearing case assemblies, face the mark FLYWHEEL to the flywheel side of the engine block [C]. Be sure the thrust washer with its oil grooves face outward.

PI–10021

Servicing the Crankshaft and Bearings Put the crankshaft on V–blocks. Install a dial indicator on the center journal [B]. Turn the crankshaft at a slow rate. If the misalignment exceeds the allowable limit, replace the crankshaft. Alignment . . . . . . . . . . . . . . . . . . . . 0.0031 in. (0,02 mm)

A–02763

Revised July 05

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320/322 Excavator Service Manual

CRANKSHAFT AND BEARINGS (Cont’d)

Servicing the Crankshaft and Bearings (Cont’d) Tighten the connecting rod cap bolts 20 to 22 ft.–lb. (27 to 30 NSm) torque. Measure the crankpin bearing I.D. [A].

120°

A–02727

Measure the crankpin O.D. [B]. Calculate the oil clearance. Crankpin Bearing I.D. . . . . . . . . . . . 1.3386 to 1.3402 in. (33,99 to 34,04 mm) Crankpin O.D. . . . . . . . . . . . . . . . . . 1.3370 to 1.3376 in. (33,96 to 33,98 mm) Oil Clearance . . . . . . . . . . . . . . . . . . 0.0008 to 0.0032 in. (0,019 to 0,081 mm) Allowable limit . . . . . . . . . . . . . . . . 0.0059 in. (0,15 mm)

A–02716

Revised July 05

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320/322 Excavator Service Manual

CRANKSHAFT AND BEARINGS (Cont’d)

Servicing the Crankshaft and Bearings (Cont’d) Remove the bearing (Item 1) [A] from the front of the engine block with the removal tool shown in [B]. Installation: Clean the new bearing and bore and apply oil to them. Install the new bearing with the installation driver tool [A].

1 PI–10024

5.12” (130 mm)

0.79” (20 mm)

1.7283–1.7303” (43.90–43.95 mm) 0.39” (10 mm) Clean the crankshaft journal and bearing. Put a strip of press gauge on the center journal.

1.5709–1.5728” (39,90–39,95 mm)

0.87” (22 mm) B–14879

Install the main bearing case halves and tighten the bolts. Remove the bearing case halves. Measure the flattened press gauge [C]. If the clearance exceeds the allowable limit, replace the crankshaft bearing. Crankshaft Journal O.D. (Flywheel side) . . . . . . . . . . . . . 1.5722 to 1.5728 in. (39,93 to 39,95 mm) Bearing I.D. . . . . . . . . . . . . . . . . . . . 1.5742 to 1.5758 in. (39,98 to 40,03 mm) Crankshaft Journal O.D. (Middle) . . . . . . . . . . . . . . . . . . 1.7297 to 1.7303 in. (43,93 to 43,95 mm) Bearing I.D. . . . . . . . . . . . . . . . . . . . 1.7317 to 1.7333 in. (43,98 to 44,03 mm) Crankshaft jounal O.D. (Front) . . . 1.5722 to 1.5728 in. (39,93 to 39,95 mm) Bearing I.D. . . . . . . . . . . . . . . . . . . . 1.5742 to 1.5763 in. (33,98 to 40,04 mm) Oil Clearance . . 0.0013 to 0.0042 in.(0,03 to 0,09 mm) Allowable Limit . . . . . . . . . . . . . . . . . . 0.008 in. (0,2 mm)

Added July 05

PI–10025

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320/322 Excavator Service Manual

CYLINDER BORE

Checking the Cylinder Bore Check the inside diameter of the cylinder liner [A].

B–10073

To find the maximum wear check the inside diameter in 6 different locations [B]. When the cylinder bore is not within specifications, bore the cylinder for an oversize piston. Cylinder Bore I.D. . . . . . . . . . . . . . . 2.6378 to 2.6385 in. (67,0 to 67,019 mm) Allowable Limit . . . . . . . . . . . . . . 2.6444 in. (67,169 mm) NOTE: Make sure you use the correct oversize pistons and rings.

A–02717

Added July 05

–7–50–

320/322 Excavator Service Manual

WATER PUMP

320ServiceManual#6724910S/N562313001&Above–EngineServiceSectionPart2of2

Removal and Installation

Drain the cooling system. Remove the radiator. (See Page 7–13.)

Remove the alternator belt.

Remove the fan. Remove the water pump bolts (Item 1) [A].

Remove the water pump.

1 Installation: Always use a new gasket (Item 2) [A] when installing the water pump.

B–14859

Disassembly and Assembly Put the water pump in a vise. Remove the pulley. Press the shaft (Item 3) [A] out of the pulley side of the water pump. Remove the seal (Item 4) [A] and impeller (Item 5) [A]. Install a new seal when assembling the water pump.

Added July 05

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320/322 Excavator Service Manual

Added July 05

–7–52–

320/322 Excavator Service Manual

TECHNICAL DATA Page Number ENGINE SPECIFICATIONS Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re–Grinding the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–7 8–7 8–6 8–7 8–6 8–9 8–6 8–6 8–8 8–7 8–7 8–10 8–6 8–8 8–6 8–6

FUEL, COOLANT AND LUBRICANTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12 HYDRAULIC EXCAVATOR SPECIFICATIONS Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STD Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–5 8–5 8–4 8–5 8–5 8–4 8–4 8–5 8–5 8–3 8–5 8–5 8–5 8–5 8–4

TECHNICAL DATA

HYDRAULIC FLUID SPECIFICATIONS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11

Revised July 05

–8–1–

320/322 Excavator Service Manual

Revised July 05

–8–2–

320/322 Excavator Service Manual

• All dimensions are shown in inches. Respective metric dimensions are given in

HYDRAULIC EXCAVATOR SPECIFICATIONS

millimeters enclosed by parentheses. • Where applicable, specifications conform to SAE standards. Specifications are subject to change without notice.

Machine Dimensions

88.34 (2243.9)

48.18 (1223.9) 9.8 (250) 28.7 (730)

17.5 (443) 1 (26)

10.3 (262)

43.8 (1112)

38.6 (980)

36 (914) 109.5 (2781.3)

53.0 (1346) 322 TRACK EXPANSION MC–1862

58.2 (1480) 151.59 (3850)

74 (1883)

MC–1859 23.6 (600)

20.1 (510)

54.2 (1377)

153.2 (3892) 149.5 (3799) 67.8 (1722)

194°

135.43 (3440)

107.9 (2740)

96.55 (2452)

MC–1888

7.3 (185.5)

3.98 (101)

61.3 (1557) 86.57 (2199)

90 (2294)

MC–1884

Revised July 05

–8–3–

320/322 Excavator Service Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS 3. SPECIFICATIONS WEIGHTS Operating Weight(Includes 20” Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . .

320 ROPS Canopy – 3180 lb. (1442 kg) ROPS Cab – 3440 lb. (1560 kg)

Travel Speed Lo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322 3220 lb. (1461 kg) 3480 lb. (1579 kg)

1.1 MPH (1,74 km/hr.) 2.1 MPH (3,43 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 . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000 RPM 32 ft.–lb. (43,4 N·m) @ 1800 RPM Three 43.9 cu.–in. (0,72L) 2.64 in. x 2.68 in. (67mm x 68mm) Forced Cartridge Type – Full Flow Dry replaceable paper cartridge

ELECTRICAL Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Volt, Reduction Drive 12 Volt, 40 Amps. 12 Volt, 530 Cold Crank Amps

Revised July 05

Kubota D722–E Diesel 15.7 HP (11,7 kW) @ 3000 RPM

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320/322 Excavator Service Manual

SPECIFICATIONS (Cont’d)

320

HYDRAULIC SYSTEM Number of Pumps . . . . . . . . . . . . . . . . . . . . . Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Triple Section Gear Pump 1 –8 GPM (30,3 L/min.) 2 – 4 GPM (15,0 L/min.)

System Relief Setting Implement Circuits . . . . . . . . . . . . . . . . . . . Travel Circuits . . . . . . . . . . . . . . . . . . . . . . . Swing Circuits . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Flow . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . 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 And Up Slopes . . . . . . . . . . . . . . BRAKES Travel Service Parking Swing Service Holding

322

2500 PSI (17241 kPa) 2500 PSI (17241 kPa) 725 to 775 PSI (5000 to 5345 kPa) 8.0 GPM (30 L/min.) 10 Spool Two Axial Piston Motors Orbit Motor Curl 2.0 sec. Retract 2.4 sec. Raise 3.9 sec. Left 4.0 sec. Raise 1.4 sec.

Dump,1.2 sec. Extend 1.6 sec. Lower 2.6 sec. Right 3.4 sec. Lower 1.0 sec.

Orbit Motor Connected to a Planetary Drive Single Row Shear Type Ball Bearings with an Internal Gear Built into Swing Circle 11.2 RPM Bore Dia. in. (mm) 2.38 (60) 2.38 (60) 2.25 (57) 3.25 (83) 2.38 (60)

Rod Dia in. (mm) 1.38 (35) 1.50 (38) 1.50 (38) 1.38 (35) 1.38 (35)

Stroke in. (mm) 13.46 (342) 16.57 (421) 15.16 (385) 14.71 (374) 2.76 (70)

Each Track is Independently Driven by an Axial Piston Motor Two Stage Planetary Gear Reduction 36.8:1 3660 (1660 kg) 25_ 15_

............................. .............................

Hydraulic Lock on Motor Hydraulic Lock on Motor

............................. .............................

Hydraulic Lock on Motor Pin Lock

UNDERCARRIAGE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 in. (250 mm) Single Assembly Three Each Side 3.38 PSI (23,3 kPa)

CAPACITIES Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . .

6.5 gal. (24.6 L) 1.5 gal. (5,7 L) 3.4 qts. (3,2 L) 3.65 gal. (13,8 L) 1.25 oz. (36 cc) 1.00 oz. (29 cc)

DIGGING FORCE Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . . . Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1971 lb. (8768 N) 3408 lb (15160 N)

Revised July 05

–8–5–

320/322 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412 to 469 PSI (2839 to 3231 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 PSI (2253 kPa) Fuel Injector Nozzles Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1991 to 2133 PSI (13726 to 14705 kPa) Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1849 PSI (12747 kPa) Fuel Injection Pump Fuel Tightness of Plunger Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sec. Initital Pressure Drop From . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2133 PSI (14696 kPa) Fuel Tightness of Delivery Valve Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sec. Initital Pressure Drop From . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2133 to 1990 PSI (14708 to 13721 kPa) Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 22 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 Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0415 to 0.0512 (1,15 to 1,30 ) Thickness of Gasket Tightened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0413 to 0.0453 (1,05 to 1,15 ) Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0197 to 0.0256 (0,50 to 0,65 ) Valves Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0835 (2,12) O.D. of Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.235 to 0.2354 (5,9168 to 5,980) I.D. of Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2366 to 0.2372 (6,01 to 6,025) Clearance between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00118 to 0.00224 (0,03 to 0,057) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 (0,1) Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 0.004 to 0.004 (–0,10 to 0,10) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 (0,30) Valve Clearance (Cold) (Intake & Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 to 0.007 (0,145 to 0,185) Valve Springs Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.244 (31,6) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.118 (28,4) Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.063 (27) Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 lb. (6,6 kg) Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 lb. (5,6 kg) Limited Permitted for Spring Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 (1,2) Rocker Arms O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4123 to 0.4128 (10,47 to 10,48) I.D. of Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4134 to 0.4141 (10,5 to 10,52) Clearance between Rocker Arm Shaft & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006 to 0.0018 (0,016 to 0,045) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15)

Revised July 05

–8–6–

320/322 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 to 1.2972 (32,93 to 32,95) I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2992 to 1.3002 (32,99 to 33,025) Clearance between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 to 0.004 (0,05 to 0,91) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 (0,01) Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0583 (26,88) Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 to 0.005 (0,047 to 0,123) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15) Cylinders I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6378 to 2.6385 (67,0 to 67,019) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6444 (67,169) Piston Rings Ring Gap, Top & Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 to 0.012 (0,15 to 0,30) Ring Gap, 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 to 0.018 (0,30 to 0,45) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 (1,2) Side Clearance of Ring in Groove; Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 (0,0) 2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0035 to 0.0043 (0,09 to 0,12) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 to 0.0031 (0,04 to 0,08) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15) Oversize of Piston & Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25) Pistons I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7874 to 0.7879 (20,0 to 20,013) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.789 (20,04) O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7875 to 0.7878 (20,002 to 20,011) I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7884 to 0.7890 (20,025 to 20,04) Clearance between Piston Pin & Bushing Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10) Connecting Rod Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Crankshaft Crankshaft Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0031 (0,02) O.D. of Crankshaft Journal No. 1 & No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5722 to 1.5728 (39,93 to 39,95) O.D. of Crankshaft Journal No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7297 to 1.7303 (43,93 to 43,95) I.D. of Crankshaft Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5742 to 1.5763 (39,98 to 40,04) I.D. of Crankshaft Bearing No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7317 to 1.7333 (43,98 to 44,03) I.D. of Crankshaft Bearing No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5742 to 1.5758 (39,98 to 40,03) Clearance between No. 1 Crankshaft Journal and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013 to 0.0042 (0,03 to 0,11) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20) Clearance between No. 2 Crankshaft Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013 to 0.0036 (0,03 to 0,09) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20) Clearance between No. 3 Crankshaft Journal and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013 to 0.0036 (0,03 to 0,09) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20) O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3370 to 1.3376 (33,96 to 33,98) I.D. of Connecting Rod Bearings‘ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386 to 1.3402 (33,99 to 34,04) Clearance between Coinnecting Rod Journals and Bearings . . . . . . . . . . . . . . . . . . . . 0.0008 to 0.0032 (0,019 to 0,081) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 to 0.012 (0,15 to 0,30) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,50)

Revised July 05

–8–7–

320/322 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 to 64 PSI (193 to 441 kPa) Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa) Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa) Rotor Lobe Clearance Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Clearance between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0028 to 0.0059 (0,07 to 0,15) End Clearance between Inner Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0029 to 0.0053 (0,075 to 0,135) Clearance between Inner Rotor and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 to 0.0055 (0,03 to 0,14) Thermostat Opening Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 to 163°F (70 to 73°C) Full Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185°F (85°C)

Revised July 05

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320/322 Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) 1. All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

ENGINE BOLT TORQUE

*Cylinder Head Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Rocker Arm Bracket Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump Mounting Bolt and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ft.–lb.

NSm

29 to 33 20 to 22 9 to 12 40 to 43 20 to 22 7 to 8 7 to 8 6 to 11 36 to 51 11 to 15 18 to 25 72 to 80 7 to 8

39 to 44 27 to 30 13 to 16 54 to 59 27 to 30 10 to 11 9 to 11 8 to 15 49 to 69 15 to 20 25 to 34 98 to 108 10 to 11

*Lightly Oiled Threads

PUNCHED NUMBER None 7 9

MATERIAL GRADE NOMINAL DIAMETER

BOLT MATERIAL GRADE Standard Bolts SS41, S20C Special Bolts S43C, 248C (Refined) Special Bolts SCM3, SCR3 (Refined)

BOLT TORQUES STANDARD BOLT SPECIAL BOLT SS42, S20C S43C, S48C (Refined)

SPECIAL BOLT SCR3, SCM3 (Refined)

6 to 7 ft.–lb. (8 to 9 NSm)

7 to 8 ft.–lb. (9 to 11 NSm)

9 to 11 ft.–lb. (12 to 15 NSm)

13 to 15 ft.–lb. (18 to 20 NSm)

17 to 20 ft.–lb. (23 to 27 NSm)

22 to 25 ft.–lb. (30–34 NSm)

M10

29 to 33 ft.–lb. (39 to 45 NSm)

35 to 41 ft.–lb. (47 to 56 NSm)

45 to 52 ft.–lb. (61 to 71 NSm)

M12

46 to 54 ft.–lb. (62 to 73 NSm)

57 to 67 ft.–lb. (77 to 91 NSm)

76 to 87 ft.–lb. (103 to 118 NSm)

M14

80 to 93 ft.–lb. (108 to 126 NSm)

91 to 109 ft.–lb. (123 to 148 NSm)

123 to 145 ft.–lb. (167 to 197 NSm)

M16

123 to 141 ft.–lb. (167 to 191 NSm)

145 to 166 ft.–lb. (197 to 225 NSm)

192 to 224 ft.–lb. (260 to 304 NSm)

M18

181 to 210 ft.–lb. (245 to 285 NSm)

203 to 235 ft.–lb. (275 to 319 NSm)

253 to 297 ft.–lb. (343 to 403 NSm)

M20

246 to 289 ft.–lb. (334 to 392 NSm)

271 to 318 ft.–lb. (367 to 431 NSm)

362 to 420 ft.–lb. (491 to 578 NSm)

Revised July 05

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320/322 Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) 320ServiceManual#6724910S/N562313001&Above–TechnicalDataSection

Re–Grinding The Crankshaft

If the standard size bearing cannot be used due to excessive wear of the crank pin and crank journal use undersize or oversize bearings. A

Grind the crankpin and journal with a wheel which has specified round corner and width without shoulder [A]. 1. 0.071 to 0.087 (1,8 to 2,2 mm) 2. 0.091 to 0.106 (2,3 to 2,7 mm) 3. Be sure to chamfer the oil hole circumference to 0.04 to 0.06” (1,0 to 1,5 mm) radius with an oil stone. 4. The crankpin must be fine finished to higher than (0,4 to S). 5. The crank journal must be fine–finished to higher than (0,4–S). 6. The crank journal side surface must be fine–finished to higher than (1,6–S).

C 1

5 4

B–5928

15861–23861

NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM. Crankshaft Bearing 1 0.008in. minus (0,2 minus) 020 US 1.5643 to 1.5650 in. Crankshaft Bearing 2 (39,734 to 39,750 mm) 0.008 in. minus (0,2 minus) 020 US Crankshaft Bearing 3 1.7218 to 1.7224 in. 0.008 minus (0,2 minus) 020 US (43,734 to 43,750 mm)

15861–23921

Crankshaft Bearing 1 0.016 in. minus (0,4 minus)

15699–23941

Crankshaft Bearing 2 0.016 in. minus (0,4 minus)

–0.0016 in. (–0,4 mm)

15861–23871

Crankshaft Bearing 3 0.016 minus (0,4 minus)

040 US

1.7139 to 1.7146 in. (43,534 to 43,550 mm)

–0.008 in. (–0,2 mm)

15861–22971

Crank Pin Bearing 0.008 in. minus (0,2 minus)

020 US

1.3291 to 1.3297 in. (33,759 to 33,775mm)

–0.016 (–0,4 mm)

15861–22981

Crank Pin Bearing 0.016 in. minus (0,4 minus)

040 US

+0.008 in. (+0,2 mm)

15261–23951

Thrust Bearing 1 0.008 in. plus (0,2 plus)

020 OS

–0.008 in. (–0,2 mm) –0.008 in. (–0,2 mm) –0.016 in. (–0,4 mm) –0.016 in. (–0,4 mm)

CODE NO.

1 1

For undersize or oversize bearing use, follow the precautions noted below.

SIZE –.008 in. (–0,2 mm)

15861–23911

15694–23931

15261–23971 +0.016 in. (+0,4 mm)

15261–23961

15261–23981 0.008 in. (0,2 mm) 0.016 in. (0,4 mm) Revised July 05

Thrust Bearing 2 0.008 in. plus (0,2 plus) Thrust Bearing 1 0.016 in. plus (0,4 plus) Thrust Bearing 2 0.016 in. plus (0,4 plus) Crankshaft over size Dimension

–8–10–

A 040 US 1.5565 to 1.5571 in. (39,534 to 39,550 mm) 040 US

1.3212 to 1.3219 in. (33,559 to 33,575 mm)

1.815 to 1.823 in. (46,1 to 46,3 mm) C 040 OS

1.823 to 1.831 in. (46,3 to 46,5 mm)

1.815 to 1.823 in. (46,1 to 46,3 mm) 1.823 to 1.831 in. (46,3 to 46,5 mm) 320/322 Excavator Service Manual

HYDRAULIC FLUID SPECIFICATIONS Specifications Use only Bobact hydraulic fluid. DO NOT use automatic transmission fluids in the excavator or permanent damage to the hydraulic system will result. Bobcat hydraulic fluid is available in: S

2.5 gal (9,5 L) qty 2 (P/N 6903117)

5 gal (18,9 L) (P/N 6903118)

55 gal (208 L) (P/N 6903119)

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. 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 from a physician familiar with this injury. W–2072–0496

When temperature below 0_F (–18_C) are common, the excavator must be kept in a warm building. Extra warm–up time must be used each time the excavator is started during cold temperature conditions. Cold fluid will not flow easily and it makes action of the hydraulic function slower. Loss of fluid flow to the hydraulic system can cause system damage in less than 60 seconds.

During cold weather 32_F (0_C) and below, do not operate machine until the engine has run for at least five (5) minutes at less than half throttle. This warm–up period is necessary for foot pedal operation and safe stopping. Do not operate controls during warm–up period. When temperatures are bleow –20_F (–30_C), the hydrostatic oil must be heated or kept warm. The hydrostatic system will not get enough oil at low temperatures. Park the machine in an area where the temperature will be above 0_F (–18_C), if possible.

W–2027–1285

Added July 05

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320/322 Excavator Service Manual

FUEL, COOLANT AND LUBRICANTS Chart 2.

* Engine Oil Change Interval Relating To Diesel Fuel Sulfur Content Sulfur Content 0.5% or Less 0.5% –1.0% Above 1.0%

Added July 05

Change Interval Change engine oil and filter as shown on the Service Schedule. (See Page 8–1.) Use 1/2 of Service Schedule interval Use 1/4 of Service Schedule interval

–8–12–

320/322 Excavator Service Manual

320–1 ®

Revision Number

17 February 1997

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

320

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6724910 (1–97)

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 6724910 (1–97). Put in the added pages as follows: TAKE OUT

PUT IN Hydraulic Schematic For Models 320 Excavator (S/N 562313001 & Above) (Standard & ISO) (Printed February 1997)

Printed in U.S.A.

320–2 ®

Revision Number

18 April 1997

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

320

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6724910 (1–97)

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 6724910 (1–97). Put in the added pages as follows: TAKE OUT

PUT IN Electrical Schematic For Models 320 Excavator (S/N 562313001 & Above) (Printed April 1997)

320/322–3 ®

Revision Number

16 September 1999

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

320/322

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

Manual No. 6724910 (1–97)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 320/322 Excavator Service Manual P/N 6724910 (1–97). Put in the added pages as follows: TAKE OUT

PUT IN

Hydraulic System Operation 320 Excavator (S/N 562313001 & Above) (ISO and STANDARD) (Printed February, 1997)

Hydraulic System Operation 320 Excavator (S/N 562313001 – 562314899)) (ISO and STANDARD) (Printed September, 1999)

Hydraulic Schematic ISO Controls 320 Excavator (S/N 562313001 & Above) (Printed February, 1997)

Hydraulic Schematic ISO Controls 320 Excavator (S/N 562313001 – 562314899) (Printed September, 1999)

Hydraulic Schematic STANDARD Controls 320 Excavator (S/N 562313001 & Above) (Printed February, 1997)

Hydraulic Schematic STANDARD Controls 320 Excavator (S/N 562313001 – 562314899)) (Printed September, 1999) Hydraulic Schematic ISO Controls 320 Excavator (S/N 562314900 – 562319999) (Printed September, 1999) Hydraulic Schematic STANDARD Controls 320 Excavator (S/N 562314900 – 562319999) (Printed September, 1999) Hydraulic Schematic ISO Controls 320 Excavator (S/N 562320001 & Above) 322 Excavator (S/N 517811001 & Above) (Printed September, 1999) Hydraulic Schematic STANDARD Controls 320 Excavator (S/N 562320001 & Above) 322 Excavator (S/N 517811001 & Above) (Printed September, 1999)

Alphabetical Index

Section 2

Section 4

Section 5

Wiring Schematic (Sheet 1 of 3) 320 Excavator (S/N 562313001 & Above) (Printed April, 1997)

Wiring Schematic (Sheet 1 of 3) 320 Excavator (S/N 562313001 – 562319999) (Printed September, 1999)

Wiring Schematic (Sheet 2 of 3) 320 Excavator (S/N 562313001 & Above) (Printed April, 1997)

Wiring Schematic (Sheet 2 of 3) 320 Excavator (S/N 562313001 – 562319999) (Printed September, 1999)

Wiring Schematic (Sheet 3 of 3) 320 Excavator (S/N 562313001 & Above) (Printed April, 1997)

Wiring Schematic (Sheet 3 of 3) 320 Excavator (S/N 562313001 – 562319999) (Printed September, 1999) Wiring Schematic 320 Excavator (S/N 562320001 & Above) 322 Excavator (S/N 517811001 & Above) (Printed September, 1999)

320/322–4 Revision Number

11 December 2000

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

320/322

Manual No. 6724910 (1–97)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the above Service Manual. Take out existing pages and put in the new pages as listed below: TAKE OUT

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CHANGE DESCRIPTION

Cover

Maintenance Safety

Added Latest Information.

2–1 – 2–2

Corrected Page Numbers

2–21 – 2–22

Revised Bolt Torques.

2–57 – 2–84

2–57 – 2–92

Added Latest Accumulator Disassembly And Assembly. Page Numbers Changed Starting With 2–62 Because Of Added Pages.

3–63 – 3–66

Revised See Page Information.

4–27 – 4–28

Revised Bolt Torque Information.

8–3 – 8–6

Added 322 Serial Numbers.

Added 322 Spec. Information.

Printed in U.S.A.

320/322–5 Revision Number

15 July 2005

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

320/322

Manual No. 6724910 (1–97)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the above Service Manual. Take out existing pages and put in the new pages as listed below: TAKE OUT

PUT IN

CHANGE DESCRIPTION

ALPHABETICAL INDEX

Contents

Revised Text Revised Text

1–1 thru 1–4

Revised Text

2–1, 2–2 2–51, 2–52

Revised Text Revised Text

4–1, 4–2 4–17 thru 4–20

Revised Text Revised Text

5–1, 5–2 5–17 thru 5–32

5–1, 5–2 5–17 thru 5–32 5–33, 5–34

Revised Text Revised Text Added Text

7–1 thru 7–48

7–1 thru 7–48 7–49 thru 7–52

Revised Text Added Text

8–1 thru 8–10

8–1 thru 8–10 8–11, 8–12

Revised Text Added Text

Printed in U.S.A.