Bobcat Excavators 320, 320L, 322, X320, X322 Repair Service Manuals
Catalog:
Model:
Complete repair service manual with Electrical Wiring Diagrams for Bobcat 320, 320L, 322, X320, X322 Excavators, with all the technical information to maintain, diagnose, and repair like professional mechanics.
Bobcat Excavators 320, 320L, 322, X320, X322 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
6722640 (2-97) - X 320 Excavator Operation & Maintenance Manual.pdf
6722642 (4-94) - X 320 Excavator Service Manual.pdf
6722642 (6-12) - X 320 Excavator Service Manual.pdf
6724026 (9-96) - X 320 Excavator Operation & Maintenance Manual.pdf
6724893 (3-99) - X 320 Excavator Operation & Maintenance Manual.pdf
6724910 (1-97) - X 320, X 322 Excavator Service Manual.pdf
6724910 (6-12) - X 320, X 322 Excavator Service Manual.pdf
6900806 (2-00) - 322 Excavator Operation & Maintenance Manual.pdf
6901016 (6-03) - 322 Excavator Operation & Maintenance Manual.pdf
6901062 (2-06) - 320, 320L, 322 Excavator Service Manual.pdf
6901062 (6-12) - 320, 320L, 322 Excavator Service Manual.pdf
6902608 (2-05) - 322 Excavator Operation & Maintenance Manual.pdf
6902668 (6-12) - 320, 322 Excavator Service Manual.pdf
6902668 (7-06) - 320, 322 Excavator Service Manual.pdf
6903817 (11-05) - 320, 320L Excavator Excavator Operation & Maintenance Manual.pdf
6903818 (11-06) - 320, 320L Excavator Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,012 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
6722640 (2-97) - X 320 Excavator Operation & Maintenance Manual...1
OPERATOR SAFETY WARNINGS...3
CONTENTS...5
REGULAR MAINTENANCE ITEMS...6
FOREWORD...7
SERIAL NUMBER LOCATIONS...9
HYDRAULIC EXCAVATOR SERIAL NUMBER...9
ENGINE SERIAL NUMBER...9
DELIVERY REPORT...9
HYDRAULIC EXCAVATOR IDENTIFICATION...10
SAFETY...11
SAFETY INSTRUCTIONS...13
FIRE PREVENTION...15
MACHINE SIGNS (DECALS)...16
OPERATING INSTRUCTIONS...19
GETTING ON AND OFF THE MACHINE...21
SEAT...22
CONTROL LEVER (JOYSTICK) LOCK...22
INSTRUMENT PANEL...23
AUDIBLE ALARM...24
KEY SWITCH...24
LIGHT SWITCH...24
AUXILIARY POWER OUTLET...24
CAB ELECTRICAL (If Equipped)...25
HEATER...25
WINDSHIELD WASHER TANK (If Equipped)...25
CONTROL LEVERS (JOYSTICKS)...26
Operation Of Left Control Lever (ISO)...26
Operation Of Right Control Lever (ISO)...26
Operation Of Left Control Lever (STANDARD)...27
Operation Of Right Control Lever (STANDARD)...27
SWING LOCK...28
HORN BUTTON...28
SPEED CONTROL LEVER...29
ENGINE STOP CONTROL...29
STEERING LEVERS/FOOT PEDALS...30
Forward And Reverse Travel...30
Turning...30
BOOM SWING PEDAL (AND LOCK/FOOT REST)...31
BLADE CONTROL LEVER...31
AUXILIARY HYDRAULIC PEDAL...31
DAILY INSPECTION...32
STARTING THE ENGINE...32
Normal Starting Procedure (With Engine Warm)...32
Cold Temperature Starting Procedure...33
OPERATING PROCEDURES...34
Breaking In A New Machine...34
General Operation Suggestions...34
Operating On Slopes...35
Operating In Water...36
PARKING THE HYDRAULIC EXCAVATOR...36
TRANSPORTING THE HYDRAULIC EXCAVATOR...37
LIFTING THE HYDRAULIC EXCAVATOR...38
LIFTING A LOAD...38
BUCKET...39
Removal...39
Installation...39
CAB OPTION...40
Opening The Front Window...40
Closing The Front Window...40
Front Window...41
Emergency Exit...41
CAB/CANOPY...41
CAB/CANOPY FOPS (Falling Object ProtectiveStructure)...41
PREVENTIVE MAINTENANCE...43
MAINTENANCE SAFETY...44
SERVICE SCHEDULE...45
ENGINE COVER...46
AIR CLEANER SERVICE...46
FUEL SYSTEM...47
Fuel System Maintenance...47
Fuel Filters...48
Removing Air From The Fuel System...48
ENGINE LUBRICATION SYSTEM...49
Engine Oil And Filter Replacement...49
COOLING SYSTEM...50
Coolant Level...50
Coolant Replacement...50
ALTERNATOR BELT ADJUSTMENT...51
ELECTRICAL SYSTEM...52
Service The Electrical System...52
Using A Booster Battery (Jump Starting)...53
Removal And Installation Of The Battery...54
HYDRAULIC SYSTEM...55
Checking And Adding Fluid...55
Diagnostic Couplers...56
Replacement of the Hydraulic Filter...56
Hydraulic Reservoir...56
Filter Screen (Factory Installed)...57
In–Line FIlter (Service Replacement)...57
LUBRICATION OF THE HYDRAULIC EXCAVATOR...58
FINAL DRIVE CASE...60
Checking Oil Level...60
Replacing Final Drive Case Oil...60
TRACK TENSION...61
Adjustment...61
JOYSTICK CONTROL CHANGE...62
ISO To Standard Control Pattern...62
Standard To ISO Control Pattern...62
MACHINE SIGN TRANSLATIONS...63
SPECIFICATIONS...71
HYDRAULIC EXCAVATOR SPECIFICATIONS...73
Machine Dimensions...73
Lifting Capacity...74
OPERATIONS & PERFORMANCE...74
ENGINE...74
HYDRAULIC SYSTEM...75
SWING SYSTEM...75
HYDRAULIC CYLINDERS...75
DRIVE SYSTEM...75
BRAKES...75
UNDERCARRIAGE...75
TRACK...75
CAPACITIES...75
DIGGING FORCE...75
FUEL, COOLANT AND LUBRICANTS...76
ENGINE OIL SPECIFICATIONS...76
Description...76
Ethlene Glycol...76
Propylene Glycol...76
BUCKET SPECIFICATIONS...77
ADDITIONAL PUBLICATIONS...78
WARRANTY...79
6722642 (4-94) - X 320 Excavator Service Manual...81
MAINTENANCE SAFETY...83
CONTENTS...85
FOREWORD...87
SAFETY INSTRUCTIONS...89
SERIAL NUMBER LOCATIONS...91
HYDRAULIC EXCAVATOR SERIAL NUMBER...91
ENGINE SERIAL NUMBER...91
DELIVERY REPORT...91
HYDRAULIC EXCAVATOR IDENTIFICATION...92
PREVENTIVE MAINTENANCE...93
SERVICE SCHEDULE...95
ENGINE COVER...96
Opening the Cover...96
AIR CLEANER SERVICE...96
FUEL SYSTEM...97
Fuel System Service...97
Maintenance...97
Fuel Filter...98
ENGINE LUBRICATION SYSTEM...99
Engine Oil and Filter Replacement...99
COOLING SYSTEM...100
Coolant Level...100
Coolant Replacement...100
HYDRAULIC SYSTEM...101
Checking and Add Fluid...101
Diagnostic Couplers...101
Replacement of the Hydraulic Filter...102
Hydraulic Reservoir...102
Replacement of the Hydraulic Fluid...102
USING A BOOSTER BATTERY (JUMP STARTING)...103
Procedure...103
LUBRICATION OF THE HYDRAULIC EXCAVATOR...104
Procedure...104
HYDRAULIC SECTION...107
HYDRAULIC SCHEMATICS...111
HYDRAULIC SYSTEM TROUBLESHOOTING...115
HYDRAULIC SERVICE INFORMATION...120
Checking the Main Relief Valves...120
Checking the Hydraulic Pump...121
HYDRAULIC PUMP...122
Disassembly...123
Assembly...125
HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411)...128
Removal And Installation...128
Parts Identification...129
Disassembly...130
Inlet Section (R.H. and L.H. Travel)...131
Disassembly...131
Assembly...132
Valve Sections (Boom, Bucket & Arm)...133
Disassembly...133
Assembly...134
Valve Sections (Auxiliary)...135
Disassembly...135
Assembly...136
Assembly...137
Port Relief Valve...138
Disassembly...138
Assembly...138
Adjustment...138
Main Relief Valve...140
Disassembly...140
Assembly...140
Adjustment...140
HYDRAULIC CONTROL VALVE (3–Spool) DUKESVALVE (S/N 511720001–511721411)...141
Removal And Installation...141
Parts Identification...142
Disassembly...143
Inlet Section (Housing Swing)...144
Disassembly...144
Assembly...144
End Cover (Boom Swing) and Valve Section (Blade)...145
Disassembly...145
Assembly...147
Load Check Block...149
Disassembly...149
Assembly...149
Build–Up Valve...151
Assembly...151
Main Relief Valve...152
Disassembly...152
Assembly...152
Adjustment...152
HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above)...153
Parts Identification...153
Disassembly...154
Inlet Section Disassembly And Assembly...155
Right Hand & Left Hand Travel Section...156
Disassembly...156
Assembly...157
Boom, Bucket & Arm Section...159
Disassembly...159
Assembly...160
Auxiliary Section...162
Disassembly...162
Assembly...163
PORT RELIEF VALVES HUSCO VALVE...166
Parts Identification...166
Port Relief Valve Pressure Setting...167
Disassembly...167
Assembly...168
Adjustment...168
MAIN RELIEF VALVES HUSCO VALVE...169
Parts Identification...169
Disassembly...170
Assembly...170
Adjusting The Main Relief Valves...171
HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above)...172
Parts Identification...172
Disassembly...173
Blade And Boom Swing Section...174
Disassembly...174
Assembly...176
Lockout Valve Assembly...177
Disassembly...177
Lockout Valve Assembly...178
Swing Motor Valve Section...179
Disassembly...179
Assembly...180
Build–Up Valve Disassembly...183
Build Up Valve Assembly...183
Build Up Valve Test Procedure...183
BOOM CYLINDER...184
Removal And Installation...184
Boom Shield...184
Boom Cylinder...184
ARM CYLINDER...185
Removal And Installation...185
BUCKET CYLINDER...186
Removal And Installation...186
BLADE CYLINDER...187
Removal And Installation...187
BOOM SWING CYLINDER...188
Removal And Installation...188
HYDRAULIC CYLINDER...189
Disassembly...189
Assembly...191
Disassembly...192
Assembly...193
HYDRAULIC FILTER ASSEMBLY...198
Removal And Installation...198
AUXILIARY COUPLERS...198
Removal And Installation...198
JOYSTICK MANIFOLD WITH ACCUMULATOR...199
Removal And Installation...199
Disassembly And Assembly...201
DRAIN BLOCK...202
Filter Screen...202
Removal And Installation...202
OIL COOLER...203
Removal And Installation...203
JOYSTICK CONTROL CHANGE...204
DRIVE SECTION...205
FLOORMAT AND FLOOR PANELS...207
Removal and Installation...207
LEFT CONTROL CONSOLE...209
Microswitch Adjustment Procedure...209
Lockout Microswitch Removal and Installation...210
Console Cover Removal and Installation...211
Joystick Removal and Installation...214
Removal and Installation...215
FUEL TANK...218
Removal and Installation...218
LOCK LEVER...220
Left Hand Removal and Installation...220
Adjustment Procedure...221
LATCH HOOK...222
Left Hand Removal and Installation...222
GAS SPRING...223
Left Hand Removal and Installation...223
UPPER CONSOLE...224
Left Hand Removal and Installation...224
RIGHT CONTROL CONSOLE...225
ROPS Canopy Models...225
Cab Models...225
Console Cover Removal and Installation...226
Joystick Removal and Installation...228
Control Console Removal and Installation...229
Hydraulic Tank Removal and Installation...233
TRAVEL LEVERS...234
Removal and Installation...234
RIGHT HAND PEDAL (Boom Swing)...236
Removal and Installation...236
LEFT HAND PEDAL (Auxiliary)...238
Removal and Installation...238
ROCKERSHAFT...240
Removal and Installation...240
LINKAGE RODS...242
Removal and Installation...242
BLADE LEVER...243
Removal and Installation...243
FINAL DRIVE...246
Removal and Installation...246
DRIVE MOTOR ASSEMBLY (Kayaba) (S/N 511720001 – 23974)...247
Parts Identification...247
Disassembly...248
Assembly...258
Checking Oil Level...267
Draining Final Drive Case...267
DRIVE MOTOR (SOM) (S/N 23975 & Above)...268
Parts Identification...268
Disassembly...269
Assembly...276
Checking Oil Level (S/N 23975 & Above)...285
JOYSTICK...286
Parts Identification...286
Disassembly and Assembly...287
UPPER WORKS AND SWING SECTION...291
SWING MOTOR...293
Testing the Cross Ports Reliefs...293
Start the Engine...293
Removing the Cross Port Reliefs...293
Removal and Installation...294
Disassembly...294
Assembly...295
Motor Timing...296
CROSS PORT RELIEF VALVE...297
Disassembly...297
Assembly...298
Description...299
UPPERSTRUCTURE...300
Removal...300
Installation...301
CENTER SWIVEL JOINT...302
Removal And Installation...302
Disassembly and Assembly...302
SWING CIRCLE GEAR...303
Removal And Installation...303
ROPS CANOPY...304
Removal And Installation...304
CAB...306
Removal And Installation...306
Door (Removal And Installation)...309
Front Window (Removal And Installation)...310
Front Lower Glass (Removal And Installation)...312
Front Upper Plexiglass (Removal And Installation)...312
Door Glass (Removal And Installation)...313
Left Hand Side Glass (Removal And Installation)...313
Rear Glass (Removal And Installation)...314
Right Hand Side Glass (Removal And Installation)...314
CAB/CANOPY REAR COVER...315
Removal...315
Installation...315
AIR BAFFLE (Cab Models Only)...316
Removal And Installation...316
BELLY PAN (Field Installed)...316
Removal And Installation...316
MAIN FRAME AND TRACKS...317
ENGINE COVER...319
Removal and Installation...319
REAR CORNER POSTS...319
Removal and Installation...319
SEAT AND SEAT MOUNT...320
Removal and Installation...320
SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING...321
Removal and Installation...321
BUCKET...322
Removal and Installation...322
Installation...322
ARM...323
Removal and Installation...323
BOOM...325
Removal and Installation...325
SWING POST...326
Removal And Installation...326
Bushing Replacement...327
Swing Post Bushing Removal...327
Bushing Installation...327
TRACK...328
Track Tension Adjustment...328
Removal and Installation...329
Damage Identification and Causes...329
TRACK FRAME...330
Disassembly and Assembly...330
TRACK IDLER...331
Parts Identification...331
Disassembly...332
Assembly...334
TRACK ROLLER...339
Parts Identification...339
Disassembly...340
Assembly...342
TRACK...346
Damage Identification and Causes...346
ELECTRICAL SYSTEM...355
ELECTRICAL SCHEMATIC...357
TROUBLESHOOTING...358
ELECTRICAL SYSTEM...358
Description...358
Fuses...359
Electrical System Service...359
BATTERY...360
Checking the Battery...360
Removal and Installation...360
BATTERY BOX...361
Removal and Installation...361
CAB ELECTRICAL (Cab Option)...361
ALTERNATOR...362
Checking the Alternator Output...362
Belt Adjustment...362
Electrical Connection...362
Removal and Installation...363
Check the Alternator Output...364
Alternator Output Test...364
Alternator Regulator Test...365
Disassembly and Assembly...366
Stator Continuity Test...366
Stator Ground Test...366
Rotor Continuity Test...367
Rotor Ground Test...367
Rectifier Continuity (Diode) Test...367
Disassembly and Assembly (New Style)...368
STARTER...369
Removal and Installation...369
Disassembly and Assembly...370
Cleaning and Inspection...370
HORN...371
Removal and Installation...371
FUEL LEVEL SENDER...371
Removal and Installation...371
ENGINE SERVICE...372
TROUBLESHOOTING...374
VALVE CLEARANCE...375
Adjustment...375
ENGINE COMPRESSION...375
Checking...375
FUEL FILTER...376
Element...376
Removing Air from the Fuel System...376
Removal and Installation...376
FUEL INJECTION PUMP...377
Checking the Injection Pump...377
Removal and Installation...377
Timing the Injection Pump...379
FUEL INJECTOR NOZZLES...380
Checking the Injector Nozzle...381
GLOW PLUGS...382
Removal and Installation...382
Checking the Glow Plug...382
ENGINE...383
Removal and Installation...383
SPARK ARRESTOR MUFFLER...388
RADIATOR...389
Checking the Radiator and Radiator Cap...389
Removal and Installation...389
Hydraulic Pump Coupler...393
CYLINDER HEAD...394
Removal of the Cylinder Head...394
Disassembly of the Cylinder Head...395
Servicing the Cylinder Head and Valves...396
Checking Valve Springs...397
Checking Rocker Arm and Shaft...398
Installing the Cylinder Head...398
TIMING GEAR COVER...400
Removal and Installation...400
TIMING GEAR, CAMSHAFT AND OIL PUMP...402
Removal and Installation...402
Oil Pump Service...404
Servicing the Camshaft...405
CRANKSHAFT AND PISTONS...407
Removal and Installation...407
Crankshaft Service...409
Servicing the Connecting Rods and Pistons...410
CYLINDER LINERS...412
Checking the Cylinder Liners...412
Cylinder Liner Installation...412
WATER PUMP...413
Removal and Installation...413
Disassembly and Assembly...413
SPECIFICATIONS...414
HYDRAULIC EXCAVATOR SPECIFICATIONS...416
Machine Dimensions...416
Lifting Capacity...417
SPECIFICATIONS...417
ENGINE SPECIFICATIONS...419
Engine...419
Fuel Injector Nozzles...419
Fuel Injection Pump...419
Cylinder Head...419
Valves...419
Valve Springs...419
Rocker Arms...419
Camshaft...420
Cylinders...420
Piston Rings...420
Pistons...420
Crankshaft...420
Oil Pump...421
Thermostat...421
Engine Torque...422
Crankshaft Re–Grind Data...423
FUEL, COOLANT AND LUBRICANTS...424
OIL SPECIFICATIONS...424
BUCKET SPECIFICATIONS...425
SERVICE MANUAL REVISON...426
320-1...426
320-2...428
320-3...430
320-4...432
6722642 (6-12) - X 320 Excavator Service Manual...434
MAINTENANCE SAFETY...436
CONTENTS...438
FOREWORD...440
SAFETY INSTRUCTIONS...442
SERIAL NUMBER LOCATIONS...444
HYDRAULIC EXCAVATOR SERIAL NUMBER...444
ENGINE SERIAL NUMBER...444
DELIVERY REPORT...444
HYDRAULIC EXCAVATOR IDENTIFICATION...445
PREVENTIVE MAINTENANCE...446
SERVICE SCHEDULE...448
ENGINE COVER...449
Opening the Cover...449
AIR CLEANER SERVICE...449
FUEL SYSTEM...450
Fuel System Service...450
Maintenance...450
Fuel Filter...451
ENGINE LUBRICATION SYSTEM...452
Engine Oil and Filter Replacement...452
COOLING SYSTEM...453
Coolant Level...453
Coolant Replacement...453
HYDRAULIC SYSTEM...454
Checking and Add Fluid...454
Diagnostic Couplers...454
Replacement of the Hydraulic Filter...455
Hydraulic Reservoir...455
Replacement of the Hydraulic Fluid...455
USING A BOOSTER BATTERY (JUMP STARTING)...456
Procedure...456
LUBRICATION OF THE HYDRAULIC EXCAVATOR...457
Procedure...457
HYDRAULIC SECTION...460
HYDRAULIC SCHEMATICS...464
HYDRAULIC SYSTEM TROUBLESHOOTING...468
HYDRAULIC SERVICE INFORMATION...473
Checking the Main Relief Valves...473
Checking the Hydraulic Pump...474
HYDRAULIC PUMP...475
Disassembly...476
Assembly...478
HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411)...481
Removal And Installation...481
Parts Identification...482
Disassembly...483
Inlet Section (R.H. and L.H. Travel)...484
Disassembly...484
Assembly...485
Valve Sections (Boom, Bucket & Arm)...486
Disassembly...486
Assembly...487
Valve Sections (Auxiliary)...488
Disassembly...488
Assembly...489
Assembly...490
Port Relief Valve...491
Disassembly...491
Assembly...491
Adjustment...491
Main Relief Valve...493
Disassembly...493
Assembly...493
Adjustment...493
HYDRAULIC CONTROL VALVE (3–Spool) DUKESVALVE (S/N 511720001–511721411)...494
Removal And Installation...494
Parts Identification...495
Disassembly...496
Inlet Section (Housing Swing)...497
Disassembly...497
Assembly...497
End Cover (Boom Swing) and Valve Section (Blade)...498
Disassembly...498
Assembly...500
Load Check Block...502
Disassembly...502
Assembly...502
Build–Up Valve...504
Assembly...504
Main Relief Valve...505
Disassembly...505
Assembly...505
Adjustment...505
HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above)...506
Parts Identification...506
Disassembly...507
Inlet Section Disassembly And Assembly...508
Right Hand & Left Hand Travel Section...509
Disassembly...509
Assembly...510
Boom, Bucket & Arm Section...512
Disassembly...512
Assembly...513
Auxiliary Section...515
Disassembly...515
Assembly...516
PORT RELIEF VALVES HUSCO VALVE...519
Parts Identification...519
Port Relief Valve Pressure Setting...520
Disassembly...520
Assembly...521
Adjustment...521
MAIN RELIEF VALVES HUSCO VALVE...522
Parts Identification...522
Disassembly...523
Assembly...523
Adjusting The Main Relief Valves...524
HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above)...525
Parts Identification...525
Disassembly...526
Blade And Boom Swing Section...527
Disassembly...527
Assembly...529
Lockout Valve Assembly...530
Disassembly...530
Lockout Valve Assembly...531
Swing Motor Valve Section...532
Disassembly...532
Assembly...533
Build–Up Valve Disassembly...536
Build Up Valve Assembly...536
Build Up Valve Test Procedure...536
BOOM CYLINDER...537
Removal And Installation...537
Boom Shield...537
Boom Cylinder...537
ARM CYLINDER...538
Removal And Installation...538
BUCKET CYLINDER...539
Removal And Installation...539
BLADE CYLINDER...540
Removal And Installation...540
BOOM SWING CYLINDER...541
Removal And Installation...541
HYDRAULIC CYLINDER...542
Disassembly...542
Assembly...544
Disassembly...545
Assembly...546
HYDRAULIC FILTER ASSEMBLY...551
Removal And Installation...551
AUXILIARY COUPLERS...551
Removal And Installation...551
JOYSTICK MANIFOLD WITH ACCUMULATOR...552
Removal And Installation...552
Disassembly And Assembly...554
DRAIN BLOCK...555
Filter Screen...555
Removal And Installation...555
OIL COOLER...556
Removal And Installation...556
JOYSTICK CONTROL CHANGE...557
DRIVE SECTION...558
FLOORMAT AND FLOOR PANELS...560
Removal and Installation...560
LEFT CONTROL CONSOLE...562
Microswitch Adjustment Procedure...562
Lockout Microswitch Removal and Installation...563
Console Cover Removal and Installation...564
Joystick Removal and Installation...567
Removal and Installation...568
FUEL TANK...571
Removal and Installation...571
LOCK LEVER...573
Left Hand Removal and Installation...573
Adjustment Procedure...574
LATCH HOOK...575
Left Hand Removal and Installation...575
GAS SPRING...576
Left Hand Removal and Installation...576
UPPER CONSOLE...577
Left Hand Removal and Installation...577
RIGHT CONTROL CONSOLE...578
ROPS Canopy Models...578
Cab Models...578
Console Cover Removal and Installation...579
Joystick Removal and Installation...581
Control Console Removal and Installation...582
Hydraulic Tank Removal and Installation...586
TRAVEL LEVERS...587
Removal and Installation...587
RIGHT HAND PEDAL (Boom Swing)...589
Removal and Installation...589
LEFT HAND PEDAL (Auxiliary)...591
Removal and Installation...591
ROCKERSHAFT...593
Removal and Installation...593
LINKAGE RODS...595
Removal and Installation...595
BLADE LEVER...596
Removal and Installation...596
FINAL DRIVE...599
Removal and Installation...599
DRIVE MOTOR ASSEMBLY (Kayaba) (S/N 511720001 – 23974)...600
Parts Identification...600
Disassembly...601
Assembly...611
Checking Oil Level...620
Draining Final Drive Case...620
DRIVE MOTOR (SOM) (S/N 23975 & Above)...621
Parts Identification...621
Disassembly...622
Assembly...629
Checking Oil Level (S/N 23975 & Above)...638
JOYSTICK...639
Parts Identification...639
Disassembly and Assembly...640
UPPER WORKS AND SWING SECTION...644
SWING MOTOR...646
Testing the Cross Ports Reliefs...646
Start the Engine...646
Removing the Cross Port Reliefs...646
Removal and Installation...647
Disassembly...647
Assembly...648
Motor Timing...649
CROSS PORT RELIEF VALVE...650
Disassembly...650
Assembly...651
Description...652
UPPERSTRUCTURE...653
Removal...653
Installation...654
CENTER SWIVEL JOINT...655
Removal And Installation...655
Disassembly and Assembly...655
SWING CIRCLE GEAR...656
Removal And Installation...656
ROPS CANOPY...657
Removal And Installation...657
CAB...659
Removal And Installation...659
Door (Removal And Installation)...662
Front Window (Removal And Installation)...663
Front Lower Glass (Removal And Installation)...665
Front Upper Plexiglass (Removal And Installation)...665
Door Glass (Removal And Installation)...666
Left Hand Side Glass (Removal And Installation)...666
Rear Glass (Removal And Installation)...667
Right Hand Side Glass (Removal And Installation)...667
CAB/CANOPY REAR COVER...668
Removal...668
Installation...668
AIR BAFFLE (Cab Models Only)...669
Removal And Installation...669
BELLY PAN (Field Installed)...669
Removal And Installation...669
MAIN FRAME AND TRACKS...670
ENGINE COVER...672
Removal and Installation...672
REAR CORNER POSTS...672
Removal and Installation...672
SEAT AND SEAT MOUNT...673
Removal and Installation...673
SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING...674
Removal and Installation...674
BUCKET...675
Removal and Installation...675
Installation...675
ARM...676
Removal and Installation...676
BOOM...678
Removal and Installation...678
SWING POST...679
Removal And Installation...679
Bushing Replacement...680
Swing Post Bushing Removal...680
Bushing Installation...680
TRACK...681
Track Tension Adjustment...681
Removal and Installation...682
Damage Identification and Causes...682
TRACK FRAME...683
Disassembly and Assembly...683
TRACK IDLER...684
Parts Identification...684
Disassembly...685
Assembly...687
TRACK ROLLER...692
Parts Identification...692
Disassembly...693
Assembly...695
TRACK...699
Damage Identification and Causes...699
ELECTRICAL SYSTEM...708
ELECTRICAL SCHEMATIC...710
TROUBLESHOOTING...712
ELECTRICAL SYSTEM...712
Description...712
Fuses...713
Electrical System Service...713
BATTERY...714
Checking the Battery...714
Removal and Installation...714
BATTERY BOX...715
Removal and Installation...715
CAB ELECTRICAL (Cab Option)...715
ALTERNATOR...716
Checking the Alternator Output...716
Belt Adjustment...716
Electrical Connection...716
Removal and Installation...717
Check the Alternator Output...718
Alternator Output Test...718
Alternator Regulator Test...719
Disassembly and Assembly...720
Stator Continuity Test...720
Stator Ground Test...720
Rotor Continuity Test...721
Rotor Ground Test...721
Rectifier Continuity (Diode) Test...721
Disassembly and Assembly (New Style)...722
STARTER...723
Removal and Installation...723
Disassembly and Assembly...724
Cleaning and Inspection...724
HORN...725
Removal and Installation...725
FUEL LEVEL SENDER...725
Removal and Installation...725
ENGINE SERVICE...726
TROUBLESHOOTING...728
VALVE CLEARANCE...729
Adjustment...729
ENGINE COMPRESSION...729
Checking...729
FUEL FILTER...730
Element...730
Removing Air from the Fuel System...730
Removal and Installation...730
FUEL INJECTION PUMP...731
Checking the Injection Pump...731
Removal and Installation...731
Timing the Injection Pump...733
FUEL INJECTOR NOZZLES...734
Checking the Injector Nozzle...735
GLOW PLUGS...736
Removal and Installation...736
Checking the Glow Plug...736
ENGINE...737
Removal and Installation...737
SPARK ARRESTOR MUFFLER...742
RADIATOR...743
Checking the Radiator and Radiator Cap...743
Removal and Installation...743
Hydraulic Pump Coupler...747
CYLINDER HEAD...748
Removal of the Cylinder Head...748
Disassembly of the Cylinder Head...749
Servicing the Cylinder Head and Valves...750
Checking Valve Springs...751
Checking Rocker Arm and Shaft...752
Installing the Cylinder Head...752
TIMING GEAR COVER...754
Removal and Installation...754
TIMING GEAR, CAMSHAFT AND OIL PUMP...756
Removal and Installation...756
Oil Pump Service...758
Servicing the Camshaft...759
CRANKSHAFT AND PISTONS...761
Removal and Installation...761
Crankshaft Service...763
Servicing the Connecting Rods and Pistons...764
CYLINDER LINERS...766
Checking the Cylinder Liners...766
Cylinder Liner Installation...766
WATER PUMP...767
Removal and Installation...767
Disassembly and Assembly...767
SPECIFICATIONS...768
HYDRAULIC EXCAVATOR SPECIFICATIONS...770
Machine Dimensions...770
Lifting Capacity...771
SPECIFICATIONS...771
ENGINE SPECIFICATIONS...773
Engine...773
Fuel Injector Nozzles...773
Fuel Injection Pump...773
Cylinder Head...773
Valves...773
Valve Springs...773
Rocker Arms...773
Camshaft...774
Cylinders...774
Piston Rings...774
Pistons...774
Crankshaft...774
Oil Pump...775
Thermostat...775
Engine Torque...776
Crankshaft Re–Grind Data...777
FUEL, COOLANT AND LUBRICANTS...778
OIL SPECIFICATIONS...778
BUCKET SPECIFICATIONS...779
SERVICE MANUAL REVISON...780
320-1...780
320-2...782
320-3...784
320-4...786
320-5...788
6724026 (9-96) - X 320 Excavator Operation & Maintenance Manual...790
CONTENTS...792
FOREWORD...794
SERIAL NUMBER LOCATIONS...796
HYDRAULIC EXCAVATOR SERIAL NUMBER...796
ENGINE SERIAL NUMBER...796
DELIVERY REPORT...796
BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION...797
SAFETY...798
SAFETY INSTRUCTIONS...800
FIRE PREVENTION...802
MACHINE SIGNS (DECALS)...803
OPERATING INSTRUCTIONS...806
GETTING ON AND OFF THE MACHINE...808
SEAT...809
CONTROL LEVER (JOYSTICK) LOCK...809
INSTRUMENTS...810
OPERATOR’S HANDBOOK...811
STORAGE COMPARTMENT...811
AUDIBLE ALARM...812
KEY SWITCH...812
LIGHT SWITCH...812
AUXILIARY POWER OUTLET...812
CAB ELECTRICAL (Cab Option)...813
HEATER...813
WINDSHIELD WASHER TANK (If equipped)...813
CONTROL LEVERS (JOYSTICKS)...814
Operation of Left Control Lever (ISO)...814
Operation of Right Control Lever (ISO)...814
CONTROL LEVERS (STANDARD)...815
Operation of Left Control Lever (STANDARD)...815
Operation of Right Control Lever (STANDARD)...815
SWING LOCK...816
HORN BUTTON...816
SPEED CONTROL LEVER...817
ENGINE STOP CONTROL...817
STEERING LEVERS/FOOT PEDALS...818
Forward and Reverse Travel...818
Turning...818
BOOM SWING PEDAL AND LOCK...819
BLADE CONTROL LEVER...819
AUXILIARY OPERATION PEDAL...820
Flush Face Couplers...820
DAILY INSPECTION...821
STARTING THE ENGINE...821
Normal Starting Procedure (With Engine Warm)...821
Cold Temperature Starting Procedure...822
OPERATING PROCEDURE...823
Breaking in a New Machine...823
General Operation Suggestions...823
Operating in Water...825
PARKING THE HYDRAULIC EXCAVATOR...825
TRANSPORTING THE HYDRAULIC EXCAVATOR...826
LIFTING THE EXCAVATOR...827
LIFTING A LOAD...827
BUCKET...828
Removal...828
Installation...828
CAB/CANOPY...829
CAB/CANOPY FOPS (Falling Object Protective Structure)...829
Front Window...829
Emergency Exit...829
CAB OPTION...830
Opening the Front Window...830
Closing the Front Window...830
PREVENTIVE MAINTENANCE...832
MAINTENANCE SAFETY...833
SERVICE SCHEDULE...834
ENGINE COVER...835
AIR CLEANER SERVICE...835
Daily Check...835
Filter Replacement...835
FUEL SYSTEM...836
Fuel Specification...836
Filling the Fuel Tank...836
Fuel System Maintenance...836
Fuel Filters...837
Removing Air from the Fuel System...837
COOLING SYSTEM...838
Coolant Level...838
Coolant Replacement...838
Propylene Glycol...838
SPARK ARRESTOR MUFFLER...839
ALTERNATOR BELT ADJUSTMENT...840
ELECTRICAL SYSTEM...841
Service the Electrical System...841
Using A Booster Battery (Jump Starting)...842
Removal and Installation of the Battery...843
HYDRAULIC SYSTEM...844
Checking and Adding Fluid...844
Diagnostic Couplers...845
Replacement of the Hydraulic Filter...845
Hydraulic Reservoir...845
Replacement of the Hydraulic Fluid...845
Filter Screen...846
In–Line FIlter (S/N 511724187 & Above)...846
LUBRICATION OF THE HYDRAULIC EXCAVATOR...847
FINAL DRIVE CASE...849
Checking Oil Level (S/N 511721116–511723974)...849
Replacing Final Drive Case Oil (S/N 511721116–511723974)...849
Checking Oil Level (S/N 511723975 & Above)...849
Replacing Final Drive Case Oil (S/N 511723975 &Above)...849
TRACK TENSION...850
Adjustment...850
JOYSTICK CONTROL CHANGE...851
ISO to Standard Control Pattern...851
Standard to ISO Control Pattern...851
MACHINE SIGN TRANSLATIONS...852
SPECIFICATIONS...860
HYDRAULIC EXCAVATOR SPECIFICATIONS...862
Machine Dimensions...862
Lifting Capacity...863
WEIGHTS...863
CONTROLS...863
ENGINE...863
ELECTRICAL...863
HYDRAULIC SYSTEM...864
SWING SYSTEM...864
HYDRAULIC CYLINDERS...864
DRIVE SYSTEM...864
BRAKES...864
UNDERCARRIAGE...864
STD TRACK SHOES...864
CAPACITIES...864
DIGGING FORCE...864
FUEL, COOLANT AND LUBRICANTS...865
ENGINE OIL SPECIFICATIONS...865
Description...865
Propylene Glycol (Factory Installed)...865
BUCKET SPECIFICATIONS...866
WARRANTY...868
6724893 (3-99) - X 320 Excavator Operation & Maintenance Manual...870
OPERATOR SAFETY WARNINGS...872
CONTENTS...874
REGULAR MAINTENANCE ITEMS...875
FOREWORD...876
SERIAL NUMBER LOCATIONS...878
HYDRAULIC EXCAVATOR SERIAL NUMBER...878
ENGINE SERIAL NUMBER...878
DELIVERY REPORT...878
SAFETY...880
SAFETY INSTRUCTIONS...882
FIRE PREVENTION...884
MACHINE SIGNS (DECALS)...885
OPERATING INSTRUCTIONS...888
INSTRUMENT PANEL...890
KEY SWITCH...890
STEERING LEVERS/FOOT PEDALS...891
Forward And Reverse Travel...891
Turning...891
Right Turn...891
Left Turn ...891
AUXILIARY POWER OUTLET...892
CAB/CANOPY...892
CAB/ CANOPY FOGS (Falling Object Guards)...892
CAB OPTION...893
Emergency Exit...893
Cab Door...893
Front Window...893
CAB OPTION (Later Models)...894
Opening The Front Window...894
Closing The Front Window...894
CAB OPTION (Early Models)...895
Opening The Front Window...895
Closing The Front Window...895
ELECTRICAL...895
WINDSHIELD WASHER TANK (If Equipped)...896
HEATER CONTROL...896
LIGHT SWITCH (Cab/Canopy)...896
FUSES...896
AUDIBLE ALARM...897
HORN BUTTON...897
SEAT...897
SPEED CONTROL LEVER...898
OPERATOR'S HANDBOOK...898
STORAGE COMPARTMENT...898
ENGINE COVER...898
TOOL BOX...898
AUXILIARY HYDRAULIC PEDAL...899
Flush Face Couplers...899
BLADE CONTROL LEVER...899
SWING LOCK...900
BOOM SWING PEDAL...900
CONTROL LEVERS (JOYSTICKS)...901
Operation Of Left Control Lever (ISO)...901
Operation Of Right Control Lever (ISO)...901
Operation Of Left Control Lever (Standard)...902
Operation Of Right Control Lever (Standard)...902
CONTROL LEVER (JOYSTICK) LOCK...903
TWO SPEED TRAVEL FOOT PEDAL...903
GETTING ON AND OFF THE MACHINE...904
DAILY INSPECTION...905
STARTING THE ENGINE...905
Normal Starting Procedure (With Engine Warm)...905
Cold Temperature Starting Procedure...907
BUCKET ...908
Removal...908
Installation...908
OPERATING PROCEDURE...909
Operating On Public Roads...909
Lifting A Load...909
Excavating...910
Boom Offset...911
Back Filling...912
Driving The Excavator...912
Operating On Slopes...913
Operating In Water...915
PARKING THE HYDRAULIC EXCAVATOR...915
TRANSPORTING THE HYDRAULIC EXCAVATOR...916
LIFTING THE HYDRAULIC EXCAVATOR...917
PREVENTIVE MAINTENANCE...918
MAINTENANCE SAFETY...919
SERVICE SCHEDULE...920
ENGINE COVER...921
Adjustment Of The Engine Cover Latch...921
AIR CLEANER SERVICE...921
Daily Check...921
Filter Replacement...922
FUEL SYSTEM...923
Filling The Fuel Tank...923
Fuel Filter...923
Fuel System Maintenance...924
Removing Air From The Fuel System...924
Fuel Specification...924
ENGINE LUBRICATION SYSTEM...925
Checking Engine Oil...925
Replacement Of Oil And Filter...925
COOLING SYSTEM...926
Coolant Level...926
Coolant Replacement...926
ALTERNATOR BELT ADJUSTMENT...927
ELECTRICAL SYSTEM...927
Electrical Relays And Diodes...927
Fuses...928
Service The Electrical System And Battery...929
Using A Booster Battery (Jump Starting)...930
Removal And Installation Of The Battery...931
Electrical Solenoid (Engine Stop)...931
HYDRAULIC SYSTEM...932
Checking And Adding Fluid...932
Diagnostic Couplers...933
Replacement Of The Hydraulic Filter...933
Hydraulic Reservoir...933
Case Drain Hydraulic Filter...933
SPARK ARRESTOR MUFFLER (If So Equipped)...934
TRACK TENSION...935
Adjustment...935
FINAL DRIVE CASE...936
Checking Oil Level...936
Draining Final Drive Case...936
JOYSTICK CONTROL CHANGE...937
ISO To Standard Control Pattern...937
Standard To ISO Control Pattern...938
LUBRICATION OF THE HYDRAULIC EXCAVATOR...939
HEATER AIR FILTER (With Cab Option Only)...941
MACHINE SIGN TRANSLATIONS...942
SPECIFICATIONS...950
HYDRAULIC EXCAVATOR SPECIFICATIONS...952
Machine Dimensions...952
Lifting Capacity...953
WEIGHTS...953
CONTROLS...953
ENGINE...953
ELECTRICAL...953
HYDRAULIC SYSTEM...954
SWING SYSTEM...954
HYDRAULIC CYLINDERS...954
DRIVE SYSTEM...954
BRAKES...954
UNDERCARRIAGE...954
STD TRACK SHOES...954
CAPACITIES...954
DIGGING FORCE...954
FUEL, COOLANT AND LUBRICANTS...955
Chart...955
ENGINE OIL SPECIFICATIONS...955
Description...955
Propylene Glycol (Factory Installed)...955
BUCKET SPECIFICATIONS...956
ADDITIONAL PUBLICATIONS & TRAINING MATERIALS...957
WARRANTY...958
6724910 (1-97) - X 320, X 322 Excavator Service Manual...960
MAINTENANCE SAFETY...962
ALPHABETICAL INDEX...964
CONTENTS...966
FOREWORD...968
SAFETY INSTRUCTIONS...970
SERIAL NUMBER LOCATIONS...973
HYDRAULIC EXCAVATOR SERIAL NUMBER...973
ENGINE SERIAL NUMBER...973
DELIVERY REPORT...973
HYDRAULIC EXCAVATOR IDENTIFICATION...974
PREVENTIVE MAINTENANCE...976
MAINTENANCE SAFETY...978
SERVICE SCHEDULE...979
ENGINE COVER...980
Adjustment of the Engine Cover Latch...980
AIR CLEANER SERVICE...980
Daily Check...980
Filter Replacement...981
FUEL SYSTEM...982
Filling the Fuel Tank...982
Fuel Filter...982
Fuel System Maintenance...983
Removing Air From the Fuel System...983
Fuel Specification...983
ENGINE LUBRICATION SYSTEM...984
Checking Engine Oil...984
Replacement of Oil and Filter...984
COOLING SYSTEM...985
Coolant Level...985
Coolant Replacement...985
Propylene Glycol (Factory Installed)...985
ALTERNATOR BELT ADJUSTMENT...986
ELECTRICAL SYSTEM...986
Electrical Relays and Diodes...986
Fuses...987
Service the Electrical System (and Battery)...987
Removal and Installation of the Battery...988
Electric Solenoid (Engine Stop)...988
HYDRAULIC SYSTEM...989
Checking and Adding Fluid...989
Diagnostic Couplers...990
Hydraulic Reservoir...990
Replacement of the Hydraulic Filter...990
Case Drain Hydraulic Filter...990
TRACK TENSION...992
Adjustment...992
FINAL DRIVE CASE...993
Checking Oil Level...993
Draining Final Drive Case...993
JOYSTICK CONTROL CHANGE...994
ISO to Standard Control Pattern...994
Standard to ISO Control Pattern...995
LUBRICATION OF THE HYDRAULIC EXCAVATOR...996
HEATER AIR FILTER (With Cab Option Only)...998
HYDRAULIC SECTION...1000
HYDRAULIC SCHEMATICS...1002
TROUBLESHOOTING...1016
HYDRAULIC SERVICE INFORMATION...1021
Checking the Main Relief Valves and Cross Port Relief Valve...1021
Checking the Hydraulic Pump...1026
HYDRAULIC PUMP...1027
Removal and Installation...1027
Coupler Removal and Installation...1028
Hydraulic Pump Assembly...1029
Disassembly...1030
Assembly...1032
HYDRAULIC CONTROL VALVE...1035
Description...1035
Removal and Installation...1035
Disassembly...1038
Outlet Section Disassembly...1039
Outlet Section Assembly...1039
Mid Inlet Section Disassembly...1039
Mid Inlet Section Assembly...1039
Left Travel, Right Travel, Auxiliary and Blade Disassembly...1040
Left Travel, Right Travel, Auxiliary and Blade Assembly...1042
Boom, Bucket Arm and Swing Disassembly...1044
Boom, Bucket, Arm and Swing Assembly...1047
Utility Block Disassembly...1049
Utility Block Assembly...1050
Boom Swing Disassembly...1051
Boom Swing Assembly...1053
Boost Disassembly...1056
Boost Assembly...1058
Assembly...1061
PORT RELIEF VALVES...1063
Parts Identification...1063
Port Relief Valve Pressure Setting...1064
Disassembly...1064
Assembly...1065
Adjustment Procedure...1065
Disassembly...1066
Assembly...1066
Adjusting the Main Relief Valves...1068
ACCUMULATOR...1069
Pressure Reducing Valve (Description)...1069
Removal and Installation...1069
Disassembly (S/N 562313001 – 562320721 &517811001 – 517811977)...1070
Assembly (S/N 562313001 – 562320721 & 517811001– 517811977)...1072
Parts Identification (S/N 562320721 & Above & 517811978 & Above)...1075
Disassembly (S/N 562320721 & Above & 517811978 & Above)...1076
Assembly (S/N 562320721 & Above & 517811978 & Above)...1078
Testing (All Models)...1081
BOOM CYLINDER...1083
Removal and Installation...1083
ARM CYLINDER...1084
Removal and Installation...1084
BUCKET CYLINDER...1085
Removal and Installation...1085
BLADE CYLINDER...1086
Removal and Installation...1086
BOOM SWING CYLINDER...1087
Removal and Installation...1087
TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above)...1088
HYDRAULIC CYLINDER...1092
Disassembly...1092
Assembly...1094
Disassembly...1095
Assembly...1096
HYDRAULIC FILTER ASSEMBLY...1102
Removal and Installation...1102
AUXILIARY FLUSH FACE COUPLERS...1102
Removal and Installation...1102
DRAIN BLOCK...1103
Removal and Installation...1103
OIL COOLER...1103
Removal and Installation...1103
JOYSTICK CONTROL CHANGE...1104
ISO To Standard...1104
Standard to ISO...1104
DRIVE SECTION...1106
FLOORMAT AND FLOOR PANELS...1108
Removal and Installation...1108
MICROSWITCH...1110
Adjustment...1110
Removal and Installation...1111
CONSOLE COVER LEFT HAND...1112
Removal and Installation...1112
JOYSTICK...1114
Removal and Installation...1114
CONTROL CONSOLE LEFT HAND...1115
Removal and Installation...1115
FUEL TANK...1118
Removal and Installation...1118
LOCK LEVER...1120
Removal and Installation...1120
Adjustment...1121
LATCH HOOK...1122
Removal and Installation...1122
GAS SPRING...1123
Removal and Installation...1123
UPPER CONSOLE...1124
Removal and Installation...1124
CONTROL CONSOLE RIGHT HAND...1125
Rops Canopy Models...1125
Cab Models...1125
CONSOLE COVER RIGHT HAND...1126
Removal and Installation...1126
CONTROL CONSOLE RIGHT HAND...1128
Removal and Installation...1128
HYDRAULIC RESERVOIR...1133
Removal and Installation...1133
TRAVEL LEVERS...1134
Removal and Installation...1134
Disassembly and Assembly...1135
PEDAL RIGHT HAND...1137
Removal and Installation...1137
Disassembly and Assembly...1137
PEDAL LEFT HAND...1139
Removal and Installation...1139
Disassembly and Assembly...1139
ROCKERSHAFT...1141
Removal and Installation...1141
Disassembly and Assembly...1142
LINKAGE RODS...1143
Removal and Installation...1143
BLADE LEVER...1144
Removal and Installation...1144
Disassembly and Assembly...1146
DRIVE MOTOR...1147
Removal and Installation...1147
Parts Identification...1148
Disassembly...1149
Assembly...1156
JOYSTICK...1165
Parts Identification...1165
Disassembly...1166
Assembly...1169
Troubleshooting...1174
UPPER WORKS AND SWING SECTION...1176
SWING MOTOR...1178
Removal and Installation...1178
Disassembly...1179
Assembly...1180
Motor Timing...1181
CENTER SWIVEL JOINT (S/N 562313001 – 562319999)...1182
Removal and Installation...1182
Disassembly and Assembly...1182
CENTER SWIVEL JOINT 320 (S/N 562320000 &Above) and 322 (S/N 517811001 & Above)...1183
Removal And Installation...1183
Parts Identification...1189
Disassembly...1190
Assembly...1194
UPPERSTRUCTURE...1198
Removal...1198
Installation...1200
SWING CIRCLE GEAR...1202
Removal and Installation...1202
ROPS CANOPY...1203
Removal and Installation...1203
CAB...1205
Removal and Installation...1205
Door (Removal and Installation)...1208
Front Window Removal and Installation...1209
Front Lower Window Removal and Installation...1210
Front Upper Window Removal and Installation...1210
Door Glass (Removal and Installation)...1211
Left Hand Side Glass (Removal and Installation)...1211
Right Hand Side Window Removal and Installation...1212
Right Hand Window Assembly Removal and Installation...1213
Rear Window Removal and Installation...1213
CAB/CANOPY REAR COVER...1214
Removal...1214
Installation...1214
AIR BAFFLE (Cab Models Only)...1215
Removal and Installation...1215
BELLY PAN (Field Installed)...1215
Removal and Installation...1215
MAIN FRAME AND TRACKS...1216
ENGINE COVER...1218
Removal and Installation...1218
CORNER POSTS...1218
Removal and Installation...1218
COUNTERWEIGHT...1219
Removal and Installation...1219
SEAT AND SEAT MOUNT...1220
Removal and Installation...1220
SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING...1221
Removal and Installation...1221
BUCKET...1222
Removal and Installation...1222
Installation...1222
ARM...1223
Removal and Installation...1223
ARM BUSHINGS...1224
Arm To Boom Bushing Removal And Installation...1224
Arm To Bucket and Bucket Link Bushing Removal and Installation...1225
BOOM...1226
Removal and Installation...1226
BOOM BUSHING...1227
Removal And Installation...1227
SWING POST...1228
Removal and Installation...1228
Bushing Replacement...1229
Swing Post Bushing Removal...1229
Bushing Installation...1229
TRACK...1230
Adjustment 320 (S/N 562313001 – 562319999)...1230
Adjustment 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)...1231
Removal and Installation...1232
Track Damage Identification and Causes...1232
TRACK FRAME...1233
Disassembly and Assembly 320 (S/N 562313001 – 562319999)...1233
Disassembly and Assembly 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)...1235
Recoil Spring Cylinder Disassembly And Assembly...1237
Removal and Installation of Expandible Track Frame (322 only)...1238
TRACK DAMAGE IDENTIFICATION...1239
Cutting of the Steel Cords...1239
Abrasion of Embedded Metals...1240
Separation of Embedded Metals Due to External Forces...1241
Separation of Embedded Metals Due To Corrosion...1242
Cuts On The Lug Side...1243
Cracks On The Lug Side Rubber Due To Fatigue...1244
Lug Abrasion...1245
Cracks and Cuts on the Lug Side Rubber at the Edges of the Embedded Metals...1246
Abrasion Of The Track Roller Side Rubber Surface...1247
Cuts On The Edges Of The Track Roller Side...1248
ELECTRICAL SYSTEM...1250
ELECTRICAL SCHEMATICS...1252
TROUBLESHOOTING...1259
Chart...1259
ELECTRICAL SYSTEM...1259
Description...1259
Fuses...1260
Electrical System Service...1260
Electrical Relays and Diodes...1261
BATTERY...1262
Using A Booster Battery (Jump Starting)...1262
Removal and Installation...1263
BATTERY BOX...1264
Removal and Installation...1264
CAB ELECTRICAL (Cab Option)...1264
Removal and Installation...1264
ALTERNATOR...1265
Checking the Alternator Output...1265
Removal and Installation...1265
Belt Adjustment...1265
STARTER...1266
Removal and Installation...1266
Disassembly and Assembly...1267
Cleaning and Inspection...1267
HORN...1268
Removal and Installation...1268
FUEL LEVEL SENDER...1268
Removal and Installation...1268
LIGHT SWITCH...1269
Removal and Installation...1269
TWO SPEED SWITCH...1270
Removal and Installation...1270
ENGINE SERVICE...1271
TROUBLESHOOTING...1273
Chart...1273
VALVE CLEARANCE...1274
Adjustment...1274
ENGINE COMPRESSION...1274
Checking...1274
FUEL SHUTOFF SOLENOID...1275
Removal and Installation...1275
Timer Module Removal and Installation...1275
FUEL INJECTION PUMP...1276
Checking the Injection Pump...1276
Timing the Injection Pump...1278
FUEL INJECTOR NOZZLES...1279
Removal and Installation...1279
Checking the Injector Nozzle...1280
GLOW PLUGS...1281
Removal and Installation...1281
Checking the Glow Plug...1281
BELT GUARD...1282
Removal and Installation...1282
RADIATOR...1283
Removal and Installation...1283
SPARK ARRESTOR MUFFLER (If Equipped)...1286
Cleaning Spark Chamber...1286
Removal and Installation...1286
AIR CLEANER...1287
Removal and Installation...1287
ENGINE...1288
Removal and Installation...1288
ENGINE FLYWHEEL (EARLY MODELS)...1293
Removal and Installation...1293
Hydraulic Pump Coupler...1294
ENGINE FLYWHEEL (LATER MODELS)...1295
Removal And Installation...1295
Hydraulic Pump Coupler...1297
Flywheel Ring Gear...1297
CYLINDER HEAD...1298
Removal and Installation...1298
Disassembly and Assembly...1299
Servicing the Cylinder Head...1300
Top Clearance...1300
VALVE, VALVE SEAT AND GUIDE...1301
Checking the Valve Guide...1301
Reconditioning the Valve and Valve Seat...1302
Valve Spring...1303
ROCKER ARM AND SHAFT...1303
Checking...1303
TIMING GEARCASE COVER...1304
Removal and Installation...1304
IDLER GEAR AND CAMSHAFT...1306
Removal and Installation...1306
Servicing the Idler Gear and Shaft...1308
TIMING GEARS...1308
Checking Backlash...1308
FUEL CAMSHAFT...1309
Removal and Installation...1309
CRANKSHAFT GEAR...1310
Removal and Installation...1310
OIL PUMP...1310
Removal and Installation...1310
Oil Pump Service...1310
Checking Engine Oil Pressure...1311
Relief Valve...1311
PISTON AND CONNECTING ROD...1312
Removal and Installation...1312
Servicing the Piston and Connecting Rod...1313
Connecting Rod Alignment...1315
CRANKSHAFT AND BEARINGS...1316
Removal and Installation...1316
Servicing the Crankshaft and Bearings...1317
CYLINDER BORE...1320
Checking the Cylinder Bore...1320
WATER PUMP...1321
Removal and Installation...1321
Disassembly and Assembly...1321
TECHNICAL DATA...1323
HYDRAULIC EXCAVATOR SPECIFICATIONS...1325
Machine Dimensions...1325
SPECIFICATIONS...1326
ENGINE SPECIFICATIONS...1328
Engine...1328
Fuel Injector Nozzles...1328
Fuel Injection Pump...1328
Cylinder Head...1328
Valves...1328
Valve Springs...1328
Rocker Arms...1328
Camshaft...1329
Cylinders...1329
Piston Rings...1329
Pistons...1329
Crankshaft...1329
Oil Pump...1330
Thermostat...1330
ENGINE BOLT TORQUE...1331
Re–Grinding The Crankshaft...1332
HYDRAULIC FLUID SPECIFICATIONS...1333
Specifications...1333
FUEL, COOLANT AND LUBRICANTS...1334
Chart...1334
SERVICE MANUAL REVISION...1335
320-1...1335
320-2...1337
320/322-3...1339
320/322-4...1341
320/322-5...1343
6724910 (6-12) - X 320, X 322 Excavator Service Manual...1345
MAINTENANCE SAFETY...1347
ALPHABETICAL INDEX...1349
CONTENTS...1351
FOREWORD...1353
SAFETY INSTRUCTIONS...1355
SERIAL NUMBER LOCATIONS...1358
HYDRAULIC EXCAVATOR SERIAL NUMBER...1358
ENGINE SERIAL NUMBER...1358
DELIVERY REPORT...1358
HYDRAULIC EXCAVATOR IDENTIFICATION...1359
PREVENTIVE MAINTENANCE...1361
MAINTENANCE SAFETY...1363
SERVICE SCHEDULE...1364
ENGINE COVER...1365
Adjustment of the Engine Cover Latch...1365
AIR CLEANER SERVICE...1365
Daily Check...1365
Filter Replacement...1366
FUEL SYSTEM...1367
Filling the Fuel Tank...1367
Fuel Filter...1367
Fuel System Maintenance...1368
Removing Air From the Fuel System...1368
Fuel Specification...1368
ENGINE LUBRICATION SYSTEM...1369
Checking Engine Oil...1369
Replacement of Oil and Filter...1369
COOLING SYSTEM...1370
Coolant Level...1370
Coolant Replacement...1370
Propylene Glycol (Factory Installed)...1370
ALTERNATOR BELT ADJUSTMENT...1371
ELECTRICAL SYSTEM...1371
Electrical Relays and Diodes...1371
Fuses...1372
Service the Electrical System (and Battery)...1372
Removal and Installation of the Battery...1373
Electric Solenoid (Engine Stop)...1373
HYDRAULIC SYSTEM...1374
Checking and Adding Fluid...1374
Diagnostic Couplers...1375
Hydraulic Reservoir...1375
Replacement of the Hydraulic Filter...1375
Case Drain Hydraulic Filter...1375
TRACK TENSION...1377
Adjustment...1377
FINAL DRIVE CASE...1378
Checking Oil Level...1378
Draining Final Drive Case...1378
JOYSTICK CONTROL CHANGE...1379
ISO to Standard Control Pattern...1379
Standard to ISO Control Pattern...1380
LUBRICATION OF THE HYDRAULIC EXCAVATOR...1381
HEATER AIR FILTER (With Cab Option Only)...1383
HYDRAULIC SECTION...1385
HYDRAULIC SCHEMATICS...1387
TROUBLESHOOTING...1405
HYDRAULIC SERVICE INFORMATION...1410
Checking the Main Relief Valves and Cross Port Relief Valve...1410
Checking the Hydraulic Pump...1415
HYDRAULIC PUMP...1416
Removal and Installation...1416
Coupler Removal and Installation...1417
Hydraulic Pump Assembly...1418
Disassembly...1419
Assembly...1421
HYDRAULIC CONTROL VALVE...1424
Description...1424
Removal and Installation...1424
Disassembly...1427
Outlet Section Disassembly...1428
Outlet Section Assembly...1428
Mid Inlet Section Disassembly...1428
Mid Inlet Section Assembly...1428
Left Travel, Right Travel, Auxiliary and Blade Disassembly...1429
Left Travel, Right Travel, Auxiliary and Blade Assembly...1431
Boom, Bucket Arm and Swing Disassembly...1433
Boom, Bucket, Arm and Swing Assembly...1436
Utility Block Disassembly...1438
Utility Block Assembly...1439
Boom Swing Disassembly...1440
Boom Swing Assembly...1442
Boost Disassembly...1445
Boost Assembly...1447
Assembly...1450
PORT RELIEF VALVES...1452
Parts Identification...1452
Port Relief Valve Pressure Setting...1453
Disassembly...1453
Assembly...1454
Adjustment Procedure...1454
Disassembly...1455
Assembly...1455
Adjusting the Main Relief Valves...1457
ACCUMULATOR...1458
Pressure Reducing Valve (Description)...1458
Removal and Installation...1458
Disassembly (S/N 562313001 – 562320721 &517811001 – 517811977)...1459
Assembly (S/N 562313001 – 562320721 & 517811001– 517811977)...1461
Parts Identification (S/N 562320721 & Above & 517811978 & Above)...1464
Disassembly (S/N 562320721 & Above & 517811978 & Above)...1465
Assembly (S/N 562320721 & Above & 517811978 & Above)...1467
Testing (All Models)...1470
BOOM CYLINDER...1472
Removal and Installation...1472
ARM CYLINDER...1473
Removal and Installation...1473
BUCKET CYLINDER...1474
Removal and Installation...1474
BLADE CYLINDER...1475
Removal and Installation...1475
BOOM SWING CYLINDER...1476
Removal and Installation...1476
TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above)...1477
HYDRAULIC CYLINDER...1481
Disassembly...1481
Assembly...1483
Disassembly...1484
Assembly...1485
HYDRAULIC FILTER ASSEMBLY...1491
Removal and Installation...1491
AUXILIARY FLUSH FACE COUPLERS...1491
Removal and Installation...1491
DRAIN BLOCK...1492
Removal and Installation...1492
OIL COOLER...1492
Removal and Installation...1492
JOYSTICK CONTROL CHANGE...1493
ISO To Standard...1493
Standard to ISO...1493
DRIVE SECTION...1495
FLOORMAT AND FLOOR PANELS...1497
Removal and Installation...1497
MICROSWITCH...1499
Adjustment...1499
Removal and Installation...1500
CONSOLE COVER LEFT HAND...1501
Removal and Installation...1501
JOYSTICK...1503
Removal and Installation...1503
CONTROL CONSOLE LEFT HAND...1504
Removal and Installation...1504
FUEL TANK...1507
Removal and Installation...1507
LOCK LEVER...1509
Removal and Installation...1509
Adjustment...1510
LATCH HOOK...1511
Removal and Installation...1511
GAS SPRING...1512
Removal and Installation...1512
UPPER CONSOLE...1513
Removal and Installation...1513
CONTROL CONSOLE RIGHT HAND...1514
Rops Canopy Models...1514
Cab Models...1514
CONSOLE COVER RIGHT HAND...1515
Removal and Installation...1515
CONTROL CONSOLE RIGHT HAND...1517
Removal and Installation...1517
HYDRAULIC RESERVOIR...1522
Removal and Installation...1522
TRAVEL LEVERS...1523
Removal and Installation...1523
Disassembly and Assembly...1524
PEDAL RIGHT HAND...1526
Removal and Installation...1526
Disassembly and Assembly...1526
PEDAL LEFT HAND...1528
Removal and Installation...1528
Disassembly and Assembly...1528
ROCKERSHAFT...1530
Removal and Installation...1530
Disassembly and Assembly...1531
LINKAGE RODS...1532
Removal and Installation...1532
BLADE LEVER...1533
Removal and Installation...1533
Disassembly and Assembly...1535
DRIVE MOTOR...1536
Removal and Installation...1536
Parts Identification...1537
Disassembly...1538
Assembly...1545
JOYSTICK...1554
Parts Identification...1554
Disassembly...1555
Assembly...1558
Troubleshooting...1563
UPPER WORKS AND SWING SECTION...1565
SWING MOTOR...1567
Removal and Installation...1567
Disassembly...1568
Assembly...1569
Motor Timing...1570
CENTER SWIVEL JOINT (S/N 562313001 – 562319999)...1571
Removal and Installation...1571
Disassembly and Assembly...1571
CENTER SWIVEL JOINT 320 (S/N 562320000 &Above) and 322 (S/N 517811001 & Above)...1572
Removal And Installation...1572
Parts Identification...1578
Disassembly...1579
Assembly...1583
UPPERSTRUCTURE...1587
Removal...1587
Installation...1589
SWING CIRCLE GEAR...1591
Removal and Installation...1591
ROPS CANOPY...1592
Removal and Installation...1592
CAB...1594
Removal and Installation...1594
Door (Removal and Installation)...1597
Front Window Removal and Installation...1598
Front Lower Window Removal and Installation...1599
Front Upper Window Removal and Installation...1599
Door Glass (Removal and Installation)...1600
Left Hand Side Glass (Removal and Installation)...1600
Right Hand Side Window Removal and Installation...1601
Right Hand Window Assembly Removal and Installation...1602
Rear Window Removal and Installation...1602
CAB/CANOPY REAR COVER...1603
Removal...1603
Installation...1603
AIR BAFFLE (Cab Models Only)...1604
Removal and Installation...1604
BELLY PAN (Field Installed)...1604
Removal and Installation...1604
MAIN FRAME AND TRACKS...1605
ENGINE COVER...1607
Removal and Installation...1607
CORNER POSTS...1607
Removal and Installation...1607
COUNTERWEIGHT...1608
Removal and Installation...1608
SEAT AND SEAT MOUNT...1609
Removal and Installation...1609
SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING...1610
Removal and Installation...1610
BUCKET...1611
Removal and Installation...1611
Installation...1611
ARM...1612
Removal and Installation...1612
ARM BUSHINGS...1613
Arm To Boom Bushing Removal And Installation...1613
Arm To Bucket and Bucket Link Bushing Removal and Installation...1614
BOOM...1615
Removal and Installation...1615
BOOM BUSHING...1616
Removal And Installation...1616
SWING POST...1617
Removal and Installation...1617
Bushing Replacement...1618
Swing Post Bushing Removal...1618
Bushing Installation...1618
TRACK...1619
Adjustment 320 (S/N 562313001 – 562319999)...1619
Adjustment 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)...1620
Removal and Installation...1621
Track Damage Identification and Causes...1621
TRACK FRAME...1622
Disassembly and Assembly 320 (S/N 562313001 – 562319999)...1622
Disassembly and Assembly 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above)...1624
Recoil Spring Cylinder Disassembly And Assembly...1626
Removal and Installation of Expandible Track Frame (322 only)...1627
TRACK DAMAGE IDENTIFICATION...1628
Cutting of the Steel Cords...1628
Abrasion of Embedded Metals...1629
Separation of Embedded Metals Due to External Forces...1630
Separation of Embedded Metals Due To Corrosion...1631
Cuts On The Lug Side...1632
Cracks On The Lug Side Rubber Due To Fatigue...1633
Lug Abrasion...1634
Cracks and Cuts on the Lug Side Rubber at the Edges of the Embedded Metals...1635
Abrasion Of The Track Roller Side Rubber Surface...1636
Cuts On The Edges Of The Track Roller Side...1637
ELECTRICAL SYSTEM...1639
ELECTRICAL SCHEMATICS...1641
TROUBLESHOOTING...1653
Chart...1653
ELECTRICAL SYSTEM...1653
Description...1653
Fuses...1654
Electrical System Service...1654
Electrical Relays and Diodes...1655
BATTERY...1656
Using A Booster Battery (Jump Starting)...1656
Removal and Installation...1657
BATTERY BOX...1658
Removal and Installation...1658
CAB ELECTRICAL (Cab Option)...1658
Removal and Installation...1658
ALTERNATOR...1659
Checking the Alternator Output...1659
Removal and Installation...1659
Belt Adjustment...1659
STARTER...1660
Removal and Installation...1660
Disassembly and Assembly...1661
Cleaning and Inspection...1661
HORN...1662
Removal and Installation...1662
FUEL LEVEL SENDER...1662
Removal and Installation...1662
LIGHT SWITCH...1663
Removal and Installation...1663
TWO SPEED SWITCH...1664
Removal and Installation...1664
ENGINE SERVICE...1665
TROUBLESHOOTING...1667
Chart...1667
VALVE CLEARANCE...1668
Adjustment...1668
ENGINE COMPRESSION...1668
Checking...1668
FUEL SHUTOFF SOLENOID...1669
Removal and Installation...1669
Timer Module Removal and Installation...1669
FUEL INJECTION PUMP...1670
Checking the Injection Pump...1670
Timing the Injection Pump...1672
FUEL INJECTOR NOZZLES...1673
Removal and Installation...1673
Checking the Injector Nozzle...1674
GLOW PLUGS...1675
Removal and Installation...1675
Checking the Glow Plug...1675
BELT GUARD...1676
Removal and Installation...1676
RADIATOR...1677
Removal and Installation...1677
SPARK ARRESTOR MUFFLER (If Equipped)...1680
Cleaning Spark Chamber...1680
Removal and Installation...1680
AIR CLEANER...1681
Removal and Installation...1681
ENGINE...1682
Removal and Installation...1682
ENGINE FLYWHEEL (EARLY MODELS)...1687
Removal and Installation...1687
Hydraulic Pump Coupler...1688
ENGINE FLYWHEEL (LATER MODELS)...1689
Removal And Installation...1689
Hydraulic Pump Coupler...1691
Flywheel Ring Gear...1691
CYLINDER HEAD...1692
Removal and Installation...1692
Disassembly and Assembly...1693
Servicing the Cylinder Head...1694
Top Clearance...1694
VALVE, VALVE SEAT AND GUIDE...1695
Checking the Valve Guide...1695
Reconditioning the Valve and Valve Seat...1696
Valve Spring...1697
ROCKER ARM AND SHAFT...1697
Checking...1697
TIMING GEARCASE COVER...1698
Removal and Installation...1698
IDLER GEAR AND CAMSHAFT...1700
Removal and Installation...1700
Servicing the Idler Gear and Shaft...1702
TIMING GEARS...1702
Checking Backlash...1702
FUEL CAMSHAFT...1703
Removal and Installation...1703
CRANKSHAFT GEAR...1704
Removal and Installation...1704
OIL PUMP...1704
Removal and Installation...1704
Oil Pump Service...1704
Checking Engine Oil Pressure...1705
Relief Valve...1705
PISTON AND CONNECTING ROD...1706
Removal and Installation...1706
Servicing the Piston and Connecting Rod...1707
Connecting Rod Alignment...1709
CRANKSHAFT AND BEARINGS...1710
Removal and Installation...1710
Servicing the Crankshaft and Bearings...1711
CYLINDER BORE...1714
Checking the Cylinder Bore...1714
WATER PUMP...1715
Removal and Installation...1715
Disassembly and Assembly...1715
TECHNICAL DATA...1717
HYDRAULIC EXCAVATOR SPECIFICATIONS...1719
Machine Dimensions...1719
SPECIFICATIONS...1720
ENGINE SPECIFICATIONS...1722
Engine...1722
Fuel Injector Nozzles...1722
Fuel Injection Pump...1722
Cylinder Head...1722
Valves...1722
Valve Springs...1722
Rocker Arms...1722
Camshaft...1723
Cylinders...1723
Piston Rings...1723
Pistons...1723
Crankshaft...1723
Oil Pump...1724
Thermostat...1724
ENGINE BOLT TORQUE...1725
Re–Grinding The Crankshaft...1726
HYDRAULIC FLUID SPECIFICATIONS...1727
Specifications...1727
FUEL, COOLANT AND LUBRICANTS...1728
Chart...1728
SERVICE MANUAL REVISION...1729
320-1...1729
320-2...1731
320/322-3...1733
320/322-4...1735
320/322-5...1737
320/322-6...1739
6900806 (2-00) - 322 Excavator Operation & Maintenance Manual...1741
OPERATOR SAFETY WARNINGS...1743
CONTENTS...1745
REGULAR MAINTENANCE ITEMS...1746
FOREWORD...1747
SERIAL NUMBER LOCATIONS...1749
HYDRAULIC EXCAVATOR SERIAL NUMBER...1749
ENGINE SERIAL NUMBER...1749
DELIVERY REPORT...1749
HYDRAULIC EXCAVATOR IDENTIFICATION...1750
SAFETY...1751
SAFETY INSTRUCTIONS...1753
FIRE PREVENTION...1755
MACHINE SIGNS (DECALS)...1756
OPERATING INSTRUCTIONS...1759
INSTRUMENT PANEL...1761
KEY SWITCH...1761
STEERING LEVERS/FOOT PEDALS...1762
Forward And Reverse Travel...1762
Turning...1762
Right Turn...1762
Left Turn...1762
AUXILIARY POWER OUTLET...1763
CAB/CANOPY...1763
CAB/CANOPY FOGS (Falling Object Guards)...1763
CAB OPTION...1764
Emergency Exit...1764
Cab Door...1764
Front Window...1764
Opening The Front Window...1765
Closing The Front Window...1765
Electrical...1766
Windshield Washer Tank...1766
Heater Control...1766
LIGHT SWITCH (Cab/Canopy)...1767
FUSES...1767
AUDIBLE ALARM...1768
HORN BUTTON...1768
SEAT...1768
SPEED CONTROL LEVER...1769
OPERATOR'S HANDBOOK...1769
STORAGE COMPARTMENT...1769
ENGINE COVER...1769
TOOL BOX...1769
BLADE/TRACK EXPANSION SWITCH...1770
BLADE CONTROL LEVER...1770
AUXILIARY HYDRAULIC PEDAL...1770
Operation...1770
Quick Couplers...1771
SWING LOCK...1772
BOOM SWING PEDAL...1772
TRACK FRAME EXPANSION...1773
CONTROL LEVERS (JOYSTICKS)...1776
Operation Of Left Control Lever (ISO)...1776
Operation OF Right Control Lever (ISO)...1776
Operation Of Left Control Lever (Standard)...1777
Operation Of Right Control Lever (Standard)...1777
CONTROL LEVER (JOYSTICK) LOCK...1778
TWO SPEED TRAVEL FOOT PEDAL...1778
ENTERING AND EXITING THE EXCAVATOR...1779
DAILY INSPECTION...1780
STARTING THE ENGINE...1780
Normal Starting Procedure (With Engine Warm)...1780
Cold Temperature Starting Procedure...1782
BUCKET...1783
Removal...1783
Installation...1783
OPERATING PROCEDURE...1784
Operating On Public Roads...1784
Lifting A Load...1784
Excavating...1785
Boom Offset...1786
Back Filling...1787
Driving The Excavator...1787
Operating On Slopes...1788
Operating In Water...1790
PARKING THE HYDRAULIC EXCAVATOR...1790
TRANSPORTING THE HYDRAULIC EXCAVATOR...1791
LIFTING THE HYDRAULIC EXCAVATOR...1792
PREVENTIVE MAINTENANCE...1793
MAINTENANCE SAFETY...1795
SERVICE SCHEDULE...1796
ENGINE COVER...1797
Adjustment Of The Engine Cover Latch...1797
AIR CLEANER SERVICE...1797
Daily Check...1797
Filter Replacement...1798
FUEL SYSTEM...1799
Filling The Fuel Tank...1799
Fuel Filter...1799
Fuel System Maintenance...1800
Removing Air From The Fuel System...1800
Fuel Specifications...1800
ENGINE LUBRICATION SYSTEM...1801
Checking Engine Oil...1801
Replacement Of Oil And Filter...1801
COOLING SYSTEM...1802
Coolant Replacement...1802
ALTERNATOR BELT ADJUSTMENT...1803
ELECTRICAL SYSTEM...1803
Electrical Relays And Diodes...1803
Fuses...1804
Service The Electrical System And Battery...1805
Using A Booster Battery (Jump Starting)...1806
Removal And Installation Of The Battery...1807
Electrical Solenoid (Engine Stop)...1807
HYDRAULIC SYSTEM...1808
Checking And Adding Fluid...1808
Diagnostic Couplers...1809
Replacement Of The Hydraulic Filter...1809
Hydraulic Reservoir...1809
Case Drain Hydraulic Filter...1809
SPARK ARRESTOR MUFFLER (If Equipped)...1810
TRACK TENSION...1811
Adjustment...1811
FINAL DRIVE CASE...1812
Checking Oil Level...1812
Draining Final Drive Case...1812
JOYSTICK CONTROL CHANGE...1813
ISO To Standard Control Pattern...1813
Standard To ISO Control Pattern...1814
LUBRICATION OF THE HYDRAULIC EXCAVATOR...1815
HEATER AIR FILTER (With Cab Option Only)...1817
BLADE EXTENSION...1817
Removal And Installation...1817
MACHINE SIGN TRANSLATIONS...1819
SPECIFICATIONS...1829
SPECIFICATIONS...1831
Machine Dimensions...1831
Lifting Capacity...1832
WEIGHTS...1832
CONTROLS...1832
ENGINE...1832
ELECTRICAL...1832
HYDRAULIC SYSTEM...1833
SWING SYSTEM...1833
HYDRAULIC CYLINDERS...1833
DRIVE SYSTEM...1833
BRAKES...1833
UNDERCARRIAGE...1833
STD TRACK SHOES...1833
CAPACITIES...1833
DIGGING FORCE...1833
FUEL, COOLANT AND LUBRICANTS...1834
Chart...1834
ENGINE OIL SPECIFICATIONS...1834
Description...1834
Propylene Glycol (Factory Installed)...1834
BUCKET SPECIFICATIONS...1835
BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...1836
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...1837
WARRANTY...1839
6901016 (6-03) - 322 Excavator Operation & Maintenance Manual...1841
OPERATOR SAFETY WARNINGS...1843
CONTENTS...1845
REGULAR MAINTENANCE ITEMS...1846
FOREWORD...1847
SERIAL NUMBER LOCATIONS...1849
Bobcat Excavator Serial Number...1849
Engine Serial Number...1849
DELIVERY REPORT...1849
BOBCAT IDENTIFICATION...1850
FEATURES AND ACCESSORIES...1851
SAFETY...1853
SAFETY INSTRUCTIONS FOR BOBCAT COMPACT EXCAVATORS AND ATTACHMENTS...1855
FIRE PREVENTION...1857
MACHINE SIGN (DECALS)...1858
OPERATING INSTRUCTIONS...1861
INSTRUMENTS AND CONSOLES...1863
Cab Instrument Panel (If Equipped)...1863
Left Console...1863
Heater (If Equipped)...1863
Wiper / Washer Fluid Reservoir (If Equipped)...1863
Right Console...1864
Right Control Panel...1864
Raising And Lowering The Console(s)...1865
TWO SPEED TRAVEL...1865
TAILGATE...1865
Opening And Closing The Tailgate...1865
OPERATOR CANOPY (ROPS / TOPS)...1866
FALLING OBJECT GUARDS (FOGS)...1866
CANOPY ENCLOSURE...1866
OPERATOR CAB (ROPS / TOPS) ...1867
Emergency Exit...1867
Cab Door...1867
Front Window Wiper...1867
Window Washer Reservoir...1867
STEERING LEVERS / FOOT PEDALS...1869
Forward And Reverse Travel...1869
Turning...1869
HYDRAULIC CONTROLS...1870
ISO Control Pattern...1870
Left Control Lever...1870
Right Control Lever...1870
Standard Control Pattern...1871
Left Control Lever...1871
Right Control Lever...1871
Control Lever (Joystick) Lock...1872
Auxiliary Hydraulic Pedal (If Equipped)...1872
Quick Couplers...1873
BLADE CONTROL LEVER...1874
TRACK FRAME EXPANSION...1875
SLEW LOCK...1877
BOOM SWING PEDAL...1878
DAILY INSPECTION...1879
PRE-STARTING PROCEDURE...1880
STARTING THE ENGINE...1882
Cold Temperature Starting Procedure...1883
BUCKETS AND ATTACHMENTS...1884
Installing...1884
Removing...1884
OPERATING PROCEDURE...1885
Operating On Public Roads...1885
Lifting A Load...1885
Excavating...1886
Boom Offset...1887
Backfilling...1888
Driving The Excavator...1888
Operating On Slopes...1889
Operating In Water...1891
PARKING THE EXCAVATOR...1891
TRANSPORTING THE EXCAVATOR...1892
LIFTING THE EXCAVATOR...1893
PREVENTIVE MAINTENANCE...1895
MAINTENANCE SAFETY...1897
SERVICE SCHEDULE...1898
TAILGATE...1899
Opening And Closing The Tailgate...1899
Adjusting The Bumper...1899
Adjusting The Tailgate Latch (Early Models Only)...1899
AIR CLEANER SERVICE...1899
Daily Check...1899
Replacing The Filters...1899
HEATER AIR FILTERS...1900
Recirculation Filter...1900
Fresh Air Filter...1900
FUEL SYSTEM...1901
Fuel Specifications...1901
Filling The Fuel Tank...1901
Removing Water From The Fuel Filter...1901
Replacing The Fuel Filter...1901
Draining The Fuel Tank...1902
Removing Air From The Fuel System...1902
ENGINE LUBRICATION SYSTEM...1903
Checking Engine Oil...1903
Replacing Oil And Filter...1903
COOLING SYSTEM...1904
Cleaning The Cooling System...1904
Checking Coolant Level...1904
Replacing The Coolant...1905
ALTERNATOR BELT...1906
Adjusting The Alternator Belt (Later Models)...1906
Adjusting The Alternator Belt (Early Models)...1906
ELECTRICAL SYSTEM...1907
Description...1907
Fuses...1907
Relays And Diodes...1907
Service The Electrical System And Battery...1908
Using A Booster Battery (Jump Starting)...1909
Removing And Installing The Battery...1910
Checking And Adding Fluid...1911
Diagnostic Couplers...1911
Replacing The Hydraulic Filter...1912
Replacing Hydraulic Fluid...1912
CONTROL CONSOLE LOCKOUTS...1912
Inspection And Maintenance...1912
SPARK ARRESTOR MUFFLER...1913
TRACK TENSION...1914
Adjusting...1914
FINAL DRIVE CASE...1915
Checking Oil Level...1915
Draining Final Drive Case...1915
LUBRICATING THE HYDRAULIC EXCAVATOR...1916
BLADE EXTENSION...1918
Installing And Removing...1918
MACHINE SIGN TRANSLATIONS...1919
SPECIFICATIONS...1929
EXCAVATOR SPECIFICATIONS...1931
RATED LIFT CAPACITY...1932
FUEL, COOLANT AND LUBRICANTS...1933
Chart...1933
BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...1934
ADDITIONAL PUBLICATIONS & TRAINING MATERIALS...1935
WARRANTY...1937
6901062 (2-06) - 320, 320L, 322 Excavator Service Manual...1939
MAINTENANCE SAFETY...1941
ALPHABETICAL INDEX...1943
CONTENTS...1945
FOREWORD...1947
SAFETY INSTRUCTIONS...1949
Fire Prevention...1951
SERIAL NUMBER LOCATIONS...1953
Excavator Serial Number...1953
Engine Serial Number...1953
DELIVERY REPORT...1954
BOBCAT EXCAVATOR IDENTIFICATION...1955
SAFETY AND MAINTENANCE...1957
LIFTING AND BLOCKING THE EXCAVATOR...1959
Procedure...1959
SWING LOCK...1961
Operation...1961
LIFTING THE EXCAVATOR...1963
3-Point Lift Procedure...1963
OPERATOR CAB...1965
Emergency Exit...1965
Cab Door...1965
Front Window...1965
TRANSPORTING THE EXCAVATOR...1967
TAILGATE...1969
Opening And Closing The Tailgate (S/N 223513558 & Below And 223812078 & Below)...1969
Adjusting The Tailgate Latch (S/N 223513558 & Below And 223812078 & Below)...1969
Opening And Closing The Tailgate (S/N 223513559 & Above And 223812079 & Above)...1970
Adjusting The Tailgate Latch (S/N 223513559 & Above And 223812079 & Above)...1970
Adjusting The Bumper...1971
SERVICE SCHEDULE...1973
Chart...1973
AIR CLEANER SERVICE...1975
Daily Check...1975
Replacing The Filters...1975
HEATER AIR FILTERS...1977
Recirculation Filter...1977
Fresh Air Filter...1977
ENGINE COOLING SYSTEM...1979
Cleaning The Cooling System...1979
Checking Coolant Level...1979
Replacing The Coolant...1980
FUEL SYSTEM...1983
Fuel Specifications...1983
Filling The Fuel Tank...1983
Removing Water From The Fuel Filter...1984
Replacing The Fuel Filter...1984
Draining The Fuel Tank...1984
Removing Air From The Fuel System...1985
ENGINE LUBRICATION SYSTEM...1987
Checking Engine Oil...1987
Replacing Oil And Filter...1987
HYDRAULIC SYSTEM...1989
Checking And Adding Fluid...1989
Diagnostic Couplers...1989
Replacing The Hydraulic Filter...1990
Replacing The Hydraulic Fluid (S/N 223512346 & Below and 223814376 & Below)...1990
Replacing The Hydraulic Fluid (S/N 223512347 & Above and 22384377 & Above)...1992
LUBRICATING THE EXCAVATOR...1995
FINAL DRIVE CASE...1999
Checking Oil Level...1999
Draining Final Drive Case...1999
SPARK ARRESTOR MUFFLER...2001
HYDRAULIC SYSTEM...2003
HYDRAULIC/HYDROSTATIC SCHEMATICS...2009
HYDRAULIC SYSTEM INFORMATION...2013
Troubleshooting Chart...2013
BOOM CYLINDER...2017
Checking The Boom Cylinder...2017
Removal and Installation...2019
Parts Identification...2021
Disassembly...2022
Assembly...2023
ARM CYLINDER...2027
Checking The Arm Cylinder...2027
Removal and Installation...2028
Parts Identification...2030
Disassembly...2031
Assembly...2033
BOOM SWING CYLINDER...2037
Checking The Boom Swing Cylinder...2037
Removal and Installation...2038
Parts Identification...2042
Disassembly...2043
Assembly...2045
BUCKET CYLINDER...2049
Checking The Bucket Cylinder...2049
Removal and Installation...2050
Parts Identification...2052
Disassembly...2053
Assembly...2055
BLADE CYLINDER...2059
Checking The Blade Cylinder...2059
Removal and Installation...2062
Parts Identification...2064
Disassembly...2065
Assembly...2066
TRACK FRAME EXPANSION CYLINDER...2071
Checking The Track Frame Expansion Cylinder...2071
Removal And Installation...2072
Parts Identification...2076
Disassembly...2077
Assembly...2078
MAIN RELIEF VALVE...2083
Testing And Adjusting The Main Relief Valve...2083
PORT RELIEF VALVES...2085
Testing And Adjusting The Port Relief Valve Pressure (S/N 223512064 & Below and 223813552 & Below)...2085
Testing And Adjusting The Port Relief Valve Pressure (S/N 223512065 & Above and 223813553 & Above)...2086
CROSSPORT RELIEF VALVES...2089
Testing And Adjusting The Crossport Relief Valve...2089
PRESSURE REDUCING VALVE...2091
Testing And Adjusting The Pressure Reducing Valve...2091
HYDRAULIC CONTROL VALVE ASSEMBLY (S/N 223512346 & BELOW AND 223814376 & BELOW)...2093
Description...2093
Removal and Installation...2093
Control Valve Identification [Figure 20-40-13]:...2097
Disassembly...2098
Auxiliary Valve Section Disassembly And Assembly...2099
Blade Valve Section Disassembly And Assembly...2101
Swing Valve Section Disassembly And Assembly...2103
Left Travel Valve Section Disassembly And Assembly...2105
Boom Valve Section Disassembly And Assembly...2107
Bucket Valve Section Disassembly And Assembly...2110
Build Up Valve...2112
Arm Valve Section Disassembly And Assembly...2112
Boom Swing Valve Section Disassembly And Assembly...2115
Right Travel Valve Section Disassembly And Assembly...2118
Assembly...2120
HYDRAULIC CONTROL VALVE ASSEMBLY (S/N 223512347 & ABOVE AND 223814377 & ABOVE)...2127
Description...2127
Removal and Installation...2127
Control Valve Identification...2131
Disassembly...2132
Auxiliary Valve Section Disassembly And Assembly...2133
Blade Valve Section Disassembly And Assembly...2137
Swing Valve Section Disassembly And Assembly...2140
Left Travel Valve Section Disassembly and Assembly...2144
Boom Valve Section Disassembly and Assembly...2147
Bucket Valve Section Disassembly and Assembly...2151
Arm Valve Section Disassembly and Assembly...2156
Boom Swing Valve Section Disassembly And Assembly...2160
Right Travel Valve Section Disassembly And Assembly...2164
Assembly...2169
GEAR PUMP...2175
Testing The Hydraulic Pump (S/N 223512064 & Below and 223813552 & Below)...2175
Testing The Hydraulic Pump (S/N 223512065 & Above and 223813553 & Above)...2176
Removal And Installation...2177
Coupler Removal And Installation...2179
Parts Identification...2180
Disassembly...2181
Assembly...2183
MANIFOLD ASSEMBLY/ACCUMULATOR...2187
Manifold (Description)...2187
Removal and Installation...2188
MANIFOLD ASSEMBLY (S/N 223513430 & BELOW AND 223811991 & BELOW)...2191
Parts Identification...2191
Disassembly...2192
Assembly...2199
MANIFOLD ASSEMBLY (S/N 223513431 & ABOVE AND 223811992 & ABOVE)...2207
Parts Identification...2207
Disassembly...2208
Assembly...2217
TRAVEL MOTOR...2227
Removal and Installation...2227
Parts Identification...2228
Disassembly...2229
Assembly...2236
SWIVEL JOINT...2245
Removal And Installation...2245
Parts Identification 320...2248
Parts Identification 322...2249
Disassembly...2250
Assembly...2254
SWING MOTOR...2259
Removal and Installation...2259
Parts Identification...2260
Disassembly...2261
Assembly...2267
Crossport Relief Valve Parts Identification...2276
Crossport Relief Valve Disassembly...2277
Crossport Relief Valve Assembly...2278
CONTROL PATTERN SELECTOR VALVE...2281
Removal And Installation...2281
Parts Identification...2283
Disassembly...2284
Assembly...2285
RIGHT CONTROL LEVER (JOYSTICK) (S/N 223512346 & BELOW AND S/N 223814376 & BELOW)...2287
Testing...2287
Removal And Installation...2288
Parts Identification...2291
Disassembly...2292
Assembly...2298
LEFT CONTROL LEVER (JOYSTICK) (S/N 223512346 & BELOW AND S/N 23814376 & BELOW)...2304
Testing...2304
Removal And Installation...2305
Parts Identification...2308
Disassembly...2309
Assembly...2313
RIGHT CONTROL LEVER (JOYSTICK) (S/N 223512347 & ABOVE AND 223814377 & ABOVE)...2319
Testing...2319
Removal And Installation...2320
Parts Identification...2322
Disassembly...2323
Assembly...2327
Handle Removal And Installation...2332
LEFT CONTROL LEVER (JOYSTICK) (S/N 223512347 & ABOVE AND 223814377 & ABOVE)...2333
Testing...2333
Removal And Installation...2334
Parts Identification...2336
Disassembly And Assembly...2337
Handle Removal And Installation...2337
HYDRAULIC FILTER...2341
Removal And Installation (S/N 223513017 & Below And 223811795 & Below)...2341
Removal And Installation (S/N 223513018 & Above And 223811796 & Above...2342
HYDRAULIC RESERVOIR...2343
Removal and Installation...2343
OIL COOLER...2345
Removal And Installation...2345
ACCUMULATORS (S/N 223811055-223811259 AND 223511138-223511609)...2347
Removal And Installation...2347
BLADE...2351
Extension Removal And Installation...2351
Blade Removal And Installation...2351
TRACKS...2353
Track Lug Height...2353
Adjustment...2354
Removal And Installation...2356
Track Damage Identification And Causes...2356
TRACK FRAME...2357
Disassembly And Assembly...2357
Removal And Installation Of Expandable Track Frame (322 Only)...2360
TRACK IDLER...2361
Parts Identification (S/N 223512998 & Below And 2238117779 & Below)...2361
Disassembly (S/N 223512998 & Below And 2238117779 & Below)...2362
Assembly (S/N 223512998 & Below And 223811779 & Below)...2365
Parts Identification (S/N 223512999 & Above And 223811780 & Above)...2369
Disassembly (S/N 223512999 & Above And 223811780 & Above)...2370
Assembly (S/N 223512999 & Above And 223811780 & Above)...2372
TRACK ROLLER...2375
Parts Identification (S/N 223511788 & Below And 223811359 & Below)...2375
Disassembly (S/N 223511788 & Below And 223811359 & Below)...2376
Assembly (S/N 223511788 & Below And 223811359 & Below)...2378
Parts Identification (S/N 223511789 & Above And 223811360 & Above)...2382
Disassembly (S/N 223511789 & Above And 223811360 & Above)...2383
Assembly (S/N 223511789 & Above And 223811360 & Above)...2385
TRACK DAMAGE IDENTIFICATION...2388
Cutting Of The Steel Cords...2388
Causes Of The Damage...2388
Abrasion Of Embedded Metals...2389
Separation Of Embedded Metals Due To External Forces...2390
Separation Of Embedded Metals Due To Corrosion...2392
Cuts On The Lug Side...2393
Cracks On The Lug Side Rubber Due To Fatigue...2394
Lug Abrasion...2395
Cracks And Cuts On The Lug Side Rubber At The Edges Of The Embedded Metals...2396
Abrasion Of The Track Roller Side Rubber Surface...2397
Cuts On The Edges Of The Track Roller Side...2398
SWING CIRCLE GEAR...2401
Removal and Installation...2401
UPPERSTRUCTURE & SWING SECTION...2403
UPPERSTRUCTURE...2407
Removal...2407
Installation...2409
ROPS CANOPY...2411
Removal And Installation...2411
CAB...2415
Removal And Installation...2415
Door Removal And Installation...2420
Front Window Removal And Installation...2421
Lower Front Window Removal And Installation...2423
Right Side Rear Sliding Window Removal And Installation (S/N 223512957 & Below and 223811744 & Below)...2424
Right Side Front Sliding Window Removal And Installation (S/N 223512957 & Below And 223811744 & Below)...2426
Right Side Rear Sliding Window Removal And Installation (S/N 223512958 & Above And 223811745 & Above)...2427
Right Side Front Sliding Window Removal And Installation (S/N 2235129584 & Above And 223811745 & Above)...2428
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...2429
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...2429
Right Side Panel And Window Assembly Removal And Installation...2430
Door, Left Side, Rear & Upper Front Window Removal & Installation...2434
SEAT AND SEAT MOUNT...2437
Removal And Installation (S/N 223512842 & Below And 223811738 & Below)...2437
Removal And Installation (S/N 223512932 & Above and 223811739 & Above)...2438
RIGHT CONSOLE...2439
Console Cover Removal And Installation (Cab Models 320L, 320, 322 & ROPS Canopy Model 320L)...2439
Console Cover Removal And Installation (ROPS Canopy Models 320 & 322)...2442
Gas Spring Removal And Installation (ROPS Canopy Models 320 & 322)...2445
Lock Lever Removal And Installation (ROPS Canopy Models 320 & 322)...2446
Adjustment (ROPS Canopy Models 320 & 322)...2448
Latch Hook Removal And Installation (ROPS Canopy Models 320 & 322)...2448
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320 & 322)...2449
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L)...2450
Upper Console Removal And Installation...2451
Console Base Removal And Installation...2452
LEFT CONSOLE...2455
Console Cover Removal And Installation...2455
Gas Spring Removal And Installation...2456
Lock Lever Removal And Installation...2457
Adjustment...2459
Latch Hook Removal And Installation...2460
Upper Console Removal And Installation...2461
Console Base Removal And Installation...2462
ENGINE SPEED CONTROL...2465
Removal and Installation...2465
Engine Speed Control Cable Removal and Installation...2466
BLADE CONTROL...2469
Removal and Installation...2469
Disassembly And Assembly...2471
SWING LOCK...2473
Removal and Installation...2473
RIGHT PEDAL AND LINKAGE...2475
Right Pedal Removal And Installation...2475
Right Pedal Disassembly And Assembly...2475
Linkage Disassembly And Assembly...2476
TRAVEL CONTROLS...2479
Right Travel Control Removal And Installation...2479
Right Travel Control Disassembly And Assembly...2479
Left Travel Control Removal And Installation...2480
Left Travel Control Disassembly And Assembly...2480
LEFT PEDAL...2481
Removal And Installation...2481
Disassembly And Assembly...2481
CONTROL LINKAGE ASSEMBLY...2483
Removal and Installation...2483
Left Pedal Linkage Disassembly And Assembly...2484
Right Travel Control Linkage Disassembly And Assembly...2485
Left Travel Control Linkage Disassembly And Assembly...2485
Linkage Rod Removal And Installation...2486
FLOOR MAT AND FLOOR PANELS...2489
Removal and Installation...2489
BLADE EXTENSION TRAY...2491
Removal And Installation...2491
FUEL TANK...2493
Removal and Installation...2493
HORN...2495
Removal and Installation...2495
SWING FRAME...2497
Removal And Installation...2497
Bushing Replacement...2499
Swing Frame Bushing Removal...2499
Swing Frame Bushing Installation...2500
Boom Pivot Bushing Removal And Installation (S/N 223511699 & Above And 223812931 & Above)...2501
BOOM...2503
Removal And Installation...2503
Boom Bushing Removal And Installation...2505
ARM...2507
Removal And Installation...2507
Arm To Boom Bushing Removal And Installation...2508
Arm To Bucket And Bucket Link Bushing Removal And Installation...2508
BUCKET...2511
Removal and Installation...2511
Installation...2512
TAILGATE...2513
Removal And Installation...2513
Tailgate Release Bracket Removal And Installation (S/N 223513558 & Below And 223812078 & Below)...2514
Tailgate Release Rod Removal And Installation (S/N 223513558 & Below And 223812078 & Below)...2515
Tailgate Latch Removal And Installation (S/N 223513558 & Below And 223812078 & Below)...2515
Tailgate Latch Removal And Installation (S/N 223513559 & Above And 223812079 & Above)...2516
ELECTRICAL SYSTEM AND ANALYSIS...2517
ELECTRICAL SCHEMATICS...2519
ELECTRICAL SYSTEM INFORMATION...2521
Troubleshooting Chart...2521
Description...2522
Fuses...2522
Relays And Diodes...2523
BATTERY...2525
Servicing...2525
Removing And Installing...2526
Using A Booster Battery (Jump Starting)...2527
ALTERNATOR...2529
Adjusting The Alternator Belt (S/N 223512942 & Below And 223811738 & Below)...2529
Adjusting The Alternator Belt (S/N 223512943 & Above And 223811739 & Above)...2529
Description...2531
Tests...2531
Alternator Output Test...2531
Full Field Test...2532
Alternator Regulator Test...2532
Alternator Regulator Test With Voltmeter...2533
Removal And Installation (S/N 223512842 & Below And 223811738 & Below)...2533
Removal And Installation (S/N 223512943 & Above and 223811739 & Above)...2535
Disassembly And Assembly...2537
STARTER...2539
Removal And Installation...2539
Disassembly And Assembly...2540
Cleaning and Inspection...2540
LIGHTS...2541
Upper Structure Light Removal And Installation (S/N 223513060 & Below And 223811816 & Below)...2541
Upper Structure Light Disassembly And Assembly (S/N 223513060 & Below And 223811816 & Below)...2541
Upper Structure Light Removal And Installation (S/N 223513061 & Above And 223811817 & Above)...2542
Upper Structure Light Disassembly And Assembly (S/N 223513061 & Above And 223811817 & Above)...2543
Boom Light Removal And Installation (S/N 223512224 & Below And 223811529 & Below)...2543
Boom Light Removal And Installation (S/N 223512225 & Above And 223811530 & Above)...2544
Boom Light Disassembly And Assembly...2544
Light Switch Removal And Installation...2545
MICROSWITCH...2547
Adjustment...2547
Testing...2548
Removal And Installation...2548
TWO-SPEED SWITCH...2549
Removal And Installation...2549
FUEL LEVEL SENDER...2551
Removal and Installation...2551
Testing...2551
ENGINE SERVICE...2553
TROUBLESHOOTING...2555
Chart...2555
SPARK ARRESTOR MUFFLER...2557
Removal And Installation...2557
AIR CLEANER...2559
Removal And Installation...2559
RADIATOR...2561
Removal And Installation...2561
ENGINE COMPONENTS AND TESTING...2567
Valve Clearance Adjustment...2567
Engine Compression Checking...2567
Fuel Shut-off Solenoid Removal And Installation...2568
Fuel Shut-Off Timer Removal And Installation...2568
Fuel Injection Pump Check...2569
Fuel Injection Pump Removal And Installation...2570
Fuel Injection Pump Timing...2571
Fuel Injector Removal And Installation...2573
Fuel Injector Checking...2574
Glow Plug Removal And Installation...2576
Glow Plug Checking...2577
ENGINE...2579
Removal and Installation...2579
ENGINE FLYWHEEL (EARLY MODELS)...2587
Removal And Installation...2587
Hydraulic Pump Coupler...2589
Flywheel Ring Gear...2589
RECONDITIONING THE ENGINE...2591
Cylinder Head Removal And Installation...2591
Cylinder Head Disassembly And Assembly...2593
Cylinder Head, Servicing...2594
Cylinder Head Top Clearance...2595
Valve Guide, Checking...2596
Valve And Valve Seat Reconditioning...2598
Valve Spring...2599
Rocker Arm And Shaft, Checking...2600
Timing Gearcase Cover Removal And Installation...2601
Idler Gear And Camshaft Removal And Installation...2603
Idler Gear and Shaft, Servicing...2605
Timing Gears Checking Backlash...2606
Fuel Camshaft Removal And Installation...2606
Fuel Camshaft Governor...2607
Crankshaft Gear Removal And Installation...2607
Oil Pump Removal And Installation...2608
Oil Pump, Service...2608
Engine Oil Pressure, Checking...2609
Relief Valve...2610
Piston And Connecting Rod Removal And Installation...2611
Piston And Connecting Rod, Servicing...2614
Connecting Rod Alignment...2616
Crankshaft And Bearings Removal And Installation...2617
Crankshaft And Bearings, Servicing...2619
Cylinder Bore, Checking...2621
Water Pump Removal And Installation...2621
Water Pump Disassembly And Assembly...2621
HEATER...2623
HEATER...2625
Removal And Installation...2625
SPECIFICATIONS...2627
HYDRAULIC EXCAVATOR SPECIFICATIONS...2629
Machine Dimensions...2629
Performance...2631
Engine...2631
Controls...2631
Drive System...2631
Hydraulic System...2632
Electrical System...2632
Instrumentation...2632
ENGINE SPECIFICATIONS...2633
Engine...2633
Fuel Injector Nozzles...2633
Fuel Injection Pump...2633
Cylinder Head...2633
Valves...2633
Valve Springs...2633
Rocker Arms...2634
Camshaft...2634
Cylinders...2634
Piston Rings...2634
Pistons...2635
Crankshaft...2635
Oil Pump...2635
Thermostat...2636
Engine Bolt Torque...2636
Re-Grinding The Crankshaft...2637
TORQUE SPECIFICATIONS FOR BOLTS...2639
Torque for General SAE Bolts...2639
Torque For General Metric Bolts...2640
HYDRAULIC CONNECTION SPECIFICATIONS...2641
O-Ring Face Seal Connection...2641
Straight Thread O-ring Fitting...2641
Tubelines And Hoses...2641
Flare Fitting...2641
O-Ring Flare Fitting...2642
Port Seal Fitting...2644
HYDRAULIC FLUID SPECIFICATIONS...2645
Specifications...2645
FUEL, COOLANT AND LUBRICANTS...2647
Chart...2647
CONVERSIONS...2649
Decimal And Millimeter Equivalents...2649
U.S. To Metric Conversion...2650
SMR...2651
320/322-1...2651
320/322-2...2653
320/322-3...2655
320/322-4...2657
320/322-5...2659
320/322-6...2661
320/322-7...2663
320/322-8...2665
6901062 (6-12) - 320, 320L, 322 Excavator Service Manual...2667
MAINTENANCE SAFETY...2669
ALPHABETICAL INDEX...2671
CONTENTS...2673
FOREWORD...2675
SAFETY INSTRUCTIONS...2677
Fire Prevention...2679
SERIAL NUMBER LOCATIONS...2681
Excavator Serial Number...2681
Engine Serial Number...2681
DELIVERY REPORT...2682
BOBCAT EXCAVATOR IDENTIFICATION...2683
SAFETY AND MAINTENANCE...2685
LIFTING AND BLOCKING THE EXCAVATOR...2687
Procedure...2687
SWING LOCK...2689
Operation...2689
LIFTING THE EXCAVATOR...2691
3-Point Lift Procedure...2691
OPERATOR CAB...2693
Emergency Exit...2693
Cab Door...2693
Front Window...2693
TRANSPORTING THE EXCAVATOR...2695
TAILGATE...2697
Opening And Closing The Tailgate (S/N 223513558 & Below And 223812078 & Below)...2697
Adjusting The Tailgate Latch (S/N 223513558 & Below And 223812078 & Below)...2697
Opening And Closing The Tailgate (S/N 223513559 & Above And 223812079 & Above)...2698
Adjusting The Tailgate Latch (S/N 223513559 & Above And 223812079 & Above)...2698
Adjusting The Bumper...2699
SERVICE SCHEDULE...2701
Chart...2701
AIR CLEANER SERVICE...2703
Daily Check...2703
Replacing The Filters...2703
HEATER AIR FILTERS...2705
Recirculation Filter...2705
Fresh Air Filter...2705
ENGINE COOLING SYSTEM...2707
Cleaning The Cooling System...2707
Checking Coolant Level...2707
Replacing The Coolant...2708
FUEL SYSTEM...2711
Fuel Specifications...2711
Filling The Fuel Tank...2711
Removing Water From The Fuel Filter...2712
Replacing The Fuel Filter...2712
Draining The Fuel Tank...2712
Removing Air From The Fuel System...2713
ENGINE LUBRICATION SYSTEM...2715
Checking Engine Oil...2715
Replacing Oil And Filter...2715
HYDRAULIC SYSTEM...2717
Checking And Adding Fluid...2717
Diagnostic Couplers...2717
Replacing The Hydraulic Filter...2718
Replacing The Hydraulic Fluid (S/N 223512346 & Below and 223814376 & Below)...2718
Replacing The Hydraulic Fluid (S/N 223512347 & Above and 22384377 & Above)...2720
LUBRICATING THE EXCAVATOR...2723
FINAL DRIVE CASE...2727
Checking Oil Level...2727
Draining Final Drive Case...2727
SPARK ARRESTOR MUFFLER...2729
HYDRAULIC SYSTEM...2731
HYDRAULIC/HYDROSTATIC SCHEMATICS...2737
HYDRAULIC SYSTEM INFORMATION...2741
Troubleshooting Chart...2741
BOOM CYLINDER...2745
Checking The Boom Cylinder...2745
Removal and Installation...2747
Parts Identification...2749
Disassembly...2750
Assembly...2751
ARM CYLINDER...2755
Checking The Arm Cylinder...2755
Removal and Installation...2756
Parts Identification...2758
Disassembly...2759
Assembly...2761
BOOM SWING CYLINDER...2765
Checking The Boom Swing Cylinder...2765
Removal and Installation...2766
Parts Identification...2770
Disassembly...2771
Assembly...2773
BUCKET CYLINDER...2777
Checking The Bucket Cylinder...2777
Removal and Installation...2778
Parts Identification...2780
Disassembly...2781
Assembly...2783
BLADE CYLINDER...2787
Checking The Blade Cylinder...2787
Removal and Installation...2790
Parts Identification...2792
Disassembly...2793
Assembly...2794
TRACK FRAME EXPANSION CYLINDER...2799
Checking The Track Frame Expansion Cylinder...2799
Removal And Installation...2800
Parts Identification...2804
Disassembly...2805
Assembly...2806
MAIN RELIEF VALVE...2811
Testing And Adjusting The Main Relief Valve...2811
PORT RELIEF VALVES...2813
Testing And Adjusting The Port Relief Valve Pressure (S/N 223512064 & Below and 223813552 & Below)...2813
Testing And Adjusting The Port Relief Valve Pressure (S/N 223512065 & Above and 223813553 & Above)...2814
CROSSPORT RELIEF VALVES...2817
Testing And Adjusting The Crossport Relief Valve...2817
PRESSURE REDUCING VALVE...2819
Testing And Adjusting The Pressure Reducing Valve...2819
HYDRAULIC CONTROL VALVE ASSEMBLY (S/N 223512346 & BELOW AND 223814376 & BELOW)...2821
Description...2821
Removal and Installation...2821
Control Valve Identification [Figure 20-40-13]:...2825
Disassembly...2826
Auxiliary Valve Section Disassembly And Assembly...2827
Blade Valve Section Disassembly And Assembly...2829
Swing Valve Section Disassembly And Assembly...2831
Left Travel Valve Section Disassembly And Assembly...2833
Boom Valve Section Disassembly And Assembly...2835
Bucket Valve Section Disassembly And Assembly...2838
Build Up Valve...2840
Arm Valve Section Disassembly And Assembly...2840
Boom Swing Valve Section Disassembly And Assembly...2843
Right Travel Valve Section Disassembly And Assembly...2846
Assembly...2848
HYDRAULIC CONTROL VALVE ASSEMBLY (S/N 223512347 & ABOVE AND 223814377 & ABOVE)...2855
Description...2855
Removal and Installation...2855
Control Valve Identification...2859
Disassembly...2860
Auxiliary Valve Section Disassembly And Assembly...2861
Blade Valve Section Disassembly And Assembly...2865
Swing Valve Section Disassembly And Assembly...2868
Left Travel Valve Section Disassembly and Assembly...2872
Boom Valve Section Disassembly and Assembly...2875
Bucket Valve Section Disassembly and Assembly...2879
Arm Valve Section Disassembly and Assembly...2884
Boom Swing Valve Section Disassembly And Assembly...2888
Right Travel Valve Section Disassembly And Assembly...2892
Assembly...2897
GEAR PUMP...2903
Testing The Hydraulic Pump (S/N 223512064 & Below and 223813552 & Below)...2903
Testing The Hydraulic Pump (S/N 223512065 & Above and 223813553 & Above)...2904
Removal And Installation...2905
Coupler Removal And Installation...2907
Parts Identification...2908
Disassembly...2909
Assembly...2911
MANIFOLD ASSEMBLY/ACCUMULATOR...2915
Manifold (Description)...2915
Removal and Installation...2916
MANIFOLD ASSEMBLY (S/N 223513430 & BELOW AND 223811991 & BELOW)...2919
Parts Identification...2919
Disassembly...2920
Assembly...2927
MANIFOLD ASSEMBLY (S/N 223513431 & ABOVE AND 223811992 & ABOVE)...2935
Parts Identification...2935
Disassembly...2936
Assembly...2945
TRAVEL MOTOR...2955
Removal and Installation...2955
Parts Identification...2956
Disassembly...2957
Assembly...2964
SWIVEL JOINT...2973
Removal And Installation...2973
Parts Identification 320...2976
Parts Identification 322...2977
Disassembly...2978
Assembly...2982
SWING MOTOR...2987
Removal and Installation...2987
Parts Identification...2988
Disassembly...2989
Assembly...2995
Crossport Relief Valve Parts Identification...3004
Crossport Relief Valve Disassembly...3005
Crossport Relief Valve Assembly...3006
CONTROL PATTERN SELECTOR VALVE...3009
Removal And Installation...3009
Parts Identification...3011
Disassembly...3012
Assembly...3013
RIGHT CONTROL LEVER (JOYSTICK) (S/N 223512346 & BELOW AND S/N 223814376 & BELOW)...3015
Testing...3015
Removal And Installation...3016
Parts Identification...3019
Disassembly...3020
Assembly...3026
LEFT CONTROL LEVER (JOYSTICK) (S/N 223512346 & BELOW AND S/N 23814376 & BELOW)...3032
Testing...3032
Removal And Installation...3033
Parts Identification...3036
Disassembly...3037
Assembly...3041
RIGHT CONTROL LEVER (JOYSTICK) (S/N 223512347 & ABOVE AND 223814377 & ABOVE)...3047
Testing...3047
Removal And Installation...3048
Parts Identification...3050
Disassembly...3051
Assembly...3055
Handle Removal And Installation...3060
LEFT CONTROL LEVER (JOYSTICK) (S/N 223512347 & ABOVE AND 223814377 & ABOVE)...3061
Testing...3061
Removal And Installation...3062
Parts Identification...3064
Disassembly And Assembly...3065
Handle Removal And Installation...3065
HYDRAULIC FILTER...3069
Removal And Installation (S/N 223513017 & Below And 223811795 & Below)...3069
Removal And Installation (S/N 223513018 & Above And 223811796 & Above...3070
HYDRAULIC RESERVOIR...3071
Removal and Installation...3071
OIL COOLER...3073
Removal And Installation...3073
ACCUMULATORS (S/N 223811055-223811259 AND 223511138-223511609)...3075
Removal And Installation...3075
BLADE...3079
Extension Removal And Installation...3079
Blade Removal And Installation...3079
TRACKS...3081
Track Lug Height...3081
Adjustment...3082
Removal And Installation...3084
Track Damage Identification And Causes...3084
TRACK FRAME...3085
Disassembly And Assembly...3085
Removal And Installation Of Expandable Track Frame (322 Only)...3088
TRACK IDLER...3089
Parts Identification (S/N 223512998 & Below And 2238117779 & Below)...3089
Disassembly (S/N 223512998 & Below And 2238117779 & Below)...3090
Assembly (S/N 223512998 & Below And 223811779 & Below)...3093
Parts Identification (S/N 223512999 & Above And 223811780 & Above)...3097
Disassembly (S/N 223512999 & Above And 223811780 & Above)...3098
Assembly (S/N 223512999 & Above And 223811780 & Above)...3100
TRACK ROLLER...3103
Parts Identification (S/N 223511788 & Below And 223811359 & Below)...3103
Disassembly (S/N 223511788 & Below And 223811359 & Below)...3104
Assembly (S/N 223511788 & Below And 223811359 & Below)...3106
Parts Identification (S/N 223511789 & Above And 223811360 & Above)...3110
Disassembly (S/N 223511789 & Above And 223811360 & Above)...3111
Assembly (S/N 223511789 & Above And 223811360 & Above)...3113
TRACK DAMAGE IDENTIFICATION...3116
Cutting Of The Steel Cords...3116
Causes Of The Damage...3116
Abrasion Of Embedded Metals...3117
Separation Of Embedded Metals Due To External Forces...3118
Separation Of Embedded Metals Due To Corrosion...3120
Cuts On The Lug Side...3121
Cracks On The Lug Side Rubber Due To Fatigue...3122
Lug Abrasion...3123
Cracks And Cuts On The Lug Side Rubber At The Edges Of The Embedded Metals...3124
Abrasion Of The Track Roller Side Rubber Surface...3125
Cuts On The Edges Of The Track Roller Side...3126
SWING CIRCLE GEAR...3129
Removal and Installation...3129
UPPERSTRUCTURE & SWING SECTION...3131
UPPERSTRUCTURE...3135
Removal...3135
Installation...3137
ROPS CANOPY...3139
Removal And Installation...3139
CAB...3143
Removal And Installation...3143
Door Removal And Installation...3148
Front Window Removal And Installation...3149
Lower Front Window Removal And Installation...3151
Right Side Rear Sliding Window Removal And Installation (S/N 223512957 & Below and 223811744 & Below)...3152
Right Side Front Sliding Window Removal And Installation (S/N 223512957 & Below And 223811744 & Below)...3154
Right Side Rear Sliding Window Removal And Installation (S/N 223512958 & Above And 223811745 & Above)...3155
Right Side Front Sliding Window Removal And Installation (S/N 2235129584 & Above And 223811745 & Above)...3156
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...3157
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...3157
Right Side Panel And Window Assembly Removal And Installation...3158
Door, Left Side, Rear & Upper Front Window Removal & Installation...3162
SEAT AND SEAT MOUNT...3165
Removal And Installation (S/N 223512842 & Below And 223811738 & Below)...3165
Removal And Installation (S/N 223512932 & Above and 223811739 & Above)...3166
RIGHT CONSOLE...3167
Console Cover Removal And Installation (Cab Models 320L, 320, 322 & ROPS Canopy Model 320L)...3167
Console Cover Removal And Installation (ROPS Canopy Models 320 & 322)...3170
Gas Spring Removal And Installation (ROPS Canopy Models 320 & 322)...3173
Lock Lever Removal And Installation (ROPS Canopy Models 320 & 322)...3174
Adjustment (ROPS Canopy Models 320 & 322)...3176
Latch Hook Removal And Installation (ROPS Canopy Models 320 & 322)...3176
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320 & 322)...3177
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L)...3178
Upper Console Removal And Installation...3179
Console Base Removal And Installation...3180
LEFT CONSOLE...3183
Console Cover Removal And Installation...3183
Gas Spring Removal And Installation...3184
Lock Lever Removal And Installation...3185
Adjustment...3187
Latch Hook Removal And Installation...3188
Upper Console Removal And Installation...3189
Console Base Removal And Installation...3190
ENGINE SPEED CONTROL...3193
Removal and Installation...3193
Engine Speed Control Cable Removal and Installation...3194
BLADE CONTROL...3197
Removal and Installation...3197
Disassembly And Assembly...3199
SWING LOCK...3201
Removal and Installation...3201
RIGHT PEDAL AND LINKAGE...3203
Right Pedal Removal And Installation...3203
Right Pedal Disassembly And Assembly...3203
Linkage Disassembly And Assembly...3204
TRAVEL CONTROLS...3207
Right Travel Control Removal And Installation...3207
Right Travel Control Disassembly And Assembly...3207
Left Travel Control Removal And Installation...3208
Left Travel Control Disassembly And Assembly...3208
LEFT PEDAL...3209
Removal And Installation...3209
Disassembly And Assembly...3209
CONTROL LINKAGE ASSEMBLY...3211
Removal and Installation...3211
Left Pedal Linkage Disassembly And Assembly...3212
Right Travel Control Linkage Disassembly And Assembly...3213
Left Travel Control Linkage Disassembly And Assembly...3213
Linkage Rod Removal And Installation...3214
FLOOR MAT AND FLOOR PANELS...3217
Removal and Installation...3217
BLADE EXTENSION TRAY...3219
Removal And Installation...3219
FUEL TANK...3221
Removal and Installation...3221
HORN...3223
Removal and Installation...3223
SWING FRAME...3225
Removal And Installation...3225
Bushing Replacement...3227
Swing Frame Bushing Removal...3227
Swing Frame Bushing Installation...3228
Boom Pivot Bushing Removal And Installation (S/N 223511699 & Above And 223812931 & Above)...3229
BOOM...3231
Removal And Installation...3231
Boom Bushing Removal And Installation...3233
ARM...3235
Removal And Installation...3235
Arm To Boom Bushing Removal And Installation...3236
Arm To Bucket And Bucket Link Bushing Removal And Installation...3236
BUCKET...3239
Removal and Installation...3239
Installation...3240
TAILGATE...3241
Removal And Installation...3241
Tailgate Release Bracket Removal And Installation (S/N 223513558 & Below And 223812078 & Below)...3242
Tailgate Release Rod Removal And Installation (S/N 223513558 & Below And 223812078 & Below)...3243
Tailgate Latch Removal And Installation (S/N 223513558 & Below And 223812078 & Below)...3243
Tailgate Latch Removal And Installation (S/N 223513559 & Above And 223812079 & Above)...3244
ELECTRICAL SYSTEM AND ANALYSIS...3245
ELECTRICAL SCHEMATICS...3247
ELECTRICAL SYSTEM INFORMATION...3249
Troubleshooting Chart...3249
Description...3250
Fuses...3250
Relays And Diodes...3251
BATTERY...3253
Servicing...3253
Removing And Installing...3254
Using A Booster Battery (Jump Starting)...3255
ALTERNATOR...3257
Adjusting The Alternator Belt (S/N 223512942 & Below And 223811738 & Below)...3257
Adjusting The Alternator Belt (S/N 223512943 & Above And 223811739 & Above)...3257
Description...3259
Tests...3259
Alternator Output Test...3259
Full Field Test...3260
Alternator Regulator Test...3260
Alternator Regulator Test With Voltmeter...3261
Removal And Installation (S/N 223512842 & Below And 223811738 & Below)...3261
Removal And Installation (S/N 223512943 & Above and 223811739 & Above)...3263
Disassembly And Assembly...3265
STARTER...3267
Removal And Installation...3267
Disassembly And Assembly...3268
Cleaning and Inspection...3268
LIGHTS...3269
Upper Structure Light Removal And Installation (S/N 223513060 & Below And 223811816 & Below)...3269
Upper Structure Light Disassembly And Assembly (S/N 223513060 & Below And 223811816 & Below)...3269
Upper Structure Light Removal And Installation (S/N 223513061 & Above And 223811817 & Above)...3270
Upper Structure Light Disassembly And Assembly (S/N 223513061 & Above And 223811817 & Above)...3271
Boom Light Removal And Installation (S/N 223512224 & Below And 223811529 & Below)...3271
Boom Light Removal And Installation (S/N 223512225 & Above And 223811530 & Above)...3272
Boom Light Disassembly And Assembly...3272
Light Switch Removal And Installation...3273
MICROSWITCH...3275
Adjustment...3275
Testing...3276
Removal And Installation...3276
TWO-SPEED SWITCH...3277
Removal And Installation...3277
FUEL LEVEL SENDER...3279
Removal and Installation...3279
Testing...3279
ENGINE SERVICE...3281
TROUBLESHOOTING...3283
Chart...3283
SPARK ARRESTOR MUFFLER...3285
Removal And Installation...3285
AIR CLEANER...3287
Removal And Installation...3287
RADIATOR...3289
Removal And Installation...3289
ENGINE COMPONENTS AND TESTING...3295
Valve Clearance Adjustment...3295
Engine Compression Checking...3295
Fuel Shut-off Solenoid Removal And Installation...3296
Fuel Shut-Off Timer Removal And Installation...3296
Fuel Injection Pump Check...3297
Fuel Injection Pump Removal And Installation...3298
Fuel Injection Pump Timing...3299
Fuel Injector Removal And Installation...3301
Fuel Injector Checking...3302
Glow Plug Removal And Installation...3304
Glow Plug Checking...3305
ENGINE...3307
Removal and Installation...3307
ENGINE FLYWHEEL (EARLY MODELS)...3315
Removal And Installation...3315
Hydraulic Pump Coupler...3317
Flywheel Ring Gear...3317
RECONDITIONING THE ENGINE...3319
Cylinder Head Removal And Installation...3319
Cylinder Head Disassembly And Assembly...3321
Cylinder Head, Servicing...3322
Cylinder Head Top Clearance...3323
Valve Guide, Checking...3324
Valve And Valve Seat Reconditioning...3326
Valve Spring...3327
Rocker Arm And Shaft, Checking...3328
Timing Gearcase Cover Removal And Installation...3329
Idler Gear And Camshaft Removal And Installation...3331
Idler Gear and Shaft, Servicing...3333
Timing Gears Checking Backlash...3334
Fuel Camshaft Removal And Installation...3334
Fuel Camshaft Governor...3335
Crankshaft Gear Removal And Installation...3335
Oil Pump Removal And Installation...3336
Oil Pump, Service...3336
Engine Oil Pressure, Checking...3337
Relief Valve...3338
Piston And Connecting Rod Removal And Installation...3339
Piston And Connecting Rod, Servicing...3342
Connecting Rod Alignment...3344
Crankshaft And Bearings Removal And Installation...3345
Crankshaft And Bearings, Servicing...3347
Cylinder Bore, Checking...3349
Water Pump Removal And Installation...3349
Water Pump Disassembly And Assembly...3349
HEATER...3351
HEATER...3353
Removal And Installation...3353
SPECIFICATIONS...3355
HYDRAULIC EXCAVATOR SPECIFICATIONS...3357
Machine Dimensions...3357
Performance...3359
Engine...3359
Controls...3359
Drive System...3359
Hydraulic System...3360
Electrical System...3360
Instrumentation...3360
ENGINE SPECIFICATIONS...3361
Engine...3361
Fuel Injector Nozzles...3361
Fuel Injection Pump...3361
Cylinder Head...3361
Valves...3361
Valve Springs...3361
Rocker Arms...3362
Camshaft...3362
Cylinders...3362
Piston Rings...3362
Pistons...3363
Crankshaft...3363
Oil Pump...3363
Thermostat...3364
Engine Bolt Torque...3364
Re-Grinding The Crankshaft...3365
TORQUE SPECIFICATIONS FOR BOLTS...3367
Torque for General SAE Bolts...3367
Torque For General Metric Bolts...3368
HYDRAULIC CONNECTION SPECIFICATIONS...3369
O-Ring Face Seal Connection...3369
Straight Thread O-ring Fitting...3369
Tubelines And Hoses...3369
Flare Fitting...3369
O-Ring Flare Fitting...3370
Port Seal Fitting...3372
HYDRAULIC FLUID SPECIFICATIONS...3373
Specifications...3373
FUEL, COOLANT AND LUBRICANTS...3375
Chart...3375
CONVERSIONS...3377
Decimal And Millimeter Equivalents...3377
U.S. To Metric Conversion...3378
SMR...3379
320/322-1...3379
320/322-2...3381
320/322-3...3383
320/322-4...3385
320/322-5...3387
320/322-6...3389
320/322-7...3391
320/322-8...3393
320/322-9...3395
6902608 (2-05) - 322 Excavator Operation & Maintenance Manual...3397
CONTENTS...3401
FOREWORD...3403
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...3405
REGULAR MAINTENANCE ITEMS...3405
MOTOR OIL...3405
SERIAL NUMBER LOCATIONS...3407
Excavator Serial Number...3407
Engine Serial Number...3407
DELIVERY REPORT...3408
BOBCAT EXCAVATOR IDENTIFICATION...3409
FEATURES, ACCESSORIES, AND ATTACHMENTS...3410
Standard Items...3410
Standard Items...3410
Options and Accessories...3410
Other...3410
Attachments...3410
Buckets...3410
SAFETY INSTRUCTIONS...3411
SAFETY INSTRUCTIONS...3413
Before Operation...3413
Safe Operation Is The Operator’s Responsibility...3414
Safe Operation Needs A Qualified Operator...3414
Fire Prevention...3415
MACHINE SIGNS (DECALS)...3416
OPERATING INSTRUCTIONS...3419
INSTRUMENTS AND CONSOLES...3421
Cab Interior Light (If Equipped)...3421
Left Console...3421
STD / ISO Selector Valve...3421
Heater (If Equipped)...3421
Right Console...3422
Right Control Panel...3423
Raising And Lowering The Console(s)...3423
TWO-SPEED TRAVEL...3424
TAILGATE...3424
Opening And Closing The Tailgate...3424
OPERATOR CANOPY (ROPS / TOPS)...3425
FALLING OBJECT GUARDS (FOGS)...3425
CANOPY ENCLOSURE...3426
OPERATOR CAB (ROPS / TOPS) (If Equipped)...3427
Emergency Exits...3427
Cab Door...3427
Front Window Wiper...3428
Window Washer Reservoir...3428
Front Window...3429
Right Side Windows...3431
STEERING LEVERS/FOOT PEDALS...3432
Forward And Reverse Travel...3432
Turning...3432
HYDRAULIC CONTROLS...3434
ISO Control Pattern...3434
Left Control Lever...3434
Right Control Lever...3434
Standard Control Pattern...3435
Left Control Lever...3435
Right Control Lever...3435
Control Lever (Joystick) Lock...3436
Auxiliary Hydraulic Pedal...3437
Quick Couplers...3438
BLADE CONTROL LEVER...3439
TRACK FRAME EXPANSION...3440
UPPERSTRUCTURE SLEW LOCK...3442
BOOM SWING PEDAL...3443
DAILY INSPECTION...3444
Service Schedule...3445
PRE-STARTING PROCEDURE...3446
STARTING THE ENGINE...3448
Cold Temperature Starting Procedure...3449
BUCKETS AND ATTACHMENTS...3450
Installing...3450
Removing...3450
OPERATING PROCEDURE...3451
Operating On Public Roads...3451
Lifting A Load...3451
Excavating...3452
Boom Swing...3454
Backfilling...3455
Driving The Excavator...3455
Operating On Slopes...3456
Operating In Water...3458
PARKING THE EXCAVATOR...3459
TRANSPORTING THE EXCAVATOR...3460
LIFTING THE EXCAVATOR...3461
PREVENTIVE MAINTENANCE...3463
MAINTENANCE SAFETY...3465
SERVICE SCHEDULE...3467
Chart...3467
TAILGATE...3468
Opening And Closing The Tailgate...3468
Adjusting the Bumper...3468
Adjusting The Tailgate Catch...3468
AIR CLEANER...3469
Daily Check...3469
Replacing The Filters...3469
SEAT BELT...3471
Inspection And Maintenance...3471
HEATER AIR FILTERS...3472
Recirculation Filter...3472
Fresh Air Filter...3472
FUEL SYSTEM...3472
Fuel Specifications...3472
Filling The Fuel Tank...3473
Removing Water From The Fuel Filter...3473
Replacing The Fuel Filter...3473
Draining The Fuel Tank...3474
Removing Air From The Fuel System...3474
ENGINE LUBRICATION SYSTEM...3475
Checking Engine Oil...3475
Replacing Oil And Filter...3475
COOLING SYSTEM...3476
Cleaning The Cooling System...3476
Checking Coolant Level...3476
Replacing The Coolant...3477
ALTERNATOR BELT...3479
Adjusting The Alternator Belt...3479
ELECTRICAL SYSTEM...3480
Description...3480
Fuses...3480
Relays And Diodes...3480
Service The Electrical System And Battery...3482
Using A Booster Battery (Jump Starting)...3483
Removing And Installing The Battery...3484
HYDRAULIC SYSTEM...3485
Checking And Adding Hydraulic Oil...3485
Diagnostic Couplers...3485
Replacing The Hydraulic Filter...3486
Replacing Hydraulic Oil...3486
CONTROL CONSOLE LOCKOUTS...3488
Inspection And Maintenance...3488
SPARK ARRESTOR MUFFLER...3489
TRACK TENSION...3490
Adjusting...3490
TRAVEL MOTOR...3492
Checking Oil Level...3492
Draining The Travel Motor...3492
LUBRICATION OF THE HYDRAULIC EXCAVATOR...3493
BLADE EXTENSION...3495
Installing And Removing...3495
MACHINE SIGN TRANSLATIONS...3497
WARNING (6808185)...3499
LIFT CHART...3500
322 (6808183)...3500
SERVICE SCHEDULE (7104075)...3502
WARNING (6807776)...3504
WARNING (6804114, 6577754, 6804233, 6809832)...3506
SPECIFICATIONS...3507
SPECIFICATIONS...3509
Performance...3511
Engine...3511
Controls...3511
Drive System...3511
Hydraulic System...3512
Electrical System...3512
Instrumentation...3512
FUEL, COOLANT AND LUBRICANTS...3513
Chart...3513
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...3514
WARRANTY...3515
6902668 (6-12) - 320, 322 Excavator Service Manual...3516
MAINTENANCE SAFETY...3518
ALPHABETICAL INDEX...3520
CONTENTS...3522
SAFETY INSTRUCTIONS...3526
Fire Prevention...3528
SERIAL NUMBER LOCATIONS...3530
Excavator Serial Number...3530
Engine Serial Number...3530
DELIVERY REPORT...3531
BOBCAT EXCAVATOR IDENTIFICATION...3532
SAFETY & MAINTENANCE...3534
LIFTING AND BLOCKING THE EXCAVATOR...3536
Procedure...3536
SWING LOCK...3538
LIFTING THE EXCAVATOR...3540
OPERATOR CAB ROPS/TOPS...3542
Emergency Exits...3542
Cab Door...3542
Front Window...3543
Right Side Windows...3545
TRANSPORTING THE EXCAVATOR...3546
TAILGATE...3548
Opening And Closing The Tailgate...3548
Adjusting The Bumper...3548
Adjusting The Tailgate Latch...3548
SERVICE SCHEDULE...3550
Chart...3550
AIR CLEANER SERVICE...3552
Daily Check...3552
Replacing The Filters...3552
HEATER AIR FILTERS...3554
Recirculation Filter...3554
Fresh Air Filter...3554
ENGINE COOLING SYSTEM...3556
Cleaning The Cooling System...3556
Checking Coolant Level...3556
Replacing The Coolant...3557
FUEL SYSTEM...3560
Fuel Specifications...3560
Filling The Fuel Tank...3560
Removing Water From The Fuel Filter...3561
Replacing The Fuel Filter...3561
Draining The Fuel Tank...3562
Removing Air From The Fuel System...3562
ENGINE LUBRICATION SYSTEM...3564
Checking Engine Oil...3564
Oil Chart...3564
Replacing Oil And Filter...3565
HYDRAULIC SYSTEM...3566
Checking And Adding Hydraulic Oil...3566
Diagnostic Couplers...3566
Replacing The Hydraulic Filter...3567
Replacing Hydraulic Oil...3567
LUBRICATION OF THE HYDRAULIC EXCAVATOR...3570
TRAVEL MOTOR...3574
Checking Oil Level...3574
Draining The Travel Motor...3574
SPARK ARRESTOR MUFFLER...3576
ALTERNATOR BELT...3578
Adjusting The Alternator Belt...3578
SEAT BELT...3580
Inspection And Maintenance...3580
CONTROL CONSOLE LOCKOUTS...3582
Inspection And Maintenance...3582
HYDRAULIC SYSTEM...3584
HYDRAULIC/HYDROSTATIC SCHEMATICS...3588
HYDRAULIC SYSTEM INFORMATION...3592
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...3592
Troubleshooting The Hydraulic Circuit...3595
Troubleshooting The Cylinder Circuit...3596
Troubleshooting The Swing (Upperstructure Slew) Circuit...3597
Troubleshooting The Travel Circuit...3598
BOOM CYLINDER...3600
Testing...3600
Removal and Installation...3602
Parts Identification...3604
Disassembly...3605
Assembly...3606
ARM CYLINDER...3610
Testing...3610
Removal and Installation...3611
Parts Identification...3613
Disassembly...3614
Assembly...3616
BOOM SWING CYLINDER...3620
Testing...3620
Removal and Installation...3621
Parts Identification...3624
Disassembly...3625
Assembly...3627
BUCKET CYLINDER...3630
Testing...3630
Removal and Installation...3631
Parts Identification...3633
Disassembly...3634
Assembly...3636
BLADE CYLINDER...3640
Testing...3640
Removal and Installation...3642
Parts Identification...3644
Disassembly...3645
Assembly...3647
TRACK FRAME EXPANSION CYLINDER...3650
Testing...3650
Removal And Installation...3651
Parts Identification...3655
Disassembly...3656
Assembly...3657
MAIN RELIEF VALVE...3662
Testing And Adjusting The Main Relief Valve...3662
PORT RELIEF VALVES...3664
Testing And Adjusting The Port Relief Valve Pressure...3664
CROSSPORT RELIEF VALVES...3666
Testing And Adjusting The Crossport Relief Valve...3666
PRESSURE REDUCING VALVE...3668
Testing And Adjusting The Pressure Reducing Valve...3668
HYDRAULIC CONTROL VALVE (320 / 322)...3670
Description...3670
Removal And Installation...3670
Parts Identification...3673
Disassembly...3674
Auxiliary Valve Section Disassembly And Assembly...3675
Blade Valve Section Disassembly And Assembly...3679
Slew Valve Section Disassembly And Assembly...3682
Left Travel Valve Section Disassembly and Assembly...3686
Boom Valve Section Disassembly and Assembly...3689
Bucket Valve Section Disassembly and Assembly...3692
Arm Valve Section Disassembly and Assembly...3696
Boom Swing Valve Section Disassembly And Assembly...3699
Right Travel Valve Section Disassembly And Assembly...3702
Assembly...3706
HYDRAULIC CONTROL VALVE (320L)...3712
Description...3712
Removal And Installation...3712
Parts Identification...3715
Disassembly...3716
Auxiliary Valve Section Disassembly And Assembly...3717
Blade Valve Section Disassembly And Assembly...3721
Slew Valve Section Disassembly And Assembly...3724
Left Travel Valve Section Disassembly And Assembly...3728
Boom Valve Section Disassembly And Assembly...3731
Bucket Valve Section Disassembly And Assembly...3734
Arm Valve Section Disassembly And Assembly...3738
Boom Swing Valve Section Disassembly And Assembly...3741
Right Travel Valve Section Disassembly And Assembly...3744
Assembly...3748
HYDRAULIC PUMP...3754
Testing The Hydraulic Pump...3754
Removal And Installation...3756
Coupler Removal And Installation...3757
Parts Identification...3758
Disassembly...3759
Assembly...3761
MANIFOLD ASSEMBLY/ACCUMULATOR...3766
Description...3766
Removal And Installation...3766
Parts Identification (S/N 223911001 - 223911247 & S/N 224011001 - 224012293)...3768
Disassembly (S/N 223911001 - 223911247 & S/N 224011001 - 224012293)...3769
Assembly (S/N 223911001 - 223911247 & S/N 224011001 - 224012293)...3778
Parts Identification (S/N 223911248 & Above & S/N 224012294 & Above)...3787
Disassembly (S/N 223911248 & Above & S/N 224012294 & Above)...3788
Assembly (S/N 223911248 & Above & S/N 224012294 & Above)...3801
TRAVEL MOTOR...3814
Removal and Installation...3814
Parts Identification...3815
Disassembly...3816
Assembly...3823
SWIVEL JOINT...3832
Removal And Installation...3832
Parts Identification 320...3835
Parts Identification 322...3836
Disassembly...3837
Assembly...3841
SWING MOTOR...3846
Removal and Installation...3846
Parts Identification...3847
Disassembly...3848
Assembly...3854
CONTROL PATTERN SELECTOR VALVE...3862
Removal And Installation...3862
Parts Identification...3864
Disassembly...3865
Assembly...3866
RIGHT CONTROL LEVER (JOYSTICK)...3868
Testing...3868
Handle Removal And Installation...3870
Removal And Installation...3871
Parts Identification...3873
Disassembly...3874
Assembly...3879
LEFT CONTROL LEVER (JOYSTICK)...3886
Testing...3886
Handle Removal And Installation...3888
Removal And Installation...3890
Parts Identification...3891
Disassembly...3892
Assembly...3897
HYDRAULIC FILTER MOUNT...3902
Removal and Installation...3902
HYDRAULIC RESERVOIR...3904
Removal and Installation...3904
OIL COOLER...3906
Removal And Installation...3906
UNDERCARRIAGE...3908
BLADE...3910
Extension Removal And Installation...3910
Blade Removal And Installation...3910
TRACKS...3912
Track Lug Height...3912
Adjustment...3913
Removal And Installation...3915
TRACK FRAME...3916
Disassembly And Assembly...3916
Removal And Installation Of Expandable Track Frame (322 Only)...3917
Recoil Spring Disassembly And Assembly...3918
TRACK DAMAGE IDENTIFICATION...3920
Cutting Of The Steel Cords...3920
Causes Of The Damage...3920
Abrasion Of Embedded Metals...3921
Separation Of Embedded Metals...3922
Separation Of Embedded Metals Due To Corrosion...3923
Cuts On The Lug Side Rubber...3924
Cracks On The Lug Side Rubber Due To Fatigue...3925
Lug Abrasion...3926
Cracks And Cuts On The Lug Side Rubber...3927
Abrasion Of The Track Roller Side...3928
Cuts On The Edges Of The Track Roller Side...3929
TRACK IDLER...3932
Parts Identification...3932
Disassembly...3933
Assembly...3935
TRACK ROLLER...3938
Parts Identification...3938
Disassembly...3939
Assembly...3941
SWING CIRCLE GEAR...3944
Removal and Installation...3944
UPPERSTRUCTURE & SWING SECTION...3946
UPPERSTRUCTURE...3950
Removal...3950
Installation...3952
ROPS CANOPY...3954
Removal And Installation...3954
CAB...3958
Removal And Installation...3958
Door Removal And Installation...3962
Front Window Removal And Installation...3963
Right Side Rear Sliding Window Removal And Installation...3966
Right Side Front Sliding Window Removal And Installation...3967
Glass Removal...3967
Glass Installation...3968
Glass Installation (Cont’d)...3969
SEAT AND SEAT MOUNT...3970
Removal And Installation...3970
RIGHT CONSOLE...3972
Console Cover Removal And Installation (Cab Models 320L, 320, 322 & ROPS Canopy Model 320L)...3972
Console Cover Removal And Installation (ROPS Canopy Models 320 & 322)...3975
Gas Spring Removal And Installation (ROPS Canopy Models 320 & 322)...3978
Lock Lever Removal And Installation (ROPS Canopy Models 320 & 322)...3979
Adjustment (ROPS Canopy Models 320 & 322)...3981
Latch Hook Removal And Installation (ROPS Canopy 320 & 322)...3981
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320 & 322)...3982
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L)...3983
Upper Console Removal And Installation...3984
Console Base Removal And Installation...3985
LEFT CONSOLE...3988
Console Cover Removal And Installation...3988
Gas Spring Removal And Installation...3990
Lock Lever Removal And Installation...3991
Adjustment...3993
Latch Hook Removal And Installation...3994
Latch Hook Disassembly And Assembly...3995
Upper Console Removal And Installation...3996
Console Base Removal And Installation...3997
ENGINE SPEED CONTROL...4000
Removal and Installation...4000
Engine Speed Control Cable Removal and Installation...4001
BLADE CONTROL...4004
Removal and Installation...4004
Disassembly And Assembly...4005
RIGHT PEDAL...4008
Right Pedal Removal And Installation...4008
Disassembly And Assembly...4009
Linkage Removal And Installation...4010
Linkage Disassembly And Assembly...4010
LEFT PEDAL...4012
Removal And Installation...4012
Disassembly And Assembly...4013
TRAVEL CONTROLS...4014
Removal And Installation...4014
Disassembly And Assembly...4014
CONTROL LINKAGE ASSEMBLY...4016
Removal And Installation...4016
Left Pedal Linkage Disassembly And Assembly...4017
Right Travel Control Linkage Disassembly And Assembly...4018
Left Travel Control Linkage Disassembly And Assembly...4019
Linkage Rod Removal And Installation...4020
Linkage Rod Adjustment...4021
FLOORMAT AND FLOORPLATES...4022
Removal and Installation...4022
FUEL TANK...4026
Removal and Installation...4026
HORN...4028
Removal and Installation...4028
SWING FRAME...4030
Removal And Installation...4030
Bushing Replacement...4032
Swing Frame Bushing Removal...4033
Swing Frame Bushing Installation...4033
Boom Pivot Bushing Removal And Installation...4034
BOOM...4036
Removal And Installation...4036
Boom Bushing Removal And Installation...4038
ARM...4040
Removal And Installation...4040
Arm To Boom Bushing Removal And Installation...4041
Arm To Bucket And Bucket Link Bushing Removal And Installation...4042
BUCKET...4044
Removal And Installation...4044
TAILGATE...4046
Removal And Installation...4046
Latch Removal And Installation...4047
SWING LOCK...4048
Removal and Installation...4048
BLADE EXTENSION TRAY...4050
Removal And Installation...4050
LEFT PEDAL...4052
Not Available At Time Of Print...4052
ELECTRICAL SYSTEM AND ANALYSIS...4054
ELECTRICAL SCHEMATICS...4056
ELECTRICAL SYSTEM...4057
Troubleshooting Chart...4057
Description...4058
Fuses...4058
Relays And Diodes...4058
BATTERY...4061
Servicing...4061
Removing And Installing The Battery...4062
Using A Booster Battery (Jump Starting)...4063
ALTERNATOR...4065
Description...4065
Tests...4065
Alternator Output Test...4066
Full Field Test...4066
Alternator Regulator Test...4067
Alternator Regulator Test With Voltmeter...4067
Removal And Installation...4068
Parts Identification...4070
Disassembly And Assembly...4070
STARTER...4071
Removal And Installation...4071
Parts Identification...4072
Disassembly And Assembly...4072
Cleaning and Inspection...4072
LIGHTS...4073
Upper Structure Light Removal And Installation...4073
Boom Light Removal And Installation...4074
Boom Light Disassembly And Assembly...4075
Light Switch Removal And Installation...4076
TWO-SPEED SWITCH...4077
Removal And Installation...4077
FUEL LEVEL SENDER...4079
Removal and Installation...4079
Testing...4079
MICROSWITCH...4081
Adjustment...4081
Testing...4083
Removal And Installation...4084
ENGINE SERVICE...4085
TROUBLESHOOTING...4089
Chart...4089
SPARK ARRESTOR MUFFLER...4091
Removal And Installation...4091
AIR CLEANER...4093
Removal And Installation...4093
RADIATOR...4095
Removal And Installation...4095
ENGINE COMPONENTS AND TESTING (S/N 223911001 - 223911621, S/N 224011001 - 224013374)...4101
Valve Clearance Adjustment...4101
Engine Compression Checking...4101
Fuel Shut-Off Solenoid Removal And Installation...4102
Fuel Shut-Off Timer Removal And Installation...4102
Fuel Injection Pump Check...4103
Fuel Injection Pump Removal And Installation...4104
Fuel Injection Pump Timing...4105
Fuel Injector Removal And Installation...4107
Fuel Injector Checking...4108
Glow Plug Removal And Installation...4109
Glow Plug Checking...4110
ENGINE COMPONENTS AND TESTING (S/N 223911622 & Above, S/N 224013375 & Above)...4111
Valve Clearance Adjustment...4111
Engine Compression Checking...4112
Fuel Shut-Off Solenoid Removal And Installation...4112
Fuel Shut-Off Timer Removal And Installation...4113
Fuel Injection Pump Check...4113
Fuel Injection Pump Removal And Installation...4114
Fuel Injection Pump Timing...4116
Fuel Injector Removal And Installation...4117
Fuel Injector Checking...4118
Glow Plug Removal And Installation...4120
ENGINE...4121
Removal and Installation...4121
ENGINE FLYWHEEL...4129
Removal And Installation...4129
Hydraulic Pump Coupler...4130
Flywheel Ring Gear...4130
RECONDITIONING THE ENGINE (S/N 223911001 - 223911621, S/N 224011001 - 224013374)...4131
Cylinder Head Removal And Installation...4131
Cylinder Head Disassembly And Assembly...4132
Cylinder Head, Servicing...4133
Cylinder Head Top Clearance...4134
Valve Guide, Checking...4134
Valve And Valve Seat Reconditioning...4136
Valve Spring...4137
Rocker Arm And Shaft, Checking...4137
Timing Gearcase Cover Removal And Installation...4138
Idler Gear And Camshaft Removal And Installation...4139
Idler Gear and Shaft, Servicing...4142
Timing Gears Checking Backlash...4143
Fuel Camshaft Removal And Installation...4143
Fuel Camshaft Governor...4144
Crankshaft Gear Removal And Installation...4144
Oil Pump Removal And Installation...4145
Oil Pump, Service...4145
Engine Oil Pressure, Checking...4146
Relief Valve...4147
Piston And Connecting Rod Removal And Installation...4147
Piston And Connecting Rod, Servicing...4149
Connecting Rod Alignment...4151
Crankshaft And Bearings Removal And Installation...4152
Crankshaft And Bearings, Servicing...4154
Cylinder Bore, Checking...4156
Water Pump Removal And Installation...4156
Water Pump Disassembly And Assembly...4156
RECONDITIONING THE ENGINE (S/N 223911622 & Above, S/N 224013375 & Above)...4157
Cylinder Head Removal And Installation...4157
Cylinder Head Disassembly And Assembly...4158
Cylinder Head, Servicing...4159
Cylinder Head Top Clearance...4160
Valve Guide, Checking...4160
Valve And Valve Seat Reconditioning...4162
Valve Spring...4163
Rocker Arm And Shaft, Checking...4163
Timing Gearcase Cover Removal And Installation...4164
Idler Gear And Camshaft Removal And Installation...4165
Idler Gear and Shaft, Servicing...4168
Timing Gears Checking Backlash...4169
Fuel Camshaft Removal And Installation...4169
Fuel Camshaft Governor...4170
Crankshaft Gear Removal And Installation...4170
Oil Pump Removal And Installation...4171
Oil Pump, Service...4171
Engine Oil Pressure, Checking...4172
Relief Valve...4173
Piston And Connecting Rod Removal And Installation...4173
Piston And Connecting Rod, Servicing...4175
Connecting Rod Alignment...4177
Crankshaft And Bearings Removal And Installation...4178
Crankshaft And Bearings, Servicing...4180
Cylinder Bore, Checking...4182
Water Pump Removal And Installation...4182
Water Pump Disassembly And Assembly...4182
HEATER...4183
HEATER...4185
Removal And Installation...4185
SPECIFICATIONS...4187
SPECIFICATIONS...4189
320/322 Excavator Machine Dimensions...4189
Performance...4191
Controls...4191
Engine...4191
Hydraulic System...4191
Hydraulic Cylinders...4192
Hydraulic Cycle Times...4192
Drive System...4192
Under Carriage...4193
Track...4193
Electrical...4193
ENGINE SPECIFICATIONS...4195
Fuel Injection Nozzles...4195
Fuel Injection Pump...4195
Cylinder Head...4195
Valves...4195
Valve Springs...4196
Rocker Arms...4196
Camshaft...4196
Cylinders...4197
Piston Rings...4197
Pistons...4197
Connecting Rods...4197
Oil Pump...4197
Crankshaft...4198
Timing Gear...4198
Thermostat...4198
Engine Bolt Torque...4199
Crankshaft Re-Grind Data...4200
TORQUE SPECIFICATIONS...4201
Torque For General SAE Bolts...4201
Torque For General Metric Bolts...4202
HYDRAULIC CONNECTION SPECIFICATIONS...4203
O-ring Face Seal Connection...4203
Straight Thread O-ring Fitting...4203
Tubelines And Hoses...4203
Flare Fitting...4204
O-ring Flare Fitting...4205
Port Seal Fitting...4207
HYDRAULIC FLUID SPECIFICATIONS...4209
Specifications...4209
FUEL, COOLANT AND LUBRICANTS...4211
Chart...4211
CONVERSIONS...4213
Decimal And Millimeter Equivalents...4213
U.S. To Metric Conversion Chart...4213
SMR...4215
320/322-1...4215
320/322-2...4217
320/322-3...4219
320/322-4...4221
6902668 (7-06) - 320, 322 Excavator Service Manual...4223
MAINTENANCE SAFETY...4225
ALPHABETICAL INDEX...4227
CONTENTS...4229
SAFETY INSTRUCTIONS...4233
Fire Prevention...4235
SERIAL NUMBER LOCATIONS...4237
Excavator Serial Number...4237
Engine Serial Number...4237
DELIVERY REPORT...4238
BOBCAT EXCAVATOR IDENTIFICATION...4239
SAFETY & MAINTENANCE...4241
LIFTING AND BLOCKING THE EXCAVATOR...4243
Procedure...4243
SWING LOCK...4245
LIFTING THE EXCAVATOR...4247
OPERATOR CAB ROPS/TOPS...4249
Emergency Exits...4249
Cab Door...4249
Front Window...4250
Right Side Windows...4252
TRANSPORTING THE EXCAVATOR...4253
TAILGATE...4255
Opening And Closing The Tailgate...4255
Adjusting The Bumper...4255
Adjusting The Tailgate Latch...4255
SERVICE SCHEDULE...4257
Chart...4257
AIR CLEANER SERVICE...4259
Daily Check...4259
Replacing The Filters...4259
HEATER AIR FILTERS...4261
Recirculation Filter...4261
Fresh Air Filter...4261
ENGINE COOLING SYSTEM...4263
Cleaning The Cooling System...4263
Checking Coolant Level...4263
Replacing The Coolant...4264
FUEL SYSTEM...4267
Fuel Specifications...4267
Filling The Fuel Tank...4267
Removing Water From The Fuel Filter...4268
Replacing The Fuel Filter...4268
Draining The Fuel Tank...4269
Removing Air From The Fuel System...4269
ENGINE LUBRICATION SYSTEM...4271
Checking Engine Oil...4271
Oil Chart...4271
Replacing Oil And Filter...4272
HYDRAULIC SYSTEM...4273
Checking And Adding Hydraulic Oil...4273
Diagnostic Couplers...4273
Replacing The Hydraulic Filter...4274
Replacing Hydraulic Oil...4274
LUBRICATION OF THE HYDRAULIC EXCAVATOR...4277
TRAVEL MOTOR...4281
Checking Oil Level...4281
Draining The Travel Motor...4281
SPARK ARRESTOR MUFFLER...4283
ALTERNATOR BELT...4285
Adjusting The Alternator Belt...4285
SEAT BELT...4287
Inspection And Maintenance...4287
CONTROL CONSOLE LOCKOUTS...4289
Inspection And Maintenance...4289
HYDRAULIC SYSTEM...4291
HYDRAULIC/HYDROSTATIC SCHEMATICS...4295
HYDRAULIC SYSTEM INFORMATION...4299
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...4299
Troubleshooting The Hydraulic Circuit...4302
Troubleshooting The Cylinder Circuit...4303
Troubleshooting The Swing (Upperstructure Slew) Circuit...4304
Troubleshooting The Travel Circuit...4305
BOOM CYLINDER...4307
Testing...4307
Removal and Installation...4309
Parts Identification...4311
Disassembly...4312
Assembly...4313
ARM CYLINDER...4317
Testing...4317
Removal and Installation...4318
Parts Identification...4320
Disassembly...4321
Assembly...4323
BOOM SWING CYLINDER...4327
Testing...4327
Removal and Installation...4328
Parts Identification...4331
Disassembly...4332
Assembly...4334
BUCKET CYLINDER...4337
Testing...4337
Removal and Installation...4338
Parts Identification...4340
Disassembly...4341
Assembly...4343
BLADE CYLINDER...4347
Testing...4347
Removal and Installation...4349
Parts Identification...4351
Disassembly...4352
Assembly...4354
TRACK FRAME EXPANSION CYLINDER...4357
Testing...4357
Removal And Installation...4358
Parts Identification...4362
Disassembly...4363
Assembly...4364
MAIN RELIEF VALVE...4369
Testing And Adjusting The Main Relief Valve...4369
PORT RELIEF VALVES...4371
Testing And Adjusting The Port Relief Valve Pressure...4371
CROSSPORT RELIEF VALVES...4373
Testing And Adjusting The Crossport Relief Valve...4373
PRESSURE REDUCING VALVE...4375
Testing And Adjusting The Pressure Reducing Valve...4375
HYDRAULIC CONTROL VALVE (320 / 322)...4377
Description...4377
Removal And Installation...4377
Parts Identification...4380
Disassembly...4381
Auxiliary Valve Section Disassembly And Assembly...4382
Blade Valve Section Disassembly And Assembly...4386
Slew Valve Section Disassembly And Assembly...4389
Left Travel Valve Section Disassembly and Assembly...4393
Boom Valve Section Disassembly and Assembly...4396
Bucket Valve Section Disassembly and Assembly...4399
Arm Valve Section Disassembly and Assembly...4403
Boom Swing Valve Section Disassembly And Assembly...4406
Right Travel Valve Section Disassembly And Assembly...4409
Assembly...4413
HYDRAULIC CONTROL VALVE (320L)...4419
Description...4419
Removal And Installation...4419
Parts Identification...4422
Disassembly...4423
Auxiliary Valve Section Disassembly And Assembly...4424
Blade Valve Section Disassembly And Assembly...4428
Slew Valve Section Disassembly And Assembly...4431
Left Travel Valve Section Disassembly And Assembly...4435
Boom Valve Section Disassembly And Assembly...4438
Bucket Valve Section Disassembly And Assembly...4441
Arm Valve Section Disassembly And Assembly...4445
Boom Swing Valve Section Disassembly And Assembly...4448
Right Travel Valve Section Disassembly And Assembly...4451
Assembly...4455
HYDRAULIC PUMP...4461
Testing The Hydraulic Pump...4461
Removal And Installation...4463
Coupler Removal And Installation...4464
Parts Identification...4465
Disassembly...4466
Assembly...4468
MANIFOLD ASSEMBLY/ACCUMULATOR...4473
Description...4473
Removal And Installation...4473
Parts Identification (S/N 223911001 - 223911247 & S/N 224011001 - 224012293)...4475
Disassembly (S/N 223911001 - 223911247 & S/N 224011001 - 224012293)...4476
Assembly (S/N 223911001 - 223911247 & S/N 224011001 - 224012293)...4485
Parts Identification (S/N 223911248 & Above & S/N 224012294 & Above)...4494
Disassembly (S/N 223911248 & Above & S/N 224012294 & Above)...4495
Assembly (S/N 223911248 & Above & S/N 224012294 & Above)...4508
TRAVEL MOTOR...4521
Removal and Installation...4521
Parts Identification...4522
Disassembly...4523
Assembly...4530
SWIVEL JOINT...4539
Removal And Installation...4539
Parts Identification 320...4542
Parts Identification 322...4543
Disassembly...4544
Assembly...4548
SWING MOTOR...4553
Removal and Installation...4553
Parts Identification...4554
Disassembly...4555
Assembly...4561
CONTROL PATTERN SELECTOR VALVE...4569
Removal And Installation...4569
Parts Identification...4571
Disassembly...4572
Assembly...4573
RIGHT CONTROL LEVER (JOYSTICK)...4575
Testing...4575
Handle Removal And Installation...4577
Removal And Installation...4578
Parts Identification...4580
Disassembly...4581
Assembly...4586
LEFT CONTROL LEVER (JOYSTICK)...4593
Testing...4593
Handle Removal And Installation...4595
Removal And Installation...4597
Parts Identification...4598
Disassembly...4599
Assembly...4604
HYDRAULIC FILTER MOUNT...4609
Removal and Installation...4609
HYDRAULIC RESERVOIR...4611
Removal and Installation...4611
OIL COOLER...4613
Removal And Installation...4613
UNDERCARRIAGE...4615
BLADE...4617
Extension Removal And Installation...4617
Blade Removal And Installation...4617
TRACKS...4619
Track Lug Height...4619
Adjustment...4620
Removal And Installation...4622
TRACK FRAME...4623
Disassembly And Assembly...4623
Removal And Installation Of Expandable Track Frame (322 Only)...4624
Recoil Spring Disassembly And Assembly...4625
TRACK DAMAGE IDENTIFICATION...4627
Cutting Of The Steel Cords...4627
Causes Of The Damage...4627
Abrasion Of Embedded Metals...4628
Separation Of Embedded Metals...4629
Separation Of Embedded Metals Due To Corrosion...4630
Cuts On The Lug Side Rubber...4631
Cracks On The Lug Side Rubber Due To Fatigue...4632
Lug Abrasion...4633
Cracks And Cuts On The Lug Side Rubber...4634
Abrasion Of The Track Roller Side...4635
Cuts On The Edges Of The Track Roller Side...4636
TRACK IDLER...4639
Parts Identification...4639
Disassembly...4640
Assembly...4642
TRACK ROLLER...4645
Parts Identification...4645
Disassembly...4646
Assembly...4648
SWING CIRCLE GEAR...4651
Removal and Installation...4651
UPPERSTRUCTURE & SWING SECTION...4653
UPPERSTRUCTURE...4657
Removal...4657
Installation...4659
ROPS CANOPY...4661
Removal And Installation...4661
CAB...4665
Removal And Installation...4665
Door Removal And Installation...4669
Front Window Removal And Installation...4670
Right Side Rear Sliding Window Removal And Installation...4673
Right Side Front Sliding Window Removal And Installation...4674
Glass Removal...4674
Glass Installation...4675
Glass Installation (Cont’d)...4676
SEAT AND SEAT MOUNT...4677
Removal And Installation...4677
RIGHT CONSOLE...4679
Console Cover Removal And Installation (Cab Models 320L, 320, 322 & ROPS Canopy Model 320L)...4679
Console Cover Removal And Installation (ROPS Canopy Models 320 & 322)...4682
Gas Spring Removal And Installation (ROPS Canopy Models 320 & 322)...4685
Lock Lever Removal And Installation (ROPS Canopy Models 320 & 322)...4686
Adjustment (ROPS Canopy Models 320 & 322)...4688
Latch Hook Removal And Installation (ROPS Canopy 320 & 322)...4688
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320 & 322)...4689
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L)...4690
Upper Console Removal And Installation...4691
Console Base Removal And Installation...4692
LEFT CONSOLE...4695
Console Cover Removal And Installation...4695
Gas Spring Removal And Installation...4697
Lock Lever Removal And Installation...4698
Adjustment...4700
Latch Hook Removal And Installation...4701
Latch Hook Disassembly And Assembly...4702
Upper Console Removal And Installation...4703
Console Base Removal And Installation...4704
ENGINE SPEED CONTROL...4707
Removal and Installation...4707
Engine Speed Control Cable Removal and Installation...4708
BLADE CONTROL...4711
Removal and Installation...4711
Disassembly And Assembly...4712
RIGHT PEDAL...4715
Right Pedal Removal And Installation...4715
Disassembly And Assembly...4716
Linkage Removal And Installation...4717
Linkage Disassembly And Assembly...4717
LEFT PEDAL...4719
Removal And Installation...4719
Disassembly And Assembly...4720
TRAVEL CONTROLS...4721
Removal And Installation...4721
Disassembly And Assembly...4721
CONTROL LINKAGE ASSEMBLY...4723
Removal And Installation...4723
Left Pedal Linkage Disassembly And Assembly...4724
Right Travel Control Linkage Disassembly And Assembly...4725
Left Travel Control Linkage Disassembly And Assembly...4726
Linkage Rod Removal And Installation...4727
Linkage Rod Adjustment...4728
FLOORMAT AND FLOORPLATES...4729
Removal and Installation...4729
FUEL TANK...4733
Removal and Installation...4733
HORN...4735
Removal and Installation...4735
SWING FRAME...4737
Removal And Installation...4737
Bushing Replacement...4739
Swing Frame Bushing Removal...4740
Swing Frame Bushing Installation...4740
Boom Pivot Bushing Removal And Installation...4741
BOOM...4743
Removal And Installation...4743
Boom Bushing Removal And Installation...4745
ARM...4747
Removal And Installation...4747
Arm To Boom Bushing Removal And Installation...4748
Arm To Bucket And Bucket Link Bushing Removal And Installation...4749
BUCKET...4751
Removal And Installation...4751
TAILGATE...4753
Removal And Installation...4753
Latch Removal And Installation...4754
SWING LOCK...4755
Removal and Installation...4755
BLADE EXTENSION TRAY...4757
Removal And Installation...4757
LEFT PEDAL...4759
Not Available At Time Of Print...4759
ELECTRICAL SYSTEM AND ANALYSIS...4761
ELECTRICAL SCHEMATICS...4763
ELECTRICAL SYSTEM...4764
Troubleshooting Chart...4764
Description...4765
Fuses...4765
Relays And Diodes...4765
BATTERY...4768
Servicing...4768
Removing And Installing The Battery...4769
Using A Booster Battery (Jump Starting)...4770
ALTERNATOR...4772
Description...4772
Tests...4772
Alternator Output Test...4773
Full Field Test...4773
Alternator Regulator Test...4774
Alternator Regulator Test With Voltmeter...4774
Removal And Installation...4775
Parts Identification...4777
Disassembly And Assembly...4777
STARTER...4778
Removal And Installation...4778
Parts Identification...4779
Disassembly And Assembly...4779
Cleaning and Inspection...4779
LIGHTS...4780
Upper Structure Light Removal And Installation...4780
Boom Light Removal And Installation...4781
Boom Light Disassembly And Assembly...4782
Light Switch Removal And Installation...4783
TWO-SPEED SWITCH...4784
Removal And Installation...4784
FUEL LEVEL SENDER...4786
Removal and Installation...4786
Testing...4786
MICROSWITCH...4788
Adjustment...4788
Testing...4790
Removal And Installation...4791
ENGINE SERVICE...4792
TROUBLESHOOTING...4796
Chart...4796
SPARK ARRESTOR MUFFLER...4798
Removal And Installation...4798
AIR CLEANER...4800
Removal And Installation...4800
RADIATOR...4802
Removal And Installation...4802
ENGINE COMPONENTS AND TESTING (S/N 223911001 - 223911621, S/N 224011001 - 224013374)...4808
Valve Clearance Adjustment...4808
Engine Compression Checking...4808
Fuel Shut-Off Solenoid Removal And Installation...4809
Fuel Shut-Off Timer Removal And Installation...4809
Fuel Injection Pump Check...4810
Fuel Injection Pump Removal And Installation...4811
Fuel Injection Pump Timing...4812
Fuel Injector Removal And Installation...4814
Fuel Injector Checking...4815
Glow Plug Removal And Installation...4816
Glow Plug Checking...4817
ENGINE COMPONENTS AND TESTING (S/N 223911622 & Above, S/N 224013375 & Above)...4818
Valve Clearance Adjustment...4818
Engine Compression Checking...4819
Fuel Shut-Off Solenoid Removal And Installation...4819
Fuel Shut-Off Timer Removal And Installation...4820
Fuel Injection Pump Check...4820
Fuel Injection Pump Removal And Installation...4821
Fuel Injection Pump Timing...4823
Fuel Injector Removal And Installation...4824
Fuel Injector Checking...4825
Glow Plug Removal And Installation...4827
ENGINE...4828
Removal and Installation...4828
ENGINE FLYWHEEL...4836
Removal And Installation...4836
Hydraulic Pump Coupler...4837
Flywheel Ring Gear...4837
RECONDITIONING THE ENGINE (S/N 223911001 - 223911621, S/N 224011001 - 224013374)...4838
Cylinder Head Removal And Installation...4838
Cylinder Head Disassembly And Assembly...4839
Cylinder Head, Servicing...4840
Cylinder Head Top Clearance...4841
Valve Guide, Checking...4841
Valve And Valve Seat Reconditioning...4843
Valve Spring...4844
Rocker Arm And Shaft, Checking...4844
Timing Gearcase Cover Removal And Installation...4845
Idler Gear And Camshaft Removal And Installation...4846
Idler Gear and Shaft, Servicing...4849
Timing Gears Checking Backlash...4850
Fuel Camshaft Removal And Installation...4850
Fuel Camshaft Governor...4851
Crankshaft Gear Removal And Installation...4851
Oil Pump Removal And Installation...4852
Oil Pump, Service...4852
Engine Oil Pressure, Checking...4853
Relief Valve...4854
Piston And Connecting Rod Removal And Installation...4854
Piston And Connecting Rod, Servicing...4856
Connecting Rod Alignment...4858
Crankshaft And Bearings Removal And Installation...4859
Crankshaft And Bearings, Servicing...4861
Cylinder Bore, Checking...4863
Water Pump Removal And Installation...4863
Water Pump Disassembly And Assembly...4863
RECONDITIONING THE ENGINE (S/N 223911622 & Above, S/N 224013375 & Above)...4864
Cylinder Head Removal And Installation...4864
Cylinder Head Disassembly And Assembly...4865
Cylinder Head, Servicing...4866
Cylinder Head Top Clearance...4867
Valve Guide, Checking...4867
Valve And Valve Seat Reconditioning...4869
Valve Spring...4870
Rocker Arm And Shaft, Checking...4870
Timing Gearcase Cover Removal And Installation...4871
Idler Gear And Camshaft Removal And Installation...4872
Idler Gear and Shaft, Servicing...4875
Timing Gears Checking Backlash...4876
Fuel Camshaft Removal And Installation...4876
Fuel Camshaft Governor...4877
Crankshaft Gear Removal And Installation...4877
Oil Pump Removal And Installation...4878
Oil Pump, Service...4878
Engine Oil Pressure, Checking...4879
Relief Valve...4880
Piston And Connecting Rod Removal And Installation...4880
Piston And Connecting Rod, Servicing...4882
Connecting Rod Alignment...4884
Crankshaft And Bearings Removal And Installation...4885
Crankshaft And Bearings, Servicing...4887
Cylinder Bore, Checking...4889
Water Pump Removal And Installation...4889
Water Pump Disassembly And Assembly...4889
HEATER...4890
HEATER...4892
Removal And Installation...4892
SPECIFICATIONS...4894
SPECIFICATIONS...4896
320/322 Excavator Machine Dimensions...4896
Performance...4898
Controls...4898
Engine...4898
Hydraulic System...4898
Hydraulic Cylinders...4899
Hydraulic Cycle Times...4899
Drive System...4899
Under Carriage...4900
Track...4900
Electrical...4900
ENGINE SPECIFICATIONS...4902
Fuel Injection Nozzles...4902
Fuel Injection Pump...4902
Cylinder Head...4902
Valves...4902
Valve Springs...4903
Rocker Arms...4903
Camshaft...4903
Cylinders...4904
Piston Rings...4904
Pistons...4904
Connecting Rods...4904
Oil Pump...4904
Crankshaft...4905
Timing Gear...4905
Thermostat...4905
Engine Bolt Torque...4906
Crankshaft Re-Grind Data...4907
TORQUE SPECIFICATIONS...4908
Torque For General SAE Bolts...4908
Torque For General Metric Bolts...4909
HYDRAULIC CONNECTION SPECIFICATIONS...4910
O-ring Face Seal Connection...4910
Straight Thread O-ring Fitting...4910
Tubelines And Hoses...4910
Flare Fitting...4911
O-ring Flare Fitting...4912
Port Seal Fitting...4914
HYDRAULIC FLUID SPECIFICATIONS...4916
Specifications...4916
FUEL, COOLANT AND LUBRICANTS...4918
Chart...4918
CONVERSIONS...4920
Decimal And Millimeter Equivalents...4920
U.S. To Metric Conversion Chart...4920
SMR...4922
320/322-1...4922
320/322-2...4924
320/322-3...4926
6903817 (11-05) - 320, 320L Excavator Excavator Operation & Maintenance Manual...4928
CONTENTS...4933
FOREWORD...4935
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...4937
REGULAR MAINTENANCE ITEMS...4937
MOTOR OIL...4937
SERIAL NUMBER LOCATIONS...4939
Excavator Serial Number...4939
Engine Serial Number...4939
DELIVERY REPORT...4940
BOBCAT EXCAVATOR IDENTIFICATION...4941
FEATURES, ACCESSORIES, AND ATTACHMENTS...4942
Standard Items...4942
Standard Items...4942
Options and Accessories...4942
Other...4942
Attachments...4942
Buckets...4942
SAFETY INSTRUCTIONS...4943
SAFETY INSTRUCTIONS...4945
Before Operation...4945
Safe Operation Is The Operator’s Responsibility...4946
Safe Operation Needs A Qualified Operator...4946
Fire Prevention...4947
MACHINE SIGNS (DECALS)...4948
OPERATING INSTRUCTIONS...4951
INSTRUMENTS AND CONSOLES...4953
Cab Interior Light (If Equipped)...4953
Left Console...4953
Heater (If Equipped)...4953
Right Console...4954
Right Control Panel...4955
Raising And Lowering The Console(s)...4955
TWO-SPEED TRAVEL - 320 ONLY...4956
TAILGATE...4956
Opening And Closing The Tailgate...4956
OPERATOR CANOPY (ROPS / TOPS)...4957
FALLING OBJECT GUARDS (FOGS)...4957
CANOPY ENCLOSURE...4958
OPERATOR CAB (ROPS / TOPS) (If Equipped)...4959
Emergency Exits...4959
OPERATOR CAB (ROPS / TOPS) (If Equipped)...4960
Cab Door...4960
Front Window Wiper...4961
Window Washer Reservoir...4961
Front Window...4962
Right Side Windows...4964
STEERING LEVERS/FOOT PEDALS...4965
Forward And Reverse Travel...4965
Turning...4965
HYDRAULIC CONTROLS...4967
ISO Control Pattern...4967
Left Control Lever...4967
Right Control Lever...4967
Control Lever (Joystick) Lock...4968
Auxiliary Hydraulic Pedal (If Equipped)...4969
Quick Couplers (If Equipped)...4970
BLADE CONTROL LEVER...4971
UPPERSTRUCTURE SLEW LOCK...4972
BOOM SWING PEDAL...4973
DAILY INSPECTION...4974
Service Schedule...4975
PRE-STARTING PROCEDURE...4976
STARTING THE ENGINE...4978
Cold Temperature Starting Procedure...4979
BUCKETS AND ATTACHMENTS...4980
Installing...4980
Removing...4980
OPERATING PROCEDURE...4981
Operating On Public Roads...4981
Lifting A Load...4981
Excavating...4982
Boom Swing...4984
Backfilling...4985
Driving The Excavator...4985
Operating On Slopes...4986
Operating In Water...4988
PARKING THE EXCAVATOR...4989
TRANSPORTING THE EXCAVATOR...4990
LIFTING THE EXCAVATOR...4991
PREVENTIVE MAINTENANCE...4993
MAINTENANCE SAFETY...4995
SERVICE SCHEDULE...4997
Chart...4997
TAILGATE...4998
Opening And Closing The Tailgate...4998
Adjusting the Bumper...4998
Adjusting The Tailgate Catch...4998
AIR CLEANER...4999
Daily Check...4999
Replacing The Filters...4999
SEAT BELT...5001
Inspection And Maintenance...5001
HEATER AIR FILTERS...5002
Recirculation Filter...5002
Fresh Air Filter...5002
FUEL SYSTEM...5002
Fuel Specifications...5002
Filling The Fuel Tank...5003
Removing Water From The Fuel Filter...5003
Replacing The Fuel Filter...5003
Draining The Fuel Tank...5004
Removing Air From The Fuel System...5004
ENGINE LUBRICATION SYSTEM...5005
Checking Engine Oil...5005
Replacing Oil And Filter...5006
COOLING SYSTEM...5006
Cleaning The Cooling System...5006
Checking Coolant Level...5006
Replacing The Coolant...5007
ALTERNATOR BELT...5009
Adjusting The Alternator Belt...5009
ELECTRICAL SYSTEM...5011
Description...5011
Fuses...5011
Relays And Diodes...5011
Service The Electrical System And Battery...5013
Using A Booster Battery (Jump Starting)...5014
Removing And Installing The Battery...5015
HYDRAULIC SYSTEM...5016
Checking And Adding Hydraulic Oil...5016
Diagnostic Couplers...5016
Replacing The Hydraulic Filter...5017
Replacing Hydraulic Oil...5017
CONTROL CONSOLE LOCKOUTS...5019
Inspection And Maintenance...5019
SPARK ARRESTOR MUFFLER...5020
TRACK TENSION...5021
Adjusting...5021
TRAVEL MOTOR...5023
Checking Oil Level...5023
Draining The Travel Motor...5023
LUBRICATION OF THE HYDRAULIC EXCAVATOR...5024
MACHINE SIGN TRANSLATIONS...5027
WARNING (6808185)...5029
LIFT CHART...5030
320/320L (6808184)...5030
SERVICE SCHEDULE (7111723)...5032
WARNING (6807776)...5034
WARNING (6815915)...5035
WARNING (6804114, 6577754, 6804233, 6809832)...5036
SPECIFICATIONS...5037
SPECIFICATIONS...5039
320 Excavator Machine Dimensions...5039
Performance...5041
Engine...5041
Controls...5041
Drive System...5041
Hydraulic System...5042
Electrical System...5042
Instrumentation...5042
FUEL, COOLANT AND LUBRICANTS...5043
Chart...5043
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...5045
WARRANTY...5047
6903818 (11-06) - 320, 320L Excavator Service Manual...5048
MAINTENANCE SAFETY...5049
ALPHABETICAL INDEX...5051
CONTENTS...5053
FOREWORD...5055
SAFETY INSTRUCTIONS...5057
Fire Prevention...5059
SERIAL NUMBER LOCATIONS...5061
Excavator Serial Number...5061
Engine Serial Number...5061
DELIVERY REPORT...5062
BOBCAT EXCAVATOR IDENTIFICATION...5063
SAFETY AND MAINTENANCE...5065
LIFTING AND BLOCKING THE EXCAVATOR...5067
Procedure...5067
UPPERSTRUCTURE SLEW LOCK...5069
LIFTING THE EXCAVATOR...5071
OPERATOR CAB ROPS/TOPS (IF EQUIPPED)...5073
Emergency Exits...5073
Cab Door...5073
Front Window Wiper...5074
Window Washer Reservoir...5075
Front Window...5075
Right Side Windows...5077
TRANSPORTING THE EXCAVATOR...5079
TAILGATE...5081
Opening And Closing The Tailgate...5081
Adjusting The Bumper...5081
Adjusting The Tailgate Latch...5081
SERVICE SCHEDULE...5083
Chart...5083
AIR CLEANER SERVICE...5085
Daily Check...5085
Replacing The Filters...5085
HEATER AIR FILTERS...5087
Recirculation Filter...5087
Fresh Air Filter...5087
ENGINE COOLING SYSTEM...5089
Cleaning The Cooling System...5089
Checking Coolant Level...5089
Replacing The Coolant...5090
FUEL SYSTEM...5093
Fuel Specifications...5093
Filling The Fuel Tank...5093
Removing Water From The Fuel Filter...5094
Replacing The Fuel Filter...5094
Draining The Fuel Tank...5095
Removing Air From The Fuel System...5095
ENGINE LUBRICATION SYSTEM...5097
Checking Engine Oil...5097
Oil Chart...5097
Replacing Oil And Filter...5098
HYDRAULIC SYSTEM...5099
Checking And Adding Hydraulic Oil...5099
Diagnostic Couplers...5099
Replacing The Hydraulic Filter...5100
Replacing Hydraulic Oil...5100
LUBRICATION OF THE HYDRAULIC EXCAVATOR...5103
TRAVEL MOTOR...5105
Checking Oil Level...5105
Draining The Travel Motor...5105
SPARK ARRESTOR MUFFLER...5107
ALTERNATOR BELT...5109
Adjusting The Alternator Belt...5109
SEAT BELT...5111
Inspection And Maintenance...5111
CONTROL CONSOLE LOCKOUTS...5113
Inspection And Maintenance...5113
HYDRAULIC SYSTEM...5115
HYDRAULIC/HYDROSTATIC SCHEMATICS...5119
HYDRAULIC SYSTEM INFORMATION...5121
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...5121
Troubleshooting The Hydraulic Circuit...5124
Troubleshooting The Cylinder Circuit...5125
Troubleshooting The Swing (Upperstructure Slew) Circuit...5126
Troubleshooting The Travel Circuit...5127
BOOM CYLINDER...5129
Testing...5129
Removal and Installation...5132
Parts Identification...5135
Disassembly...5136
Assembly...5138
ARM CYLINDER...5141
Testing...5141
Removal And Installation...5142
Parts Identification...5144
Disassembly...5145
Assembly...5147
BOOM SWING CYLINDER...5151
Testing...5151
Removal And Installation...5152
Parts Identification...5155
Disassembly...5156
Assembly...5158
BUCKET CYLINDER...5161
Testing...5161
Removal And Installation...5162
Parts Identification...5164
Disassembly...5165
Assembly...5167
BLADE CYLINDER...5171
Testing...5171
Removal And Installation...5173
Parts Identification...5175
Disassembly...5176
Assembly...5178
MAIN RELIEF VALVE...5181
Testing And Adjusting The Main Relief Valve...5181
PORT RELIEF VALVES...5183
Testing And Adjusting The Port Relief Valve Pressure...5183
CROSSPORT RELIEF VALVES...5185
Testing And Adjusting The Crossport Relief Valve...5185
PRESSURE REDUCING VALVE...5187
Testing And Adjusting The Pressure Reducing Valve...5187
HYDRAULIC CONTROL VALVE (320)...5189
Description...5189
Removal And Installation...5189
Parts Identification...5192
Disassembly...5193
Auxiliary Valve Section Disassembly And Assembly...5194
Blade Valve Section Disassembly And Assembly...5198
Slew Valve Section Disassembly And Assembly...5201
Left Travel Valve Section Disassembly And Assembly...5205
Boom Valve Section Disassembly And Assembly...5208
Bucket Valve Section Disassembly And Assembly...5211
Arm Valve Section Disassembly And Assembly...5215
Boom Swing Valve Section Disassembly And Assembly...5218
Right Travel Valve Section Disassembly And Assembly...5221
Assembly...5225
HYDRAULIC CONTROL VALVE (320L)...5231
Description...5231
Removal And Installation...5231
Parts Identification...5234
Disassembly...5235
Auxiliary Valve Section Disassembly And Assembly...5236
Blade Valve Section Disassembly And Assembly...5240
Slew Valve Section Disassembly And Assembly...5243
Left Travel Valve Section Disassembly And Assembly...5247
Boom Valve Section Disassembly And Assembly...5250
Bucket Valve Section Disassembly And Assembly...5253
Arm Valve Section Disassembly And Assembly...5257
Boom Swing Valve Section Disassembly And Assembly...5260
Right Travel Valve Section Disassembly And Assembly...5263
Assembly...5267
HYDRAULIC PUMP...5273
Testing The Hydraulic Pump...5273
Removal And Installation...5275
Parts Identification...5277
Disassembly...5278
Assembly...5280
MANIFOLD ASSEMBLY/ACCUMULATOR...5285
Description...5285
Removal And Installation...5285
Parts Identification - 320...5287
Disassembly - 320...5288
Assembly - 320...5297
Parts Identification - 320L...5306
Disassembly - 320L...5307
Assembly - 320L...5316
TRAVEL MOTOR...5325
Removal and Installation...5325
Parts Identification...5326
Disassembly...5327
Assembly...5334
SWIVEL JOINT...5343
Removal And Installation...5343
Parts Identification...5345
Disassembly...5346
Assembly...5348
SWING MOTOR...5351
Removal and Installation...5351
Parts Identification...5352
Disassembly...5353
Assembly...5359
RIGHT CONTROL LEVER (JOYSTICK)...5367
Testing...5367
Handle Removal And Installation...5369
Removal And Installation...5370
Parts Identification...5371
Disassembly...5372
Assembly...5377
LEFT CONTROL LEVER (JOYSTICK)...5383
Testing...5383
Handle Removal And Installation...5385
Removal And Installation...5387
Parts Identification...5388
Disassembly...5389
Assembly...5394
HYDRAULIC FILTER MOUNT...5399
Removal and Installation...5399
HYDRAULIC RESERVOIR...5401
Removal and Installation...5401
OIL COOLER...5403
Removal And Installation...5403
UNDERCARRIAGE...5405
BLADE...5407
Extension Removal And Installation (320 Only)...5407
Blade Removal And Installation...5407
TRACKS...5409
Track Lug Height...5409
Track Tension Adjustment...5410
Removal And Installation...5412
TRACK FRAME...5413
Disassembly And Assembly...5413
Removal And Installation Of Track Frame...5415
TRACK DAMAGE IDENTIFICATION...5417
Cutting Of The Steel Cords...5417
Causes Of The Damage...5417
Abrasion Of Embedded Metals...5418
Separation Of Embedded Metals...5419
Separation Of Embedded Metals Due To Corrosion...5420
Cuts On The Lug Side Rubber...5421
Cracks On The Lug Side Rubber Due To Fatigue...5422
Lug Abrasion...5423
Cracks And Cuts On The Lug Side Rubber...5424
Abrasion Of The Track Roller Side...5425
Cuts On The Edges Of The Track Roller Side...5426
TRACK IDLER...5429
Parts Identification...5429
Disassembly...5430
Assembly...5432
TRACK ROLLER...5435
Parts Identification...5435
Disassembly...5436
Assembly...5438
SWING CIRCLE GEAR...5441
Removal and Installation...5441
UPPERSTRUCTURE & SWING SECTION...5443
UPPERSTRUCTURE...5447
Removal...5447
Installation...5449
ROPS CANOPY...5453
Removal And Installation...5453
CAB...5457
Removal And Installation...5457
Door Removal And Installation...5461
Front Window Removal And Installation...5462
Right Side Rear Sliding Window Removal And Installation...5465
Right Side Front Sliding Window Removal And Installation...5466
Glass Removal...5466
Glass Installation...5467
SEAT AND SEAT MOUNT...5469
Removal And Installation...5469
RIGHT CONSOLE...5471
Console Cover Removal And Installation (Cab)...5471
Console Cover Removal And Installation (ROPS Canopy)...5474
Gas Spring Removal And Installation (ROPS Canopy)...5477
Lock Lever Removal And Installation (ROPS Canopy)...5478
Adjustment (ROPS Canopy Models)...5480
Latch Hook Removal And Installation (ROPS Canopy)...5480
Latch Hook Disassembly And Assembly (ROPS Canopy)...5481
Cab Models...5482
Upper Console Removal And Installation...5483
Console Base Removal And Installation...5484
LEFT CONSOLE...5487
Console Cover Removal And Installation...5487
Gas Spring Removal And Installation...5489
Lock Lever Removal And Installation...5490
Adjustment...5492
Latch Hook Removal And Installation...5493
Latch Hook Disassembly And Assembly...5494
Upper Console Removal And Installation...5495
Console Base Removal And Installation...5496
ENGINE SPEED CONTROL...5499
Removal And Installation...5499
Engine Speed Control Cable Removal And Installation...5500
BLADE CONTROL...5503
Removal and Installation...5503
Disassembly And Assembly...5504
SLEW LOCK...5507
Removal And Installation...5507
RIGHT PEDAL AND LINKAGE...5509
Right Pedal Removal And Installation...5509
Disassembly And Assembly...5510
Linkage Removal And Installation...5511
Linkage Disassembly And Assembly...5511
TRAVEL CONTROLS...5513
Removal And Installation...5513
Disassembly And Assembly...5513
LEFT PEDAL...5515
Removal And Installation (320 Only)...5515
Disassembly And Assembly (320 Only)...5516
CONTROL LINKAGE ASSEMBLY (320)...5517
Removal And Installation...5517
Left Pedal Linkage Disassembly And Assembly...5518
Right Travel Control Linkage Disassembly And Assembly...5519
Left Travel Control Linkage Disassembly And Assembly...5520
Linkage Rod Removal And Installation...5521
Linkage Rod Adjustment...5522
CONTROL LINKAGE ASSEMBLY (320L)...5523
Removal And Installation...5523
Right Travel Control Linkage Disassembly And Assembly...5524
Left Travel Control Linkage Disassembly And Assembly...5525
Linkage Rod Removal And Installation...5526
Linkage Rod Adjustment...5527
FLOOR MAT AND FLOOR PANELS...5529
Removal And Installation (320 Only)...5529
Removal And Installation (320L Only)...5531
BLADE EXTENSION TRAY...5535
Removal And Installation (320 Only)...5535
FUEL TANK...5537
Removal And Installation...5537
HORN...5539
Removal And Installation (Earlier Models)...5539
Removal And Installation (Later Models)...5539
SWING FRAME...5541
Removal And Installation...5541
Bushing Replacement...5543
Swing Frame Bushing Removal...5544
Swing Frame Bushing Installation...5544
Boom Pivot Bushing Removal And Installation...5545
BOOM...5547
Removal And Installation...5547
Boom Bushing Removal And Installation...5549
ARM...5551
Removal And Installation...5551
Arm To Boom Bushing Removal And Installation...5552
Arm To Bucket And Bucket Link Bushing Removal And Installation...5553
BUCKET...5555
Removal And Installation...5555
TAILGATE...5557
Removal And Installation...5557
Latch Removal And Installation...5558
ELECTRICAL SYSTEM AND ANALYSIS...5559
ELECTRICAL SCHEMATICS...5561
ELECTRICAL SYSTEM...5562
Troubleshooting Chart...5562
Description...5563
Fuses...5563
Relays And Diodes...5563
BATTERY...5566
Servicing...5566
Removing And Installing The Battery...5567
Using A Booster Battery (Jump Starting)...5568
ALTERNATOR...5570
Description...5570
Tests...5570
Alternator Output Test...5571
Full Field Test...5571
Alternator Regulator Test...5572
Alternator Regulator Test With Voltmeter...5572
Removal And Installation...5573
Parts Identification...5575
Disassembly And Assembly...5575
STARTER...5576
Removal And Installation...5576
Parts Identification...5577
Disassembly And Assembly...5577
Cleaning And Inspection...5577
LIGHTS...5578
Upperstructure Light Removal And Installation...5578
Upperstructure Light Disassembly And Assembly...5578
Boom Light Removal And Installation (320 Only) (Earlier Models)...5579
Boom Light Disassembly and Assembly (320 Only) (Earlier Models)...5579
Boom Light Removal And Installation (320 Only) (Later Models)...5580
Boom Light Bulb Replacement (320 Only) (Later Models)...5580
Light Switch Removal And Installation...5581
MICROSWITCH...5582
Adjustment...5582
Testing...5584
Removal And Installation...5585
TWO-SPEED SWITCH (320 ONLY)...5586
Removal And Installation...5586
FUEL LEVEL SENDER...5588
Removal And Installation...5588
Testing...5588
ENGINE SERVICE...5590
TROUBLESHOOTING...5592
Chart...5592
SPARK ARRESTOR MUFFLER...5594
Removal And Installation...5594
AIR CLEANER...5596
Removal And Installation...5596
RADIATOR...5598
Removal And Installation...5598
ENGINE COMPONENTS AND TESTING...5604
Valve Clearance Adjustment...5604
Engine Compression Checking...5605
Fuel Shut-Off Solenoid Removal And Installation...5605
Fuel Shut-Off Timer Removal And Installation...5606
Fuel Injection Pump Check...5606
Fuel Injection Pump Removal And Installation...5607
Fuel Injection Pump Timing...5609
Fuel Injector Removal And Installation...5610
Fuel Injector Checking...5611
Glow Plug Removal And Installation...5613
ENGINE...5614
Removal And Installation...5614
ENGINE FLYWHEEL...5622
Removal And Installation...5622
Hydraulic Pump Coupler Removal And Installation...5623
Hydraulic Pump Coupler Disassembly And Assembly...5624
Flywheel Ring Gear...5624
RECONDITIONING THE ENGINE...5626
Cylinder Head Removal And Installation...5626
Cylinder Head Disassembly And Assembly...5627
Cylinder Head, Servicing...5628
Cylinder Head Top Clearance...5629
Valve Guide, Checking...5629
Valve And Valve Seat Reconditioning...5631
Valve Spring...5632
Rocker Arm And Shaft, Checking...5632
Timing Gearcase Cover Removal And Installation...5633
Idler Gear And Camshaft Removal And Installation...5634
Idler Gear and Shaft, Servicing...5637
Timing Gears Checking Backlash...5638
Fuel Camshaft Removal And Installation...5638
Fuel Camshaft Governor...5639
Crankshaft Gear Removal And Installation...5639
Oil Pump Removal And Installation...5640
Oil Pump, Service...5640
Engine Oil Pressure, Checking...5641
Relief Valve...5642
Piston And Connecting Rod Removal And Installation...5642
Piston And Connecting Rod, Servicing...5644
Connecting Rod Alignment...5646
Crankshaft And Bearings Removal And Installation...5647
Crankshaft And Bearings, Servicing...5649
Cylinder Bore, Checking...5651
Water Pump Removal And Installation...5651
Water Pump Disassembly And Assembly...5651
HEATER...5652
HEATER...5654
Removal And Installation...5654
SPECIFICATIONS...5656
SPECIFICATIONS...5658
320/320L Excavator Machine Dimensions...5658
Performance...5660
Controls...5660
Engine...5660
Hydraulic System...5661
Hydraulic Cylinders...5661
Hydraulic Cycle Times...5662
Drive System...5662
Undercarriage...5662
Track...5662
Electrical...5663
ENGINE SPECIFICATIONS...5664
Engine...5664
Fuel Injector Nozzles...5664
Fuel Injection Pump...5664
Cylinder Head...5664
Valves...5664
Valve Springs...5664
Rocker Arms...5665
Camshaft...5665
Cylinders...5665
Piston Rings...5665
Pistons...5666
Connecting Rods...5666
Crankshaft...5666
Oil Pump...5666
Thermostat...5667
Engine Bolt Torque...5667
Crankshaft Re-Grind Data...5669
TORQUE SPECIFICATIONS...5670
Torque For General SAE Bolts...5670
Torque For General Metric Bolts...5671
HYDRAULIC CONNECTION SPECIFICATIONS...5672
O-ring Face Seal Connection...5672
Straight Thread O-ring Fitting...5672
Tubelines And Hoses...5672
Flare Fitting...5673
O-ring Flare Fitting...5674
Port Seal Fitting...5676
HYDRAULIC FLUID SPECIFICATIONS...5678
Specifications...5678
FUEL, COOLANT AND LUBRICANTS...5680
Chart...5680
CONVERSIONS...5682
Decimal And Millimeter Equivalents...5682
U.S. To Metric Conversion...5683
SMR...5684
Revision No: 320-1...5684
Revision No: 320-2...5686
Revision No: 320-3...5688
Bobcat Excavators 320, 320L, 322, X320, X322 Repair Service Manuals
