Bobcat Excavator (320 325 331 Series) Service and Owners Manual
320 325 331 series
SERVICE AND OWNERS MANUAL
BOBCAT EXCAVATOR (320 325 331 SERIES) - SERVICE AND OWNERS MANUAL - Service Manual And Owners Manual, to Bobcat Excavator (320 325 331 Series). CONTENTS: 320 6722640 OM 2-97 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - INSTRUMENT PANEL - AUDIBLE ALARM - KEY SWITCH - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (If Equipped) - HEATER - WINDSHIELD WASHER TANK (If Equipped) - CONTROL LEVERS (JOYSTICKS) - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (STANDARD) - Operation Of Right Control Lever (STANDARD) - SWING LOCK - HORN BUTTON - SPEED CONTROL LEVER - ENGINE STOP CONTROL - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - BOOM SWING PEDAL (AND LOCK/FOOT REST) - BLADE CONTROL LEVER - AUXILIARY HYDRAULIC PEDAL - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - OPERATING PROCEDURES - Breaking In A New Machine - General Operation Suggestions - Operating On Slopes - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - LIFTING A LOAD - BUCKET - Removal - Installation - CAB OPTION - Opening The Front Window - Closing The Front Window - Front Window - Emergency Exit - CAB/CANOPY - CAB/CANOPY FOPS (Falling Object ProtectiveStructure) - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Maintenance - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Diagnostic Couplers - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Filter Screen (Factory Installed) - In–Line FIlter (Service Replacement) - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Replacing Final Drive Case Oil - TRACK TENSION - Adjustment - JOYSTICK CONTROL CHANGE - ISO To Standard Control Pattern - Standard To ISO Control Pattern - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - TRACK - CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Ethlene Glycol - Propylene Glycol - BUCKET SPECIFICATIONS - ADDITIONAL PUBLICATIONS - WARRANTY 320 6722642 SM 4-94 - MAINTENANCE SAFETY - CONTENTS - FOREWORD - SAFETY INSTRUCTIONS - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - PREVENTIVE MAINTENANCE - SERVICE SCHEDULE - ENGINE COVER - Opening the Cover - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Maintenance - Fuel Filter - ENGINE LUBRICATION SYSTEM - Engine Oil and Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - HYDRAULIC SYSTEM - Checking and Add Fluid - Diagnostic Couplers - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Replacement of the Hydraulic Fluid - USING A BOOSTER BATTERY (JUMP STARTING) - Procedure - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Procedure - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - HYDRAULIC SYSTEM TROUBLESHOOTING - HYDRAULIC SERVICE INFORMATION - Checking the Main Relief Valves - Checking the Hydraulic Pump - HYDRAULIC PUMP - Disassembly - Assembly - HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511720001–511721411) - Removal And Installation - Parts Identification - Disassembly - Inlet Section (R.H. and L.H. Travel) - Disassembly - Assembly - Valve Sections (Boom, Bucket & Arm) - Disassembly - Assembly - Valve Sections (Auxiliary) - Disassembly - Assembly - Assembly - Port Relief Valve - Disassembly - Assembly - Adjustment - Main Relief Valve - Disassembly - Assembly - Adjustment - HYDRAULIC CONTROL VALVE (3–Spool) DUKESVALVE (S/N 511720001–511721411) - Removal And Installation - Parts Identification - Disassembly - Inlet Section (Housing Swing) - Disassembly - Assembly - End Cover (Boom Swing) and Valve Section (Blade) - Disassembly - Assembly - Load Check Block - Disassembly - Assembly - Build–Up Valve - Assembly - Main Relief Valve - Disassembly - Assembly - Adjustment - HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE(S/N 511721412 & Above) - Parts Identification - Disassembly - Inlet Section Disassembly And Assembly - Right Hand & Left Hand Travel Section - Disassembly - Assembly - Boom, Bucket & Arm Section - Disassembly - Assembly - Auxiliary Section - Disassembly - Assembly - PORT RELIEF VALVES HUSCO VALVE - Parts Identification - Port Relief Valve Pressure Setting - Disassembly - Assembly - Adjustment - MAIN RELIEF VALVES HUSCO VALVE - Parts Identification - Disassembly - Assembly - Adjusting The Main Relief Valves - HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511721412 & Above) - Parts Identification - Disassembly - Blade And Boom Swing Section - Disassembly - Assembly - Lockout Valve Assembly - Disassembly - Lockout Valve Assembly - Swing Motor Valve Section - Disassembly - Assembly - Build–Up Valve Disassembly - Build Up Valve Assembly - Build Up Valve Test Procedure - BOOM CYLINDER - Removal And Installation - Boom Shield - Boom Cylinder - ARM CYLINDER - Removal And Installation - BUCKET CYLINDER - Removal And Installation - BLADE CYLINDER - Removal And Installation - BOOM SWING CYLINDER - Removal And Installation - HYDRAULIC CYLINDER - Disassembly - Assembly - Disassembly - Assembly - HYDRAULIC FILTER ASSEMBLY - Removal And Installation - AUXILIARY COUPLERS - Removal And Installation - JOYSTICK MANIFOLD WITH ACCUMULATOR - Removal And Installation - Disassembly And Assembly - DRAIN BLOCK - Filter Screen - Removal And Installation - OIL COOLER - Removal And Installation - JOYSTICK CONTROL CHANGE - DRIVE SECTION - FLOORMAT AND FLOOR PANELS - Removal and Installation - LEFT CONTROL CONSOLE - Microswitch Adjustment Procedure - Lockout Microswitch Removal and Installation - Console Cover Removal and Installation - Joystick Removal and Installation - Removal and Installation - FUEL TANK - Removal and Installation - LOCK LEVER - Left Hand Removal and Installation - Adjustment Procedure - LATCH HOOK - Left Hand Removal and Installation - GAS SPRING - Left Hand Removal and Installation - UPPER CONSOLE - Left Hand Removal and Installation - RIGHT CONTROL CONSOLE - ROPS Canopy Models - Cab Models - Console Cover Removal and Installation - Joystick Removal and Installation - Control Console Removal and Installation - Hydraulic Tank Removal and Installation - TRAVEL LEVERS - Removal and Installation - RIGHT HAND PEDAL (Boom Swing) - Removal and Installation - LEFT HAND PEDAL (Auxiliary) - Removal and Installation - ROCKERSHAFT - Removal and Installation - LINKAGE RODS - Removal and Installation - BLADE LEVER - Removal and Installation - FINAL DRIVE - Removal and Installation - DRIVE MOTOR ASSEMBLY (Kayaba) (S/N 511720001 – 23974) - Parts Identification - Disassembly - Assembly - Checking Oil Level - Draining Final Drive Case - DRIVE MOTOR (SOM) (S/N 23975 & Above) - Parts Identification - Disassembly - Assembly - Checking Oil Level (S/N 23975 & Above) - JOYSTICK - Parts Identification - Disassembly and Assembly - UPPER WORKS AND SWING SECTION - SWING MOTOR - Testing the Cross Ports Reliefs - Start the Engine - Removing the Cross Port Reliefs - Removal and Installation - Disassembly - Assembly - Motor Timing - CROSS PORT RELIEF VALVE - Disassembly - Assembly - Description - UPPERSTRUCTURE - Removal - Installation - CENTER SWIVEL JOINT - Removal And Installation - Disassembly and Assembly - SWING CIRCLE GEAR - Removal And Installation - ROPS CANOPY - Removal And Installation - CAB - Removal And Installation - Door (Removal And Installation) - Front Window (Removal And Installation) - Front Lower Glass (Removal And Installation) - Front Upper Plexiglass (Removal And Installation) - Door Glass (Removal And Installation) - Left Hand Side Glass (Removal And Installation) - Rear Glass (Removal And Installation) - Right Hand Side Glass (Removal And Installation) - CAB/CANOPY REAR COVER - Removal - Installation - AIR BAFFLE (Cab Models Only) - Removal And Installation - BELLY PAN (Field Installed) - Removal And Installation - MAIN FRAME AND TRACKS - ENGINE COVER - Removal and Installation - REAR CORNER POSTS - Removal and Installation - SEAT AND SEAT MOUNT - Removal and Installation - SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING - Removal and Installation - BUCKET - Removal and Installation - Installation - ARM - Removal and Installation - BOOM - Removal and Installation - SWING POST - Removal And Installation - Bushing Replacement - Swing Post Bushing Removal - Bushing Installation - TRACK - Track Tension Adjustment - Removal and Installation - Damage Identification and Causes - TRACK FRAME - Disassembly and Assembly - TRACK IDLER - Parts Identification - Disassembly - Assembly - TRACK ROLLER - Parts Identification - Disassembly - Assembly - TRACK - Damage Identification and Causes - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATIC - TROUBLESHOOTING - ELECTRICAL SYSTEM - Description - Fuses - Electrical System Service - BATTERY - Checking the Battery - Removal and Installation - BATTERY BOX - Removal and Installation - CAB ELECTRICAL (Cab Option) - ALTERNATOR - Checking the Alternator Output - Belt Adjustment - Electrical Connection - Removal and Installation - Check the Alternator Output - Alternator Output Test - Alternator Regulator Test - Disassembly and Assembly - Stator Continuity Test - Stator Ground Test - Rotor Continuity Test - Rotor Ground Test - Rectifier Continuity (Diode) Test - Disassembly and Assembly (New Style) - STARTER - Removal and Installation - Disassembly and Assembly - Cleaning and Inspection - HORN - Removal and Installation - FUEL LEVEL SENDER - Removal and Installation - ENGINE SERVICE - TROUBLESHOOTING - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - FUEL FILTER - Element - Removing Air from the Fuel System - Removal and Installation - FUEL INJECTION PUMP - Checking the Injection Pump - Removal and Installation - Timing the Injection Pump - FUEL INJECTOR NOZZLES - Checking the Injector Nozzle - GLOW PLUGS - Removal and Installation - Checking the Glow Plug - ENGINE - Removal and Installation - SPARK ARRESTOR MUFFLER - RADIATOR - Checking the Radiator and Radiator Cap - Removal and Installation - Hydraulic Pump Coupler - CYLINDER HEAD - Removal of the Cylinder Head - Disassembly of the Cylinder Head - Servicing the Cylinder Head and Valves - Checking Valve Springs - Checking Rocker Arm and Shaft - Installing the Cylinder Head - TIMING GEAR COVER - Removal and Installation - TIMING GEAR, CAMSHAFT AND OIL PUMP - Removal and Installation - Oil Pump Service - Servicing the Camshaft - CRANKSHAFT AND PISTONS - Removal and Installation - Crankshaft Service - Servicing the Connecting Rods and Pistons - CYLINDER LINERS - Checking the Cylinder Liners - Cylinder Liner Installation - WATER PUMP - Removal and Installation - Disassembly and Assembly - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - SPECIFICATIONS - ENGINE SPECIFICATIONS - Engine - Fuel Injector Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Rocker Arms - Camshaft - Cylinders - Piston Rings - Pistons - Crankshaft - Oil Pump - Thermostat - Engine Torque - Crankshaft Re–Grind Data - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - BUCKET SPECIFICATIONS - SERVICE MANUAL REVISON - 320-1 - 320-2 - 320-3 - 320-4 320 6724026 OM 9-96 - CONTENTS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - INSTRUMENTS - OPERATOR’S HANDBOOK - STORAGE COMPARTMENT - AUDIBLE ALARM - KEY SWITCH - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (Cab Option) - HEATER - WINDSHIELD WASHER TANK (If equipped) - CONTROL LEVERS (JOYSTICKS) - Operation of Left Control Lever (ISO) - Operation of Right Control Lever (ISO) - CONTROL LEVERS (STANDARD) - Operation of Left Control Lever (STANDARD) - Operation of Right Control Lever (STANDARD) - SWING LOCK - HORN BUTTON - SPEED CONTROL LEVER - ENGINE STOP CONTROL - STEERING LEVERS/FOOT PEDALS - Forward and Reverse Travel - Turning - BOOM SWING PEDAL AND LOCK - BLADE CONTROL LEVER - AUXILIARY OPERATION PEDAL - Flush Face Couplers - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - OPERATING PROCEDURE - Breaking in a New Machine - General Operation Suggestions - Operating in Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE EXCAVATOR - LIFTING A LOAD - BUCKET - Removal - Installation - CAB/CANOPY - CAB/CANOPY FOPS (Falling Object Protective Structure) - Front Window - Emergency Exit - CAB OPTION - Opening the Front Window - Closing the Front Window - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - Daily Check - Filter Replacement - FUEL SYSTEM - Fuel Specification - Filling the Fuel Tank - Fuel System Maintenance - Fuel Filters - Removing Air from the Fuel System - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol - SPARK ARRESTOR MUFFLER - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Service the Electrical System - Using A Booster Battery (Jump Starting) - Removal and Installation of the Battery - HYDRAULIC SYSTEM - Checking and Adding Fluid - Diagnostic Couplers - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Replacement of the Hydraulic Fluid - Filter Screen - In–Line FIlter (S/N 511724187 & Above) - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level (S/N 511721116–511723974) - Replacing Final Drive Case Oil (S/N 511721116–511723974) - Checking Oil Level (S/N 511723975 & Above) - Replacing Final Drive Case Oil (S/N 511723975 &Above) - TRACK TENSION - Adjustment - JOYSTICK CONTROL CHANGE - ISO to Standard Control Pattern - Standard to ISO Control Pattern - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - WEIGHTS - CONTROLS - ENGINE - ELECTRICAL - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Propylene Glycol (Factory Installed) - BUCKET SPECIFICATIONS - WARRANTY 320 6724893 OM 3-99 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - INSTRUMENT PANEL - KEY SWITCH - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - Right Turn - Left Turn - AUXILIARY POWER OUTLET - CAB/CANOPY - CAB/ CANOPY FOGS (Falling Object Guards) - CAB OPTION - Emergency Exit - Cab Door - Front Window - CAB OPTION (Later Models) - Opening The Front Window - Closing The Front Window - CAB OPTION (Early Models) - Opening The Front Window - Closing The Front Window - ELECTRICAL - WINDSHIELD WASHER TANK (If Equipped) - HEATER CONTROL - LIGHT SWITCH (Cab/Canopy) - FUSES - AUDIBLE ALARM - HORN BUTTON - SEAT - SPEED CONTROL LEVER - OPERATOR'S HANDBOOK - STORAGE COMPARTMENT - ENGINE COVER - TOOL BOX - AUXILIARY HYDRAULIC PEDAL - Flush Face Couplers - BLADE CONTROL LEVER - SWING LOCK - BOOM SWING PEDAL - CONTROL LEVERS (JOYSTICKS) - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (Standard) - Operation Of Right Control Lever (Standard) - CONTROL LEVER (JOYSTICK) LOCK - TWO SPEED TRAVEL FOOT PEDAL - GETTING ON AND OFF THE MACHINE - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - BUCKET - Removal - Installation - OPERATING PROCEDURE - Operating On Public Roads - Lifting A Load - Excavating - Boom Offset - Back Filling - Driving The Excavator - Operating On Slopes - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - Adjustment Of The Engine Cover Latch - AIR CLEANER SERVICE - Daily Check - Filter Replacement - FUEL SYSTEM - Filling The Fuel Tank - Fuel Filter - Fuel System Maintenance - Removing Air From The Fuel System - Fuel Specification - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Replacement Of Oil And Filter - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Electrical Relays And Diodes - Fuses - Service The Electrical System And Battery - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - Electrical Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking And Adding Fluid - Diagnostic Couplers - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - Case Drain Hydraulic Filter - SPARK ARRESTOR MUFFLER (If So Equipped) - TRACK TENSION - Adjustment - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - JOYSTICK CONTROL CHANGE - ISO To Standard Control Pattern - Standard To ISO Control Pattern - LUBRICATION OF THE HYDRAULIC EXCAVATOR - HEATER AIR FILTER (With Cab Option Only) - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - WEIGHTS - CONTROLS - ENGINE - ELECTRICAL - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - Chart - ENGINE OIL SPECIFICATIONS - Description - Propylene Glycol (Factory Installed) - BUCKET SPECIFICATIONS - ADDITIONAL PUBLICATIONS & TRAINING MATERIALS - WARRANTY 320 6724910 SM 1-97 - MAINTENANCE SAFETY - ALPHABETICAL INDEX - CONTENTS - FOREWORD - SAFETY INSTRUCTIONS - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - Adjustment of the Engine Cover Latch - AIR CLEANER SERVICE - Daily Check - Filter Replacement - FUEL SYSTEM - Filling the Fuel Tank - Fuel Filter - Fuel System Maintenance - Removing Air From the Fuel System - Fuel Specification - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Replacement of Oil and Filter - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol (Factory Installed) - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Electrical Relays and Diodes - Fuses - Service the Electrical System (and Battery) - Removal and Installation of the Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking and Adding Fluid - Diagnostic Couplers - Hydraulic Reservoir - Replacement of the Hydraulic Filter - Case Drain Hydraulic Filter - TRACK TENSION - Adjustment - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - JOYSTICK CONTROL CHANGE - ISO to Standard Control Pattern - Standard to ISO Control Pattern - LUBRICATION OF THE HYDRAULIC EXCAVATOR - HEATER AIR FILTER (With Cab Option Only) - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - TROUBLESHOOTING - HYDRAULIC SERVICE INFORMATION - Checking the Main Relief Valves and Cross Port Relief Valve - Checking the Hydraulic Pump - HYDRAULIC PUMP - Removal and Installation - Coupler Removal and Installation - Hydraulic Pump Assembly - Disassembly - Assembly - HYDRAULIC CONTROL VALVE - Description - Removal and Installation - Disassembly - Outlet Section Disassembly - Outlet Section Assembly - Mid Inlet Section Disassembly - Mid Inlet Section Assembly - Left Travel, Right Travel, Auxiliary and Blade Disassembly - Left Travel, Right Travel, Auxiliary and Blade Assembly - Boom, Bucket Arm and Swing Disassembly - Boom, Bucket, Arm and Swing Assembly - Utility Block Disassembly - Utility Block Assembly - Boom Swing Disassembly - Boom Swing Assembly - Boost Disassembly - Boost Assembly - Assembly - PORT RELIEF VALVES - Parts Identification - Port Relief Valve Pressure Setting - Disassembly - Assembly - Adjustment Procedure - Disassembly - Assembly - Adjusting the Main Relief Valves - ACCUMULATOR - Pressure Reducing Valve (Description) - Removal and Installation - Disassembly (S/N 562313001 – 562320721 &517811001 – 517811977) - Assembly (S/N 562313001 – 562320721 & 517811001– 517811977) - Parts Identification (S/N 562320721 & Above & 517811978 & Above) - Disassembly (S/N 562320721 & Above & 517811978 & Above) - Assembly (S/N 562320721 & Above & 517811978 & Above) - Testing (All Models) - BOOM CYLINDER - Removal and Installation - ARM CYLINDER - Removal and Installation - BUCKET CYLINDER - Removal and Installation - BLADE CYLINDER - Removal and Installation - BOOM SWING CYLINDER - Removal and Installation - TRACK FRAME EXPANSION CYLINDER 322 (S/N 517811001 & Above) - HYDRAULIC CYLINDER - Disassembly - Assembly - Disassembly - Assembly - HYDRAULIC FILTER ASSEMBLY - Removal and Installation - AUXILIARY FLUSH FACE COUPLERS - Removal and Installation - DRAIN BLOCK - Removal and Installation - OIL COOLER - Removal and Installation - JOYSTICK CONTROL CHANGE - ISO To Standard - Standard to ISO - DRIVE SECTION - FLOORMAT AND FLOOR PANELS - Removal and Installation - MICROSWITCH - Adjustment - Removal and Installation - CONSOLE COVER LEFT HAND - Removal and Installation - JOYSTICK - Removal and Installation - CONTROL CONSOLE LEFT HAND - Removal and Installation - FUEL TANK - Removal and Installation - LOCK LEVER - Removal and Installation - Adjustment - LATCH HOOK - Removal and Installation - GAS SPRING - Removal and Installation - UPPER CONSOLE - Removal and Installation - CONTROL CONSOLE RIGHT HAND - Rops Canopy Models - Cab Models - CONSOLE COVER RIGHT HAND - Removal and Installation - CONTROL CONSOLE RIGHT HAND - Removal and Installation - HYDRAULIC RESERVOIR - Removal and Installation - TRAVEL LEVERS - Removal and Installation - Disassembly and Assembly - PEDAL RIGHT HAND - Removal and Installation - Disassembly and Assembly - PEDAL LEFT HAND - Removal and Installation - Disassembly and Assembly - ROCKERSHAFT - Removal and Installation - Disassembly and Assembly - LINKAGE RODS - Removal and Installation - BLADE LEVER - Removal and Installation - Disassembly and Assembly - DRIVE MOTOR - Removal and Installation - Parts Identification - Disassembly - Assembly - JOYSTICK - Parts Identification - Disassembly - Assembly - Troubleshooting - UPPER WORKS AND SWING SECTION - SWING MOTOR - Removal and Installation - Disassembly - Assembly - Motor Timing - CENTER SWIVEL JOINT (S/N 562313001 – 562319999) - Removal and Installation - Disassembly and Assembly - CENTER SWIVEL JOINT 320 (S/N 562320000 &Above) and 322 (S/N 517811001 & Above) - Removal And Installation - Parts Identification - Disassembly - Assembly - UPPERSTRUCTURE - Removal - Installation - SWING CIRCLE GEAR - Removal and Installation - ROPS CANOPY - Removal and Installation - CAB - Removal and Installation - Door (Removal and Installation) - Front Window Removal and Installation - Front Lower Window Removal and Installation - Front Upper Window Removal and Installation - Door Glass (Removal and Installation) - Left Hand Side Glass (Removal and Installation) - Right Hand Side Window Removal and Installation - Right Hand Window Assembly Removal and Installation - Rear Window Removal and Installation - CAB/CANOPY REAR COVER - Removal - Installation - AIR BAFFLE (Cab Models Only) - Removal and Installation - BELLY PAN (Field Installed) - Removal and Installation - MAIN FRAME AND TRACKS - ENGINE COVER - Removal and Installation - CORNER POSTS - Removal and Installation - COUNTERWEIGHT - Removal and Installation - SEAT AND SEAT MOUNT - Removal and Installation - SPEED CONTROL LEVER/SWING LOCK LEVER AND MOUNTING - Removal and Installation - BUCKET - Removal and Installation - Installation - ARM - Removal and Installation - ARM BUSHINGS - Arm To Boom Bushing Removal And Installation - Arm To Bucket and Bucket Link Bushing Removal and Installation - BOOM - Removal and Installation - BOOM BUSHING - Removal And Installation - SWING POST - Removal and Installation - Bushing Replacement - Swing Post Bushing Removal - Bushing Installation - TRACK - Adjustment 320 (S/N 562313001 – 562319999) - Adjustment 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) - Removal and Installation - Track Damage Identification and Causes - TRACK FRAME - Disassembly and Assembly 320 (S/N 562313001 – 562319999) - Disassembly and Assembly 320 (S/N 562320000 & Above) and 322 (S/N 517811001 & Above) - Recoil Spring Cylinder Disassembly And Assembly - Removal and Installation of Expandible Track Frame (322 only) - TRACK DAMAGE IDENTIFICATION - Cutting of the Steel Cords - Abrasion of Embedded Metals - Separation of Embedded Metals Due to External Forces - Separation of Embedded Metals Due To Corrosion - Cuts On The Lug Side - Cracks On The Lug Side Rubber Due To Fatigue - Lug Abrasion - Cracks and Cuts on the Lug Side Rubber at the Edges of the Embedded Metals - Abrasion Of The Track Roller Side Rubber Surface - Cuts On The Edges Of The Track Roller Side - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATICS - TROUBLESHOOTING - Chart - ELECTRICAL SYSTEM - Description - Fuses - Electrical System Service - Electrical Relays and Diodes - BATTERY - Using A Booster Battery (Jump Starting) - Removal and Installation - BATTERY BOX - Removal and Installation - CAB ELECTRICAL (Cab Option) - Removal and Installation - ALTERNATOR - Checking the Alternator Output - Removal and Installation - Belt Adjustment - STARTER - Removal and Installation - Disassembly and Assembly - Cleaning and Inspection - HORN - Removal and Installation - FUEL LEVEL SENDER - Removal and Installation - LIGHT SWITCH - Removal and Installation - TWO SPEED SWITCH - Removal and Installation - ENGINE SERVICE - TROUBLESHOOTING - Chart - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - FUEL SHUTOFF SOLENOID - Removal and Installation - Timer Module Removal and Installation - FUEL INJECTION PUMP - Checking the Injection Pump - Timing the Injection Pump - FUEL INJECTOR NOZZLES - Removal and Installation - Checking the Injector Nozzle - GLOW PLUGS - Removal and Installation - Checking the Glow Plug - BELT GUARD - Removal and Installation - RADIATOR - Removal and Installation - SPARK ARRESTOR MUFFLER (If Equipped) - Cleaning Spark Chamber - Removal and Installation - AIR CLEANER - Removal and Installation - ENGINE - Removal and Installation - ENGINE FLYWHEEL (EARLY MODELS) - Removal and Installation - Hydraulic Pump Coupler - ENGINE FLYWHEEL (LATER MODELS) - Removal And Installation - Hydraulic Pump Coupler - Flywheel Ring Gear - CYLINDER HEAD - Removal and Installation - Disassembly and Assembly - Servicing the Cylinder Head - Top Clearance - VALVE, VALVE SEAT AND GUIDE - Checking the Valve Guide - Reconditioning the Valve and Valve Seat - Valve Spring - ROCKER ARM AND SHAFT - Checking - TIMING GEARCASE COVER - Removal and Installation - IDLER GEAR AND CAMSHAFT - Removal and Installation - Servicing the Idler Gear and Shaft - TIMING GEARS - Checking Backlash - FUEL CAMSHAFT - Removal and Installation - CRANKSHAFT GEAR - Removal and Installation - OIL PUMP - Removal and Installation - Oil Pump Service - Checking Engine Oil Pressure - Relief Valve - PISTON AND CONNECTING ROD - Removal and Installation - Servicing the Piston and Connecting Rod - Connecting Rod Alignment - CRANKSHAFT AND BEARINGS - Removal and Installation - Servicing the Crankshaft and Bearings - CYLINDER BORE - Checking the Cylinder Bore - WATER PUMP - Removal and Installation - Disassembly and Assembly - TECHNICAL DATA - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - SPECIFICATIONS - ENGINE SPECIFICATIONS - Engine - Fuel Injector Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Rocker Arms - Camshaft - Cylinders - Piston Rings - Pistons - Crankshaft - Oil Pump - Thermostat - ENGINE BOLT TORQUE - Re–Grinding The Crankshaft - HYDRAULIC FLUID SPECIFICATIONS - Specifications - FUEL, COOLANT AND LUBRICANTS - Chart - SERVICE MANUAL REVISION - 320-1 - 320-2 - 320/322-3 - 320/322-4 - 320/322-5 325 6722714 OM 9-97 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL CONSOLE LEVER LOCK - INSTRUMENT PANEL - FUSES - AUDIBLE ALARM - KEY SWITCH - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (Cab Option) - HEATER CONTROL - WASHER - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (STANDARD) - Operation Of Right Control Lever (STANDARD) - SWING LOCKING LEVER - HORN BUTTON - SPEED CONTROL LEVER - ENGINE STOP CONTROL - STEERING LEVERS/FOOT PEDALS - Forward and Reverse Travel - Turning - Making A Counter–Rotation Turn - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL LOCK/FOOTREST - BLADE CONTROL LEVER - DAILY INSPECTION - STARTING/STOPPING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Condition - OPERATING PROCEDURE - Breaking In A New Machine - Operating On Slopes - Operating in Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE EXCAVATOR - LIFTING A LOAD - BUCKET - Removal - Installation - OPERATOR’S HANDBOOK (If Equipped) - STORAGE COMPARTMENT (If Equipped) - CAB OPTION - Opening the Front Window - Closing the Front Window - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel Specifications - Fuel System Service - Fuel Filter - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - Ethylene Glycol - Propylene Glycol - ALTERNATOR/FAN BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal and Installation of the Battery (S/N 511820001–511820294) - Removal and Installation of the Battery (S/N 511820295 & Above) - HYDRAULIC SYSTEM - Checking and Adding Fluid - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Case Drain Line Filter - Diagnostic Couplers - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - JOYSTICK CONTROL CHANGE - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATION & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - CYLINDER CYCLE TIMES - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - BRAKES - TRACKS - CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Ethylene Glycol - Propylene Glycol - BUCKET SPECIFICATIONS - ADDITIONAL PUBLICATIONS - WARRANTY 325 6722849 SM 4-94 - MAINTENANCE SAFETY - ALPHABETICAL INDEX - FOREWORD - CONTENTS - SAFETY INSTRUCTIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - PREVENTIVE MAINTENANCE - SERVICE SCHEDULE - ENGINE COVER - Procedure - AIR CLEANER SERVICE - Replacing The Filter Element - FUEL SYSTEM - Fuel Specification - Fuel System Service - Fuel Filter - Maintenance - Removal And Installation - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Checking The Engine Oil - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - HYDRAULIC SYSTEM - Checking And Adding Fluid - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - USING A BOOSTER BATTERY (Jump Starting) - Procedure - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Procedure - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - HYDRAULIC SECTION - HYDRAULIC SCHEMATIC - HYDRAULIC SERVICE INFORMATION - Checking The Main Relief Valve - Checking The Hydraulic Pump - Removal And Installation - Parts Identification (S/N 51182001 – 511820408) - Disassembly And Assembly (S/N 511820001–511820408) - Parts Identification (S/N 511820409 & Above) - Disassembly (S/N 511820409 & Above) - Assembly (S/N 511820409 & Above) - HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511820001–511820519) - Removal And Installation - Parts Identification - Disassembly - Inlet Section (R.H. and L.H. Travel) - Disassembly - Assembly - Valve Sections (Boom, Bucket & Arm) - Disassembly - Assembly - Valve Sections (Auxiliary) - Disassembly - Assembly - Port Relief Valve - Disassembly - Assembly - Adjustment - Main Relief Valve - Disassembly - Assembly - Adjustment - HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511820001–511820519) - Removal And Installation - Parts Identification - Disassembly - Inlet Section (Housing Swing) - Disassembly - Assembly - End Cover (Boom Swing) And Valve Section (Blade) - Disassembly - Assembly - Load Check Block - Disassembly - Assembly - Build–up Valve - Disassembly - Assembly - Disassembly - Assembly - Adjustment - HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE (S/N 511820520 & Above) - Description - Removal And Installation - Parts Identification - Disassembly - Inlet Section Disassembly And Assembly - Right Hand And Left Hand Travel Section - Disassembly - Assembly - Boom, Bucket And Arm Section - Disassembly - Assembly - Auxiliary Valve Section - Disassembly - Assembly - PORT RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above) - Parts Identification - Disassembly - Assembly - Adjustment - MAIN RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above) - Parts Identification - Disassembly - Assembly - Adjusting The Main Relief Valves - HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511820520 & Above) - Removal And Installation - Parts Identification - Disassembly - Blade And Boom Swing Section - Disassembly - Assembly - Lockout Valve Disassembly - Lockout Valve Assembly - Swing Motor Section - Disassembly - Assembly - Build Up Valve Disassembly - Build Up Valve Assembly - Build Up Valve Test Procedure - ACCUMULATOR - Pressure Reducing Valve - Removal And Installation - Parts Identification - Disassembly - Assembly - Setting The Safety Relief Valve - Charging - PORT BLOCK - Removal And Installation - OIL COOLER - Removal And Installation - HYDRAULIC RESERVOIR - Removal And Installation - HYDRAULIC FILTER ASSEMBLY - Removal And Installation - BOOM CYLINDER - Removal And Installation - Boom Cylinder Shield - ARM CYLINDER - Removal And Installation - BUCKET CYLINDER - Removal And Installation - BLADE CYLINDER - Removal And Installation - BOOM SWING CYLINDER - Removal And Installation - HYDRAULIC CYLINDER - Disassembly - Assembly - JOYSTICK CONTROL CHANGE - DRIVE SECTION - LEFT CONSOLE - Lockout Valve Removal And Installation - Cylinder Removal And Installation - Removal And Installation - LEFT JOYSTICK - Removal And Installation - JOYSTICK - Disassembly And Assembly - CONTROL LEVERS - Removal And Installation - Speed Control Lever - Blade Lever - RIGHT CONSOLE - Removal And Installation - RIGHT JOYSTICK - Removal And Installation - FOOT PEDALS AND STEERING LEVERS - Removal And Installation - Bushing Removal And Installation - UPPER WORKS AND SWING SECTION - ENGINE COVER - Removal And Installation - SEAT AND MOUNTING FRAME - Removal And Installation - CENTER FLOOR PANEL - Removal And Installation - SWING MOTOR COVER - Removal And Installation - REAR FLOOR PANEL - Removal And Installation - INSPECTION COVER - Removal And Installation - TOOL BOX - Removal And Installation - LEFT HAND SIDE COVER - Removal And Installation - CORNER POST - Removal And Installation - COUNTERWEIGHTS - Removal And Installation - FRONT ENGINE COVER - Removal And Installation - FUEL TANK - Removal And Installation - BUCKET - Removal And Installation - BUCKET TEETH - Removal And Installation - ARM - Removal And Installation - BOOM - Removal And Installation - BOOM SWING BRACKET - Removal And Installation - Replacing Boom Swing Bracket Bushings - SWING MOTOR - Removal And Installation - Parts Identification - Disassembly - Assembly - CROSS PORT RELIEF VALVE (S/N 511820001–511820519) - Disassembly - Assembly - Description - COUNTER BALANCE VALVE (S/N 511820520 &Above) - Removal And Installation - Disassembly - Assembly - SWING GEAR BOX ASSEMBLY - Parts Identification - Disassembly - Assembly - UPPERSTRUCTURE AND SWING CIRCLE GEAR - Removal And Installation - Swing Bearing Removal - Swing Bearing Installation - Alignment Pins (Threaded) - Alignment Pins (Not Threaded) - CENTER SWIVEL JOINT - Removal And Installation (Through Upper Access Cover) - Removal And Installation (Through Bottom Access Cover) - Parts Identification (S/N 511820001–511820197) - Parts Identification (S/N 511820198 & Above) - Description - Disassembly (S/N 511820198 & Above) - Assembly (S/N 511820198 & Above) - ROPS CANOPY - Removal And Installation - CAB - Removal And Installation - Door Removal And Installation - Front Window Removal And Installation - Front Lower Glass Removal And Installation - Front Upper Plexiglass Removal And Installation - Door Glass Removal And Installation - Left Hand Side Glass Removal And Installation - Rear Glass Removal And Installation - Right Hand Side Glass Removal And Installation - CAB/CANOPY REAR COVER - Removal And Installation - MAIN FRAME AND TRACKS - BLADE - Removal And Installation - TRACK - Track Tension Adjustment - Rubber Tracks - Steel Tracks - Removal And Installation - TRACK FRAME - Disassembly And Assembly - TRACK IDLER - Parts Identification - Disassembly - Assembly - TRACK ROLLER - Parts Identification - Disassembly - Assembly - FINAL DRIVE - Removal And Installation - Parts Identification - FINAL DRIVE - Parts Identification - TRAVEL MOTOR - Disassembly - Assembly - FINAL DRIVE CASE - Check Oil Level - Draining Final Drive Case - TRACK - Damage Identification And Causes - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATICS - TROUBLESHOOTING - ELECTRICAL SYSTEM - Description - Fuses - Electrical System Service - BATTERY (S/N 20001–20294) - Checking The Battery - Removal And Installation - BATTERY(S/N 20295 and up) - Checking The Battery - Removal And Installation - ALTERNATOR - Belt Adjustment - Removal And Installation - STARTER - Removal And Installation - Disassembly And Assembly - Cleaning And Inspection - FUEL LEVEL SENDER - Removal And Installation - Checking - INSTRUMENT PANEL - Removal And Installation - CAB ELECTRICAL (Cab Option) - ENGINE SERVICE - TROUBLESHOOTING - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - ELECTRIC FUEL PUMP - Remove Air From The Fuel System - Removal And Installation - FUEL FILTER - Removal And Installation - FUEL INJECTION PUMP - Checking The Injection Pump - Removal And Installation - Timing The Injection Pump - FUEL INJECTOR NOZZLES - Removal And Installation - Checking The Injector Nozzle - GLOW PLUGS - Removal And Installation - Checking The Glow Plug - RADIATOR - Removal And Installation - MUFFLER - Removal And Installation - AIR CLEANER - Removal And Installation - ENGINE - Removal And Installation - ENGINE FLYWHEEL - Removal And Installation - Flywheel Ring Gear - CYLINDER HEAD - Removal - Disassembly Of The Cylinder Head - Servicing The Cylinder Head And Valves - Checking Valve Springs - Checking Rocker Arm And Shaft - Assembling The Cylinder Head - Installing The Cylinder Head - TIMING GEAR COVER - Removal And Installation - TIMING GEAR, CAMSHAFT AND OIL PUMP - Removal And Installation - Oil Pump Service - Servicing The Camshaft - CRANKSHAFT & PISTONS - Removal And Installation - Crankshaft Service - Servicing The Connecting Rods And Pistons - Checking The Cylinder Liners - Cylinder Liner Installation - WATER PUMP - Removal And Installation - Disassembly And Assembly - SPECIFICATIONS - EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - PERFORMANCE & OPERATION - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - CYLINDER CYCLE TIMES - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - TRACK - CAPACITIES - DIGGING FORCE - ENGINE SPECIFICATIONS - Fuel Injection Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Rocker Arms - Camshaft - Cylinders - Piston Rings - Pistons - Crankshaft - Oil Pump - Engine Oil - Specifications - ENGINE BOLT TORQUE - FUEL, COOLANT AND LUBRICANTS - CHART - ENGINE OIL SPECIFICATIONS - Description - Ethylene Glycol - Propylene Glycol - Re–Grinding The Crankshaft - BUCKET SPECIFICATIONS - DECIMAL AND MILLIMETER EQUIVALENTS - U.S. TO METRIC CONVERSION - SERVICE MANUAL REVISION - 325-1 - 325-2 - 325-3 325 6724322 OM 6-95 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL CONSOLE LEVER LOCK - INSTRUMENT PANEL - FUSES - OPERATOR'S HANDBOOK - STORAGE COMPARTMENT - AUDIBLE ALARM - KEY SWITCH - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (Cab Option) - HEATER CONTROL - WASHER - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (STANDARD) - Operation Of Right Control Lever (STANDARD) - SWING LOCKING LEVER - HORN BUTTON - SPEED CONTROL LEVER - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL - BLADE CONTROL LEVER - DAILY INSPECTION - STARTING/STOPPING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Condition - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - LIFTING THE EXCAVATOR - LIFTING A LOAD - TRANSPORTING THE HYDRAULIC EXCAVATOR - BUCKET - Removal - Installation - CAB OPTION - Opening The Front Window - Closing The Front Window - CAB/CANOPY FOPS (Falling Object Protective Structure) - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel Specifications - Filling The Fuel Tank - Fuel System Maintenance - Fuel Filter - Removing Air Fron The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol (Factory Installed) - ALTERNATOR/FAN BELT ADJUSTMENT - ELECTRICAL RELAYS AND DIODES - ELECTRICAL SYSTEM - Fuses - Service The Electrical System (And Battery) - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking And Adding Fluid - Return Line Filter Service - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - Diagnostic Couplers - SPARK ARRESTOR MUFFLER - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - JOYSTICK CONTROL CHANGE - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATION & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - CYLINDER CYCLE TIMES - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - BRAKES - TRACKS - CAPACITIES - DIGGING FORCE - VIBRATION DATA - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Propylene Glycol (Factory Installed) - BUCKET SPECIFICATIONS - WARRANTY 325 6724480 SM 11-95 - MAINTENANCE SAFETY - ALPHABETICAL INDEX - CONTENTS - FOREWORD - SAFETY INSTRUCTIONS - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - PREVENTIVE MAINTENANCE - SERVICE SCHEDULE - LIFTING AND BLOCKING THE EXCAVATOR - Procedure - TRANSPORTING THE HYDRAULIC EXCAVATOR - Procedure - ENGINE COVER - Procedure - AIR CLEANER SERVICE - Replacing the Filter Element - FUEL SYSTEM - Fuel Specifications - Filling the Fuel Tank - Fuel System Maintenance - Fuel Filter - Removing Air From the Fuel System - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Engine Oil and Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol (Factory Installed) - HYDRAULIC SYSTEM - Checking and Adding Fluid - Return Line Filter Service - Replacement of the Hydraulic Filter - Hydraulic Reservoir - USING A BOOSTER BATTERY (Jump Starting) - Procedure - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level (S/N 12999 & Below) - Draining Final Drive Case (S/N 12999 & Below) - Checking Oil Level (S/N 13001 & Above) - Draining Final Drive Case (S/N 13001 & Above) - HEATER AIR FILTER SERVICE - SPARK ARRESTOR MUFFLER - Cleaning Spark Arrestor Muffler - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - HYDRAULIC SYSTEM TROUBLESHOOTING - HYDRAULIC SERVICE INFORMATION - Checking the Main Relief Valves (S/N 11001–12999) - Checking the Main Relief Valves (S/N 13001 & Above) - Testing the 4050 PSI (27925 kPa) Circuit Relief Valve - Testing the Auxiliary and Bucket Circuit Relief Valve - Testing the Left Hand Travel Circuit Relief Valve - Testing the Right Hand Travel Circuit Relief Valve - Testing the Boom Circuit Relief Valve - Checking the Hydraulic Pump - HYDRAULIC PUMP - Removal and Installation - Parts Identification - Disassembly - Assembly - HYDRAULIC CONTROL VALVE (6 Spool) HUSCO VALVE (S/N 11001–12999) - Removal and Installation - Parts Identification - Disassembly - Inlet Section - Right Hand & Left Hand Travel - Disassembly - Assembly - Boom, Bucket & Arm - Disassembly - Assembly - Port Relief Valves (Adjustable) - Auxiliary - Disassembly - Assembly - Port Relief Valves (Adjustable) - Parts Identification - Port Relief Valve Pressure Setting - Disassembly - Assembly - Adjustment Procedure - Main Relief Valves - Parts Identification - Disassembly - Assembly - Adjusting the Main Relief Valves - HYDRAULIC CONTROL VALVE (3 Spool) HUSCO VALVE (S/N 11001 –12999) - Description - Removal and Installation - Parts Identification - Disassembly - Blade and Boom Swing - Disassembly - Assembly - Lockout Valve Assembly - Disassembly - Assembly - Swing Motor Valve - Disassembly - Assembly - Build–Up Valve - Disassembly - Assembly - Test Procedure - HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above) - Left Travel, Right Travel, Boom, Bucket and Auxiliary - Description - Removal and Installation - Parts Identification - Disassembly - Outlet Sections Disassembly - Outlet Sections Assembly - Mid Inlet Section Disassembly - Mid Inlet Section Assembly - Left Travel, Right Travel and Auxiliary Disassembly - Left Travel, Right Travel and Auxiliary Assembly - Boom and Bucket Disassembly - Boom and Bucket Assembly - Assembly - PORT RELIEF VALVES AND MAIN RELIEF VALVES (S/N 13001 & Above) - Parts Identification - Port Relief Valve Pressure Setting - Disassembly - Assembly - MAIN RELIEF VALVES (Adjustable) (S/N 13001 & Above) - Parts Identification - Assembly - Disassembly - Assembly - Adjusting the Main Relief Valves - HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above) - Boost, Arm, Boom Swing, Blade and Swing Section - Description - Removal and Installation - Parts Identification - Disassembly - Inlet Section - Arm, Boost and Swing Motor Disassembly - Arm, Boost and Swing Motor Assembly - Boom Swing Disassembly - Boom Swing Assembly - Blade Disassembly - Blade Assembly - Assembly - ACCUMULATOR (S/N 11001 – 12999) - Pressure Reducing Valve - Description - Test Procedure - Removal and Installation - Parts Identification - Disassembly - Assembly - Charging - Setting the Safety Relief Valve - ACCUMULATOR (S/N 13001 & Above) - Removal and Installation - Parts Identification - PORT BLOCK - Removal and Installation (S/N 11001–12999) - Removal and Installation (S/N 13001 & Above) - AUXILIARY SELECTOR VALVE - Removal and Installation (S/N 11001–12999) - Removal and Installation (S/N 13001 & Above) - Disassembly and Assembly - TWO SPEED VALVE (S/N 13001 & Above) - Removal and Installation - OIL COOLER - Removal and Installation - HYDRAULIC RESERVOIR - Removal and Installation - HYDRAULIC FILTER ASSEMBLY - Removal and Installation - RETURN LINE FILTER - Removal and Installation - BOOM CYLINDER - Removal and Installation - BOOM CYLINDER SHIELD - Removal and Installation - ARM CYLINDER - Removal and Installation - BUCKET CYLINDER - Removal and Installation - BLADE CYLINDER - Removal and Installation - BOOM SWING CYLINDER - Removal and Installation - HYDRAULIC CYLINDERS - Disassembly - Assembly - JOYSTICK CONTROL CHANGE - ISO to STANDARD Control Pattern (S/N 12999 & Below) - STANDARD to ISO Control Pattern (S/N 12999 & Below) - ISO to STANDARD Control Pattern (S/N 13001 & Above) - STANDARD to ISO Control Pattern (S/N 13001 & Above) - DRIVE SECTION - LEFT CONSOLE (S/N 11001 – 12999) - Lockout Valve Removal and Installation - Cylinder Removal and Installation - Removal and Installation - LEFT CONSOLE (S/N 13001 & Above) - Control Lock Micro–Switch - Removal and Installation - Cylinder Removal and Installation - Removal and Installation - Release Handle - Removal and Installation - Disassembly and Assembly - Adjustment - Latch Plate - Adjustment - JOYSTICK (S/N 11001 –12999) - Left Joystick - Removal and Installation - Parts Identification - Right Joystick - Removal and Installation - Troubleshooting - Parts Identification - Disassembly and Assembly - JOYSTICK (S/N 13001 & Above ) - Removal and Installation - Parts Identification - Disassembly - Assembly - Troubleshooting - CONTROL LEVERS - Removal and Installation - Low Idle Adjustment - High Idle Adjustment - Speed Control Lever - Blade Lever - RIGHT CONSOLE - Removal and Installation (S/N 11001 –12999) - Removal and Installation (S/N 13001 & Above) - FOOT PEDALS AND STEERING LEVERS - Removal and Installation - Bushing Removal and Installation - UPPER WORKS AND SWING SECTION - REAR ENGINE COVER - Removal and Installation - SEAT AND MOUNTING FRAME - Removal and Installation - CENTER FLOOR PANEL - Removal and Installation - S/N 12999 & Below - S/N 13001 & Above - SWING MOTOR COVER - Removal and Installation - REAR FLOOR PANEL - Removal and Installation - TOOL BOX - Removal and Installation - LEFT SIDE COVER - Removal and Installation - CORNER POST - Removal and Installation - COUNTERWEIGHTS - Removal and Installation - FRONT ENGINE COVER - Removal and Installation - FUEL TANK - Removal and Installation - BUCKET - Removal and Installation - ARM - Removal and Installation - BOOM - Removal and Installation - BOOM SWING BRACKET - Removal - Installation - Hose Installation - SWING BRACKET BUSHING - Bushing Removal - Bushing Installation - SWING MOTOR - Removal and Installation - Parts Identification - Disassembly - Assembly - CROSS PORT RELIEF VALVE - Disassembly - Assembly - Description - Testing - SWING MOTOR DRIVE CARRIER - Removal and Installation - Parts Identification - Disassembly - Assembly - UPPERSTRUCTURE AND SWING CIRCLE GEAR - Removal and Installation - Swing Bearing Removal - Swing Bearing Installation - Alignment Pins (Threaded) - Alignment Pins (Not Threaded) - CENTER SWIVEL JOINT - Removal and Installation (Through Upper AccessCover) - Removal and Installation (Through Bottom Access Cover) (S/N 11001–12999) - Removal and Installation (Through Bottom Access Cover) (S/N 13001 & Above) - Parts Identification - Description - Disassembly - Assembly - ROPS CANOPY - Removal and Installation - CAB - Removal and Installation - Two Piece Side Window - Three Piece Side Windows - Door Removal and Installation - Front Window Removal and Installation - Front Lower Glass Removal and Installation - Front Upper Plexiglass Removal and Installation - Left Hand Side Glass Removal and Installation - Door Glass Removal and Installation - Rear Glass Removal and Installation - Right Hand Side Glass Removal and Installation - Two Piece Side Window - Three Piece Side Window - CAB/CANOPY REAR COVER - Removal - Installation - MAIN FRAME AND TRACKS - BLADE - Removal and Installation - TRACK - Track Lug Height - Track Tension - Rubber Tracks - Steel Tracks - Adjustment (S/N 11001–12999) - Adjustment (S/N 13001 & Above) - Removal and Installation - TRACK FRAME - Disassembly and Assembly (S/N 11001–12999) - Disassembly and Assembly (S/N 13001 & Above) - TRAVEL MOTOR - Testing - Removal and Installation (S/N 11001–12999) - Removal and Installation (S/N 13001 & Above) - Parts Identification (S/N 11001–12999) - Disassembly (S/N 11001–12999) - Assembly (S/N 11001–12999) - Check Oil Level (S/N 11001–12999) - Draining Final Drive Case (S/N 11001–12999) - TRAVEL MOTOR (SOM) - Checking Oil Level (S/N 13001 & Above) - Draining Final Drive Case (S/N 13001 & Above) - Parts Identification (S/N 13001 & Above) - Disassembly (S/N 13001 & Above) - Assembly (S/N 13001 & Above) - TRACK DAMAGE IDENTIFICATION - Cutting of Steel Cords - Abrasion of Embedded Metals - Separation of Embedded Metals - Separation of Embedded Metals Due To Corrosion - Cuts On The Lug Side Rubber - Cracks Of The Lug Side Rubber Due To Fatigue - Lug Abrasion - Cracks And Cuts On The Lug Side Rubber - Abrasion Of The Track Roller Side - Cuts On The Edges Of Track Roller Side - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATICS - TROUBLESHOOTING - Chart - ELECTRICAL SYSTEM - Description - Fuses - Electrical System Service - BATTERY - Checking the Battery - Removal and Installation - ALTERNATOR - Belt Adjustment - Removal and Installation - Disassembly and Inspection - Stator Continuity Test - Stator Ground Test - Rotor Continuity Test - Rotor Ground Test - Rectifier Continuity (Diode) Test - Assembly - STARTER - Removal and Installation - Parts Identification - Disassembly and Assembly - Cleaning and Inspection - FUEL LEVEL SENDER - Removal and Installation - Checking - INSTRUMENT PANEL - Removal and Installation - GAUGES - Removal and Installation - GAUGE LIGHTS - Removal and Installation - CAB ELECTRICAL (Cab Option) - ENGINE SYSTEM - TROUBLESHOOTING - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - FUEL SHUTOFF SOLENOID - Adjustment - Removal and Installation - Timer Module Removal and Installation - FUEL INJECTION PUMP - Checking the Injection Pump - Removal and Installation - Timing the Injection Pump - FUEL INJECTOR NOZZLES - Removal and Installation - Checking the Injector Nozzle - GLOW PLUGS - Removal and Installation - Checking the Glow Plug - FAN GUARD - Removal and Installation - RADIATOR - Removal and Installation - MUFFLER - Removal and Installation - AIR CLEANER - Removal and Installation - ENGINE - Removal and Installation - ENGINE FLYWHEEL - Removal and Installation - FLYWHEEL RING GEAR - CYLINDER HEAD - Removal and Installation - Disassembly and Assembly of the Cylinder Head - Servicing the Cylinder Head - Top Clearance - VALVE, VALVE SEAT AND GUIDE - Checking the Valve Guide - Reconditioning the Valve and Valve Seat - Valve Spring - ROCKER ARM AND SHAFT - Checking - TIMING GEARCASE COVER - Removal and Installation - IDLER GEAR AND CAMSHAFT - Removal and Installation - Servicing the Idler Gear and Shaft - TIMING GEARS - Checking Backlash - FUEL CAMSHAFT - Removal and Installation - Governor - CRANKSHAFT GEAR - Removal and Installation - OIL PUMP - Removal and Installation - Oil Pump Service - Checking Engine Oil Pressure - Relief Valve - PISTON AND CONNECTING ROD - Removal and Installation - Servicing the Piston and Connecting Rod - Connecting Rod Alignment - CRANKSHAFT AND BEARINGS - Removal and Installation - Servicing the Crankshaft and Bearings - CYLINDER BORE - Checking the Cylinder Bore - WATER PUMP - Disassembly and Assembly - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - CAPACITIES - DIGGING FORCE - ENGINE SPECIFICATIONS - Fuel Injection Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Valve Timing - Rocker Arms - Camshaft - Tappet - Cylinders - Piston Rings - Pistons - Connecting Rod - Oil Pump - Crankshaft - Timing Gear - Thermostat - Engine Bolt Torque - Re–Grinding The Crankshaft - FUEL, COOLANT AND LUBRICANTS CHART - ENGINE OIL SPECIFICATIONS - Description - Ethylene Glycol - Propylene Glycol - BUCKET SPECIFICATIONS - DECIMAL AND MILLIMETER EQUIVALENTS - U.S. TO METRIC CONVERSION - SERVICE MANUAL REVISION - 325-1 - 325-2 - 325-3 - 325-4 - 325-5 325 6724546 OM 5-97 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - INSTRUMENT PANEL - KEY SWITCH - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - Right Turn - Left Turn - AUXILIARY POWER OUTLET - CAB/CANOPY - CAB/CANOPY FOPS (Falling Object Protective Structure) - Front Window - Emergency Exit - CAB OPTION - Opening The Front Window - Closing The Front Window - ELECTRICAL - WINDSHIELD WASHER TANK (If Equipped) - HEATER CONTROL - LIGHT SWITCH (Cab/Canopy) - FUSES - AUDIBLE ALARM - HORN BUTTON - SEAT - SPEED CONTROL LEVER - OPERATOR'S HANDBOOK - STORAGE COMPARTMENT - ENGINE COVER - AUXILIARY OPERATION PEDAL - Flush Face Couplers - BLADE CONTROL LEVER - SWING LOCK - BOOM SWING PEDAL - CONTROL LEVERS (JOYSTICKS) - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (Standard) - Operation Of Right Control Lever (Standard) - CONTROL LEVER (JOYSTICK) LOCK - TWO SPEED FOOT PEDAL - GETTING ON AND OFF THE MACHINE - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - BUCKET - Removal - Installation - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestons - Operating On Slopes - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - LIFTING A LOAD - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - Adjustment Of The Engine Cover Latch - AIR CLEANER SERVICE - FUEL SYSTEM - Filling The Fuel Tank - Fuel Filter - Fuel System Maintenance - Removing Air From The Fuel System - Fuel Specification - ENGINE LUBRICATON SYSTEM - Checking Engine Oil - Replacement Of Oil And Filter - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol (Factory Installed) - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Electrical Relays And Diodes - Fuses - Service The Electrical System (And Battery) - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking And Adding Fluid - Diagnostic Couplers - Hydraulic Reservoir - Replacement Of The Hydraulic Filter - Drain Return Line Filter Service - SPARK ARRESTOR MUFFLER - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - JOYSTICK CONTROL CHANGE - ISO To STANDARD Control Pattern - STANDARD To ISO Control Pattern - LUBRICATION OF THE HYDRAULIC EXCAVATOR - HEATER AIR FILTER (With Cab Option Only) - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions (S/N 13001 & Above) - Lifting Capacity - OPERATION & PERFORMANCE - WEIGHTS - CONTROLS - ELECTRICAL - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Propylene Glycol (Factory Installed) - BUCKET SPECIFICATIONS - ADDITIONAL PUBLICATIONS - WARRANTY 331 6722716 OM 10-96 - OPERATOR SAFETY WARNINGS - CONTENTS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS TRANSLATIONS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - INSTRUMENT PANEL - FUSES - AUDIBLE ALARM - KEY SWITCH - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (Cab Option) - HEATER - WASHER - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (Standard) - Operation Of Right Control Lever (Standard) - SWING LOCKING LEVER - HORN BUTTON - SPEED CONTROL LEVER - TWO SPEED FOOT PEDAL - STEERING LEVERS / FOOT PEDALS - Forward And Reverse Travel - Turning - Making A Counter-Rotation Turn - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL AND LOCK / FOOT REST - BLADE CONTROL LEVER - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (W/ Engine Warm) - Cold Temperature Starting Condition - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - BUCKET - Removal - Installation - OPERATOR'S CAB FRONT WINDOW (OPTION) - Closing The Front Window - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From The Fuel System - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Check And Adding Fluid - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - Diagnostic Couplers - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - JOYSTICK CONTROL CHANGE - HEATER AIR FILTER (With Cab Option Only) - (S/N 512920394 & Above Only) - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - CYLINDER CYCLE TIMES - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - BRAKES - TRACK - CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Description - BUCKET SPECIFICATONS - WARRANTY 331 6722918 SM 5-94 - MAINTENANCE SAFETY - CONTENTS - FOREWORD - SAFETY INSTRUCTIONS - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - MACHINE SIGNS TRANSLATIONS (DECALS) - PREVENTIVE MAINTENANCE - SERVICE SCHEDULE - ENGINE COVER - Procedure - AIR CLEANER SERVICE - Replacing the Filter Element - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From the Fuel System - ENGINE LUBRICATION SYSTEM - Checking The Engine Oil - Engine Oil and Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - HYDRAULIC SYSTEM - Checking and Adding Fluid - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Diagnostic Couplers - USING A BOOSTER BATTERY (JUMP STARTING) - Procedure - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Procedure - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - HYDRAULIC SERVICE INFORMATION - Description - MAIN RELIEF VALVES - Checking the Dual Pressure Relief Valves at Diagnostic Couplers - Check the Single Pressure Relief Valve (3 Spool Valve) - 6 Spool Dual Pressure Relief Valve Adjustment Procedure - High Pressure Adjustment Procedure (6 Spool Only) - Low Pressure Adjustment Procedure (6 Spool Only) - 3 Spool Single Pressure Relief Valve Adjustment Procedure - HYDRAULIC PUMP - Checking the Hydraulic Pump - Removal and Installation - Parts Identification - Disassembly - Assembly - HYDRAULIC CONTROL VALVE (6 Spool) - Removal and Installation - Parts Identification - CONTROL VALVE (6 Spool) - Disassembly and Assembly - Disassembly - Assembly - Right Hand Travel - Spool Wiper and Spool Seal Installation - Boom, Bucket and Arm - Relief Valves - Auxiliary - Spool Seal and Spool Wiper Installation - Left Hand Travel - Relief Valve - Load Check Plug Assembly - Spool Seal and Spool Wiper Installation - End Cover–Supply and Relief Valve - End Cover - HYDRAULIC CONTROL VALVE (3 Spool) - Removal and Installation - PARTS IDENTIFICATION - CONTROL VALVE (3 Spool) - Disassembly and Assembly - Disassembly - Assembly - House Swing Section - Blade and Boom Swing Section - Spool Seal and Spool Wiper Installation - End Cover–Supply - End Cover - Pressure Build–up Valve - Adjustment Procedure - PRESSURE REDUCING VALVE WITH ACCUMULATOR - Removal and Installation - Parts Identification - ACCUMULATOR - Disassembly - Assembly - Setting the Safety Relief Valve - Charging - AUXILIARY SELECTOR VALVE - Removal and Installation - Disassembly And Assembly - TWO SPEED VALVE - Removal and Installation - Parts Identification - PORT BLOCK - Removal and Installation - OIL COOLER - Removal And Installation - HYDRAULIC RESERVOIR AND FUEL RESERVOIR - HYDRAULIC FILTER ASSEMBLY - Removal And Installation - BOOM CYLINDER - Removal And Installation - Parts Identification - ARM CYLINDER - Removal And Installation - Parts Identification - BUCKET CYLINDER - Removal And Installation - Parts Identification - BLADE CYLINDER - Removal And Installation - Parts Identification - BOOM SWING CYLINDER - Removal And Installation - Parts Identification - HYDRAULIC CYLINDER - Disassembly - Assembly - JOYSTICK CONTROL CHANGE - To change from I.S.O. to STANDARD control patterndo the following - To change STANDARD to I.S.O. control pattern dothe following - DRIVE SECTION - LEFT CONSOLE - Lockout Valve Removal and Installation - Cylinder Removal and Installation - Removal and Installation - LEFT JOYSTICK - Removal and Installation - Parts Identification - Disassembly and Assembly - RIGHT CONSOLE - Removal and Installation - RIGHT CONSOLE COVER - Removal and Installation - SPEED CONTROL LEVER - Low Idle Adjustment - High Idle Adjustment - Removal and Installation - BLADE CONTROL LEVER - STEERING LEVERS AND PEDALS - Removal and Installation - UPPER WORKS AND SWING SECTION - ENGINE COVER - Removal and Installation - SEAT AND SEAT MOUNT - Removal and Installation - FLOORMAT AND FLOOR PLATE - Removal and Installation - REAR FLOOR PLATE - Removal and Installation - SWING MOTOR COVER - Removal and Installation - INSPECTION COVER - Removal and Installation - TOOL BOX - Removal and Installation - LEFT HAND SIDE COVER - Removal and Installation - RIGHT HAND SIDE COVER - Removal and Installation - RIGHT HAND CORNER POST - Removal and Installation - LEFT HAND CORNER POST - Removal and Installation - COUNTERWEIGHTS - Removal and Installation - FRONT ENGINE COVER - Removal and Installation - BUCKET - Removal and Installation - BUCKET TEETH - Removal and Installation - ARM - Removal and Installation - BOOM - Removal and Installation - BOOM SWING BRACKET - Removal and Installation - Hose Installation - Swing Bracket Bushing Replacement - Bushing Removal - Bushing Installation - Boom Pivot Bushing Replacement - Bushing Removal - Bushing Installation - SWING MOTOR - Removal and Installation - Disassembly - Assembly - CROSS PORT RELIEF VALVE - Disassembly - Assembly - Description - Testing - SWING GEAR BOX ASSEMBLY - Parts Identification - Disassembly - Assembly - UPPERSTRUCTURE AND SWING CIRCLE GEAR - Removal and Installation - Removal and Installation - Swing Bearing Removal - Swing Bearing Installation - Alignment Pins (Threaded) - Alignment Pins (Not Threaded) - CENTER SWIVEL JOINT - Removal And Installation (Through Bottom Access Cover) - Parts Identification - ROPS CANOPY - Removal And Installation - CAB - Removal And Installation - Door Removal And Installation - Front Window Removal And Installation - Front Lower Glass Removal And Installation - Front Upper Plexiglass Removal And Installation - Door Glass Removal And Installation - Left Hand Side Glass Removal And Installation - Rear Glass Removal And Installation - Right Hand Side Glass Removal and Installation - Right Hand Window Assembly Removal AndInstallation - CAB/CANOPY REAR COVER - Removal And Installation - Installation - MAIN FRAME AND TRACKS - BLADE - Removal and Installation - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - TRACK - Removal and Installation - For Rubber Track: - For Steel Track: - TRACK FRAME - Disassembly and Assembly - TRACK IDLER - Parts Identification - Disassembly - Assembly - TRACK ROLLER - Parts Identification - Disassembly - Assembly - TRAVEL MOTOR - Removal and Installation - Parts Identification - TRAVEL MOTOR - Disassembly - Assembly - TRACK - Damage Identification and Causes - Cutting of the steel cords - Abrasion of embedded metals - Separation of embedded metals due to external forces - Separation of embedded metals due to corrosion - Cuts on the lug side rubber - Cracks of the lug side rubber due to fatigue - Lug abrasion - Cracks and cuts on the lug side rubber at the edges of the embedded metals - Abrasion of the track roller side rubber surface - Cuts on the edges of track roller side rubber - ELECTRICAL SYSTEM - ELECTRICAL SYSTEM - TROUBLESHOOTING - ELECTRICAL SYSTEM - Description - Fuses - Fuse Arrangement - Electrical System Service - BATTERY - Checking the Battery - Removal and Installation - ALTERNATOR - Belt Adjustment - Removal and Installation - STARTER - Removal and Installation - Disassembly and Assembly - Cleaning and Inspection - FUEL LEVEL SENDER - Removal and Installation - Checking - INSTRUMENT PANEL - Removal and Installation - CAB ELECTRICAL (Cab Option) - ENGINE SERVICE - TROUBLESHOOTING - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - ELECTRIC FUEL PUMP - Removal and Installation - Removing Air From the Fuel System - FUEL FILTER - Removal and Installation - FUEL SHUT–OFF SOLENOID - Adjustment - FUEL SHUT–OFF SOLENOID - Removal and Installation - Timer Module - Removal and Installation - FUEL INJECTION PUMP - Checking the Injection Pump - Removal and Installation - Timing the Injection Pump - FUEL INJECTOR NOZZLES - Removal and Installation - Checking the Injector Nozzle - GLOW PLUGS - Removal and Installation - Checking the Glow Plug - FAN GUARD - Removal and Installation - RADIATOR - Removal and Installation (S/N 20001–20067) - Removal and Installation - Removal and Installation (S/N 20068 & Above) - AIR CLEANER - Removal and Installation - MUFFLER - Removal and Installation - ENGINE - Removal and Installation - ENGINE FLYWHEEL - Removal and Installation - Flywheel Ring Gear - CYLINDER HEAD - Removal - Disassembly - Servicing the Cylinder Head - Assembly - Installation - ENGINE REPAIR - Removing the Gearcase - Removing the Timing Gear, Camshaft and Oil Pump - Servicing the Timing Gear and Camshaft - Servicing the Crankshaft - Servicing the Cylinder Liners - Lubrication System - Oil Pump Service - Water Pump Service - ENGINE ASSEMBLY - Installing the Crankshaft - Installing the Pistons - Installing the Camshaft and Timing Gears - Installing the Gearcase - TECHNICAL DATA - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - CYLINDER CYCLE TIMES - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - BRAKES - TRACK - CAPACITIES - DIGGING FORCE - ENGINE SPECIFICATIONS - Fuel Injection Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Rocker Arms - Camshaft - Cylinder - Piston Rings - Pistons - Crankshaft - Oil Pump - Engine Oil Specifications - Engine Bolt Torque - Re–Grinding The Crankshaft - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Description - BUCKET SPECIFICATIONS - SERVICE MANUAL REVISIONS - 331-1 - 331-2 - 331-3 331 6722999 OM 6-96 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - OPERATOR'S HANDBOOK - STORAGE COMPARTMENT - INSTRUMENT PANEL - KEY SWITCH - FUSES - AUDIBLE ALARM - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (Cab Option) - HEATER - WINDSHIELD WASHER TANK (If Equipped) - CONTROL LEVERS (JOYSTICKS) - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (Standard) - Operation Of Right Control Lever (Standard) - SWING LOCK - HORN BUTTON - SPEED CONTROL LEVER - TWO SPEED FOOT PEDAL - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - Right Turn - Left Turn - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL - BLADE CONTROL LEVER - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - Operating On Slopes - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - LIFTING A LOAD - BUCKET - Removal - Installation - OPERATOR'S CAB FRONT WINDOW (OPTION) - Opening The Front Window - Closing The Front Window - CAB/CANOPY FOPS (Falling Object Protective Structure) - Front Window - Emergency Exit - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel Specification - Filling The Fuel Tank - Fuel System Maintenance - Fuel Filter - Removing Air From The Fuel System - Fuel Specification - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Replacement Of Oil And Filter - COOLING SYSTEM - Coolant Level - Coolant Replacement - Ethylene Glycol - Propylene Glycol - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removing And Installation Of The Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking And Adding Fluid - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - Diagnostic Couplers - SPARK ARRESTOR MUFFLER - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - JOYSTICK CONTROL CHANGE - ISO To SANDARD Control Pattern - STANDARD To ISO Control Pattern - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - CYLINDER CYCLE TIMES - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - BRAKES - TRACK - CAPACITIES - DIGGING FORCE - VIBRATION DATA - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Ethylene Glycol - Propylene Glycol - BUCKET SPECIFICATIONS - WARRANTY 331 6724222 SM 2-96 - MAINTENANCE SAFETY - ALPHABETICAL INDEX - CONTENTS - FOREWORD - SAFETY INSTRUCTIONS - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - MACHINE SIGNS TRANSLATIONS (DECALS) - PREVENTIVE MAINTENANCE - SERVICE SCHEDULE (S/N 11001–11999) - SERVICE SCHEDULE (S/N 12001 & Above) - PREVENTIVE MAINTENANCE - LIFTING AND BLOCKING THE EXCAVATOR - Procedure - TRANSPORTING THE EXCAVATOR - Procedure - ENGINE COVER - Opening the Cover - AIR CLEANER - Servicing the Air Cleaner (S/N 11001–11999) - Servicing the Air Cleaner (S/N 12001–12999) - Servicing the Air Cleaner (S/N 13001 & Above) - FUEL SYSTEM - Fuel Specification - Filling the Fuel Tank - Fuel System Service - Fuel Filter - Removing Air from the Fuel System - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Replacing Oil and Filter - COOLING SYSTEM - Coolant Level - Ethylene Glycol - Propylene Glycol - Coolant Replacement - HYDRAULIC SYSTEM - Checking and Adding Fluid - Replacing the Hydraulic Filter (S/N 11001–11999) - Replacing the Hydraulic Filter (S/N 12001 & Above) - Return Line Filter Service (S/N 12240 & Above) - Hydraulic Reservoir - Diagnostic Couplers - USING A BOOSTER BATTERY (Jump Starting) - Procedure (S/N 11001–11999) - Procedure (S/N 12001 & Above) - SPARK ARRESTOR MUFFLER - Cleaning Spark Arrestor Muffler (S/N 11001–11999) - Cleaning Spark Arrestor Muffler (S/N 12001 & Above) - LUBRICATION OF THE EXCAVATOR - Procedure (S/N 11001 – 11999) - Procedure (S/N 12001 & Above) - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - HEATER AIR FILTER SERVICE - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - HYDRAULIC SYSTEM TROUBLESHOOTING - HYDRAULIC SERVICE INFORMATION (S/N11001–12999) - Description - MAIN RELIEF VALVES (S/N 11001–12999) - Description - Checking Dual Pressure Relief Valves - Checking Single Pressure Relief Valve - Dual Pressure Relief Valve Adjustment (6–Spool Valve) - Single Pressure Relief Valve Adjustment (3–Spool Valve) - HYDRAULIC SERVICE INFORMATION (S/N 13001 &Above) - Description - MAIN RELIEF VALVE (Adjustable) (S/N 13001 & Above) - Checking the Main Relief Valves - Testing the Blade, Boom Swing, Arm and Boost Circuit Relief Valves - Testing the 4050 PSI (27925 kPa) Circuit Relief - Testing the Auxiliary and Bucket Circuit Relief Valve - Testing the Left Hand Travel Circuit Relief Valve - Testing the Right Hand Travel Circuit Relief Valve - Testing the Boom Circuit Relief Valve - HYDRAULIC PUMP - Checking the Hydraulic Pump - Removal and Installation - Parts Identification - Disassembly - Assembly - HYDRAULIC CONTROL VALVE (6–Spool) (S/N 12999 & Below) - Removal and Installation - Parts Identification - Disassembly - Assembly - Right Hand Travel Section Disassembly and Assembly - Boom, Bucket and Arm Section Disassembly and Assembly - Auxiliary Section Disassembly and Assembly - Left Hand Travel Section Disassembly and Assembly - End Cover Disassembly and Assembly - HYDRAULIC CONTROL VALVE (3–Spool) (S/N 12999 & Below) - Description - Removal and Installation - Parts Identification - Disassembly - Assembly - Housing Swing Section Disassembly and Assembly - Blade and Boom Swing Section Disassembly and Assembly - End Cover Disassembly and Assembly - HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above) - Left Travel, Right Travel, Boom, Bucket and Auxiliary - Removal and Installation - Parts Identification - Disassembly - Outlet Sections Disassembly - Outlet Sections Assembly - Mid Inlet Section Disassembly - Mid Inlet Section Assembly - Left Travel, Right Travel and Auxiliary Disassembly - Left Travel, Right Travel and Auxiliary Assembly - Boom and Bucket Disassembly - Boom and Bucket Assembly - Assembly - PORT RELIEF VALVES AND MAIN RELIEF VALVES (S/N 13001 & Above) - Parts Identification - Port Relief Valve Pressure Setting - Disassembly - Assembly - MAIN RELIEF VALVES (Adjustable) (S/N 13001 & Above) - Parts Identification - Assembly - Disassembly - Assembly - Adjusting the Main Relief Valves - HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above) - Boost, Arm, Boom Swing, Blade and Swing Section - Description - Removal and Installation - Parts Identification - Disassembly - Inlet Section - Arm, Boost and Swing Motor Disassembly - Arm, Boost and Swing Motor Assembly - Boom Swing Disassembly - Boom Swing Assembly - Blade Disassembly - Blade Assembly - Assembly - ACCUMULATOR (S/N 12999 & Below) - Adjustment - Pressure Reducing Valve - Testing - Removal and Installation - Parts Identification - Disassembly - Assembly - Setting the Safety Relief Valve - Charging - ACCUMULATOR (S/N 13001 & Above) - Removal and Installation - Parts Identification - AUXILIARY SELECTOR VALVE - Removal and Installation (S/N 12999 & Below) - Removal and Installation (S/N 13001 & Above) - Disassembly and Assembly - TWO SPEED VALVE (S/N 12999 & Below) - Removal and Installation - Parts Identification - Disassembly - Assembly - TWO SPEED SWITCH (S/N 13001 & Above) - Removal and Installation - PORT BLOCK - Removal and Installation (S/N 12999 & Below) - Removal and Installation (S/N 13001 & Above) - OIL COOLER - Removal and Installation (S/N 11001 – 11999) - Removal and Installation (S/N 12001 & Above) - HYDRAULIC RESERVOIR AND FUEL RESERVOIR - Removal and Installation - HYDRAULIC FILTER ASSEMBLY - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - BOOM CYLINDER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - Parts Identification - ARM CYLINDER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - Parts Identification - BUCKET CYLINDER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - Parts Identification - BLADE CYLINDER - Removal and Installation - Parts Identification - BOOM SWING CYLINDER - Removal and Installation - Parts Identification - HYDRAULIC CYLINDER - Disassembly - Assembly - JOYSTICK CONTROL CHANGE - ISO to STANDARD Control Pattern (S/N 12999 & Below) - STANDARD to ISO Control Pattern (S/N 12999 & Below) - ISO to STANDARD Control Pattern (S/N 13001 & Above) - STANDARD to ISO Control Pattern (S/N 13001 & Above) - DRIVE SECTION - LEFT CONSOLE (S/N 12999 & Below) - Lockout Valve Removal and Installation - Cylinder Removal and Installation - Removal and Installation - LEFT CONSOLE (S/N 13001 & Above) - Control Lock Micro–Switch Removal and Installation - Cylinder Removal and Installation - Removal and Installation - LEFT CONSOLE RELEASE HANDLE (S/N 13001 & Above) - Removal and Installation - Adjustment - JOYSTICK (S/N 12999 & Below) - Removal and Installation - Parts Identification - Disassembly and Assembly - JOYSTICK (S/N 13001 & Above) - Removal and Installation - JOYSTICK (S/N 13001 & Above) - Parts Identification - Disassembly - Assembly - Troubleshooting - RIGHT CONSOLE - Removal and Installation (S/N 12999 & Below) - Removal and Installation (S/N 13001 & Above) - RIGHT CONSOLE COVER - Removal and Installation - SPEED CONTROL LEVER - Low Idle Adjustment - High Idle Adjustment - Removal and Installation - BLADE CONTROL LEVER AND CABLE - Removal and Installation - STEERING LEVERS AND PEDALS - Removal and Installation - Adjusting Linkage Rods - UPPER WORKS AND SWING SECTION - ENGINE COVER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - SEAT AND SEAT MOUNT - Removal and Installation - FLOORMAT AND FLOOR PLATE - Removal and Installation - REAR FLOOR PLATE - Removal and Installation - SWING MOTOR COVER - Removal and Installation - INSPECTION COVER (S/N 11001–11999) - Removal and Installation - TOOL BOX - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - LEFT HAND SIDE COVER - Removal and Installation (S/N 11001–11999) - Removal & Installation (S/N 12001 & Above) - RIGHT HAND SIDE COVER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - RIGHT HAND CORNER POST - Removal and Installation - LEFT HAND CORNER POST - Removal and Installation - COUNTERWEIGHTS - Removal and Installation - FRONT ENGINE COVER - Removal and Installation - BUCKET - Removal and Installation - BUCKET TEETH - Removal and Installation - ARM - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - BOOM - Removal and Installation - BOOM SWING BRACKET - Removal and Installation - Hose Installation - SWING BRACKET BUSHING - Bushing Removal - Bushing Installation - BOOM PIVOT BUSHING - Bushing Removal - Bushing Installation - SWING MOTOR - Removal and Installation (S/N 11001–11056) - Removal and Installation (S/N 11057–12999) - Disassembly (S/N 11001–12999) - Assembly (S/N 11001–12999) - CROSS PORT RELIEF VALVE (S/N 11001–11056 S/N 13001 & Above) - Disassembly - Assembly - Description - Testing - COUNTERBALANCE VALVE (S/N 11057–12999) - Description - Removal and Installation - Disassembly - Assembly - SWING GEAR BOX - Parts Identification (S/N 11001–12999) - Disassembly (S/N 11001–12999) - Assembly (S/N 11001–12999) - SWING MOTOR - Removal and Installation (S/N 13001 & Above) - SWING MOTOR DRIVE CARRIER (S/N 13001 & Above) - Removal and Installation - Parts Identification - Disassembly - Assembly - UPPERSTRUCTURE AND SWING CIRCLE GEAR - Removal and Installation - Swing Bearing Removal - Swing Bearing Installation - Alignment Pins (Not Threaded) - CENTER SWIVEL JOINT - Removal and Installation (S/N 12999 & Below) - Removal and Installation (S/N 13001 & Above) - Parts Identification - Disassembly - Assembly - ROPS CANOPY - Removal and Installation - CAB - Removal and Installation - Front Window Removal and Installation - Front Lower Window Removal and Installation - Front Upper Window Removal and Installation - Door Removal and Installation - Door Window Removal and Installation - Left Hand Side Window Removal and Installation - Right Hand Side Window Removal and Installation - Right Hand Window Assembly Removal and Installation - Rear Window Removal and Installation - CAB/CANOPY REAR COVER - Removal - Installation - MAIN FRAME AND TRACKS - BLADE - Removal and Installation - TRACK - Track Lug Height - Track Tension Adjustment - Rubber Track Clearance - Steel Track Clearance - Adjustment (S/N 512912999 & Below) - Adjustment (S/N 512913001 & Above) - Rubber Track Removal and Installation - Steel Track Removal and Installation - TRACK FRAME - Disassembly and Assembly (S/N 512912999 & Below) - Disassembly and Assembly (S/N 512913001 & Above) - TRAVEL MOTOR - Testing - Removal and Installation - (S/N 512911001–512913404) - Parts Identification - Disassembly - Assembly - (S/N 512913405 & Above) - Parts Identification - Disassembly - Assembly - TRACK DAMAGE IDENTIFICATION - Cutting Of Steel Cords - Abrasion Of Embedded Metals - Separation Of Embedded Metals - Separation Of Embedded Metals Due To Corrosion - Cuts On The Lug Side Rubber - Cracks Of The Lug Side Rubber Due To Fatigue - Lug Abrasion - Cracks And Cuts On The Lug Side Rubber - Abrasion Of The Track Roller Side - Cuts On The Edges Of Track Roller Side - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATICS - TROUBLESHOOTING - ELECTRICAL SYSTEM - Description - Fuses - Fuse Arrangement - Electrical System Service - BATTERY - Check the Battery - Removal and Installation (S/N 11001–11999) - Removal & Installation (S/N 12001 & Above) - ALTERNATOR - Belt Adjustment - Removal and Installation - Parts Identification - Disassembly and Inspection - Stator Continuity Test - Stator Ground Test - Rotor Continuity Test - Rotor Ground Test - Rectifier Continuity (Diode) Test - Assembly - STARTER - Removal and Installation - Disassembly and Assembly - Cleaning and Inspection - Part Identification - FUEL LEVEL SENDER - Removal and Installation - Checking - INSTRUMENT PANEL - Removal and Installation - GAUGES - Removal and Installation - GAUGE LIGHTS - Removal and Installation - CAB ELECTRICAL - Cab Option - ENGINE SERVICE - TROUBLESHOOTING - Chart - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - GLOW PLUGS - Removal and Installation - Checking the Glow Plug - FUEL SHUT–OFF SOLENOID - Adjustment - Removal and Installation - Timer Module Removal and Installation - FUEL INJECTION PUMP - Checking the Injection Pump - Removal and Installation - Timing the Injection Pump - FUEL INJECTOR NOZZLES - Removal and Installation - Checking the Injector Nozzle - FAN GUARD - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - RADIATOR - Removal and Installation (S/N 11001 – 11999) - Removal and Installation (12001 & Above) - MUFFLER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001 & Above) - AIR CLEANER - Removal and Installation (S/N 11001–11999) - Removal and Installation (S/N 12001–12999) - Removal and Installation (S/N 13001 & Above) - ENGINE - Removal and Installation - ENGINE FLYWHEEL - Removal and Installation - Flywheel Ring Gear - CYLINDER HEAD - Removal and Installation - Disassembly and Assembly - Servicing the Cylinder Head - Top Clearance - VALVE, VALVE SEAT AND GUIDE - Checking the Valve Guide - Reconditioning the Valve and Valve Seat - Valve Spring - ROCKER ARM AND SHAFT - Checking - TIMING GEARCASE COVER - Removal and Installation - IDLER GEAR AND CAMSHAFT - Removal and Installation - Servicing the Camshaft - Servicing the Idler Gear and Shaft - TIMING GEARS - Checking Backlash - FUEL CAMSHAFT - Removal and Installation - Governor - CRANKSHAFT GEAR - Removal and Installation - OIL PUMP - Removal and Installation - Oil Pump Service - ENGINE COMPRESSION - Checking Engine Oil Pressure - Relief Valve - PISTON AND CONNECTING ROD - Removal and Installation - Servicing the Piston and Connecting Rod - Connecting Rod Alignment - CRANKSHAFT AND BEARINGS - Removal and Installation - Servicing the Crankshaft and Bearings - CYLINDER BORE - Checking the Cylinder Bore - WATER PUMP - Removal and Installation - Disassembly and Assembly - SPECIFICATIONS - EXCAVATOR SPECIFICATIONS - Machine Dimensions (S/N 11001–11999) - Machine Dimensions (S/N 12001 & Above) - Lifting Capacity - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - REFILL CAPACITIES - DIGGING FORCE - Machine Dimensions (S/N 13001 & Above) - Lifting Capacity - WEIGHTS - CONTROLS - ENGINE - ELECTRICAL - HYDRAULIC SYSTEM - CYLINDER CYCLE TIME - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - REFILL CAPACITIES - DIGGING FORCE - ENGINE SPECIFICATIONS - Fuel Injection Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Valve Timing - Rocker Arms - Camshaft - Tappet - Piston Rings - Pistons - Connecting Rod - Oil Pump - Crankshaft - Timing Gear - Thermostat - Engine Bolt Torque - Crankshaft Re–Grind Data - Torque For General Metric Bolts - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Ethylene Glycol - Propylene Glycol - DECIMAL AND MILLIMETER EQUIVALENTS - U.S. TO METRIC CONVERSION - SERVICE MANUAL REVISION - 331-1 - 331-2 - 331-3 - 331-4 - 331-5 331 6724466 OM 8-00 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS FOR BOBCAT COMPACT EXCAVATORS AND ATTACHMENTS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - INSTRUMENT PANEL - KEY SWITCH - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - AUXILIARY POWER OUTLET - CAB/CANOPY - CAB/CANOPY FOPS (Falling Object Protective Structure) - Front Window - Emergency Exit - CAB OPTION - Opening The Front Window (S/N 512913001–512914197) - Closing The Front Window (S/N 512913001–512914197) - Opening The Front Window (S/N 512914198–512915199) - Closing The Front Window (S/N 512914198–512915199) - ELECTRICAL - WINDSHIELD WASHER TANK (If Equipped) - HEATER CONTROL - LIGHT SWITCH - FUSES - AUDIBLE ALARM - HORN BUTTON - SEAT - SPEED CONTROL LEVER - OPERATOR’S HANDBOOK - STORAGE COMPARTMENT - ENGINE COVER - AUXILIARY OPERATION PEDAL - Flush Face Couplers - BLADE CONTROL LEVER - SWING LOCK - BOOM SWING PEDAL - CONTROL LEVERS (JOYSTICKS) - Operation oO Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (Standard) - Operation Of Right Control Lever (Standard) - CONTROL LEVER (JOYSTICK) LOCK - TWO SPEED FOOT PEDAL - GETTING ON AND OFF THE MACHINE - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - BUCKET - Removal - Installation - OPERATING PROCEDURE - Operating On Public Roads - Lifting A Load - OPERATING PROCEDURE - Excavating - Boom Offset - Back Filling - Driving The Excavator - Operating On Slopes - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - Adjustment Of The Engine Cover Latch - AIR CLEANER SERVICE - FUEL SYSTEM - Filling The Fuel Tank - Fuel Filter - Fuel System Maintenance - Removing Air From The Fuel System - Fuel Specifications - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Replacement Of Oil And Filter - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol (Factory Installed) - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Electrical Relays And Diodes - Fuses - Service The Electrical System (and Battery) - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking And Adding Fluid - Diagnostic Couplers - Hydraulic Reservoir - Replacement Of The Hydraulic Filter - Drain Return Line Filter Service - SPARK ARRESTOR MUFFLER - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - JOYSTICK CONTROL CHANGE - ISO to STANDARD Control Pattern - STANDARD To ISO Control Pattern - LUBRICATION OF THE HYDRAULIC EXCAVATOR - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions (S/N 512913001 & Above) - Lifting Capacity - SPECIFICATIONS - CONTROLS - ENGINE - ELECTRICAL - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - STD TRACK SHOES - REFILL CAPACITIES - DIGGING FORCE - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - Propylene Glycol (Factory Installed) - BUCKET SPECIFICATIONS - ADDITIONAL PUBLICATIONS - WARRANTY 331 6724471 OM 8-95 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - OPERATOR’S HANDBOOK - STORAGE COMPARTMENT - INSTRUMENT PANEL - KEY SWITCH - FUSES - AUDIBLE ALARM - LIGHT SWITCH - AUXILIARY POWER OUTLET - CAB ELECTRICAL (Cab Option) - HEATER - WINDSHIELD WASHER TANK (if equipped) - CONTROL LEVERS (JOYSTICKS) - Operation of Left Control Lever (ISO) - Operation of Right Control Lever (ISO) - Operation of Left Control Lever (Standard) - Operation of Right Control Lever (Standard) - SWING LOCK - HORN BUTTON - SPEED CONTROL LEVER - TWO SPEED FOOT PEDAL - STEERING LEVERS/FOOT PEDALS - Forward and Reverse Travel - Turning - Right Turn - Left Turn - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL - BLADE CONTROL LEVER - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - OPERATING PROCEDURE - Breaking in a New Machine - General Operation Suggestions - Operating in Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - LIFTING A LOAD - BUCKET - Removal - Installation - CAB OPTION - Opening the Front Window - Closing the Front Window - CAB/CANOPY FOPS (Falling Object Protective Structure) - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel Specification - Filling the Fuel Tank - Fuel System Maintenance - Fuel Filter - Removing Air from the Fuel System - ENGINE LUBRICATION SYSTEM - Checking Engine Oil - Replacement of Oil and Filter - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol (Factory Installed) - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL RELAYS AND DIODES - ELECTRICAL SYSTEM - Service the Electrical System (and Battery) - Using A Booster Battery (Jump Starting) - Removal and Installation of the Battery - Electric Solenoid (Engine Stop) - HYDRAULIC SYSTEM - Checking and Adding Fluid - Return Line Filter Service - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Diagnostic Couplers - SPARK ARRESTOR MUFFLER - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - JOYSTICK CONTROL CHANGE - ISO to STANDARD Control Pattern - STANDARD to ISO Control Pattern - HEATER AIR FILTER (With Cab Option Only) - MACHINE SIGN TRANSLATIONS - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - CYLINDER CYCLE TIMES - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - BRAKES - TRACK - CAPACITIES - DIGGING FORCE - VIBRATION DATA - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Propylene Glycol (Factory Installed) - BUCKET SPECIFICATIONS - WARRANTY
Bobcat Excavator (320 325 331 Series) Service and Owners Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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