Bobcat 320 322 G Series Mini Excavator 6902668

320
322
Service
Manual
320 - S/N 223911001 & Above
322 - S/N 224011001 & Above
(G Series)
6902668 (7-06) Printed in U.S.A. ©Bobcat Company 2006
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731A B-19964 B-19959

Never service the Bobcat Compact Use the correct procedure to lift Cleaning and maintenance are
Excavator without instructions. and support the excavator. required daily.
WRONG WRONG WRONG
B-19965 B-19960 B-19966

Have good ventilation when Vent exhaust to outside when Always lower the bucket and
welding or grinding painted parts. engine must be run for service. blade to the ground before doing
Wear dust mask when grinding Exhaust system must be tightly any maintenance.
painted parts. Toxic dust and gas sealed. Exhaust fumes can kill Never modify equipment or add
can be produced. without warning. attachments not approved by
Bobcat Company.
WRONG WRONG WRONG
B-19962 B-19958 B-19798

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, electrical flammable and explosive gases.
checking fluids. contact, hot parts and exhaust. Keep arcs, sparks, flames and
Never service or adjust machine Wear eye protection to guard from lighted tobacco away from
with the engine running unless battery acid, compressed springs, batteries.
instructed to do so in the fluids under pressure and flying Batteries contain acid which
manual. debris when engines are running burns eyes or skin on contact.
Avoid contact with leaking or tools are used. Use eye Wear protective clothing. If acid
hydraulic fluid or diesel fuel protections approved for type of contacts body, flush well with
under pressure. It can penetrate welding. water. For eye contact flush well
the skin or eyes. Keep tailgate closed except for and get immediate medical
Never fill fuel tank with engine service. Close and latch tailgate attention.
running, while smoking, or when before operating the excavator.
near open flame.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW28-0805
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ALPHABETICAL INDEX
AIR CLEANER ........................................................ 60-01 LEFT CONSOLE .....................................................40-01

AIRCLEANER SERVICE ........................................ 10-01 LEFT CONTROL LEVER (JOYSTICK) ..................20-01
ALTERNATOR ....................................................... 50-01 LEFT PEDAL ...........................................................40-01
ALTERNATOR BELT ............................................. 10-01 LIFTING AND BLOCKING THE EXCAVATOR .......10-01
ARM ....................................................................... 40-01 LIFTING THE EXCAVATOR ...................................10-01
ARM CYLINDER .................................................... 20-01 LIGHTS....................................................................50-01
LUBRICATION OF THE HYDRAULIC
BATTERY ............................................................... 50-01 EXCAVATOR ........................................................10-01
BLADE ................................................................... 30-01
BLADE CONTROL.................................................. 40-01 MAIN RELIEF VALVE .............................................20-01
BLADE CYLINDER ................................................. 20-01 MANIFOLD ASSEMBLY/ACCUMULATOR .............20-01
BLADE EXTENSION TRAY .................................... 40-01 MICROSWITCH ......................................................50-01
BOOM ..................................................................... 40-01
BOOM CYLINDER .................................................. 20-01 OIL COOLER...........................................................20-01
BOOM SWING CYLINDER..................................... 20-01 OPERATOR CAB (ROPS/TOPS)............................10-01
BUCKET ................................................................. 40-01
BUCKET CYLINDER .............................................. 20-01 PORT RELIEF VALVES ..........................................20-01
PRESSURE REDUCING VALVE ............................20-01
CAB......................................................................... 40-01
CONTROL CONSOLE LOCKOUTS ....................... 10-01 RADIATOR .............................................................60-01
CONTROL LINKAGE ASSEMBLY ......................... 40-01 RECONDITIONING THE ENGINE .........................60-01
CONTROL PATTERN SELECTOR VALVE............ 20-01 RIGHT CONSOLE ...................................................40-01
CONVERSIONS ...............................................SPEC-01 RIGHT CONTROL LEVER (JOYSTICK) .................20-01
CROSSPORT RELIEF VALVES............................. 20-01 RIGHT PEDAL.........................................................40-01
ROPS CANOPY.......................................................40-01
ELECTRICAL SYSTEM .......................................... 50-01
ENGINE .................................................................. 60-01 SEAT AND SEAT MOUNT .....................................40-01
ENGINE COMPONENTS AND TESTING .............. 60-01 SEAT BELT ............................................................ 10-01
ENGINE COOLING SYSTEM ................................. 10-01 SERVICE SCHEDULE ............................................10-01
ENGINE FLYWHEEL .............................................. 60-01 SPARK ARRESTOR MUFFLER ..................10-01, 60-01
ENGINE LUBRICATION SYSTEM ......................... 10-01 SPECIFICATIONS............................................. SPEC-01
ENGINE SPECIFICATIONS ..............................SPEC-01 STARTER ................................................................50-01
ENGINE SPEED CONTROL .................................. 40-01 SWING CIRCLE GEAR ...........................................30-01
SWING FRAME .......................................................40-01
FLOORMAT AND FLOORPLATES ........................ 40-01 SWING LOCK...............................................10-01, 40-01
FUEL, COOLANT AND LUBRICANTS .............SPEC-01 SWING MOTOR .....................................................20-01
FUEL LEVEL SENDER........................................... 50-01 SWIVEL JOINT .......................................................20-01
FUEL SYSTEM ....................................................... 10-01
FUEL TANK ............................................................ 40-01 TAILGATE ...............................................................40-01
TORQUE SPECIFICATIONS ............................SPEC-01
HEATER VALVE ..................................................... 70-01 TRACKS ..................................................................30-01
HEATER AIR FILTERS .......................................... 10-01 TRACK DAMAGE IDENTIFICATION ......................30-01
HEATER ................................................................. 70-01 TRACK FRAME ......................................................30-01
HORN .................................................................... 40-01 TRACK IDLER .........................................................30-01
HYDRAULIC CONNECTION TRACK FRAME EXPANSION CYLINDER..............20-01
SPECIFICATIONS ...........................................SPEC-01 TRACK ROLLER .....................................................30-01
HYDRAULIC CONTROL VALVE ........................... 20-01 TRANSPORTING THE EXCAVATOR.....................10-01
HYDRAULIC FILTER MOUNT................................ 20-01 TRAVEL CONTROLS..............................................40-01
HYDRAULIC FLUID SPECIFICATIONS ........... SPEC-01 TRAVEL MOTOR .........................................10-01, 20-01
HYDRAULIC PUMP ................................................ 20-01 TROUBLESHOOTING ............................................60-01
HYDRAULIC RESERVOIR ..................................... 20-01 TWO SPEED SWITCH ............................................50-01
HYDRAULIC SYSTEM ........................................... 10-01
HYDRAULIC SYSTEM INFORMATION ................ 20-01 UPPERSTRUCTURE ..............................................40-01
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CONTENTS
SAFETY AND
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III MAINTENANCE
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
HYDRAULIC
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
UNDER-
BOBCAT EXCAVATOR IDENTIFICATION. . . . . . . . . . . . . . . . . . . . XI CARRIAGE
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
UPPER-
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 STRUCTURE &
SWING SECTION
UNDERCARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
eELECTRICAL
UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01
sSYSTEM AND
AANALYSISRI
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE

SERVICE
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HEATER
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat Hydraulic Excavator mechanic. It provides necessary servicing and adjustment procedures
for the hydraulic Excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for
operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the hydraulic Excavator has had service or repair:
1. Check that ROPS/TOPS/ 9. Safety treads must be in good
FOPS is in good condition condition.
and is NOT modified.
2. Check that ROPS/TOPS 10. Check for correct function of

mounting hardware is indicator lamps (Optional on
tightened and is Bobcat some models.
approved.
3. The seat belt must be 11. Check hydraulic fluid level,

correctly installed, functional engine oil level and fuel
and in good condition. supply.
4. Inspect for loose or broken 12. Inspect for fuel, oil or

parts or connections. hydraulic fluid leaks.
5. Machine signs must be 13. Lubricate the Excavator.

legible and in the correct
location.
6. Steering levers, control levers 14. Check the condition of the

and foot pedals must return to battery and cables.
neutral. Check that foot
pedals lock and control lever
locks are in working order.
7. Inspect the air cleaner for Recommend to the owner that all
damage or leaks. Check the necessary corrections be made
condition of the filters. before the machine is returned to
service.
8. Check the electrical charging

system.
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IV Service Manual
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Compact Excavator Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Bobcat Excavator. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
• The Bobcat Compact Excavator Safety Video is

available from your Bobcat dealer or at
www.training.bobcat.com or www.bobcat.com.
SI EXC-0206 SM
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.
Call Before You Dig

1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI EXC-0206 SM
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SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
• The operator cab, engine compartment, and engine

• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI EXC-0206 SM
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SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the Excavator when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service 1
operation.
Excavator Serial Number
Figure 1
P-49279
Figure 3
P-49272 1
The Excavator serial number plate (Item 1) is located on

the frame of the machine in the location shown [Figure
1].
Explanation of Excavator Serial Number:

XXXX XXXXX
P-49280
Module 2. - Production
Sequence (Series)
The engine serial number (Item 1) [Figure 2] & [Figure
Module 1. - Model / Engine 3] is located on the engine in the locations shown.
Combination
1. The four digit Model/Engine Combination Module

number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies

the order which the Excavator is produced.
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DELIVERY REPORT
Figure 4
B-16315
The delivery report must be filled out by the dealer and

signed by the owner or operator when the Bobcat
Excavator is delivered. An explanation of the form must
be given to the owner. Make sure it is filled out
completely [Figure 4].
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BOBCAT EXCAVATOR IDENTIFICATION
HYDRAULIC
*CANOPY/CAB CONTROL LEVERS
(ROPS/TOPS) (JOYSTICKS)
GRAB
HANDLES
TAILGATE
UPPERSTRUCTURE
TRACK
TRACK FRAME
TIE DOWN
OPERATOR’S
HANDBOOK GRAB
HANDLES
ARM LIFT POINT

CYLINDER
AUXILIARY HYDRAULIC
QUICK COUPLERS
(OPTIONAL)
OPERATOR SEAT
WITH SEAT BELT
BUCKET
CYLINDER BOOM
BOOM
CYLINDER
ARM
BUCKET LINK BLADE

CYLINDER
TIE DOWNS/
LIFT POINT
BLADE
BUCKET
B-23067
* FOGS (Falling Object Guards) is available from your Bobcat Excavator dealer. B-23066
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SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 SAFETY &
MAINTENANCE
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . 10-140-1
CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . 10-160-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-160-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 DRIVE

Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 SYSTEM
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 ELECTRICAL
SYSTEM &
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 ANALYSIS
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 ENGINE
Removing Air From The Fuel System . . . . . . . . . . . . . . . . 10-80-3 SERVICE
Removing Water From The Fuel Filter. . . . . . . . . . . . . . . . 10-80-2
Replacing The Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
HEATER AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1 SPECIFICATIONS

Fresh Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Recirculation Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . 10-100-1
Diagnostic Couplers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Replacing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Replacing The Hydraulic Filter. . . . . . . . . . . . . . . . . . . . . 10-100-2
LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1
LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . 10-110-1
Continued On Next Page
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SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB ROPS/TOPS . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Emergency Exits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-130-1
SWING LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Adjusting The Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Adjusting The Tailgate Latch . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Opening And Closing The Tailgate . . . . . . . . . . . . . . . . . . 10-40-1
TRANSPORTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . 10-30-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Draining The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
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LIFTING AND BLOCKING THE EXCAVATOR
Procedure
Always park the machine on a level surface.
Figure 10-10-1
P-49769
Raise one side of the machine (approximately 4 inches)

using the boom and arm as shown in [Figure 10-10-1].
Raise the blade fully and install jackstands under the

blade and the track frame. Lower the machine until all
machine weight is on the jackstands.
Stop the engine.
WARNING
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
or fall and result in injury or death
W-2218-1195
WARNING
AVOID INJURY OR DEATH
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0189
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SWING LOCK Figure 10-11-3
Figure 10-11-2
P-30224
P-30223
Move the lever (Item 1) [Figure 10-11-3] up to disengage
the upperstructure from the track frame. Secure the lever
Move the lever (Item 1) [Figure 10-11-2] down to engage in the unlocked position.
the Slew Lock. When the Slew Lock is engaged (locked),
the upperstructure of the Excavator is locked to the track
frame and will not rotate. The upper structure must be
parallel to the track frame to engage the Slew Lock.
WARNING
AVOID INJURY
The slew lock lever must be engaged when
transporting the machine.
W-2197-1203
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LIFTING THE EXCAVATOR Figure 10-12-5
Figure 10-12-4
1 1
1
P-49779
P-49777
Fasten chains to the ends of the blade (Item 1) [Figure
10-12-4] and [Figure 10-12-5] and up to a lifting fixture
Fully extend the cylinders of the bucket, arm, and boom above the canopy/cab. The lifting fixture must extend over
so that the Excavator is in the position as shown [Figure the sides of the canopy/cab to prevent the chains from
10-12-4]. hitting the ROPS/TOPS.
Engage the upperstructure slew lock. (See SWING Figure 10-12-6

LOCK on Page 10-11-1.)
Raise the blade all the way.
Put all the control levers in neutral.

1
WARNING
• Use a lifting fixture with sufficient capacity for the
weight of the Excavator plus any added
attachments.
P-49778
• Maintain center of gravity and balance when
lifting.
• Do not swing boom or upperstructure. Engage Install a one inch (25 mm) bolt and nut (Grade 5 or 8)
the slew locking lever. through the holes at the boom (Item 1) [Figure 10-12-4]
• Never lift with operator on machine. and [Figure 10-12-6]. Fasten a chain from the bolt to the
W-2202-0595
lift fixture.
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10-12-2 Servicee Manual
26 of 705
OPERATOR CAB ROPS/TOPS Cab Door
Emergency Exits Figure 10-20-9
The left door, front window, and right side rear window
provide exits.
Figure 10-20-7 3
2
P-49727
The cab door can be locked (Item 1) [Figure 10-20-9]

with the same key as the starter switch.
P-49726
Push the door all the way open (Item 2) [Figure 10-20-9]
until the latch engages to hold the door in the open
Figure 10-20-8 position.
Pull the door away from the cab (Item 3) [Figure 10-20-9]
to disengage the latch and close the door.
P-49127
Slide the window to the front of the Excavator and exit

through the side window [Figure 10-20-7], or open the
front window and exit [Figure 10-20-8].
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OPERATOR CAB (ROPS / TOPS) (CONT’D) Figure 10-20-12
Front Window
Opening The Front Window
Figure 10-20-10
P-49127
Use both window grab handles to pull the top of the

window in [Figure 10-20-12].
P-49097 Continue moving the window in and up over the

operator’s head until the window is fully raised.
Retract the two top window latch pins (Item 1) [Figure Figure 10-20-13
10-20-10].
Figure 10-20-11
1
2
P-49099
1
P-49098 When the window is fully raised, the latch (Item 1) will
close on the bracket. Turn the two top latches (Item 2)
[Figure 10-20-13] to the locked position.
Turn the two top latches (Item 1) [Figure 10-20-11] to the
unlocked position.
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OPERATOR CAB (ROPS/TOPS) (CONT’D)
Closing The Front Window
Support the window while releasing both window latch

pins and placing the pins in the unlocked position [Figure
10-20-13 on Page 10-20-2].
Support the window using the left grab handle and pull
down on the latch (Item 1) [Figure 10-20-13 on Page 10-
20-2] to release the window.
Use both window grab handles to pull the window down

[Figure 10-20-12 on Page 10-20-2].
Rotate the top latches (Item 1) [Figure 10-20-11 on

Page 10-20-2] to the locked position (Item 1) [Figure 10-
20-10 on Page 10-20-2].
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OPERATOR CAB (ROPS/TOPS) (CONT’D) Opening the right front window
Right Side Windows Figure 10-20-16
Opening the right rear window
Figure 10-20-14
1
1
P-49119
Pull back on the latch (Item 1) [Figure 10-20-16].

P-49176
Figure 10-20-17
Pull forward on the latch (Item 1) [Figure 10-20-14].
Figure 10-20-15
1 P-49120
Pull the latch/handle (Item 1) [Figure 10-20-17] back to

P-49177 open the window.
Push the handle forward to close the window.

Pull the latch/handle (Item 1) [Figure 10-20-15] forward
to open the window.
Push the handle back to close the window.
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TRANSPORTING THE EXCAVATOR Stop the engine and remove the key. Put blocks under
the front and rear of the tracks.
When transporting the machine, observe the rules, motor
vehicle laws and vehicle limit ordinances. Use a transport Figure 10-30-19
and towing vehicle of adequate length and capacity.
Secure the parking brakes and block the wheels of the

transport vehicle.
Remove the blade extensions (If equipped). See Blade

Extension Removal And Installation. (See Extension
Removal And Installation on Page 30-10-1)
Retract the track frame if required. See the correct

Operation And Maintenance Manual for the proper
procedure.
Align the ramps with the center of the transport vehicle.

Secure the ramps to the truck bed and be sure ramp P-49775
angle does not exceed 15 degrees.
Use metal loading ramps with a slip resistant surface that Figure 10-30-20
are the correct length and width, and can support the
weight of the machine.
The rear of the trailer must be blocked or supported when

loading or unloading the Excavator to prevent the front of
the transport vehicle from raising.
Determine the direction of the track movement before

moving the machine (blade forward). Engage the slew
lock . (See SWING LOCK on Page 10-11-1.)
Figure 10-30-18
P-49776
Fasten chains to the front corners of the blade and to the

tie down loop at the rear [Figure 10-30-19] & [Figure 10-
30-20] to prevent it from moving when going up or down
slopes, or during sudden stops.
Use chain binders to tighten the chains and then safely

tie the chain binder levers to prevent loosening.
WARNING
P-49773
Move the machine forward onto the transport vehicle

Adequately designed ramps of sufficient strength are
[Figure 10-30-18].
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
Do not change direction of the machine while it is on the
break and cause personal injury.
ramps. Lower the boom, arm, and bucket to the transport
W-2058-0494
vehicle.
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TAILGATE Adjusting The Bumper
Opening And Closing The Tailgate Figure 10-40-2
WARNING 1

Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
WARNING P-30227
Keep the rear door closed when operating the

machine. Failure to do so could seriously injure a
The door bumper (Item 1) [Figure 10-40-2] can be
bystander.
adjusted for alignment with the tailgate.
W-2020-1285
Close the tailgate before operating the Excavator.

Figure 10-40-1
Adjusting The Tailgate Latch
Figure 10-40-3
P-49725 1
Release the latch (Item 1) [Figure 10-40-1] and pull the

P-49742
tailgate open.
Push firmly to close the tailgate. The door catch (Item 1) [Figure 10-40-3] can be adjusted
by loosening the two bolts, moving the catch, and
Note: The tailgate can be locked using the start key. tightening the two bolts.
Close the tailgate before operating the Excavator.
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SERVICE SCHEDULE
WARNING
Chart
Maintenance work must be done at regular intervals.
Failure to do so will result in excessive wear and early
failures. The service schedule is a guide for correct Instructions are necessary before operating or
maintenance of the Bobcat Excavator. servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0903
SERVICE SCHEDULE HOURS

■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Coolant Check coolant level. Add premixed coolant as needed.
Engine Oil Check the engine oil level and add as needed.
Hydraulic Fluid, Hoses and Check the hydraulic fluid level and add as needed. Check for damage and
Tubelines leaks. Repair or replace as needed.
Engine Air Filter and Air System Check condition indicator and empty dust cup as needed. Check air system
for leaks.
Tracks Check and adjust track tension as needed.
Indicators and Lights Check for correct operation of all indicators and lights.
Control Console Lockout Check for proper function. Repair or replace as needed.
Operator Canopy/Cab Check condition. Check mounting hardware.
Seat Belt Check condition. Check mounting hardware.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Pivot Points Grease all machinery pivot points.
Cab Heater Air Filter (Option) Clean the filter as needed.
Swing Circle and Pinion Grease three fittings.
Fuel Tank & Filter Drain water and sediment from fuel tank and fuel filter.
Battery Check battery, cables, connections and electrolyte level. Add distilled water
as needed.
Engine Oil and Filter Replace oil & filter. Use CD or better grade oil and Bobcat filter. •
Alternator / Fan Belt Check condition of belt and adjust as needed. •
Spark Arrestor Muffler Clean the spark chamber.
Fuel Filter Replace fuel filter.
Travel Motor Check lubricant level in both travel motors. ••
Radiator, & Oil Cooler Clean debris from the radiator fins.
Hydraulic Filter Replace the filter. ••
Engine Air Cleaner Replace the air cleaner filter.
Alternator & Starter Check the alternator and starter connections. ••
Engine Valves Check and adjust the engine valve clearance.
Case Drain Filter Replace the filter.
Travel Motor Replace lubricant in both travel motors.
Engine Cooling System Drain and flush the cooling system. Replace premixed coolant.
Hydraulic System Replace the hydraulic fluid and filters. Clean the reservoir. ••
• Also at first 50 hours

•• Also at first 100 Hours
■ Or every 6 months.
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AIR CLEANER SERVICE Replacing The Filters
See the SERVICE SCHEDULE for the correct service Outer Filter
interval. (See SERVICE SCHEDULE on Page 10-50-1.)
Pull the locking tab (Item 2) [Figure 10-60-4].
Daily Check
Turn the dust cup (Item 3) [Figure 10-60-4] counter-
Figure 10-60-4 clockwise about 1/8 turn.
Remove and clean the dust cup.
Figure 10-60-5
1 3
P-30228
1
Check the condition indicator (Item 1) [Figure 10-60-4]. If
the red ring shows in the condition indicator, the filter
P-30229
needs to be replaced.
Replace the inner filter every third time the outer filter is Pull the outer filter (Item 1) [Figure 10-60-5] from the air
replaced or as indicated. cleaner housing.
Check the housing for damage.
Clean the housing and the seal surface. DO NOT use

compressed air.
Install a new outer filter.
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AIR CLEANER (CONT’D) Figure PM-7
Replacing The Filters (Cont’d)
Figure 10-60-6
1 1
P-30230
Install the new inner filter. [Figure PM-7].

P-30228
Install the outer filter and the dust cup.
Install the dust cup and turn about 1/8 turn [Figure 10- Press the button on the condition indicator to remove the
60-6]. red ring.
Push locking tab in (Item 1) [Figure 10-60-6].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
Inner Filter
Only replace the inner filter under the following

conditions:
• Replace the inner filter every third time the outer filter
is replaced.
• After the outer filter has been replaced, press the

button (Item 2) [Figure 10-60-6] on the top of the
condition indicator and start the engine. Run at full
RPM, then reduce engine speed and stop the engine.
If the red ring shows in the condition indicator, replace
the inner filter.
Remove the dust cup, outer filter and inner filter.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
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HEATER AIR FILTERS Fresh Air Filter
Recirculation Filter The fresh air filter must be cleaned regularly.
The recirculation filter must be cleaned regularly. The The fresh air filter is located on the bottom of the heater,
filter is located at the left of the operator seat. (Item 2) [Figure 10-61-8].
Figure 10-61-8 Remove the filter. Wash the filter with a mild detergent
and water. Dry the filter before installing. Install the filter
and secure.
P19669
The recirculation filter is located on the front of the heater

panel (Item 1) [Figure 10-61-8].
Remove the knobs and remove the filter. Wash the filter
with a mild detergent and water. Dry the filter before
installing. Install the filter and tighten knobs.
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ENGINE COOLING SYSTEM Figure 10-70-9
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
Cleaning The Cooling System 1
Open the tailgate.
Use air pressure or water pressure to clean the radiator

and oil cooler.
Checking Coolant Level
WARNING
P-49748
When the engine is cool, remove the radiator cap (Item

AVOID BURNS 1) [Figure 10-70-9].
Do not remove radiator cap when the engine is hot.
You can be seriously burned. The coolant level must be 0.750 to 1.0 inch (20 - 25 mm)
W-2070-1003
below the filler neck.
If the coolant level is low, add premixed coolant to the

radiator.
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist: IMPORTANT
• When fluids are under pressure.
• Flying debris or loose material is present. AVOID ENGINE DAMAGE
• Engine is running. Always use the correct ratio of water to antifreeze.
• Tools are being used.
W-2019-1285 Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
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ENGINE COOLING SYSTEM (CONT’D) Figure PM-11
Replacing The Coolant 1
See the SERVICE SCHEDULE for correct service

intervals. (See SERVICE SCHEDULE on Page 10-50-1.)
P-30238
Turn the upperstructure so there is access to the engine
and radiator from between the tracks. Stop the engine.
WARNING
AVOID BURNS
P-30231
You can be seriously burned.
W-2070-1003
Open the drain valve (Item 1) [Figure PM-11] at the
bottom of the radiator and drain the coolant into a
Figure 10-70-10 container.
Figure 10-70-12
1
P-49748
P-30232
When the engine is cool, loosen and remove the radiator
cap (Item 1) [Figure 10-70-10].
Open the drain valve (Item 1) [Figure 10-70-12] on the
engine block and drain the coolant into a container.
After all the coolant is removed, close the drain valve.
Recycle or dispose of the used coolant in an

environmentally safe manner.
Mix the coolant in a separate container. (See FUEL,

COOLANT AND LUBRICANTS on Page SPEC-60-1.)
NOTE: The cooling system is factory filled with

propylene glycol (purple color). DO NOT mix
propylene glycol with ethylene glycol.
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ENGINE COOLING SYSTEM (CONT’D)
Replacing The Coolant (Cont’d)
Add premixed coolant; 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with

one gallon of water is the correct mixture of coolant to
provide a -34°F (-37°C) freeze protection.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Add premixed coolant until the level is correct.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level and add as needed.
Install the radiator cap and tighten.
Add coolant to the recovery tank as needed.
Close the tailgate.
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FUEL SYSTEM Filling The Fuel Tank
Fuel Specifications Open the tailgate.
Use only clean, high quality diesel fuel, Grade No. 2 or Figure 10-80-1
Grade No. 1.
The following is a suggested blending guideline which

should prevent fuel gelling problems during freezing
temperature 1
Temp. F° (C°) No. 2 No. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
See your fuel supplier for local recommendations.
P-30228
WARNING Remove the fuel fill cap (Item 1) [Figure 10-80-1].

Stop and cool the engine before adding fuel. NO
Use a clean, approved safety container to add fuel. Add
SMOKING! Failure to obey warnings can cause an
fuel only in an area that has a free movement of air and
explosion or fire.
no flames or sparks. NO SMOKING!
W-2063-0887
Install and tighten the fuel fill cap. Close the tailgate.
See the SERVICE SCHEDULE for the service interval

WARNING when to remove water from or replace the fuel filter. (See
SERVICE SCHEDULE on Page 10-50-1.)
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
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FUEL SYSTEM (CONT’D)
Removing Water From The Fuel Filter
Open the tailgate.
Figure 10-80-2
1
P-30227
Loosen the drain (Item 1) [Figure 10-80-2] at the bottom

of the filter to drain water from the filter.
Replacing The Fuel Filter
Remove the filter (Item 2) [Figure 10-80-2].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and hand
tighten.
Remove the air from the fuel system. See Removing

Water From The Fuel Filter on Page 10-80-2
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FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Draining The Fuel Tank After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system
See the SERVICE SCHEDULE for the correct service before starting the engine.
Figure 10-80-4
Turn the upperstructure until the fuel tank drain is
centered between the rear tracks.
Figure 10-80-3
3
1
2
1
P-49746
Open the fuel filter vent (Item 1) [Figure 10-80-4].

P16463
Operate the hand pump (priming bulb) (Item 2) [Figure
10-80-4] until the fuel flows from the vent with no air
Remove the access panel (Item 1) [Figure 10-80-3] on bubbles.
the bottom of the engine compartment. Loosen the clamp
and disconnect the fuel hose. Close the vent (Item 1) [Figure 10-80-4] on the fuel filter
housing.
Drain the fuel into a container.
Start the engine. It may be necessary to open the vent
Reuse, recycle or dispose of fuel in an environmentally (Item 3) [Figure 10-80-4] (at the fuel injection pump)
safe manner. briefly until the engine runs smoothly.
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
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ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil Figure 10-90-6
Check the engine oil every day before starting the engine
for the work shift.
Figure 10-90-5
3
P-30231
2
Use a good quality motor oil that meets the correct API
Service Classification. See the oil chart [Figure 10-90-6].
P-30235
P-30231
Open the rear door and remove the dipstick (Item 1)

[Figure 10-90-5].
Keep the oil level between the marks on the dipstick.
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ENGINE LUBRICATIONS SYSTEM (CONT’D) Figure 10-90-7
Replacing Oil And Filter

1
See the SERVICE SCHEDULE for the service interval for
replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-50-1.)
Run the engine until it is at operating temperature. Stop

the engine.
Open the rear door.
Remove the drain plug (Item 2) [Figure 10-90-5 on Page

1]. Drain the oil into a container and recycle or dispose of
used oil in an environmentally safe manner. P-30237
Remove the oil filter element (Item 3) [Figure 10-90-5 on

Page 1] and clean the filter housing surface. Remove the fill cap (Item 1) [Figure 10-90-7].
Use a genuine Bobcat filter element. Put in 3.4 qts. (3,2 L) of oil into the engine. (See FUEL,
Put clean oil on the filter gasket.
Install the fill cap.
Install the filter and hand tighten.
Start the engine and let it run for several minutes.
Install and tighten the oil drain plug.
Stop the engine. Check for leaks at the oil filter. Check
the oil level.
Add oil as needed if it is not at the top mark on the

dipstick.
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HYDRAULIC SYSTEM Install the cap. Close the tailgate.
Checking And Adding Hydraulic Oil
Put the machine on a level surface.

WARNING
Retract the arm and bucket cylinders, put the bucket on
the ground and raise the blade. Stop the engine. Always clean up spilled fuel or oil. Keep heat, flames,
Figure 10-100-8 Failure to use care around combustibles can cause
W-2103-1285
Diagnostic Couplers
Figure 10-100-10
1
1
P-49750 1
Open the tailgate. The fluid must be at the center of the

sight gauge (Item 1) [Figure 10-100-8].
Remove oil fill cap (Item 2) [Figure 10-100-8].

P-30240
Figure 10-100-9
The diagnostic couplers (Item 1) [Figure 10-100-10] are
located on the hydraulic block.
The couplers can be used by your Bobcat dealer to

check circuit pressures.
P-49751
Check the condition of the screen (Item 1) [Figure 10-

100-9] in the fill neck of the reservoir. The screen must be
installed in fill neck when adding oil.
Add the correct fluid to the reservoir until it is at the

center of the sight gauge (Item 1) [Figure 10-100-8].
(See FUEL, COOLANT AND LUBRICANTS on Page
SPEC-60-1.)
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HYDRAULIC SYSTEM (CONT’D) Replacing Hydraulic Oil
Replacing The Hydraulic Filter See the SERVICE SCHEDULE for the correct service
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-50-1.) Retract the arm and bucket cylinders, lower the bucket to
the ground. Stop the engine.
Open the tailgate.
Remove and replace the hydraulic filter.
Figure 10-100-11
Figure 10-100-12
1
2
P-49750
P-33134
Remove the filter (Item 1) [Figure 10-100-11].

A hole (Item 1) [Figure 10-100-12] is provided in the
Clean the housing where the filter gasket makes contact. housing for ease of draining the hydraulic fluid.
Put clean hydraulic fluid on the gasket. Install the new Figure 10-100-13
filter and hand tighten only.
Start the engine. Run the Excavator through the hydraulic

functions. Stop the engine. Check the fluid level at the
sight gauge (Item 2) [Figure 10-100-11] and add as
needed. Check the filter area for leaks.
1
P-33133
Install a funnel (Item 1) [Figure 10-100-13] in the hole.
Place a container under the funnel.
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HYDRAULIC SYSTEM (CONT’D) Figure 10-100-15
Replacing Hydraulic Oil (Cont’d)
Figure 10-100-14
P-49750
Add fluid to the reservoir until it is at the center of the

P-49752 sight gauge (Item 1) [Figure 10-100-15]. (See FUEL,
Remove the drain plug (Item 1) [Figure 10-100-14] and Run the Excavator through the hydraulic functions. Stop
drain the hydraulic fluid into the container. the engine. Check the fluid level and add as needed.
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be deposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499
IMPORTANT
If the fluid is being drained because of a system
failure, remove and clean all hydraulic lines.
I-2045-0788
Install the drain plug.
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LUBRICATION OF THE HYDRAULIC EXCAVATOR 4. Boom Swing Cylinder-Rod End, every 8-10 hours (1)
[Figure 10-110-17]
Lubricate the Hydraulic Excavator as specified in the
SERVICE SCHEDULE for the best performance of the 5. Boom Cylinder-Base End, every 8-10 hours (1)
machine. (See SERVICE SCHEDULE on Page 10-50-1.) [Figure 10-110-17]
Record the operating hours each time you lubricate the Figure 10-110-18
Hydraulic Excavator.
6
Always use a good quality lithium based multi-purpose
grease when lubricating the Excavator. Apply the
lubricant until extra grease shows.
Figure 10-110-16
7
1 7
2 P16896
2
6. Boom Base Pivot, every 8-10 hours (1) [Figure 10-

3 110-18]
7. Boom Swing Pivot, every 8-10 hours (2) [Figure 10-

P15009 110-18]
Ref Description (# of Fittings)
1. Blade Cylinder-Rod End, every 8-10 hours (1)

[Figure 10-110-16]
2. Blade Pivots, every 8-10 hours (2) [Figure 10-110-

16]
3. Blade Cylinder-Base End, every 8-10 hours (1)

[Figure 10-110-16]
Figure 10-110-17
P15010
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LUBRICATION OF THE HYDRAULIC EXCAVATOR 15. Bucket Pivots, every 8-10 hours (3) [Figure 10-110-
(CONT’D) 20]
Figure 10-110-19 Figure 10-110-21

9
10
11 17 18
16
8
12
P15013
P-49720
8. Boom Cylinder-Rod End, every 8-10 hours (1) 16. Swing Circle Pinion, every 50 hours. Pump 4 times
[Figure 10-110-19] with a grease gun. Rotate the upperstructure 180°
and repeat. [Figure 10-110-21]
9. Arm Cylinder-Base End, every 8-10 hours (1) [Figure
10-110-19] 17. Swing Circle Bearing, every 50 hours [Figure 10-110-
21]
10. Arm Cylinder-Rod End, every 8-10 hours (1) [Figure
10-110-19] NOTE: Do not over-grease the swing circle; damage
to the seal could result. Pump 4 to 5 times with
11. Arm Pivot, every 8-10 hours (1) [Figure 10-110-19] a grease gun. Rotate the upperstructure 90°
and repeat three more times.
12. Bucket Cylinder-Base End, every 8-10 hours (1)
[Figure 10-110-19] 18. Boom Swing Cylinder-Base End every 50 hours
[Figure 10-110-21]
Figure 10-110-20
Figure 10-110-22
14
19 19
15
13
15
15
P16898
P16901
13. Bucket Cylinder-Rod End, every 8-10 hours (1)

[Figure 10-110-20] 19. Track Expansion Tube, as required [Figure 10-110-
22].
14. Bucket Link Pivots, every 8-10 hours (2) [Figure 10-
110-20] NOTE: Spread lubriplate gearshield extra heavy
grease evenly on wear surfaces on both sides
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TRAVEL MOTOR Draining The Travel Motor
Checking Oil Level See Service Schedule for the correct service interval.
(See SERVICE SCHEDULE on Page 10-50-1)
Figure 10-120-23
Put the machine on a level surface with the plugs
positioned as shown (Items 1 & 2) [Figure 10-120-23].
Remove the bottom plug (Item 2) and top plug (Item 1)

[Figure 10-120-23] and drain into a container. Recycle or
dispose of the used lubricant in an environmentally safe
manner.
After all the gear lube is removed, install plug (Item 2)

[Figure 10-120-23].
1
Add gear lube to the plug hole (Item 1) [Figure 10-120-
2 23] until the gear lube level is at the bottom edge of the
plug hole. See Chart for capacity and type. (See FUEL,
P-49755 COOLANT AND LUBRICANTS on Page SPEC-60-1.)
Install and tighten the plug.

Put the machine on a level surface with the plugs
positioned as shown (Items 1 & 2) [Figure 10-120-23]. Repeat the procedure for the other side.
Remove the plug (Item 1) [Figure 10-120-23]. The oil
level should be at the bottom edge of the plug hole.
Add gear lube through the hole if the oil level is below the
hole. See Chart for capacity and type. (See FUEL,
Install and tighten both plugs.
Repeat the procedure for the other side.
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SPARK ARRESTOR MUFFLER
See the SERVICE SCHEDULE for the correct service

WARNING
Do not operate the Excavator with a defective exhaust When an engine is running in an enclosed area, fresh
system. air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
Stop the engine. Open the rear door. outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Figure 10-130-1 W-2050-1285
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
N-22544
WARNING
Never use machine in atmosphere with explosive
Remove the plug (Item 1) [Figure 10-130-1] from the dust or gases or where exhaust can contact
bottom of the muffler. flammable material. Failure to obey warnings can
cause injury or death.
Start the engine and run for about ten seconds while a W-2068-1285
second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler. (The carbon deposits
will be forced out of the muffler cleanout hole.)
Stop the engine. Install and tighten the plug.

WARNING
Close the rear door. When the engine is running during service, the
steering levers must be in neutral.
Failure to do so can cause injury or death.

W-2203-0595
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ALTERNATOR BELT Figure 10-140-4
Adjusting The Alternator Belt
Replace the belt if it has stretched or there are cracks in

the belt. Replace the pulley if the belt contacts the bottom
of the groove in the pulley.
Stop the engine. 1

1
Figure 10-140-2 2
P-49756
Remove two bolts (Item 1) and remove the access panel

(Item 2) [Figure 10-140-4].
Figure 10-140-5
1
2
P-49739
1
Release the seat lever (Item 1) [Figure 10-140-2]. Pull
the seat to the front and remove it from the Excavator.
Use the start key to remove the cover (Item 1) [Figure

10-140-2] from the storage compartment.
Figure 10-140-3
P-30252
Loosen the alternator mounting and adjustment bolts

(Item 1) [Figure 10-140-5].
Move the alternator toward the front of the machine

[Figure 10-140-5] until the belt has 0.50 inch (13 mm)
movement at the middle of the belt span with 13 lbs. (58
N) of force.
Tighten the mounting and adjustment bolts.
1 P-30248 Install the access panel, lower the seat pan and engage
the latch.
Reach into the storage compartment (Item 1) and turn Install the seat and the storage compartment cover.
the release for the seat pan. Raise the seat pan and tip it
toward the rear of the machine [Figure 10-140-3].
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SEAT BELT Figure 10-150-6
Inspection And Maintenance
WARNING
Failure to properly inspect and maintain the seat belt
can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
Check the seat belt daily for correct function.
Inspect the seat belt system thoroughly yearly or more

often if the machine is exposed to severe environmental
conditions or applications.
The seat belt system should be repaired or replaced if it

shows cuts, fraying, extreme or unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,
dusty/dirty conditions, abrasion to the seat belt webbing,
or damage to the buckle, latch plate, retractor (if
equipped), or hardware.
B-22283
The items below are referenced in [Figure 10-150-6].
1. Check the seat belt webbing. If the system is

equipped with a retractor, pull the webbing completely
out and inspect the full length of the webbing. look for
cuts, wear, fraying, dirt and stiffness.
2. Check the buckle and latch for proper function. Make

sure latch plate is not excessively worn, deformed or
buckle is not damaged.
3. Check the retractor web storage device (if equipped)

by extending the seat belt webbing to determine if it
extends and retracts the webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have weakened.
See your Bobcat dealer for approved seat belt system

replacement parts for your machine.
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CONTROL CONSOLE LOCKOUTS Raise the left console. (Green light on the consoles will
go off.)
Inspection And Maintenance
Move the joystick control levers. There should be no
Figure 10-160-7 movement of the boom, crowd, house swing or bucket.
Move the steering control levers. there should be no

movement of the Excavator tracks.
Lower the left console. Raise the right console and

repeat the inspection procedure.
The joystick control levers and traction system must be

deactivated when either console is raised.
Service the system if these controls do not deactivate

when either control console is raised. (See your Bobcat
dealer for service.)
“
N-22463
Figure 10-160-8
N-22465
When either console is raised [Figure 10-160-7] &

[Figure 10-160-8], the hydraulic control levers (joysticks)
and traction system must not function.
Sit in the operator's seat, fasten the seat belt and start
the engine.
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HYDRAULIC SYSTEM
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 HYDRAULIC
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2 SYSTEM
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-6
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . . . . . 20-100-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
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HYDRAULIC SYSTEM (CONT’D)
CROSSPORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1

Testing And Adjusting The Crossport Relief Valve . . . . . . . . . . . . . . 20-32-1
HYDRAULIC CONTROL VALVE (320 / 322) . . . . . . . . . . . . . . . . . . . . . 20-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-37
Arm Valve Section Disassembly and Assembly . . . . . . . . . . . . . . . 20-40-27
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-40-6
Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-40-10
Boom Swing Valve Section Disassembly And Assembly . . . . . . . . 20-40-30
Boom Valve Section Disassembly and Assembly . . . . . . . . . . . . . . 20-40-20
Bucket Valve Section Disassembly and Assembly . . . . . . . . . . . . . 20-40-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Left Travel Valve Section Disassembly and Assembly . . . . . . . . . . 20-40-17
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Right Travel Valve Section Disassembly And Assembly . . . . . . . . . 20-40-33
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . 20-40-13
HYDRAULIC CONTROL VALVE (320L) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-37
Arm Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . 20-41-27
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-41-6
Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-41-10
Boom Swing Valve Section Disassembly And Assembly . . . . . . . . 20-41-30
Boom Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-41-20
Bucket Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-41-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
Left Travel Valve Section Disassembly And Assembly . . . . . . . . . . 20-41-17
Right Travel Valve Section Disassembly And Assembly . . . . . . . . . 20-41-33
Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . 20-41-13
HYDRAULIC FILTER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Testing The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
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HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic/Hydrostatic Symbols For Excavators . . . 20-10-1
Troubleshooting The Cylinder Circuit. . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . 20-10-4
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . . . . . 20-10-7
Troubleshooting The Swing (Upperstructure Slew) Circuit . . . . 20-10-6
LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . . . 20-111-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-7
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-111-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Testing And Adjusting The Main Relief Valve . . . . . . . . . . . . . . 20-30-1
MANIFOLD ASSEMBLY/ACCUMULATOR. . . . . . . . . . . . . . . . . . . 20-60-1

Assembly (S/N 223911001 - 223911247 & S/N 224011001 -
224012293) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-13
Assembly (S/N 223911248 & Above & S/N 224012294 & Above) 20-60-
36
Disassembly (S/N 223911001 - 223911247 & S/N 224011001 -
224012293) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Disassembly (S/N 223911248 & Above & S/N 224012294 & Above) 20-
60-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Parts Identification (S/N 223911001 - 223911247 & S/N 224011001 -
224012293) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Parts Identification (S/N 223911248 & Above & S/N 224012294 &
Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-22
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Testing And Adjusting The Port Relief Valve Pressure . . . . . . . 20-31-1
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33-1

Testing And Adjusting The Pressure Reducing Valve . . . . . . . . 20-33-1
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RIGHT CONTROL LEVER (JOYSTICK). . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-7
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-6
Parts Identification 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
Parts Identification 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-5
TRACK FRAME EXPANSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 20-25-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
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HYDRAULIC/HYDROSTATIC SCHEMATIC
320L (S/N 223911001 AND ABOVE)
(PRINTED JULY 2006)
V-0849le
LEGEND
1 HYDRAULIC RESERVOIR 15 PORT RELIEF VALVE
(PRESSURIZED)with FILL Bucket Cylinder (Rod End)
STRAINER 3335 PSI (230 Bar)
Capacity . . . . . . . 6.8 Qts. (6,5 L)
16 PORT RELIEF VALVE
2 Bucket Cylinder (Base End)
PRESSURIZED BREATHER/FILL CAP
2900 PSI (200 Bar)
with FILTER
5 PSI (0,34 Bar) - Outlet
0.435 PSI (0,03 Bar) - Inlet 17 PORT RELIEF VALVE
Arm Cylinder (Rod End)
3 SOLENOID VALVE - SYSTEM BY-PASS 3335 PSI (230 Bar)

4 MAIN RELIEF VALVE Arm Cylinder (Base End)
2500 PSI (172 Bar) 2900 PSI (200 Bar)
5 TEST PORT - "G" Port - Gauge Test Port 19 TEST PORT - "F" Port - Factory Fill Port
6 HYDRAULIC FILTER ELEMENT

10 Micron 20 PRESSURE REDUCING VALVE
435 PSI (30 Bar)
7 FILTER BY-PASS 25 PSI (1,72 Bar)
21 ACCUMULATOR
Nitrogen . . . . . 165 PSI (11 Bar)
8 SWING MOTOR CROSS PORT RELIEF non-rechargeable
VALVE . . . . . . . 1475 PSI (102 Bar)
When Tested at "G" Port
22 CONSOLE LOCK OUT SOLENOID
9 HYDRAULIC PUMP . Triple Section -
Gear Pump: 23 BUILD UP VALVE . 218 PSI (15 Bar)
Pump Section 1
8.0 GPM (30,0 L/min.) at High Engine Idle 24 ORIFICE . . . . . . . . . . 0.063" (1.70 mm)
Pump Sections 2 & 3 Bore of Tee Fitting
4.0 GPM (15,0 L/min.) at High Engine Idle
25 OIL COOLER
10 TRAVEL MOTOR SPOOL - RIGHT HAND
11 TRAVEL MOTOR SPOOL - LEFT HAND
12 ORIFICE . . . . .0.040 inch (1,02 mm)

Boom Cylinder (Rod End)
3335 PSI (230 Bar) NOTE: Unless otherwise specified
springs have NO significant
Boom Cylinder (Base End) pressure value.
3335 PSI (230 Bar)
Printed in U.S.A. V-0849le (7-10-06)
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HYDRAULIC CONTROL VALVE
320L (S/N 223911001 AND ABOVE) P1 MANIFOLD ASSEMBLY
(PRINTED JULY 2006) PS1
V-0849 22
T1 21
RIGHT HAND TRAVEL MOTOR Printable Version Click Here RIGHT HAND
TRAVEL PS2
A 5 G 20
10
B B PUMP 1
P1 V1
9
P2
A V2
BOOM
BOOM SWING
SWING PUMP 2
CYLINDER A
T1
V3
B F 4 PUMP 3
19
BLADE HYDRAULIC PUMPS
CYLINDER 3
ARM
ARM
CYLINDER
A T
12 P2 RIGHT HAND JOYSTICK
1
B
P3
17 4
3 3
1 1
18
8B BUCKET P
5 5
7 7 T
A
8A 8
B 3
6 6
15
4 4 2
16
LEFT HAND JOYSTICK
1
23
CENTER
SWIVEL JOINT 4
P
T1 14
T
11 13
A
P1 3
L3
IS
L3
O
P2 B
2
L1
L1
BOOM
IS
O
ST
O
IS
D
R
FRONT
1
IS
BOOM
R1
O
BACK
CYLINDER
LEFT HAND TRAVEL MOTOR A
R3
R3
IS
O
B US OPTION
BUCKET
ISO/STD CONVERTER
CYLINDER LEFT HAND
(ISO SHOWN)
TRAVEL
T2
BREATHER CAP
SLEW
SWING MOTOR
2
TOP A
BOTTOM B
8
8
BLADE 1
FILTER WITH BY-PASS
24 A
6
WORKING CIRCUITS
PILOT CIRCUITS B
DRAIN CIRCUITS FRONT

COMPONENTS AUXILIARY
HYDRAULICS AUXILIARY
MALE (RETURN) 25
(OPTIONAL) A 7
B
FEMALE (PRESSURE)
Printed in U.S.A. V-0849 (7-10-06)
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320 (S/N 223911001 AND ABOVE))
322 (S/N 224011001 AND ABOVE)
(PRINTED JULY 2006)
V-0488le
LEGEND
1 HYDRAULIC RESERVOIR 15 PORT RELIEF VALVE
(PRESSURIZED)with FILL Bucket Cylinder (Rod End)
STRAINER 3335 PSI (230 Bar)
Capacity . . . . . . . 6.8 Qts. (6,5 L)
2 Bucket Cylinder (Base End)
PRESSURIZED BREATHER/FILL CAP
2900 PSI (200 Bar)
with FILTER
5 PSI (0,34 Bar) - Outlet
0.435 PSI (0,03 Bar) - Inlet 17 PORT RELIEF VALVE
Arm Cylinder (Rod End)
3 SOLENOID VALVE - SYSTEM BY-PASS 3335 PSI (230 Bar)

4 MAIN RELIEF VALVE Arm Cylinder (Base End)
2500 PSI (172 Bar) 2900 PSI (200 Bar)
5 SOLENOID VALVE - TWO SPEED 19 SOLENOID VALVE . . . . . . 322 ONLY
Blade/Track Expansion
6 HYDRAULIC FILTER ELEMENT 20 PRESSURE REDUCING VALVE

10 Micron 435 PSI (30 Bar)
21 ACCUMULATOR
7 FILTER BY-PASS 25 PSI (1,72 Bar)
Nitrogen . . . . . 165 PSI (11 Bar)
non-rechargeable
8 SWING MOTOR CROSS PORT RELIEF
VALVE . . . . . . . 1475 PSI (102 Bar) 22 CONSOLE LOCK OUT SOLENOID
When Tested at "G" Port
9 23 BUILD UP VALVE . 218 PSI (15 Bar)

HYDRAULIC PUMP . Triple Section -
Gear Pump:
Pump Section 1 24 ORIFICE . . . . . . . . . . 0.063" (1.70 mm)
8.0 GPM (30,0 L/min.) at High Engine Idle Bore of Tee Fitting
Pump Sections 2 & 3
4.0 GPM (15,0 L/min.) at High Engine Idle 25 OIL COOLER
10 TRAVEL MOTOR SPOOL - RIGHT HAND 26 TEST PORT - "F" Port - Factory Fill Port
11 TRAVEL MOTOR SPOOL - LEFT HAND 27 TEST PORT - "G" Port - Gauge Test Port
12 ORIFICE . . . . .0.040 inch (1,02 mm)

Boom Cylinder (Rod End) NOTE: Unless otherwise specified
3335 PSI (230 Bar) springs have NO significant
pressure value.
Boom Cylinder (Base End)
3335 PSI (230 Bar)
Printed in U.S.A. V-0488le (7-10-06)
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Printable Version Click Here
320 (S/N 223911001 AND ABOVE) HYDRAULIC CONTROL VALVE
322 (S/N 224011001 AND ABOVE) P1 MANIFOLD ASSEMBLY
(PRINTED JULY 2006) PS1
V-0488 22
3 3 T1 21
RIGHT HAND TRAVEL MOTOR 1 1 RIGHT HAND
TRAVEL PS2
A 27
CENTER G 20
10
B SWIVEL JOINT B PUMP 1
320 ONLY
P1 V1
9
P2
A V2
BOOM
BOOM SWING
SWING PUMP 2
CYLINDER A
T1 V3
B F 4 PUMP 3
26
BLADE HYDRAULIC PUMPS
PB
CYLINDER 3
ARM
ARM 5
CYLINDER
A T
12 P2 RIGHT HAND JOYSTICK
1
B
P3
17 4
3 3
1A 1 18
1B BUCKET P
8B
5 5
7 7 T
A
8A 8
6 6
4 4
B 3
19 15
2 2
16
LEFT HAND JOYSTICK
1
CENTER 23
SWIVEL JOINT 4
322 ONLY
14
T
13
A
EXPAND CYL
3
L3
322 ONLY
IS
L3
O
B
2
L1
L1
BOOM
IS
O
S
O
TD
IS
R
FRONT
1
IS
BOOM
1
O
R
T1 CYLINDER
BACK
3
3
R
IS
O
11
B US OPTION
BUCKET
P1 ISO/STD CONVERTER
CYLINDER LEFT HAND
(ISO SHOWN)
TRAVEL
P2
T2
LEFT HAND TRAVEL MOTOR

BREATHER CAP
SLEW
SWING MOTOR
2
TOP A
BOTTOM B
8
8
BLADE 1
FILTER WITH BY-PASS
24 A
6
WORKING CIRCUITS
PILOT CIRCUITS B
DRAIN CIRCUITS
COMPONENTS FRONT AUXILIARY
AUXILIARY MALE (RETURN) 25
HYDRAULICS A 7
PB
B
FEMALE (PRESSURE)
V-0488 (7-10-06)
Printed in U.S.A.
76 of 705
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
MS-1892-1 (6-2-98)
320/322 Excavator
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HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators (Cont’d)
MS-1892-2 (6-2-98)
320/322 Excavator
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Glossary Of Hydraulic/Hydrostatic Symbols For Excavators (Cont’d)
MS-1892-3 (6-2-98)
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Troubleshooting The Hydraulic Circuit
TROUBLESHOOTING THE HYDRAULIC CIRCUIT

PROBLEM CAUSE CORRECTION
No hydraulic operation at one or Hydraulic oil level low. Refill with correct oil.
more circuits. Hydraulic pump drive coupling damaged. Replace.
Hydraulic pump defective. Check, repair or replace.
Main relief valve defective. Readjust or replace.
Hydraulic power insufficient to one Main relief valve pressure setting incorrect. Readjust or replace.
or more circuits.
Hydraulic speed too slow. Hydraulic oil level or viscosity incorrect. Refill or replace.
Engine RPM reduced. Readjust or replace.
Control valve linkage defective. Check, repair or replace
Hydraulic pump volume low. Check, repair or replace.
Oil temperature too high. Oil cooler or radiator fins plugged. Clean oil cooler external
surface.
Hydraulic oil level low. Refill or replace.
Non recommended hydraulic oil Replace.
Relief valve excessively activated. Use proper operating
procedures.
One or more relief valves not set correctly. Test, readjust or replace.
Extreme operating conditions. High ambient
temperature (IE: enclosed structure).
Alternator belt loose. Tighten alternator belt.
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Troubleshooting The Cylinder Circuit
TROUBLESHOOTING THE CYLINDER CIRCUIT

Cylinder inoperable. Control console(s) raised. Lower control console.
Loose fittings or broken hoses. Repair or replace.
Lever linkage misadjusted. Readjust.
Control console lockout switch. Readjust or replace.
Cylinder internal leakage excessive. Repair or replace.
Control lever (joystick) manifold solenoid coil Test, repair or replace.
defective.
Control lever (joystick) manifold solenoid valve Test, repair or replace.
defective.
Control lever (joystick) manifold pressure reducing Test, repair or replace.
valve defective.
Control lever (joystick) internal leakage excessive. Repair or replace.
Cylinder force insufficient. Main relief valve pressure too low. Readjust or replace.
Work port relief pressure too low. Readjust or replace.
Cylinder speed too slow. Lever linkage misadjusted. Readjust.
Cylinder internal leakage excessive. Repair or replace.
Control lever (joystick) manifold solenoid valve Repair or replace.
defective.
Control lever (joystick) manifold pressure reducing Repair or replace.
valve defective.
Control valve internal leakage excessive. Repair or replace.
Cylinder drift excessive. Cylinder internal leakage excessive. Repair or replace.
Work port relief valve seals leaking. Test, repair or replace.
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Troubleshooting The Swing (Upperstructure Slew) Circuit
TROUBLESHOOTING THE SWING (UPPERSTRUCTURE SLEW) CIRCUIT

Swing not operating. Control console(s) raised. Lower control console(s).
Control console lockout switch defective. Readjust or replace.
Swing lock pin engaged. Disengage lock pin.
Control lever (joystick) manifold pressure reducing Repair or replace.
valve defective.
Control lever (joystick) manifold solenoid coil Replace.
defective.
Control lever (joystick) manifold solenoid valve Repair or replace.
defective.
Swing motor gear defective. Repair or replace.
Control lever (joystick) internal leakage excessive. Repair or replace
Swing motor defective. Repair or replace.
Swing force. Main relief valve set too low. Readjust or replace.
Swing motor relief valve pressure too low. Readjust or replace.
Swing speed too slow. Pump flow low. Check, repair or replace.
Blocked or restricted line to swing motor. Replace.
Swing motor internal leakage excessive. Repair or replace.
Swing over run excessive. Control valve spool sticking. Repair or replace.
Control lever (joystick) spool sticking. Repair or replace.
Swing motor relief valve set too low. Repair or replace.
Swing motor internal leakage excessive. Repair or replace.
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Troubleshooting The Travel Circuit
TROUBLESHOOTING THE TRAVEL CIRCUIT

Travel system inoperable. Lever linkage incorrectly adjusted. Readjust.
Track tension too tight. Readjust.
Defective pump. Check, repair or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Travel motor internal leakage excessive. Repair or replace.
Travel motor defective. Repair or replace.
Travel motor gears defective. Repair or replace.
Swivel joint defective. Repair or replace.
Main relief valve pressure too low. Readjust or replace.
Travel power. Track tension too tight. Readjust.
Main relief valve pressure too low. Readjust or replace.
Speed too slow. Lever linkage incorrectly adjusted. Readjust.
Swivel joint internal leakage excessive. Repair or replace.
Low pump pressure. Check, repair or replace.
Travel motor internal leakage excessive. Repair or replace.
Machine not running straight. Lever linkage incorrectly adjusted. Readjust.
Track tension not equal. Readjust.
Pump output not equal. Repair or replace.
Travel motor internal leakage not equal. Repair or replace.
Main relief valve pressure set too low. Repair or replace.
Swivel joint internal leakage excessive. Repair or replace.
Control valve internal leakage not equal. Repair or replace.
Machine will not hold on slope or Travel motor counterbalance valve leakage Repair or replace.
while digging. excessive.
Hose damage. Replace.
Blade drops while machine is Lever linkage misadjusted. Readjust.
moving. Cylinder internal leakage excessive. Repair or replace.
Swivel joint internal leakage from travel motor Repair or replace.
pressure circuit into blade cylinder circuit.
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BOOM CYLINDER Figure 20-20-3
Testing
Lower the boom/bucket and blade to the ground.
Stop the engine. Raise the control console.
Figure 20-20-1 3
1
2
N-22590
Remove the retaining ring (Item 1) and washer (Item 2)

[Figure 20-20-3] from the rod end pivot pin.
1
Remove the pivot pin (Item 3) [Figure 20-20-3].
N-22589 Figure 20-20-4
Support the boom using a chain hoist [Figure 20-20-1].
Remove the boom shield mounting bolt (Item 1) [Figure

20-20-1].
Figure 20-20-2
N-22592
1 Support the boom cylinder [Figure 20-20-4].

3
P-16441
Remove the spacer (Item 1) and slide the shield down

until the shield can be removed from the boom cylinder
shield mounting stud (Item 2). The shield will come out of
the key hole (Item 3) [Figure 20-20-2].
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BOOM CYLINDER (CONT’D) Figure 20-20-6
Testing (Cont’d)
Figure 20-20-5
N-22594
Install a cap (Item 1) [Figure 20-20-6] on the hose fitting

N-22593 and tighten.
Lower control console and fasten seat belt. Start the

Lower control console and fasten the seat belt. Start the engine and retract the boom cylinder.
engine and retract the boom cylinder [Figure 20-20-5].
If there is any leakage from the base end fitting on the
With the key in the ON position and the engine stopped, boom cylinder, remove the cylinder for repair or
move the hydraulic controls to release the hydraulic replacement.
pressure. Raise the control console.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Disconnect the boom cylinder base end hose (Item 1)

[Figure 20-20-5] at the hose tubeline connection.
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Removal and Installation

2
Lower the boom/bucket and blade to the ground. Stop
the engine.
Figure 20-20-7
1
3
P-16441
Remove the spacer (Item 1) and slide the shield down

until the shield can be removed from boom cylinder
1 shield mounting stud (Item 2). The shield will come out of
the key hole (Item 3) [Figure 20-20-8].
N-22635
Figure 20-20-9

2
With the key in the ON position, move the hydraulic
controls to release the hydraulic pressure.
IMPORTANT 2
When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 3
P-16433
damage the system.
I-2003-0888
Remove hose retainer clamp (Item 1) [Figure 20-20-9]
Remove the boom shield mounting bolt (Item 1) [Figure from hoses and cylinder.
20-20-7].
Disconnect and cap the two hoses (Item 2) [Figure 20-
20-9] from the boom cylinder.
Remove the snap ring (Item 3) [Figure 20-20-9] and

washers from the boom cylinder base end pin.
Remove the cylinder base end pin.
Lower the base end of the cylinder to the floor.
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BOOM CYLINDER (CONT’D)
Removal and Installation (Cont’d)

WARNING
Figure 20-20-10
immediately.
W-2145-0290
1
WARNING
N-22636
Remove the snap ring (Item 1) [Figure 20-20-10] and W-2103-1285
washer from the cylinder rod end pin.
Remove the cylinder rod end pin. Remove the boom

cylinder from the boom.
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Parts Identification
1. Rod 7. Piston
2. Wiper 8. Nut
3. Seal 9. Housing
4. Head 10. Plug
5. O-Ring 11. Bushing
6. Backup Ring
2
3
4 5
5
6
5
3
10
5
11
10
B-14213A B-14213B
B-13593A
B-14213
320/322 Excavator
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BOOM CYLINDER (CONT’D) Remove the head and the rod assembly from the cylinder
[Figure 20-20-12]. Put the rod end in a vise.
Disassembly
Remove the nut (Item 1), piston (Item 2) and head (Item
Clean the outside of the boom cylinder before 3) [Figure 20-20-12].
disassembly.
Figure 20-20-13
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench 3
MEL1075-1 - Standard Pins
1 2
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise.
Figure 20-20-11
N-22355
1 Cushion Piston: Remove the seal (Item 1) and O-ring

(Item 2) from the piston (Item 3) [Figure 20-20-13].
Figure 20-20-14
1 4
2
1
N-22352
Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-20-11] to loosen the head.
Figure 20-20-12
N-22356
3
2
1
Remove the O-ring (Item 1) and the back-up ring (Item 2)
from the groove in the head (Item 3) [Figure 20-20-14].
Remove the O-ring (Item 4) [Figure 20-20-14].
N-22354
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BOOM CYLINDER (CONT’D) Assembly
Disassembly (Cont’d) Use the following tools to assemble the cylinder:
Figure 20-20-15 MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
3 Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
2 Clean all parts in solvent and dry with compressed air.
1
Inspect all parts for wear or damage. Replace any worn
or damaged parts.
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
Figure 20-20-17
N-22357
Remove the wiper seal (Item 1) and rod seal (Item 2)

from the inside of the head (Item 3) [Figure 20-20-15].
Figure 20-20-16
P-7424
2
Install new seal on the tool and slowly stretch it until it fits
1 the piston [Figure 20-20-17].
Allow the seal to stretch for 30 seconds before installing it

N-22364 on the piston.
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-

16].
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Assembly (Cont’d)
Figure 20-20-18
1
2
P-7427
Install the rod seal on the rod seal tool [Figure 20-20-20].
N-22355
NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Cushion Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-20-18]. Rotate the handles to collapse the rod seal [Figure 20-
20-20].
Figure 20-20-19
Figure 20-20-21
N-22358
P-7425
Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about Install the rod seal in the head [Figure 20-20-21].
three minutes [Figure 20-20-19].
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Assembly (Cont’d)
Figure 20-20-22 1
2
3
N-22354
1
Install the head (Item 1) and the piston (Item 2) [Figure

N-22359 20-20-24] on the rod as shown.
Grease the piston where the nut contacts the piston. Do

Install the wiper seal with the wiper (Item 1) [Figure 20- not get grease on the threads.
20-22] toward the outside of the head.
Provide an adequate support for the cylinder before
Figure 20-20-23 tightening.
4 Install the nut (Item 3) [Figure 20-20-24].
NOTE: Clean and dry the rod threads, from the kit
1 install a NEW NUT with pre-applied LOCTITE.
3 2
Tighten the nut to 600 ft.-lbs. (813 Nm) torque.
Figure 20-20-25
N-22356
Install the O-ring (Item 1) [Figure 20-20-23]. 2

1
Install the back-up ring (Item 2) and O-ring (Item 3) into
the groove on the head (Item 4) [Figure 20-20-23].
N-22364
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

20-25].
Tighten the plug to 8 ft.-lbs. (11 Nm) torque.
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Assembly (Cont’d)
Put the base end of the hydraulic cylinder in a vise.
Figure 20-20-26
N-22352
(Item 1) [Figure 20-20-26] to tighten the head. Head to
be torqued until flush with end of the housing.
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ARM CYLINDER
Testing
WARNING
Stop the engine. Raise the control console. sufficient force to enter a person’s body by
Figure 20-21-1 and possible death if proper medical treatment by a
immediately.
2 W-2145-0290
1
Figure 20-21-3
N-22595
Support the boom using a chain hoist [Figure 20-21-1]. 1
Remove the retaining ring (Item 1) and washer (Item 2)

N-22597
Figure 20-21-2 Lower control console and fasten the seat belt. Start the
engine and retract the arm cylinder [Figure 20-21-3].
2 Stop the engine. With the key in the ON position, move

the hydraulic controls to release the hydraulic pressure.
Raise the control console.
Disconnect the arm cylinder base end hose (Item 1)

[Figure 20-21-3] back at the hose tubeline connection.
N-22596
Support the arm cylinder (Item 1) [Figure 20-21-2].
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ARM CYLINDER (CONT’D) Removal and Installation
Testing (Cont’d) Lower the boom/bucket and blade to the ground. Stop
the engine.
Figure 20-21-4
Figure 20-21-5
2 1
1
3
N-22598
N-22637A N-22637
Install a plug (Item 1) [Figure 20-21-4] on the tubeline

and tighten. Support the boom using a chain hoist [Figure 20-21-5].
Lower control console and fasten the seat belt. Start the With the key in the ON position, move the hydraulic
engine and retract the arm cylinder. controls to release the hydraulic pressure.
If there is any leakage from the base end hose on the

arm cylinder, remove the cylinder for repair or
replacement.
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Remove and plug the two hoses (Item 1) [Figure 20-21-

5] from the arm cylinder.
Remove the hose clamp (Item 2) [Figure 20-21-5] from

the arm cylinder.

washer from the boom cylinder base end pin.
Remove the cylinder base end pin.
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ARM CYLINDER (CONT’D)
Removal And Installation (Cont’d)
WARNING
immediately.
W-2145-0290
WARNING
W-2103-1285
Figure 20-21-6
P-16440

washer from the cylinder rod end pin.
Remove the cylinder rod end pin.
Remove the cylinder from the arm.
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ARM CYLINDER (CONT’D)
1. Seal 1
2. Bushing 2
3. Rod
4. Wiper
5. Head 1
6. Spacer
7. O-Ring
8. Backup Ring
9. Piston 3
10. Nut
11. Plug
12. Housing 4
6
5 1
7
8
7
7
1
10
11
7
11
14
B-14213A B-14213B
B-13593A
B-14212
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ARM CYLINDER (CONT’D) Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
[Figure 20-21-8] and head (Item 4) [Figure 20-21-8].
Disassembly
Figure 20-21-9
Clean the outside of the arm cylinder before disassembly.
Use the following tools to disassemble the cylinder: 3

MEL1075 - Adjustable Gland Nut Wrench 2
MEL1075-2 - Special Offset Pins 1

cylinder.
Figure 20-21-7 N-22418
Standard Piston: Remove the seal (Item 1) and O-ring

1
Figure 20-21-10
3
1 2
1
N-22421
Figure 20-21-8 N-22356

3 4
2 from the groove in the head (Item 3) [Figure 20-21-10].
1
N-22423
Remove the head and the rod assembly from the cylinder
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ARM CYLINDER (CONT’D) Figure 20-21-13
Disassembly (Cont’d)
1
Figure 20-21-11
2
1 1 2
N-22419
Remove the seals (Item 1) and bushing (Item 2) [Figure

N-22357 20-21-13].

Figure 20-21-12
N-22364

12].
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Assembly
3
Use the following tools to assemble the cylinder:
1
MEL1396 - Universal Seal Expander
2
Piston Ring Compressor
MEL1075-2 - Special Offset Pins
Clean all parts in solvent and dry with compressed air.

or damaged parts. N-22418

and O-rings with clean hydraulic fluid before installation. Standard Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-21-15].
Figure 20-21-14
Figure 20-21-16
P-7424
N-22358
Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-21-14]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it three minutes [Figure 20-21-16].
on the piston.
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Assembly (Cont’d)
Figure 20-21-17
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
P-07427 21-19] toward the outside of the head.
Figure 20-21-20
NOTE: During installation the spring side of the seal 4

1
Rotate the handles to collapse the rod seal [Figure 20- 2
3
21-17].
Figure 20-21-18
N-22356
Install the O-ring (Item 1) [Figure 20-21-20].

N-7425
Install the rod seal in the head [Figure 20-21-18].
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ARM CYLINDER (CONT’D) Install the O-ring (Item 1) and plug (Item 2) [Figure 20-
21-22].
Assembly (Cont’d)
Figure 20-21-21
1 Figure 20-21-23
3 2
N-22423
1
Install the head (Item 1), spacer (Item 2) and the piston
N-22421
(Item 3) [Figure 20-21-21] on the rod.
Grease the piston where the nut contacts the piston. Do Insert the adjustable gland nut wrench into the two holes
not get grease on the threads. (Item 1) [Figure 20-21-23] to tighten the head. Head to
tightening. Figure 20-21-24
Install the nut (Item 4) [Figure 20-21-21].

2
install a NEW NUT with pre-applied LOCTITE.
Reclean thread area for LOCTITE residue.
Figure 20-21-22
2 1
N-22419
Install the bushing (Item 1) [Figure 20-21-24]. The

bushing must be aligned with the grease channel in the
rod end of the cylinder.
1 Install the seals (Item 2) [Figure 20-21-24] with the lips

facing out.
2
N-22364
320/322 Excavator
103 of 705
320/322 Excavator
104 of 705
BOOM SWING CYLINDER Figure 20-22-3
Testing
Stop the engine. Raise the control console.
Figure 20-22-1
P-56052
2
Support the rod end of the cylinder [Figure 20-22-3]
1 Remove the floormat and floorplates. (See Removal and

Installation on Page 40-120-1.)
P-56050
Figure 20-22-4
Remove the retaining ring (Item 1) and washers (Item 2)

from the rod end pivot pin (Item 3) [Figure 20-22-1].
Remove the pivot pin.
Figure 20-22-2
1
P-16482
Remove the base end hose (Item 1) [Figure 20-22-4] at

the control valve assembly connection.
P-56051
Lower the control console and fasten the seat belt. Start
the engine and retract the swing cylinder [Figure 20-22-
2].
Stop the engine. With the key in the ON position, move

the hydraulic controls to release the hydraulic pressure.
320/322 Excavator
105 of 705
BOOM SWING CYLINDER (CONT’D) Removal and Installation
Testing (Cont’d)
Figure 20-22-5
IMPORTANT
2 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
WARNING
P-16483 Hydraulic fluid escaping under pressure can have
Install a cap (Item 1) [Figure 20-22-5] on the control and possible death if proper medical treatment by a
valve assembly fitting and tighten. physician familiar with this injury is not received
immediately.
Lower control console and fasten the seat belt. Start the W-2145-0290
engine and retract the cylinder.
If there is any leakage from the base end hose (Item 2)

[Figure 20-22-5] on the cylinder, remove the cylinder for
repair or replacement. WARNING
W-2103-1285
Swing the upperstructure so the pin in the base end of

the cylinder is located between the tracks.
Offset the boom slightly for additional working space.

the engine.
Remove the floormat and floorplate. (See Removal and

320/322 Excavator
106 of 705
BOOM SWING CYLINDER (CONT’D) Figure 20-22-8
Figure 20-22-6
1 P-56057
Support the rod end of the cylinder [Figure 20-22-8].

P-56055
Figure 20-22-9

washers from the rod end pin.
Lower the control console and fasten the seat belt.
Figure 20-22-7 2 1
P-56058
Remove the base end pin retainer bolt, washer and

spacer (Item 1) [Figure 20-22-9] from under the
upperstructure.
Installation: Tighten the bolt to 29-37 ft.-lbs. (39-50 Nm)

torque.
P-56056
Remove the pivot pin (Item 2) [Figure 20-22-9] down.
Start the Excavator and fully retract the cylinder [Figure

20-22-7].
Stop the engine.
320/322 Excavator
107 of 705
Figure 20-22-10
P-56061
Remove the grease hose (Item 1) [Figure 20-22-12].

P-56059
Figure 20-22-13
Slide the cylinder forward [Figure 20-22-10].
Remove the hose (Item 1) [Figure 20-22-10].
Figure 20-22-11
P-56062
Slide the cylinder out the front of the Excavator frame

[Figure 20-22-13].
P-56060
320/322 Excavator
108 of 705
BOOM SWING CYLINDER (CONT’D)
1. Bushing
2. Rod
3. Wiper
4. Seal
5. Head
6. O-Ring
7. Backup Ring
8. Piston
9. Nut
10. Housing 1
11. Plug
3
4
5
7 8
6
4
11
10
11
6
C-3317C
320/322 Excavator
109 of 705
Disassembly
3
2
Clean the outside of the boom swing cylinder before
1
disassembly.


cylinder. P-22365

Remove the head and the rod assembly from the cylinder
Figure 20-22-14 [Figure 20-22-15]. Put the rod end in a vise.
3) [Figure 20-22-15].
Figure 20-22-16
1
3
2
1
1
P-22350
P-22367
Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-22-16].
320/322 Excavator
110 of 705
Figure 20-22-17
3
2 2
1
1
P-22364

P-22356 19].
Figure 20-22-20
[Figure 20-22-17].
Figure 20-22-18
2
1
1
P-16562
Remove the bushing (Item 1) [Figure 20-22-20].
P-22357

320/322 Excavator
111 of 705
Assembly
3
1
MEL1033 - Rod Seal Installation Tool 2

or damaged parts. P-22367

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-22-22].
Figure 20-22-21
Figure 20-22-23
P-7424
P-22358
on the piston.
320/322 Excavator
112 of 705
Assembly (Cont’d)
Figure 20-22-24
P-22359
Figure 20-22-27


22-24]. 3 2
Figure 20-22-25
P-22356
Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-22-27].
P-7425
320/322 Excavator
113 of 705
BOOM SWING CYLINDER (CONT’D) Tighten the plug to 8 ft.-lbs. (11 Nm) torque.
Assembly (Cont’d) Put the base end of the hydraulic cylinder in a vise.
Figure 20-22-28 Figure 20-22-30
1
2
3
1
P-22365 P-22350
Install the head (Item 1) and the piston (Item 2) [Figure Insert the adjustable gland nut wrench into the two holes
20-22-28] on the rod. (Item 1) [Figure 20-22-30] to tighten the head. Head to
not get grease on the threads. Figure 20-22-31

tightening.
Figure 20-22-29
1
P-16562

P-22364
Install O-ring (Item 1) and plug (Item 2) [Figure 20-22-

29].
320/322 Excavator
114 of 705
BUCKET CYLINDER
Testing
WARNING
Figure 20-23-1
immediately.
W-2145-0290
Figure 20-23-3
1
2
N-22619
Lower the boom/bucket and blade to the ground [Figure

20-23-1].
Stop the engine. Raise the control console. 1

N-22622
Remove the retaining pin (Item 1) and washers (Item 2)
[Figure 20-23-1] from the outside pivot pin.
Remove the bucket cylinder base end hose (Item 1)
Remove the pivot pin (Item 3) [Figure 20-23-1]. [Figure 20-23-3].
Figure 20-23-2 Figure 20-23-4
N-22621 N-22623
Lower control console and fasten the seat belt. Start the Install a plug (Item 1) [Figure 20-23-4] on the hose fitting
engine and retract the bucket cylinder [Figure 20-23-2]. and tighten.
Stop the engine. With the key in the ON position, move Lower control console and fasten the seat belt. Start the
the hydraulic controls to release the hydraulic pressure. engine and retract the bucket cylinder.
320/322 Excavator
115 of 705
BUCKET CYLINDER (CONT’D) Remove the base end pin and lower the base end to the
floor.
Testing (Cont’d)
Figure 20-23-6
bucket cylinder, remove the cylinder for repair or
replacement.
2
Removal and Installation 1 1

the engine.
Support the boom using a chain hoist.

3
With the key in the ON position, move the hydraulic
controls to release the hydraulic pressure.
Figure 20-23-5 N-22638
2
Remove the two snap rings (Item 1) and two washers
(Item 2) [Figure 20-23-6].
Remove the bucket link (Item 3) [Figure 20-23-6].
IMPORTANT
damage the system.
I-2003-0888
WARNING
1
immediately.
P-16442
W-2145-0290
Remove and plug the two hoses (Item 1) [Figure 20-23-

5] from the bucket cylinder.

washer from the cylinder base end pin.
320/322 Excavator
116 of 705
BUCKET CYLINDER (CONT’D)
WARNING
W-2103-1285
Figure 20-23-7
1 1
N-22639
Remove the bucket link pins (Item 1) [Figure 20-23-7].
Remove the bucket cylinder.
320/322 Excavator
117 of 705
BUCKET CYLINDER (CONT’D)
1. Seal
2. Bushing
3. Rod
4. Wiper
5. Head 1
6. O-Ring
7. Backup Ring 2
8. Head
9. Nut 1
10. Plug
11. Housing
4
1 6
5
6
6
1
11
6
6
10
10
B-14213A B-14213B
B-13593A
B-14214
320/322 Excavator
118 of 705
BUCKET CYLINDER (CONT’D) Remove the head and the rod assembly from the cylinder
Disassembly
Clean the outside of the bucket cylinder before 3) [Figure 20-23-9].
disassembly.
Figure 20-23-10
3
2
1
cylinder.
Figure 20-23-8
N-22414

1 (Item 2) from the piston (Item 3) [Figure 20-23-10].
Figure 20-23-11
3
1
4
1 2
N-22434
Figure 20-23-9
N-22356
2 3
1
N-22436
320/322 Excavator
119 of 705
BUCKET CYLINDER (CONT’D) Figure 20-23-14
Figure 20-23-12 1
2
1 1
2
N-22433
Remove the seals (Item 1) and bushing (Item 2) [Figure

N-22357 20-23-14].

Figure 20-23-13
N-22364

13].
320/322 Excavator
120 of 705
Assembly
3
1
2


Figure 20-23-15
Figure 20-23-17
P-7424
N-22358
on the piston.
320/322 Excavator
121 of 705
Assembly (Cont’d)
Figure 20-23-18
N-22359
Figure 20-23-21

1
3
23-18].
Figure 20-23-19
N-22356

N-7425
320/322 Excavator
122 of 705
BUCKET CYLINDER (CONT’D) Tighten the plug to 8 ft.-lbs. (11 Nm) torque.
Assembly (Cont’d) Put the base end of the hydraulic cylinder in a vise.
Figure 20-23-22 Be careful no to damage the cylinder tube.
Figure 20-23-24
2 1
3
1
N-22436
N-22434
Install the head (Item 1) [Figure 20-23-22] and the piston
(Item 2) [Figure 20-23-22] on the rod.
Grease the piston where the nut contacts the piston. Do (Item 1) [Figure 20-23-24] to tighten the head. Head to
not get grease on the threads. be torqued until flush with end of cylinder housing.
Provide an adequate support for the cylinder before Figure 20-23-25

tightening.

2
Figure 20-23-23
2
1
N-22433

1
Install the seals (Item 2) [Figure 20-23-25] with the lips
2 facing out.
N-22364

23].
320/322 Excavator
123 of 705
320/322 Excavator
124 of 705
BLADE CYLINDER
Testing
WARNING
Swing the upperstructure out of the way. Lower the
boom/bucket to the ground. Raise the blade up until it Hydraulic fluid escaping under pressure can have
stops. sufficient force to enter a person’s body by
Stop the engine. and possible death if proper medical treatment by a
Figure 20-24-1 immediately.
W-2145-0290
1
Figure 20-24-3
2
3
1
N-22624
Support the blade [Figure 20-24-1]. With the key in the

N-22626
ON position, move the blade control to release the
hydraulic pressure. Raise the control console.
Remove the blade cylinder base end hose (Item 1)
Loosen and slide the hose clamps (Item 1) [Figure 20- [Figure 20-24-3].
24-1] off the shield.
Figure 20-24-4
Remove the top two nuts (Item 2) and loosen the bottom
two nuts (Item 3) [Figure 20-24-1] fastening the shield to
the blade cylinder.
Figure 20-24-2
1 1
N-11325
NOTE: Use care not to lose the orifice (Item 1) [Figure

20-24-4] located in the blade cylinder base
end hose. (If equipped)
N-22625
Remove the blade cylinder shields (Item 1) [Figure 20-

24-2] from the blade cylinder.
320/322 Excavator
125 of 705
BLADE CYLINDER (CONT’D)
Testing (Cont’d)
Figure 20-24-5
N-22627
Install a plug (Item 1) [Figure 20-24-5] on the hose fitting

and tighten.
Lower control console. Start the engine and retract the

blade cylinder.

blade cylinder, remove the cylinder for repair or
replacement.
320/322 Excavator
126 of 705
BLADE CYLINDER (CONT’D) Figure 20-24-8

the engine.
With the key in the ON position, move the blade control to

release the hydraulic pressure. 1
Figure 20-24-6
N-16446
Remove and plug the blade cylinder hoses (Item 1)

1 [Figure 20-24-8].
IMPORTANT
N-16444
Loosen the two bolts (Item 1) [Figure 20-24-6] and slide parts clean. Always use caps and plugs on hoses,
hose clamps off of shield. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 20-24-7 I-2003-0888
Figure 20-24-9
1
2
2
1
1
N-16445
N-11325
Remove the top two nuts (Item 1) [Figure 20-24-7] and
loosen the bottom two nuts fastening the shield to the
blade cylinder. NOTE: Use care not to lose the orifice (Item 1) [Figure
20-24-9] located in the cylinder base end
Remove the blade cylinder shields (Item 2) [Figure 20- hose. (If equipped)
24-7].
320/322 Excavator
127 of 705
Figure 20-24-10
2 1
2 1
N-22628
Remove the snap rings (Item 1) [Figure 20-24-10] and

washers from the cylinder base and rod ends.
Remove the cylinder retaining pins (Item 2) [Figure 20-

24-10].
Remove the blade cylinder.
WARNING
W-2103-1285
320/322 Excavator
128 of 705
1. Rod
2. Wiper
3. Seal
4. Head
5. O-ring
6. Backup Ring
7. Piston
8. Nut
9. Housing
10. Plug
1 B-13593A
2
3 5
6
7
8
7
5
3
10
5
5
10
B-14213D B-14213B
B-14214A
320/322 Excavator
129 of 705
BLADE CYLINDER (CONT’D) Remove the head and the rod assembly from the cylinder
Disassembly
Clean the outside of the blade cylinder before 3) [Figure 20-24-12].
disassembly.
Figure 20-24-13
MEL1074 - O-ring Seal Hook 3

2
Hold the hydraulic cylinder over a drain pan and move 1
cylinder.
Figure 20-24-11
N-22414

1 Figure 20-24-14
4
1 1 2
N-22442
Figure 20-24-12
N-22356
3
2 Remove the O-ring (Item 1) and the back-up ring (Item 2)
1
N-22413
320/322 Excavator
130 of 705
Figure 20-24-15
2
1
N-22357

Figure 20-24-16
N-22364

16].
320/322 Excavator
131 of 705
Assembly
3

1
MEL1033 - Rod Seal Installation Tool 2


Figure 20-24-17
Figure 20-24-19
N-07424
N-22358
on the piston.
320/322 Excavator
132 of 705
Assembly (Cont’d)
Figure 20-24-20
P-22359
Figure 20-24-23

1
Rotate the handles to collapse the rod seal [Figure 20- 3 2
24-20].
Figure 20-24-21
N-22356

P-07425
320/322 Excavator
133 of 705
Assembly (Cont’d)
Figure 20-24-24
1
2
3
1
N-22364

N-22413
25].

Install the head (Item 1) and piston (Item 2) [Figure 20-
24-24] on the rod. Put the base end of the hydraulic cylinder in a vise.
Grease the piston where the nut contacts the piston. Do Figure 20-24-26
not get grease on the threads.

tightening.
NOTE: Clean and dry the rod threads. From the kit 1
Tighten 0.875 inch nuts with the aluminum piston to 250

ft.-lbs. (339 Nm) torque.
1
Tighten 0.875 inch nuts with the gray iron piston to 350
ft.-lbs. (474 Nm) torque. N-22442
Tighten 1.0 inch nuts with the gray iron piston to 600 ft.-
lbs. (814 Nm) torque. Insert the adjustable gland nut wrench into the two holes
320/322 Excavator
134 of 705
TRACK FRAME EXPANSION CYLINDER Figure 20-25-3
Testing
Retract the track frame fully.
Figure 20-25-1
P-16462
Remove the expansion cylinder base end hose (Item 1)

[Figure 20-25-3].
N-22649
Place blocks under the Excavator tracks. Lower the

WARNING
bucket to the ground and the blade on the blocks [Figure
20-25-1]. Hydraulic fluid escaping under pressure can have
Stop the engine. Raise the control console. penetrating the skin. This can cause serious injury
Figure 20-25-2 physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-25-4
1 1
N-22629
Remove the four bolts (Item 1) [Figure 20-25-2]

fastening the cover to the bottom side of the 1
P-16464
undercarriage. Remove the cover.
Install a plug (Item 1) [Figure 20-25-4] on the hose fitting

and tighten.
Lower control console and fasten the seat belt. Start the
engine and retract the expansion cylinder.
320/322 Excavator
135 of 705
TRACK FRAME EXPANSION CYLINDER (CONT’D) Figure 20-25-7
Testing (Cont’d)

expansion cylinder, remove the cylinder for repair or
replacement.
Removal And Installation
Expand the track frame fully.
Figure 20-25-5
1
P-15311
Remove the hose (Item 1) [Figure 20-25-7] from the

cylinder rod end.
IMPORTANT
N-22631
Place blocks under the Excavator tracks for increased damage the system.
access to the expansion cylinder [Figure 20-25-5]. I-2003-0888
Figure 20-25-6
WARNING
1
1 sufficient force to enter a person’s body by
1 immediately.
W-2145-0290
P-15316
Remove the four bolts (Item 1) [Figure 20-25-6].
Remove the access plate (Item 2) [Figure 20-25-6].
320/322 Excavator
136 of 705
Figure 20-25-8
1 2
N-22634
1
Plug the base end hose (Item 1) [Figure 20-25-10].

P-15310
Install a hose (Item 2) [Figure 20-25-10] on the cylinder
base end. Place the other end of the hose in a drain pan.
Install a hose (Item 1) [Figure 20-25-8] on the cylinder
rod end. Place the other end of the hose in a drain pan. Figure 20-25-11
Figure 20-25-9
1 1
1
P-15309
N-22633
Remove the three nuts (Item 1) [Figure 20-25-11] from
the rod end of the cylinder.
cylinder base end. Installation: Tighten the nuts to 32-35 ft lbs (43-47 Nm)
torque.
320/322 Excavator
137 of 705
Figure 20-25-12
1
P-15306
Remove the three bolts (Item 1) [Figure 20-25-14] and

P-15308 retaining clips from the track frame.
Figure 20-25-15
Slightly compress the cylinder. Remove the two plates
(Item 1) [Figure 20-25-12] from the rod end of the
cylinder.
Figure 20-25-13
P-15305
1
Remove the three nuts (Item 1) [Figure 20-25-15] from
the base end of the cylinder.
P-15307
Installation: Tighten the nuts to 32-35 ft.-lbs. (43-47 Nm)
torque.
Remove the mount plate (Item 1) [Figure 20-25-13] from
the track frame.
320/322 Excavator
138 of 705
Figure 20-25-16
1 P-15302
1
Remove the three bolts (Item 1) [Figure 20-25-18] and
P-15304 retaining clips from the track frame.
Compress the cylinder.

Pull the cylinder out of the mount. Remove the two plates
(Item 1) [Figure 20-25-16] from the base end of the Rotate the cylinder until the hose clamp is accessible.
cylinder.
Figure 20-25-19
Figure 20-25-17
1 P-15301
P-15303
Remove the bolt (Item 1) [Figure 20-25-19].

Remove the mount plate (Item 1) [Figure 20-25-17] from
the track frame. Remove the cylinder.
WARNING
W-2103-1285
320/322 Excavator
139 of 705
TRACK FRAME EXPANSION CYLINDER (CONT’D)
1. Plug
2. O-ring
3. Housing 1
4. Nut
5. Piston
6. Seal 2
7. Backup Ring
8. Head
9. Wiper
10. Rod
1
2
5
6
2
2
7
2
6
9
10
MS-1027
320/322 Excavator
140 of 705
TRACK FRAME EXANSION CYLINDER (CONT’D) Remove the head and the rod assembly from the cylinder
Disassembly
Clean the outside of the expansion cylinder before 3) [Figure 20-25-21].
disassembly.
Figure 20-25-22
MEL1074 - O-ring Seal Hook 3

2
Hold the hydraulic cylinder over a drain pan and move 1
cylinder.
Figure 20-25-20
N-22418

1
Figure 20-25-23
4
1
1 2
N-22440
Figure 20-25-21
N-22356
3
2
1 Remove the O-ring (Item 1) and the back-up ring (Item 2)
Remove the thin O-ring (Item 4) [Figure 20-25-23].
N-22416
320/322 Excavator
141 of 705
TRACK FRAME EXPANSION CYLINDER (CONT’D) Assembly
Disassembly (Cont’d) Use the following tools to assemble the cylinder:
Figure 20-25-24 MEL1396 - Universal Seal Expander

3
2 Clean all parts in solvent and dry with compressed air.

1
or damaged parts.

Figure 20-25-26
N-22357

Figure 20-25-25
P-07424
2
the piston [Figure 20-25-26].
1
Allow the seal to stretch for 30 seconds before installing it
N-22364 on the piston.

25].
320/322 Excavator
142 of 705
Assembly (Cont’d)
Figure 20-25-27
1
2
P-07427
N-22418
Standard Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-25-27]. Rotate the handles to collapse the rod seal [Figure 20-
25-29].
Figure 20-25-28
Figure 20-25-30
N-22358
P-07425
Use a ring compressor to compress the seal to the

correct size. Leave the piston in the compressor for about Install the rod seal in the head [Figure 20-25-30].
three minutes [Figure 20-25-28].
320/322 Excavator
143 of 705
Assembly (Cont’d)
1
Figure 20-25-31 2
3
1
N-22416
Install the head (Item 1) and the piston (Item 2) [Figure

N-22359 20-25-33] on the rod.

Install the wiper seal with the wiper (Item 1) [Figure 20- not get grease on the threads.
25-31] toward the outside of the head.
Figure 20-25-32 tightening.

4
1 install a NEW NUT with pre-applied LOCTITE.
3 2
Figure 20-25-34
N-22356

1
Install the back-up ring (Item 2) and thick O-ring (Item 3)
into the groove on the head (Item 4) [Figure 20-25-32].
2
N-22364
Install the O-ring (Item 1) [Figure 20-25-34] and plug

(Item 2) [Figure 20-25-34].
320/322 Excavator
144 of 705
TRACK FRAME EXPANSION CYLINDER (CONT’D)
Assembly (Cont’d)
Figure 20-25-35
1
N-22440
320/322 Excavator
145 of 705
320/322 Excavator
146 of 705
MAIN RELIEF VALVE There is one diagnostic coupler (Item 1) [Figure 20-30-1]
on the manifold assembly for checking each of the pump
Testing And Adjusting The Main Relief Valve section pressure.
All testing is done with the hydraulic oil at operating The following tools will be needed for the testing at the
temperature and the engine at high speed setting of diagnostic coupler:
2550-2620 RPM.
MEL1355 - Test Kit includes the following:
Figure 20-30-1 MEL1355-3 - 5000 PSI Gauge
MEL1355-12 - Coupler
MEL1355-9 - Thermometer
System Pressures At Gauge Port Specifications
1 TEST CONDITIONS
1. Engine High Idle Speed
2. Warm oil over relief function to minimum 150° F (66°

C). Cycle all functions during warm up procedure.
Warm oil until the pressure build-up valve stabilizes
near its target pressure.
P-56063 3. Activate function until cylinder movement stops. Hold
TEST TARGET
SYSTEM CHECK FUNCTION TO ENGAGE CIRCUIT PRESSURIZED PORT (PSI) ACCEPTABLE RANGE (PSI)
JOYSTICK PILOT PRESSURE ANY JOYSTICK FUNCTION JOYSTICK PILOT * 435 406 - 450
PRESSURE BUILD - UP VALVE NONE - CONSOLE DOWN P2 & P3 G 415 345-485
SYSTEM BY - PASS NONE - CONSOLE UP DUMP TO TANK G 115 MAX ALLOWABLE 155
MAIN RELIEF ON MANIFOLD BLOCK BOOM P3 G 2475 2375-2525
MAIN RELIEF ON MANIFOLD BLOCK AUXILIARY P1 G 2515 2415-2565
MAIN RELIEF ON MANIFOLD BLOCK ARM P2 & P3 G 2515 2415-2565
SWING MOTOR - CROSS PORT RELIEF SLEW RIGHT P1 G 1475 1400-1550
SWING MOTOR - CROSS PORT RELIEF SLEW LEFT P1 G 1475 1400-1550
* Under seat at bulkhead
320/322 Excavator
147 of 705
MAIN RELIEF VALVE (CONT’D) Figure 20-30-3
Testing And Adjusting The Main Relief Valve (Cont’d)
Figure 20-30-2
1
2
P-56065
If adjustment is needed, loosen the nut (Item 1) [Figure

P-56064 20-30-3].
Turn the adjustment bolt (Item 2) [Figure 20-30-3]

Connect the test gauge coupler from the test kit to the “G” clockwise to increase the pressure or counterclockwise
diagnostic port [Figure 20-30-2]. to decrease the pressure.
Lower the control console and fasten seat belt. Tighten the nut (Item 1) [Figure 20-30-3].
Start the engine and run at low RPM until hydraulic fluid Retest the main relief valve after adjustment.
is at operating temperatures 150° F (66° C).
With the hydraulic fluid at operating temperature, run

engine at full RPM.
Operate the following circuits over relief and record the

pressure for each circuit.
NOTE: Do not operate the blade circuit due to a by-

pass orifice in spool.
The main relief valve pressure at “G” diagnostic port

[Figure 20-30-2] should be as follows:
Boom up:
2375 - 2525 PSI (163.8 - 174 Bar)
Arm in:
2415 - 2565 (166.5 - 176.9 Bar)
Auxiliary:
2415 - 2565 (166.5 - 176.9 Bar)
NOTE: The pressure rise in the arm in and auxiliary

circuits is caused by increased flow.
Stop the engine.
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PORT RELIEF VALVES Figure 20-31-2
Testing And Adjusting The Port Relief Valve Pressure
Figure 20-31-1
6 4 2
P-19015
Install the hand pump hose and a pressure gauge

5 3 1
MS1373 (minimum of 5000 PSI) into the valve section work port in
which the port relief valve is located [Figure 20-31-2].
Boom Port Relief set at: Slowly pressurize this section with the hand pump until
the port relief valve opens and make a note of the
Rod End (Item 1) [Figure 20-31-1] 3335 PSI (230 Bar)
pressure reading.
Base End (Item 2) [Figure 20-31-1] 3335 PSI (230 Bar)
NOTE: Pumping the hand pump too fast will alter the
pressure readings up to 50 PSI (3.4 Bar).
Bucket Port Relief set at:
Rod End (Item 3) [Figure 20-31-1] 3335 PSI (230 Bar) If the port relief pressure setting is incorrect, replace the
Base End (Item 4) [Figure 20-31-1] 2900 PSI (200 Bar) port relief valve.
Arm Port Relief set at:

Rod End (Item 5) [Figure 20-31-1] 3335 PSI (230 Bar)
Base End (Item 6) [Figure 20-31-1] 2900 PSI (200 Bar)
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
NOTE: The reliefs are located below the spool covers • When fluids are under pressure.
on the valve sections. • Flying debris or loose material is present.
• Engine is running.
A portable hydraulic hand pump will be used to test the • Tools are being used.
work port relief valves. The hand pump must have clean W-2019-1285
hydraulic fluid that is compatible with the Bobcat
hydraulic fluid.
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320/322 Excavator
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CROSSPORT RELIEF VALVES Figure 20-32-1
Testing And Adjusting The Crossport Relief Valve
The hydraulic system has two crossport relief valves that

protect the swing motor from high pressure.
The following tools will be needed for the testing at the

diagnostic coupler:

MEL1355-3 - 5000 PSI Gauge
MEL1355-12 - Coupler
MEL1355-9 - Thermometer 1
System Pressures At Gauge Port Specifications P-56063
TEST CONDITIONS
Figure 20-32-2
1. Engine High Idle Speed
2. Warm oil over relief function to minimum 150° F (66°

C). Cycle all functions during warm up procedure.
Warm oil until the pressure build-up valve stabilizes
near its target pressure.
3. Activate function until cylinder movement stops. Hold

over relief for 5-10 seconds. 1
Record pressure.
Open the tailgate.
P-56064
Connect the test gauge coupler from the test kit to the “G”
diagnostic port (Item 1) [Figure 20-32-1] & [Figure 20-
32-2].
Lower the control console and fasten the seat belt.
TEST TARGET
SYSTEM CHECK FUNCTION TO ENGAGE CIRCUIT PRESSURIZED PORT (PSI) ACCEPTABLE RANGE (PSI)
JOYSTICK PILOT PRESSURE ANY JOYSTICK FUNCTION JOYSTICK PILOT * 435 406 - 450
PRESSURE BUILD - UP VALVE NONE - CONSOLE DOWN P2 & P3 G 415 345-485

SYSTEM BY - PASS NONE - CONSOLE UP DUMP TO TANK G 115 MAX ALLOWABLE 155
MAIN RELIEF ON MANIFOLD BLOCK BOOM P3 G 2475 2375-2525
MAIN RELIEF ON MANIFOLD BLOCK AUXILIARY P1 G 2515 2415-2565
MAIN RELIEF ON MANIFOLD BLOCK ARM P2 & P3 G 2515 2415-2565
SWING MOTOR - CROSS PORT RELIEF SWING RIGHT P1 G 1475 1400-1550
SWING MOTOR - CROSS PORT RELIEF SWING LEFT P1 G 1475 1400-1550
*Under seat at bulkhead
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CROSSPORT RELIEF VALVES (CONT’D) Figure 20-32-4
Testing And Adjusting The Crossport Relief Valve

(Cont’d)
Figure 20-32-3
1
1
P-56145
Remove the two crossport relief valves (Item 1) [Figure

20-32-4].
P-30223
Clean the two crossport relief valves.
Start the engine and run at low RPM until the hydraulic Install the two crossport relief valves and tighten to 30-40
fluid is at operating temperatures 150° F (66° C). ft.-lbs. (40,6-46,1 Nm).
Move the swing lock lever (Item 1) [Figure 20-32-3] to Retest the crossport relief valves after cleaning.
the locked position.
If pressure is still incorrect, replace the crossport relief
With the hydraulic fluid at operating temperature, run valves.
engine at full RPM.
Move the left control lever (joystick) to engage the swing

circuit in the clockwise direction. Record the pressure.
Move the left control lever (joystick) to engage the swing

circuit in the counterclockwise direction. Record the
pressure.
The swing (Slew) crossport relief valve pressure at “G”

diagnostic port [Figure 20-32-2] should be as follows:
1475 PSI (102 Bar) with an acceptable range of 1400-

1550 PSI (97-107 Bar).
If the pressure is incorrect, remove the blade extension

tray. (See Removal And Installation on Page 40-210-1.)
320/322 Excavator
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PRESSURE REDUCING VALVE Figure 20-33-6
Testing And Adjusting The Pressure Reducing Valve

1
The following tools will be needed for testing the pressure
reducing valve:

MEL1355-2 - 1000 PSI Gauge 2
MEL1355-9 - Thermometer
Remove the seat and raise the seat mount. (See

Removal And Installation on Page 40-40-1.)
Figure 20-33-5
P-16878
If adjustment is needed, loosen the nut (Item 1) [Figure

20-33-6].
Turn the adjustment screw (Item 2) [Figure 20-33-6]

clockwise to increase the pressure or counterclockwise
to decrease the pressure.
Tighten the nut (Item 1) [Figure 20-33-6].
Retest the pressure reducing valve after adjustment.
P-16873 If pressure is still incorrect, remove the pressure reducing

valve from the manifold assembly and inspect.
Install a 1000 PSI (6895 kPa) gauge on the tee fitting

[Figure 20-33-5].
Lower control console and fasten seat belt.
Start the engine and warm the hydraulic fluid to operating

temperatures 150°F (66°C).
With the hydraulic fluid at operating temperature, run

engine at full RPM.
Operate the circuit over relief and record the pressure.
The pressure reducing valve pressure at the bulkhead

fitting [Figure 20-33-5] should be as follows:
435 psi (30 Bar) with an acceptable range of 406-450 psi

(28-31 Bar)
Stop the engine.
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PRESSURE REDUCING VALVE (CONT’D) If the O-rings and back-up rings were not worn or
damaged and the pressures at the bulkhead fitting could
Testing And Adjusting The Pressure Reducing Valve not be achieved, replace pressure reducing valve.
(Cont’d)
Inspect the port of the pressure reducing valve on the

manifold assembly to verify no damage. If damaged
replace manifold assembly.
Figure 20-33-7
P-16878
Figure 20-33-8
N-22443
Inspect the O-rings and back-up rings on the pressure

reducing valve (Item 1) [Figure 20-33-7] & [Figure 20-
33-8]. If O-rings and back-up rings are worn or damaged,
replace O-rings and back-up rings. (See Testing And
Adjusting The Pressure Reducing Valve on Page 20-33-
1.)
Re-install the pressure reducing valve in the manifold

assembly.
Repeat pressure reducing valve test.
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HYDRAULIC CONTROL VALVE (320 / 322) Figure 20-40-2
Description
The hydraulic control valve has 3335 PSI (230 Bar) and 1
2900 PSI (200 Bar) work port relief valves for the boom, 1
bucket and arm sections.
1 1
The 218 PSI (15 Bar) buildup valve is located in the
bucket section.
With the engine off, turn the start key to the ON position P-32917
and move both hydraulic control levers to relieve
hydraulic pressure.
Remove the clevis pins and cotter pins (Item 1) [Figure
20-40-2].
IMPORTANT Figure 20-40-3

1
damage the system.
I-2003-0888

Remove the seat and seat mount. (See Removal And

P-32920
Figure 20-40-1
Disconnect the wire harness (Item 1) [Figure 20-40-3]

from the two speed switch.
WARNING
immediately.
P-32918
W-2145-0290
Mark all tubes and hoses for ease of assembly [Figure

20-40-1].
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HYDRAULIC CONTROL VALVE (320 / 322) (CONT’D) Figure 20-40-6
Figure 20-40-4 1
1 1 1
1
P-32924
Remove the tubelines (Item 1) [Figure 20-40-6].

P-32921
Figure 20-40-7
Remove the hoses (Item 1) [Figure 20-40-4].
Figure 20-40-5
1 1
1 P-32925
1

P-32922
NOTE: The hoses will be removed with the valve.
Remove the hoses (Item 1) [Figure 20-40-5] from the top

of the control valve.
320/322 Excavator
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Figure 20-40-8
2 2
4
3 P-32931
5
P-32926
Figure 20-40-11
Disconnect the tubelines (Item 1) [Figure 20-40-8] from

the control valve.
Disconnect the hoses (Item 2) [Figure 20-40-8] from the

control valve.
Remove the clevis pin and cotter pin (Item 3) [Figure 20-
40-8] from the blade cable linkage.
Loosen the nuts (Item 4) and remove the cable linkage

(Item 5) [Figure 20-40-8].
Figure 20-40-9
P-33147
Remove the control valve [Figure 20-40-11].

1
P-32929
Remove the bolts (Item 1) [Figure 20-40-9].
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HYDRAULIC CONTROL VALVE (320 / 322) (CONT’D)
Item Description
1. AUXILIARY SECTION
2. BLADE SECTION
3. SWING SECTION
4. LEFT TRAVEL SECTION
5. BOOM SECTION
6. BUCKET SECTION
7. ARM SECTION
8. BOOM SWING SECTION
9. RIGHT TRAVEL SECTION
10. PORT RELIEF - 3335 PSI (330 Bar) (Below Spool Cover)
11. PORT RELIEF - 2900 PSI (200 Bar) (Below Spool Cover)
11 11 10
9 8 7 6 5 4 3 2 1
10 10 10
MS-1373
320/322 Excavator
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Disassembly 8 6 4 2
9 7 5 3 1
Clean the outside of the hydraulic control valve before
disassembly.
IMPORTANT
P-32984
damage the system.
I-2003-0888
Mark the valve sections for ease of assembly [Figure 20-
Figure 20-40-12 40-13].
1. Auxiliary Valve
2. Blade Valve
3. Swing Valve
4. Left Travel Valve
5. Boom Valve
6. Bucket Valve
7. Arm Valve
8. Boom Swing Valve
9. Right Travel Valve
P-33109 Figure 20-40-14
Remove the hoses and fittings [Figure 20-40-12].
P-32985
Remove the tie rod nuts (Item 1) [Figure 20-40-14] and

washers.
320/322 Excavator
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Auxiliary Valve Section Disassembly And Assembly

or damaged parts.

Figure 20-40-15
1
P-32988
Remove the plug (Item 1) [Figure 20-40-17].
Figure 20-40-18
1
P-32986
Remove the auxiliary valve section (Item 1) [Figure 20-

40-15] from the valve assembly.
Figure 20-40-16
P-32989
Remove the O-ring (Item 1) [Figure 20-40-18] from the

plug.
P-32987
Remove the O-rings (Item 1) [Figure 20-40-16] from the

auxiliary valve block.
320/322 Excavator
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(Cont’d)
Figure 20-40-19
3
2
1 P-32993
Remove the bolts (Item 1) and retaining plate (Item 2)

from the actuating end of the spool (Item 3) [Figure 20-
P-33145 40-21].
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m)

Remove the load check valve assembly (Item 1) [Figure torque.
20-40-19].
Figure 20-40-22
NOTE: The load check valve assembly is serviced
only as a unit.
Installation: Tighten the load check valve to 18 ft.-lb. (24

N•m) torque. 1
Figure 20-40-20
P-32994
Remove the seal (Item 1) [Figure 20-40-22] from the

retaining plate.
P-32991

load check valve.
320/322 Excavator
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(Cont’d)
Figure 20-40-23
3
2
1
P-32998
2
Remove the washer (Item 1) and O-ring (Item 2) from the

actuating end of the spool (Item 3) [Figure 20-40-25].
P-33906
Figure 20-40-26
Installation: Make sure the lip (Item 1) on the seal fits

inside the lip on the retaining plate (Item 2) [Figure 20-
40-23].
Figure 20-40-24 4
3
2
1
3
P-32999
2
Remove the spring assembly (Item 1), washer (Item 2),

1
O-ring (Item 3) and spool (Item 4) [Figure 20-40-26] from
the auxiliary valve.
P-32997
The spool and valve block are not serviced separately.
Remove the bolts (Item 1) and end cap (Item 2) from the NOTE: When the spool is removed, use care not to
spool (Item 3) [Figure 20-40-24]. scratch the spool surface and do not
interchange spools and valve blocks.
torque. Installation: Tighten the spring retaining bolt to 18 ft.-lb.
(24 N•m) torque.
320/322 Excavator
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(Cont’d)
Figure 20-40-27
P-33006

1
P-33001 Installation: Tighten the plug to 31 ft.-lb. (42 N•m)
torque.
Remove the fitting (Item 1) [Figure 20-40-27] from the Figure 20-40-30
auxiliary valve.
Installation: Tighten the fitting to 31 ft.-lb. (42 N•m)

torque.
1
Figure 20-40-28
2
1
1
1
P-33007
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-40-30] from the plug.
2
P-33003

[Figure 20-40-28] from the fitting.
320/322 Excavator
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HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-33
Blade Valve Section Disassembly And Assembly

1

or damaged parts.

Figure 20-40-31
P-33011
Remove the load check valve (Item 1) [Figure 20-40-34].

N•m) torque.
1 IMPORTANT
P-33009
Remove the blade valve section (Item 1) [Figure 20-40- parts clean. Always use caps and plugs on hoses,
31] from the valve assembly. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 20-40-32 I-2003-0888
Figure 20-40-34
P-33010
P-32991
blade valve block.
load check valve.
320/322 Excavator
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(Cont’d) 1
Figure 20-40-35
3
2
1
P-33906

2
inside the lip of the retainer (Item 2) [Figure 20-40-37].
1
P-33014 Tighten the bolts to 5 ft.-lb. (6,6 N•m) torque.
Figure 20-40-38
Remove the bolts (Item 1) and cover (Item 2) from the
spool (Item 3) [Figure 20-40-35].

torque.
Figure 20-40-36
2
1
P-33020
Remove the washer (Item 1) and O-ring (Item 2) [Figure

3 20-40-38].
1
2
P-33016
Remove the bolts (Item 1), spool retainer (Item 2) and

seal (Item 3) from the actuating end of the spool (Item 4)
[Figure 20-40-36].
320/322 Excavator
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(Cont’d)
Figure 20-40-39
3
2
1
P-33021

O-ring (Item 3) and spool (Item 4) [Figure 20-40-39].
NOTE: When the spool is removed, use care not to

scratch the spool surface. Do not interchange
spools and valve blocks.
Installation: Tighten the spring retaining bolt to 18 ft.-lb.

(24 N•m) torque.
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Slew Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
P-33023
Inspect all parts for wear or damage. Replace any worn Remove the O-rings (Item 1) [Figure 20-40-41] from the
or damaged parts. swing valve block.
Always install new seals and O-rings. Lubricate all seals Figure 20-40-42
Figure 20-40-40
1
P-33025
1
P-33022

Remove the slew valve section (Item 1) [Figure 20-40- N•m) torque.
40] from the valve assembly.
320/322 Excavator
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(Cont’d)
6
Figure 20-40-43
2
5
4
3
1
P-33065
Remove the bolts (Item 1), spool cover (Item 2), spring
seat (Item 3), spring (Item 4) and spring retainer (Item 5)
P-32991 [Figure 20-40-45].
NOTE: Install the lip of the spring retainer (Item 5)

Remove the O-ring (Item 1) [Figure 20-40-43] from the over the spool (Item 6) [Figure 20-40-45].
load check valve.
Figure 20-40-44 torque.
4 2
1
5
3
P-33027
Remove the bolts (Item 2), actuator (Item 2), spring

retainer (Item 3), spring (Item 4) and spring retainer (Item
5) [Figure 20-40-44].

over the spool (Item 6) [Figure 20-40-44].

torque.
320/322 Excavator
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(Cont’d)
1
Figure 20-40-46 1 2
P-33003
Remove the O-rings (Item 1) and backup ring (Item 2)

P-33066
Figure 20-40-49
Remove the spool (Item 1) [Figure 20-40-46].

scratch the spool surface and do not
1
Figure 20-40-47
P-33071
1
Remove the plug (Item 1) [[Figure 20-40-49]
Installation: Tighten the plug to 31 ft.-lb. (42 N•m)

torque.
P-33069
Remove the fitting (Item 1) [Figure 20-40-47].

torque.
320/322 Excavator
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(Cont’d)
Figure 20-40-50
1
2
1
P-33007

320/322 Excavator
170 of 705
Left Travel Valve Section Disassembly and Assembly 1
IMPORTANT
damage the system.
I-2003-0888
P-33073
Inspect all parts for wear or damage. Replace any worn Remove the plug (Item 1) [Figure 20-40-52] from the left
or damaged parts. travel valve block.
Always install new seals and O-rings. Lubricate all seals Installation: Tighten the plug to 18 ft.-lb. (24 N•m)
and O-rings with clean hydraulic fluid before installation. torque.
Figure 20-40-51 Figure 20-40-53
1
P-33072 P-33074
Remove the left travel valve section (Item 1) [Figure 20- Remove the O-ring (Item 1) [Figure 20-40-53] from the
40-51] from the valve assembly. plug.
320/322 Excavator
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Left Travel Valve Section Disassembly and Assembly

(Cont’d)
3
Figure 20-40-54
2
4 1
P-33077
1
3
actuating end of the spool (item 3) [Figure 20-40-56].
P-33076
Figure 20-40-57
Remove the bolts (Item 1) retainer (Item 2) and seal (Item

3) from the spool (Item 4) [Figure 20-40-54].
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m) 5

torque.
4 3
Figure 20-40-55 2
1
P-33079
Remove the cap and bolts (Item 1) spring assembly (Item

2 2), washer (Item 3), O-ring (Item 4) and spool (Item 5)
[Figure 20-40-57].

P-33906 torque.

Installation: Make sure the lip (Item 1) of the seal fits
inside the retainer (Item 2) [Figure 20-40-55]. NOTE: When the spool is removed, use care not to
Installation: Tighten the spring assembly (Item 2)

[Figure 20-40-57] to 18 ft.-lb. (24 N•m) torque.
320/322 Excavator
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Left Travel Valve Section Disassembly and Assembly

(Cont’d)
Figure 20-40-58
P-33083

torque.
Remove the fitting (Item 1) [Figure 20-40-58]. Figure 20-40-61

torque.
Figure 20-40-59 1
2
1
1
1 2
P-33007

P-33003

320/322 Excavator
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Boom Valve Section Disassembly and Assembly
IMPORTANT
damage the system.
I-2003-0888 1
P-33085
or damaged parts. boom valve block.
1
Figure 20-40-62
P-33086
1

P-33084

Remove the boom valve section (Item 1) [Figure 20-40- N•m) torque.
320/322 Excavator
174 of 705

(Cont’d) 6
Figure 20-40-65 2
5
4 1
P-33090
P-32991 5) [Figure 20-40-67].
Installation: Make sure the lip on the spring retainer

Remove the O-ring (Item 1) [Figure 20-40-65] from the (Item 5) fits over the spool (Item 6) [Figure 20-40-67].
load check valve.
Figure 20-40-68
3
1
5
4
2
P-33088
P-33091
5) [Figure 20-40-66]. Remove the spool (Item 1) [Figure 20-40-68].
Installation: Install the lip of the spring retainer (Item 5) The spool and valve block are not serviced separately.
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m) scratch the spool surface. Do not interchange
torque. spools and valve blocks.
320/322 Excavator
175 of 705

(Cont’d)
Figure 20-40-69
1 3 1
3
2 2
P-33095
Remove the plug (Item 1), spring (Item 2) and spring

assembly (Item 3) [Figure 20-40-69] from both relief
valves.
Installation: Tighten the plugs to 18 ft.-lb. (24 N•m)

torque.
Figure 20-40-70
P-33094

plug.
320/322 Excavator
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Bucket Valve Section Disassembly and Assembly
IMPORTANT 1

damage the system.
I-2003-0888
P-33119
Inspect all parts for wear or damage. Replace any worn Installation: Align the hole in the buildup valve with the
or damaged parts. hole (Item 1) [Figure 20-40-72] in the bucket valve
section. Fully depress the buildup valve and slide the
Always install new seals and O-rings. Lubricate all seals bucket valve section on the tie rods.
Figure 20-40-73
Figure 20-40-71
3
2
1
1 P-33122
P-33116
Remove the buildup valve (Item 1), spring (Item 2) and

Remove the bucket valve section (Item 1) from the valve piston (Item 3) [Figure 20-40-73].
assembly by depressing the buildup valve (Item 2)
[Figure 20-40-71] and sliding the valve section off the tie
rods.
NOTE: Use care while removing the bucket valve

section. The buildup valve is spring loaded.
320/322 Excavator
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(Cont’d)
Figure 20-40-74
P-33099

opposite side of the bucket valve section.
P-33123
Figure 20-40-77
Remove the O-ring (Item 1) [Figure 20-40-74]. 1
Figure 20-40-75
P-33100
1
P-33098
N•m) torque.
side of the bucket valve section.
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(Cont’d) 6
Figure 20-40-78
5
4
3
2
1
P-33104
Remove the bolts (Item 1), actuator (Item 2), spring seat
(Item 3), spring (Item 4) and spring retainer (Item 5)
P-32991 [Figure 20-40-80].
Installation: Install the lip of the spring retainer (Item 5)

load check valve.
Figure 20-40-81
6
1
5
4
3
2 1
P-33102
P-33105
[Figure 20-40-79]. Remove the spool (Item 1) [Figure 20-40-81].
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m) The spool and valve block are not serviced separately.
torque.
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(Cont’d)
Figure 20-40-82
1
1
2
3
3
2
P-33107
Remove the plug (Item 1), spring (Item 2) and valve

valves.

torque.
Figure 20-40-83
P-33094
Remove the O-ring (Item 1) [Figure 20-40-83] from both

plugs.
320/322 Excavator
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Arm Valve Section Disassembly and Assembly
IMPORTANT
damage the system.
I-2003-0888
P-32933
or damaged parts. arm valve block.
1
Figure 20-40-84
P-32934
1
P-32932

Remove the arm valve section (Item 1) [Figure 20-40- N•m) torque.
320/322 Excavator
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(Cont’d) 6
Figure 20-40-87
5
4
3
2
1
P-32938
P-32991 [Figure 20-40-89].

load check valve.
Figure 20-40-90
5
4
3
2 1
P-32936
P-32939
Remove the bolts (Item 1) spool cover (Item 2), spring
[Figure 20-40-88]. Remove the spool (item 1) [Figure 20-40-90].
320/322 Excavator
182 of 705

(Cont’d)
Figure 20-40-91
1
2
3
3
2
1
P-32941
Remove the plug (Item 1), spring (Item 2) and relief valve
assemblies (Item 3) [Figure 20-40-91] from both relief
valves.

torque.
Figure 20-40-92
P-33094

plugs.
320/322 Excavator
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Boom Swing Valve Section Disassembly And

Assembly
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888
P-32943

Inspect all parts for wear or damage. Replace any worn boom swing valve block.
or damaged parts.
Figure 20-40-95
and O-rings with clean hydraulic fluid before installation. 1
Figure 20-40-93
P-32944
1 Remove the load check valve (Item 1) [Figure 20-40-95].

P-32942
N•m) torque.
Remove the boom swing valve section (Item 1) [Figure
20-40-93] from the valve assembly.
320/322 Excavator
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Assembly (Cont’d) 1
Figure 20-40-96
P-33906

inside the retainer (Item 2) [Figure 20-40-97].
P-32991
Figure 20-40-99

load check valve.
Figure 20-40-97
2
1
1 P-32949
3 Remove the bolts (Item 1) and cap (Item 2) [Figure 20-

40-99].
2 P-32947
torque.
Remove the bolts (Item 1), retainer (Item 2) and seal
(Item 3) [Figure 20-40-97].

torque.
320/322 Excavator
185 of 705

Assembly (Cont’d)
Figure 20-40-100
1 1
2 3
3
2 3 2
P-32953
1

P-32950 valves.

Remove the washer (Item 1) and O-ring (Item 2) from the torque.
Figure 20-40-103
Figure 20-40-101
4
3
2
1
P-33094
P-32951

Remove the spring assembly (Item 1), washer (Item 2), plugs.

Installation: Tighten the spring retaining screw to 18 ft.-

lbs. (24 Nm) torque.
320/322 Excavator
186 of 705
Right Travel Valve Section Disassembly And

Assembly 1
IMPORTANT
damage the system.
I-2003-0888
P-32955

Remove the plug (Item 1) [Figure 20-40-105] from the
Inspect all parts for wear or damage. Replace any worn right travel valve section.
or damaged parts.
Always install new seals and O-rings. Lubricate all seals torque.
Figure 20-40-106
Figure 20-40-104
2
P-32990
P-32954

Remove the tie rods (Item 1) from the right travel valve plug.
section (Item 2) [Figure 20-40-104].
320/322 Excavator
187 of 705

Assembly (Cont’d)
Figure 20-40-107
1
2
P-32961
3
Remove the bolts (Item 1) and spool cover (Item 2)
2 1 [Figure 20-40-109].
P-32958
torque.
Remove the bolts (Item 1), retaining plate (Item 2) and
seal (Item 3) [Figure 20-40-107]. Figure 20-40-110

torque.
Figure 20-40-108
P-32962
2
P-33906

inside the retaining plate (Item 2) [Figure 20-40-107].
320/322 Excavator
188 of 705

Assembly (Cont’d)
Figure 20-40-111
4
3 3
2
1
2
1
P-32966

P-32963
Remove the washer (Item 1) and O-ring (Item 2) from the NOTE: When the spool is removed, use care not to
spool (Item 3) [Figure 20-40-111]. scratch the spool surface. Do not interchange
Figure 20-40-112
lb. (24 N•m) torque.
Figure 20-40-114
1
1
P-32965
Remove the bolts and cap (Item 1) [Figure 20-40-112].

P-32968
torque.

torque.
320/322 Excavator
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Assembly (Cont’d)
Figure 20-40-115 1
2
1
P-33007
2 1 Remove the O-rings (Item 1) and backup ring (Item 2)

1
P-33003

Figure 20-40-116
P-32970

torque.
320/322 Excavator
190 of 705
Assembly

or damaged parts.

IMPORTANT P-32943

clean the work area before disassembly and keep all Install the O-rings (Item 1) [Figure 20-40-119] on the
parts clean. Always use caps and plugs on hoses, boom swing valve section.
damage the system. Figure 20-40-120
I-2003-0888
Figure 20-40-118
1
1
P-32942
2
Install the boom swing valve section (Item 1) [Figure 20-
P-32954
40-120] on the tie rods.
Install the tie rods (Item 1) on the right travel valve

320/322 Excavator
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Assembly (Cont’d)
Figure 20-40-121
P-33098
1
Install the O-rings (Item 1) [Figure 20-40-123] on the

P-32933 right side of the bucket valve.
Figure 20-40-124
Install the O-rings (Item 1) [Figure 20-40-121] on the arm
valve section.
Figure 20-40-122
1
P-33099
1 Install the O-rings (Item 1) [Figure 20-40-124] on the left

P-32932 side of the bucket valve section.
Install the arm valve section (Item 1) [Figure 20-40-122]

on the tie rods.
320/322 Excavator
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Assembly (Cont’d)
Figure 20-40-125
1
1
P-33119
Figure 20-40-127
P-33123
Align the hole (Item 1) in the buildup valve with the hole
(Item 2) [Figure 20-40-124] in the bucket valve section.
1
P-33097
Fully depress the buildup valve (Item 1) [Figure 20-40-

126] and install the bucket valve section (Item 1) [Figure
20-40-127] on the tie rods.
320/322 Excavator
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Assembly (Cont’d)
Figure 20-40-128
1
P-33072
Install the left travel valve section (Item 1) [Figure 20-40-

130] on the tie rods.
1
P-33085 Figure 20-40-131

boom valve section.
Figure 20-40-129
P-33023
1
swing valve section.
P-33084
Install the boom valve section (Item 1) [Figure 20-40-

320/322 Excavator
194 of 705
HYDRAULIC CONTROL VALV (320 / 322)E (CONT’D) Figure 20-40-134
Assembly (Cont’d)
Figure 20-40-132
1
P-33009
1
Install the blade valve section (Item 1) [Figure 20-40-
P-33022 134] on the tie rods.
Figure 20-40-135
Install the swing valve section (Item 1) [Figure 20-40-
Figure 20-40-133
P-32987
1
P-33010 auxiliary valve section.

blade valve section.
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HYDRAULIC CONTROL VALVE (320 / 322) (CONT’D) The spools must not stick, if the spools do stick, loosen
the tie rod nuts and tighten per above information.
Assembly (Cont’d)
Recheck the control valve assembly for level settings.
Figure 20-40-136
Figure 20-40-138
1
P-32986
P-33109
Install the auxiliary valve section (Item 1) [Figure 20-40-

136] on the tie rods. Install the hoses and fittings [Figure 20-40-138].
Figure 20-40-137
P-32985
Install the washers and nuts (Item 1) [Figure 20-40-137]

on the tie rods, finger tight.
Be sure the valve assembly does not rock on a flat

surface.
Initially tighten the tie rod nuts (Item 1) [Figure 20-40-

137] to 10 ft.-lb. (13 N•m) torque in a crisscross manner.
Final tighten the tie rod nuts (Item 1) [Figure 20-40-137]

to 18 ft.-lb. (24 N•m) torque.
The valve assembly must not have any spacing between

the valve sections and the spools must be free when
pushed in and released.
320/322 Excavator
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HYDRAULIC CONTROL VALVE (320L) Figure 20-41-2
Description
The hydraulic control valve has 3335 PSI (230 bar) and
2900 PSI (200 bar) work port relief valves for the boom, 1
1
bucket and arm sections.
1
The 218 PSI (15 bar) buildup valve is located in the
bucket section.
With the engine off, turn the start key to the ON position P-62899
and move both hydraulic control levers to relieve
hydraulic pressure.
Remove the clevis pins and cotter pins (Item 1) [Figure
20-41-2].
IMPORTANT
WARNING
parts clean. Always use caps and plugs on hoses, Hydraulic fluid escaping under pressure can have
tubelines and ports to keep dirt out. Dirt can quickly sufficient force to enter a person’s body by
damage the system. penetrating the skin. This can cause serious injury
I-2003-0888 and possible death if proper medical treatment by a
immediately.
Remove the floormat and floor panels. (See Removal W-2145-0290
and Installation on Page 40-140-1.)
Remove the seat and seat mount. (See Removal And Figure 20-41-3
Figure 20-41-1
1
1
P-62898

P-62900
Mark all tubes and hoses for ease of assembly [Figure

20-41-1].
320/322 Excavator
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HYDRAULIC CONTROL VALVE (320L) (CONT’D) Figure 20-41-6
Figure 20-41-4
1
1
P-62895
1
1
Disconnect the hoses (Item 1) [Figure 20-41-6].
P-62897
NOTE: The hoses will be removed with the valve.
Remove the hoses (Item 1) [Figure 20-41-4] from the top Figure 20-41-7
of the control valve.
Figure 20-41-5
1
3 2 2
1
1
1
1
4
5
P-62894
1
P-62896 Disconnect the tubeline (Item 1) [Figure 20-41-7] from

the control valve.
Remove the tubelines (Item 1) [Figure 20-41-5]. Disconnect the hoses (Item 2) [Figure 20-41-7] from the
control valve.
41-7] from the blade cable linkage.
Loosen the nuts (Item 4) and remove the cable linkage

(Item 5) [Figure 20-41-7].
320/322 Excavator
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Figure 20-41-8
P-62891
Remove the control valve [Figure 20-41-10].

P-62893
Remove the bolts and nuts (Item 1) [Figure 20-41-8].
Figure 20-41-9
P-62892
Remove the bolt and nut (Item 1) [Figure 20-41-9].
320/322 Excavator
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HYDRAULIC CONTROL VALVE (320L) (CONT’D)
Item Description
1. AUXILIARY SECTION
2. BLADE SECTION
3. SLEW SECTION
4. LEFT TRAVEL SECTION
5. BOOM SECTION
6. BUCKET SECTION
7. ARM SECTION
8. BOOM SWING SECTION
9. RIGHT TRAVEL SECTION
10. PORT RELIEF - 3335 PSI (330 bar) (Below Spool Cover)
11. PORT RELIEF - 2900 PSI (200 bar) (Below Spool Cover)
11 11 10
9 8 7 6 5 4 3 2 1
10 10 10
MS1373A
320/322 Excavator
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Disassembly 8 6 4 2
9 7 5 3 1
Clean the outside of the hydraulic control valve before
disassembly.
IMPORTANT
P-62963
damage the system.
I-2003-0888
Mark the valve sections for ease of assembly [Figure 20-
Figure 20-41-11 41-12].
1. Auxiliary Valve
2. Blade Valve
3. Slew Valve
4. Left Travel Valve
5. Boom Valve
6. Bucket Valve
7. Arm Valve
8. Boom Swing Valve
9. Right Travel Valve
P-62960 Figure 20-41-13
Remove the hoses and fittings [Figure 20-41-11].
P-62964
Remove the tie rod nuts (Item 1) [Figure 20-41-13] and

washers.
320/322 Excavator
201 of 705

or damaged parts.

Figure 20-41-14
1
P-62993
Figure 20-41-17
1
P-62965
Remove the auxiliary valve section (Item 1) [Figure 20-

Figure 20-41-15
P-32989

plug.
P-62966

auxiliary valve block.
320/322 Excavator
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(Cont’d)
Figure 20-41-18
3
1 2 P-62995
Remove the bolts (Item 1) and retaining plate (Item 2)

from the actuating end of the spool (Item 3) [Figure 20-
P-62994 41-20].

Remove the load check valve assembly (Item 1) [Figure torque.
20-41-18].
Figure 20-41-21
NOTE: The load check valve assembly is serviced
only as a unit.

N•m) torque. 1
Figure 20-41-19
P-32994

retaining plate.
P-32991

load check valve.
320/322 Excavator
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(Cont’d)
Figure 20-41-22
3
1
2
1
P-62997
2

P-33906
Figure 20-41-25

inside the lip on the retaining plate (Item 2) [Figure 20-
41-22].
Figure 20-41-23 4
3
2
1
3
P-62998
2
1 O-ring (Item 3) and spool (Item 4) [Figure 20-41-25] from
the auxiliary valve.
P-62996
Remove the bolts (Item 1) and end cap (Item 2) from the NOTE: When the spool is removed, use care not to
spool (Item 3) [Figure 20-41-23]. scratch the spool surface and do not
torque. Installation: Tighten the spring retaining bolt to 18 ft.-lb.
(24 N•m) torque.
320/322 Excavator
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(Cont’d)
Figure 20-41-26
1 P-64000
1 Installation: Tighten the plug to 31 ft.-lb. (42 N•m)

P-62999
torque.
Remove the fitting (Item 1) [Figure 20-41-26] from the Figure 20-41-29
auxiliary valve.

torque.
1
Figure 20-41-27
2
1
2
1
P-33007

P-33007

320/322 Excavator
205 of 705

1

or damaged parts.

Figure 20-41-30
P-33011

N•m) torque.
IMPORTANT
1 P-64001
Remove the blade valve section (Item 1) [Figure 20-41- parts clean. Always use caps and plugs on hoses,
30] from the valve assembly. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 20-41-31 I-2003-0888
Figure 20-41-33
P-33010
P-32991
blade valve block.
load check valve.
320/322 Excavator
206 of 705

(Cont’d) 1
Figure 20-41-34
3
2
1
P-33906

2
inside the lip of the retainer (Item 2) [Figure 20-41-36].
1
P-33014 Tighten the bolts to 5 ft.-lb. (6,6 N•m) torque.
Figure 20-41-37
Remove the bolts (Item 1) and cover (Item 2) from the

torque.
Figure 20-41-35
2
1
P-33020
Remove the washer (Item 1) and O-ring (Item 2) [Figure

3 20-41-37].
1
2
P-33016
Remove the bolts (Item 1), spool retainer (Item 2) and

seal (Item 3) from the actuating end of the spool (Item 4)
[Figure 20-41-35].
320/322 Excavator
207 of 705

(Cont’d)
Figure 20-41-38
3
2
1
P-33021


Installation: Tighten the spring retaining bolt to 18 ft.-lb.

(24 N•m) torque.
320/322 Excavator
208 of 705
IMPORTANT
damage the system.
I-2003-0888
P-33023
or damaged parts. slew valve block.
Figure 20-41-39
1
P-33025
1
P-64002

Remove the slew valve section (Item 1) [Figure 20-41- N•m) torque.
320/322 Excavator
209 of 705

(Cont’d)
6
Figure 20-41-42
2
5
4
3
1
P-33065
P-32991 [Figure 20-41-44].

load check valve.
4 2
1
5
3
P-33027
Remove the bolts (Item 1), actuator (Item 2), spring

5) [Figure 20-41-43].


torque.
320/322 Excavator
210 of 705

(Cont’d)
1
Figure 20-41-45 1 2
P-33003

P-33066
Figure 20-41-48
Remove the spool (Item 1) [Figure 20-41-45].

scratch the spool surface and do not
1
Figure 20-41-46
P-33071
1
Remove the plug (Item 1) [[Figure 20-41-48]

torque.
P-33069

torque.
320/322 Excavator
211 of 705

(Cont’d)
Figure 20-41-49
1
2
1
P-33007

320/322 Excavator
212 of 705
Left Travel Valve Section Disassembly And 1

Assembly
IMPORTANT
damage the system.
I-2003-0888
P-33073

Remove the plug (Item 1) [Figure 20-41-51] from the left
Inspect all parts for wear or damage. Replace any worn travel valve block.
or damaged parts.
Figure 20-41-52
Figure 20-41-50
1
P-33074
1
P-64003

Remove the left travel valve section (Item 1) [Figure 20- plug.
320/322 Excavator
213 of 705
Left Travel Valve Section Disassembly And

Assembly (Cont’d)
3
Figure 20-41-53
2
4 1
P-33077
1
3
P-33076
Figure 20-41-56
Remove the bolts (Item 1) retainer (Item 2) and seal

(Item 3) from the spool (Item 4) [Figure 20-41-53].
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m) 5

torque.
4 3
Figure 20-41-54 2
1
P-33079
Remove the cap and bolts (Item 1) spring assembly (Item

2 2), washer (Item 3), O-ring (Item 4) and spool (Item 5)
[Figure 20-41-56].

P-33906 torque.

inside the retainer (Item 2) [Figure 20-41-54]. NOTE: When the spool is removed, use care not to
Installation: Tighten the spring assembly (Item 2)

[Figure 20-41-56] to 18 ft.-lb. (24 N•m) torque.
320/322 Excavator
214 of 705
Left Travel Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-41-57
P-33083

torque.
Remove the fitting (Item 1) [Figure 20-41-57]. Figure 20-41-60

torque.
Figure 20-41-58 1
2
1
1
1 2
P-33007

P-33003

320/322 Excavator
215 of 705
Boom Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888 1
P-33085
or damaged parts. boom valve block.
1
Figure 20-41-61
P-33086
1 Remove the load check valve (Item 1) [Figure 20-41-63].

P-64004

Remove the boom valve section (Item 1) [Figure 20-41- N•m) torque.
320/322 Excavator
216 of 705

(Cont’d) 6
Figure 20-41-64 2
5
4 1
P-33090
P-32991 5) [Figure 20-41-66].
Installation: Make sure the lip on the spring retainer

Remove the O-ring (Item 1) [Figure 20-41-64] from the (Item 5) fits over the spool (Item 6) [Figure 20-41-66].
load check valve.
Figure 20-41-67
3
1
5
4
2
P-33088
P-33091
5) [Figure 20-41-65]. Remove the spool (Item 1) [Figure 20-41-67].
320/322 Excavator
217 of 705

(Cont’d)
Figure 20-41-68
1 3 1
3
2 2
P-33095
Remove the plug (Item 1), spring (Item 2) and spring

valves.

torque.
Figure 20-41-69
P-33094

plug.
320/322 Excavator
218 of 705
Bucket Valve Section Disassembly And Assembly
IMPORTANT 1

damage the system.
I-2003-0888
P-33119
Inspect all parts for wear or damage. Replace any worn Installation: Align the hole in the buildup valve with the
or damaged parts. hole (Item 1) [Figure 20-41-71] in the bucket valve
section. Fully depress the buildup valve and slide the
Always install new seals and O-rings. Lubricate all seals bucket valve section on the tie rods.
Figure 20-41-72
Figure 20-41-70
3
2
1
1 P-33122
P-33116
Remove the buildup valve (Item 1), spring (Item 2) and

Remove the bucket valve section (Item 1) from the valve piston (Item 3) [Figure 20-41-72].
assembly by depressing the buildup valve (Item 2)
[Figure 20-41-70] and sliding the valve section off the tie
rods.
NOTE: Use care while removing the bucket valve

section. The buildup valve is spring loaded.
320/322 Excavator
219 of 705

(Cont’d)
Figure 20-41-73
P-33099

opposite side of the bucket valve section.
P-33123
Figure 20-41-76
Remove the O-ring (Item 1) [Figure 20-41-73]. 1
Figure 20-41-74
P-33100
1
P-33098
N•m) torque.
side of the bucket valve section.
320/322 Excavator
220 of 705

(Cont’d) 6
Figure 20-41-77
5
4
3
2
1
P-33104
Remove the bolts (Item 1), actuator (Item 2), spring seat
(Item 3), spring (Item 4) and spring retainer (Item 5)
P-32991 [Figure 20-41-79].

load check valve.
Figure 20-41-80
6
1
5
4
3
2 1
P-33102
P-33105
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m) The spool and valve block are not serviced separately.
torque.
320/322 Excavator
221 of 705

(Cont’d)
Figure 20-41-81
1
1
2
3
3
2
P-33107

valves.

torque.
Figure 20-41-82
P-33094

plugs.
320/322 Excavator
222 of 705
Arm Valve Section Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
P-32933
or damaged parts. arm valve block.
1
Figure 20-41-83
P-32934
1
P-64006

Remove the arm valve section (Item 1) [Figure 20-41- N•m) torque.
320/322 Excavator
223 of 705

(Cont’d) 6
Figure 20-41-86
5
4
3
2
1
P-32938
P-32991 [Figure 20-41-88].

load check valve.
Figure 20-41-89
5
4
3
2 1
P-32936
P-32939
Remove the bolts (Item 1) spool cover (Item 2), spring
320/322 Excavator
224 of 705

(Cont’d)
Figure 20-41-90
1
2
3
3
2
1
P-32941
Remove the plug (Item 1), spring (Item 2) and relief valve
assemblies (Item 3) [Figure 20-41-90] from both relief
valves.

torque.
Figure 20-41-91
P-33094

plugs.
320/322 Excavator
225 of 705

Assembly
IMPORTANT
damage the system.
I-2003-0888
P-32943

Inspect all parts for wear or damage. Replace any worn boom swing valve block.
or damaged parts.
Figure 20-41-94
and O-rings with clean hydraulic fluid before installation. 1
Figure 20-41-92
P-32944
1
P-64007
N•m) torque.
Remove the boom swing valve section (Item 1) [Figure
20-41-92] from the valve assembly.
320/322 Excavator
226 of 705

Assembly (Cont’d) 1
Figure 20-41-95
P-33906

inside the retainer (Item 2) [Figure 20-41-97].
P-32991
Figure 20-41-98

load check valve.
Figure 20-41-96
2
1
1 P-32949
3 Remove the bolts (Item 1) and cap (Item 2) [Figure 20-

41-98].
2 P-32947
torque.
Remove the bolts (Item 1), retainer (Item 2) and seal
(Item 3) [Figure 20-41-96].

torque.
320/322 Excavator
227 of 705

Assembly (Cont’d)
Figure 20-41-99
1 1
2 3
3
2 3 2
P-32953
1

P-32950 valves.

Remove the washer (Item 1) and O-ring (Item 2) from the torque.
Figure 20-41-102
Figure 20-41-100
4
3
2
1
P-33094
P-32951

Remove the spring assembly (Item 1), washer (Item 2), plugs.


320/322 Excavator
228 of 705
Right Travel Valve Section Disassembly And 1

Assembly
IMPORTANT
damage the system.
I-2003-0888
P-64009

Inspect all parts for wear or damage. Replace any worn right travel valve section.
or damaged parts.
Figure 20-41-105
Figure 20-41-103
2
P-32990
P-64008

Remove the tie rods (Item 1) from the right travel valve plug.
320/322 Excavator
229 of 705

Assembly (Cont’d)
3
Figure 20-41-106
2
1
1
P-32963
3 Remove the washer (Item 1) and O-ring (Item 2) from the

2 P-64010
Figure 20-41-109
Remove the bolts (Item 1), retaining plate (Item 2) and

seal (Item 3) [Figure 20-41-106].

torque.
Figure 20-41-107
1
P-32965
Remove the bolts and cap (Item 1) [Figure 20-41-109].

2
torque.
P-33906

inside the retaining plate (Item 2) [Figure 20-41-107].
320/322 Excavator
230 of 705

Assembly (Cont’d)
Figure 20-41-110
2 1
1
3
2
1
P-33003

P-32966
Figure 20-41-113


scratch the spool surface. Do not interchange 1

Figure 20-41-111
P-32970

torque.
1
P-32968

torque.
320/322 Excavator
231 of 705

Assembly (Cont’d)
Figure 20-41-114
2
1
P-33007

320/322 Excavator
232 of 705
Assembly

or damaged parts.

IMPORTANT P-32943

clean the work area before disassembly and keep all Install the O-rings (Item 1) [Figure 20-41-116] on the
parts clean. Always use caps and plugs on hoses, boom swing valve section.
damage the system. Figure 20-41-117
I-2003-0888
Figure 20-41-115
1 1
P-64007
2
Install the boom swing valve section (Item 1) [Figure 20-

P-64008
41-117] on the tie rods.
Install the tie rods (Item 1) on the right travel valve

320/322 Excavator
233 of 705
Assembly (Cont’d)
Figure 20-41-118
P-33098
1

P-32933 right side of the bucket valve.
Figure 20-41-121
Install the O-rings (Item 1) [Figure 20-41-118] on the arm
valve section.
Figure 20-41-119
1
P-33099
1 Install the O-rings (Item 1) [Figure 20-41-121] on the left

P-64006 side of the bucket valve section.
Install the arm valve section (Item 1) [Figure 20-41-119]

on the tie rods.
320/322 Excavator
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Assembly (Cont’d)
Figure 20-41-122
1
1
P-33119
Figure 20-41-124
P-33123
Align the hole (Item 1) [Figure 20-41-122] in the buildup

valve with the hole (Item 2) [Figure 20-41-121] in the
bucket valve section.
1
P-64005
Fully depress the buildup valve (Item 1) [Figure 20-41-

123] and install the bucket valve section (Item 1) [Figure
20-41-124] on the tie rods.
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Assembly (Cont’d)
Figure 20-41-125
1 P-64003
Install the left travel valve section (Item 1) [Figure 20-41-

1
P-33085 Figure 20-41-128

boom valve section.
Figure 20-41-126
P-33023

1 slew valve section.
P-64004
Install the boom valve section (Item 1) [Figure 20-41-

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Assembly (Cont’d)
Figure 20-41-129
1
P-64001
1
Install the blade valve section (Item 1) [Figure 20-41-
P-64002 131] on the tie rods.
Figure 20-41-132
Install the slew valve section (Item 1) [Figure 20-41-129]
on the tie rods.
Figure 20-41-130
P-62966
1
P-33010 auxiliary valve section.

blade valve section.
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FT.-LB.HYDRAULIC CONTROL VALVE (320L) The spools must not stick, if the spools do stick, loosen
(CONT’D) the tie rod nuts and tighten per above information.
Assembly (Cont’d) Recheck the control valve assembly for level settings.
Figure 20-41-133 Figure 20-41-135
1
P-62965
P-62960
Install the auxiliary valve section (Item 1) [Figure 20-41- Install the hoses and fittings [Figure 20-41-135].
Figure 20-41-134
P-62964
Install the washers and nuts (Item 1) [Figure 20-41-134]

on the tie rods, finger tight.
Be sure the valve assembly does not rock on a flat

surface.
Initially tighten the tie rod nuts (Item 1) [Figure 20-41-

134] to 10 ft.-lb. (13 N•m) torque in a crisscross manner.
Final tighten the tie rod nuts (Item 1) [Figure 20-41-134]

The valve assembly must not have any spacing between

the valve sections and the spools must be free when
pushed in and released.
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HYDRAULIC PUMP Figure 20-50-140
Testing The Hydraulic Pump 2
The hydraulic pump flow is 3.96 GPM (15 L/min.) for

pump sections one and 7.92 GPM (30 L/min.) for pump
section three at 3000 RPM.
NOTE: Pump Section 1 is closest to the engine.
The following tool will be needed for the hydraulic pump

test: 1
MEL10003 - Hydraulic Tester
Stop the engine. P-16670
Open the tailgate.

Connect the hose removed from the pump (Item 1)
Figure 20-50-139 [Figure 20-50-140] to the outlet of the tester.
Connect the inlet hose of the tester to the fitting on the

pump (Item 2) [Figure 20-50-140].
NOTE: The tester connections will be the same for

each pump section.
Figure 20-50-141
P-19009
1
Remove the outlet hose, of the section to be tested, from

the hydraulic pump section for testing [Figure 20-50-
139].
P-16671
NOTE: Open the flow control knob on the hydraulic

tester (Item 1) [Figure 20-50-141] fully to
prevent pump damage.
Start the engine and run at low RPM until the hydraulic
fluid is warm 150°F (66°C). Make sure the tester is
connected correctly. If no flow is indicated at the tester,
the hoses are connected wrong.
Increase the engine speed to full RPM.
Record the pump free flow GPM (L/min).
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HYDRAULIC PUMP (CONT’D)
Testing The Hydraulic Pump (Cont’d)
Close the flow control knob (Item 1) [Figure 20-50-141

on Page 1] slowly to approximately 100 PSI below the
relief valve setting which is 2475 PSI (170 Bar) for pump
section three and 2515 PSI (173 Bar) for pump section
one and two.
Record the pump high pressure flow GPM (L/min).
NOTE: The high pressure flow must be at least 80% of

free flow.
HIGH PRESSURE FLOW (GPM) x 100

%=
FREE FLOW (GPM)
If the high pressure flow is less than 80% of free flow,

remove the hydraulic pump for repair or replacement.
Repeat the testing procedure for each pump section.
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WARNING
Relieve hydraulic pressure. sufficient force to enter a person’s body by
Drain the hydraulic reservoir. (See Replacing Hydraulic and possible death if proper medical treatment by a
Oil on Page 10-100-2.) physician familiar with this injury is not received
immediately.
W-2145-0290
IMPORTANT Figure 20-50-143

1
damage the system.
I-2003-0888
Figure 20-50-142
N-23223
2
Remove the three pressure hoses (Item 1) [Figure 20-
50-143].
Cap and plug the hoses and fittings.
Figure 20-50-144
1
N-23222
Remove the bolts and nuts (Item 1) [Figure 20-50-142] 1

from the fuel filter bracket.
Move the fuel filter and bracket assembly (Item 2)

[Figure 20-50-142] away from the front of the hydraulic
pump.
N-23220
Remove the bolts (Item 1) [Figure 20-50-144] from the

pump flange.
Installation: Tighten the bolts to 29-37 ft.-lb. (40-50 N•m)

torque.
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HYDRAULIC PUMP (CONT’D) Figure 20-50-147
Removal And Installation (Cont’d) 3
Figure 20-50-145
1
2.04”
(51,8 mm)
P-33138
1
Remove the two bolts (Item 1) from the inlet block (Item
P-16649 2) [Figure 20-50-147].
Remove the inlet block. (Later style only, early style used
Remove the hydraulic pump (Item 1) from the flywheel two elbow fittings.)
housing by sliding the pump straight out and pivoting the
end of the pump to the back of the Excavator [Figure 20- Figure 20-50-148
50-145] to clear the flywheel housing. Pull the pump
outwards until the splined coupler is loose from the
flywheel coupling.
Figure 20-50-146
1
P-33137

inlet block.
P-16648
Coupler Removal And Installation
Release the hose clamp (Item 1) [Figure 20-50-146] on Loosen the bolt (Item 3) [Figure 20-50-147] from the
the inlet hose and pull the inlet hose off of the pump. coupler.
Remove the hydraulic pump from the Excavator. Slide the coupler off of the pump shaft.
NOTE: Early style pumps used two inlet hoses and When installing the coupler, maintain 2.04 inch (51,8 mm)
elbows. Later style pumps use the single inlet gap from the pump mount flange to the coupler [Figure
block (as shown). 20-50-147].
Tighten the bolt (Item 3) [Figure 20-50-147] to 36 ft.-lb.

(48 N•m) torque.
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1. Snap Ring
2. Seal 1 3
3. End Plate 2
4. Backup Ring 4 5
5. E-Seal 6
6. Bearing 7
8
7. O-ring 9
8. Dowel Pin
9. Housing 8
10. Gear 10
11. Coupler
12. Plate
13. End Cap 8
6
14. Bolt 5
4 12
8
4 10
5 11
6
7
9
8
7
10
6
5
8 4
12
10
11
4
5
6
7
9
8
7
10
6
5
13
8
14
10
B-14045
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Disassembly
1
Photos may appear different than your pump but the 1
procedure is the same. Later model pumps used one
inlet port verses the early style with two inlet ports (as
shown in these photos).
Clean the outside of the gear pump before disassembly.
2
IMPORTANT
CD-0193A
parts clean. Always use caps and plugs on hoses, Put the pump, mounting flange down, in a protected jaw
tubelines and ports to keep dirt out. Dirt can quickly vise. Remove the four assembly bolts (Item 1) [Figure
damage the system. 20-50-150].
I-2003-0888
NOTE: The pump has only two inlet ports. The pump
Figure 20-50-149 section without the inlet port is located in
section 1 (closest to the input shaft) (Item 2)
[Figure 20-50-150].
Figure 20-50-151
4 6
1 2 3 5
7 1
2 2
CD-0222
Using a center punch, mark both sides of each

separation point (Items 1-6) [Figure 20-50-149] on the CD-0223
inlet side of the pump, as shown, with the corresponding
separation point number.
Remove the end cap (or separating plate) (Item 1) and
Tape the shaft splines (Item 7) [Figure 20-50-149] to two dowel pins (Item 2) [Figure 20-50-151].
make sure that the splines will not damage the oil seal
when the shaft is removed.
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1
Figure 20-50-152
1 Remove the
O-ring from
the end of
the housing
2 2
CD-0197
Remove the drive and idler gears (Item 1) [Figure 20-50-

CD-0224 154].
Figure 20-50-155
Remove the gear housing (Item 1) and two dowel pins
(Item 2) [Figure 20-50-152].
Remove the O-ring from each end of the gear housing 1

[Figure 20-50-152].
Figure 20-50-153
Back-up ring (white)

E-seal (Black)
1
CD-0198
Remove the lower bearing (Item 1) [Figure 20-50-155].
Remove the back-up ring and E-seal from the bearing.
CD-0196
Remove the upper bearing (Item 1) [Figure 20-50-153].
Remove the back-up ring and E-seal from the bearing.
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HYDRAULIC PUMP (CONT’D) Assembly
Disassembly (Cont’d) Clean all parts in solvent and dry with compressed air.
Figure 20-50-156 Inspect all parts for wear or damage. Replace any worn
or damaged parts.

1 and O-rings with clean hydraulic fluid and all E-seals with
assembly lube before installation.
Use the correct size driver and install the oil seal (seal
lips to the inside of the pump) (Item 4) into the mounting
flange (Item 2). Install the retaining ring (Item 1) [Figure
20-50-157].
Figure 20-50-158
CD-0226
2
Remove the coupling (Item 1) [Figure 20-50-156].
Repeat step [Figure 20-50-151 on Page 6] through step 3

[Figure 20-50-156] to disassemble each of the remaining
pump sections. Keep the parts from each section
separate from the other sections.
4
NOTE: The gear housing, two bearings, drive gear
and idler gear in each pump section are not
serviced separately. These parts are matched 1
CD-0192
sets which are run in at the factory. If any part
is damaged, the entire section must be
replaced. Install an E-seal (Item 1) [Figure 20-50-158] stepped
side up, into each E-seal groove. Push each E-seal down
Figure 20-50-157 into the groove.
Install the back-up ring (Item 2) [Figure 20-50-158] into

the groove made by the E-seal and bearing. Push the
back-up ring down flush with the E-seal.
3 NOTE: There is a notch (Items 3 & 4) [Figure 20-50-

158] in the center of the back-up ring and E-
4 seal. When installing the back-up ring, make
sure that these notches are aligned. If the
1
back-up ring or E-seal are not installed
correctly the back-up ring will not sit flush
2
with the E-seal.
CD-0209
Remove the retaining ring (Item 1) from the mounting

flange, (Item 2). Using a seal puller (Item 3), remove the
oil seal (Item 4) [Figure 20-50-157].
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Assembly (Cont’d) Open side of E-seal

1 must go towards the
Figure 20-50-159 inlet ports on housings
Open side of E-seal

must go towards the 2
inlet ports on
housings 2
1
1
CD-0203
Install the upper bearing (Item 1), seal side up, on the
CD-0201 drive and idler gears (Item 2). The open side of the E-
seal must point toward the inlet port side (marked side) of
the pump [Figure 20-50-161].
Put the mounting flange, oil seal side down, in a
protected jaw vise [Figure 20-50-159]. Figure 20-50-162
Install the two dowel pins (Item 1) [Figure 20-50-159] Install O-ring on Upper bearing
into the mounting flange (or separating plate). each side of the must be slightly
housing lower than
Install the lower bearing (Item 2), seal side down, on the housing
mounting flange (or separating plate). The open side of 2
2
the E-seal must point toward the inlet port side (marked
side) of the pump [Figure 20-50-159].
1
Figure 20-50-160
CD-0229
Install O-rings (Item 1) [Figure 20-50-162] on each end

1 of the gear housing.
Align the marks made during disassembly on the gear

housing and mounting flange (or separating plate).
Carefully install the gear housing over the bearings and
gears [Figure 20-50-162].
CD-0202
NOTE: The upper bearing must be slightly lower than
the gear housing. If the bearing is higher than
Tape the splined end (Item 1) [Figure 20-50-160] of the the housing, disassemble the pump section to
drive gear to make sure that the splines will not damage verify that the E-seal, back-up ring, or O-ring
the oil seal during installation. have not moved out of position.
Apply oil to the drive gear and idler gear and to the side Install the two dowel pins (Item 2) [Figure 20-50-162]
faces of the gears. Install the gears into the lower bearing into the gear housing.
[Figure 20-50-160].
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Assembly (Cont’d)
Figure 20-50-163
1
2
CD-0227
Align the marks made during disassembly on the

CD-0226 separating plate and gear housing. Install the separating
plate (Item 1) [Figure 20-50-165].
Apply oil to the coupling (Item 1) [Figure 20-50-163]. Figure 20-50-166
Install the coupling into the drive gear (Item 2) [Figure 1

20-50-163].
Figure 20-50-164
Oil passages
must align to
supply oil to
section one
CD-0223
Repeat step [Figure 20-50-158 on Page 8] through

1 Page 20-50-11 step [Figure 20-50-162 on Page 9] to
CD-0207 assemble pump section 2.
Repeat step [Figure 20-50-158 on Page 8] through step

NOTE: When installing the first section gear housing [Figure 20-50-162 on Page 9] to assemble pump
(Item 1) (with no inlet port), make sure that the section 3.
oil passage in the housing and the separation
plate align. Section one gear housing must Align the marks made during disassembly on the end cap
receive oil flow through this passage from and gear housing. Install the end cap (Item 1) [Figure
section two (center) gear housing (Item 2) 20-50-166].
[Figure 20-50-164].
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Assembly (Cont’d)
Figure 20-50-167
1
1
CD-0193A
Install the four assembly bolts (Item 1) [Figure 20-50-

167].
Evenly tighten the bolts to a final torque of 38-43 ft.-lb.

(52-58 N•m).
Rotate the input shaft periodically while tightening the

bolts to make sure the pump is assembled correctly.
Using a locking plier, rotate the pump shaft to be sure

there is no binding.
NOTE: Use care not to damage the pump shaft.
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MANIFOLD ASSEMBLY/ACCUMULATOR
Description
NOTE: The 320L manifold is not equipped with a two

speed solenoid. The photos may appear IMPORTANT
different, the procedure is the same.
The manifold body contains a two speed solenoid valve, clean the work area before disassembly and keep all
a system bypass valve, a pressure reducing valve and a parts clean. Always use caps and plugs on hoses,
safety relief valve. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
The body is connected to the accumulator. I-2003-0888
The manifold supplies 435 PSI (30 Bar) to the joysticks to From the operator's seat, drain the residual pressure
activate the control valve spools. from the accumulator by stroking a function with the
engine off and the key in the run position.
The accumulator provides short term reserve pressure
for joystick function with the engine off and the key in the Figure 20-60-1
ON position.
Lower the boom/bucket and blade to the ground. 2
WARNING
sufficient force to enter a person’s body by 1
physician familiar with this injury is not received P-56066
immediately.
W-2145-0290
Open the tailgate. Remove the accumulator (Item 1)
[Figure 20-60-1] from the manifold.
Installation: Tighten the accumulator and O-ring to 22-

24 ft.-lb. (29-33 N•m) torque.
Remove the nut (Item 2) [Figure 20-60-1].
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MANIFOLD ASSEMBLY/ACCUMULATOR (CONT’D) Figure 20-60-4

1
Figure 20-60-2
P-16655
Mark and remove the hoses (Item 1) [Figure 20-60-4]

P-16400 from under the upperstructure.
Figure 20-60-5
accumulator.
Figure 20-60-3
1 1
1
2
N-22549
Remove the bolts (Item 1) [Figure 20-60-5] from under

P-56067 the upperstructure.
Remove the manifold.

Disconnect the wire harnesses (Item 1) [Figure 20-60-3]
from the coils.
Mark and remove the hoses and tubelines (Item 2)

[Figure 20-60-3] from the manifold.
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MANIFOLD ASSEMBLY/ACCUMULATOR (CONT’D)
Parts Identification (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293)
1. Pressure Reducing Valve

2. O-Ring
3. Backup Ring
4. O-Ring
5. O-Ring
6. Nut
7. Coil with green tie strap 5
8. Coil with yellow tie strap
9. Coil with orange tie strap
10. O-Ring 6
11. Solenoid
12. Solenoid 1 7
13. Plug
14. O-Ring 10
5
15. Spring
16. Bolt 11 6
17. Seat 5
18. Plug 2 8 6
19. Relief Valve
3
20. O-Ring 10
4
21. Valve Body 2
3 13
3 12 8
4 13
4 10
3 13
3 14
4
4 2 12
3 4 15 14 14
4
3
16 15
2 15
4 17 16
16
19 3 17
14
17
14
18 14
15 20 14
17
16
14 14
18
14
14
17
16
21
15
14
14
17
16
13 15
13 14
MS-1400A
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293)
Figure 20-60-6
1
P-29499
Remove the relief valve (Item 1) [Figure 20-60-8] from

1
the manifold.
P-29497
Figure 20-60-9
Remove the accumulator extension (Item 1) [Figure 20- 1

60-6] from the manifold.
Figure 20-60-7
2
4 3
P-29500
1
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

60-9] from the relief valve.
P-29498
Remove the backup ring (Item 3) and O-ring (Item 4)
[Figure 20-60-9] from the relief valve.
accumulator extension.
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-10
1 P-29503

manifold.
1
P-29501
Figure 20-60-13

manifold.
Figure 20-60-11
3
2
1
P-29504
1
Remove the spring (Item 1), check ball (Item 2) and seat
(Item 3) [Figure 20-60-13].
P-29502

plug.
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-14
1
P-29507

1
P-29505 Figure 20-60-17

plug.
Figure 20-60-15
P-29508
1 Remove the O-ring (Item 1) [Figure 20-60-17] from the

plug.
P-29506

seat.
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
1
2 4 6
Figure 20-60-18
5 3 5
1
P-29554
Remove the top of the valve (Item 1), spring (Item 2),
spring seat (Item 3) and spool (Item 4) [Figure 20-60-20]
P-29509 from the bottom of the valve.
Remove the O-rings (Item 5) and back-up rings (Item 6)

Remove the pressure reducing valve (Item 1) [Figure 20- [Figure 20-60-20].
Figure 20-60-21
Figure 20-60-19
1
1
P-29511
P-29556
Remove the nut (Item 1) [Figure 20-60-21] from the

Place the bottom of the pressure reducing valve (Item 1) joystick lockout solenoid.
[Figure 20-60-19] in a vise equipped with padded jaws.
Loosen the top of the pressure reducing valve (Item 2)

[Figure 20-60-19].
Remove the valve from the vise.
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-22
1
P-29514

solenoid.
P-29512
Figure 20-60-25
Remove the coil with the green tie strap (Item 1) [Figure
20-60-22] from the solenoid.
Figure 20-60-23
P-29515
1
Remove the solenoid (Item 1) [Figure 20-60-25].
P-29513

coil.
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Disassembly (S/N 223911001 - 223911247 &

1 1
S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-26 3
2
P-29517
1 Remove the nut (Item 1) from the two speed solenoid

(Item 2) and system bypass solenoid (Item 3) [Figure 20-
P-29557 60-28].
The 320L is not equipped with the two speed solenoid.

Place the bottom of the solenoid (Item 1) [Figure 20-60-
26] in a vise equipped with padded jaws. Figure 20-60-29
Loosen the top of the solenoid (Item 2) [Figure 20-60-

26].
1
Remove the solenoid from the vise.
2
Figure 20-60-27
5 5
3 4 5
P-29518
6 6 Remove the coil with the yellow tie strap (Item 1) and the
1 2
coil with the orange tie strap (Item 2) [Figure 20-60-29]
from the solenoids.
P-29528
Remove the top of the solenoid (Item 1), spring (Item 2),
spring seat (Item 3) and spool (Item 4) [Figure 20-60-27]
from the bottom of the solenoid.

[Figure 20-60-27].
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-30 1
1
P-29520
1
Remove the solenoids (Item 1) [Figure 20-60-32].
P-29513 Figure 20-60-33

coils.
Figure 20-60-31
2
1
1 P-29555

33] in a vise equipped with padded jaws.
P-29519 Loosen the top of the solenoid (Item 2) [Figure 20-60-

33].
Remove the O-ring (Item 1) [Figure 20-60-31] from both Remove the solenoid from the vise.
solenoids.
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Disassembly (S/N 223911001 - 223911247 &

3
S/N 224011001 - 224012293) (Cont’d)
2
1
Figure 20-60-34
3 3
4
3
1
2
4 1
P-29523
1 2 4
Figure 20-60-37
3 2 1
P-29526
Remove the top of the solenoid (Item 1) and the spool

(Item 2) [Figure 20-60-34] from the bottom of the 4
solenoid.

[Figure 20-60-34].
Figure 20-60-35 1
3 2
1
P-29522
Remove the springs (Item 1), check balls (Item 2) and

1 seats (Item 3) [Figure 20-60-36] & [Figure 20-60-37].
Remove the O-rings (Item 4) [Figure 20-60-36] &

[Figure 20-60-37] from the plugs.
P-29521
Remove the plugs (Item 1) [Figure 20-60-35] from the

top and side of the manifold.
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Disassembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-38
P-29508
1
plugs.
P-29506

seats.
Figure 20-60-39
P-29524
Remove the plugs (Item 1) [Figure 20-60-39].
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Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) 1

or damaged parts.

Figure 20-60-41
P-29506

seats.
2 Figure 20-60-44
1
2
3 4
1
P-29508
Install the O-rings (Item 1) on the plugs (Item 2) [Figure

20-60-41]. 5
1
3
Figure 20-60-42 2
5 3
P-29523
Install the seats (Item 1), check balls (Item 2) and springs
(Item 3) in the top ports (Item 4) [Figure 20-60-44].

1
plugs.
P-29524
Install the plugs (Item 1) [Figure 20-60-42].
Tighten the plugs to 8-10 ft.-lb. (11-14 N•m) torque.
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Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
4 2
3
Figure 20-60-45
1 2 3 5
1 1 1
P-29526
1 2 3 5
Install the O-rings (Item 1) and backup ring (Item 2)
[Figure 20-60-47] on the solenoids.
P-29522
Install the spool (Item 3) [Figure 20-60-47] in the bottom
of the solenoid.
(Item 3) in the side ports (Item 4) [Figure 20-60-45]. Install the top of the solenoid (Item 4) [Figure 20-60-47]
on the bottom of the solenoid.
plugs. Figure 20-60-48
Figure 20-60-46
1
P-29555
P-29521
48] in a vise equipped with padded jaws.
Tighten the top of the solenoid (Item 2) [Figure 20-60-48]
Tighten the plugs to 44 ft.-lb. (60 N•m) torque. to 37 ft.-lb. (50 N•m) torque.
320/322 Excavator
264 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-49
1
1
P-29513
Install the O-rings (Item 1) [Figure 20-60-51] on both

coils.
P-29520
Figure 20-60-52
Install the solenoids (Item 1) [Figure 20-60-49].
Tighten the solenoids to 37 ft.-lb. (50 N•m) torque. 1

2
Figure 20-60-50
1 1
P-29518
Install the coil with the yellow tie strap (Item 1) [Figure
20-60-52] on the two speed solenoid.
P-29519 Install the coil with the orange tie strap (Item 2) [Figure
20-60-52] on the system bypass solenoid.

solenoids.
320/322 Excavator
265 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-53
1 1
2 1
P-29532
NOTE: Make sure the spool (Item 1) is installed in the

spring seat (Item 2) [Figure 20-60-55] before
P-29517 installing the spool/spring seat in the bottom
of the solenoid.
Install the nuts (Item 1) [Figure 20-60-53] on the Figure 20-60-56

solenoids.
Tighten the nuts to 3-4.5 ft.-lb. (4,1 - 6,1 N•m) torque.
NOTE: Overtightening the nut (Item 1) [Figure 20-60- 2

53] may cause solenoid or coil failure.
Figure 20-60-54 1
2 2
P-29557

1 3 4 5 1 56] in a vise equipped with padded jaws.
Install the top of the solenoid (Item 2) [Figure 20-60-56]

on the bottom of the solenoid.
P-29528
Tighten the top of the solenoid (Item 2) [Figure 20-60-56]
Install the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-60-54] on the solenoid.
Install the spring (Item 3), spring seat (Item 4) and spool
(Item 5) [Figure 20-60-54] in the bottom of the solenoid.
320/322 Excavator
266 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-57
P-29513
1
Install the O-ring (Item 1) [Figure 20-60-59] on the coil.
P-29515 Figure 20-60-60
Install the solenoid (Item 1) [Figure 20-60-57].
Tighten the solenoid to 22 ft.-lb. (30 N•m) torque.
Figure 20-60-58
P-29512
1 Install the coil with the green tie strap (Item 1) [Figure
20-60-60] on the joystick lockout solenoid.
P-29514
Install the O-ring (Item 1) [Figure 20-60-58] on the

solenoid.
320/322 Excavator
267 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-61 2
1 1
P-29556
Place the bottom of the valve (Item 1) [Figure 20-60-63]

in a vise equipped with padded jaws.
P-29511
Tighten the top of the valve (Item 2) [Figure 20-60-63] to
22 ft.-lb. (30 N•m) torque.
Install the nut (Item 1) [Figure 20-60-61] on the solenoid.
Figure 20-60-64
Tighten the nut to 3-4.5 ft. -lbs. (4,1 - 6,1 N•m) torque.
NOTE: Overtightening the nut (Item 1) [Figure 20-60-

Figure 20-60-62
1
2 2
P-29509
1 1
6 1 5 4 3
Install the pressure reducing valve (Item 1) [Figure 20-
60-64] in the manifold.
P-29554 Tighten the valve to 22 ft.-lb. (30 N•m) torque.
Install the O-rings (Item 1) and backup rings (Item 2)

[Figure 20-60-62] on the pressure reducing valve.
Install the spool (Item 3) seat (Item 4) and spring (Item 5)

in the bottom of the valve. Install the top of the valve
(Item 6) [Figure 20-60-62].
320/322 Excavator
268 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-65
P-29506
1 Install the O-ring (Item 1) [Figure 20-60-67] on the seat.
P-29508 Figure 20-60-68
Install the O-ring (Item 1) [Figure 20-60-65] on the plug.
Figure 20-60-66
P-29505

1
P-29507
Install the plug (Item 1) [Figure 20-60-66].
Tighten the plug to 37 ft.-lb. (50 N•m) torque.
320/322 Excavator
269 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-69
2
1
P-29502
1
3 Install the O-ring (Item 1) [Figure 20-60-71] on the plug.
P-29504 Figure 20-60-72
Install the seat (Item 1), check ball (Item 2) and spring
(Item 3) [Figure 20-60-69].
Figure 20-60-70
1
P-29501
Install the plug (Item 1) [Figure 20-60-72] in the

1 manifold.
P-29503 Tighten the plug to 37 ft.-lb. (50 N•m) torque.

manifold.
320/322 Excavator
270 of 705
Assembly (S/N 223911001 - 223911247 &

S/N 224011001 - 224012293) (Cont’d)
Figure 20-60-73
2
1
P-29498
4 3 Install the O-ring (Item 1) [Figure 20-60-75] on the

P-29500
Figure 20-60-76
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

60-73] on the relief valve.
Install the O-ring (Item 3) and back-up ring (Item 4)

[Figure 20-60-73] on the relief valve.
Figure 20-60-74
P-29497
Install the accumulator extension (Item 1) [Figure 20-60-

76] on the manifold.
Tighten the extension to 22-24 ft.-lb. (29-33 N•m) torque.

1
P-29499
Install the relief valve (Item 1) [Figure 20-60-74] in the

manifold.
Tighten the valve to 18-22 ft.-lb. (25-30 N•m) torque.
320/322 Excavator
271 of 705
MANIFOLD ASSEMBLY/ACCUMULATOR (CONT’D)
Parts Identification (S/N 223911248 & Above &

S/N 224012294 & Above)
1. Pressure Reducing Valve

2. O-Ring
3. Backup Ring 5
4. O-Ring 6 5
5. Nut
6. O-Ring 6
9
7. Nut
8. Coil without tie strap 7
9. Coil with green tie strap 10
10. Coil with yellow tie strap 12 6
11. Coil with orange tie strap
12 7
12. O-Ring
13. Solenoid Stem 11 6
14. Solenoid Stem 1
15. Plug 13
16. O-Ring 12
17. Spring 13 8
18. Check Ball
19. Seat 2 12
2
20. Plug
21. Relief Valve 3 2
3 14
22. Backup Ring 4 4 15
23. O-Ring 3 3 3
4 14
24. Valve Body 3 16
3 3
4 4 2
3 3 3
17
4 4
3 3
20 18
2
16
4 19
3
21 16
20
16
16
18 22 23
17
19
16
20 20
16
16
20
16
16 24 20
19
18
17
16
15 MS2044S
320/322 Excavator
272 of 705
Disassembly (S/N 223911248 & Above &

S/N 224012294 & Above)
Figure 20-60-77
P-59477
1 Remove the relief valve (Item 1) [Figure 20-60-79] from

the manifold.
P-59476
Figure 20-60-80
Remove the accumulator extension (Item 1) [Figure 20-

1
Figure 20-60-78 2
P-59478
1
Remove the backup ring (Item 1) O-ring (Item 2) [Figure

20-60-80] from the relief valve.
P-29498
relief valve.
320/322 Excavator
273 of 705
Disassembly (S/N 223911248 And Above &

S/N 224012294 And Above) (Cont’d)
Figure 20-60-81
1 P-59481

manifold.
1
P-59479
Figure 20-60-84

manifold.
Figure 20-60-82
3
2
1
P-59482
1
Remove the spring (Item 1), check ball (Item 2) and seat
(Item 3) [Figure 20-60-84].
P-59480

plug.
320/322 Excavator
274 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-85
1 P-59485
1 Remove the plug (Item 1) [Figure 20-60-87].
P-59483 Figure 20-60-88

plug.
Figure 20-60-86
P-59486

1 plug.
P-59484

seat.
320/322 Excavator
275 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-89
P-59490

console (joystick) lockout solenoid.
P-59487
Figure 20-60-92
Remove the pressure reducing valve (Item 1) [Figure 20-

Figure 20-60-90
2 2 1
P-59491
1 Remove the coil with the green tie strap (Item 1) [Figure
20-60-92] from the solenoid stem.
P-59488
Remove the O-rings (Item 1) and backup rings (Item 2)

[Figure 20-60-90].
320/322 Excavator
276 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-93
P-59494
1 Remove the solenoid stem (Item 1) [Figure 20-60-95].
P-59492 Figure 20-60-96
Remove the O-ring (Item 1) [Figure 20-60-93] from the 2 2

coil.
Figure 20-60-94
P-59495
1
[Figure 20-60-96].
P-59493

solenoid stem.
320/322 Excavator
277 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-97
P-59492

coil.
P-59497
Figure 20-60-100
Remove the nut (Item 1) from the two speed boost

solenoid (Item 2) [Figure 20-60-97].
Figure 20-60-98
1 1
P-59499

solenoid stem.
P-59498
Remove the coil with yellow tie strap (Item 1) [Figure 20-
60-98] from the solenoid stem.
320/322 Excavator
278 of 705

S/N 224012294 & Above) (Cont’d)
1
Figure 20-60-101
2
P-59501
Remove the nut (Item 1) from the system by-pass

P-59500
Figure 20-60-104
Remove the solenoid stem (Item 1) [Figure 20-60-101].
Figure 20-60-102 1
2 2
P-59502
1
Remove the coil with orange strap (Item 1) [Figure 20-

P-59495 60-104] from the solenoid stem.

[Figure 20-60-102].
320/322 Excavator
279 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-105
1
P-59504
1 Remove the solenoid stem (Item 1) [Figure 20-60-107].
P-59492 Figure 20-60-108

2
coil.
Figure 20-60-106
1
P-59505

[Figure 20-60-108].
P-59503

solenoid stem.
320/322 Excavator
280 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-109
1
2
P-59492

coil.
P-59507
Figure 20-60-112
Remove the nut (Item 1) from the two speed solenoid

(Item 2) [Figure 20-60-109].
Figure 20-60-110
1
1
P-59509

solenoid stem.
P-59508
Remove the coil with no strap (Item 1) [Figure 20-60-

110] from the solenoid stem.
320/322 Excavator
281 of 705

S/N 224012294 & Above) (Cont’d)
1
Figure 20-60-113
P-59511

top of the manifold.
P-59510
Figure 20-60-116
Remove the solenoid stem (Item 1) [Figure 20-60-113].
Figure 20-60-114
2
1
P-59512
1

P-59505 coil.

[Figure 20-60-114].
320/322 Excavator
282 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-117
P-59515

plugs.
P-59513
Figure 20-60-120

top of the manifold.
Figure 20-60-118
3
2
1
1
P-59516
3
1 2 Remove the O-ring (Item 1) [Figure 20-60-120] from the
seats.
1
P-59514

seats (Item 3) [Figure 20-60-118].
320/322 Excavator
283 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-121
1
P-59515

plugs.
P-59517
Figure 20-60-124

side of the manifold.
Figure 20-60-122
3
2 1
1
P-59516
3 Remove the O-ring (Item 1) [Figure 20-60-124] from the

2 seats.
1
P-59518

seats (Item 3) [Figure 20-60-122].
320/322 Excavator
284 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-125
1
P-59521
1
P-59519 Figure 20-60-128
Figure 20-60-126
P-59522

plug.
P-59520

plug.
320/322 Excavator
285 of 705
Assembly (S/N 223911248 & Above &

S/N 224012294 & Above)
Clean all parts in solvent and dry with compressed air. 2

Inspect all parts for wear or damage. Replace any worn 1
or damaged parts.
Always install new backup rings and O-rings. Lubricate

all backup rings and O-rings with clean hydraulic fluid
before installation.
Figure 20-60-129
P-59520
Install the O-ring (Item 1) on the plug (Item 2) [Figure 20-

60-131].
2
1 Figure 20-60-132
P-59522
Install the O-ring (Item 1) on the plug (Item 2) [Figure 20-

60-129].
1
Figure 20-60-130
P-59519
P-59521
320/322 Excavator
286 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-133
1
2 3
1
2
3
P-59518
1
(Item 3) [Figure 20-60-135] in the side of the manifold.
P-59516
NOTE: Install O-ring face on seat towards the center
of the manifold.
seats. Figure 20-60-136
Figure 20-60-134
P-59517
P-59515
Install the O-rings (Item 1) [Figure 20-60-134] on the Tighten the plugs to 44 ft.-lb. (60 N•m) torque.
plugs.
320/322 Excavator
287 of 705

S/N 224012294 & Above) (Cont’d)
1
Figure 20-60-137 2
3
1
3 2
3
P-59514
1
(Item 3) [Figure 20-60-139] in the top of the manifold.
P-59516
of the manifold.
seats. Figure 20-60-140
Figure 20-60-138
1
P-59513
P-59515
Install the O-rings (Item 1) [Figure 20-60-138] on the Tighten the plugs to 44 ft.-lb. (60 N•m) torque.
plugs.
320/322 Excavator
288 of 705

S/N 224012294 & Above) (Cont’d)
2
Figure 20-60-141
1
1
P-59505

[Figure 20-60-143].
P-59512
Figure 20-60-144
Figure 20-60-142
1
P-59510
Install the solenoid stem (Item 1) [Figure 20-60-144].

P-59511
Tighten the solenoid stem to 37 ft.-lb. (50 N•m) torque.
320/322 Excavator
289 of 705

S/N 224012294 & Above) (Cont’d)
1
Figure 20-60-145
P-59508
Install the coil with no strap (Item 1) [Figure 20-60-147]

on the solenoid stem.
P-59509
Figure 20-60-148

solenoid stem.
1
Figure 20-60-146 2
P-59507
1 Install the nut (Item 1) on the two speed solenoid (Item 2)

[Figure 20-60-148].
P-59492
Tighten the nuts to 4.4 ft.-lb. (6 N•m) torque.
Install the O-ring (Item 1) [Figure 20-60-146] on the coil. NOTE: Overtightening the nut (Item 1) [Figure 20-60-
320/322 Excavator
290 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-149
2
1
P-59503
1
solenoid stem.
P-59505
Figure 20-60-152

[Figure 20-60-149].
Figure 20-60-150
P-59492
P-59504
320/322 Excavator
291 of 705

S/N 224012294 & Above) (Cont’d) 2 2
Figure 20-60-153
P-59495

[Figure 20-60-155].
P-59502
Figure 20-60-156
Install the coil with the orange tie strap (Item 1) [Figure
20-60-153] on the system by-pass solenoid stem.
Figure 20-60-154
1
P-59500
P-59501 Tighten the solenoid stem to 22 ft.-lb. (30 N•m) torque.
Install the nut (Item 1) on the system by-pass solenoid

(Item 2) [Figure 20-60-154].

320/322 Excavator
292 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-157 1
1
P-59498
Install the coil with yellow tie strap (Item 1) [Figure 20-
60-159] on the two speed boost solenoid stem.
P-59499
Figure 20-60-160

solenoid stem.
1
Figure 20-60-158
2
P-59497
1 Install the nut (Item 1) on the two speed boost solenoid

(Item 2) [Figure 20-60-160].
P-59492
Install the O-ring (Item 1) [Figure 20-60-158] on the coil. NOTE: Overtightening the nut (Item 1) [Figure 20-60-
320/322 Excavator
293 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-161
2 2
P-59493
1
solenoid stem.
P-59495
Figure 20-60-164

[Figure 20-60-161].
Figure 20-60-162
P-59492
1
P-59494
320/322 Excavator
294 of 705

S/N 224012294 & Above) (Cont’d)
2 2
Figure 20-60-165
1
1
P-59488

[Figure 20-60-167].
P-59491
Figure 20-60-168
Install the coil with the green tie strap (Item 1) [Figure
20-60-165] on the console (joystick) lockout solenoid
stem.
Figure 20-60-166
1
P-59487
2
Install the pressure reducing valve (Item 1) [Figure 20-

P-59490 Tighten the valve to 22 ft.-lb. (30 N•m) torque.
Install the nut (Item 1) on the console (joystick) lockout


320/322 Excavator
295 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-169
P-59484
1 Install the O-ring (Item 1) [Figure 20-60-171] on the seat.
P-59486 Figure 20-60-172
Figure 20-60-170
P-59483

1
P-59485
320/322 Excavator
296 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-173
P-59480
1
2 Install the O-ring (Item 1) [Figure 20-60-175] on the plug.
3
P-59482 Figure 20-60-176
Install the seat (Item 1), check ball (Item 2) and spring
(Item 3) [Figure 20-60-173].

of the manifold.
Figure 20-60-174
1
P-59479

manifold.
1 P-59481

manifold.
320/322 Excavator
297 of 705

S/N 224012294 & Above) (Cont’d)
Figure 20-60-177
1
2
1
P-29498
3
P-59478
Figure 20-60-180
Install the back-up ring (Item 1) O-ring (Item 2) [Figure

20-60-177] on the relief valve.
Install the O-ring (Item 3) [Figure 20-60-177] on the relief

valve.
Figure 20-60-178
P-59476
Install the accumulator extension (Item 1) [Figure 20-60-

180] on the manifold.
1 Tighten the extension to 21-24 ft.-lb. (29-33 N•m) torque.
P-59477
Install the relief valve (Item 1) [Figure 20-60-178] in the

manifold.
Tighten the valve to 44 ft.-lb. (60 N•m) torque.
320/322 Excavator
298 of 705
TRAVEL MOTOR Figure 20-70-2
Remove the track. (See Removal And Installation on

Page 30-20-4.)
IMPORTANT
2 1
P-11249
damage the system.
I-2003-0888
Remove the hoses (Item 1) [Figure 20-70-2] from the
Figure 20-70-1 travel motor.
Remove the travel motor mounting bolts (Item 2) [Figure

20-70-2].
Installation: Tighten the bolts to 29-37 ft.-lbs. (40-50

Nm) torque.
Remove the travel motor.
The drive sprocket can be removed without removing the

travel motor.
If removing the sprocket from a travel motor that has

been removed from the track frame, clamp the motor in a
P-11248 vise.
Figure 20-70-3
Remove the bolts from the track frame cover [Figure 20-
70-1].
Installation: Tighten the bolts to 15-18 ft.-lbs. (20-25 1

Nm) torque.
Remove the cover.
Mark the hoses for correct installation.
P-29389
Remove the sprocket bolts. Remove the sprocket (Item

1) [Figure 20-70-3].

Nm) torque.
320/322 Excavator
299 of 705
TRAVEL MOTOR (CONT’D)
1. Snap Ring
2. Plug
3. Cover
39
4. O-ring 37
5. Bushing 41
42 36 38
6. Sun Gear 40
7. Snap Ring 35
40
8. Sun Gear 39
9. Planetary Carrier 34
10. Snap Ring 31
38 30
11. Anti-rotation Washers 37
12. Bearings 33 29
13. Planetary Gear 32 28 26
14. Thrust Washer
15. Planetary Carrier
16. Ring Gear 27
17. Snap Ring
18. Bearing
19. Snap Ring 23
20. O-ring 25 23
22
21. Seal Ring
22. Snap Ring 24
23. Snap Ring
24. Bearing 21
25. Drive Shaft
26. Hub 18
27. Seal
28. Alignment Pin 20
29. Swash Plate 19
30. Rotating Block 18
31. Motor Plate
17 14
34. Bearing 11
35. O-ring 10
36. Motor Cover
37. Plug 12
38. O-ring
39. Spring 14
13
40. Washer 11
41. Spool 10 15
42. Bolt
12
7 4
6 3
1
9 8
2
5
B-14478
320/322 Excavator
300 of 705
TRAVEL MOTOR (CONT’D) Figure 20-70-5
Disassembly
IMPORTANT
hen repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888
B-14650
Clean the outside of the travel motor before disassembly.
The following tool will need to be ordered from OTC tool Remove the internal snap ring from the travel motor case
to reassemble the travel motor: [Figure 20-70-5].
MEL1468 for torque ring and seal ring assembly. Figure 20-70-6
Figure 20-70-4
B-14649
B-14497
To remove the cover, install two threaded pins in the
drain holes and lift the cover off [Figure 20-70-6].
Remove the drain plugs (Item 1) [Figure 20-70-4] from
the end cover.
Drain the oil into a container.
320/322 Excavator
301 of 705
Figure 20-70-7
B-14646
Remove the planetary carrier [Figure 20-70-9].

B-14648
Figure 20-70-10
Air pressure may also be used to remove the cover, 1

screw the adapter in a drain hole and apply 8-11 PSI
2
[Figure 20-70-7].
4
NOTE: Do not use excess pressure or seal damage
may result. 3
Figure 20-70-8 5
B-14645
Remove the snap rings (Item 1) anti-rotation washers

(Item 2), gears (Item 3), bearings (Item 4) and the bottom
thrust washers (Item 5) [Figure 20-70-10] from the
planetary carrier assembly.
B-14647
Remove the outer sun gear (Item 1) [Figure 20-70-8] by

using two levers and prying on the bottom of the gear.
320/322 Excavator
302 of 705
1
Figure 20-70-11
2
2 4
1
3
B-14642
Remove the snap rings (Item 1), anti-rotation washers

B-14644 (Item 2), gears (Item 3), bearings (Item 4) and bottom
thrust washers (Item 5) [Figure 20-70-13] from the
planetary carrier assembly.
Remove the inner sun gear (Item 1) [Figure 20-70-11],
from the first stage planetary carrier. Figure 20-70-14
Removal of the sun gear snap ring (Item 2) [Figure 20-

70-11] is not necessary.
Figure 20-70-12
B-14641
Remove the external snap ring from the hub to free the
two bearings, ring gear and motor [Figure 20-70-14].
B-14643
Install three 10 mm bolts through the hub mounts, and
tighten to separate the hub and ring gear assembly.
Remove the planetary carrier [Figure 20-70-12].
320/322 Excavator
303 of 705
Figure 20-70-15
B-14638
1 Remove the bearing from the carrier by pressing it out

B-14640 the flanged side of the carrier [Figure 20-70-17].
Figure 20-70-18
NOTE: Place a piece of scrap metal (Item 1) [Figure
20-70-15] in between the bolt and ring gear
flange to prevent damage to the flange when 1.97”
tightening the bolts. (50 mm)
Figure 20-70-16
2.56”
1 (65 mm)
1.38”
(35 mm) B-14637A
Install a support cap [Figure 20-70-18], over the drive

shaft and gear, to protect the splines from damage.
B-14639 Obtain the support cap locally.
The dimensions of the support cap are as follows:

Remove the O-ring (Item 1) and internal snap ring (Item
2) [Figure 20-70-16] from the ring gear. Height 2.56 inch (65 mm)
I.D. 1.38 inch (35 mm)
O.D. 1.97 inch (50 mm)
320/322 Excavator
304 of 705
Disassembly (Cont’d) 4
3
Figure 20-70-19
1 2
3
2
1
B-14635
Remove the two plugs (Item 1), springs (Item 2), and
B-14595 washers (Item 3) [Figure 20-70-21] from each end of the
housing.
Press the bearing off the motor hub [Figure 20-70-19]. Remove the spool (Item 4) [Figure 20-70-21].
NOTE: Do not damage the bottom surface of the Figure 20-70-22

bearing as it is lapped (polished) to mate with
the front seal ring.
Figure 20-70-20
B-14492
To disassemble the spool, insert a hardened pin through

B-14636 the hole in the spool and use a vise with protective jaws
to hold the spool [Figure 20-70-22].
Remove the front seal ring from the motor hub [Figure NOTE: Do not use any type of tool to grip the spool or
20-70-20]. damage to the spool will result.
Remove the two end plugs from the end of the spool
[Figure 20-70-22].
320/322 Excavator
305 of 705
1
Figure 20-70-23
2 2
1
3
2
B-14677
3
1
Remove the bronze motor plate (Item 1) and dowel pin
B-14491 (Item 2) [Figure 20-70-25].
Figure 20-70-26
Remove the spring (Item 1) poppet (Item 2) and check
ball (Item 3) [Figure 20-70-23] from the ends of the 1
spool. 2
Figure 20-70-24
3
B-14633
Remove the O-ring (Item 1) bearing (Item 2) and the two

alignment pins (Item 3) remove the bearing (Item 2)
B-14634 [Figure 20-70-26] with a bearing puller.
Remove the six bolts and remove the motor cover

[Figure 20-70-24].
320/322 Excavator
306 of 705
Figure 20-70-27
2
3
1
B-14629
Remove the swash plate (Item 1), seal (Item 2) and

B-14631 alignment pin (Item 3) [Figure 20-70-29].
Figure 20-70-30
Invert the hub and the rotating block will slide out [Figure
20-70-27].
1
Figure 20-70-28
2
3
1
B-14628
Remove the snap ring (Item 1), bearing (Item 2) and

B-14630 second snap ring (Item 3) [Figure 20-70-30] from the
drive shaft.
Remove the internal snap ring (Item 1) retaining the

bearing/drive shaft to the hub and press the drive shaft
(Item 2) [Figure 20-70-28] out of the hub.
320/322 Excavator
307 of 705
TRAVEL MOTOR (CONT’D) Install the snap ring (Item 2) on the drive shaft in the
second groove (Item 3) [Figure 20-70-32].
Assembly
Figure 20-70-33
Inspect all parts and replace any that are damaged. If
any of the planetary gears are damaged, replace all the
planetary gears and sun gear from the stage (first or
second) that the damaged gear is from. One damaged
gear can cause microscopic fatigue crack in mating teeth
and cause premature failure after servicing. Apply oil to
all O-rings (do not oil the rubber torque ring) and light
grease to the ball and roller bearings before installation.
Figure 20-70-31
2
B-14625
1
Invert the hub and press the drive shaft into the hub and
bearing assembly. [Figure 20-70-33]
Figure 20-70-34
B-14626
Press the bearing (Item 1) [Figure 20-70-31] in the motor

hub.
Install the internal snap ring (Item 2) [Figure 20-70-31] in

the motor hub.
Wrap glossy paper around the snap ring grooves to

prevent damage to the seal.
B-14624
Figure 20-70-32
Install the new seal into the seal seat in the motor hub
using the seal seating tool [Figure 20-70-34]. Obtain the
seal seating tool locally. The dimensions of the seal
seating tool are as follows:
3 Height 2.75 inch (70 mm)

I.D. .677 inch (17, 2 mm)
O.D. .708 inch (18 mm)
1
2
B-14675
Lubricate with oil, and install the seal (Item 1) [Figure 20-
70-32] on the drive shaft.
320/322 Excavator
308 of 705
Assembly (Cont’d)
Figure 20-70-35
B-14652
Lubricate with oil, and install the rotating block in the

B-14672 motor hub [Figure 20-70-37].
Figure 20-70-38
Invert the motor hub and install the external snap ring
(Item 1) [Figure 20-70-35].
Figure 20-70-36
2
1
2
3
B-14654
Press the bearing (Item 1) [Figure 20-70-38] into the

B-14651 motor cover.
Apply oil and install the O-ring (Item 2) [Figure 20-70-

Install the swash plate (Item 1) and alignment pin (Item 2) 38].
[Figure 20-70-36] in the motor hub.
Install the two alignment pins (Item 3) [Figure 20-70-36]

in the motor hub.
320/322 Excavator
309 of 705
Assembly (Cont’d)
Figure 20-70-39
0.098-0.110”
(2,5-2,8 mm)
B-14655
Lubricate the bearing with oil and install the motor cover
B-14777 onto the hub with six bolts [Figure 20-70-41].
Tighten the bolts in a crisscross manner to 18-22 ft. lbs.

The bearing (Item 1) [Figure 20-70-39] must extend from (25-30 Nm) torque.
the face of the cover 0.098-0.110 inch (2,5-2,8 mm).
Figure 20-70-42
Figure 20-70-40
4
2 2
5
1 2 3
4 1
5
1
3
B-14491
B-14677
Install the check ball (Item 1), poppet (Item 2) and spring
Install the alignment pin (Item 1) [Figure 20-70-40] on (Item 3) [Figure 20-70-42] into both ends of the spool.
the motor cover.
Apply oil and install the new O-rings (Item 4) on the plugs
Install the valve plate (Item 2) on the motor cover, with (Item 5) [Figure 20-70-42].
the alignment notch, in the valve plate (Item 2) sliding
over the alignment pin (Item 1) [Figure 20-70-40].
320/322 Excavator
310 of 705
TRAVEL MOTOR (CONT’D) Apply oil to the O-rings and install the new O-rings on the
plugs (Item 4) [Figure 20-70-44].
Assembly (Cont’d)
Install the plugs (Item 4) [Figure 20-70-44] in the motor
Figure 20-70-43 cover.
Figure 20-70-45
B-14492
B-14657
To assemble the spool, insert a hardened pin through the
hole in the spool and use a vise with protective jaws to
hold the spool [Figure 20-70-43]. Apply oil to the outer edge of the bearing and press the
bearing in the housing, using the bearing installation tool
NOTE: Do not use any type of tool to grip the spool or [Figure 20-70-45].
damage to the spool will result.
Obtain the bearing installation tool locally.
Install the two plugs in both ends of the spool [Figure 20-
70-43]. Figure 20-70-46
Tighten the plugs to 18-22 ft. lbs. (25-30 Nm) torque. 3.78”
(96 mm)
Figure 20-70-44
1 4.27”
2 (108,4 mm)
4
3
2
5.69”
(144,5 mm) B-14593
3
4
The dimensions of the bearing installation tool [Figure
B-14656 20-70-46] are as follows:
Height 4.27 inch (108, 4 mm)

Apply oil to the spool and install the spool (Item 1)
[Figure 20-70-44] in the motor cover. I.D. 3.78 inch (96 mm)
O.D. 5.69 inch (144,5 mm)
Install the washer (Item 2) and spring (Item 3) [Figure
20-70-44] in the motor cover.
320/322 Excavator
311 of 705
Assembly (Cont’d)
2
Figure 20-70-47 1
B-14496
Install the O-ring (Item 1) on the seal ring (Item 2)

B-14658 [Figure 20-70-49].
NOTE: Inspect the seal ring for burrs before installing

Install the internal snap ring (item 1) [Figure 20-70-47] in the O-ring. Install the seal ring making sure it
the housing. is not twisted. To remove any twists, gently
pull a section of the O-ring and let it snap
Apply oil on the O-ring and install the O-ring (Item 2) back.
[Figure 20-70-47] in the housing.
The O-ring, seal ring and motor assembly must be clean
Figure 20-70-48 and free of any dust, oil film or foreign matter.
Figure 20-70-50
B-14659
B-14594
Apply oil to the outer edge of the second bearing and
press the bearing in the housing [Figure 20-70-48].
Install the seal seating tool (MEL1468) on the seal ring
NOTE: Make sure the O-ring is correctly installed in [Figure 20-70-50].
the housing so it is not damaged when the
second bearing is installed.
320/322 Excavator
312 of 705
Assembly (Cont’d)
Figure 20-70-51
B-14494
After the seal ring is installed, check the stand out height
B-14495 [Figure 20-70-53] in four places, 90° apart.
The stand out height is 0.30 ± 0.02 inches (7.7 ± 0,5

The seal ring assembly must be lubricated with alcohol, mm).
so the O-ring will slip past the housing retaining ring and
seal uniform in the motor housing radius [Figure 20-70- NOTE: If the seal ring does not meet the height
51]. specifications inspect the torque ring for
twists or obvious bulges.
The O-ring on the seal ring assembly must be lubricated
with alcohol. Apply a light film of oil to the seal ring and lapped face of
the bearing.
This will allow the O-ring to slide on the motor housing
sealing surface without twisting [Figure 20-70-51]. NOTE: Do not get any oil on the O-ring.
Dip the O-ring and seal ring assembly in a pan of alcohol. Figure 20-70-54
Figure 20-70-52
B-14661
B-14493
Press the reduction unit and motor assembly into the
seat of the bearings [Figure 20-70-54]. The inner
Shake off the excess alcohol and install the seal ring bearing may move deeper into the housing as the motor
assembly on the motor [Figure 20-70-52]. assembly is pressed into the housing. If this happens,
press the inner bearing down to its original position.
Use firm even pressure on the installation tool
(MEL1468) to pop the O-ring into the motor housing.
320/322 Excavator
313 of 705
Assembly (Cont’d)
Figure 20-70-55
B-14664
Install the planetary assembly in the hub [Figure 20-70-

B-14662 57].
Figure 20-70-58
Install the external snap ring (Item 1) [Figure 20-70-55]
in the motor reduction unit.
Figure 20-70-56
5
4
3
1
B-14665
Install the sun gear into the outer planetary carrier

B-14663 [Figure 20-70-58].
Install the thrust washers (Item 1), planetary gears (Item

2), bearing (Item 3) anti-rotation washers (Item 4) and
external snap rings (Item 5) [Figure 20-70-56].
Install the snap rings so the opening of the snap ring is

towards the outside.
320/322 Excavator
314 of 705
Assembly (Cont’d)
Figure 20-70-59
2
4 1
3
1
B-14676
Inspect the cover bushing (Item 1) [Figure 20-70-61] for

B-14666 wear.
If the bushing (Item 1) [Figure 20-70-61] needs to be

Install the thrust washers (Item 1) planetary gears (Item replaced, drill a hole in the center of the bushing using a
2) bearings (Item 3) anti-rotation washers (Item 4) and number 3 drill bit.
external snap rings (Item 5) [Figure 20-70-59].
Thread the hole with a 1/4 X 28 inch NF tap.
Install the snap rings so the opening of the snap ring is
towards the outside. Install a 1/4 X 28 inch bolt (Item 2) [Figure 20-70-61] in
the bushing and pull the bushing out of the cover.
Figure 20-70-60
Install the new bushing in the cover with the bevel down.
The clearance between the cover bushing and the sun

gear must be 0.008-0.031 inch (0,2-0,8 mm).
Figure 20-70-62
B-14667
Install the outer planetary assembly in the hub [Figure

20-70-60].
B-14771
Place a 1/2 inch (13 mm) long piece of 1/16 inch (1,5
mm) solder on the sun gear [Figure 20-70-62].
Seat the cover in the hub.
Remove the cover and measure the solder.

320/322 Excavator
315 of 705
Assembly (Cont’d)
If the clearance between the sun gear and cover bushing

does not meet specifications, order the bushing shim kit
from Bobcat Parts. 1
Shim Thickness Part Number

0.020 inch (0,5 mm) 6669597
0.030 inch (0,76 mm) 6669598
0.050 inch (1,27 mm) 6669599
Remove the bushing.

B-14671
Install the correct shim under the bushing and install the
bushing.
Install the internal snap ring (Item 1) [Figure 20-70-64]
NOTE: Make sure there are no burrs on the bushing securing the cover to the travel motor.
face from bushing removal.
Figure 20-70-65
Repeat the procedure for checking clearance between
the sun gear and cover bushing.
Figure 20-70-63
1
2 2
B-14498
Add 1.06 qts. (1,0 L) of gear lube 90W to the top plug
hole (Item 1) until the gear lube is at the bottom of the
B-14670 plug hole (Item 2) [Figure 20-70-65].
Lubricate and install the O-ring (Item 1) [Figure 20-70- Install and tighten the two plugs.
63] on the cover.
Install the cover (Item 2) [Figure 20-70-63] on the hub.
320/322 Excavator
316 of 705
SWIVEL JOINT

IMPORTANT
Expand the track frame fully.
Figure 20-80-66 clean the work area before disassembly and keep all
damage the system.
I-2003-0888
Mark all hoses and tubelines for ease of assembly.
Figure 20-80-67
P-56264
Place blocks under the Excavator tracks [Figure 20-80-

66].
Relieve hydraulic pressure.

P-56230

Installation on Page 40-40-1.) Remove the hoses (Item 1) [Figure 20-80-67] from the
top of the swivel joint.
Remove the floormat and floorplates. (See Removal and
Figure 20-80-68
Drain the hydraulic reservoir. (See Replacing Hydraulic
Oil on Page 10-100-2.)
1 1
WARNING
immediately.
W-2145-0290 P-56231
Remove the tubelines (Item 1) [Figure 20-80-68] from

the top of the swivel joint and control valve.
320/322 Excavator
317 of 705
SWIVEL JOINT (CONT’D) Figure 20-80-71
Figure 20-80-69
2
1
1
1
1
P16601
1
Remove the bolts (Item 1) and plate (Item 2) [Figure 20-

P-56232 80-71] from the underside of the Excavator.
Figure 20-80-70
P-56233
Disconnect the wire harness (Item 1) [Figure 20-80-70].
320/322 Excavator
318 of 705

1
Figure 20-80-72
1 1
2
1
2
1
1
P-56235
2
Remove the four nuts (Item 1) [Figure 20-80-73] and

P-56234 slide the swivel joint out from the underside of the
Excavator.
Remove the five hoses (Item 1) [Figure 20-80-72] from

the left side of the swivel joint.
Remove the five hoses (Item 2) [Figure 20-80-72] from

the right side of the swivel joint.
NOTE: Support the swivel joint on the underside of

the Excavator to prevent the swivel joint from
falling when the four nuts are removed.
320/322 Excavator
319 of 705
SWIVEL JOINT (CONT’D)
Parts Identification 320
1. Seal
2. O-Ring
3. Washer
4. Snap Ring
5. Stud
6. Plug
7. Housing
8. Rotor 1
6
3
2
2
2 5
2 6 8
2 2
3 7
6 2
3 2 6
6
4
PE-1579
320/322 Excavator
320 of 705
SWIVEL JOINT (CONT’D)
Parts Identification 322
1. Seal
2. O-Ring
3. Washer
4. Snap Ring
5. Stud
6. Housing
7. Plug
8. Rotor
9. Spool
10. Coil
11. Nut
1
2
3
7
2 2
5
2
2 1 6
2
8
3 7
10
2
3 9 2
2 2 11
7 7
4
PE-1578
320/322 Excavator
321 of 705
Disassembly
2 1
NOTE: The disassembly and assembly of the 322
swivel joint is shown. The procedure for the
320 is the same, except for the coil and spool
installed in the track expansion/blade port.
Figure 20-80-74
P-16708
1
Remove the O-ring (Item 1) from the nut (Item 2) [Figure

20-80-76].
Figure 20-80-77
P-16707
2
Remove the fittings (Item 1) [Figure 20-80-74].
Figure 20-80-75
P-16705
2
Remove the spool (Item 1) and fitting (Item 2) [Figure 20-

1 80-77].
P-16706
Remove the nut (Item 1) and coil (Item 2) [Figure 20-80-

75].
320/322 Excavator
322 of 705
Figure 20-80-78
2
2
1
P-16710
3
1 Remove the snap ring (Item 1) and steel washer (Item 2)
P-16704 [Figure 20-80-80] from the bottom of the swivel joint.
Figure 20-80-81
Remove the O-ring (Item 1) back-up ring (Item 2) and
seals (Item 3) [Figure 20-80-78].
Figure 20-80-79
2 1
1
1 P-16711
Remove the nylon washer (Item 1) [Figure 20-80-81].

P-16709
Remove the three bolts (Item 1). Remove the mount

(Item 2) [Figure 20-80-79].
320/322 Excavator
323 of 705
1
Figure 20-80-82
P-15261
1 Remove the O-ring (Item 1) [Figure 20-80-84].

P-16712
Figure 20-80-85
Tap the end of the rotor (Item 1) [Figure 20-80-82] with a

rubber mallet to drive the rotor out of the housing.
1 1 1 1
Figure 20-80-83
P-15262
Remove the seals (Item 1) [Figure 20-80-85].
P-15260 NOTE: The 320 swivel joint is equipped with seven

seals and the 322 swivel joint is equipped with
eight seals.
Remove the seal (Item 1) [Figure 20-80-83].
320/322 Excavator
324 of 705
1
Figure 20-80-86
1 1 1 1
2
P-15265

P-15263
Remove the nylon washer (Item 2) [Figure 20-80-88].
Remove the O-rings (Item 1) [Figure 20-80-86].
NOTE: The 320 Excavators have seven O-rings

installed on the rotor. The 322 Excavators
have eight O-rings installed on the rotor.
Figure 20-80-87
P-15264
320/322 Excavator
325 of 705
Assembly
1 1 1 1
Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new O-rings
and seals. Lubricate all seals and O-rings with clean
hydraulic fluid before installation.
Figure 20-80-89
2
P-15263
Install the O-rings (Item 1) [Figure 20-80-91].
NOTE: The 320 Excavators have seven O-rings

installed on the rotor. The 322 Excavators
have eight O-rings installed on the rotor.
Heat the seals in hydraulic fluid for three minutes at

130°F (54°C).
1 P-15265
Figure 20-80-92
Install the nylon washer (Item 1) [Figure 20-80-89].

1 1 1 1
Heat the seal in hydraulic fluid for three minutes at 130°F

(54°C).
Figure 20-80-90
P-15262
Install the seals (Item 1) [Figure 20-80-92].
NOTE: The 320 Excavators have seven seals installed

on the rotor. The 322 Excavators have eight
seals installed on the rotor.
P-15264
Install the seal (Item 1) [Figure 20-80-90] on the O-ring.
320/322 Excavator
326 of 705
Assembly (Cont’d)
1
Figure 20-80-93
P-15266
NOTE: A ring compressor (Item 1) may be used to fit

P-15261 the seals into the seal grove [Figure 20-80-95].
Compress the seals for three minutes.
Install the O-ring (Item 1) [Figure 20-80-93]. Figure 20-80-96
Heat the seal in hydraulic fluid for three minutes at 130°F

(54°C).
1
Figure 20-80-94
P-15267
Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

in the housing [Figure 20-80-96].
P-15260
Install the seal (Item 1) [Figure 20-80-94].
320/322 Excavator
327 of 705
Assembly (Cont’d)
Figure 20-80-97
P-16709
1
Install the mount on the swivel joint. Install the bolts (Item
P-16711 1) [Figure 20-80-99]. Tighten the bolts to 32-35 ft.-lbs.
(43-47 Nm) torque.
Install the nylon washer (Item 1) [Figure 20-80-97]. Figure 20-80-100
Figure 20-80-98
2
3
1
P-16704
P-16710
Install the O-ring (Item 1) back-up ring (Item 2) and seals
(Item 3) [Figure 20-80-100].
Install the steel washer (Item 1) and snap ring (Item 2)
[Figure 20-80-98].
320/322 Excavator
328 of 705
Assembly (Cont’d)
Figure 20-80-101
1
2
1
P-16706
Install the coil (Item 1) and nut (Item 2) [Figure 20-80-

P-16705 103] on the spool.
Figure 20-80-104
Install the spool (Item 1) [Figure 20-80-101] in the swivel
joint. Tighten the spool to 35 ft.-lbs. (47 Nm) torque.
Install the fitting (Item 2) [Figure 20-80-101] in the swivel

joint.
Figure 20-80-102 1
P-16707
Install the fittings (Item 1) [Figure 20-80-104].
P-16708
Install the O-ring (Item 1) [Figure 20-80-102] in the nut.
320/322 Excavator
329 of 705
320/322 Excavator
330 of 705
SWING MOTOR Figure 20-90-2
IMPORTANT
damage the system. 1
I-2003-0888
P-56226
Remove hose (Item 1) [Figure 20-90-2].
Installation on Page 40-40-1.) Figure 20-90-3
Remove blade extension tray. (See Removal And

Figure 20-90-1
1
1
1
P-56227
Remove the six bolts (Item 1) [Figure 20-90-3] from the

swing motor.
P-56225
Nm) torque.
Mark the hose and tubelines for ease of assembly
[Figure 20-90-1]. Remove the swing motor from the Excavator.
320/322 Excavator
331 of 705
SWING MOTOR (CONT’D)
1. Plug
2. Shaft
3. Bearing
4. Seal
5. Housing
9
6. Snap Ring 7
7. O-Ring
8
8. Plate
9. Drive Shaft
10. Geroler 4
11. Valve Plate 7
12. Valve
6
13. Balance Ring 3
14. Pin 5
15. Spring
16. Bolt
17. Ball
18. Crossport Relief Valve 4
3
2 16
15 1
1 1
1
4 15 7
17
4
13
12
7 14
11
1
7 9
10
18
B-23189
320/322 Excavator
332 of 705
SWING MOTOR (CONT’D) Figure 20-90-6
Disassembly
1
1
Clean the outside of the swing motor before disassembly.
Mark the outside of the swing motor for ease of

assembly.
Figure 20-90-4
1 P-53554
1

crossport relief valves.
Figure 20-90-7
P-53519
1
Remove the crossport relief valve (Item 1) [Figure 20-90-
4].
Figure 20-90-5
1
P-53555

plugs.
P-53524

crossport relief valves.
320/322 Excavator
333 of 705
1
Figure 20-90-8 2
3
2
2
1
P-32097
2 Remove the top of the motor (Item 2) [Figure 20-90-9] by

1
P-53556 lifting straight up. If done carefully, the springs (Item 1),
pins (Item 2) and balance ring assembly (Item 3) [Figure
20-90-10] will remain on the valve for easy removal.
Remove the springs (Item 1) and balls (Item 2) [Figure
20-90-8]. Figure 20-90-11
Figure 20-90-9
1 1
P-53522
P-53557
320/322 Excavator
334 of 705
Figure 20-90-12 2
1
1 1
2 2
P-32099
Remove the inner seal (Item 1) and outer seal (Item 2)

P-53521 [Figure 20-90-14].
Figure 20-90-15
Remove the springs (Item 1) and pins (Item 2) [Figure
20-90-12].
Figure 20-90-13
P-53526
Remove the valve (Item 1) [Figure 20-90-15].

P-53525
Remove the balance ring (Item 1) [Figure 20-90-13].
320/322 Excavator
335 of 705
1
Figure 20-90-16
1
P-53529

P-53527
Figure 20-90-19
Remove the drive shaft (Item 1) [Figure 20-90-16].
Figure 20-90-17
P-53530
Remove the geroler (Item 1) [Figure 20-90-19].

P-53528
NOTE: Do not disassemble the geroler.
Remove the valve plate (Item 1) [Figure 20-90-17].
320/322 Excavator
336 of 705
Figure 20-90-20
P-53533

P-53531
Figure 20-90-23
Figure 20-90-21 1
3 2
P-53534
Remove the drive shaft (Item 1). Remove the O-ring

P-53532 (Item 2) [Figure 20-90-23].
Remove the snap ring (Item 3) [Figure 20-90-23].

Remove the valve plate (Item 1) [Figure 20-90-21].
320/322 Excavator
337 of 705
Figure 20-90-24
P-53538
1 Remove the bearing (Item 1) [Figure 20-90-25] &

P-53536 [Figure 20-90-26] from the housing.
Figure 20-90-27
Press the shaft (Item 1) [Figure 20-90-24] out of the
housing.
Figure 20-90-25
P-53539

P-56278
Press the bearing (Item 1) [Figure 20-90-25] off of the

shaft.
320/322 Excavator
338 of 705
Assembly
Inspect all parts for wear or damage. Replace any worn 1

or damaged parts.

Figure 20-90-28
P-53541
1 Press the shaft (Item 1) [Figure 20-90-30] in the housing.
Figure 20-90-31
P-53539
1
Install the seal (Item 1) [Figure 20-90-28] in the housing.
Figure 20-90-29
P-56279
Apply assembly lube to the bearing and press the

1 bearing (Item 1) [Figure 20-90-31] in the housing.
P-53540
Press the bearing (Item 1) [Figure 20-90-29] on the

shaft.
320/322 Excavator
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Assembly (Cont’d)
Figure 20-90-32
2
P-53533
Install the seal (Item 1) [Figure 20-90-34] in the plate.

P-53544
Figure 20-90-35
Install the snap ring (Item 1)and O-ring (Item 2) [Figure

20-90-32].
Figure 20-90-33
1
P-53532
Install the plate (Item 1) [Figure 20-90-35].
P-53545
Install the drive shaft (Item 1) [Figure 20-90-33].
320/322 Excavator
340 of 705
Assembly (Cont’d)
1
1
Figure 20-90-36
P-53529

P-53531 valve plate.
Motor Timing
Install the O-rings (Item 1) [Figure 20-90-36].
The direction that the output shaft rotates is determined
Figure 20-90-37 by timing. Time the motor as follows:
Figure 20-90-39
1
P-53530
P-53546
Install the geroler (Item 1) [Figure 20-90-37].
Locate the largest open pocket in the geroler (Item 1)

[Figure 20-90-39].
320/322 Excavator
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Assembly (Cont’d)
Figure 20-90-40
P-53522
1
P-53548
Figure 20-90-43
Install the valve plate and locate the open slot (Item 1)
[Figure 20-90-40] that is over the largest open Geroler
pocket.
Install the drive (Item 2) [Figure 20-90-40].

1
Figure 20-90-41
1
P-53549
1
Apply assembly lube to the springs, and install the
springs (Item 1) [Figure 20-90-43].
P-53526
Align one of the side openings (Item 1) [Figure 20-90-41]

in the valve with the valve plate slot that is over the
largest open Geroler pocket.
Engage the valve with the valve drive by rotating it 15°

clockwise until the spline teeth mesh.
NOTE: If the valve is turned clockwise the motor will

rotate in the opposite direction.
320/322 Excavator
342 of 705
Assembly (Cont’d)
Figure 20-90-44
3
1
2
1
Balance Ring
1
B-13495A
Install the inner (Item 1) and outer (Item 2) [Figure 20-

P-53550 90-45] & [Figure 20-90-46] face seals on the balance
ring as shown
Install the pins (Item 1) [Figure 20-90-44]. Figure 20-90-47
Figure 20-90-45
1
1 2
P-53551
P-32099
Install the balance ring (Item 1) [Figure 20-90-47]. Make
sure the pins engage the pin notches (Item 3) [Figure
20-90-46] in the balance ring.
320/322 Excavator
343 of 705
Assembly (Cont’d)
Figure 20-90-48
1 1
P-53557
Install the bolts (Item 1) [Figure 20-90-50]. Tighten the

P-53552 bolts to 37 ft.-lbs. (50 Nm) torque in a crisscross pattern.
Figure 20-90-51
Insert a small screw driver through the port in the
housing. Apply pressure to the side of the balance ring
assembly until the valve housing is in place [Figure 20-
90-48].
Figure 20-90-49
1
2
1
1
2
P-53556
2 Install the balls (Item 1) and springs (Item 2) [Figure 20-

90-51].
P-53558
Install the housing (Item 1) [Figure 20-90-49] on the

motor.
Remove the screwdriver (Item 2) [Figure 20-90-49].
320/322 Excavator
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Assembly (Cont’d)
Figure 20-90-52
P-53524

P-53555 crossport relief valves.
Figure 20-90-55
Install the O-ring (Item 1) [Figure 20-90-52] on the plugs.
Figure 20-90-53
1
1
1
1
P-53519
P-53554 Install the crossport relief valves (Item 1) [Figure 20-90-

55].
Install the plugs (Item 1) [Figure 20-90-53]. Tighten the valves to 69 ft.-lbs. (94 Nm) torque.
Tighten the plugs to 42 ft.-lbs. (57 Nm) torque.
320/322 Excavator
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SWING MOTOR (CONT’D)
Assembly (Cont’d)
Clamp the motor in a vise.
Figure 20-90-56
P-53520
Turn the shaft (Item 1) [Figure 20-90-56] in a clockwise

direction.
If the motor is correctly timed, there will be suction at the

top port (Item 2) [Figure 20-90-56].
320/322 Excavator
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CONTROL PATTERN SELECTOR VALVE Figure 20-100-3
Figure 20-100-1
1
1
N-23213
Remove the control pattern selector valve lever (Item 1)

P-50685 [Figure 20-100-3].
Mark the eight hoses for ease of assembly.

Figure 20-100-2
Figure 20-100-4
2
1 1
N-23210
1 1 N-23214
Remove the four screws (Item 1) [Figure 20-100-1] &

[Figure 20-100-2] from the left console cover. Remove the eight hoses (Item 1) [Figure 20-100-4] from
the control pattern selector valve. Cap and plug the
Remove the left console cover plate (Item 2) [Figure 20- fittings and hoses.
100-2].
320/322 Excavator
347 of 705
CONTROL PATTERN SELECTOR VALVE (CONT’D)
Figure 20-100-5
N-23215
Figure 20-100-6
N-23211
Remove the two bolts (Item 1) [Figure 20-100-5] &

[Figure 20-100-6].
NOTE: Do not loosen the two spacers (Item 2) [Figure

20-100-5] between the valve and console side
plate.
320/322 Excavator
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CONTROL PATTERN SELECTOR VALVE (CONT’D)
1. Handle
2. Snap Ring
3. Roll Pin
4. Spool
5. Housing
6. Washer
1 2
5
4
3
3
TS-1353
320/322 Excavator
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CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-9
Disassembly
Clean the outside of the control pattern selector valve

before disassembly.
Clamp the valve in a vise equipped with padded jaws.

1
Figure 20-100-7
P-11961
Pull the spool (Item 1) [Figure 20-100-9] out of the

1 housing.
Figure 20-100-10
P-11959

1
Figure 20-100-8
P-11962

spool.
1
P-11960
Remove the wave washer (Item 1) [Figure 20-100-8].
320/322 Excavator
350 of 705
CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-13
Assembly

or damaged parts.
Always install new O-rings. Lubricate all O-rings with

clean hydraulic fluid before installation.
1
Figure 20-100-11
P-11960
Install the wave washer (Item 1) [Figure 20-100-13] on

the end of the spool.
Figure 20-100-14
1 1
P-11962
Apply oil to and install new O-rings (Item 1) [Figure 20- 1

100-11] on the spool.
Figure 20-100-12
P-11959
Install the snap ring (Item 1) [Figure 20-100-14] on the

spool.
P-11961
Apply oil to and install the spool (Item 1) [Figure 20-100-

12] in the housing.
320/322 Excavator
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320/322 Excavator
352 of 705
RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-2
Testing
Check the pressure reducing valve for the correct

pressure. (See Testing And Adjusting The Pressure
Reducing Valve on Page 20-33-1.) 1
The following tools will be needed to do the procedure:
MEL1355 - Hydraulic Test Kit

P-56224
Stop the engine.
Remove the floormat and floorplates. (See Removal and Remove the hose (Item 1) [Figure 20-110-2] from the
Installation on Page 40-120-1.) short control valve extension hose.
Figure 20-110-1 Figure 20-110-3
1 2
P-56223 P16880
At the control valve assembly, find the pilot line (Item 1) From the test kit, install a fitting and test port (Item 1)
[Figure 20-110-1] of the control lever (joystick) that is to [Figure 20-110-3] to the control lever (joystick) hose.
be checked. Arm, Bucket, Boom, and Swing (slew).
Cap the short control valve extension hose (Item 2)
NOTE: These four valves (Arm, Bucket, Boom & [Figure 20-110-3].
Swing (Slew) have short extension hoses with
connectors for ease of valve removal and
testing.
WARNING
immediately.
W-2145-0290
320/322 Excavator
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RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)
Testing (Cont’d)
Install a 1000 PSI (69 Bar) gauge and female coupler on

the test port.
Start the engine and warm the hydraulic oil to operating

temperature 150°F (66°C).
Check the gauge with the control levers (joystick) in

neutral. The hydraulic pressure should be 0 PSI (0 Bar).
Engage the circuit to be tested. Record the operating

pressure.
The operating pressure should be as follows:
435 PSI (30 Bar) with an acceptable range of 406-450

PSI (28-31 Bar).
If the operating pressure is correct, check the valve

section spool for proper operation.
If the operating pressure is incorrect, remove the

pressure reducing valve, clean, install and retest. (See
Testing And Adjusting The Pressure Reducing Valve on
Page 20-33-1.)
If the pressure is still incorrect replace the pressure

reducing valve. (See Testing And Adjusting The
Pressure Reducing Valve on Page 20-33-1.)
320/322 Excavator
354 of 705
RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-6
Handle Removal And Installation
Figure 20-110-4
1
P-32510
Hold the dust boot (Item 1) down and loosen the jam nut
P-32509 (Item 1) [Figure 20-110-6].
Figure 20-110-7
Remove the dust boot (Item 1) from the handle (Item 2)
[Figure 20-110-4].
Figure 20-110-5
P-32512
Remove the handle [Figure 20-110-7].

P-32511
Installation: Align the top of the dust boot (Item 1) with

the groove (Item 2) [Figure 20-110-5] in the control
handle.
320/322 Excavator
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RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-8
Stop the engine.
Remove the console cover. (See Console Cover

Removal And Installation (Cab Models 320L, 320, 322 &
ROPS Canopy Model 320L) on Page 40-50-1 or See
Console Cover Removal And Installation (ROPS Canopy
Models 320 & 322) on Page 40-50-4)
P-56165
IMPORTANT Mark the hoses for ease of assembly [Figure 20-110-8].
Remove the hoses while the control lever (joystick) is

When repairing hydrostatic and hydraulic systems, bolted to the console [Figure 20-110-8].
parts clean. Always use caps and plugs on hoses, Figure 20-110-9
damage the system.
I-2003-0888
WARNING 1
Hydraulic fluid escaping under pressure can have 2

P-56166
immediately.
W-2145-0290
Raise the dust boot (Item 1) up from the mounting plate
(Item 2) [Figure 20-110-9].
320/322 Excavator
356 of 705
Figure 20-110-10
1
1
1
P-56167

control lever (joystick) mounting plate.
Remove the control lever (joystick).
320/322 Excavator
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RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)
1. Handle
2. Dust Boot
3. Coupler
4. Actuator Control Plate 1
5. U-Joint
6. Plate
7. Plunger Assembly
8. Spool
9. Spring
10. Housing
10
MS1353
320/322 Excavator
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Disassembly
Remove the right handle. (See Handle Removal And

2
Clean the outside of the control lever before disassembly.
Figure 20-110-11
1
1
P-32576
2 Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-110-13].
Figure 20-110-14
P-32560 3
Remove the boot (Item 1) from the control lever (joystick)

(Item 2) [Figure 20-110-11]. 2
Figure 20-110-12
2
1
3 P-32574
1 Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-110-14] for correct installation.
P-32568
Mark the coupler (Item 1) nut (Item 2), and connector

(Item 3) [Figure 20-110-12] for correct assembly.
320/322 Excavator
359 of 705
Disassembly (Cont'd)
1
Figure 20-110-15
1 2
P-32578
Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-110-17].
NOTE: The plate (Item 2) [Figure 20-110-17] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-110-15]. removed.
Figure 20-110-16 Figure 20-110-18
2
1
1
2
P-32577 P-32582
Remove the control plate (Item 1) from the U-Joint (Item Remove the plate (Item 1) [Figure 20-110-18].
2) [Figure 20-110-16].
NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-110-18] are spring
loaded.
320/322 Excavator
360 of 705
1
Figure 20-110-19
P-32588
Remove the spool assemblies (Item 1) [Figure 20-110-

P-32583 21].
Figure 20-110-22
Remove the plunger assemblies (Item 1) [Figure 20-110-
19].
Figure 20-110-20 1
1
2
3
P-32591
Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-110-22].
Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-110-20].
NOTE: Mark the spool assemblies for installation in

their original location.
320/322 Excavator
361 of 705
1
Figure 20-110-23 1
2 1
P-32579

P-32590
Remove the spring (Item 1) and shim (Item 2) from the

Figure 20-110-24
P-32592
Remove the springs (Item 1) [Figure 20-110-24] from the

housing.
Clamp the housing in a vise that is equipped with padded

jaws.
320/322 Excavator
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RIGHT CONTROL LEVER (JOYSTICK) (CONT'D)
Figure 20-110-26
P-32593
Remove the end cap (Item 1) [Figure 20-110-26].
Figure 20-110-27
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

110-27].
320/322 Excavator
363 of 705
Assembly 1

or damaged parts.

Figure 20-110-28
P-32593
1
2
Install the end cap (Item 1) [Figure 20-110-29].
Figure 20-110-30
1 1
P-32594
Clamp the housing in a vise equipped with padded jaws.

110-28].
P-32580
Install the bolts (Item 1) [Figure 20-110-30].
Turn the housing over.
320/322 Excavator
364 of 705
Assembly (Cont'd)
Figure 20-110-31 1
P-32591
Compress the spring (Item 1) and install the spring seat

P-32592 (Item 2) [Figure 20-110-33].
Install the springs (Item 1) [Figure 20-110-31].
Figure 20-110-32
1
2
P-32590
Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-110-32].
320/322 Excavator
365 of 705
Assembly (Cont'd)
Figure 20-110-34 1
P-32584

P-32588 bushing.
Figure 20-110-37
Install the spool assemblies (Item 1) [Figure 20-110-34]
into the housing.
1
Figure 20-110-35
1
2
P-32583
Install the plunger assemblies (Item 1) [Figure 20-110-

P-32586 37] into the housing.
Install the plunger (Item 1) into the bushing (Item 2)

[Figure 20-110-35].
320/322 Excavator
366 of 705
Assembly (Cont'd)
Figure 20-110-38 1
P-32577
Install the control plate (Item 1) until the plate makes light
P-32582 contact with all four plungers (Item 2) [Figure 20-110-
40].
Install the plate (Item 1) [Figure 20-110-38]. Figure 20-110-41
NOTE: Spring pressure can dislodge the plunger

assemblies until the plate (Item 1) [Figure 20-
1
110-38] is secured in place.
Figure 20-110-39
2
2
P-32574
Align the coupler (Item 1) with the control plate (Item 2)

and plate (Item 3) [Figure 20-110-41]. Tighten the
coupler.
P-32578
Press down on the plate (Item 1) to seat the plunger

assemblies (Item 2). Install the U-joint (Item 3) [Figure
20-110-39].
320/322 Excavator
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RIGHT CONTROL LEVER (JOYSTICK) (CONT'D)
Assembly (Cont'd)
Figure 20-110-42
1
3
P-32573
Install the connector (Item 1) [Figure 20-110-42].
Align the connector with the coupler (Item 2) and tighten

the nut (Item 3) [Figure 20-110-42].
Figure 20-110-43
P-32560
Install the tabs of the boot (Item 1) in between the joystick

flange and mounting plate (Item 2) [Figure 20-110-43].
Install the handle. (See Handle Removal And Installation

on Page 20-110-3.)
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320/322 Excavator
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320/322 Excavator
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LEFT CONTROL LEVER (JOYSTICK) NOTE: These four valves (Arm, Bucket, Boom &
Swing (Slew) have short extension hoses with
Testing connectors for fast valve removal and testing.
Check the pressure reducing valve for the correct Figure 20-113-2
pressure. (See Testing And Adjusting The Pressure
Reducing Valve on Page 20-33-1.)
The following tools will be needed to do the procedure:
MEL1355 - Hydraulic Test Kit
Stop the engine.
WARNING P-56223
Disconnect the hydraulic hose (Item 1) [Figure 20-113-2]

from the short control valve extension hose.
Figure 20-113-3
immediately.
W-2145-0290
Open the tailgate.
Remove the floormat and floorplates. (See Removal and 2

Installation on Page 40-120-1.) 3
Figure 20-113-1
1
P-16880
1
From the test kit, install a hydraulic fitting and test port
(Item 1) [Figure 20-113-3] to the control lever (joystick)
hydraulic hose.
Cap the short control valve extension hose (Item 2)

[Figure 20-113-3].
Install a 1000 PSI (69 Bar) gauge and female coupler

P-56224 (Item 3) [Figure 20-113-3] on the test port.
Start the engine and warm the hydraulic oil to operating

At the control valve assembly, find the pilot line (Item 1) temperature 150°F (66°C).
[Figure 20-113-1] of the control lever (joystick) that is to
be checked. Arm, Bucket, Boom, and Swing (slew).
320/322 Excavator
371 of 705
LEFT CONTROL LEVER (JOYSTICK) (CONT’D)
Testing (Cont’d)
Check the gauge with the control levers (joystick) in

neutral. The hydraulic pressure should be 0 psi (0 Bar).
Engage the circuit to be tested. Record the operating

pressure.
The operating pressure should be as follows:
435 PSI (300 Bar) with an acceptable range of (406-450

PSI (28-31 Bar).
If the operating pressure is correct, check the valve

section spool for proper operation.
If the operating pressure is incorrect, remove the

pressure reducing valve, clean, install and retest. (See
Testing And Adjusting The Pressure Reducing Valve on
Page 20-33-1.)
If the pressure is still incorrect replace the pressure

reducing valve. (See Testing And Adjusting The Pressure
Reducing Valve on Page 20-33-1.)
320/322 Excavator
372 of 705
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-113-6
Handle Removal And Installation
Remove the horn switch connector. (See Removal and

Figure 20-113-4
1
1
P-32515
Figure 20-113-7
P-32520
1
Remove the dust boot (Item 1) from the handle (Item 2)

[Figure 20-113-4].
Figure 20-113-5
2 P-32915
3
1 Remove the lock (Item 1) [Figure 20-113-7] from the
electrical connector.
P-32521
Installation: Align the top of the dust boot (Item 1) with

the groove (Item 2) [Figure 20-113-5].
Hold the dust boot (Item 1) down and loosen the nut
(Item 3) [Figure 20-113-5].

320/322 Excavator
373 of 705
Handle Removal And Installation (Cont’d)
Figure 20-113-8
2
3
2
P-32513
1 Raise the dust boot (Item 1) and pull the grommet (Item
P-32914 2) up through the mount plate (Item 3) [Figure 20-113-
10].
With a small piece of wire, depress the wire terminal tabs Figure 20-113-11
(Item 1) [Figure 20-113-8].
Remove the individual wires from the back of the

electrical connector.
Figure 20-113-9
1
1
P-32517
Remove the grommet and wire (Item 1) [Figure 20-113-

1 11] from the mount plate and remove the handle.
P-32916
Installation: Use a small piece of wire and rebend the

tab (Item 1) [Figure 20-113-9] on each wire before
installing in the electrical connector.
Installation: The wires must be installed in the proper

locations in the wire connector, listed below.
C Red
D Black
Check each wire to be certain the tab locks into position.
320/322 Excavator
374 of 705
Stop the engine.

IMPORTANT P-56250
When repairing hydrostatic and hydraulic systems, Mark the hoses for ease of assembly. Remove the six
clean the work area before disassembly and keep all hoses from the housing [Figure 20-113-13].
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-113-14
damage the system.
I-2003-0888
1
Figure 20-113-12
3
3
P-56251
1
Raise the dust boot (Item 1) up from the plate (Item 2)

[Figure 20-113-14].
P-56249

Disconnect the wire connector (Item 1) [Figure 20-113- joystick plate.
12].
Remove the joystick.
WARNING
immediately.
W-2145-0290
320/322 Excavator
375 of 705
1. Handle
2. Dust Boot
3. Coupler
4. Actuator Control Plate
5. U-Joint
6. Grommet 1
7. Plate
8. Plunger Assembly
9. Spool
10. Spring
11. Housing
12. Wire Harness
13. Lock 2
14. Pin
15. Connector
4
6
10
11
12
13
14
15
MS-1354
320/322 Excavator
376 of 705
Disassembly
Remove the handle. See Handle Removal And 2

Installation on Page 20-111-3
Clean the outside of the control lever before disassembly.
Figure 20-111-15
1
1
P-32576
2 Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-111-17].
Figure 20-111-18
1
P-32560
2
Remove the boot (Item 1) from the control lever (joystick)
(Item 2) [Figure 20-111-15].
Figure 20-111-16
3
3 2
P-32574
1
Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-111-18] for correct installation.
P-32568
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-111-16] for correct assembly.
320/322 Excavator
377 of 705
1
Figure 20-111-19
1 1
P-32578
Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-111-21].
NOTE: The plate (Item 2) [Figure 20-111-21] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-111-19]. removed.
Figure 20-111-20 Figure 20-111-22
2
1 1
P-32577 P-32582
Remove the control plate (Item 1) from the U-joint (Item Remove the plate (Item 1) [Figure 20-111-22].
2) [Figure 20-111-20].
NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-111-22] are spring
loaded.
320/322 Excavator
378 of 705
1
Figure 20-111-23
P-32588
Remove the spool assemblies (Item 1) [Figure 20-111-

P-32583 25].
Figure 20-111-26
Remove the plunger assemblies (Item 1) [Figure 20-111-
23].
1
Figure 20-111-24
1
2
3
P-32591
Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-111-26].
Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-111-24].
NOTE: Mark the spool assemblies for installation in

their original location.
320/322 Excavator
379 of 705
1
Figure 20-111-27 1
1
1
P-32579

P-32590
Remove the spring (Item 1) and shim (Item 2) from the

Figure 20-111-28
P-32592
Remove the springs (Item 1) [Figure 20-111-28] from the

housing.
320/322 Excavator
380 of 705
Figure 20-111-30
P-32593
Remove the end cap (Item 1) [Figure 20-111-30]
Figure 20-113-31
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

113-31].
320/322 Excavator
381 of 705
Assembly
1
or damaged parts.
Always install new seals and o-rings.
Lubricate all seals and O-rings with clean hydraulic fluid

before installation.
Figure 20-113-32
P-32593
1 2
Install the end cap (Item 1) [Figure 20-111-33].
Figure 20-111-34
1
1
P-32594

113-32].
P-32580
Install the bolts (Item 1) [Figure 20-111-34].
Turn the housing over.
320/322 Excavator
382 of 705
Assembly (Cont’d)
Figure 20-111-35 2
P-32591
Compress the spring (Item 1) and install the spring seat

P-32592 (Item 2) [Figure 20-111-37].
Install the springs (Item 1) [Figure 20-111-35].
Figure 20-111-36
1
2
P-32590
Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-111-36].
320/322 Excavator
383 of 705
Assembly (Cont’d)
1
Figure 20-111-38
P-32584

P-32588 bushing.
Figure 20-111-41
Install the spool assemblies (Item 1) [Figure 20-111-38]
into the housing.
1
Figure 20-111-39
1
2
P-32583
Install the plunger assemblies (Item 1) [Figure 20-111-

P-32586 41] into the housing.
Install the plunger (Item 1) into the bushing (Item 2)

[Figure 20-111-39].
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Assembly (Cont’d)
1
Figure 20-111-42
P-32577
Install the control plate (Item 1) until the plate makes light
P-32582 contact with all four plungers (Item 2) [Figure 20-111-44].
Figure 20-111-45
Install the plate (Item 1) [Figure 20-111-42].
1
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate (Item 1) [Figure 20-
111-42] is secured in place.
2
Figure 20-111-43
3
1
P-32574
2
Align the coupler (Item 1) with the control plate (Item 2)

and plunger (Item 3) [Figure 20-111-45]. Tighten the
coupler.
P-32578
Press down on the plate (Item 1) to seat the four plunger

assemblies (Item 2). Install the U-joint (Item 3) [Figure
20-111-43].
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Assembly (Cont’d)
Figure 20-111-46
1 3
P-32573
Install the connector [Figure 20-111-46].
Align the connector with the coupler (Item 2) and tighten

the nut (Item 3) [Figure 20-111-46].
Figure 20-111-47
P-32560
Install the tabs of the boot (Item 1) in between the joystick

flange and the mounting plate (Item 2) [Figure 20-111-
47].
Install the handle. See Handle Removal And Installation

on Page 20-111-3
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HYDRAULIC FILTER MOUNT Figure 20-120-49
IMPORTANT
1
damage the system.
I-2003-0888
P-29983
Open the tailgate.
Figure 20-120-48 Remove the screws (Item 1) [Figure 20-120-49] from the
filter mount bracket.
3
Remove the bracket.
2
1
P-29982
Loosen the hose clamp (Item 1) [Figure 20-120-48] and

remove the hose.
Remove the tube line (Item 2) [Figure 20-120-48].
NOTE: Support the hose in approximately the same

position as when attached to the filter mount
to avoid any hydraulic fluid from draining out
of the hydraulic reservoir.
Remove the filter and filter mount.
Installation: Tighten the bolts to 28 ft.-lbs. (38 Nm)

torque.
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20-120-2 Service ManualReviseddddd
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HYDRAULIC RESERVOIR Figure 20-130-3
Open tailgate.
Drain hydraulic reservoir. (See Replacing Hydraulic Oil

on Page 10-100-2.)
Remove the muffler and extension. (See Removal And

1
Figure 20-130-1
P-50688
Remove the two bolts (Item 1) [Figure 20-130-2] &

1 [Figure 20-130-3] from the hydraulic reservoir bracket.
Figure 20-130-4
N-23204
Remove the hose (Item 1) [Figure 20-130-1] from the 1

hydraulic reservoir tee fitting.
Disconnect the fuel level sender harness (Item 2) [Figure

20-130-1] from the fuel level sender.
Figure 20-130-2 N-23217
Release the hose clamps (Item 1) [Figure 20-130-4] and

remove hoses from tee fitting on reservoir.
Tilt hydraulic reservoir towards engine and slide reservoir

out [Figure 20-130-4].
1
N-23206
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OIL COOLER Figure 20-140-3
Open tailgate.
Drain hydraulic reservoir. (See Replacing Hydraulic Oil

on Page 10-100-2)
Figure 20-140-1
1 1
3 P-50687
Remove the four bolts (Item 1) [Figure 20-140-3] holding

the grill to the side frame.
1 Push the grill in and slide the grill out the back of the
Excavator.
P16651 NOTE: Use a magnet or hook pick to prevent the grill

from dropping and being scratched or
damaged.
Remove tie strap (Item 1) [Figure 20-140-1].
NOTE: Support the oil cooler before removing the
Remove the tubeline (Item 2) and plug hose (Item 3) mounting bolts.
[Figure 20-140-1] from the top of the oil cooler.
Figure 20-140-4
Figure 20-140-2
P-50686
P-16652
Remove the bolt (Item 1) [Figure 20-140-4] mounting the

Remove the tubelines (Item 1) [Figure 20-140-2] from oil cooler to the radiator.
the bottom of the oil cooler.
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OIL COOLER (CONT’D)
Figure 20-140-5
P-16653
Remove the bolt (Item 1) [Figure 20-140-5] mounting the

oil cooler to the radiator.
Remove the oil cooler from rear of Excavator.
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UNDERCARRIAGE
BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Blade Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Extension Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-10-1
SWING CIRCLE GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

UNDER-
TRACK DAMAGE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . 30-40-1 CARRIAGE
Abrasion Of Embedded Metals . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Abrasion Of The Track Roller Side . . . . . . . . . . . . . . . . . . . . . 30-40-9
Cracks On The Lug Side Rubber Due To Fatigue . . . . . . . . . . 30-40-6
Cracks And Cuts On The Lug Side Rubber . . . . . . . . . . . . . . . 30-40-8
Cuts On The Edges Of The Track Roller Side. . . . . . . . . . . . 30-40-10
Cuts On The Lug Side Rubber. . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Cutting Of The Steel Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Lug Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Separation Of Embedded Metals. . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Separation Of Embedded Metals Due To Corrosion . . . . . . . . 30-40-4
TRACK FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Recoil Spring Disassembly And Assembly . . . . . . . . . . . . . . . 30-30-3
Removal And Installation Of Expandable Track Frame (322 Only) . . 30-30-2
TRACK IDLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
TRACK ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
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BLADE Blade Removal And Installation
Extension Removal And Installation Expand the tracks.
Figure 30-10-1 Lower the blade to the ground.
Remove the blade cylinder. (See Removal and

Installation on Page 20-24-3)
1
Figure 30-10-3
P-15018
Put a block (Item 1) [Figure 30-10-1] under the blade.

1 2
Fully lower the blade to the block.
P-16904
Stop the engine.

Figure 30-10-4
Slide the extension (Item 2) [Figure 30-10-1] into the
blade frame.
Figure 30-10-2
1
2
1
P-16905
Remove the snap ring (Item 1) [Figure 30-10-3] &

P-15017 [Figure 30-10-4] and washer from the blade arm pivot
pins (both sides).
Install the pin (Item 1) [Figure 30-10-2]. Remove the blade arm pivot pins (Item 2) [Figure 30-10-
3] & [Figure 30-10-4].
Remove the blade extensions when transporting the
Excavator, or when a narrow operating width is needed. Remove blade from Excavator.
Under normal operating conditions, the blade width
should match the track width.
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TRACKS
Track Lug Height
Rubber Track
The lug height of a new rubber track is 0.984 inch (25,0

mm).
Figure 30-20-1
Straight Edge
B-14489
To find the percentage of wear on an Excavator track,

measure the height of the lug by placing a straight edge
across the top of three lugs and measure the distance
from the base of the track to the bottom of the straight
edge [Figure 30-20-1].
Divide this measurement by the new track height and

multiply by 100. This will give the percentage of track lug
left.
Example: lug height 0.787 inch (20,0 mm)

0.787
0.984 x 100 = 80
80% of the track lug is remaining with 20% wear on the

track lugs.
The rubber track should be replaced when lug height

measures .246 inch. (6,25 mm) from the base of the track
to the top of the lug.
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TRACKS (CONT’D) Figure 30-20-3
Adjustment
NOTE: The wear of undercarriage parts vary with

working conditions and types of soil
conditions. Maintain the correct track tension
by inspecting regularly. See Service Schedule
for the correct service interval. (See SERVICE
SCHEDULE on Page 10-50-1.)
Figure 30-20-2
P-49770
Figure 30-20-4
RUBBER
Track Frame
Rubber
Track Sag
0.33-0.53 inch
(8-13 mm)
P-49769
Track
Roller
Raise one side of the machine (approximately four inches
[102 mm]) using the boom and arm as shown in [Figure
30-20-2]. Rubber
Track B-14067
Raise the blade fully and install jackstands under the
blade and the track frame. Lower the machine until all
machine weight is on the jackstands. Figure 30-20-5
Stop the engine. STEEL

Track Frame
WARNING Steel
Track Sag
0.65-0.85 inch
(17-22 mm)
AVOID INJURY
Keep fingers and hands out of pinch points when Track
Roller
checking the track tension.
W-2142-0903
Steel
Track
B-14067A
Measure the rubber or steel track sag at the middle track

roller [Figure 30-20-3]. Do not get your fingers into pinch
points between the track and the track roller. Use material
of appropriate size to check the gap between the contact
edge of the roller and top edge of the track guide lug
[Figure 30-20-3], [Figure 30-20-4] & [Figure 30-20-5].
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TRACK TENSION (CONT’D) Repeat the procedure for the other side.
Adjustment (Cont’d) If the track tension is still loose after adjusting to the
mentioned limit, it indicates the track is worn.
Figure 30-20-6
WARNING
Do not loosen the grease fitting more than one
complete rotation. Also, be careful not to loosen any
part other than the grease fitting. If the grease fitting
1 or any part is loosened too much, it can fly off under
1
high pressure. If the grease does not ooze smoothly,
try moving the machine back and forth for a short
distance.
W-2143-0189
P-49771
Loosen the two bolts (Item 1) [Figure 30-20-6] on the

cover. Pivot the cover downward.
Figure 30-20-7
6804114
1 2
P-49753
Add grease to the fitting (Item 1) [Figure 30-20-7] until

the track tension is correct.
If tension is too tight, loosen the bleed screw (Item 2)

[Figure 30-20-7] (1 turn maximum) and let grease flow
out of the bleed screw. When tension is correct, tighten
the bleed screw.
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TRACKS (CONT’D) Figure 30-20-10
Lift and block the side of the machine where the track will
be removed. (See LIFTING AND BLOCKING THE
EXCAVATOR on Page 10-10-1.)
Figure 30-20-8
P-11226
1
Turn the track until the bar contacts the frame [Figure 30-
20-10].
Pry the track off the idler wheel.
P-49753 Remove the track from the drive sprocket.
To install the rubber track:

Slowly loosen the bleed screw fitting (Item 1) [Figure 30-
20-8] (one turn maximum) to remove track tension. Put the track over the rear drive sprocket lugs.
NOTE: Apply additional pressure to the track by Put the front of the track onto the front idler wheel.
standing on the lower track span so all the
tension is released from the grease cylinder See Adjustment on Page 30-20-2 for adding grease to
for easier removal of the track. the grease spring and for checking track tension.
Figure 30-20-9
P-11225
Install a round bar (Approximately 1.25 inch [30 mm]

diameter) between the drive lugs [Figure 30-20-9].
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TRACK FRAME Figure 30-30-13
Disassembly And Assembly

Page 30-20-4.)
Figure 30-30-11
P-15151
Slide the recoil spring cylinder forward and remove it

from the track frame [Figure 30-30-13].
Figure 30-30-14
P-15319
Slide the front track idler out of the track frame to remove
it [Figure 30-30-11].
Figure 30-30-12
P-15153
Loosen the nuts from the track roller on both sides of the
track frame [Figure 30-30-14].
Installation: Tighten the nuts to 125 - 140 ft.-lb. (170-190

P-15320 N•m) torque.
Remove the track roller (Item 1) [Figure 30-30-14].

Remove the sliding plate [Figure 30-30-12].
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TRACK FRAME (CONT’D) Figure 30-30-17
Disassembly And Assembly (Cont’d)
Figure 30-30-15
P-15154
1
Remove the nut (Item 1) [Figure 30-30-17] from the track

P-15155 expansion stop rod.
Figure 30-30-18
Inspect the track guide (Item 1) [Figure 30-30-15] for
wear or damage.
Removal And Installation Of Expandable Track Frame

(322 Only)
Remove the track expansion cylinder. (See Removal And

Lift and block the track frame.

Page 30-20-4.)
Figure 30-30-16 P-15157
Install a chain hoist on the track frame [Figure 30-30-18].

Lift the frame a small amount while pulling the frame
away from the Excavator.
2
Using a 10 X 1.5 mm tap, clean the track frame bolt holes
to remove the old thread locking compound.
P-15156
Remove the travel motor cover. Remove the hoses (Item

1) [Figure 30-30-16] from the travel motor.
Remove the hose clamp (Item 2) [Figure 30-30-16] from

the track frame.
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TRACK FRAME (CONT’D) Figure 30-30-20
Recoil Spring Disassembly And Assembly
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 2) [Figure 30-30-19].
1
WARNING
3
2
P-15318
Remove the seal (Item 1), back-up ring (Item 2) and O-

ring (Item 3) [Figure 30-30-20] from the cylinder.
P-62574

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly.
W-2617-1004
Figure 30-30-19
2
1
P-15317
Remove the cylinder (Item 1) from the coil spring

assembly (Item 2) [Figure 30-30-19].
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TRACK DAMAGE IDENTIFICATION Causes Of The Damage
Cutting Of The Steel Cords When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
Damage: of the embedded steel cords causes steel cords to be
cut:
Figure 30-40-22
Figure 30-40-24
P-03864
PI-13035
Figure 30-40-23
When the rubber track is detracking, the idler or sprocket
rides on the projections of the embedded metal [Figure
30-40-24].
When the rubber track is detracted, projections of rubber

tracks get stuck between the frame of the undercarriage.
The rubber track is clogged with stones or foreign

obstacles.
When moisture penetrates through a cut on the lug side

rubber surface, the embedded steel cords will corrode.
The deterioration of the design strength may lead to the
breaking off of the steel cords.
Steel Cords PI-13034
Prevention
Embedded steel cords are cut off [Figure 30-40-22] & The following preventions should be taken to minimize
[Figure 30-40-23]. the risk of this damage:
Replacement: Periodically check on site, recommended track tension.
(See Adjustment on Page 30-20-2.)
Replacement is required [Figure 30-40-22] & [Figure
30-40-23]. Avoid quick turns on bumpy and rocky fields.
Drive carefully to avoid having stones and other articles

clog the rubber tracks.
Avoid driving over sharp objects. If this is impossible, do

not make turns while driving over sharp objects.
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TRACK DAMAGE IDENTIFICATION (CONT’D) Rubber tracks are driven with an extraordinary heavy
load on them.
Abrasion Of Embedded Metals
Rubber tracks are used on sandy fields.
Damage:
Prevention
Figure 30-40-25
As long as rubber tracks are used under normal
operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.
P-3865
In proportion to the service time, embedded metals will

gradually wear away by friction [Figure 30-40-25].
Replacement:
Figure 30-40-26
Abrasion
D D1 = 0.67D
PI-13037
Replacement is required when the width of the

embedded metals (D1) becomes 67% of their original
width (D) [Figure 30-40-26].
Causes Of The Damage
When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
inevitable. The following cases sometimes accelerate
rubber track abrasion:
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TRACK DAMAGE IDENTIFICATION (CONT’D) When the idler continually rides on the projections of
embedded metals, the embedded metals will eventually
Separation Of Embedded Metals peel off [Figure 30-40-28].
Damage: Figure 30-40-29
Figure 30-40-27
Guide
PI-13040
P-04379
When a rubber track is detracted, it becomes stuck
between the guide or the undercarriage frame, causing
Extraordinary outer forces applied to embedded metals the separation of embedded metals [Figure 30-40-29].
cause their separation from the rubber track's body
[Figure 30-40-27]. Figure 30-40-30
Replacement:
Even a partial separation of embedded metals requires

replacement of the track.
Causes Of The Damage:

Abrasion
Embedded metals adhere between the steel cords and
the rubber body. The following cases generate external
forces greater than the adhesion strength, causing
separation of the embedded metals:
Figure 30-40-28
PI-13041
Idler Abnormally worn sprockets as shown will pull embedded

metals out [Figure 30-40-30].
Prevention:
Rubber Similar to the prevention against the cutting of the steel

Track cords:
Periodically check on site, recommended track tension.

(See Adjustment on Page 30-20-2.)
PI-13039
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TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage
Separation Of Embedded Metals (Cont’d) Figure 30-40-32
Quick turns on bumpy and rocky fields should be

avoided.
Embedded metal
If abnormal wear of sprockets is observed, they should
be immediately replaced. Good
Separation Of Embedded Metals Due To Corrosion
Damage:
Separation of bonded
Figure 30-40-31 rubber cover
PI-13043
Embedded metals are bonded to the rubber body. The

following operating conditions cause embedded metals
to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals
from the rubber body [Figure 30-40-32].
Excessively salty fields, like the sea shore.
Strong acidic or alkali soil conditions

P-04378
Compost spread grounds
Due to corrosion of embedded metals, the adhesion to On tracks that are out of adjustment, the track rollers,
the rubber body deteriorates, resulting in complete idlers and sprockets will gradually wear the rubber
separation [Figure 30-40-31]. surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
Replacement: will corrode resulting in their separation from the rubber
body.
Even a partial separation of embedded metals requires a
rubber track replacement. Prevention:
If rubber tracks are used under such field conditions as

described under (Causes Of The Damage), they should
be washed with plenty of water. After being completely
dried, they should be stored correctly.
When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.
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TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Cuts On The Lug Side Rubber Figure 30-40-34
Damage:
Figure 30-40-33 Cuts
PI-13045
When rubber tracks drive over projections or sharp

P-04377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
Cuts on the lug side rubber often occurs as one of the will have an even higher chance to be cut. If the cuts run
most typical failure modes [Figure 30-40-33] through the embedded steel cords, it might result in the
breakage of steel cords due to corrosion. It is highly
Replacement: recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-40-34].
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Prevention:
with cold vulcanization rubber.
Machine operators should drive with great attention to
the ground surface, especially in terrains of the following
type:
Construction sites
Demolition sites
Paths covered with rocks and wood
Concrete ridges
Stumpy fields
When operating on terrains as mentioned above, quick

high speed turns and overloading should be avoided.
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TRACK DAMAGE IDENTIFICATION (CONT’D) Replacement:
Cracks On The Lug Side Rubber Due To Fatigue When the cracks become deep enough to expose the
steel cords, track replacement is required.
Damage:
Figure 30-40-35
Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
even small external cracks.
Also when operating near seashores or under cold

temperatures, rubber tracks are more likely to suffer from
ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
P-04382 external damage on the lug side rubber, increases the
possibility of cracking. Machine operators should observe
soil conditions when driving, to prevent external damage
Figure 30-40-36 to the lug side rubber. In order to minimize the
occurrence of ozone cracks, follow these maintenance
instructions:
Avoid exposing stored tracks to direct sun light.
Avoid exposing stored tracks to direct rain and snowfall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Small cracks around the root of the lug are a result from
operation fatigue [Figure 30-40-35] & [Figure 30-40-36]
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TRACK DAMAGE IDENTIFICATION (CONT’D) Replacement:
Lug Abrasion No replacement is required.
Damage: Causes Of The Damage:
Figure 30-40-37 Lug abrasion will occur as operation time increases.

Even as lug abrasion increases, the rubber track can be
used. However, as the traction performance deteriorates,
it is highly recommended to replace the abraded tracks
with new ones when the lug height becomes less than 5
mm.
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads.
P-04381
Driving up and down hilly paths with slippage.
Figure 30-40-38 Making frequent turns on paths covered with rocks and
wood.
Lug abrasion
t
PI-13049
As operation time increases, the lug side undergoes

abrasion [Figure 30-40-37] & [Figure 30-40-38].
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Cracks And Cuts On The Lug Side Rubber Figure 30-40-40
Damage:
Figure 30-40-39
Crack at the edge Cut on lug side
of embedded rubber
PI-13051
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals
Sometimes cracks and cuts on the lug side rubber at the [Figure 30-40-40].
edges of the embedded metals can be observed [Figure
30-40-39]. Prevention:
Replacement: To avoid extensive stress applied to the lug root where

metals are embedded, machine operators should avoid
Basically, no replacement is required unless the cuts on driving over stumps and ridges.
the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.
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Abrasion Of The Track Roller Side Figure 30-40-42
Damage:
Figure 30-40-41
Track roller
Abrasion
PI-13053
The abrasion of the track roller side rubber surface

P-04383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
The rubber surface on which track rollers run is gradually the side of the rubber track to cause the abrasion [Figure
abraded. It will result in the exposure of the embedded 30-40-42].
metals [Figure 30-40-41].
The level of abrasion is highly dependent on terrain
Replacement: conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
It is recommended to replace the rubber track when more stones and gravel. Small stones hardened with mud,
than half of the embedded metals are completely stuck to the track rollers increase the abrasion level. After
exposed. an extended period of abrasion, it will be more likely for
exposed embedded metals to catch moisture through the
inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.
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TRACK DAMAGE IDENTIFICATION (CONT’D) Both edges of a rubber track [Figure 30-40-43] have no
special reinforcement. During operation the edges may
Cuts On The Edges Of The Track Roller Side become cut or torn off [Figure 30-40-44] & [Figure 30-
40-45].
Damage:
Replacement:
Figure 30-40-43
In such case, the rubber track does not have to be
replaced.

Edge Edge
This damage is caused by objects on the ground or by
interference with the machine frame.
In case of damage by objects on the operating ground:
The edges of rubber track are often deformed largely due

to a bumpy ground surface, stones and other objects.
This causes extensive stress on the edges resulting in
the damage.
PI-13055
When driving a machine over concrete ridges, this type of
damage easily occurs.
Figure 30-40-44
In case of damage by interference with the machine
frame.
Figure 30-40-46
P-04384
Figure 30-40-45
PI-13056
If a machine continues operating with rubber tracks being

Cut
detracked, the rubber tracks may get caught up in the
machine frame or undercarriage parts resulting in
damage. Furthermore, when a machine travels along
side slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
undercarriage parts, which causes cutting, gouging and
Tear rubbing of rubber tracks in the end [Figure 30-40-46].
PI-13057
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TRACK DAMAGE IDENTIFICATION (CONT’D)
Cuts On The Edges Of The Track Roller Side (Cont’d)
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracking.
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320/322 Excavator
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TRACK IDLER
1. Roll Pin
2. Block
3. Seal
4. Snap Ring
5. Bearing
6. Shaft
7. Idler 1
2
5 7
3
1
2
PE2202S
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TRACK IDLER (CONT’D) Figure 30-50-49
Disassembly 1
The following tools must be fabricated for this procedure:
Figure 30-50-47
3.50”
2.75” (90 mm)
(70 mm)
P-47351
0.03” 1.35” Remove any corrosion or paint from both ends of the
(0,75 mm) (35 mm) Dia. exposed shaft (Item 1) [Figure 30-50-49] that could
Chamfer affect seal removal or damage the new seal during
3 Places
B-14204 installation.
Apply penetrating oil to both ends of the exposed shaft to

1. Driver Tool - see figure [Figure 30-50-47]. ease removal of the seal.
2. Support Fixture - Tube, 3.0 inches ID x 0.250 inch wall
x 6.0 inches long. Remove the seal (Item 2) [Figure 30-50-49] from both
sides of the idler.
Figure 30-50-48
Figure 30-50-50
2
1
P-29390
P-29393
Remove the roll pin (Item 1) and block (Item 2) [Figure

30-50-48] from each end of the shaft. Remove the snap ring (Item 1) [Figure 30-50-50].
NOTE: The snap ring is installed on one side of the

idler. The other side is stepped to retain the
bearing.
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TRACK IDLER (CONT’D)
Figure 30-50-51
P-29394
Place the idler on the support fixture (Item 1) [Figure 30-

50-51].
Using a soft faced hammer, tap the shaft (Item 2) [Figure

30-50-51] and bearing out the bottom of the idler.
Figure 30-50-52
1 2 1
P-29398
Slide the bearings (Item 1) off of the shaft (Item 2)

[Figure 30-50-52].
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Assembly
Figure 30-50-53
P-29401
2
1 Using a bearing driver, install the bearing in the idler
1 [Figure 30-50-55].
P-29398 Figure 30-50-56
2
Inspect the bearings (Item 1) and shaft (Item 2) [Figure
30-50-53] for wear or damage. Replace any worn or
damaged parts.
The bearings are sealed. If the bearings do not roll

smoothly, or if the seals are damaged, replace the
bearings.
Figure 30-50-54 1
P-29403
Place the idler on the support fixture (Item 1) [Figure 30-

50-56].
Install the shaft (Item 2) [Figure 30-50-56].

1
P-29399
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-50-54] on both sides of the idler.
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Assembly (Cont’d)
Figure 30-50-57 1
1 2
P-29456
Apply assembly lube to the inside diameter (Item 1)

P-29404 [Figure 30-50-59] of the seal.
Apply a small bead of high temperature silicone sealant

Install the bearing (Item 1) [Figure 30-50-57]. Use a around the flange surface (Item 2) [Figure 30-50-59] of
brass drift to seat the bearing. the seal.
Figure 30-50-58 Figure 30-50-60
P-29405 P-47352
Install the snap ring (Item 1) [Figure 30-50-58]. Using the driving tool, install the seal (Item 1) [Figure 30-
50-60] on both sides of the idler.
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TRACK IDLER (CONT’D)
Assembly (Cont’d)
Figure 30-50-61
P-29390
Install the block (Item 1) and roll pin (Item 2) [Figure 30-
50-61] on both sides of the shaft.
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TRACK ROLLER
1. Nut
2. Lock Washer
3. Washer
4. Seal
5. Roller 6
6. Bearing
7. Shaft
8. Snapring 5
3
2
1
2
3
4
PE1914S
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TRACK ROLLER (CONT’D) Figure 30-60-64
Disassembly
The following tools must be fabricated for this procedure:
Figure 30-60-62
3.50”
(90 mm)
2.25”
0.03” (60 mm) P-29459
(0,75 mm)
Chamfer
3 places
1.20”
(20 mm) Dia. NOTE: The snapring is installed on one side of the
2.00”
(50 mm) B-14203 roller. The other side is stepped to retain the
bearing.
1. Driver Tool - see [Figure 30-60-62].

2. Support Fixture - Tube, 3" ID x 1/4" wall x 6 inches
long.
Figure 30-60-63
P-46606
Support the roller in the support fixture (Item 1). Remove

the seal (Item 2) [Figure 30-60-63] from both sides of the
roller.
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TRACK ROLLER (CONT’D)
Figure 30-60-65
P-46607
Turn the roller over and tap the shaft (Item 1) [Figure 30-
60-65] and bearings out the bottom of the roller.
Figure 30-60-66
P-29461
Press the bearings (Item 1) [Figure 30-60-66] off the

shaft.
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Assembly
Figure 30-60-67
P-29462
2
1 1 Press the bearings (Item 1) [Figure 30-60-69] on the
shaft.
P-29463 Figure 30-60-70
Inspect the bearings (Item 1) and shaft (Item 2) [Figure

30-60-67] for wear or damage. 2
The bearings are sealed. If the bearings do not roll

smoothly or if the seals are damaged, replace the
bearings.
Replace any worn or damaged parts.

1
Figure 30-60-68
P-29464
Place the roller on the support fixture (Item 1) [Figure

30-60-70].
Tap the shaft and bearing assembly (Item 2) [Figure 30-

1
60-70] into the roller.
P-29465
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-60-68] on both sides of the roller.
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Assembly (Cont’d)
Figure 30-60-71 1
P-46606
Using the driving tool, install the seal (Item 1) [Figure 30-
P-29466 60-73] on both sides of the roller.
Install the snap ring (Item 1) [Figure 30-60-71].
Figure 30-60-72
P-29456
Apply assembly lube to the inside diameter (Item 1)

[Figure 30-60-72] of the seal.
Apply a small bead of high temperature silicone sealant

around the flange surface (Item 2) [Figure 30-60-72] of
the seal.
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320/322 Excavator
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SWING CIRCLE GEAR Figure 30-70-3
Remove the upperstructure from the swing circle gear.

(See Removal on Page 40-10-1.)
Figure 30-70-1
2
N-00855
1
Remove the bolts from the swing circle gear [Figure 30-
70-3].
Installation: Apply thread lock adhesive (LOCTITE

MC-1415 #242) to the bolt threads and tighten to 78 - 85 ft.-lb. (105
- 115 Nm) torque.
Figure 30-70-2 Figure 30-70-4
N-00854 N-00856
The swing gear and outer ring both have a soft zone. The Using a 10 X 1.5 mm tap, clean the track frame bolt holes
swing gear soft zone is identified with an S (Item 1) to remove the old thread lock adhesive.
stamped in the swing gear. The outer ring soft zone is
identified by a filler plug (Item 2) [Figure 30-70-1] &
[Figure 30-70-2] pressed into the outer ring.
The soft zones of both the swing gear and outer ring
must be positioned to the right side of the center line of
the Excavator.
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UPPERSTRUCTURE & SWING SECTION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . 40-170-2
Arm To Bucket And Bucket Link Bushing Removal And Installation 40-170-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
BLADE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

BLADE EXTENSION TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Boom Bushing Removal And Installation. . . . . . . . . . . . . . . . 40-160-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1 UPPERSTRUCTURE
& SWING
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1 SECTION
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-30-5
Front Window Removal And Installation . . . . . . . . . . . . . . . . . 40-30-6
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-11
Glass Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-10
Right Side Front Sliding Window Removal And Installation. . 40-30-10
Right Side Rear Sliding Window Removal And Installation . . . 40-30-9
CONTROL LINKAGE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Left Pedal Linkage Disassembly And Assembly . . . . . . . . . . 40-110-2
Left Travel Control Linkage Disassembly And Assembly . . . 40-110-4
Linkage Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-6
Linkage Rod Removal And Installation . . . . . . . . . . . . . . . . . 40-110-5
Right Travel Control Linkage Disassembly And Assembly . . 40-110-3
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Engine Speed Control Cable Removal and Installation . . . . . . 40-70-2
FLOORMAT AND FLOORPLATES. . . . . . . . . . . . . . . . . . . . . . . 40-120-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
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UPPERSTRUCTURE & SWING SECTION (CONT’D)
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-6
Console Base Removal And Installation . . . . . . . . . . . . . . . . 40-60-10
Console Cover Removal And Installation . . . . . . . . . . . . . . . . 40-60-1
Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . 40-60-3
Latch Hook Disassembly And Assembly . . . . . . . . . . . . . . . . . 40-60-8
Latch Hook Removal And Installation . . . . . . . . . . . . . . . . . . . 40-60-7
Lock Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . 40-60-4
Upper Console Removal And Installation . . . . . . . . . . . . . . . . 40-60-9
LEFT PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1

RIGHT CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Adjustment (ROPS Canopy Models 320 & 322) . . . . . . . . . . 40-50-10
Cab Models (320L, 320 & 322, And ROPS Canopy Model 320L) . .40-50-12
Console Base Removal And Installation . . . . . . . . . . . . . . . . 40-50-14
Console Cover Removal And Installation (Cab Models 320L, 320, 322
& ROPS Canopy Model 320L) . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Console Cover Removal And Installation (ROPS Canopy Models 320
& 322) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-4
Gas Spring Removal And Installation (ROPS Canopy Models 320 &
322) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-7
Latch Hook Disassembly And Assembly (ROPS Canopy Models 320
& 322) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-11
Latch Hook Removal And Installation (ROPS Canopy 320 & 322) .40-50-10
Lock Lever Removal And Installation (ROPS Canopy Models 320 &
322) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-8
Upper Console Removal And Installation . . . . . . . . . . . . . . . 40-50-13
RIGHT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 40-90-3
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-90-3
Right Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . 40-90-1
320/322 Excavator
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UPPERSTRUCTURE & SWING SECTION (CONT’D)
ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

SWING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1

Boom Pivot Bushing Removal And Installation . . . . . . . . . . . . 40-150-5
Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-3
Swing Frame Bushing Installation . . . . . . . . . . . . . . . . . . . . . . 40-150-4
Swing Frame Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . 40-150-4
SWING LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-190-2
TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
320/322 Excavator
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320/322 Excavator
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UPPERSTRUCTURE
Removal
WARNING
Fully extend the cylinders of the bucket, arm & boom.
Lower the blade to the ground. • Use a lifting fixture with sufficient capacity for the
weight of the excavator plus any added
Disconnect the battery negative (-) cable. (See attachments.
Removing And Installing The Battery on Page 50-20-2.) • Maintain center of gravity and balance when
lifting.
Remove the cab or canopy. (See Removal And • Do not swing boom or upperstructure. Engage
Installation on Page 40-30-1.) the swing locking lever.
• Never lift with operator on machine.
Drain the hydraulic reservoir. (See Replacing Hydraulic W-2202-0595
Figure 40-10-2

Remove the hydraulic control valve. (See Removal And

Remove the swing motor. (See Removal and Installation

on Page 20-90-1.)
Figure 40-10-1
2
N-23124
Mark the upperstructure to the swing bearing and to the

track frame for assembly [Figure 40-10-2].
Figure 40-10-3
P-19760
Install eye bolts (Item 1) [Figure 40-10-1] in the rear cab/

canopy mounts.
Fasten chains to the eyebolts and up to the chain hoist.
Install a 1 inch (.25 mm) bolt (Grade 5) (Item 2) [Figure

N-23128
40-10-1] through the hole at the top of the boom. Fasten
a chain from the bolt to the chain hoist.
Mark and remove the remaining hoses from the swivel
joint [Figure 40-10-3].
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UPPERSTRUCTURE (CONT’D) Figure 40-10-5
Removal (Cont’d)
Figure 40-10-4
1 1 1
N-23130
1 1 Remove the sixteen bolts (Item 1) [Figure 40-10-5] from

N-23129 the upperstructure.
Lift the upperstructure off the swing bearing. Position the

Remove the swivel joint nuts (Item 1) [Figure 40-10-4]. upperstructure onto supporting stands or blocks.
NOTE: Keep tension on the chain hoist to support the

boom and arm when the upperstructure is
IMPORTANT supported on stands or blocks.

damage the system.
I-2003-0888
Apply a small amount of lifting pressure to the

upperstructure with the chain hoist.
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Installation Alignment pin

P/N 6539805
Lower the frame onto the swing bearing. Maintain a slight
amount of weight on the hoist.
Figure 40-10-6
1
1
B-13728
2 Insert the three alignment pins (P/N 639805) [Figure 40-

10-7] & (Item 1) [Figure 40-10-6] into the alignment
1 holes.
N-23130 Reposition the frame as necessary until the alignment

pins will slide through the frame and into the teeth of the
swing bearing.
Remove any paint from the three alignment pin holes
(Item 1) [Figure 40-10-6] in the frame. With the pins installed, lower the upperstructure onto the
swing bearing and remove the hoist.
Apply thread lock adhesive (LOCTITE #242) to the
threads of the bolts. Tighten the bolts to 44-47 ft.-lbs. (60-65 Nm) torque.
Install the sixteen bolts and washers (Item 2) [Figure 40- Remove the alignment pins.
10-6] through the frame and into the swing bearing.
DO NOT tighten the bolts at this time.
320/322 Excavator
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Installation (Cont’d)
Figure 40-10-8
2
1 1
1
2
1
2 1
2
N-23127
Install the swivel joint nuts (Item 1) [Figure 40-10-9].

N-23127
Install the hoses (Item 2) [Figure 40-10-9] on the swivel
joint.
Install the swing motor (Item 1) [Figure 40-10-8].
Install the hydraulic control valve. (See Removal And
Apply thread lock adhesive (LOCTITE #242) to the Installation on Page 20-40-1.)
threads of the six bolts (Item 2) [Figure 40-10-8] and
install. Install the floormat and floorplates. (See Removal and
Tighten the bolts to 29-37 ft.-lbs. (40-50 Nm) torque.
Install the seat and seat mount. (See Removal And
Remove the caps and/or plugs from the swing motor. Do Installation on Page 40-40-1.)
not install any hoses.
Fill the hydraulic reservoir. (See Replacing Hydraulic Oil
The swing motor gear to the swing bearing gear on Page 10-100-2.)
engagement must be checked for back lash between the
gears through 360° of frame rotation. Install the cab or canopy. (See Removal And Installation
on Page 40-30-1.)
Check for back lash by moving the frame back and forth
at several points throughout the frames rotation. There Connect the negative (-) battery cable. (See Removing
must be some backlash present. And Installing The Battery on Page 50-20-2.)
320/322 Excavator
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ROPS CANOPY
Build the service lifting bracket used to remove and install the ROPS canopy. Use the dimensions shown [Figure 40-20-
10] to build the service lifting bracket.
Figure 40-20-10
Material: 2 X 2 - .25 inch wall hot rolled steel tubing

.25 inch hot rolled steel plate
MS1933
320/322 Excavator
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ROPS CANOPY (CONT’D) Figure 40-20-12
Remove the upperstructure light. (See Upper Structure 1

Light Removal And Installation on Page 50-50-1.) 1
Figure 40-20-11
1
2
3
P-19040
Remove the bolts, nuts and washers (Item 1) [Figure 40-

20-12] from the front of the canopy.
Installation: Tighten the bolts to 118-133 ft.-lbs. (160-

P-53290 180 Nm) torque.
Figure 40-20-13
Install the chain hoist (Item 1) in the end hole of the lifting
bracket (Item 2) [Figure 40-20-11].
Install the cab/canopy service lifting bracket on the cab

(Item 2) [Figure 40-20-11].
NOTE: Use a lifting device of sufficient capacity.
Adjust the lifting bracket to the proper width by moving

the bracket (Item 3) [Figure 40-20-11].
1
WARNING P-19041
Never use the cab/canopy service lifting bracket to

lift the excavator. The bracket is not strong enough Remove the bolt and washer (Item 1) [Figure 40-20-13]
and can fail causing serious injury or death. from the right rear of the canopy.
W-2384-1000
Installation: Tighten the bolt to 118-133 ft.-lbs. (160-180

Nm) torque.
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ROPS CANOPY (CONT’D)
Figure 40-20-14
P-19043
Open and remove the Operation & Maintenance Manual

storage door (Item 1) [Figure 40-20-14] with the start
key.
NOTE: Later models are not equipped with the

storage door.
Remove the bolt and washer (Item 2) [Figure 40-20-14]

from the left rear of the canopy.
Installation: Tighten the bolt to 118-133 ft.-lbs. (160-180

Nm) torque.
Remove the canopy from the upperstructure.
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320/322 Excavator
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CAB
Build the service lifting bracket used to remove and install the cab. Use the dimensions shown [Figure 40-30-15] to build
the service lifting bracket.
Figure 40-30-15
Material: 2 X 2 - 0.25 inch wall hot rolled steel tubing

0.25 inch hot rolled steel plate
MS1933
320/322 Excavator
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CAB (CONT’D) Figure 40-30-17
Remove the upperstructure light. (See Upper Structure

Light Removal And Installation on Page 50-50-1.)
Figure 40-30-16 1
P-53047
2
Adjust the lifting bracket to the proper width by moving
the bracket (Item 1) [Figure 40-30-17].
Figure 40-30-18
P-53048
Install the chain hoist (Item 1) in the end hole of the lifting
bracket (Item 2) [Figure 40-30-16]. 1
Install the cab/canopy service lifting bracket on the cab

[Figure 40-30-16].
NOTE: Use a chain hoist of sufficient capacity.
WARNING P-56253
Never use the cab/canopy service lifting bracket to

lift the Excavator. The bracket is not strong enough Remove the grommet (Item 1) [Figure 40-30-18] located
and can fail causing serious injury or death. in the left rear corner of the cab.
W-2384-1000
320/322 Excavator
444 of 705

1
Figure 40-30-19
1
1
1 P-56256
Remove the screws (Item 1) [Figure 40-30-21].

P-56254
Figure 40-30-22
Remove the wire harness from the cab frame and

disconnect the wire connectors (Item 1) [Figure 40-30-
19].
2
Figure 40-30-20
1 3
2
3 P-56257
Remove the windshield washer hose (Item 1) [Figure 40-

30-22] from the nozzle.
P-56255 Remove the wire harness (Item 2) and washer hose from
the channel (Item 3) [Figure 40-30-22].
Disconnect the wire harness (Item 1) and remove the

screws (Item 2) [Figure 40-30-20].
Remove the wire harness from the channel (Item 3)

[Figure 40-30-20].
320/322 Excavator
445 of 705
Figure 40-30-23 1
1
1
P-53069
Installation: Install the cab mounts (Item 1) [Figure 40-

P-56215 30-25] on the four corners of the cab.
Remove the bolts and washers (Item 1) [Figure 40-30-

23] from the rear of the cab.
Figure 40-30-24
1
1
P-56214
Remove the bolts and washers (Item 1) [Figure 40-30-

24] from the front of the cab.
Installation: Tighten the bolts to 118-133 ft.-lbs. (160-

180 Nm) torque.
Raise the hoist and remove the cab.
320/322 Excavator
446 of 705
CAB (CONT’D)
Door Removal And Installation
Figure 40-30-26
P-56258
The door can be removed from the cab by slowly

swinging the door back and forth while lifting up on the
door [Figure 40-30-26].
Installation: Align the hinges and swing the door back

and forth until the door weight settles the hinges to full
engagement.
320/322 Excavator
447 of 705
Front Window Removal And Installation
Figure 40-30-27
1
1
P-52936
Remove the nuts (Item 1) [Figure 40-30-29].

P-52934
Figure 40-30-30
Figure 40-30-28 2
2
1
P-52937
Remove the wiper assembly (Item 1) from the pivot

P-52935 mounts (Item 2) [Figure 40-30-30].
Remove the wire harness (Item 1) from the channel (Item

2) [Figure 40-30-28].
320/322 Excavator
448 of 705
Front Window Removal And Installation (Cont’d)
Figure 40-30-31
1 2
1 1
1
P-52941
Remove the seals (Item 1) and bushings [Figure 40-30-

P-52938 33].
Figure 40-30-34
Remove the nuts and washers (Item 1) [Figure 40-30-
31].
NOTE: Support the wiper motor before removing the

bolts.
Figure 40-30-32 1
P-52942
Remove the screw (Item 1) [Figure 40-30-34] holding the

wire harness clamp to the top of the front window.
1
P-52939
Remove the plate (Item 1), washer (Item 2), and wiper
motor (Item 3) [Figure 40-30-32].
320/322 Excavator
449 of 705
Front Window Removal And Installation (Cont’d)
Figure 40-30-35
1
4 3
2
P-52946
With the help of a second person holding the front

P-56259 window, remove the retainer (Item 1), spring (Item 2),
roller (Item 3), and handle (Item 4) [Figure 40-30-37]
from both sides of the front window.
Remove the screw (Item 1) [Figure 40-30-35] holding the
wire harness clamp to the bottom of the front window. Figure 40-30-38
Figure 40-30-36
P-56260
P-52945
Tilt the front window (Item 1) [Figure 40-30-38]. Remove
the front window from the cab.
Remove the wire harness (Item 1) from the channel (Item
2) [Figure 40-30-36].
320/322 Excavator
450 of 705
CAB (CONT’D)
Right Side Rear Sliding Window Removal And

Installation
Close and latch the front and rear sliding windows.
Figure 40-30-39
P-56261
Use a pick to pull the felt (Item 1) [Figure 40-30-39] from

the top window channel.
Unlatch the rear sliding window and slide the window

open until it stops.
Figure 40-30-40
P-56262
Lift the window up into the top channel and tilt the bottom
edge out [Figure 40-30-40]. Remove the window from
the cab.
320/322 Excavator
451 of 705
CAB (CONT’D) Glass Removal
Right Side Front Sliding Window Removal And Use the following procedure to remove the glass from the
Installation rear of the cab and right side window assembly.
NOTE: The rear sliding window must be removed Figure 40-30-43

before the front sliding window can be
removed.
Unlatch the front sliding window and slide the window

open until it stops.
Figure 40-30-41
P-52953
1
Push a small diameter wire (Item 1) [Figure 40-30-43]

through the adhesive. Pull the wire around the perimeter
of the glass to cut the adhesive.
P-52951 Remove the glass.
NOTE: The right side window frame is aluminum and

Use a pick to pull the felt (Item 1) [Figure 40-30-41] from will be destroyed when removed.
the inside top window channel.
Figure 40-30-42
P-56263
Lift the window up into the channel and tilt the bottom
edge out [Figure 40-30-42]. Remove the window from
the cab.
320/322 Excavator
452 of 705
CAB (CONT’D) Shake the combo primer for one minute.
Glass Installation Apply the combo primer to the perimeter of the cab and
glass (Item 2) [Figure 40-30-45]. Apply the primer in one
Rear and front lower glass direction only, using a dauber. Do not dip the dauber in
the primer more than once. Use multiple daubers if
Remove the majority of the old urethane adhesive from needed.
the perimeter of the cab.
Allow the combo primer to dry for five minutes. Dry time
NOTE: Leave a thin film of the old urethane on the cab doubles if the primer is applied in two coats.
frame, fresh urethane will bond to the
remaining film. Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good
Prime and paint any bare metal or scratches. contact with the glass around the entire perimeter.
Clean the metal surfaces with general purposes adhesive Figure 40-30-46
cleaner. Clean the glass surface with glass cleaner.
Figure 40-30-44 1
1
2
1
1
MS1993
2 Apply a 0.3 x 0.25 inch bead of urethane adhesive (Item

PE2199S
1) [Figure 40-30-46] to the perimeter of the cab.
Figure 40-30-45 Figure 40-30-47
1 1
MS1992 MS1994
Install the seal (Item 1) on the glass (Item 2) [Figure 40- Install the glass and seal assembly (Item 1) [Figure 40-
30-44] & [Figure 40-30-45]. 30-47]. Press the glass into the cab to make complete
contact with the adhesive. Tape the glass in place.
320/322 Excavator
453 of 705
CAB (CONT’D) Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good
Glass Installation (Cont’d) contact with the glass around the entire perimeter.
Allow 2 hours for curing at normal conditions (65° F, 75% Figure 40-30-49
relative humidity).
Remove the tape after the adhesive is cured. 1

Top, right side and left side glass
Remove the majority of the old urethane adhesive from

the perimeter of the cab.
NOTE: Leave a thin film of the old urethane on the cab

frame, fresh urethane will bond to the 1
remaining film.
Prime and paint any bare metal or scratches.

MS1993
Clean the metal surfaces with general purposes adhesive
cleaner. Clean the glass surface with glass cleaner.
Apply a 0.3 x 0.25 inch bead of urethane adhesive (Item
Shake the combo primer for one minute. 1) [Figure 40-30-49] to the perimeter of the cab.
Figure 40-30-48 Figure 40-30-50
2
MS1995
2 Install the glass (Item 1) [Figure 40-30-50]. Press the

1 glass into the cab to make complete contact with the
adhesive. Tape the glass in place.
PE2198S
Allow 2 hours for curing at normal conditions (65° F, 75%
relative humidity).
Apply combo primer to the perimeter of the cab (Item 1)
Remove the tape after the adhesive is cured.
and glass (Item 2) [Figure 40-30-48]. Apply the primer in
one direction only, using a dauber. Do not dip the dauber
Door and front window glass
in the primer more than once. Use multiple daubers if
needed.
The door and front window glass are not available
separately.
Allow the combo primer to dry for five minutes. Dry time
doubles if the primer is applied in two coats.
Order and install the door or front window frame and
glass assembly.
320/322 Excavator
454 of 705
SEAT AND SEAT MOUNT Figure 40-40-53
Removal And Installation 1
Figure 40-40-51
1
1
1 2
P-29998

P-29988
Remove the seat mount (Item 2) [Figure 40-40-53]
Pull the slide handle (Item 1) [Figure 40-40-51] out and NOTE: If the lower seat slide rails (Item 3) [Figure 40-
slide the seat forward and remove. 40-53] are removed from the seat pan, the
lower rails must be realigned with the seat
Figure 40-40-52 rails for proper fit. With the seat and the pan
removed from the Excavator, install the lower
seat rails onto the main seat rails. Install the
seat to the seat pan and tighten the bolts.
P-29989
Using the start key, unlock and remove the front cover
(Item 1) [Figure 40-40-52].
320/322 Excavator
455 of 705
320/322 Excavator
456 of 705
RIGHT CONSOLE Figure 40-50-3
Console Cover Removal And Installation (Cab

Models 320L, 320, 322 & ROPS Canopy Model 320L)
1
Disconnect the battery negative (-) cable. (See Removing

And Installing The Battery on Page 50-20-2)
Figure 40-50-1
2
P-56160
1
Remove the bolts (Item 1) from the access plate (Item 2)

[Figure 40-50-3].
3
Remove the access plate.
Mark the electrical wires for ease of assembly.
P-56158 Figure 40-50-4
Remove the key (Item 1) [Figure 40-50-1].
Remove the nut (Item 2) and the decal plate (Item 3)

[Figure 40-50-1] from the ignition switch.
Push the key switch inside the console cover.

1 3
Figure 40-50-2 2
P-56161
1
Remove the wire harness from the auxiliary power plug
(Item 1) [Figure 40-50-4].
1 Turn the inner auxiliary power plug housing (Item 2)

1 [Figure 40-50-4] and remove it from the housing.
1
Remove the outer auxiliary power plug (Item 3) [Figure
P-56159 40-50-4].
Remove the four screws (Item 1) [Figure 40-50-2] from

the console cover. (Both sides)
320/322 Excavator
457 of 705
RIGHT CONSOLE (CONT’D) Figure 40-50-7

(Cont’d)
1
Figure 40-50-5
1 3
P-19051
Remove the indicator lights (Item 1) [Figure 40-50-7] by

squeezing together the mounting tabs on the indicator
light and pushing the indicator out of the top of the
P-56162 console cover.
Remove the two speed indicator (Item 2) by removing the

Mark and remove the wires from the indicator lamps retaining clip (Item 3) [Figure 40-50-7] and pushing the
(Item 1) [Figure 40-50-5]. indicator out of the top of the console cover. (If equipped)
Figure 40-50-6
1 2
P-56163
Mark and remove the wires from the horn (Item 1) and
two speed indicator (Item 2) [Figure 40-50-6]. (If
equipped)
Lift the console cover over the control lever (joystick)

handle.
320/322 Excavator
458 of 705
RIGHT CONSOLE (CONT’D)

(Cont’d)
Figure 40-50-8
2
1
P-19050
Remove the bolts (Item 1) and retainer plate (Item 2)

[Figure 40-50-8] from the console cover.
Figure 40-50-9
3 P-19052
Remove the armrest (Item 3) [Figure 40-50-9].
320/322 Excavator
459 of 705
Console Cover Removal And Installation (ROPS

Canopy Models 320 & 322)

And Installing The Battery on Page 50-20-2.)
Figure 40-50-10
1
P-19046
3
Remove the bolts (Item 1) from the access plate (Item 2)
[Figure 40-50-12].
1 2
Remove the access plate.
Mark the electrical wires for ease of assembly.
P-19044 Figure 40-50-13
Remove the key (Item 1) [Figure 40-50-10].
Remove the nut (Item 2) and the decal plate (Item 3)

[Figure 40-50-10] from the key switch. 3
Push the key switch inside the console cover.
Raise the console.

2
Figure 40-50-11
1
P-19047
Remove the wires from the auxiliary power plug (Item 1)

[Figure 40-50-13].
2
Turn the inner auxiliary power plug housing (Item 2)
[Figure 40-50-13] and remove it from the housing.
Remove the outer auxiliary power plug (Item 3) [Figure

40-50-13].
1
P-19045
Remove the latch lever knob (Item 1) [Figure 40-50-11].

the console cover. (Both sides)
320/322 Excavator
460 of 705

Canopy Models 320 & 322) (Cont’d)
Figure 40-50-14 1
2
1
P-19051
Remove the indicator lights (Item 1) [Figure 40-50-16] by

squeezing together the mounting tabs on the indicator
P-19048 light and pushing the indicator out of the top of the
console cover.
Mark and remove the wires from the indicator lamps Remove the two speed indicator (Item 2) by removing the
(Item 1) [Figure 40-50-14]. retaining clip (Item 3) [Figure 40-50-16] and pushing the
indicator out of the top of the console cover.
Figure 40-50-15
P-19049
Mark and remove the wires from the horn (Item 1) and
two speed indicator (Item 2) [Figure 40-50-15].

handle.
320/322 Excavator
461 of 705
RIGHT CONSOLE (CONT’D)

Canopy Models 320 & 322) (Cont’d)
Figure 40-50-17
2
1
P-19050
Remove the bolts (Item 1) and retainer plate (Item 2)

from the console cover [Figure 40-50-17].
Figure 40-50-18
3 P-19052
320/322 Excavator
462 of 705
RIGHT CONSOLE (CONT’D) NOTE: Support the console before removing the gas
spring.
Gas Spring Removal And Installation (ROPS Canopy
Models 320 & 322) Remove the top of the gas spring from the mount [Figure
40-50-19] and remove the gas spring from the console.
Remove the washer (Item 3) [Figure 40-50-19].

WARNING Figure 40-50-21
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Raise the console.

1
Figure 40-50-19
3
3 2
1
2 P-19100
Remove the cotter pin (Item 1) and washer (Item 2) from

the lower mount and remove the mount (Item 3) [Figure
40-50-21].
P-19077
Remove the cotter pin (Item 1) and the washer (Item 2)

[Figure 40-50-19] from the mount.
Figure 40-50-20
P-19312
Remove the bolt (Item 1) [Figure 40-50-20] from the

bottom of the console.
320/322 Excavator
463 of 705
Lock Lever Removal And Installation (ROPS Canopy

Models 320 & 322)

Removal And Installation (ROPS Canopy Models 320 &
322) on Page 40-50-4) 1
Remove the gas spring. (See Gas Spring Removal And

Installation (ROPS Canopy Models 320 & 322) on Page
40-50-7)
Figure 40-50-22
P-19082
Remove the nuts and bolts (Item 1) [Figure 40-50-24]

1
from the lock lever assembly.
Figure 40-50-25
1
P-19064
3
Remove the return spring (Item 1) [Figure 40-50-22]
from the lock lever.
2
Figure 40-50-23
P-19083
Slide the top lever (Item 1) away from the operators seat
and remove the release rod (Item 2) [Figure 40-50-25].
1 Remove the bottom lever (Item 3) [Figure 40-50-25].
Installation: Install the release rod (Item 2) [Figure 40-

50-25] through the lever. Position the levers over the
lever mounts and spread them so there is no play
between the mount and the lever but loose enough so
the levers do not bind against the mounts and the spring
P-19081 will return the levers to the latched position without
interference.
Slide the protective sleeve (Item 1) [Figure 40-50-23] to NOTE: When installing nuts and bolts, the nuts must
the side. be to the top side of the lock levers so the bolt
threads do not rub against the hoses.
Pull the actuating rod forward to release the console latch

and tilt the console up.
320/322 Excavator
464 of 705
Lock Lever Removal And Installation (ROPS Canopy

Models 320 & 322) (Cont’d)
Figure 40-50-26
1 P-19086
Tilt the pivot release rod (Item 1) [Figure 40-50-28] and

remove the rod from the upper console.
P-19084
Remove the bolts (Item 1) [Figure 40-50-26] holding the

console latch bracket.
Figure 40-50-27
P-19085
Slide the latch bracket (Item 1) [Figure 40-50-27] down.
320/322 Excavator
465 of 705
RIGHT CONSOLE (CONT’D) Latch Hook Removal And Installation (ROPS Canopy
320 & 322)
Adjustment (ROPS Canopy Models 320 & 322)
Raise the console.
NOTE: Before the lock lever adjustments can be
made, the microswitch must be moved to the Figure 40-50-30
top of the adjustment slots. Switch damage
may occur if this is not done prior to the lock
lever adjustments. See Microswitch Removal
And Testing. (See MICROSWITCH on Page 50-
3
80-1.)
Figure 40-50-29
1
1
Flush contact
between latch
and hook.
2
P-19119
Loosen these Remove the bolts (Item 1 & 2) [Figure 40-50-30] from
two bolts. the plate.
Installation: Tighten the bolts to 6-7 ft.-lbs. (8-10 Nm)

MC-1733 torque.
NOTE: Install the long bolts (Item 2) [Figure 40-50-30]

Loosen the two bolts that hold the latch bracket to the in the front of the plate.
console so the latch bracket will not move when the
control console is closed but loose enough so the bolt Remove the plate (Item 3) [Figure 40-50-30].
heads can be tapped with a punch to move the latch for
proper adjustment [Figure 40-50-29]. Figure 40-50-31
Lower the control console to latched position.
Push down on the console to remove the gas spring

pressure.
Adjust the latch until the spring loaded hook will just 1
make contact with the latch bracket when the console is
lowered [Figure 40-50-29].
P-19106
Remove the bolt and the nut (Item 1) [Figure 40-50-31]

from the latch pivot.

torque.
320/322 Excavator
466 of 705
Latch Hook Disassembly And Assembly (ROPS 4

Canopy Models 320 & 322)
6
Figure 40-50-32 8
1
11
2
12 3
13 5
7
9
10
P-19108
Item No. Description
P-19107 1 Bolt
2 Washer
3 Bushing
Disassemble the latch pivot [Figure 40-50-32]. 4 Pivot
5 O-rings
6 Sleeve
7 Shim
8 Wave Washer
9 Latch Hook
10 Spring
11 Spacer
12 Washer
13 Nut [Figure 40-50-33]
Installation: Tighten the nut (Item 1) [Figure 40-50-33]

to 29-37 ft.-lbs. (40-50 Nm) torque.
NOTE: Install the bushings (Item 3) with a pilot shaft

to avoid bushing damage. Verify the sleeve
(Item 6) [Figure 40-50-33] will pivot freely
inside the bushings.
Apply oil to the O-rings (Item 5) before installing the

sleeve (Item 6) into the pivot (Item 4) [Figure 40-50-33].
Make sure the shim (Item 7) is properly positioned over

the sleeve and after tightening the nut, the hook (Item 9)
[Figure 40-50-33] pivots freely.
320/322 Excavator
467 of 705
Cab Models (320L, 320 & 322, And ROPS Canopy

Model 320L)
On Excavators 320L, 320 & 322 equipped with a cab and

320L equipped with a ROPS canopy, the right hand
control console is stationary (will not raise and lower with
a release lever).
Figure 40-50-34
CD-12894
Remove the console cover plate [Figure 40-50-36].
Figure 40-50-37
CD-12933
1
To raise the console, remove the two bolts from the
console [Figure 40-50-34].
Figure 40-50-35
CD-13009
The right hand console harness uses a jumper harness

(Item 1) [Figure 40-50-37] in place of the microswitch so
the control lever (joystick) manifold/accumulator will
function properly.
CD-12934
Remove the two bolts from the console plate [Figure 40-
50-35].
320/322 Excavator
468 of 705
Upper Console Removal And Installation

ROPS Canopy Model 320L) on Page 40-50-1)
Remove the control lever (joystick). (See Removal And

Remove the gas spring. (See Gas Spring Removal And 1

Installation (ROPS Canopy Models 320 & 322) on Page
40-50-7) (If equipped) P-19088
Figure 40-50-38
Drive the roll pin (Item 1) [Figure 40-50-39] through the
1 pivot shaft towards the back of the console base.
Figure 40-50-40
P-19065 1
Disconnect the lock out microswitch harness connector

(Item 1) [Figure 40-50-38]. (If equipped) P-19089
Raise the console.

Drive the pivot shaft (Item 1) through and remove the
upper console (Item 2) [Figure 40-50-40].
NOTE: Feed the hoses and wire harness through the

upper console during removal to avoid hose
and harness damage.
320/322 Excavator
469 of 705
Console Base Removal And Installation


ROPS Canopy Model 320L) on Page 40-50-1)

1 P-16964
Remove the upper console. (See Upper Console
Figure 40-50-41 the cover panel.
Figure 40-50-43
1
2
P-19090
P-16985
Remove the lever lock knob (Item 1) [Figure 40-50-41].
Remove the bolt (Item 2) [Figure 40-50-41] from the right Mark the wires and disconnect the wires and wire
console and floorplate. harness from the switches and hourmeter [Figure 40-50-
43].
320/322 Excavator
470 of 705
Console Base Removal And Installation (Cont’d)
Figure 40-50-44
P-19080
Figure 40-50-47
P-19091
Remove the bolts and nuts (Item 1) [Figure 40-50-44]

fastening the blade linkage assembly to the console
base.
Remove the blade linkage assembly from the right

console. 2
Figure 40-50-45
1
P-19097
Remove the bolt and nut (Item 1) [Figure 40-50-46] &

[Figure 40-50-47] holding the plastic block (Item 2)
1 [Figure 40-50-47] to the inside console base.
P-19103
Disconnect the speed control cable (Item 1) [Figure 40-

50-45].
320/322 Excavator
471 of 705
Figure 40-50-48
1
1
P-19098
Remove the console base (Item 1) [Figure 40-50-50]

P-19095 from the Excavator.

Remove the bolts (Item 1) [Figure 40-50-48] holding the console base during removal to avoid hose
console base to the frame. and harness damage.
Figure 40-50-49
P-19096

inside of the console base.
320/322 Excavator
472 of 705
LEFT CONSOLE Figure 40-60-3
Console Cover Removal And Installation

1

And Installing The Battery on Page 50-20-2.)
Raise the console. 2
Figure 40-60-1
P-19113
Remove the bulb connector assembly (Item 1) from the

fuel gauge (Item 2) [Figure 40-60-3].
2
Figure 40-60-4
1
1
P-19111
3
Remove the latch lever knob (Item 1) [Figure 40-60-1].

both sides of the console cover. (Both sides)
2
Figure 40-60-2
P-19115
2
Remove the bulb (Item 1) [Figure 40-60-4] for
replacement.
1 Mark the electrical wires for ease of assembly.
Remove the wires from the fuel gauge (Item 2) and lock
out indicator (Item 3) [Figure 40-60-4].

handle.
P-19112
Remove the bolts (Item 1) from the plate (Item 2) [Figure

40-60-2].
Remove the plate.
320/322 Excavator
473 of 705
LEFT CONSOLE (CONT’D) Figure 40-60-7
Console Cover Removal And Installation (Cont’d)
Figure 40-60-5
1
2
1
P-19105
3 P-19105
5 4
P-19117
Remove the nuts (Item 1) and clamp (Item 2) Push the

fuel gauge (Item 3) [Figure 40-60-5] out the top of the
console cover.
Remove the lock out indicator (Item 4) by removing the

retaining clip (Item 5) [Figure 40-60-5] and pushing the
indicator out of the top of the console cover.
Figure 40-60-6
2
1
P-1118
P-19105
Remove the bolts (Item 1) and plate (Item 2) [Figure 40-

60-6] from the console cover.
320/322 Excavator
474 of 705
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death. 1
W-2113-0288
Raise the console.

P-19135
Figure 40-60-8

3 bottom side of the console.
2
NOTE: Hold the console up to remove the gas spring.
Remove the top of the gas spring from the mount [Figure
40-60-8] and remove the gas spring from the console.
1 Remove the washer (Item 3) [Figure 40-60-8].
Figure 40-60-10
P-19136
Remove the cotter pin (Item 1) and the washer (Item 2)

[Figure 40-60-8] from the mount. 1
2
P-19100
Remove the cotter pin (Item 1) and washer (Item 2) from

the lower mount and remove the mount (Item 3) [Figure
40-60-10].
320/322 Excavator
475 of 705
Lock Lever Removal And Installation

Removal And Installation on Page 40-60-1.) 1

Figure 40-60-11
P-19147
1

from the lock lever assembly.
Figure 40-60-14
P-19145
1
Remove the return spring (Item 1) [Figure 40-60-11]
from the lock lever. 3
Figure 40-60-12 2
1
P-19184
Slide the top lever (Item 1) away from the operators seat
and remove the release rod (Item 2) [Figure 40-60-14].
Remove the bottom lever (Item 3) [Figure 40-60-14].
Installation: Install the release rod (Item 2) [Figure 40-

60-14] through the lever. Position the levers over the lever
P-19146 mounts and spread them so there is no play between the
mount and the lever but loose enough so the levers do
not bind against the mounts and the spring will return the
Slide the protective sleeve (Item 1) [Figure 40-60-12] to levers to the latched position without interference.
the side.
NOTE: When installing the nuts and bolts, the nuts
must be to the top side of the lock levers so
the bolt threads do not rub against the hoses.
Pull the actuating rod forward to release the console latch

and raise the console.
320/322 Excavator
476 of 705
Lock Lever Removal And Installation (Cont’d)
Figure 40-60-15
1
P-19182
Tilt the pivot release rod (Item 1) [Figure 40-60-17] and

P-19180 remove from the upper console.
Remove the release rod and the latch bracket with the
Remove the bolts (Item 1) [Figure 40-60-15] holding the microswitch [Figure 40-60-16].
console latch bracket.
NOTE: See Microswitch Removal And Testing. (See
Figure 40-60-16 MICROSWITCH on Page 50-80-1.)
P-19181
Slide the latch bracket (Item 1) [Figure 40-60-16] down.
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Adjustment
NOTE: Before the lock lever adjustments can be Flush contact

made, the microswitch must be moved to the between latch
top of the adjustment slots. Switch damage and hook.
may occur if this is not done prior to the lock
lever adjustments.
Figure 40-60-18
Loosen these
two bolts
1
MC-1733
Adjust the latch until the spring loaded hook will just
make contact with the latch bracket when the console is
lowered [Figure 40-60-19].
P19180
Loosen the two bolts (Item 1) [Figure 40-60-18] that hold

the latch bracket to the console so the latch bracket will
not move when the control console is closed, but loose
enough so the bolt heads can be tapped with a punch to
move the latch for proper adjustment.
Lower the control console to the latched position.
Push down on the console to remove the gas spring

pressure.
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478 of 705
LEFT CONSOLE (CONT’D)
Latch Hook Removal And Installation
Raise the console.
Figure 40-60-20
2 P-19110
Remove the bolts (Item 1) and (Item 2) [Figure 40-60-20]

from the plate.
Installation: Tighten the bolts to 6-7 ft.-lbs. (8-10 Nm)

torque.
NOTE: Install the long bolts (Item 2) [Figure 40-60-20]

in the front of the plate.
Remove the mounting plate (Item 3) [Figure 40-60-20].
Figure 40-60-21
P-19149
Remove the bolt and the nut (Item 1) [Figure 40-60-21]

from the latch pivot.

torque.
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LEFT CONSOLE (CONT’D) Installation: Tighten the nut (Item 13) [Figure 40-60-23]
to 29-37 ft.-lbs. (40-50 Nm) torque.
Latch Hook Disassembly And Assembly
Figure 40-60-22 to avoid bushing damage. Verify the sleeve
(Item 8) [Figure 40-60-23] will pivot freely
inside the bushings.
Apply oil to the O-rings (Item 7) before installing the

sleeve (Item 8) into the pivot (Item 6) [Figure 40-60-23].
Make sure that the shim (Item 4) is properly positioned

over the sleeve and after tightening the nut, the hook
(Item 9) [Figure 40-60-23] pivots freely.
P-19131
Disassemble the latch pivot [Figure 40-60-22].
Figure 40-60-23
12
6 10
7
4
3 13
2
11
1
8 9
5
P-19133
Item No. Description
1 Bolt
2 Washer
3 Wave Washer
4 Shim
5 Bushing
6 Pivot
7 O-rings
8 Sleeve
9 Latch Hook
10 Spring
11 Spacer
12 Washer
13 Nut [Figure 40-60-23]
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Upper Console Removal And Installation

1
Figure 40-60-24
P19191
Drive the roll pin (Item 1) [Figure 40-60-26] through the

pivot shaft towards the back of the console base.
Figure 40-60-27
2
P-56249
Raise and support the console. 1
Figure 40-60-25
P19186
1
Drive the pivot shaft (Item 1) through and remove the

upper console (Item 2) [Figure 40-60-27].

upper console during removal to avoid hose
and harness damage.
P-56250
Disconnect the wire harness (Item 1) and remove the

hoses (Item 2) [Figure 40-60-25] from the control lever
(joystick).
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Console Base Removal And Installation

Remove the heater (If equipped). (See Removal And


1

P-56229
Remove the upper console. (See Upper Console Remove the bolt (Item 1) [Figure 40-60-29].
Figure 40-60-30
Remove the control pattern selector valve. (See Removal
And Installation on Page 20-100-1.)
Figure 40-60-28
P-19187
Remove the bolts (Item 1) [Figure 40-60-30] holding the

P19185 console base to the frame.
Remove the bolt (Item 1) [Figure 40-60-28] from the left

console and floorplate.
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LEFT CONSOLE (CONT’D)
Figure 40-60-31
P-53705
Remove the console base (Item 1) [Figure 40-60-31]

from the Excavator.

console base during removal to avoid hose
and harness damage.
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320/322 Excavator
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ENGINE SPEED CONTROL Figure 40-70-3
Figure 40-70-1
1
1
P-19094
1
Figure 40-70-4
P-16964
5 6
4
Remove the four screws (Item 1) [Figure 40-70-1] from 3
the cover panel. 2
1
7
Figure 40-70-2
P-19101
Remove the bolts and nuts (Item 1) [Figure 40-70-3] &

[Figure 40-70-4], the bracket (Item 2), the two wave
washers (Item 3), the friction washer (Item 4), the nylon
spacer (Item 5), and the lever (Item 6) [Figure 40-70-4].
P-16985
Disconnect the engine speed control cable (Item 7)
[Figure 40-70-4] from the ball joint.
Mark the wires for ease of assembly. Disconnect the
wires and wire harness from the switches and hourmeter
[Figure 40-70-2].
Remove the cover panel.
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ENGINE SPEED CONTROL (CONT’D) Figure 40-70-7
Engine Speed Control Cable Removal and

Installation
Figure 40-70-5
1
1
P-19103
Disconnect the engine speed control cable (Item 1)

1
[Figure 40-70-7] from the ball joint.
P-16964
Figure 40-70-8

the cover panel.
Figure 40-70-6
P-19104
Loosen the u-bolt (Item 1) [Figure 40-70-8] on the cable.
P-16985
Mark the wires for ease of assembly. Disconnect the

wires and wire harness from the switches and hourmeter
[Figure 40-70-6].
Remove the cover panel.
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ENGINE SPEED CONTROL (CONT’D)
Engine Speed Control Cable Removal and

Figure 40-70-9
6.27 “ (159 mm)
1
1 2
P-16763
Loosen the nuts (Item 1) [Figure 40-70-9] fastening the

cable to the bracket.
Disconnect the linkage (Item 2) [Figure 40-70-9] from

the bracket.
Installation: The cable linkage measurement from

bracket to the center of the ball joint is 6.27 inches (159
mm).
Figure 40-70-10
P-16776
Remove the nut and clamp (Item 1) [Figure 40-70-10].
Move the cable away from the engine.
Pull the cable down from the right console and out the
back of the Excavator.
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BLADE CONTROL Figure 40-80-3

2
Remove the seat and seat mount. (SSee Removal And
Figure 40-80-1
1
P-56148
Remove the nut holding the ball joint of the blade/track

expansion cable (Item 1) [Figure 40-80-3].
Loosen the nut (Item 2) [Figure 40-80-3] and slide the

P-56146 cable assembly out of the bracket.
Figure 40-80-4
Disconnect the two speed wire harness (Item 1) [Figure
40-80-1]. (If Equipped)
Figure 40-80-2 1
1
P-56149
Remove the nut and bolt (Item 1) [Figure 40-80-4].

P-56147
Remove the bellcrank and pivot mount (Item 2) [Figure
40-80-4].
Remove the bolts and clamps (Item 1). Remove the
blade/track expansion lever (Item 2) [Figure 40-80-2].
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BLADE CONTROL (CONT’D) Disassembly And Assembly
Removal and Installation (Cont’d) Figure 40-80-6

Figure 40-80-5
1
2
N-23055
2 3 1
Remove the screws (Item 1) [Figure 40-80-6] from the

two piece handle.
P-16600
Remove the connector (Item 2) [Figure 40-80-6] from the
wires.
Loosen the nut (Item 1) and remove the clevis pin and
cotter pin (Item 2) [Figure 40-80-5]. Figure 40-80-7
Remove the cable (Item 3) [Figure 40-80-5]. 1
2
1
N-23079
Remove the two halves of the handle (Item 1) [Figure 40-

80-7].
Remove the two speed switch and wire assembly (Item

2) [Figure 40-80-7] from the tube.
NOTE: The 320L is not equipped with a two speed.
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BLADE CONTROL (CONT’D) Figure 40-80-10
Disassembly And Assembly (Cont’d)
Figure 40-80-8
1 2
P-56152
1 Remove the bushing (Item 1) from the bellcrank (Item 2)

P-56150 [Figure 40-80-10]. (Both Sides)
Figure 40-80-11
Figure 40-80-9
2
6
1
5
4
3 P-56153
1
1 2
P-56151 Remove the O-rings (Item 1) from the sleeve (Item 2)
[Figure 40-80-11].
Remove the washers (Item 1), bellcrank (Item 2), sleeve

(Item 3), washer (Item 4) and bolt (Item 5) from the pivot
mount (Item 6) [Figure 40-80-9].
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RIGHT PEDAL Figure 40-90-2
Right Pedal Removal And Installation

Figure 40-90-1
1
1
2
2
P-56101
Figure 40-90-3
P-56102
Remove the nut (Item 1) and linkage rod (Item 2) [Figure

40-90-1].
P-56103

[Figure 40-90-3].
Remove the pedal assembly (Item 2) [Figure 40-90-2]

from the floorplate.
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RIGHT PEDAL (CONT’D) Figure 40-90-6
Figure 40-90-4
P-56106
1

P-56104 shaft.
Figure 40-90-7
Remove the nut and washer (Item 1) [Figure 40-90-4].
Figure 40-90-5
1
4 3 P-56107
5 2
1
P-56105 Remove the lock (Item 1) from the mount (Item 2)
[Figure 40-90-7].
Remove the rear pedal (Item 1), bushing (Item 2), wave Remove the O-ring (Item 3) [Figure 40-90-7] from the
washer (Item 3) and front pedal (Item 4) from the mount shaft.
(Item 5) [Figure 40-90-5].
NOTE: Do not lubricate the O-ring (Item 3) with grease
during installation. The O-ring works as a
friction lock to prevent the lock (Item 1)
[Figure 40-90-7] from pivoting freely.
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RIGHT PEDAL AND LINKAGE (CONT’D) Figure 40-90-10
Linkage Removal And Installation

1
Figure 40-90-8
P-19020
1
Pull the right pedal bracket (Item 1) [Figure 40-90-10]

away from the frame.
Remove the bolt (Item 2) [Figure 40-90-10] fastening the

P-19022 bellcrank to the right pedal bracket.
Pull the right pedal bracket through the frame towards the
Remove the nut (Item 1) [Figure 40-90-8] from the lower control valve assembly.
linkage rod ball joint.
Linkage Disassembly And Assembly
Remove the linkage rod ball joint from the right pedal
bracket (Item 2) [Figure 40-90-8]. Figure 40-90-11
Figure 40-90-9
2 4
2
1
6
7
3
1
5
P-19019
P-19021
Disassemble the bellcrank. Sleeve (Item 1), O-rings (Item
2), washer (Item 3), bushings (Item 4), bellcrank (Item 5),
Remove the bolt and nut (Item 1) fastening the bellcrank washer (Item 6), bracket (Item 7) and bolt (Item 8)
(Item 2) [Figure 40-90-9] to the frame. [Figure 40-90-11].

to avoid bushing damage. Verify sleeve (Item
1) [Figure 40-90-11] will pivot freely inside the
bushings.
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LEFT PEDAL

Figure 40-91-1
P-56095
Figure 40-91-2
P-56096

[Figure 40-91-2].
Remove the pedal assembly (Item 2) [Figure 40-91-1]

from the floorplate.
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LEFT PEDAL (CONT’D) Figure 40-91-5
Figure 40-91-3
1
P-56099
1

P-56097 shaft.
Figure 40-91-6
Remove the nut and washer (Item 1) [Figure 40-91-3].
Figure 40-91-4
3
2 1
P-56100
5
4
3
2 1 Remove the lock (Item 1) from the mount (Item 2)
P-56098
[Figure 40-91-6].
Remove the rear pedal (Item 1), bushing (Item 2), wave Remove the O-ring (Item 3) [Figure 40-91-6] from the
washer (Item 3), and front pedal (Item 4) from the mount shaft.
(Item 5) [Figure 40-91-4].
NOTE: Do not lubricate the O-ring (Item 3) with grease
during installation. The O-ring works as a
friction lock to prevent the lock (Item 1)
[Figure 40-91-6] from pivoting freely.
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TRAVEL CONTROLS Disassembly And Assembly
Removal And Installation NOTE: The procedure is the same for both left and
right travel controls. The left travel control is
Remove the floormat and floorplates. (See Removal and shown.
Figure 40-100-3
NOTE: The procedure is the same for both travel
controls. The left travel control is shown.
Figure 40-100-1
1
1
P-56110
Remove the nut and washer (Item 1) [Figure 40-100-3]

2
P-56108 holding the pedals to the mount.
Figure 40-100-4
Figure 40-100-2
5
4
3
2
1
P-56111
P-56109
Remove the rear pedal (Item 1), wave washer (Item 2),
Remove the bolt and nut (Item 1) [Figure 40-100-1] & bushing (Item 3) and front pedal (Item 4) from the mount
[Figure 40-100-2]. (Item 5) [Figure 40-100-4].
Remove the left travel control assembly (Item 2) [Figure

40-100-1] from the floorplate.
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320/322 Excavator
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CONTROL LINKAGE ASSEMBLY

Figure 40-110-1
1
N-23083
Remove the cotter pins and clevis pins (Item 1) [Figure

40-110-1] from the clevis at the control valve.
Figure 40-110-2
1
1
N-23082

control linkage assembly mounting brackets by accessing
the bolt heads through the clearance holes in the side
frame.
Remove the control linkage assembly from the

Excavator.
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CONTROL LINKAGE ASSEMBLY (CONT’D) Installation: The distance between the center lines of
the linkage rod ball joints (Item 2) [Figure 40-110-4] is
Left Pedal Linkage Disassembly And Assembly 4.93 in (125.2 mm).
Mark the linkage rods and their orientation on the Figure 40-110-5
bellcranks. Mark bellcrank assemblies location and
orientation on the shaft for ease of assembly.
Figure 40-110-3
1
1
2
P-19845
NOTE: Linkage rod ball joint dimensions (Item 2)

P-16636 [Figure 40-110-4] may need final adjustment,
with pedal (valve) in neutral, to ensure the
lock (Item 1) [Figure 40-110-5] engages the
Slide the left pedal bellcrank assembly (Item 1) [Figure pedal lock pin (Item 2) [Figure 40-110-5] when
40-110-3] off the end of the shaft. the floor panel is re-installed.
Figure 40-110-4
2
1
7
3
4.93
1.83
4
5
6
P16639A

40-110-4] from the left pedal bellcrank.
Remove the nut (Item 3), linkage plate (Item 4), spacer
(Item 5) and bolt (Item 6) [Figure 40-110-4] from the
bellcrank.
Remove the bushings (Item 7) [Figure 40-110-4] from

the bellcrank.
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CONTROL LINKAGE ASSEMBLY (CONT'D) Remove the bushings (Item 7) [Figure 40-110-7] from
the bellcrank.
Right Travel Control Linkage Disassembly And
Assembly NOTE: The orientation of the linkage plate (Item 5)
[Figure 40-110-7] mounting hole is up towards
Figure 40-110-6 the linkage rod.
Installation: The distance between the center lines of

the linkage rod ball joints (Item 2) [Figure 40-110-7] is
1 4.78 in. (121.4 mm).
P-16640
Slide the right travel bellcrank assembly (Item 1) [Figure

40-110-6] off the end of the shaft.
Figure 40-110-7
2
1
7
6
4.78
1.70
5
7
3 4
P16642A

40-110-7] from the right travel bellcrank.
Remove the nut (Item 3), spacer (Item 4), linkage plate
bellcrank.
320/322 Excavator
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CONTROL LINKAGE ASSEMBLY (CONT'D) NOTE: The orientation of the linkage plate (Item 5)
[Figure 40-110-9] mounting hole is up towards
Left Travel Control Linkage Disassembly And the linkage rod.
Assembly
Installation: The distance between the center lines of
Figure 40-110-8 the linkage rod ball joints (Item 2) [Figure 40-110-9] is
4.78 in. (121.4 mm).
2 Figure 40-110-10
1
P-16643
P-19846
Remove the roll pins (Item 1) [Figure 40-110-8] from the
shaft.
NOTE: Linkage rod ball joints dimensions may need
Slide the left travel bellcrank assembly (Item 2) [Figure final adjustment to ensure the travel levers
40-110-8] off the end of the shaft. (Item 1) [Figure 40-110-10], with valve (levers)
in neutral, are even (in-line) with each other
Figure 40-110-9 when the floor panel is installed.
Figure 40-110-11
2
1
7
7
3
4.78 4
1.70
5
6 P16645A
P-16637
40-110-9] from the left travel bellcrank.
NOTE: The control linkage assembly must be
Remove the nut (Item 3), spacer (Item 4), linkage plate assembled as shown [Figure 40-110-11].
auxiliary bellcrank.
Remove the bushings (Item 7) [Figure 40-110-9 on Page

40-110-4] from the bellcrank.
320/322 Excavator
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CONTROL LINKAGE ASSEMBLY (CONT’D) Figure 40-110-14
Linkage Rod Removal And Installation
Remove the floormat and floorplates. (See Removal and 1

NOTE: Before disassembling the linkages, measure

the distance between the center lines of the
linkage end and the orientation for ease of
assembly. 2
Figure 40-110-12 3
P-19022
2
Remove the nut (Item 1) from the end of the ball joint on
the right pedal linkage rod (Item 2) [Figure 40-110-14].
110-14].
1
Remove the linkage rod.
Figure 40-110-15
P-16914
Remove the nut (Item 1) from the end of the ball joint on
the left pedal linkage rod (Item 2) [Figure 40-110-12].
1
Figure 40-110-13
2
3
2
P-56102
1 1 Remove the nut (Item 1) from the end of the ball joint on
the right pedal linkage rod (Item 2) [Figure 40-110-15].
Remove the linkage rod.

P-16915
Remove the nuts (Item 1) from the end of the ball joints
on the left and right travel control linkage rods (Items 2 &
3) [Figure 40-110-13].
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CONTROL LINKAGE ASSEMBLY (CONT’D) Figure 40-110-18
Linkage Rod Adjustment
Figure 40-110-16
2.60
3.73
.98
.70
1 B-19113
Adjust the linkage rods for the right pedal as dimensioned

P-16916 [Figure 40-110-18].
Figure 40-110-19
Loosen the nut (Item 1) [Figure 40-110-16] on the end of
the ball joint.
Figure 40-110-17
4.78 4.78 4.93 2

1.70 1.70 1.83
P-56222
NOTE: Linkage rod ball joint dimensions [Figure 40-

B-19112 110-18] may need final adjustment, with pedal
(valve) in neutral, to ensure the lock (Item 1)
[Figure 40-110-19] engages the pedal lock pin
Adjust the linkage rods for the left pedal, left and right (Item 2) [Figure 40-110-19] when the floor
travel controls as dimensioned [Figure 40-110-17]. panel is installed.
NOTE: Linkage rod ball joint dimensions [Figure 40-

110-17] may need final adjustment, with pedal
and levers (valve) in neutral, to ensure the
lock engages the pedal lock pin or travel
levers are even (in-line) with each other when
the floor panel is installed. ([Figure 40-110-5
on Page 40-110-2] and [Figure 40-110-10 on
Page 40-110-4].)
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FLOORMAT AND FLOORPLATES Figure 40-120-3

2
Figure 40-120-1
1 1
1
N-22644
2
Remove the floormat (Item 1) [Figure 40-120-3].
N-22641
Remove the cover (Item 2) [Figure 40-120-3].
Remove the bolts (Item 1) [Figure 40-120-1] in both Figure 40-120-4

floormat retaining plates.
1
Remove the floormat retaining plate (Item 2) [Figure 40-
120-1] from both sides. 1
Figure 40-120-2
1
1
N-22646
1 1 Remove the bolts (Item 1) [Figure 40-120-4] from the

rear floorplate.
N-22642 Remove the rear floorplate.
Remove the spacers (Item 1) [Figure 40-120-2] from

both sides of the floormat.
NOTE: Excavators that are equipped with a cab have

a floormat retainer plate only on the door side.
320/322 Excavator
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FLOORMAT AND FLOORPLATES (CONT’D) Figure 40-120-7
Figure 40-120-5
1
N-16551
The linkage for the boom swing pedal (Item 1) [Figure

N-16549 40-120-7] is located under the floorplate and accessed
through the front hole in the upperstructure above the
boom swing cylinder.
auxiliary pedal linkage. Figure 40-120-8
Figure 40-120-6
1
1
N-16552
N-16550
boom swing lever linkage.
Remove the nuts (Item 1) [Figure 40-120-6] from the left
and right travel pedal linkage.
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FLOORMAT AND FLOORPLATES (CONT’D)
Figure 40-120-9
N-16553
Remove the four bolts (Item 1) [Figure 40-120-9] from

the front floorplate. Remove the plate.
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FUEL TANK Figure 40-130-2
Open the tailgate.
Remove the muffler. (See Removal And Installation on

Page 60-20-1.)
Remove the hydraulic reservoir. (See Removal and

1
Remove the hydraulic filter bracket assembly. (See
Removal and Installation on Page 20-120-1.)
Remove the engine. (See Removal and Installation on P-16805

Page 60-60-1.)
Remove the floormat and floorplates. (See Removal and Remove the nut (Item 1) [Figure 40-130-2] from the fuel
Installation on Page 40-120-1.) tank mounting bolt under the left console.
Remove the seat and seat mount. (See Removal And Figure 40-130-3
Remove the blade extension tray. (See Removal And 1 2

Figure 40-130-1
P-16804
Remove the short bolt (Item 1) and the long bolt (Item 2)
[Figure 40-130-3] from the fuel tank mounting bracket.
P-16807
Remove the nut (Item 1) [Figure 40-130-1] from the fuel

tank mounting bolt behind the swing motor.
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FUEL TANK (CONT’D)
Figure 40-130-4
1
P-16810
Remove the fuel tank (Item 1) [Figure 40-130-4] from the

back of the Excavator.
NOTE: The bulk head hoses (Item 2) [Figure 40-130-4]

may need to be loosened and rotated away
from the fuel tank bracket.
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HORN

Figure 40-140-1
1
P-16675
Remove the wire (Item 1) [Figure 40-140-1] from the

horn.
Remove the horn.
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SWING FRAME Figure 40-150-2
Rotate the upperstructure until the blade is to the rear of 2

the Excavator.
Remove the bucket. (See Removal And Installation on

Page 40-180-1.)
Remove the arm. (See Removal And Installation on Page

40-170-1.) 3
Remove the boom. (See Removal And Installation on

Page 40-160-1.) 1 4
P-19242
Figure 40-150-1
Remove the snap ring and washer (Item 1) [Figure 40-

150-2] from the cylinder pivot pin.
Remove the bolt (Item 3) from the hose cover plate (Item
4) [Figure 40-150-2].
Figure 40-150-3
P-19243
Remove the bolt (Item 1) from the hose cover plate (Item
2) [Figure 40-150-3].
P-19234
Remove the hose cover plate.
Install a chain hoist on the swing frame [Figure 40-150-

1].
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SWING FRAME (CONT’D) Figure 40-150-6
Figure 40-150-4
P-19267
Remove the swing frame from the Excavator [Figure 40-

P-19244 150-6].
Figure 40-150-5
1
P-19245
Remove the snap ring (Item 1) [Figure 40-150-4] &

[Figure 40-150-5] from the top and bottom of the swing
frame.
Remove the excess paint from the inside of the top and
bottom bushings of the swing frame.
Use a large punch and drive the swing frame pin (Item 2)
[Figure 40-150-4] out the bottom of the swing frame.
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SWING FRAME (CONT’D)
Bushing Replacement
Figure 40-150-7
P-19266
Insert the bushing driver through the top bushing and

against the bottom bushing [Figure 40-150-7].
Drive the bottom bushing out of the upperstructure

[Figure 40-150-7].
To remove the top bushing, install the bushing driver from

the bottom and drive the bushing out.
To install the new bushings, use a bushing driver of the

correct size and install the new bushings into the
upperstructure.
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SWING FRAME (CONT’D) Install the washer (Item 3) [Figure 40-150-8] & [Figure
40-150-9] on the opposite end of the bushing. The
Swing Frame Bushing Removal washer must be centered on the bushing and must not
contact the casting.
The following parts will be needed for removal and
installation of the swing frame bushings: Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
150-8] & [Figure 40-150-9] through the washers and
Bolt - 0.625 x 4.5 inch long spacer.
Nut - 0.625 inch
Tighten the bolt and nut to remove the bushing from the
Washer - 0.625 inch I.D. x 2.312 inch O.D. x 0.25 inch
thick casting.
Washer - 0.625 inch I.D. x 3.5 inch O.D. x 0.25 inch thick
Swing Frame Bushing Installation
Spacer - 2.875 inch I.D. x 3.375 inch O.D. x 1.5 inch thick
Apply a film of grease to the outer diameter of the
Figure 40-150-8 bushing and the inner diameter of the casting.
5 Center the bushing on the casting hole.

2
NOTE: Make sure the bushing is centered in the
casting hole and is started in the hole evenly
1 and square.
Put the washer (Item 3) over the flanged end of the

bushing. Put the washer (Item 2) [Figure 40-150-9] over
the bushing hole casting, center the washer over the
3 bushing hole.
4 Install the bolt (Item 4) through the washers and the

bushing and install the nut (Item 5) [Figure 40-150-9].
P-19262
Tighten the bolt and nut until the bushing is seated in the
casting.
Figure 40-150-9
5 2
P-19265
Install the spacer (Item 1) and washer (Item 2) [Figure

40-150-8] & [Figure 40-150-9] over the flanged end of
the bushing.
The spacer (Item 1) [Figure 40-150-8] & [Figure 40-150-

9] must be centered over the bushing to avoid contact
between the bushing and the spacer during removal.
320/322 Excavator
518 of 705
SWING FRAME (CONT’D) The spacer (Item 1) [Figure 40-150-11] must be
centered over the bushing to avoid contact between the
Boom Pivot Bushing Removal And Installation bushing and the spacer during removal.
Figure 40-150-10 Install the washer (Item 3) [Figure 40-150-11] on the

opposite end of the bushing. This washer must be
centered on the bushing and must not contact the
casting.
1 Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
150-11] through the washers and spacer.
Tighten the bolt and nut to remove the bushing from the
casting.
Installation:
Apply a film of grease to the outer diameter of the

bushing and the inner diameter of the casting.
P-32529
Center the bushing in the casting hole.
The following parts will be needed for removal and NOTE: Make sure the bushing is centered into the
installation of the boom pivot bushings (Item 1) [Figure casting hole and is started in the hole evenly
40-150-10]. and square.
Bolt - 0.625 x 4.5 inch long Put the washer (Item 3) over the flanged end of the
Nut - 0.625 inch bushing. Put the washer (Item 2) [Figure 40-150-11] over
the bushing hole casting, center the washer over the
Washer - 0.625 inch I.D. x1.370 inch O.D. x 0.25 inch
bushing hole.
thick
Washer - 0.625 inch I.D. x 2.375 inch O.D. x 0.25 inch Install the bolt (Item 4) through the washers and the
thick bushing and install the nut (Item 5) [Figure 40-150-11].
Spacer - 2.000 inch I.D. x 2.375 inch O.D. x 1.5 inch
thick Tighten the bolt and nut until the bushing is seated in the
casting.
Figure 40-150-11
2
3
5 4
P-32533
Install the spacer (Item 1) and washer (Item 2) [Figure

40-150-11] over the flanged end of the bushing.
320/322 Excavator
519 of 705
320/322 Excavator
520 of 705
BOOM Figure 40-160-3
Remove the bucket. (See Removal And Installation on 2

Page 40-180-1.)
Remove the arm. (See Removal And Installation on Page

40-170-1.)
Figure 40-160-1
1
P-19236
Remove the bolt (Item 1) [Figure 40-160-3] and wire

harness clamp.
Disconnect the wire connector (Item 2) [Figure 40-160-

3].
Figure 40-160-4
N-22635
Install a chain hoist on the boom [Figure 40-160-1].
Remove the boom cylinder. (See Removal and

Figure 40-160-2 1
1
P-19239
Remove the snap ring and washer (Item 1) [Figure 40-

160-4] from the boom pivot pin.
P-19235
IMPORTANT
Remove the bolts (Item 1) and the retainer plates. clean the work area before disassembly and keep all
Remove the wire harness (Item 2) [Figure 40-160-2] parts clean. Always use caps and plugs on hoses,
from the retainer. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Mark the hoses for ease of assembly. I-2003-0888
Remove the six hoses from the tubes [Figure 40-160-2].
320/322 Excavator
521 of 705
BOOM (CONT’D) Figure 40-160-6
Figure 40-160-5
P-19241
Figure 40-160-7
P-19240
Remove the boom pivot pin (Item 1) [Figure 40-160-5].
P-19270
Lift the boom from the swing frame [Figure 40-160-6] &
[Figure 40-160-7].
NOTE: If shims are present between the boom and

the swing frame, install the shims in the same
locations. Side play of the boom should not
exceed 0.03 inch. (0,7 mm). Add shims equally
to both sides of boom.
320/322 Excavator
522 of 705
BOOM (CONT’D)
Boom Bushing Removal And Installation
Remove the boom. (See Removal And Installation on

Page 40-160-1.)
Remove the dust seals from both sides of the boom.
Remove the bushings from both sides of the boom.
Install the new bushings in the boom.
Figure 40-160-8
0.197” (5 mm) TS-01614
Install the bushings until they are seated 0.197 inch (5

mm) in the pin boss [Figure 40-160-8].
320/322 Excavator
523 of 705
320/322 Excavator
524 of 705
ARM

IMPORTANT
Remove the bucket. (See Removal And Installation on
Page 40-180-1.) When repairing hydrostatic and hydraulic systems,
Figure 40-170-1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 40-170-3
1
N-22595
Support the boom with a chain hoist [Figure 40-170-1]. 1
Figure 40-170-2
N-22622
Remove the hoses (Item 1) [Figure 40-170-3] from the

2 bucket cylinder.
1
P-16440
Remove the snap ring (Item 1) and washer (Item 2)

Remove the rod end of the cylinder from the arm.
320/322 Excavator
525 of 705
ARM (CONT’D) Arm To Boom Bushing Removal And Installation
Removal And Installation (Cont’d) Remove the dust seal from both sides of the arm.
Figure 40-170-4 Figure 40-170-5
2 3
1
P-16922 N-16505
Reinstall the rod end pivot pin, washer and snap ring Remove the bushings (Item 1) [Figure 40-170-5] from
(Item 1) [Figure 40-170-4] and attach a chain hoist. both sides of the arm.
Remove the nut and washer (Item 2) [Figure 40-170-4] Figure 40-170-6
from the boom/arm pivot pin.
Installation: Tighten the nut until it is seated firmly

against the boom. Do not overtighten and deflect the
boom mounting plate. The arm must pivot freely.
Remove the arm from the boom.
0.197” (5mm) TS-01614
Install the new bushings until they are seated 0.197

inches (5 mm) in the pin boss [Figure 40-170-6].
Install new dust seals.
320/322 Excavator
526 of 705
ARM (CONT’D) Figure 40-170-9
Arm To Bucket And Bucket Link Bushing Removal

And Installation
Figure 40-170-7
0.197” (5mm) TS-01614

1
Install the bushings until they are seated 0.197 inches (5

mm) in the pin boss [Figure 40-170-9].
N-16507
Install the dust seals on both sides of the arm.
Remove the dust seals (Item 1) [Figure 40-170-7] from

both sides of the arm.
Figure 40-170-8
N-16506
Remove the bushings (Item 1) [Figure 40-170-8] from

both sides of the arm.
320/322 Excavator
527 of 705
320/322 Excavator
528 of 705
BUCKET Remove the pivot pins (Item 2) [Figure 40-180-2].
Removal And Installation Keep the pins clean. Do not damage the dust seals in the
arm when removing the bucket.
Install the arm into the bucket and align the hole.
WARNING Install the pivot pin.
Extend the bucket cylinder until the connecting link aligns
Stop the machine on a firm flat surface. When remov-
with the other bucket pin hole.
ing or installing attachments (such as a bucket),
always have a second person in the operator’s seat,
Install the washers (Item 1) [Figure 40-180-2].
give clear signals and work carefully.
W-2140-0189
Install the pin retainer clips (Item 1) [Figure 40-180-1].
Park the Excavator on a flat level surface. Put the bucket Add grease to the pivot pins before operation.
on the ground.
Figure 40-180-1
WARNING
Never use attachments or buckets which are not
approved by Bobcat Company. Buckets and
attachments for safe loads of specified densities are
approved for each model. Unapproved attachments
can cause injury or death.
W-2052-0500
P-11050
Remove the pin retainer clips (Item 1) [Figure 40-180-1].
Figure 40-180-2
2
P-11051
Remove the washers (Item 1) [Figure 40-180-2]
320/322 Excavator
529 of 705
320/322 Excavator
530 of 705
TAILGATE Figure 40-190-3
Open the tailgate.
Figure 40-190-1
1
P-19800
Install and tighten two c-clamps (Item 1) [Figure 40-190-

1] equally spaced from the sides on the top of the
1
tailgate.
NOTE: To prevent paint damage use rubber pads on

the c-clamps.
P-19797
Figure 40-190-2

from the hinges.
Remove the tailgate from the Excavator.
P-19794
Install chains to the c-clamps and chain hoist [Figure 40-

190-2].
NOTE: Use a lifting device of sufficient capacity.

Approximate weight of the tailgate is 160 lbs.
(352 kg).
320/322 Excavator
531 of 705
TAILGATE (CONT’D) Figure 40-190-6
Latch Removal And Installation

2
Figure 40-190-4
4
2
P-29987
3
Remove the bolt (Item 1). Remove the latch assembly

P-29984 (Item 2) [Figure 40-190-6] from the tailgate.
Remove the bolt (Item 1), nut (Item 2), outer rollers (Item
3) and inner roller (Item 4) [Figure 40-190-4].
Figure 40-190-5
1
2
P-29985
For ease of assembly, mark around the outside edge

(Item 1) [Figure 40-190-5] of the latch bracket.
Remove the two bolts (Item 2) [Figure 40-190-5], washer

and nuts.
See Adjusting The Tailgate Latch on Page 10-40-1
Remove the bracket (Item 1) [Figure 40-190-5].
320/322 Excavator
532 of 705
SWING LOCK

Remove the blade extension tray. (See Removal And

Remove the battery. (See Removing And Installing The

Battery on Page 50-20-2.)
Figure 40-200-7
1
2
P-56154
Remove the nuts and bolt (Item 1) from the swing lock
lever and pin (Item 2) [Figure 40-200-7].
Remove the swing lock pin.
Figure 40-200-8
P-56155

lever.
Remove the lever.
320/322 Excavator
533 of 705
320/322 Excavator
534 of 705
BLADE EXTENSION TRAY

Figure 40-210-1
1 2
N-23045
Remove the bolt (Item 1) and nut (Item 2) [Figure 40-

210-1].
Remove the blade extension tray.
320/322 Excavator
535 of 705
320/322 Excavator
536 of 705
LEFT PEDAL
Not Available At Time Of Print
320/322 Excavator
537 of 705
320/322 Excavator
538 of 705
ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Regulator Test. . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3 SAFETY &
Alternator Regulator Test With Voltmeter . . . . . . . . . . . . . 50-30-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Full Field Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Removing And Installing The Battery. . . . . . . . . . . . . . . . . 50-20-2
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 50-20-3 ELECTRICAL
SYSTEM &
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1 ANALYSIS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Relays And Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Disassembly And Assembly . . . . . . . . . . . . . . 50-50-3
Boom Light Removal And Installation . . . . . . . . . . . . . . . . 50-50-2
Light Switch Removal And Installation. . . . . . . . . . . . . . . . 50-50-4
Upper Structure Light Removal And Installation . . . . . . . . 50-50-1
MICROSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
TWO-SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

320/322 Excavator
539 of 705
320/322 Excavator
540 of 705
3230
320 & 322 EXCAVATOR 3220 3210 8010

EXPANDABLE
UNDERCARRIAGE SWITCH
GLOW PLUG
OFF 2280
(322 ONLY)
WIRING SCHEMATIC ENGINE OIL RUN 2260

PRESSURE
ENGINE WATER ALTERNATOR LAMP RIGHT HAND CONSOLE START
TEMERATURE 2200
LAMP 1330 1320 HARNESS 6807427
LAMP
2000
320 / 320L (S/N 223911001 AND ABOVE) SYSTEM
2190 2270
WARNING
322 (S/N 224011001 AND ABOVE) BUZZER HORN 2180
3110
3250
8050
(PRINTED JULY 2006) TIMER
SO 2170
2160
2170
- + AUXILIARY
V-0487 1270 POWER 2150
SOCKET
7020
2160 8030
ST
B
Printable Version Click Here GLOW
1220
2180
PLUG
3210
LAMP
HORN
1190 3070
3200
SWITCH
3020
B1 1170
6020 I
IGNITION SWITCH
7000 3120 3130 3160 3170
R
DIODE DIODE
6020
3180
B2
6010 6000
BOOM
LIGHT
3060
H
HOUSE
LIGHT
3140 3100 3040

TWO SPEED INDICATOR
1350
DIODE (NOT USED ON 320L)
C852
B B 2150 3190 1190 3240 2270

TRAVEL SWITCH
C854
C855
B A W
A A 6030
C751 LIGHT SWITCH 1340 4010 4070 4080 E E OUT
C853
M
B A 4060 D D SW
BOOM LIGHT HEATER 2260 B B GND
HARNESS 6807747 HOURMETER H
4120 A A PWR
C851
C C
2000
6000
6010
2190
1360
3190
7000
6040
A A TWO SPEED MODULE
3040
1150
3020
1170
3070
1190
8050
4010
3050
8010
1200
2000
1240
1220
8030
2200
4200
1280
2090
4120
(NOT USED ON 320L)
B B 3080
C750
6000 A A
2000 B B 2280 D F B C E A RIGHT CONSOLE LOCK
4060
OUT SWITCH E D G C F A B A F D E B G C B A
C250 (THIS SWITCH ONLY
A B C
E C B D F A USED ON MODELS C151 C152 C153 C154

CAB WITH ROPS CANOPY) TWO ENGINE
SPEED B A C D F G E A F C E G B D B A A B C
HARNESS 7101054 HARNESS 6807426
SWITCH
1360
2190
6240
6310
6400
WASHER
4110
C253
1280
2090
4120
M
3080
2950
2200
4200
3050
2000
SWITCHED
4010
8050
3020
3040
1170
1150
1190
8010
8030
1220
1240
1200
A A EXPANDABLE
ACCESSORY
IGNITION
2190 2960 UNDERCARRIAGE
20A
2820 B B SOLENOID FUSE 2 20A FUSE 3
2820
(322 ONLY)
INSTRUMENT
ENGINE COOLANT
TEMPERATURE
3090
3060
1300
10A
FUSE 1 - 10A FUSE 1 15A FUSE 4
SWITCH
1360
6240
6310
7110
7120
7100
2960 1160 1130 CAB

2950
FUSE 5 - 15A
1240 1080
FUSE 4 - 15A
SWITCHED
A B A B A C B C A B
2 4 1 6 3 5
POWER
1190 1070
NON-
15A
FUSE 8 FUSE 5
C252 C251 C254 C255 C850 FUSE 3 - 20A
SWITCHED
A B A B 2 4 1 6 3 5 A C B 1230 1100
C A B
TIMER
15A
FUSE 7
LEFT HAND CONSOLE FUSE 6 - 15A 15A FUSE 6
HARNESS 6807428 1250 1060

NON-SWITCHED
C163
6240
6310
6400
2950
TIMER
GRN
FOR MOTION ALARM (IF EQUIPPED)

BRN
1210
YEL
3090
3060
1300
OPTIONS
LEFT CONSOLE 20A HARNESS 6808973
LOCKOUT SWITCH FUSED FUSE BLOCK
ACCESSORY
FUSE 2 - 20A RIGHT TRAVEL
C950
C C 1140 1260 SWITCH

2860
WIPER SWITCH A A 3090

2860
C155
A C B 1150 1260 1410
B B 4070
1 C257 1130
3 4
2120 2120
B A
2
A C B 1170 1120 1270
SWITCHED POWER RELAY 20A
3060
PARK FUSE 7 - 15A 1510
A B SWITCHED
C257 3
2050
2 1
8080 ACCESSORY
B A C256 WIPER 5
4
8040
86 85
2040 STOP
1400
1500
A B FUEL
WASHER FUEL GAUGE
2310
TIMER
1530
1110 1090 SOLENOID
6 BACKLIGHT 87 30 OIL PRESSURE MODULE LEFT
SWITCH TRAVEL
87A
WIPER SWITCH
2130
MOTOR 3030
V P 3020 HR
DOME LIGHT M
GLOW PLUGS
G
2880
RIGHT HAND LEFT HAND BEACON ALARM

LIGHT LIGHT MOTION ALARM RELAY
8050 STARTER 86 85
1520 2300
C854 C855
C C 3010 B M S 4010 4070
1010 1290 87 30 TO RIGHT
4000 E E 4000 PREHEAT RELAY HAND
87A
C156
B B CONSOLE
3250
4010
D D 86 85
2030 8070
3000 A A 3000 GREEN ORANGE YELLOWTIE 8060 1030
2080 F F 2080 TIE TIE STRAP 87 30
CONSOLE DIODE
1180
STRAP STRAP -
DOWN 87A
+
INDICATOR 8030
2130
4030
2140
4040
2110
4010
2280
CAB AND WIPER WIRING (IF EQUIPPED) DIODE

2280
STARTER RELAY
FRAME
2070
3000
HARNESS 7100774 GROUND
2140
86 85
1030
1010
8020
1050
2020
1090
8010
8000
G B A B A B A BATTERY
1290 1040
87 30
B A
C159 C160 C161
3000 87A
S B A B A B A 2020
I
C157 2030
2040 2010
FUEL GAUGE B A C162 2050
2130
2120
1020
2080
WIRES CONNECT BY LETTER FUEL SENDER 2110
PUR
BLK
ACROSS CONNECTORS 2140 HARNESS 2070

BATTERY FEED 1000-1999 RED, RED/WHT, RNG RED = RED
6587177 B 2000 2060
A B RNG = ORANGE
GROUND 2000-2999 BLK BLK = BLACK 2080
2130
B A LBL = LIGHT BLUE ALTERNATOR 2100
MONITORING 3000-3999 LBL DBL = DARK BLUE 2140
B A DUMP VALVE
HYDRAULIC 4000-4999 LGN
LGN = LIGHT GREEN JOYSTICK LOCKOUT SOLENOID TWO SPEED SOLENOID
SOME CONNECTOR DGN = DARK GREEN SOLENOID (NOT USED ON 320L)
BODIES NOT SHOWN ATTACHMENT CONTROLS 5000-5999 YEL YEL = YELLOW C158
FOR DRAWING CLARITY PNK = PINK B A
LIGHTS 6000-6999 PNK WHT = WHITE
BRN = BROWN
ACCESSORIES 7000-7999 WHT TAN = TAN
PUR = PURPLE
ENGINE 8000-8999 TAN
GRY = GRAY
COMMUNICATION 9000-9999 PUR
541 of 705 FUEL LEVEL
Printed in U.S.A. SENSOR V-0487 (7-10-06)
ELECTRICAL SYSTEM
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service personnel Operation & Maintenance Manual, Handbook and
only. signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow instructions can
W-2003-0199
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE

1. Engine accessory drive belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
320/322 Excavator
542 of 705
ELECTRICAL SYSTEM (CONT’D) Fuses
Description Figure 50-10-2
Figure 50-10-1
4 6
3 5
2
1
1 7
2 8
B-14855
P-30239
1. Instrument - 10A (SW) Hourmeter, Warning Buzzer
& Fuel Gauge Back Light [Figure 50-10-2]
The Excavator has a 12 volt, negative ground electrical
system. The electrical system is controlled by fuses and 2. Accessory - 20A (SW) Accessory Connector, Heater
relays located in the right side of the engine compartment & Horn [Figure 50-10-2]
(Items 1 & 2) [Figure 50-10-1]. The fuses will protect the
electrical system when there is an electrical overload. 3. Start - 20A (SW) Key Switch, Unswitched Accessory
The reason for the overload must be found before Connector [Figure 50-10-2]
starting the engine again.
4. Cab - 15A (SW) Cab Power, Lights, Wiper & Dome
Light [Figure 50-10-2]
5. Power - 15A (UNSW) Appliance Socket [Figure 50-

10-2]
6. Timer Power - 15A (UNSW) Stop Timer Module

[Figure 50-10-2]
7. Power - 15A (SW) Stop Timer Module [Figure 50-10-

2]
8. Open - Not Used [Figure 50-10-2]
Always replace fuses using the same type and capacity.
Relays And Diodes
The three electrical relays (Item 2) [Figure 50-10-1] are

located in the engine compartment to the right of the fuel
fill. The three relays control the starter, glow plugs and
switched power circuits.
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ELECTRICAL SYSTEM (CONT’D) Figure PM-4
Relays And Diodes (Cont’d)
Figure 50-10-3
1
1
P-49721
There are two diodes (Item 1) [Figure PM-4] in the

P-30234 harness behind the starter. They are for alternator
feedback protection and the glow plug during start
function.
The fuel shut-off timer (Item 1) [Figure 50-10-3] is
located on the right side of the engine compartment.
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BATTERY Check for broken or loose connections.
Servicing If the battery cables are removed for any reason,

disconnect the negative (-) cable first. When installing the
Figure 50-20-5 battery cables, make the last connection the negative (-)
cable to the battery.
The original equipment battery is maintenance free. If a

2 replacement battery is installed, check the electrolyte
level in the battery.
If the electrolyte level is lower than 0.50 inch (13 mm)

above the plates, add distilled water only.
1 WARNING
P-30246
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
The battery is located under the operator's seat, behind
the storage compartment cover (Item 1). Use the key In case of acid contact, wash immediately with water.
(Item 2) [Figure 50-20-5] to open the compartment. In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
Figure 50-20-6 minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
1 W-2065-1296
P9589 P9590
The battery cables must be clean and tight [Figure 50-

20-6]. Remove acid or corrosion from the battery and
cables using a sodium bicarbonate and water solution.
Cover the battery terminals and cable ends with battery
saver grease to prevent corrosion.
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BATTERY (CONT’D) Figure 50-20-9
Removing And Installing The Battery
Figure 50-20-7 3
1
P-49756
1
Disconnect the negative (-) cable (Item 1) [Figure 50-20-
P-30246 9] first.
Disconnect the positive (+) cable (Item 2) [Figure 50-20-

Open the storage compartment cover (Item 1) [Figure 9].
50-20-7].
Remove the bolts (Item 3) [Figure 50-20-9] from the hold
Remove seat and seat pan. down clamp and remove the clamp.
Figure 50-20-8 Remove the battery.
Always clean the terminals and the cable ends, even

when installing a new battery.
Install the battery. Install the hold down clamp and tighten
the bolts.
Connect the battery cables. Connect the negative (-)

cable (Item 1) [Figure 50-20-9] last to prevent sparks.
WARNING
P-30248
Batteries contain acid which burns eyes and skin on
Remove seat and raise the seat pan [Figure 50-20-8]. rubber gloves to keep acid off body.
(See Removal And Installation on Page 40-40-1.)
In case of acid contact, wash immediately with water.
Remove the blade extensions (Item 1) [Figure 50-20-8]. In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

W-2065-1296
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BATTERY (CONT’D)
Using A Booster Battery (Jump Starting)

IMPORTANT
Damage to the alternator can occur if:
IMPORTANT • Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
If jump starting the Excavator from a second charger or when welding on the Excavator.
machine: (Remove both cables from the battery.)
When jump starting the Excavator from a battery • Extra battery cables (booster cables) are
installed in a second machine. Make sure the second connected wrong.
machine is NOT running while using the glow plugs. I-2222-0903
High voltage spikes from a running machine can
burn out the glow plugs.
Start the engine. After the engine has started, remove the
I-2060-0195
negative (-) cable first (Item 2) [Figure 50-20-10].
If it is necessary to use a booster battery to start the Disconnect the cable from the Excavator starter (Item 1)
engine. BE CAREFUL! There must be one person in the [Figure 50-20-10].
operator's seat and one person to connect and
disconnect the battery cables.
Engage the upperstructure slew lock. Be sure the key

switch is OFF. The booster battery must be 12 volt.
WARNING
Figure 50-20-10 Batteries contain acid which burns eyes and skin on
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
1 and wash eye with clean, cool water for at least 15
minutes.

2
W-2065-1296
P-49772
Open the tailgate [Figure 50-20-10].
Connect one end of the first cable to the positive (+)

terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
[Figure 50-20-10] of the Excavator starter.
Connect one end of the second cable to the negative (-)

terminal of the booster battery. Connect the other end of
the same cable to the negative Excavator cable (Item 2)
[Figure 50-20-10] where it is fastened to the frame.
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ALTERNATOR Tests
Description Perform the following alternator tests in this order:
Figure 50-30-11 Alternator Output Test: Tests the alternator and regulator
output.
3
4 2
Full Field Test: Tests the maximum amperage output of
1 the alternator.
Alternator Regulator Test: Tests the regulator voltage

output.
P-10018
Figure 50-30-12
1
3 2
4
5 P-10023
The output terminal (Item 1) [Figure 50-30-11] & [Figure

50-30-12].
The battery or power sensing terminal (Item 2) [Figure

50-30-11] & [Figure 50-30-12].
The ignition terminal (Item 3) [Figure 50-30-11] &

[Figure 50-30-12].
Open terminal not used in the Excavator harness (Item 4)

[Figure 50-30-11] & [Figure 50-30-12].
Access hole for full field test (Item 5) [Figure 50-30-11] &
[Figure 50-30-12].
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ALTERNATOR (CONT’D) Full Field Test
Alternator Output Test Start the engine and run at full RPM.
Check the battery and battery connections. (See Figure 50-30-14

BATTERY on Page 50-20-1.)
Figure 50-30-13
1
1
P-10021
P-16853 Place a small screw driver in the test port (Item 1)

[Figure 50-30-14] to provide a ground to the alternator
case. This will give maximum amperage output from the
Use an induction meter and loop around the positive (+) alternator.
wire (Item 1) [Figure 50-30-13] at the alternator.
NOTE: The Full Field Test should only last long
Start the engine and run at full RPM. enough to get ammeter reading to prevent
damage to the alternator.
The ammeter reading should be between 35 and 40
amps. The ammeter reading should be above 35 amps.
If the ammeter reading is less than 35 amps do the full If the ammeter reading is low, repair or replace the
field test. alternator.
WARNING WARNING
When an engine is running in an enclosed area, fresh When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning. gases which can kill without warning.
W-2050-1285 W-2050-1285
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ALTERNATOR (CONT’D) Alternator Regulator Test With Voltmeter
Alternator Regulator Test Figure 50-30-15
Disconnect the fuel stop solenoid connector.
Turn the lights on (if equipped) and crank the engine for 1 2
30 seconds to discharge the battery.
Connect the fuel stop solenoid connector.
Start the engine and run at full RPM.
The ammeter reading should be around 35 amps and

slowly decrease with alternator output.
If ammeter reading is low or does not decrease with time,

replace the alternator's regulator. P-16871
Disconnect the negative (-) cable from the battery.

Connect the positive (+) voltmeter lead to the positive (+)
Reconnect the alternator wires. battery terminal (Item 1) [Figure 50-30-15].
Reconnect the negative (-) cable from the battery. Connect the negative (-) voltmeter lead to the negative (-
) battery terminal (Item 2) [Figure 50-30-15].
NOTE: The alternator regulator test can also be run
using a voltmeter. Start the engine and run at full RPM.
The voltmeter should read between 13.9 and 14.7 volts.
If the voltmeter reading is not within this range, replace

the alternator's regulator.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
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ALTERNATOR (CONT’D) Figure 50-30-18
Figure 50-30-16
1
P-29996
Unlatch the seat pan lever (Item 1) [Figure 50-30-18].

P-29988
Raise the seat pan.
Release the seat lever (Item 1) [Figure 50-30-16]. Pull Figure 50-30-19
the seat to the front and remove it from the Excavator.
Figure 50-30-17
1 1
P-56156
P-29989 Disconnect the negative ( - ) battery cable (Item 1)

[Figure 50-30-20].
Using the start key, unlock and remove the cover (Item 1)
[Figure 50-30-17] from the storage compartment.
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ALTERNATOR (CONT’D) Figure 50-30-22
Figure 50-30-20
2 1
P-29993
Remove the bottom mount bolt (Item 1) [Figure 50-30-

P-29991 22].
Remove alternator adjustment bolt (Item 2) [Figure 50-

Remove the bolts (Item 1) [Figure 50-30-20]. 30-22].
Remove the access panel (Item 2) [Figure 50-30-20]. Figure 50-30-23
Figure 50-30-21
1 2 3 4
P-29995
P-29992
NOTE: Alternator will fall if not supported while
removing adjustment bolt.
Disconnect the red wire (Item 1) [Figure 50-30-21].
Remove belt from the alternator pulley.
Disconnect the wire harness connector (Item 2) [Figure
50-30-21]. Remove alternator.
NOTE: The lower alternator mounting bolt (Item 1) is

assembled with a washer (Item 2) spacer (Item
3) and retaining bracket with nut (Item 4)
[Figure 50-30-23] which will fall during
disassembly.
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ALTERNATOR (CONT’D)
1. Alternator 15. Nut

2. Frame Assy. 16. Insulator
3. Plate 17. Bolt
4
4. Screw 18. Screw 6 3 23
5. Bearing 19. Nut 2 22
5
6. Stud 20. Nut
7. Frame End 21. Rotor Assy.
8. Holder 22. Bearing 21
9. Holder 23. Cover
24. Pulley 28
10. Seal
11. Brush 25. Spacer 24
12. Spring 26. Bolt
14
13. Regulator 27. Screw 26
14. Cover 28. Screw 27
25 10
20 9
15
16
19 28
12
7 11
18
1
13
17 8
C-3456
Remove the regulator cover and regulator.
Remove the three bolts holding halves together.
Pry the halves apart.
Use a soft jaw vise to hold rotor while removing pulley

nut.
Remove front case half from the rotor using a plastic

hammer.
Unsolder the stator leads from the rectifier. Remove the

stator.
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STARTER Figure 50-40-3

1
Open tailgate. (See Opening And Closing The Tailgate on
Page 10-40-1.)
Remove the storage compartment cover using the

ignition key to unlock the cover.
Figure 50-40-1
1
P-16662
Remove the mounting bolts (Item 1) [Figure 50-40-3]

from the starter.
Remove the starter from the bell housing.
1
P-49756
Disconnect the negative (-) cable (Item 1) [Figure 50-40-

1] from the battery.
Mark the starter wires for ease of assembly.
Figure 50-40-2
P-16661
Disconnect the wires (Item 1) [Figure 50-40-2] from the

starter.
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STARTER (CONT’D) Cleaning and Inspection
Figure 50-40-4
WARNING
1 Wear safety glasses to prevent eye injury when any
of the following conditions exist:
1 • When fluids are under pressure.
2 • Flying debris or loose material is present.
• Tools are being used.
4
W-2019-1285
3
Use a brush and air pressure to clean the drive, field
coils, armature and starter housing.
5
10 NOTE: Do not use solvent to clean the drive
assembly. The solvent will remove the
lubricant and the drive will slip.
Check the following items:

7
Armature
6 Broken or burned insulation.
1. Starter
Loose connections at commutator.
2. Frame 8 Open or grounded circuits.
3. Brush
Worn shaft or bearings.
4. Armature 9
Rough commutator.
5. Yoke
6. Housing
Field Coils
7. Pinion
Broken or burned insulation.
8. Clutch
Electrical continuity.
9. Housing
Brush connections.
10. Plunger B-19162
Drive Gear
Disassembly And Assembly Worn teeth.
Tooth engagement (drive gear must engage ring gear
Disassemble the starter as shown [Figure 50-40-4]. by 1/2 the depth of the ring gear tooth).
Brush Holders
Broken springs.
Broken insulation.
Spring tension.
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LIGHTS Figure 50-50-7
Upper Structure Light Removal And Installation

1
Figure 50-50-5
P-32223
Figure 50-50-8
P-32221
1
Push in on the light housing (Item 1) [Figure 50-50-5]
until the light is inside the upper structure.
Figure 50-50-6
P-32224
Remove the light bulb assembly (Item 1) [Figure 50-50-

1 7] & [Figure 50-50-8] from the lens.
P-32222
Turn and pull the light (Item 1) [Figure 50-50-6] out of the
upper structure.
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LIGHTS (CONT’D)
Boom Light Removal And Installation
Figure 50-50-9
P-32226
Remove the nut and bolt (Item 2) [Figure 50-50-9].
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LIGHTS (CONT’D) Figure 50-50-12
Boom Light Disassembly And Assembly 1

3
Figure 50-50-10
1 2
P-16883
Remove the light bulb assembly (Item 1) from the lens

P-16881 assembly (Item 2) [Figure 50-50-12].
Disconnect the wire connector (Item 3) [Figure 50-50-12]

Remove the screw (Item 1) [Figure 50-50-10] from the from the light bulb assembly.
side of the light.
Figure 50-50-11
P-16882
Remove the cover (Item 1) and lens assembly (Item 2)

[Figure 50-50-11].
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LIGHTS (CONT’D) Figure 50-50-15
Light Switch Removal And Installation
Figure 50-50-13
1
1
2 P-16985

P-16964 from the switch.
Remove the switch from the bottom of the panel.

Remove the screw (Item 1) and knob (Item 2) [Figure 50-
50-13] from the switch.
Figure 50-50-14
2
P-16961
Remove the nut and lock washer (Item 1) [Figure 50-50-

14] from the switch.

the cover panel.
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TWO-SPEED SWITCH Figure 50-60-3

2
NOTE: The 320L is not equipped with a two-speed. 1
2
Figure 50-60-1 3
P-32920
Disconnect the wire harness (Item 1). Remove the two

bolts (Item 2) and plate (Item 3) [Figure 50-60-3].
Figure 50-60-4
P-32918
Locate the two-speed switch (Item 1) [Figure 50-60-1] on

the front right side of the control valve assembly.
Figure 50-60-2 1
P-33019

1 plate.
P-32917
Remove the cotter pin and clevis pin (Item 1) [Figure 50-
60-2].
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TWO-SPEED SWITCH (CONT’D)
Figure 50-60-5
2
1
P-32959
Remove the bolts (Item 1) and switch (Item 2) [Figure

50-60-3].
NOTE: The valve section is shown removed for photo

clarity.
Figure 50-60-6
P-32962

switch.
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FUEL LEVEL SENDER Testing
Removal and Installation Use an ohmmeter to check the resistance of the fuel level
sender.
Open the tailgate.
Figure 50-70-3
Figure 50-70-1
INSERT ONE
OHM TESTER
FUEL SENDER LEAD INTO
TOP VIEW EACH OF THE
FUEL SENDER
CONNECTIONS
FUEL SENDER
TOP VIEW
P-16680

from the fuel level sender.
Figure 50-70-2
B-14140
Insert one of the ohm tester leads into each of the fuel
sender electrical connectors in the end of the fuel sender
[Figure 50-70-3].
P-16681
With the fuel sender in the position shown [Figure 50-70-
3], read the ohms in the empty position. Slide the float
Remove the sender (Item 1) [Figure 50-70-2] from the upwards and the ohm reading will decrease. See
fuel tank. resistance chart below.
The approximate resistance should read as follows:
FULL: 15-35 Ohms.

HALF: 120-145 Ohms.
EMPTY: 230-250 Ohms.
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MICROSWITCH Figure 50-80-3
Adjustment
Adjust the console latch. (See Adjustment (ROPS

Canopy Models 320 & 322) on Page 40-50-10.) 1
NOTE: Make sure that the microswitch is at the top of

the adjustment slots prior to adjusting the
console latch or switch damage may occur.
Lower the console to the latched position.
Figure 50-80-1
Set the feeler gauges to the new measurement and lay

the feeler gauges (Item 1) [Figure 50-80-3] beside the
microswitch .
Figure 50-80-4
1
P-19565
Use feeler gauges and measure the distance between

the two latch mounting plates [Figure 50-80-1].
Raise the console.
Take the measurement from the feeler gauges and

subtract .12 inch (3 mm) from the measurement. P-19765
Figure 50-80-2
Lay a straight edge (Item 1) [Figure 50-80-3] across the
feeler gauges and listen for the microswitch to engage
(click). If the microswitch does not engage (click), pivot
the switch down and lay the straight edge across again.
Once the microswitch engages at the height of the feeler

gauges, tighten the microswitch mounting hardware
while holding the microswitch at the proper adjustment.
1
P-19771

microswitch to the bracket.
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MICROSWITCH (CONT’D)
Adjustment (Cont’d)
Figure 50-80-5
P-19766
Lower the console and verify the green light (Item 1)

[Figure 50-80-5] is lit when the key switch is turned to
the ON position. If the green light is not lit, loosen and
pivot the microswitch down slightly and recheck.
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MICROSWITCH (CONT’D) By pushing the actuator on the microswitch, the gauge
reading should show a completed circuit. If not, the
Testing microswitch is faulty and must be replaced.
Remove the access plate. (See Console Cover Removal

And Installation (Cab Models 320L, 320, 322 & ROPS
Canopy Model 320L) on Page 40-50-1.)
Figure 50-80-6
P-19767
Disconnect the microswitch harness (Item 1) [Figure 50-

80-6] from the control harness.
Figure 50-80-7
P-19769
Use a continuity tester to check the microswitch prior to

removal. Test the continuity between the black and white
wire pins (Item 1) [Figure 50-80-7].
The microswitch is normally open.
With the console raised the gauge reading should show

no current.
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MICROSWITCH (CONT’D)
Figure 50-80-8
P-19771
Remove the nuts, lock washers and bolts (Item 1)

[Figure 50-80-8] holding the microswitch.
Figure 50-80-9
P-19774
Remove the microswitch [Figure 50-80-9].
NOTE: The adjustment procedure must be performed

after a new microswitch has been installed.
(See Adjustment on Page 50-80-1)
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ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
ENGINE COMPONENTS AND TESTING (S/N 223911001 - 223911621, S/

N 224011001 - 224013374) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Engine Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Fuel Injection Pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . 60-50-4
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Fuel Injector Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . 60-50-7
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . . . . . 60-50-2
Fuel Shut-Off Timer Removal And Installation. . . . . . . . . . . . . . 60-50-2
Glow Plug Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-50-9
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
ENGINE
ENGINE COMPONENTS AND TESTING (S/N 223911622 & ABOVE, S/N SERVICE
224013375 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-1
Engine Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-2
Fuel Injection Pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-3
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . 60-51-4
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-6
Fuel Injector Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-8
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . 60-51-7
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . . . . . 60-51-2
Fuel Shut-Off Timer Removal And Installation. . . . . . . . . . . . . . 60-51-3
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-51-10
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-1
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Hydraulic Pump Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
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ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE (S/N 223911001 - 223911621, S/N

224011001 - 224013374) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-21
Crankshaft And Bearings Removal And Installation . . . . . . . . 60-80-22
Crankshaft And Bearings, Servicing . . . . . . . . . . . . . . . . . . . . 60-80-24
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . 60-80-14
Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-26
Cylinder Head Disassembly And Assembly. . . . . . . . . . . . . . . . 60-80-2
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . 60-80-1
Cylinder Head, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-3
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-4
Engine Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . 60-80-16
Fuel Camshaft Removal And Installation. . . . . . . . . . . . . . . . . 60-80-13
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-14
Idler Gear And Camshaft Removal And Installation . . . . . . . . . 60-80-9
Idler Gear and Shaft, Servicing . . . . . . . . . . . . . . . . . . . . . . . . 60-80-12
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-80-15
Oil Pump, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-15
Piston And Connecting Rod Removal And Installation . . . . . . 60-80-17
Piston And Connecting Rod, Servicing . . . . . . . . . . . . . . . . . . 60-80-19
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-17
Rocker Arm And Shaft, Checking . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . . . . . . 60-80-13
Timing Gearcase Cover Removal And Installation . . . . . . . . . . 60-80-8
Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-4
Valve And Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . 60-80-6
Valve Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . 60-80-26
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . 60-80-26
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ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE (S/N 223911622 & ABOVE, S/N

224013375 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-21
Crankshaft And Bearings Removal And Installation . . . . . . . . 60-81-22
Crankshaft And Bearings, Servicing . . . . . . . . . . . . . . . . . . . . 60-81-24
Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-26
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . 60-81-14
Cylinder Head Disassembly And Assembly. . . . . . . . . . . . . . . . 60-81-2
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . 60-81-1
Cylinder Head, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-3
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-4
Engine Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . 60-81-16
Fuel Camshaft Removal And Installation. . . . . . . . . . . . . . . . . 60-81-13
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-14
Idler Gear And Camshaft Removal And Installation . . . . . . . . . 60-81-9
Idler Gear and Shaft, Servicing . . . . . . . . . . . . . . . . . . . . . . . . 60-81-12
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-81-15
Oil Pump, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-15
Piston And Connecting Rod Removal And Installation . . . . . . 60-81-17
Piston And Connecting Rod, Servicing . . . . . . . . . . . . . . . . . . 60-81-19
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-17
Rocker Arm And Shaft, Checking . . . . . . . . . . . . . . . . . . . . . . . 60-81-7
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . . . . . . 60-81-13
Timing Gearcase Cover Removal And Installation . . . . . . . . . . 60-81-8
Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-4
Valve And Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . 60-81-6
Valve Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-7
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . 60-81-26
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . 60-81-26
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
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TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop 9, 10, 11
KEY TO CORRECT THE CAUSE

1. Battery capacity low 28. Worn valves and seat
2. Bad electrical connections 29. Broken or worn piston rings
3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores
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SPARK ARRESTOR MUFFLER

WARNING
Figure 60-20-1
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
1 W-2050-1285
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
N-23201
Failure to obey can cause serious injury.
W-2011-1285
Loosen the exhaust extension clamp (Item 1) [Figure 60-

20-1].
Installation: Tighten clamp to 5.90-7.37 ft.-lbs. (8-10 WARNING

Nm) torque.
Never use machine in atmosphere with explosive
Figure 60-20-2 dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
W-2068-1285
Figure 60-20-3
2
1
N-23202
1
exhaust extension mounting bracket.
N-23200
Slide exhaust extension (Item 2) [Figure 60-20-2] off
muffler and remove from Excavator.
Remove the four bolts (Item 1) [Figure 60-20-3] from the
muffler mount flange.
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SPARK ARRESTOR MUFFLER (CONT’D)
Figure 60-20-4
N-23203
Remove the two bolts (Item 1) [Figure 60-20-4] from the

muffler mounting bracket.
Remove the muffler.
NOTE: Plug the exhaust manifold hole after muffler

removal so no contamination can get into the
engine.
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AIR CLEANER Figure 60-30-3

1
Open the tailgate.
Figure 60-30-1
1
P-16756
Loosen the hose clamp (Item 1) [Figure 60-30-3] and

2 remove hose from the top of the air cleaner.
P-16754 Figure 60-30-4
Loosen the hose clamp (Item 1) [Figure 60-30-1] on the

air intake hose.
NOTE: Plug the intake manifold hole to prevent any

contamination from getting into the engine. 1
Figure 60-30-2
P-16753
1
Remove the two bolts (Item 1) [Figure 60-30-4] fastening
the fuse bracket to the Excavator.
Move the fuse assembly aside to expose the two air

cleaner mounting bolts.
P-16752

back of the air cleaner.
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AIR CLEANER (CONT’D)
Figure 60-30-5
P-16755
Remove the two bolts (Item 1) [Figure 60-30-5].
Remove the air cleaner and intake hose assembly.
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RADIATOR Figure 60-40-2
Removal And Installation 1
Open the tailgate.
WARNING
You can be seriously burned.
W-2070-1285
Drain the hydraulic reservoir. (See Replacing Hydraulic P-16760

Figure 60-40-1 Remove the bolts (Item 1) [Figure 60-40-2] fastening the
relays to the frame.
Figure 60-40-3
1
1
P-16885
Open the radiator drain valve (Item 1) [Figure 60-40-1] P-56068

and drain the coolant into a container.
Loosen the radiator cap from the radiator fill neck. Remove the bolts (Item 1) [Figure 60-40-3] fastening the
fuse bracket assembly to the frame.
Mark the three electrical relays for ease of assembly.
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RADIATOR (CONT’D) Figure 60-40-6
Removal And Installation (Cont’d) 6.27 (159 mm)
Figure 60-40-4
2
1 1 2
1
3
P-16763
2

P-56069 cable to the bracket.
Disconnect the linkage (Item 2) [Figure 60-40-6] from

Remove the tie straps (Item 1) and bolts (Item 2) [Figure the bracket.
60-40-4] fastening the wire harness to the radiator.
Remove the nut and cable clamp (Item 3) [Figure 60-40-
Figure 60-40-5 6] from the engine mount.
Installation: The linkage measurement from bracket to

4 the center of the ball joint is 6.27 inches (159 mm).
1
Figure 60-40-7
1
3
2 2
P-56070
1
Remove the bolts (Item 1) and tie strap (Item 2) [Figure

60-40-5] on the fan guard.
P-16764
Remove the nuts (Item 3) and remove the fan guard
(Item 4) [Figure 60-40-5].
Remove the tubeline (Item 1) [Figure 60-40-7] from the
manifold assembly to the oil cooler. Remove the tubeline
by pulling the tubeline through the radiator bracket from
the engine side of the radiator.
Push the engine speed control cable (Item 2) [Figure 60-

40-7] through the radiator bracket towards the tailgate.
Move the cable to the side.
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Figure 60-40-8 2
1 1
P-16762
Slide the hose clamp (Item 1) [Figure 60-40-10] away

P-16765 from the end of the upper radiator hose.
Remove the upper radiator hose (Item 2) [Figure 60-40-

Remove the tubeline (Item 1) [Figure 60-40-8] from the 10].
oil cooler to the control valve assembly.
Figure 60-40-11
IMPORTANT
damage the system.
I-2003-0888
2
Figure 60-40-9
P-16771

2 from the end of the lower radiator hose.
Remove the lower radiator hose (Item 2) [Figure 60-40-

11].
3 1
P-16761
Remove the tie strap (Item 1) [Figure 60-40-9].
Remove the tubeline (Item 2) and hose (Item 3) [Figure

60-40-9] from the top of the oil cooler.
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Figure 60-40-12
P-56072
Remove the top bolts (Item 1) [Figure 60-40-14]

P-16766 mounting the radiator to the frame.
Figure 60-40-15
Move the wire harness and battery cable down below the
radiator bracket. This allows the radiator and oil cooler
assembly to pass over the harness and cable during
removal [Figure 60-40-12].
1
Figure 60-40-13
P-56073
1 1
Remove the bottom bolt (Item 1) [Figure 60-40-15]

mounting the radiator to the frame.
P-56071
Remove the screws (Item 1) and grill (Item 2) [Figure 60-

40-13].
Remove the grill.
NOTE: Use a magnet or pick to prevent the grill from

dropping and being scratched or damaged.
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Figure 60-40-16
1 1
1 P-11282
Remove the bolts (Item 1) [Figure 60-40-18] from the oil

P-16769 cooler.
Remove the oil cooler from the radiator.

Remove the bottom bolt (Item 1) [Figure 60-40-16]
mounting the radiator to the frame.
Figure 60-40-17
P-56074
Remove the bolts (Item 1) [Figure 60-40-17] on the

underside of the upperstructure.
Slide the radiator and oil cooler assembly out the back of
the Excavator.
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ENGINE COMPONENTS AND TESTING (S/N Engine Compression Checking
223911001 - 223911621, S/N 224011001 - 224013374)
The tools listed will be needed to do the following
Valve Clearance Adjustment procedure:
Adjust the valve clearance with the engine stopped and OEM1074 - Engine Compression Kit
cold.
The engine must be at operating temperature.
Remove the valve cover.
Remove the glow plugs from the engine. (See Glow Plug
Figure 60-50-1 Removal And Installation on Page 60-50-9.)
0.006”-0.007” Figure 60-50-3

(0,15-0,19 mm)
A-2730A
P-33289
The correct valve clearance is 0.006-0.007 inch (0,15-
0,19 mm) [Figure 60-50-1].
Install the compression adapter into the glow plug ports
Make sure the piston is at T.D.C. when making the in the cylinder head [Figure 60-50-3].
adjustment for the valves of the particular cylinder.
Figure 60-50-4
Figure 60-50-2
P-33290
B-5893
Connect the compression gauge [Figure 60-50-4].

Put the correct size feeler gauge between the rocker arm
and valve stem. Turn the adjustment bolt until the Turn the engine with the starter at 200 to 300 RPM. Run
clearance is correct [Figure 60-50-2]. the test for each cylinder two times for 5-10 seconds.
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ENGINE COMPONENTS AND TESTING (S/N Fuel Shut-Off Timer Removal And Installation
223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D) The fuel shut-off timers function is to provide pull in
current to the fuel solenoid for only a short duration. This
Engine Compression Checking (Cont’d)
provides longer fuel solenoid service life and also allows
for more starter cranking power.
The compression of the Kubota D722-B(E) is 412-469
PSI (28-32 Bar) with the allowable limit of 327 PSI (23
Figure 60-50-6
Bar) and no more than 10% difference between
cylinders.
Fuel Shut-Off Solenoid Removal And Installation 2
Figure 60-50-5
1 2
P-16891
3

from the timer module [Figure 60-50-6].
P-16942 Remove the nut (Item 2) [Figure 60-50-6].
Remove the fuel shut-off timer.

Disconnect the wire from the solenoid (Item 1) [Figure
60-50-5].
Remove the solenoid mounting bolts (Item 2) [Figure 60-

50-5].
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ENGINE COMPONENTS AND TESTING (S/N Turn the flywheel by hand to increase the pressure. If the
223911001 - 223911621, S/N 224011001 - 224013374) pressure can not reach the allowable limit, replace the
(CONT’D) injection pump assembly.
Fuel Injection Pump Check
Fuel Tightness of Pump Element
The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on Allowable Limit 2133 PSI (147 Bar)
the performance of the engine.
Measure the time needed to decrease the pressure from
2133 PSI to 1990 PSI (147 to 137 Bar). If the
measurement is less than the allowable limit, replace the
WARNING delivery valve.
Fuel Tightness of Delivery Valve

penetrate skin or eyes, causing serious injury or Allowable Limit 5 seconds
not use your bare hand. Wear safety goggles. If fluid
W-2072-0496

procedure:
MEL1237 - Adapter Fuel Line

MEL1173-1 - Pressure Gauge
To check the discharge pressure at the fuel injection

pump, use the following procedure:
Disconnect a high pressure fuel line from the injection

pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.
Figure 60-50-7
B-8235
Connect the adapter fuel line (Item 1) to the fitting and

connect the pressure gauge (Item 2) [Figure 60-50-7].
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ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-10
223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D)
Fuel Injection Pump Removal And Installation
Clean around the injection pump. 2
Figure 60-50-8
1
3
4
4
P-16948
Disconnect the high pressure lines (Item 1) [Figure 60-

50-10] from the fuel injector and fuel injection pump.
Disconnect the fuel return hose (Item 2) and the fuel feed
1
hose (Item 3) [Figure 60-50-10].
P-16946
Remove the four injection pump mounting bolts (Item 4)

[Figure 60-50-10].
Remove the air intake hose (Item 1) [Figure 60-50-8]
and cap.
Installation: Tighten the nuts to 17-20 ft.-lb. (23-27 N•m)
torque.
Figure 60-50-9
P-16947
Remove the fuel line clamps (Item 1) [Figure 60-50-9].
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ENGINE COMPONENTS AND TESTING (S/N Fuel Injection Pump Timing
223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D) Timing the injection pump is done by changing the
number of shims between the injection pump and the
injection pump mounting surface.
(Cont’d)
Figure 60-50-12
IMPORTANT 1
2
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 60-50-11
P-16950
Remove the fuel line clamp (Item 1) [Figure 60-50-12].
Remove the number one cylinder high pressure line

1 (Item 2) [Figure 60-50-12] from the injection pump.
Remove the exhaust extension tube. (See Removal And

B-14423
Align the pin (Item 1) [Figure 60-50-11] in the control

rack with the slot in the engine block. IMPORTANT
Remove the injection pump. Do not bend the high pressure fuel injection tubes
Installation: When the injection pump is installed, make I-2029-0289
sure the pin (Item 1) [Figure 60-50-11] on the control
rack is correctly installed on the fork lever. If the slot is
not installed correctly, the engine will run over maximum
IMPORTANT
speed and serious damage can result.
NOTE: Make sure the same number shims are

installed under the injection pump. The shims Do not attempt to maintain or adjust unless you are
are used for engine timing. trained and have the correct equipment.
I-2028-0289
Turn the fuel supply lever to the ON position. Install a

short plastic tube in the fitting of the number one cylinder
port. Point the tube vertical.
Turn the engine by hand clockwise until fuel flows out of

the injection pumps number 1 cylinder nozzle. (Install a
tool on the crankshaft at the front of the engine to turn the
engine).
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223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D)
Fuel Injection Pump Timing (Cont’d)
Figure 60-50-13
1
1
N-23203
Figure 60-50-15
P-13132
Install a short plastic tube (Item 1) [Figure 60-50-13] in

the number one cylinder port of the injection pump. The
tube should fit tight in the port and point upward.
1
NOTE: The fuel must be in the tube before attempting
timing.
Move the fuel lever on the injection pump to full fuel

position (or full throttle).
B-14422
Turn the flywheel clockwise slowly until the start of fuel
rise in the plastic tube (Item 1) [Figure 60-50-13].
The correct engine timing for all Kubota D722-B(E)
At this point look at the timing mark (located on the engines is 20-22° B.T.D.C. Add or subtract shims (Item 1)
flywheel) for proper alignment (Item 1) [Figure 60-50- [Figure 60-50-14] to time the engine to 20-22° B.T.D.C.
13]. When the timing mark is aligned as shown the timing The engine is correctly timed when the 20-22° B.T.D.C.
is correct for the injection pump, which is 20-22° B.T.D.C. mark on the flywheel is aligned with the notch in the
timing hole [Figure 60-50-15].
NOTE: Adding or reducing the shim thickness by

0.05 mm retards or advances the injection
timing by approximately 0.5°.
Some problems caused by faulty injector nozzles:
• The engine is hard to start or will not start.

• Rough engine operation at idle.
• The engine will not have full power.
• The engine exhaust smoke is black, white or blue.
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ENGINE COMPONENTS AND TESTING (S/N Remove the high pressure fuel lines.
223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D) Disconnect the return fuel hoses (Item 3) [Figure 60-50-
17].
Fuel Injector Removal And Installation
Remove the retainer nut from the top of the fuel injectors.
Remove the fuel return pipe (Item 4) [Figure 60-50-17].

IMPORTANT Loosen the injector nozzle.
Do not bend the high pressure fuel injection tubes Installation: Tighten the injector nozzle to 36-51 ft.-lbs.
when removing or installing them. (40-69 Nm) torque.
I-2029-0289
Remove the injector nozzle from the cylinder head.
Figure 60-50-16 NOTE: Be sure to replace the copper washer and

nozzle cap anytime new or reconditioned fuel
injectors are installed.
WARNING
1 not use your bare hand. Wear safety goggles. If fluid
P-16946 W-2072-0496
Remove the high pressure fuel line clamps (Item 1)

[Figure 60-50-16].
Figure 60-50-17
1
3
1 4
2
P-16948
Disconnect the high pressure fuel lines from the fuel

injectors (Item 1) [Figure 60-50-17].
Disconnect the fuel lines (Item 2) [Figure 60-50-17] from

the injection pump.
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ENGINE COMPONENTS AND TESTING (S/N Each spacer will change the release pressure by about
223911001 - 223911621, S/N 224011001 - 224013374) 142 PSI (9.8 Bar).
(CONT’D)
Fuel Injector Checking Fuel Injection Pressure. 1991-2133 PSI

(137-147 Bar)
Figure 60-50-19
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
I-2027-0284
The tool listed will be needed to do the following

procedure:
MEL10018 - Injector Nozzle Tester
Figure 60-50-18
A-2513
Assemble the injector nozzle. Connect the nozzle to the

tester with the nozzle down[Figure 60-50-19].
Operate the hand lever at a slow rate and record the

opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove the spacer
(Item 2) [Figure 60-50-18] as needed.
1
When the injector nozzle is assembled, tighten the
nozzle body to 36-51 ft.-lbs. (40-69 Nm) torque.
Check for inside leakage. Operate the hand lever until

2 the pressure 1850 PSI (128 Bar). Keep the nozzle under
this pressure for 10 seconds, check to see if fuel leaks
3 from the nozzle. If fuel leaks, replace the nozzle.
4 (1) Nozzle Holder
5 (2) Adjusting Washer
(3) Nozzle Spring
(4) Push Rod
6
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
7
PI-09981
The nozzle release pressure can be adjusted by adding

or removing washer(s) (Item 2) from the top of the nozzle
spring (Item 3) [Figure 60-50-18].
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ENGINE COMPONENTS AND TESTING (S/N Glow Plug Removal And Installation
223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D)
IMPORTANT
Fuel Injector Checking (Cont’d)
Figure 60-50-20
I-2029-0289
CORRECT WRONG
Figure 60-50-21
A-2621
1
Check that the spray pattern is correct [Figure 60-50-
20]:
1. Fuel does not come out the side of the nozzle. P-16953
2. Drops of fuel are not present at the nozzle.
3. The injector has an even flow coming from the
nozzle. Remove the tie straps (Item 1) [Figure 60-50-21].
Figure 60-50-22
P-16951
Remove the glow plug lead (Item 2) [Figure 60-50-22]

and nut.
320/322 Excavator
594 of 705
ENGINE COMPONENTS AND TESTING (S/N Glow Plug Checking
223911001 - 223911621, S/N 224011001 - 224013374)
(CONT’D) Figure 60-50-24
Glow Plug Removal And Installation (Cont’d)
Figure 60-50-23
B-15856
Connect an ohmmeter to the terminal end of the glow

P-16952 plug, touch the other lead from the ohmmeter to the
heating end of the glow plug [Figure 60-50-24].
Remove the glow plugs (Item 1) [Figure 60-50-23] from
The reading will be approximately 0.9 OHMS. If the
the cylinder head.
resistance is zero OHMS, the glow plug has a short
circuit. If the resistance is infinite, the coil of the glow plug
Installation: Tighten the glow plugs to 6-11 ft.-lb. (8-15
is broken.
N•m) torque.
320/322 Excavator
595 of 705
223911622 & ABOVE, S/N 224013375 & ABOVE)
Valve Clearance Adjustment
NOTE: The valve clearance must be checked and

adjusted when the engine is cold.
Figure 60-51-1
2
P-62023
1
3
With No. 1 piston at TDC (compression) both the intake
and exhaust valves are up. Set both No. 1 valves, No. 2
exhaust valve and No. 3 intake valve. [Figure 60-51-2].
Rotate the flywheel 360°, No. 1 (overlap position). Set

P-62022 No. 2 intake valve and No. 3 exhaust valve. [Figure 60-
51-2].
Remove the cylinder head cover and the glow plugs. Figure 60-51-3
Adjust the valve clearance as follows:

0.0057-0.0073”
Loosen the lock nut (Item 1) [Figure 60-51-1]. (0,145-0,185 mm)
Turn the adjustment screw (Item 2) [Figure 60-51-1] until

the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
60-51-1].
If adjustments are necessary, tighten lock nut before

moving on to the next rocker arm.
A-2730
Make sure the piston is at TDC when adjusting the

clearance at the valves. The correct clearance is 0.0057-
0.0073 inch (0,145-0,185 mm) cold clearance [Figure
60-51-3].
320/322 Excavator
596 of 705
ENGINE COMPONENTS AND TESTING (S/N If the pressures are not within 10% of each other, apply a
223911622 & ABOVE, S/N 224013375 & ABOVE) small amount of oil in the cylinders and retest.
(CONT’D)
If the pressures increase after applying oil, check cylinder
Engine Compression Checking
walls and piston rings.
Figure 60-51-4
If the pressures do not increase after applying oil, check
top clearance, valve clearance and cylinder head.
Fuel Shut-Off Solenoid Removal And Installation
Figure 60-51-5
1
P-62149
3
procedure:
MEL10630 - Engine Compression Test Kit P-59337
Warm the engine.

Disconnect the wire from the solenoid (Item 1) [Figure
60-51-5].
Remove the glow plugs, muffler and air cleaner from the
engine. (If testing through glow plug hole.)
Remove the solenoid mounting bolts (Item 2) [Figure 60-
51-5].
Remove the air cleaner, muffler and all injector nozzles.
(If testing through injector nozzle hole.)
Install the compression adapter in the cylinder head.
Connect the compression gauge to the adapter [Figure

60-51-4].
Ensure the speed control lever is set at the low idle

setting.
Hold fuel shut off lever to no fuel. (shut-off) See arrow,

[Figure 60-51-4]. Shut off solenoid does not need to be
removed.
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder more than twice for 5 to 10
seconds each time and take the average reading. Make
sure you are using a fully charged battery.
The correct compression for the engine is 412-469 PSI

(28-32 bar) with no more than 10% difference between
the cylinders.
320/322 Excavator
597 of 705
ENGINE COMPONENTS AND TESTING (S/N Fuel Injection Pump Check
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D) NOTE: Never try to disassemble the injection pump
assembly. For repairs, you should contact a
Fuel Shut-Off Timer Removal And Installation
Kubota-authorized pump service shop.
The fuel shut-off timers function is to provide pull in
Remove the air cleaner housing. (See Removal And
current to the fuel solenoid for only a short duration. This
provides longer fuel solenoid service life and also allows
for more starter cranking power.
Remove the engine stop solenoid.
Figure 60-51-6
procedure:
2 MEL1237 - Adapter Fuel Line

MEL1173-1 - Pressure Gauge
1 WARNING
P-59336 not use your bare hand. Wear safety goggles. If fluid
Disconnect the wire harness (Item 1) from the timer W-2072-0496
module [Figure 60-51-6].
Remove the nut (Item 2) [Figure 60-51-6]. Figure 60-51-7
Remove the fuel shut-off timer.
1
P-59331
To check the initial discharge pressure, remove a high

pressure tubeline (Item 1) [Figure 60-51-7] from the fuel
injection pump.
Loosen the other end of the tubeline at the injector, so

that the tubeline can be turned away from the fitting.
320/322 Excavator
598 of 705
ENGINE COMPONENTS AND TESTING (S/N Fuel Injection Pump Removal And Installation
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D)
IMPORTANT
Figure 60-51-8
Do not attempt to maintain or adjust unless you are

trained and have the correct equipment.
I-2028-0289
Clean the injection pump and area around it with a

2 3 cleaning solvent or steam cleaning.
1
IMPORTANT
B-8235 Never steam clean or put cold water on an injection
pump while the engine is running or while it is hot. If
Connect a pressure gauge (Item 1) to the long leg of the you do it will cause serious damage to the injection
test tubeline (Item 2) [Figure 60-51-8] and tighten. pump.
I-2135-0997
Connect the short leg of the tubeline to the fitting at the

fuel injection pump (Item 3) [Figure 60-51-8].
Set the speed control lever to the maximum engine

speed position to allow full fuel delivery.
IMPORTANT
Fuel Tighteness of Pump Element Do not bend the high pressure fuel injection tubes
I-2029-0289
With the starter, rotate the engine to increase the
pressure to 1991 PSI (137 bar).
Clean around the injection pump.
If the pressure cannot be reached, replace the pump with
a new one or send to a Kubota-authorized pump service Figure 60-51-9
shop.
Fuel Tightness of Delivery Valve
Manually turn the flywheel to raise the pressure to

approx. 1991 PSI (137 bar). Now turn the flywheel back
about 1/2 turn (to keep the plunger free), and clock the
time taken for the pressure to drop from 1991-1849 PSI
(137-127 bar) .
The pressure should hold at 1991 PSI (137 bar), for at

least 5 seconds or more. 1
If the time is less than the allowable limit, replace the
pump with a new one, or send to a Kubota-authorized P-59335
pump service shop.
Remove the air intake hose (Item 1) [Figure 60-51-9]

and cap.
320/322 Excavator
599 of 705
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D)

(Cont’d)
Figure 60-51-10
B-14423
Align the pin (Item 1) [Figure 60-51-12] in the control

1 rack with the slot in the engine block.
Remove the injection pump.

P-59331
Installation: When the injection pump is installed, make

sure the pin (Item 1) [Figure 60-51-12] on the control
Remove the fuel line clamps (Item 1) [Figure 60-51-10].
rack is correctly installed on the fork lever. If the slot is
not installed correctly, the engine will run over maximum
Figure 60-51-11
speed and serious damage can result.
NOTE: Make sure the same number shims are

installed under the injection pump. The shims
are used for engine timing.
2
3 1 4
P-59334
Disconnect the high pressure lines (Item 1) [Figure 60-

51-11] from the fuel injector and fuel injection pump.
Disconnect the fuel return hose (Item 2) and the fuel feed
hose (Item 3) [Figure 60-51-11].
Remove the four injection pump mounting bolts (Item 4)

[Figure 60-51-11].
Installation: Tighten the pipe retaining nuts to 18-25 ft.-

lb. (25-34 N•m) torque.
320/322 Excavator
600 of 705
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D)
Fuel Injection Pump Timing

1
Timing the injection pump is done by changing the
number of shims between the injection pump and the
injection pump mounting surface.
Figure 60-51-13
1 P-13132
Install a short plastic tube (Item 1) [Figure 60-51-14] in

2
the number one cylinder port of the injection pump. The
tube should fit tight in the port and point upward.
NOTE: The fuel must be in the tube before attempting

timing.
P-59331 Move the fuel lever on the injection pump to full fuel
position (or full throttle).
Remove the fuel line clamp (Item 1) [Figure 60-51-13].
Turn the flywheel counterclockwise (facing the flywheel)
slowly until the start of fuel rise in the plastic tube (Item 1)
Remove the number one cylinder high pressure line
[Figure 60-51-14].
(Item 2) [Figure 60-51-13] from the injection pump.
Figure 60-51-15
Remove the exhaust extension tube. (See Removal And
IMPORTANT
I-2029-0289 1
IMPORTANT N-23203
Do not attempt to maintain or adjust unless you are At this point look at the timing mark (located on the
trained and have the correct equipment. flywheel) for proper alignment (Item 1) [Figure 60-51-
I-2028-0289
15]. When the timing mark is aligned as shown the timing
is correct for the injection pump, which is 19-21° B.T.D.C.
320/322 Excavator
601 of 705
ENGINE COMPONENTS AND TESTING (S/N Fuel Injector Removal And Installation
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D)
IMPORTANT
Fuel Injection Pump Timing (Cont’d)
Figure 60-51-16
I-2029-0289
Figure 60-51-17
B-14422
The correct engine timing for all Kubota D722-E2B 1

engines is 19-21° B.T.D.C. Add or subtract shims (Item 1)
[Figure 60-51-16] to time the engine to 19-21° B.T.D.C.
The engine is correctly timed when the 19-21° B.T.D.C. P-59331
mark on the flywheel is aligned with the notch in the
timing hole [Figure 60-51-16].
Remove the high pressure fuel line clamps (Item 1)
NOTE: Adding or reducing the shim thickness by [Figure 60-51-17].
0.05 mm retards or advances the injection
timing by approximately 0.5°. Figure 60-51-18
1
Some problems caused by faulty injector nozzles:
• The engine is hard to start or will not start.

• Rough engine operation at idle.
• The engine will not have full power. 3
• The engine exhaust smoke is black, white or blue.
1 4
2 P-59332
Disconnect the high pressure fuel lines from the fuel

injectors (Item 1) [Figure 60-51-18].
Disconnect the fuel lines (Item 2) [Figure 60-51-18] from

the injection pump.
320/322 Excavator
602 of 705
ENGINE COMPONENTS AND TESTING (S/N ENGINE COMPONENTS AND TESTING (CONT’D)
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D) Fuel Injector Checking
Fuel Injector Removal And Installation (Cont’d)
Remove the high pressure fuel lines.

IMPORTANT
Disconnect the return fuel hoses (Item 3) [Figure 60-51-
18]. Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
Remove the retainer nut from the top of the fuel injectors. tools.
I-2027-0284
Remove the fuel return pipe (Item 4) [Figure 60-51-18].
Loosen the injector nozzle.
procedure:
Installation: Tighten the injector nozzle to 36-51 ft.-lb.
MEL10018 - Injector Nozzle Tester
(49-69 N•m) torque.
Figure 60-51-19
Remove the injector nozzle from the cylinder head.
NOTE: Be sure to replace the copper washer and

nozzle cap anytime new or reconditioned fuel
injectors are installed.
WARNING
Diesel fuel or hydraulic fluid under pressure can 1
not use your bare hand. Wear safety goggles. If fluid 2
from a physician familiar with this injury. 3
W-2072-0496
4 (1) Nozzle Holder
5 (2) Adjusting Washer
(3) Nozzle Spring
(4) Push Rod
6
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
7
PI-09981
The nozzle release pressure can be adjusted by adding

or removing washer(s) (Item 2) from the top of the nozzle
spring (Item 3) [Figure 60-51-19].
320/322 Excavator
603 of 705
ENGINE COMPONENTS AND TESTING (S/N
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D)
WARNING
Fuel Injector Checking (Cont’d)
Each spacer will change the release pressure by about penetrate skin or eyes, causing serious injury or
34 PSI (2,3 bar). death. Fluid leaks under pressure may not be visible.
Fuel Injection Pressure. 1991-2134 PSI (137-147 bar) not use your bare hand. Wear safety goggles. If fluid
Figure 60-51-20 from a physician familiar with this injury.
W-2072-0496
Figure 60-51-21
CORRECT WRONG
A-2513
Assemble the injector nozzle. Connect the nozzle to the

A-2621
tester with the nozzle down [Figure 60-51-20].
Operate the hand lever at a slow rate and record the Check that the spray pattern is correct [Figure 60-51-
opening pressure. If the pressure is not correct, 21]:
disassemble the nozzle and add or remove the spacer
(Item 2) [Figure 60-51-19] as needed. 1. Fuel does not come out the side of the nozzle.
2. Drops of fuel are not present at the nozzle.
NOTE: When assembling the injector nozzle, tighten 3. The injector has an even flow coming from the
the retainer nut (Item 1) [Figure 60-51-19] to nozzle.
23.5-28.9 ft.-lb. (25,3-28,9 N•m) torque. Any
higher torque will cause slow action of the
valve.
When the injector nozzle is assembled, tighten the

nozzle body to 36-51 ft.-lb. (49-69 N•m) torque.
Check for inside leakage. Operate the hand lever until

the pressure 1849 PSI (127 bar). Keep the nozzle under
this pressure for 10 seconds, check to see if fuel leaks
from the nozzle. If fuel leaks, replace the nozzle.
320/322 Excavator
604 of 705
223911622 & ABOVE, S/N 224013375 & ABOVE)
(CONT’D)
Glow Plug Removal And Installation
IMPORTANT 1
I-2029-0289
Figure 60-51-22
P-59330
Remove the glow plugs (Item 1) [Figure 60-51-24] from

1 the cylinder head.
Installation: Tighten the glow plugs to 6-11 ft.-lb. (8-15

N•m) torque.
Figure 60-51-25
1
P-59328
Remove the tie straps (Item 1) [Figure 60-51-22].
Figure 60-51-23
2 B-15856
Connect an ohmmeter to the terminal end of the glow

1 plug, touch the other lead from the ohmmeter to the
heating end of the glow plug [Figure 60-51-25].
The reading will be approximately 0.9 ohm. If the

resistance is zero ohm, the glow plug has a short circuit.
If the resistance is infinite, the coil of the glow plug is
broken.
P-59329
Remove the glow plug lead (Item 2) [Figure 60-51-23]

and nut.
320/322 Excavator
605 of 705
ENGINE Figure 60-60-1
Removal and Installation 1

4
Open the tailgate. (See Opening And Closing The
Tailgate on Page 10-40-1.)
Remove the muffler. (See Removal And Installation on

Page 60-20-1.)
3
Drain and remove the hydraulic reservoir. (See Removal
and Installation on Page 20-130-1.)
Remove the hydraulic filter bracket assembly. (See 2

Removal and Installation on Page 20-120-1)
P-16757
Drain the cooling system. (See Replacing The Coolant
on Page 10-70-2.)
Remove the bolt (Item 1) and tie strap (Item 2) [Figure
60-60-1] from the fan guard.
IMPORTANT Remove the nuts (Item 3) [Figure 60-60-1] and remove

the fan guard (Item 4) [Figure 60-60-1].
When repairing hydrostatic and hydraulic systems, Figure 60-60-2

damage the system.
I-2003-0888
2
IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be deposed of in an
environmentally safe manner. Some regulations 4
require that certain spills and leaks on the ground 3 1
P-16782
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal.
I-2067-0499 Remove the accumulator (Item 1). Do not remove the
accumulator extension tube (Item 2) [Figure 60-60-2]
from the motor mount and manifold assembly.
Remove the bolt (Item 3) from the engine ground wire

(Item 4) [Figure 60-60-2].
320/322 Excavator
606 of 705
Figure 60-60-3 ENGINE (CONT’D)
Figure 60-60-4
2
2
P-16771 1

from the end of the lower radiator hose. P-16762
Remove the lower radiator hose (Item 2) [Figure 60-60-

3] and cap. Slide the hose clamp (Item 1) [Figure 60-60-4] away
from the end of the upper radiator hose.
Remove the upper radiator hose (Item 2) [Figure 60-60-

4] and cap.
Figure 60-60-5
P-16754

from the end of the air in-take hose.
Remove the air in-take hose (Item 2) [Figure 60-60-5]

and cap.
320/322 Excavator
607 of 705
Figure 60-60-8
2
1 2
P-16754

throttle cable to the bracket. P-16777
Disconnect the throttle linkage (Item 2) [Figure 60-60-6]

from the throttle bracket. Disconnect the red wire (Item 1) [Figure 60-60-8] from
the alternator.
Figure 60-60-7
Disconnect the wire harness connector (Item 2) [Figure
60-60-8] from the alternator.

from the fuel shutoff.
Figure 60-60-9
1
1
P-16776
Remove nut and cable clamp (Item 1) [Figure 60-60-7]

from engine mount bracket.
Move the throttle cable out of the way of the engine.

P-16779

from the oil pressure sending unit on the back side of the
engine.
320/322 Excavator
608 of 705

2
3 Figure 60-60-12
3
1
P-16778
1
Remove the wire harness from the water temperature

sending unit (Item 1) and the glow plugs (Item 2) [Figure P-16781
60-60-10].
Remove the tie straps (Item 3) [Figure 60-60-10]. Disconnect the grounding wire (Item 1) [Figure 60-60-
12] from the starter mounting bolt.
Figure 60-60-11
Figure 60-60-13
P-16774 2 3
P-16780
Disconnect the positive wires from the starter and

separate the two red wires from the protective cover Disconnect the wire connectors (Item 1) [Figure 60-60-
[Figure 60-60-11]. 13] from the three solenoids.

from the fuel level sender wire harness.
Remove the bolt (Item 3) [Figure 60-60-13] fastening the

wire harness clamp to the engine mount.
Move the wire harness out of the way of the engine.
320/322 Excavator
609 of 705
Figure 60-60-16
3
1 2
P-16783
1
Remove and cap the return fuel line (Item 1) [Figure 60-
60-14]. P-16786
Remove and cap the fuel lines (Item 2) [Figure 60-60-

14]. Remove tie strap (Item 1) [Figure 60-60-16].
Remove tie strap (Item 3) [Figure 60-60-14]. Disconnect the wire connector (Item 2) [Figure 60-60-16]
to the fuel level sender.
Figure 60-60-15
Figure 60-60-17
P-16784
1 P-16785
Remove the bolt (Item 1) [Figure 60-60-15] from the fuel

line clamp. Remove the two bolts (Item 1) [Figure 60-60-17] from
the fuel filter bracket.
Remove the fuel filter assembly with fuel lines from the
engine compartment.
320/322 Excavator
610 of 705
Figure 60-60-20
1
P-16787
Disconnect and cap the hose (Item 1) [Figure 60-60-18] 1

on the side of the manifold assembly. P-16788
Figure 60-60-19
Remove the two bolts (Item 1) [Figure 60-60-20]
fastening the manifold assembly to the upperstructure.
1
Figure 60-60-21
2
1
P-16655
Mark and disconnect the four hoses (Item 1) [Figure 60-

60-19] on the backside of the manifold assembly. P-16799
Disconnect the four hoses from the underside of
upperstructure.
Support the end of the manifold assembly with a strap
(Item 1) to the engine [Figure 60-60-21].
NOTE: Manifold assembly and pump hoses (Item 2)

[Figure 60-60-21] can be left assembled
during engine removal.
320/322 Excavator
611 of 705
Figure 60-60-24
1
1
1
2
1 P-16795
2
Figure 60-60-23
P-16793
Connect a chain (Item 1) to the two engine lifting brackets

(Item 2) [Figure 60-60-24].
Figure 60-60-25
P-16796
Remove the six engine mount bolts (Item 1) [Figure 60-

60-22] & [Figure 60-60-23].
NOTE: The engine mounts are left assembled to the

engine and will be removed with the engine. P-16792
Lift and slide the engine out while turning the engine to
provide clearance during engine removal [Figure 60-60-
25].
NOTE: Protect the back of the Excavator canopy/cab

from lifting chain damage during engine
removal.
320/322 Excavator
612 of 705
320/322 Excavator
613 of 705
ENGINE FLYWHEEL Figure 60-70-3
Drain the hydraulic reservoir. (See Replacing Hydraulic

Oil on Page 10-100-2.) 1
Remove the hydraulic gear pump. (See Removal And

Figure 60-70-1
1
1
P-16868
Remove four flywheel housing bolts (Item 1) [Figure 60-

70-3].

Nm) torque.
Remove the flywheel housing.

P-16867
NOTE: Check that the alignment dowels are installed
in the flywheel housing for assembly.
Install a chain hoist to the engine lifting eye to support the
engine (Item 1) [Figure 60-70-1]. Figure 60-70-4
Figure 60-70-2
1
1
P-16860
P-16869
Remove the three bolts (Item 1) [Figure 60-70-4] from
the hydraulic pump coupler.
Remove the mount bolts and nuts (Item 1) [Figure 60-
70-2] from the engine mount. Installation: Apply LOCTITE 242 (Blue) to bolts and
tighten the bolts to 29-37 ft.-lbs. (40-50 Nm) torque.
Remove the hydraulic pump coupler.
320/322 Excavator
614 of 705
ENGINE FLYWHEEL (CONT’D) Flywheel Ring Gear
Remove the five bolts (Item 2) [Figure 60-70-4] from the

flywheel.
WARNING
Installation: Tighten the bolts to 40-43 ft.-lbs. (54-59 Wear safety glasses to prevent eye injury when any
Nm) torque. of the following conditions exist:
• When fluids are under pressure.
Remove the flywheel. • Flying debris or loose material is present.
Hydraulic Pump Coupler • Tools are being used.
W-2019-1285
Figure 60-70-5
The ring gear is installed on the flywheel with an
interference fit. Heat the ring gear enough to expand it
and hit it with a hammer, (evenly) to remove it.
Clean the ring gear mounting surface of the flywheel to

give a smooth fit.
1
Clean the new ring gear and heat it to a temperature of
450-500° F (232-260° C).
Fit the ring gear over the flywheel. Make sure the gear is
1 seated correctly.
P-16860
Remove the three bolts (Item 1) [Figure 60-70-5] from

the hydraulic pump coupler.
Installation: Apply LOCTITE 242 (Blue) to bolts and

tighten the bolts to 29-37 ft.-lbs. (40-50 Nm) torque.
Remove the hydraulic pump coupler.
320/322 Excavator
615 of 705
RECONDITIONING THE ENGINE (S/N 223911001 - Remove the intake and exhaust manifolds.
223911621, S/N 224011001 - 224013374)
Figure 60-80-3
Cylinder Head Removal And Installation
Figure 60-80-1
B-14417
B-14415
Remove the water return hose [Figure 60-80-3].
Remove the bolts (Item 1) [Figure 60-80-1] from the Figure 60-80-4
valve cover and remove the valve cover and gasket.
Installation: Tighten the bolts to 2.9-4.3 ft.-lb. (3,9-5,9

N•m) torque.
Remove the fuel injector nozzles. (See Fuel Injector

Remove the glow plugs. (See Glow Plug Removal And

Remove the alternator. (See Removal And Installation on

Page 50-30-4.)
Figure 60-80-2
B-14490
1 Remove the cylinder head bolts in order of #14 to #1

[Figure 60-80-4].
Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence to 29-33 ft.-lb. (39-44 N•m)
torque.
NOTE: Re-tighten the cylinder head bolts in the

correct sequence after the engine has been
run for 30 minutes.
Remove the cylinder head from the engine block.

B-14416
Remove the rocker arm and shaft assembly (Item 1)

[Figure 60-80-2].
Installation: Tighten the nuts to 7-8 in.-lbs. (9,8-11,3

N•m) torque.
320/322 Excavator
616 of 705
RECONDITIONING THE ENGINE (S/N 223911001 - Cylinder Head Disassembly And Assembly
223911621, S/N 224011001 - 224013374) (CONT’D)
Figure 60-80-6
Cylinder Head Removal And Installation (Cont’d)
Figure 60-80-5
4 B-14418
1
Use a valve spring compressor to compress the valve
spring [Figure 60-80-6].
Installation: Always use a new head gasket and new O- Figure 60-80-7
ring. Make sure the O-ring (Item 1) [Figure 60-80-5] is
seated over the dowel.
1 2 3 4 5 6
B-4122
Remove the valve cap (Item 1) [Figure 60-80-7] and

valve spring collet (Item 2) [Figure 60-80-6] & [Figure
60-80-7].
Remove the valve spring retainer (Item 3) [Figure 60-80-

6] & [Figure 60-80-7] and the spring (Item 4) [Figure 60-
80-6] & [Figure 60-80-7].
Remove the valve (Item 5) [Figure 60-80-6] & [Figure

60-80-7].
320/322 Excavator
617 of 705
RECONDITIONING THE ENGINE (S/N 223911001 - Cylinder Head, Servicing
223911621, S/N 224011001 - 224013374) (CONT’D)
Clean the surface of the cylinder head.
Cylinder Head Disassembly And Assembly (Cont’d)
Figure 60-80-9
Figure 60-80-8
1
A-2735
B-3643
Put a straight edge (Item 1) [Figure 60-80-9] on the

Remove the thermostat cover and thermostat from the cylinder head.
cylinder head. Remove the thermostat housing (Item 1)
[Figure 60-80-8]. NOTE: Do not put the straight edge across
combustion chambers.
Installation: Apply Liquid-Type Gasket (Three Bond
1215 or equivalent) to both sides of the new thermostat Put a feeler gauge (Item 2) [Figure 60-80-9] between the
cover gasket and new thermostat housing gasket. straight edge and the surface of the cylinder head.
Figure 60-80-10
PI-9988
Put the straight edge on the cylinder head's four sides

and two diagonal as shown in figure [Figure 60-80-10].
The maximum distortion of the head surface ± 0.002 in.

(± 0,05 mm). If the measurement is more than the
specification, remove the combustion chambers, then
grind the cylinder head. Grind the same amount of
material from the bottom of the combustion chambers as
was removed from the head.
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RECONDITIONING THE ENGINE (S/N 223911001 - Valve Guide, Checking
223911621, S/N 224011001 - 224013374) (CONT’D)
Remove the valve and spring from the cylinder head.
Cylinder Head Top Clearance (See Cylinder Head Removal And Installation on Page
60-80-1)
Figure 60-80-11
Clean the valve seat and combustion chamber.
2 Figure 60-80-12
1
3
PI-9989
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 60-80-11] being checked at T.D.C. B-3634
Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2) Install the valve into the guide. Measure the valve
[Figure 60-80-11] on the top piston. Use grease to hold recessing with a depth gauge [Figure 60-80-12].
them in position.
Figure 60-80-13
NOTE: Put the solder in position so they do not touch
the valves. 2
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque

in the correct sequence. (See Cylinder Head Removal 1
And Installation on Page 60-80-1).
Turn the crankshaft until the piston exceeds T.D.C.

Remove the cylinder head.
1. Cylinder Head
Remove the solder wire (Item 3) [Figure 60-80-11] and Surface
measure it. 2. Recessing
PI-9990
If the measurement exceeds the specifications, check the
oil clearance of the crank pin journal or the piston pin.
If the measurement exceeds the allowable limit, replace
Top clearance 0.0197-0.0256 in. (0,50-0,65 mm) the valve or cylinder head [Figure 60-80-13].
Recessing 0.004 in. (0,10 mm)

Allowable Limit (Recessing) 0.012 in. (0,3 mm)
Remove the carbon from the valve guide.
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RECONDITIONING THE ENGINE (S/N 223911001 - Figure 60-80-16
223911621, S/N 224011001 - 224013374) (CONT’D)
Valve Guide, Checking (Cont’d)
Figure 60-80-14
PI-9992
Press the used valve guide out of the cylinder head using
the special driver tool [Figure 60-80-16]. (See previous
B-14335 page for tool dimensions.)
Put oil on the outside diameter of the new valve guide.

Measure the valve stem O.D. [Figure 60-80-14]. Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Item 1 & 2) [Figure
Measure the valve guide I.D. [Figure 60-80-14]. 60-80-16], press the new guide until the tools contact the
cylinder head.
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide. Ream the valve guide to the correct specifications.
Valve Guide I.D 0.2366-0.2372 in. (6,01-6,025 mm) NOTE: Valve guide I.D. (Intake and Exhaust) factory
Valve Stem O.D 0.2350-0.2354 in. (5,969-5,980 mm) spec. is .2366-.2372 in. (6,01-6,03 mm)
Clearance Between Valve Stem and Guide
0.0012-0.0022 in. (0,03-0,057 mm)
Allowable Limit 0.0039 in. (0,1 mm)
Figure 60-80-15
7.87” (200 mm)

0.1.57”
3.15"(80mm) (40mm)
0.79”
(20 mm) 0.3921-0.3929”
(9,96-9,98 mm)
0.2165-0.2244”
(5,5-5,7 mm)
0.2” 0.276” 0.71”

(5,0 mm) (7 mm) (18,0 mm)
0.236-0.240” 0.59” 0.417-0.421”

(6,0-6,1 mm) (15,0 mm) (10,6-10,7 mm)
MC-1364
To remove and replace the valve guide, make the driver

tools as shown in figure [Figure 60-80-15].
320/322 Excavator
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223911621, S/N 224011001 - 224013374) (CONT’D)
1 2
Valve And Valve Seat Reconditioning
Figure 60-80-17 15°
0.0835” (2,12 mm)

PI-9995
Check the seat surface and valve face (Item 1) [Figure

60-80-19].
PI-9993
If the seat surface is too wide, use a 15 degree cutter
(Item 2) to get the correct width (Item 3) [Figure 60-80-
Grind the valve face to the correct angle using a valve 19].
refacer [Figure 60-80-17] & [Figure 60-80-19].
Valve Seat Width
Figure 60-80-18
Intake 0.0835 in. (2,12 mm)
Exhaust 0.0835 in. (2,12 mm)
Valve Seat & Face Angle
Intake 45°
Exhaust 45°
15° 45° (30°)
PI-9994
Grind the valve surface in the cylinder head to the correct

angle [Figure 60-80-18].
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RECONDITIONING THE ENGINE (S/N 223911001 - Put the spring on a tester and compress to specified
223911621, S/N 224011001 - 224013374) (CONT’D) length [Figure 60-80-21].
Valve Spring Read the compressed load on the gauge. If the

measurement exceeds allowable limit, replace the
Figure 60-80-20 spring.
Setting Length 1.063 in. (27 mm)

Setting Load 14.6 lbs. (64.7 N)
Allowable Limit (setting load)
12.3 lbs. (54.9 N)
Rocker Arm And Shaft, Checking
Figure 60-80-22
B-3680
2 1
Measure the length of the valve spring. If the
Free Length 1.244 in. (31,6 mm)

Put the spring on a flat surface, place a square on the B-3697

side of the spring [Figure 60-80-20].
Rotate the spring and measure the maximum tilt. If the Measure the rocker arm I.D. (Item 1) [Figure 60-80-22]
measurement is in excess of the allowable limit, replace with an inside micrometer.
the spring.
Measure the rocker shaft O.D. (Item 2) [Figure 60-80-22]
Tilt 0.047 in. (1,2 mm) with an outside micrometer.
Figure 60-80-21 If the clearance exceeds the allowable limit, replace the
rocker arm and measure the clearance again.
If the clearance still exceeds the allowable limit after the

rocker arm is replaced, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm & Shaft

0.0006-0.0018 in. (0,016-0,045 mm)
Rocker Arm Shaft 0.4123-0.4128 in. (10,47-10,48 mm)
Rocker Arm I.D. 0.4134-0.4141 in. (10,5-10,52 mm)
A-2759
320/322 Excavator
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223911621, S/N 224011001 - 224013374) (CONT’D)
Timing Gearcase Cover Removal And Installation
Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 60-50-4.)
1
Remove the cylinder head, rocker arms and push rods.
(See Cylinder Head Removal And Installation on Page
60-80-1)
Figure 60-80-23
2
1
B-14870
Remove the bolt (Item 1) and disconnect the shaft spring

2 (Item 2) [Figure 60-80-25].
Remove the crankshaft pulley bolt.
Installation: Tighten the bolt 72-80 ft.-lb. (98-108 N•m)

torque.
1
Figure 60-80-26
B-14868
Remove the screws (Item 1) from the speed control plate

(Item 2) [Figure 60-80-23].
NOTE: Take care not to damage the spring.
Figure 60-80-24
1
B-14871
Use a puller and remove the crankshaft pulley [Figure

60-80-26].
B-14869
Separate the speed control plate from the engine and

remove the spring (Item 1) [Figure 60-80-24].
Remove the speed control plate.
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223911621, S/N 224011001 - 224013374) (CONT’D)

(Cont’d)
Figure 60-80-27
Oil Seal O-rings
B-3617
Installation: Install three new O-rings and the oil seal

into the timing gear case cover [Figure 60-80-29].
B-14872 Idler Gear And Camshaft Removal And Installation
Figure 60-80-30
When installing the crank shaft pulley, make sure the
alignment marks are aligned [Figure 60-80-27].
Remove the timing gear case cover bolts.

torque.
Figure 60-80-28
1
3 2
Remove the snap ring (Item 1) and collar (Item 2) from

the idler gear shaft (Item 3) [Figure 60-80-30].
B-14873
Remove the timing gear case [Figure 60-80-28].
320/322 Excavator
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223911621, S/N 224011001 - 224013374) (CONT’D)
Idler Gear And Camshaft Removal And Installation

(Cont’d)
Figure 60-80-31
B-3655
Remove the camshaft from the engine block [Figure 60-

80-33].
B-3699 Figure 60-80-34
Remove the idler gear (Item 1) [Figure 60-80-31].
Figure 60-80-32
B-3620
Measure the camshaft bearing in the engine block

[Figure 60-80-34].
B-14874
Installation: Make sure the timing marks are in correct

alignment when installing the timing gears [Figure 60-80-
32].
Align the holes on the camshaft gear with the camshaft

retainer plate bolts.
Remove the bolts.
Installation: Tighten the camshaft retainer bolts to 14-15

ft.-lb. (18-21 N•m) torque.
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RECONDITIONING THE ENGINE (S/N 223911001 - If the measurement is less than the allowable limit,
223911621, S/N 224011001 - 224013374) (CONT’D) replace the camshaft.

Cam Lob Height 1.058 in. (26,88 mm)
(Cont’d)
Figure 60-80-35
Figure 60-80-37
A-2761
A-2760
Measure the camshaft journal [Figure 60-80-35].

Put the camshaft in V-blocks. Install a dial indicator
Calculate the oil clearance. If the clearance exceeds the [Figure 60-80-37].
allowable limit, replace the camshaft.
Turn the camshaft at a slow rate. If the misalignment
Bearing I.D. 1.299-1.300 in. (33,0-33,03 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.2966-1.2972 in. (32,93-32,95 mm)
Camshaft Alignment Allowable Limit
Clearance of Camshaft Journal
0.0004 in. (0,01 mm)
0.002-0.004 in. (0,05-0,09 mm)
Figure 60-80-36
B-5001
Measure the cam lobes at their highest point [Figure 60-

80-36].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - To replace the idler gear bushing, make a driver tool as
223911621, S/N 224011001 - 224013374) (CONT’D) shown in figure [Figure 60-80-39].
Idler Gear and Shaft, Servicing Figure 60-80-40
Figure 60-80-38
0-.008 in
(0-0,2 mm)
PI-10004
PI-10003
Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 60-80-40].
Measure the O.D. of the idler gear shaft [Figure 60-80-
38].
Measure the I.D. of the idler gear bushing [Figure 60-80-

38].
If the clearance exceeds the allowable limit, replace the

bushing.
Idler Gear Shaft 0.786-0.787 in. (19,97-19,98 mm)

O.D.
Idler Gear Shaft I.D. 0.787-0.789 in. (20,00-20,05 mm)
Oil Clearance between Idler Shaft & Gear Bushing
0.0008-0.0033 in. (0,020-0,084 mm)
Figure 60-80-39
0.79” (20 mm)
5.91” (150 mm)

0.98”
(25 mm) 1.18”
(30 mm)
0.862-0.864”
(21,9-21,95)
0.784-0.785”
(19,9-19,95 mm)
MC-1366A
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Fuel Camshaft Removal And Installation
223911621, S/N 224011001 - 224013374) (CONT’D)
Remove the timing gearcase cover. (See Timing
Timing Gears Checking Backlash Gearcase Cover Removal And Installation on Page 60-
80-8)
When the gears are installed, check the backlash of the
gears. Remove the idler gear. (See Cylinder Head Removal And
Figure 60-80-41
Figure 60-80-42
1
PI-10005
B-14342
Install a dial indicator with its tip on a gear tooth [Figure

60-80-41]. Remove the bolt (Item 1) from the retainer plate (Item 2)
[Figure 60-80-42].
Hold one gear while turning the other gear [Figure 60-
80-41]. Installation: Tighten the bolt to 60-72 in.-lbs. (6,8-8,1
N•m) torque.
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is Remove the fuel camshaft retainer plate (Item 2) [Figure
correct, replace the gears. 60-80-42].
Crank Gear & Idler Gear. Remove the fuel camshaft and fork lever assembly at the
0.002-0.005 in. (0,043-0,124 mm) same time.
Cam Gear & Idler Gear
0.002-0.005 in. (0,047-0,12 mm)
Injection Pump Gear & Idler Gear
0.002-0.005 in. (0,046-0,124 mm)
Oil Pump Gear & Crankshaft Cover
0.002-0.005 in. (0,041-0,123 mm)
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Crankshaft Gear Removal And Installation
223911621, S/N 224011001 - 224013374) (CONT’D)
Fuel Camshaft Governor Gearcase Cover Removal And Installation on Page 60-
80-8.)
The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to Remove the idler gear. (See Idler Gear And Camshaft
the engine according to changes in the load. Removal And Installation on Page 60-80-9.)
Figure 60-80-43 Figure 60-80-44
1 4
3
11
10
6 B-3686
9
8 Remove the crankshaft gear with a puller [Figure 60-80-
7
44].
1. Start Spring
2. Governor Spring
Remove the crankshaft key.
3. Fork Lever
4. Fork Lever
5. Fork Lever Shaft
6. Governor Sleeve
7. Retaining Plate
8. Bearing
9. Fuel Camshaft
10. Bearing
11. Snap Ring
B-14875
Disassemble and assemble the governor and fuel

camshaft as shown in figure [Figure 60-80-43].
Check all the parts for wear or damage and replace as

needed.
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Oil Pump, Service
223911621, S/N 224011001 - 224013374) (CONT’D)
Figure 60-80-46
Oil Pump Removal And Installation

Gearcase Cover Removal And Installation on Page 60-
80-8.)
Remove the crankshaft gear.
Figure 60-80-45
B-3616
Measure the clearance between the lobes of the inner

rotor and outer rotor with a feeler gauge [Figure 60-80-
2 46].
Figure 60-80-47
B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 60-80-45].
Remove the oil pump mounting bolts. Remove the oil

Installation: Tighten the oil pump mounting bolts to 60-

72 in.-lbs. (6,9-8,1 N•m) torque.
A-2732
Measure the clearance between the outer rotor and

pump body with a feeler gauge [Figure 60-80-47].
If the clearance exceeds the factory limit, replace the oil

pump rotor assembly.
Clearance Between Inner & Outer Rotor

0.012-0.006 in. (0,03-0,14 mm)
Clearance Between Outer Rotor & Body
0.003-0.006 in. (0,07-0,15 mm)
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Engine Oil Pressure, Checking
223911621, S/N 224011001 - 224013374) (CONT’D)
Remove the oil pressure sensor.
Oil Pump, Service, (Cont’d)
Figure 60-80-49
Figure 60-80-48
B-14876
PI-10009
Install a pressure gauge [Figure 60-80-49].

Put a piece of press gauge on the rotor face [Figure 60-
80-48]. Start the engine and run until it is at operating
temperature.
Install the cover and tighten the bolts.
Measure oil pressure at both idling and rated speeds.
Remove the cover carefully. Measure the width of the
press gauge [Figure 60-80-48]. If the oil pressure is less than the allowable limit, check
the following item:
If the clearance exceeds the factory limit replace the oil
pump rotor assembly. • Engine Oil Insufficient
• Oil Pump Defective
End Clearance 0.003-0.005 in. (0,08-0,14 mm) • Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Oil Clearance
• Foreign Matter in Relief Valve
• Oil Filer Cartridge plugged
At Idle Speed Allowable Limit 14 PSI (1 Bar)

At Rated Speed 28-64 PSI (2-4 Bar)
Allowable Limit 14 PSI (1 Bar)
Installation: After checking engine oil pressure, tighten

oil pressure sensor to 11-15 ft.-lb. (14,7-19,6 N•m).
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RECONDITIONING THE ENGINE (S/N 223911001 - Piston And Connecting Rod Removal And
223911621, S/N 224011001 - 224013374) (CONT’D) Installation
Relief Valve Remove the cylinder head. (See Cylinder Head Removal
And Installation on Page 60-80-1)
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is a ball Remove the top edge from the cylinder bore with a ridge
type. reamer.
Figure 60-80-50 Remove the oil pan.
Figure 60-80-51
1 3
PI-10011
B-14344
Remove the valve seat (Item 1) [Figure 60-80-50], ball
(Item 2) [Figure 60-80-50] and spring (Item 3) [Figure
60-80-50]. Remove the oil pump strainer (Item 1) [Figure 60-80-51].
Check the parts for wear or damage and replace as Turn the flywheel and put a pair of connecting rods at
needed. bottom dead center.
Remove the connecting rod bolts.
Installation: Tighten the connecting rod bolts to 20-22

Figure 60-80-52
PI-10013B PI-10013A
Remove the rod cap and bearing [Figure 60-80-52].
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RECONDITIONING THE ENGINE (S/N 223911001 - Remove the second compression ring (Item 2) [Figure
223911621, S/N 224011001 - 224013374) (CONT’D) 60-80-54].
Piston And Connecting Rod Removal And Remove the oil ring (Item 3) [Figure 60-80-54].
Remove the snap ring (Item 4) and piston pin (Item 5)
Use a hammer handle and push the piston connecting [Figure 60-80-54].
rod assembly out of the cylinder bore [Figure 60-80-52].
Separate the piston (Item 6) from the connecting rod
NOTE: Make sure the pistons are marked so they will (Item 7) [Figure 60-80-54].
be returned to the same cylinder bore.
NOTE: Make sure the piston and rod assembly is
Figure 60-80-53 marked so as not to change the piston rod
assembly with another piston or connecting
rod.
Figure 60-80-55
2
828
1
828
180°
1
A-2903
3
Installation: Make sure the marks (Item 1) on the
connecting rod and bearing are aligned when installing
PI-10015A PI-10015
the bearing cap [Figure 60-80-53].
Repeat the procedure to remove the other piston/ Installation: When installing new rings, assemble the
connecting rod assemblies from the engine block. ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
Figure 60-80-54 joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-80-55].
6 1
4
5 2
B-3621
Remove the first compression ring (Item 1) [Figure 60-

80-54].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Piston And Connecting Rod, Servicing
223911621, S/N 224011001 - 224013374) (CONT’D)
Figure 60-80-57
Piston And Connecting Rod Removal And
Figure 60-80-56
3 4
1
2
A-2733
Measure the I.D. of the piston pin bore in both horizontal

PI-10014B 5 PI-10014A and vertical direction [Figure 60-80-57].

Installation: When reassembling, align the marks (Item the piston.
1) on the connecting rod and piston (Item 2). Heat the
piston in oil to 176° F (80° C) for 10 to 15 minutes and tap
Piston Pin Bore I.D. 0.7874-0.7879 in.
the piston pin into position. Place the piston rings so that
there are gaps every 120° (Item 3, 4 & 5) [Figure 60-80- (20,0-20,013 mm)
56] with no gap facing the piston pin in the cylinder. Allowable Limit 0.789 in. (20,05 mm)
Figure 60-80-58
1
B-3633
Measure the O.D. of the piston pin (Item 1) [Figure 60-

80-58].
Measure the I.D. of the connecting rod small end (Item 2)

[Figure 60-80-58].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Installation: Clean the small end bushing and bore. Put
223911621, S/N 224011001 - 224013374) (CONT’D) oil on the bushing and press into the connecting rod until
it is flush [Figure 60-80-60].
Piston And Connecting Rod, Servicing (Cont’d)
Figure 60-80-61
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.7875-0.7878 in. (20,002-20,011 mm)

Bushing I.D. 0.7884-0.7890 in. (20,025-20,04 mm)
Oil Clearance between Piston Pin & Bushing
0.0006-0.0015 in. (0,014-0,038 mm)
Figure 60-80-59
B-3622
0.79” (20 mm)
0.98” 5.7” (145 mm) Install a new piston ring into the lower part of the cylinder
(25 mm) 0.98” bore. Measure the ring gap with a feeler gauge [Figure
(25 mm) 60-80-61].
If the gap exceeds the allowable limit, replace the piston

ring.
0.8622-0.8642”
(21,9-21,96 mm) 0.7835-0.7854” Top Compression Ring & Oil Ring
(19,9-19,95 mm)
0.006-0.012 in. (0,15-0,30 mm)
MC-1366A Second Compression Ring
0.012-0.018 in. (0,30-0,45 mm)
To replace the connecting rod small end bushing, make a Allowable Limit 0.047 in. (1,2 mm)
driver tool as shown in figure [Figure 60-80-59].
Figure 60-80-60
Removing Installing
PI-10016
Use a press and special driver tool to remove the small

end bushing [Figure 60-80-60].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Connecting Rod Alignment
223911621, S/N 224011001 - 224013374) (CONT’D)
NOTE: The small end bushing is the basis of this
Piston And Connecting Rod, Servicing (Cont’d) check, check the bushing for wear before
doing this check.
Figure 60-80-62
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 60-80-63
B-14475
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler
gauge [Figure 60-80-62].
Second ring 0.0035-0.0043 in. (0,09-0,12 mm)

Oil ring 0.0016-0.0031 in. (0,04-0,08 mm) B-4067
Allowable limit second ring

0.0059 in. (0,15 mm) If the gauge does not fit squarely against the face place,
Allowable limit oil ring measure the space between the gauge and face plate
[Figure 60-80-63].
0.0059 in. (0,15 mm)
If the clearance exceeds the allowable limit, replace the the connecting rod.
piston.
Rod Alignment Allowable Limit
0.002 in.(0,05 mm)
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RECONDITIONING THE ENGINE (S/N 223911001 - Installation: When installing the cover (Item 1), make
223911621, S/N 224011001 - 224013374)(CONT’D) sure the casting mark (Item 2) [Figure 60-80-65] is in the
up position. Apply Liquid-Type Gasket (Three Bond 1215
Crankshaft And Bearings Removal And Installation or equivalent) to both sides of the new gasket.
Remove the piston and connecting rod assemblies. (See Figure 60-80-66
Piston And Connecting Rod Removal And Installation on
Page 60-80-17.)
Remove the engine flywheel. (See Cylinder Head

Remove the bolts which fasten the bearing case cover to

the block.
Installation: Tighten the bearing case cover bolts to 7-8

ft.-lb. (10-11 N•m) torque. Tighten bolts with even force
on the diagonal line.
Figure 60-80-64
B-9565
Before removing the crankshaft/main bearings, check the

end play. Install a dial indicator. Measure the end play by
moving the crankshaft back and forth [Figure 60-80-66].

the thrust washers.
End Play 0.006-0.012 in. (0,15-0,31 mm)

B-3648 Figure 60-80-67
Install two bolts into the bearing case cover and pull the
cover out [Figure 60-80-64].
2
Figure 60-80-65
1
B-14346
1
Remove the main bearing case bolt (Item 1) [Figure 60-

80-67].
B-14877 Installation: Align the bearing case hole (Item 2) [Figure

60-80-67] with the hole in the block. Put oil on the bolt
threads and tighten to 20-22 ft.-lb. (27-30 N•m) torque.
320/322 Excavator
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223911621, S/N 224011001 - 224013374) (CONT’D)
Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 60-80-68
PI-10021
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [Figure 60-80-70]. Be sure the
B-14878 thrust washer with its oil grooves face outward.
Remove the crankshaft/main bearing assembly from the

engine block [Figure 60-80-68].
Mark the bearing case halves for correct installation.
Figure 60-80-69
B-4092
Remove the two bearing case bolts [Figure 60-80-69].
Remove the bearing case and bearing.
Installation: Tighten the bearing case bolts to 9-12 ft.-lb.

(13-16 N•m) torque.
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223911621, S/N 224011001 - 224013374) (CONT’D)
Crankshaft And Bearings, Servicing
Figure 60-80-71
A-2716
Measure the crankpin O.D. [Figure 60-80-73].
A-2763 Calculate the oil clearance.
Crankpin Bearing I.D.

Put the crankshaft on V-blocks. Install a dial indicator on
the center journal [Figure 60-80-71]. 1.338-1.340 in. (33,99 -34,04 mm)
Crankpin O.D. 1.337-1.338 in. (33,96-33,98 mm)
Turn the crankshaft at a slow rate.
Oil Clearance 0.0008-0.0032 in.(0,019-0,081 mm)
If the misalignment exceeds the allowable limit, replace Allowable limit 0.0059 in. (0,15 mm)
the crankshaft.
Figure 60-80-74
Alignment 0.0004 in. (0,01 mm)
Tighten the connecting rod cap bolts 20-22 ft.-lb. (27-30

N•m) torque.
Figure 60-80-72
1
PI-10024B
120°
A-2727
Measure the crankpin bearing I.D. [Figure 60-80-72].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - If the clearance exceeds the allowable limit, replace the
223911621, S/N 224011001 - 224013374) (CONT’D) crankshaft bearing.
Crankshaft And Bearings, Servicing (Cont’d)

Crankshaft Journal O.D. (Flywheel side)
Figure 60-80-75 1.7297-1.7303 in. (43,93-43,95 mm)
Bearing I.D. 1.7317-1.7333 in. (43,98-44,03 mm)
5.12”
(130 mm) Crankshaft Journal O.D. (Middle)
1.5722-1.5728 in. (39,93-39,95 mm)
Bearing I.D. 1.5742-1.5758 in. (39,98-40,03 mm)
Crankshaft journal O.D. (Front)
0.79” 1.5709-1.5728”
(20 mm) (39,90-39,95mm)
1.5722-1.5728 in. (39,93-39,95 mm)
Bearing I.D. 1.5742-1.5758 in. (39,98-40,03 mm)
Oil Clearance 0.001-0.004 in. (0,034-0,092 mm)
1.7283-1.7303” 0.87”
(43.90-43.95mm) (22 mm)
0.39”
(10 mm) B-14879
Remove the bearing (Item 1) [Figure 60-80-74] from the

front of the engine block with the removal tool shown in
[Figure 60-80-75].
Installation: Clean the new bearing and bore and apply

oil to them. Install the new bearing with the installation
driver tool [Figure 60-80-74].
Clean the crankshaft journal and bearing. Put a strip of

press gauge on the center journal.
Install the main bearing case halves and tighten the bolts
to 9-12 ft.-lb. (12,7-15,7 N•m) torque. Remove the
bearing case halves.
Figure 60-80-76
PI-10025
Measure the flattened press gauge [Figure 60-80-76].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911001 - Water Pump Removal And Installation
223911621, S/N 224011001 - 224013374) (CONT’D)
Drain the cooling system.
Cylinder Bore, Checking
Remove the radiator. (See Removal And Installation on
Figure 60-80-77 Page 60-40-1.)
Remove the alternator belt.
Remove the fan.
Figure 60-80-79
3
B-10073
5
Check the inside diameter of the cylinder line [Figure 60-
80-77].
Figure 60-80-78 2
1 B-14859A
Remove the water pump bolts (Item 1) [Figure 60-80-

79].
Remove the water pump.
Installation: Always use a new gasket (Item 2) [Figure

60-80-79] when installing the water pump and apply
Liquid-Type Gasket (Three Bond 1215 or equivalent) to
both sides of new gasket.
Water Pump Disassembly And Assembly
A-2717A Put the water pump in a vise.
Remove the pulley.

To find the maximum wear check the inside diameter in
six different locations [Figure 60-80-78].
pulley side of the water pump. Press out the shaft with
When the cylinder bore is not within specifications, bore
the impeller on it.
and hone the cylinder for an oversize piston.
Remove the seal (Item 4) and impeller (Item 5) [Figure
Cylinder Bore I.D. 2.638-2.639 in. (67,0-67,02 mm) 60-80-79].
Install a new seal when assembling the water pump.
NOTE: Make sure you use the correct oversize
pistons and rings.
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Remove the rocker arm bracket screws (Item 1) and
ABOVE, S/N 224013375 & ABOVE) shaft assembly (Item 2) [Figure 60-81-2].
Cylinder Head Removal And Installation Installation: Tighten the nuts to 7-8 in.-lb. (9,8-11,3 N•m)
torque.
Figure 60-81-1
Remove the pushrods (Item 3) [Figure 60-81-2].
2 3
Remove the intake and exhaust manifolds.
Figure 60-81-3
1
1
2
P-62177
Remove the breather hose (Item 1) [Figure 60-81-1].
Remove the bolts (Item 2) from the valve cover and P-62174
remove the valve cover and gasket (Item 3) [Figure 60-
81-1].
Remove the water return hose [Figure 60-81-3].
torque. Gradually tighten center bolts before the end Figure 60-81-4
bolts to avoid cracking valve cover.
Remove the fuel injector nozzles. (See Fuel Injector

Remove the glow plugs. (See Glow Plug Removal And

Remove the alternator. (See Removal And Installation on

Page 50-30-4.)
Figure 60-81-2
2
1
B-14490
Remove the cylinder head bolts in order of #14 to #1

[Figure 60-81-4].
Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence of #1 to #14 to 28-31 ft.-lb. (38-
42 N•m) torque.
NOTE: Re-tighten the cylinder head bolts in the

correct sequence after the engine has been
run for 30 minutes.
3 P-62176
Remove the cylinder head from the engine block.
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Cylinder Head Disassembly And Assembly
ABOVE, S/N 224013375 & ABOVE) (CONT’D)
Figure 60-81-6
Cylinder Head Removal And Installation (Cont’d)
Figure 60-81-5
4 B-14418
1
P-62175 Use a valve spring compressor to compress the valve
Installation: Always use a new head gasket and new O- Figure 60-81-7
ring. Make sure the O-ring (Item 1) [Figure 60-81-5] is
seated over the dowel.
1 2 3 4 5 6
B-4122
Remove the valve cap (Item 1) [Figure 60-81-7] and

valve spring collet (Item 2) [Figure 60-81-6] & [Figure
60-81-7].
Remove the valve spring retainer (Item 3) [Figure 60-81-

6] & [Figure 60-81-7] and the spring (Item 4) [Figure 60-
81-6] & [Figure 60-81-7].
Remove the valve (Item 5) [Figure 60-81-6] & [Figure

60-81-7].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Cylinder Head, Servicing
Figure 60-81-9
Cylinder Head Disassembly And Assembly (Cont’d)
Figure 60-81-8
1
A-2735
1
B-3643 Clean the surface of the cylinder head.
Put a straight edge (Item 1) [Figure 60-81-9] on the

Remove the thermostat cover and thermostat from the cylinder head.
cylinder head. Remove the thermostat housing (Item 1)
[Figure 60-81-8]. NOTE: Do not put the straight edge across
combustion chambers.
Installation: Apply Liquid-Type Gasket (Three Bond
1215 or equivalent) to both sides of the new thermostat Put a feeler gauge (Item 2) [Figure 60-81-9] between the
cover gasket and new thermostat housing gasket. straight edge and the surface of the cylinder head.
Figure 60-81-10
PI-9988
Put the straight edge on the cylinder head's four sides

and two diagonal as shown in figure [Figure 60-81-10].
The maximum distortion of the head surface ± 0.002 in.

(± 0,05 mm). If the measurement is more than the
specification, remove the combustion chambers, then
grind the cylinder head. Grind the same amount of
material from the bottom of the combustion chambers as
was removed from the head.
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RECONDITIONING THE ENGINE (S/N 223911622 & Figure 60-81-12
Cylinder Head Top Clearance
Figure 60-81-11
B-3634
1
3 Install the valve into the guide. Measure the valve
recessing with a depth gauge [Figure 60-81-12].
PI-9989
Figure 60-81-13
Install the cylinder head gasket. Put the piston (Item 1) 2

[Figure 60-81-11] being checked at T.D.C.
Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)

[Figure 60-81-11] on the top piston. Use grease to hold
them in position. 1
NOTE: Put the solder in position so they do not touch

the valves.
Turn the piston to bottom dead center. 1. Cylinder Head

Surface
Install the cylinder head and tighten to the correct torque 2. Recessing
in the correct sequence. (See Cylinder Head Removal
PI-9990
Turn the crankshaft until the piston exceeds T.D.C. If the measurement exceeds the allowable limit, replace
Remove the cylinder head. the valve or cylinder head [Figure 60-81-13].
Remove the solder wire (Item 3) [Figure 60-81-11] and Recessing 0.004 in. (0,10 mm)
measure it.
Allowable Limit (Recessing) 0.012 in. (0,30 mm)
If the measurement exceeds the specifications, check the
oil clearance of the crank pin journal or the piston pin. Remove the carbon from the valve guide.
Top clearance 0.0197-0.0276 in. (0,50-0,70 mm)
Valve Guide, Checking
Remove the valve and spring from the cylinder head.

60-51-1.)
Clean the valve seat and combustion chamber.
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Valve Guide, Checking (Cont’d)
Figure 60-81-14
PI-9992
Press the used valve guide out of the cylinder head using
the special driver tool [Figure 60-81-16]. (See previous
B-14335 page for tool dimensions.)
Put oil on the outside diameter of the new valve guide.

Measure the valve stem O.D. [Figure 60-81-14]. Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Item 1 & 2) [Figure
Measure the valve guide I.D. [Figure 60-81-14]. 60-81-16], press the new guide until the tools contact the
cylinder head.
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide. Ream the valve guide to the correct specifications.
Valve Guide I.D 0.2366-0.2372 in. (6,01-6,025 mm) NOTE: Valve guide I.D. (Intake and Exhaust) factory
Valve Stem O.D 0.2350-0.2354 in. (5,968-5,980 mm) spec. is .2366-.2372 in. (6,01-6,025 mm)
Clearance Between Valve Stem and Guide
0.0012-0.0022 in. (0,03-0,057 mm)
Figure 60-81-15
7.87” (200 mm)

0.1.57”
3.15"(80mm) (40mm)
0.79”
(20 mm) 0.3921-0.3929”
(9,96-9,98 mm)
0.2165-0.2244”
(5,5-5,7 mm)
0.2” 0.276” 0.71”

(5,0 mm) (7 mm) (18,0 mm)
0.236-0.240” 0.59” 0.417-0.421”

(6,0-6,1 mm) (15,0 mm) (10,6-10,7 mm)
MC-1364
To remove and replace the valve guide, make the driver

tools as shown in figure [Figure 60-81-15].
320/322 Excavator
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1 2
Valve And Valve Seat Reconditioning
Figure 60-81-17 15°
0.0835” (2,12 mm)

PI-9995
Check the seat surface and valve face (Item 1) [Figure

60-81-19].
PI-9993
If the seat surface is too wide, use a 15 degree cutter
(Item 2) to get the correct width (Item 3) [Figure 60-81-
Grind the valve face to the correct angle using a valve 19].
refacer [Figure 60-81-17] & [Figure 60-81-19].
Valve Seat Width
Figure 60-81-18
Intake 0.0835 in. (2,12 mm)
Exhaust 0.0835 in. (2,12 mm)
Valve Seat & Face Angle
Intake 45°
Exhaust 45°
15° 45° (30°)
PI-9994
Grind the valve surface in the cylinder head to the correct

angle [Figure 60-81-18].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Put the spring on a tester and compress to specified
ABOVE, S/N 224013375 & ABOVE) (CONT’D) length [Figure 60-81-21].
Valve Spring Read the compressed load on the gauge. If the

measurement exceeds allowable limit, replace the
Figure 60-81-20 spring.
Setting Length 1.063 in. (27 mm)

Setting Load 14.6 lb. (64.7 N)
Allowable Limit (setting load)
12.3 lb. (54.9 N)
Rocker Arm And Shaft, Checking
Figure 60-81-22
B-3680
2 1
Measure the length of the valve spring. If the
Free Length 1.232 - 1.252 in. (31,3 - 31,8 mm)

Put the spring on a flat surface, place a square on the B-3697

side of the spring [Figure 60-81-20].
Rotate the spring and measure the maximum tilt. If the Measure the rocker arm I.D. (Item 1) [Figure 60-81-22]
measurement is in excess of the allowable limit, replace with an inside micrometer.
the spring.
Measure the rocker shaft O.D. (Item 2) [Figure 60-81-22]
Tilt 0.047 in. (1,2 mm) with an outside micrometer.
Figure 60-81-21 If the clearance exceeds the allowable limit, replace the
rocker arm and measure the clearance again.
If the clearance still exceeds the allowable limit after the

rocker arm is replaced, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm & Shaft

0.0006-0.0018 in. (0,016-0,045 mm)
Rocker Arm Shaft 0.4123-0.4128 in. (10,47-10,48 mm)
Rocker Arm I.D. 0.4134-0.4141 in. (10,5-10,52 mm)
A-2759
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Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 60-51-4.)
1
Figure 60-81-23
2 B-14870
Remove the bolt (Item 1) and disconnect the shaft spring

(Item 2) [Figure 60-81-25].
1 Figure 60-81-26
B-14868
Remove the cylinder head, rocker arms and push rods.

60-80-1.)
Remove the screws (Item 1) from the speed control plate

(Item 2) [Figure 60-81-23].
NOTE: Take care not to damage the spring.
Figure 60-81-24
B-14871
Remove the crankshaft pulley bolt.
1 Installation: Tighten the bolt 72-80 ft.-lb. (98-108 N•m)

torque.
Use a puller and remove the crankshaft pulley [Figure

60-81-26].
B-14869
Separate the speed control plate from the engine and

remove the spring (Item 1) [Figure 60-81-24].
Remove the speed control plate.
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(Cont’d)
Figure 60-81-27
Oil Seal O-rings
B-3617
Installation: Install three new O-rings and the oil seal

into the timing gear case cover [Figure 60-81-29].
B-14872 Idler Gear And Camshaft Removal And Installation
Figure 60-81-30
When installing the crank shaft pulley, make sure the
alignment marks are aligned [Figure 60-81-27].
Figure 60-81-28
3 2
Remove the snap ring (Item 1) and collar (Item 2) from

B-14873 the idler gear shaft (Item 3) [Figure 60-81-30].
Remove the timing gear case cover bolts.

torque.
Remove the timing gear case [Figure 60-81-28].
320/322 Excavator
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(Cont’d)
Figure 60-81-31
B-3655
2 Remove the camshaft from the engine block [Figure 60-

81-33].
B-3699 Installation: Tighten the camshaft retainer bolts to 14-15

Remove the idler gear (Item 1) [Figure 60-81-31]. Figure 60-81-34
Remove idler gear mounting screws (Item 2) [Figure 60-

81-31].
Installation: Tighten screws to 7-8 ft.-lb. (10-11 N•m)

torque.
Figure 60-81-32
B-3620
Measure the camshaft bearing in the engine block

[Figure 60-81-34].
B-14874
Installation: Make sure the timing marks are in correct

alignment when installing the timing gears [Figure 60-81-
32].
Align the holes on the camshaft gear with the camshaft

retainer plate bolts.
Remove the bolts.
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & If the measurement is less than the allowable limit,
ABOVE, S/N 224013375 & ABOVE) (CONT’D) replace the camshaft.

Cam Lob Height 1.058 in. (26,88 mm)
(Cont’d)
Figure 60-81-35
Figure 60-81-37
A-2761
A-2760
Measure the camshaft journal [Figure 60-81-35].

Put the camshaft in V-blocks. Install a dial indicator
Calculate the oil clearance. If the clearance exceeds the [Figure 60-81-37].
allowable limit, replace the camshaft.
Turn the camshaft at a slow rate. If the misalignment
Bearing I.D. 1.299-1.300 in. (33,00-33,03 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.2966-1.2972 in. (32,93-32,95 mm)
Camshaft Alignment Allowable Limit
Clearance of Camshaft Journal
0.0004 in. (0,01 mm)
0.002-0.004 in. (0,05-0,09 mm)
Figure 60-81-36
B-5001
Measure the cam lobes at their highest point [Figure 60-

81-36].
320/322 Excavator
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Idler Gear and Shaft, Servicing

0.79” (20 mm)
Figure 60-81-38
5.91” (150 mm)
0.98”
(25 mm) 1.18”
(30 mm)
0.862-0.864”
(21,9-21,95)
0.784-0.785”
(19,9-19,95 mm)
MC-1366A
To replace the idler gear bushing, make a driver tool as

shown in figure [Figure 60-81-39].
PI-10003
Figure 60-81-40
Measure the O.D. of the idler gear shaft [Figure 60-81-

38].
Measure the I.D. of the idler gear bushing [Figure 60-81-

38].
If the clearance exceeds the allowable limit, replace the

bushing.
Idler Gear Shaft 0.786-0.787 in. (19,97-19,98 mm)

O.D.
Idler Gear Shaft I.D. 0.787-0.789 in. (20,00-20,05 mm) 0-.008 in
(0-0,2 mm)
Oil Clearance between Idler Shaft & Gear Bushing
PI-10004
0.0008-0.0033 in. (0,020-0,084 mm)
Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 60-81-40].
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Fuel Camshaft Removal And Installation
Timing Gears Checking Backlash Gearcase Cover Removal And Installation on Page 60-
80-8.)
Figure 60-81-41
Remove the idler gear. (See Cylinder Head Removal And
Figure 60-81-42
PI-10005
1
When the gears are installed, check the backlash of the
gears.
B-14342
Install a dial indicator with its tip on a gear tooth [Figure

60-81-41]. Remove the bolt (Item 1) from the retainer plate (Item 2)
[Figure 60-81-42].
Hold one gear while turning the other gear [Figure 60-
81-41]. Installation: Tighten the bolt to 60-72 in.-lb. (6,8-8,1
N•m) torque.
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is Remove the fuel camshaft retainer plate (Item 2) [Figure
correct, replace the gears. 60-81-42].
Crank Gear & Idler Gear. Remove the fuel camshaft and fork lever assembly at the
0.002-0.005 in. (0,043-0,124 mm) same time.
Cam Gear & Idler Gear
0.002-0.005 in. (0,047-0,12 mm)
Injection Pump Gear & Idler Gear
0.002-0.005 in. (0,046-0,124 mm)
Oil Pump Gear & Crankshaft Cover
0.002-0.005 in. (0,041-0,123 mm)
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Crankshaft Gear Removal And Installation
Fuel Camshaft Governor Gearcase Cover Removal And Installation on Page 60-
80-8.)
The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to Remove the idler gear. (See Idler Gear And Camshaft
the engine according to changes in the load. Removal And Installation on Page 60-80-9.)
Figure 60-81-43 Figure 60-81-44
1 4
3
11
10
6 B-3686
9
8
7 Remove the crankshaft gear with a puller [Figure 60-81-
1. Start Spring 44].
2. Governor Spring
3. Fork Lever Remove the crankshaft key.
4. Fork Lever
5. Fork Lever Shaft
6. Governor Sleeve
7. Retaining Plate
8. Bearing
9. Fuel Camshaft
10. Bearing
11. Snap Ring
B-14875
Disassemble and assemble the governor and fuel

camshaft as shown in [Figure 60-81-43].
Check all the parts for wear or damage and replace as

needed.
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Oil Pump, Service
Figure 60-81-46
Oil Pump Removal And Installation

Gearcase Cover Removal And Installation on Page 60-
80-8.)
Remove the crankshaft gear.
Figure 60-81-45
B-3616
Measure the clearance between the lobes of the inner

rotor and outer rotor with a feeler gauge [Figure 60-81-
2 46].
Figure 60-81-47
B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 60-81-45].
Remove the oil pump mounting bolts. Remove the oil

Installation: Tighten the oil pump mounting bolts to 60-

72 in.-lb. (6,9-8,1 N•m) torque.
A-2732
Measure the clearance between the outer rotor and

pump body with a feeler gauge [Figure 60-81-47].
If the clearance exceeds the factory limit, replace the oil

pump rotor assembly.
Clearance Between Inner & Outer Rotor

0.001-0.006 in. (0,03-0,14 mm)
Clearance Between Outer Rotor & Body
0.003-0.006 in. (0,07-0,15 mm)
320/322 Excavator
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RECONDITIONING THE ENGINE (S/N 223911622 & Engine Oil Pressure, Checking
Figure 60-81-49
Oil Pump, Service, (Cont’d)
Figure 60-81-48
B-14876
PI-10009 Remove the oil pressure sensor.
Install a pressure gauge [Figure 60-81-49].

Put a piece of press gauge on the rotor face [Figure 60-
81-48]. Start the engine and run until it is at operating
temperature.
Install the cover and tighten the bolts.
Measure oil pressure at both idling and rated speeds.
Remove the cover carefully. Measure the width of the
press gauge [Figure 60-81-48]. If the oil pressure is less than the allowable limit, check
the following item:
If the clearance exceeds the factory limit replace the oil
pump rotor assembly. • Engine Oil Insufficient
• Oil Pump Defective
End Clearance 0.003-0.005 in. (0,08-0,14 mm) • Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Oil Clearance
• Foreign Matter in Relief Valve
• Oil Filer Cartridge plugged
At Idle Speed Allowable Limit 7 PSI (0,48 bar)

At Rated Speed 28-64 PSI (2-4 bar)
Allowable Limit 21 PSI (1 bar)
Installation: After checking engine oil pressure, tighten

oil pressure sensor to 11-15 ft.-lb. (15-20 N•m).
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RECONDITIONING THE ENGINE (S/N 223911622 & Piston And Connecting Rod Removal And
ABOVE, S/N 224013375 & ABOVE) (CONT’D) Installation
Relief Valve Remove the cylinder head. (See Cylinder Head Removal
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is a ball Remove the top edge from the cylinder bore with a ridge
type. reamer.
Figure 60-81-50 Remove the oil pan.
Figure 60-81-51
3 2
1
1
4
C-3438
P-62179
Remove the valve seat (Item 1) [Figure 60-81-50], ball
(Item 2) [Figure 60-81-50] and spring (Item 3) [Figure
60-81-50]. Remove the oil pump strainer (Item 1) [Figure 60-81-51].
Check the parts for wear or damage and replace as Figure 60-81-52
needed.
2
Spring Free Length 1
Factory Spec 1.26 in. (32 mm)
Allowable Limit 1.10 in. (28 mm)
Installation: Tighten the oil fiter adapter (Item 4) [Figure

60-81-50] to 29-36 ft.-lb. (39-49 N•m) torque.
P-62187
Installation: Check o-ring (Item 1) on strainer and use

hole 3 (Item 2) [Figure 60-81-52] when installing strainer.
Turn the flywheel and put a pair of connecting rods at

bottom dead center.
Remove the connecting rod bolts.
Installation: Tighten the connecting rod bolts to 20-22

320/322 Excavator
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Piston And Connecting Rod Removal And 6 1

Installation (Cont’d) 4
Figure 60-81-53 5 2
B-3621
Remove the first compression ring (Item 1) [Figure 60-

81-55].
PI-10013 Remove the second compression ring (Item 2) [Figure

60-81-55].
Remove the rod cap and bearing [Figure 60-81-53]. Remove the oil ring (Item 3) [Figure 60-81-55].
Use a hammer handle and push the piston connecting Remove the snap ring (Item 4) and piston pin (Item 5)
rod assembly out of the cylinder bore [Figure 60-81-53]. [Figure 60-81-55].
NOTE: Make sure the pistons are marked so they will Separate the piston (Item 6) from the connecting rod
be returned to the same cylinder bore. (Item 7) [Figure 60-81-55].
Figure 60-81-54 NOTE: Make sure the piston and rod assembly is
marked so as not to change the piston rod
assembly with another piston or connecting
rod.
Figure 60-81-56
2
828
1
828
180°
1
A-2903
3
Installation: Make sure the marks (Item 1) on the
connecting rod and bearing are aligned when installing
the bearing cap [Figure 60-81-54]. PI-10015A PI-10015
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block. Installation: When installing new rings, assemble the
ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-81-56].
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RECONDITIONING THE ENGINE (S/N 223911622 & Piston And Connecting Rod, Servicing
Figure 60-81-58
Piston And Connecting Rod Removal And
Figure 60-81-57
3 4
1
2
A-2733
Measure the I.D. of the piston pin bore in both horizontal

PI-10014B 5 PI-10014A and vertical direction [Figure 60-81-58].

Installation: When reassembling, align the marks (Item the piston.
1) on the connecting rod and piston (Item 2). Heat the
piston in oil to 176° F (80° C) for 10 to 15 minutes and tap
Piston Pin Bore I.D. 0.7874-0.7879 in.
the piston pin into position. Place the piston rings so that
there are gaps every 120° (Items 3, 4 & 5) [Figure 60-81- (20,00-20,013 mm)
57] with no gap facing the piston pin in the cylinder. Allowable Limit 0.789 in. (20,05 mm)
Figure 60-81-59
1
B-3633
Measure the O.D. of the piston pin (Item 1) [Figure 60-

81-59].
Measure the I.D. of the connecting rod small end (Item 2)

[Figure 60-81-59].
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RECONDITIONING THE ENGINE (S/N 223911622 & Installation: Clean the small end bushing and bore. Put
ABOVE, S/N 224013375 & ABOVE) (CONT’D) oil on the bushing and press into the connecting rod until
it is flush [Figure 60-81-61].
Piston And Connecting Rod, Servicing (Cont’d)
Figure 60-81-62
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.7875-0.7878 in. (20,002-20,011 mm)

Bushing I.D. 0.7884-0.7890 in. (20,025-20,04 mm)
Oil Clearance between Piston Pin & Bushing
0.0006-0.0015 in. (0,014-0,038 mm)
Figure 60-81-60
B-3622
0.79” (20 mm)
0.98” 5.7” (145 mm) Install a new piston ring into the lower part of the cylinder
(25 mm) 0.98” bore. Measure the ring gap with a feeler gauge [Figure
(25 mm) 60-81-62].
If the gap exceeds the allowable limit, replace the piston

ring.
0.8622-0.8642”
(21,9-21,96 mm) 0.7835-0.7854” Top Compression Ring & Oil Ring
(19,9-19,95 mm)
0.006-0.012 in. (0,15-0,30 mm)
MC-1366A Second Compression Ring
0.012-0.018 in. (0,30-0,45 mm)
To replace the connecting rod small end bushing, make a Allowable Limit 0.047 in. (1,2 mm)
driver tool as shown in figure [Figure 60-81-60].
Figure 60-81-61
Removing Installing
PI-10016
Use a press and special driver tool to remove the small

end bushing [Figure 60-81-61].
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RECONDITIONING THE ENGINE (S/N 223911622 & Connecting Rod Alignment
NOTE: The small end bushing is the basis of this
Piston And Connecting Rod, Servicing (Cont’d) check, check the bushing for wear before
doing this check.
Figure 60-81-63
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 60-81-64
B-14475
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler
gauge [Figure 60-81-63].
Second ring 0.0033-0.0045 in. (0,09-0,12 mm)

Oil ring 0.0016-0.0031 in. (0,04-0,08 mm) B-4067
Allowable limit second ring

0.0059 in. (0,15 mm) If the gauge does not fit squarely against the face place,
Allowable limit oil ring measure the space between the gauge and face plate
[Figure 60-81-64].
0.0059 in. (0,15 mm)
If the clearance exceeds the allowable limit, replace the the connecting rod.
piston.
Rod Alignment Allowable Limit
0.002 in.(0,05 mm)
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Crankshaft And Bearings Removal And Installation 3
Remove the piston and connecting rod assemblies. (See

Piston And Connecting Rod Removal And Installation on
Page 60-80-17.)
Remove the engine flywheel. (See Cylinder Head

Remove the bolts which fasten the bearing case cover to
the block.
Installation: Tighten the bearing case cover bolts to 7-8
ft.-lb. (10-11 N•m) torque. Tighten bolts with even force 2 1
on the diagonal line.
P-62181
Figure 60-81-65
Installation: When installing the bearing case gasket

(Item 1) [Figure 60-81-66] and [Figure 60-81-67], and
the bearing case cover gasket (Item 2) [Figure 60-81-66]
and [Figure 60-81-67] make sure the mark (Item 3)
[Figure 60-81-67] is in the up position.
Figure 60-81-68
B-3648
Install two bolts into the bearing case cover and pull the
cover out [Figure 60-81-65].
Figure 60-81-66
B-9565
3
2 Before removing the crankshaft/main bearings, check the
1 end play. Install a dial indicator. Measure the end play by
moving the crankshaft back and forth [Figure 60-81-68].

the thrust washers.
End Play 0.006-0.012 in. (0,15-0,31 mm)

4
P-62185
Installation: When installing the cover (Item 4) [Figure

60-81-66], make sure the casting mark (Item 3) [Figure
60-81-66] is in the up position. Lightly oil inside lip of oil
seal (Item 3) [Figure 60-81-66].
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Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 60-81-69
B-4092
Remove the two bearing case bolts [Figure 60-81-71].

1
Remove the bearing case and bearing.
B-14346
Installation: Tighten the bearing case bolts (Item 1)
[Figure 60-81-72] to 9-12 ft.-lb. (13-16 N•m) torque.
Remove the main bearing case bolt (Item 1) [Figure 60-
81-69]. Figure 60-81-72
Installation: Align the bearing case hole (Item 2) [Figure

60-81-69] with the hole in the block. Put oil on the bolt 1
threads and tighten to 20-22 ft.-lb. (27-30 N•m) torque.
Figure 60-81-70
3
P-62182
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [Figure 60-81-72]. Be sure the
B-14878 thrust washer with its oil grooves face outward.
Identification marks on on the main bearing case

Remove the crankshaft/main bearing assembly from the assemblies are the alignment number (Item 2) and the
engine block [Figure 60-81-70]. marking “1” or “2” (Item 3) [Figure 60-81-72] can be
found on the main bearing case assemblies to ensure
Mark the bearing case halves for correct installation. proper assembly.
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Crankshaft And Bearings, Servicing
Figure 60-81-73
A-2716
Measure the crankpin O.D. [Figure 60-81-75].
A-2763 Calculate the oil clearance.
Crankpin Bearing I.D.

Put the crankshaft on V-blocks. Install a dial indicator on
the center journal [Figure 60-81-73]. 1.3389-1.3390 in. (33,99 -34,01 mm)
Crankpin O.D. 1.3370-1.3376 in. (33,96-33,98 mm)
Turn the crankshaft at a slow rate.
Oil Clearance 0.0008-0.0020 in.(0,020-0,051 mm)
If the misalignment exceeds the allowable limit, replace Allowable limit 0.0059 in. (0,15 mm)
the crankshaft.
Alignment 0.0008 in. (0,02 mm)
Tighten the connecting rod cap bolts 20-22 ft.-lb. (27-30

N•m) torque.
Figure 60-81-74
120°
A-2727
Measure the crankpin bearing I.D. [Figure 60-81-74].
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Crankshaft And Bearings, Servicing (Cont’d)
Figure 60-81-76
PI-10025
1 Measure the flattened press gauge [Figure 60-81-78].
PI-10024B If the clearance exceeds the allowable limit, replace the

crankshaft bearing.
Figure 60-81-77
Crankshaft Journal O.D. (Flywheel side)
5.12” 1.7297-1.7303 in. (43,93-43,95 mm)
(130 mm)
Bearing I.D. 1.7317-1.7333 in. (43,98-44,03 mm)
R 1.57”
(40 mm)
Crankshaft Journal O.D. (Middle)
1.5722-1.5728 in. (39,93-39,95 mm)
0.79” Bearing I.D. 1.5742-1.5758 in. (39,98-40,03 mm)
1.5709-1.5728”
(20 mm) (39,90-39,95mm) Crankshaft journal O.D. (Front)
2.83” 1.5722-1.5728 in. (39,93-39,95 mm)
(72 mm)
Bearing I.D. 1.5714-1.5764 in. (39,98-40,04 mm)
2.68” 0.95”
(68 mm) (24 mm)
Oil Clearance 0.0013-0.0042 in. (0,034-0,106 mm)
0.35”
(9 mm) B-14879
Remove the bearing (Item 1) [Figure 60-81-76] from the

front of the engine block with the removal tool shown in
[Figure 60-81-77].
Installation: Clean the new bearing and bore and apply

oil to them. Install the new bearing with the installation
driver tool [Figure 60-81-76].
Clean the crankshaft journal and bearing. Put a strip of

press gauge on the center journal.
Install the main bearing case halves and tighten the bolts
to 9-12 ft.-lb. (12,7-15,7 N•m) torque. Remove the
bearing case halves.
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RECONDITIONING THE ENGINE (S/N 223911622 & Water Pump Removal And Installation
Drain the cooling system.
Cylinder Bore, Checking
Remove the radiator. (See Removal And Installation on
Figure 60-81-79 Page 60-40-1.)
Remove the alternator belt.
Remove the fan.
Figure 60-81-81
3
B-10073
5
Check the inside diameter of the cylinder line [Figure 60-
81-79].
Figure 60-81-80 2
1 B-14859A
Remove the water pump bolts (Item 1) [Figure 60-81-

81].
Remove the water pump.
Installation: Always use a new gasket (Item 2) [Figure

60-81-81] when installing the water pump and apply
Liquid-Type Gasket (Three Bond 1215 or equivalent) to
both sides of new gasket.
Water Pump Disassembly And Assembly
A-2717A Put the water pump in a vise.
Remove the pulley.

To find the maximum wear check the inside diameter in
six different locations [Figure 60-81-80].
pulley side of the water pump. Press out the shaft with
When the cylinder bore is not within specifications, bore
the impeller on it.
and hone the cylinder for an oversize piston.
Remove the seal (Item 4) and impeller (Item 5) [Figure
Cylinder Bore I.D. 2.638-2.639 in. (67,0-67,02 mm) 60-81-81].
Install a new seal when assembling the water pump.
NOTE: Make sure you use the correct oversize
pistons and rings.
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HEATER
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
SAFETY &
MAINTENANCE
DRIVE
SYSTEM
HEATER
SPECIFICATIONS
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HEATER Cap the heater fittings once the hoses are removed.
Removal And Installation Remove the tie strap (Item 2) and duct hose (Item 3)
[Figure 70-10-2] from heater.
Drain the engine coolant. (See Replacing The Coolant on
Page 10-70-2.)
Figure 70-10-3
Remove floor mat and floor panels. (See Removal and
Remove seat and seat mount. (See Removal And

2 1
Remove blade extension tray. (See Removal And
Figure 70-10-1 2
P-19633

the front of the heater.
1
Remove heater assembly (Item 2) [Figure 70-10-3] from
the Excavator.
Figure 70-10-4
P-19660
1
Disconnect the heater wire harness (Item 1) [Figure 70-

10-1].
Figure 70-10-2
2 2
1 1
P-19679
3
NOTE: During the installation of heater assembly,

verify that the engine speed cable (Item 1) is
on the heater side of the buckhead fitting
(Item 2) [Figure 70-10-4] otherwise the cable
P-19657 will be pinched between the bulkhead fittings
and blade extension tray.
Mark the two hoses (Item 1) [Figure 70-10-2] for ease of
assembly.
Disconnect and cap the two hoses (Item 2) [Figure 70-

10-2].
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SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . SPEC-70-1 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 DRIVE
Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5 SYSTEM
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 ELECTRICAL
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 SYSTEM &
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 ANALYSIS
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . SPEC-60-1 ENGINE

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SERVICE
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-40-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-40-1 SPECIFICATIONS
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-40-1
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
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SPEC-01 Service Manual
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SPECIFICATIONS (CONT’D)
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-50-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
320/322 Excavator Machine Dimensions. . . . . . . . . . . SPEC-10-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Lift Chart 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Lift Chart 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Under Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-30-2
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . SPEC-30-1
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SPEC-02 Service Manual
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SPECIFICATIONS
320/322 Excavator Machine Dimensions
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
320
322 W/ Track Expanded
MS-1894
320/322 Excavator
SPEC-10-1 Service Manual
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320/322 Excavator Machine Dimensions (Cont’d)
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
MS-1895
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Performance
320 322
Operating weight with Canopy 3484 lb. (1580 kg) 3526 lb. (1599 kg)
(w/ 20 inch Bucket)
Operating weight with Cab 3724 lb. (1689 kg) 3766 lb. (1708 kg)
(w/ 20 inch Bucket)
Add 117 lb. (53 kg) if equipped with
steel traqcks.
Travel Speed Low .93 MPH (1,50 km/hr)
High 1.8 MPH (2,90 km/hr)
Controls
Steering Two hand levers or foot pedals

Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and
upperstructure slew
Brakes
Travel
Service & Parking Hydraulic lock in motor circuit
Swing
Service Hydraulic lock on motor
Holding Locking Pin
Engine
S/N 223911001 - 223911621, S/N 223911622 & Above,

S/N 224011001 - 224013374 S/N 224013375 & Above
Make/Model Kubota D722-EB Kubota D722-E2B
Fuel/Cooling Diesel/Liquid (Antifreeze mixture)
Horsepower (SAE Net) 15.7 HP (11,7 kW) @ 3000 RPM
Number Of Cylinders Three
Lubrication Pressure System with Filter
Air Cleaner Dry replaceable cartridge
Maximum Governed Speed 3000 RPM 3150 RPM
Displacement 43.9 ci (0.726L)
Borex Stroke 2.64 x 2.68 in. (67 x 68 mm)
Hydraulic System
Three engine driven, One - 7.9 GPM (30,0 L/min.)

gear-type pumps Two - 4 GPM (15,0 L/min.)
Auxiliary Flow 7.9 GPM (30,0 L/min.)
System Relief Pressure
Travel Circuits 2500 PSI (172 bar)
Slew Circuit 1475 PSI (102 bar)
Boom, Arm, Bucket, Blade,
Boom Swing, Auxiliary Hydraulics 2500 PSI (172 bar)
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Hydraulic Cylinders
Cylinder Bore Rod Stroke

Boom 2.38 in. (60 mm) 1.38 in. (35 mm) 13.59 in. (345 mm)
Arm 2.38 in. (60 mm) 1.50 in. (38 mm) 16.57 in. (421 mm)
Bucket 2.25 in. (57 mm) 1.50 in. (38 mm) 15.16 in. (385 mm)
Boom Swing 3.25 in. (83 mm) 1.25 in. (32 mm) 14.71 in. (374 mm)
Blade 2.38 in. (60 mm) 1.38 in. (35 mm) 5.20 in. (132 mm)
Undercarriage - 322 Only 2.00 in. (51 mm) 1.00 in. (25 mm) 14.96 in. (380 mm)
Hydraulic Cycle Times
Bucket Curl 2.1 Seconds

Bucket Dump 1.4 Seconds
Arm Retract 2.6 Seconds
Arm Extend 1.6 Seconds
Boom Raise 4.3 Seconds
Boom Lower 3.2 Seconds
Boom Swing Left 4.2 Seconds
Boom Swing Right 3.6 Seconds
Blade Raise 3.5 Seconds
Blade Lower 3.1 Seconds
Undercarriage Expand (322 Only) 6.3 Seconds
Undercarriage Retract (322 Only) 6.9 Seconds
Slew 11.2 RPM
Drive System
Travel Motor Each track is driven by hydrostatic axial piston motor

Drive Reduction Two stage planetary
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Under Carriage
Crawler Tractor Design

Rollers Sealed rollers with box section track roller frame
Track Adjusters Grease type track adjusters with shock absorbing recoil spring
Track
Width 9.06 in. (230 mm)

No. of Shoes Single Assembly
No. of Track Rollers Three Each Side
Rubber Tracks Steel Tracks

Ground Pressure - 320 3.93 PSI (27,1 kPa) 4.06 PSI (28,0 kPa)
Ground Pressure - 322 3.98 PSI (27,4 kPa) 4.11 PSI (28,3 kPa)
Electrical
Alternator 12 - volts, 40 amp, open, negative ground

Battery 12 volts - 530 CCA @ 0° F (-18° C)
Starter 12 volts, Reduction Drive
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ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles
Opening Pressure 1991 - 2133 PSI (137 - 147 bar)

Fuel Tightness Nozzle Seat Dry Nozzle at 1849 PSI (128 bar)
Fuel Injection Pump
Fuel Tightness Plunger 8 sec: initial pressure 2133 - 1990 PSI (147 - 137 bar)
Allowable Limit 5 seconds
Injection Timing 20-22 degrees B.T.D.C.
Cylinder Head
Cylinder Head Surface Distortion 0.002 in 3.9 (0,05 in 100) Max.

Thickness of Gasket (Used) 0.0413 - 0.0453 (1,05 - 1,15)
(New) 0.0415 - 0.0512 (1,15 - 1,30)
Top Clearance (Piston to Head) 0.02 - 0.03 (0,50 - 0,65)
Compression 412 - 469 PSI (28 - 32 bar)
Allowable Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake & Exhaust) 0.0835 (2,12)

O.D. of Valve Stems 0.235 - 0.2354 (5,969 - 5,979)
I.D. of Valve Guides 0.2366 - 0.2372 (6,01 - 6,025)
Clearance Between Valve Stem & Guide 0.0012 - 0.0022 (0,03 - 0,057)
Allowable Limit 0.004 (0,1)
Valve Clearance (Cold) 0.066 - 0.007 (0,145 - 0,185)
Valve Recessing (Protrusion) 0.004 (0,10)
Allowable Limit (Recess) 0.0118 (0,30)
Valve Seat Angle (Int.) 45 degrees
Valve Seat Angle (Exh.) 45 degrees
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ENGINE SPECIFICATIONS (CONT’D)
parentheses.
Valve Springs
Free Length 1.244 (31,6)

Fitted Length 1.063 (27)
Compress to Fitted Length 14.6 lb. (65 N)
Allowable Limit 12.3 lb. (55 N)
Inclination Allowable Limit 0.047 (1,2)
Rocker Arms
O.D. of Rocker Arm Shaft 0.4123 - 0.4128 (10,47 - 10,48)

I.D. of Rocker Arm 0.4134 - 0.4141 (10,5 - 10,52)
Clearance Between Rocker Arm & Shaft 0.0006 - 0.0018 (0,016 - 0,045)
Camshaft
Journal O.D. 1.2966 - 1.2972 (32,93 - 32,95)

Bearing I.D. 1.2992 - 1.3002 (32,99 - 33,025)
Oil Clearance 0.002 - 0.004 (0,05 - 0,91)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height 1.0583 (26,88)
End Clearance 0.002 - 0.005 (0,047 - 0,123)
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parentheses.
Cylinders
Cylinder Liner I.D. 2.6378 - 2.6385 (67,0 - 67,169)

Allowable Limit (Standard) +0.006 (+0,15)
Piston Rings
Ring Gap (Top) 0.006 - 0.012 (0,15 - 0,30)

Ring Gap (2nd Ring) 0.012 - 0.018 (0,30 - 0,45)
Ring Gap (Oil Ring) 0.006 - 0.012 (0,15 - 0,30)
Allowable Limit (All Rings) 0.05 (1,25)
Side Clearance of Ring Groove:
Oversize of Piston And Ring 0.010 (0,25)
Top Ring 0.00 (0,0)
2nd Ring 0.0035 - 0.0043 (0,09 - 0,012)
Oil Ring 0.002 - 0.003 (0,04 - 0,08)
Pistons
Piston Pin Bore 0.7874 - 0.07879 (20,0 - 20,013)

Connecting Rods
Piston Pin O.D. 0.7875 - 0.7878 (20,002 - 20,011)

Small End Bushing I.D. 0.7884 - 0.7890 (20,025 - 20,04)
Clearance Between Piston Pin & Small End Bushing 0.0006 - 0.0015 (0,014 - 0,038)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)
Oil Pump
Oil Pressure at Rated RPM 28-64 PSI (2 - 4 bar)

Idle Speed Allowable Limit 14 PSI (1 bar)
Clearance Between Inner Rotor & Outer Rotor 0,012 - 0,006 (0,03 - 0,14)
Clearance Between Outer Rotor & Pump Body 0.003 - 0.006 (0,07 - 0,15)
End Clearance Between Inner Rotor & Cover 0.003 - 0.005 (0,08 - 0,14)
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parentheses.
Crankshaft
Crankshaft Alignment Allowable Limit 0.0004 (0,01)

Oil Clearance Between Journal & Bearing #1 0.001 - 0.004 (0,034 - 0,092)
Journal O.D. #2 1.5722 - 1.5728 (39,93 - 39,95)
Bearing I.D. #2 1.5742 - 1.5758 (39,98 - 40,03)
Oil Clearance Between Journal & Bearing #2 0.001 - 0.004 (0,034 - 0,092)
Journal O.D. #3 1.7297 - 1.7303 (43,93 - 43,95)
Bearing I.D. #3 1.7317 - 1.7333 (43,98 - 44,03)
Oil Clearance Between Crank Pin & Bearing 0.0008 - 0.0032 (0,019 - 0,081)
Crank Pin O.D. 1.337 - 1.338 (33,96 - 33,98)
Crank Pin Bearing I.D. 1.338 - 1.340 (33,99 - 34,04)
Crankshaft Side Clearance 0.066 - 0.012 (0,15 - 0,31)
Timing Gear
Timing Gear Backlash

Crank Gear - Idle Gear 0.002 - 0.005 (0,043 - 0,124)
Idle Gear - Cam Gear 0.002 - 0.005 (0,047 - 0,12)
Idle Gear - Injection Pump Gear 0.002 - 0.005 (0,046 - 0,124)
Gear Crank Gear - Oil Pump Gear 0.002 - 0.005 (0,046 - 0,124)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.0008 - 0.0033 (0,020 - 0,084)
Thermostat
Valve Opening Temperature 157 - 163° F (70 - 73° C)

Valve Fully Open 185° F (85° C)
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parentheses.
Engine Bolt Torque
Ft. - Lb. N•m

Camshaft Retainer Plate Bolts 14-15 18-21
* Connecting Rod Bolts 20-22 27-30
* Crankshaft Bolt 72-80 98-108
* Cylinder Head Bolts 29-33 39-44
Drain Plug 24-28 32-37
* Flywheel Bolts 40-43 54-59
Fuel Camshaft Retainer Bolts 5-6 6,8-8,1
Fuel Injection Tubeline Fittings 18-25 25-34
Glow Plugs 6-11 8-15
* Idler Gear Shaft Bolt 7-8 10-11
Injection Nozzle Clamp 36-51 49-69
Injection Pump Mounting Bolts 17-20 23-27
* Main Bearing Bolts 20-22 27-30
* Main Bearing Case Bolts 20-22 27-30
Oil Switch 11-15 15-20
Starter Terminal “B” Connector Nut 7-8 10-11
* Lightly Oiled Threads
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Crankshaft Re-Grind Data
If the standard size bearing cannot be used due to Figure SPEC-20-1

excessive wear of the crank pin and crank journal use
undersize or oversize bearings. B
6 1
3
For undersize or oversize bearing use, follow the 1
precautions noted below.
Grind the crankpin and journal with a wheel which has

specified round corner and width without shoulder [Figure
A
SPEC-20-1].
1. 0.071 - 0.087 (1,8 - 2,2 mm)
2. 0.091 - 0.106 (2,3 - 2,7 mm) 4
C
3. Be sure to chamfer the oil hole circumference to 0.04 2
D
- 0.06 in. (1,0 - 1,5 mm) radius with an oil stone.
4. The crankpin must be fine-finished to higher than (0,4 1 5
- S). B-5928
5. The crank journal must be fine-finished to higher than

(0,4 - S).
6. The crank journal side surface must be fine-finished
to higher than (1,6 - S)
SIZE CODE NO. NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM
-.008 in. 15861 - 23911 Crankshaft Bearing 1 020 US
(-0,2 mm) 0.008 in. minus (0,2 minus) 1.5643 - 1.5650 in.
-0.008 in. 15694 - 23931 Crankshaft Bearing 2 020 US (39,734 - 39,750 mm)
(-0,2 mm) 0.008 in. minus (0,2 minus)
-0.008 in. 15861 - 23861 Crankshaft Bearing 3 020 US 1.7218 - 1.7224 in.
(-0,2 mm) 0.008 minus (0,2 minus) (43,734 - 43,750 mm)
-0.016 in. 15861 - 23921 Crankshaft Bearing 1 040 US A 1.5565 - 1.5571 in.
(-0,4 mm) 0.016 in. minus (0,4 minus) (39,534 - 39,550 mm)
-0.016 in. 15699 - 23941 Crankshaft Bearing 2 040 US
(-0,4 mm) 0.016 in. minus (0,4 minus)
-0.0016 in. 15861 - 23871 Crankshaft Bearing 3 040 US 1.7139 - 1.7146 in.
(-0,4 mm) 0.016 minus (0,4 minus) (43,534 - 43,550 mm)
-0.008 in. 15861 - 22971 Crank Pin Bearing 020 US 1.3291 - 1.3297 in.
(-0,2 mm) 0.008 in. minus (0,2 minus) (33,759 - 33,775 mm)
-0.016 in. 15861 - 22981 Crank Pin Bearing 040 US B 1.3212 - 1.3219 in.
(-0,4 mm) 0.016 in. minus (0,4 minus) 33,559 - 33,575 mm
+0.008 in. 15261 - 23951 Thrust Bearing 1 020 OS
(-0,2 MM) 0.008 in. plus (0,2 plus) 1.815 - 1.823 in.
15261 - 23971 Thrust Bearing 2 (46,1-46,3 mm)
0.008 in. plus (0,2 plus)
C
+0.016 in. 15261 - 23961 Thrust Bearing 1 040 OS
(+0,4 mm) 0.016 plus (0,4 plus) 1.823 - 1.831 in.
15261 - 23981 Thrust Bearing 2 (46,3 - 46,5 mm)
0.016 in. (0,4 plus)
0.008 in. Crankshaft over size 1.815 - 1.823 in.
(0,2 mm) Dimension D (46,1 - 46,3 mm)
0.016 in. 1.823 - 1.831 in.
(0,4 mm) (46,3 - 46,5 mm)
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TORQUE SPECIFICATIONS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

INCH. .250 80-90 (9,0-10,2) 110-120 (12,4-13,6)
LBS. .3125 180-200 (20,3-22,6) 215-240 (24,2-27,1)
(Nm)
FOOT .375 25-28 (34-38) 35-40 (47-54)
LBS. .4375 40-45 (54-61) 60-65 (81-88)
(Nm)
.500 65-70 (88-95) 90-100 (122-136)
.5625 90-100 (122-136) 125-140 (170-190)
.625 125-140 (170-190) 175-190 (240-260)
.750 220-245 (300-330) 300-330 (410-450)
.875 330-360 (450-490) 475-525 (645-710)
1.000 475-525 (645-710) 725-800 (985-1085)
1.125 650-720 (880-975) 1050-1175 (1425-1600)
1.250 900-1000 (1200-1360) 1475-1625 (2000-2200)
1.375 1200-1350 (1630-1830) 2000-2200 (2720-2980)
1.500 1500-1650 (2040-2240) 2600-2850 (3530-3870)
1.625 2000-2800 (2720-2980) 3450-3800 (4680-5150)
1.750 2500-2750 (3390-3730) 4300-4800 (5830-6500)
1.875 3150-3500 (4270-4750) 5500-6100 (7450-8300)
2.000 3800-4200 (5150-5700) 6500-7200 (8800-9800)
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TORQUE SPECIFICATIONS (CONT’D)
Torque For General Metric Bolts
GRADE STANDARD SCREW AND BOLT SPECIAL SCREW AND BOLT
4 7
NOMINAL
UNIT NM KFG M FT LBS NM KFG M FT LBS
DIAMETER
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
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HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-40-2
IMPORTANT Nut Nut

Washer
clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, O-ring
damage the system. O-ring
I-2003-0888
Figure SPEC-40-1
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
2].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-7575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-1].
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HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it makes contact with the seat. Make
(CONT’D) a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-3].
Flare Fitting
Use the chart below to find the correct tightness needed
Use the following procedure to tighten the flare fitting: (Item 2) [Figure SPEC-40-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
Figure SPEC-40-3 damage.
TS-1619
FLARE FITTING TIGHTENING TORQUE
TUBELINE NEW ROTATE RE-ASSEMBLY

TORQUE FT.-
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
LBS. (NM)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4
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HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT’D) fitting.
O-ring Flare Fitting Figure SPEC-40-5
Figure SPEC-40-4 Hex Flat Tightening Method
Primary O-Ring Flare

Seal
1
Secondary TS-1619
Seal
P13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts of
The flare is the primary seal, the O-ring is the secondary the connection (Item 1) [Figure SPEC-40-5].
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-40-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring.
O-RING FLARE FITTING TIGHTENING TORQUE
** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE FT.-
NO. OF HEX ROTATE NO. OF
DIAMETER LBS. (NM)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a new *** If using the hex flat tightening method to tighten a used
hose/tubeline. fitting to a new hose/tubeline.
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HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT’D)
O-ring Flare Fitting (Cont'd)
NOTE: O-ring flare fittings are not recommended in 2

all applications. Use the standard flare fittings
in these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Figure SPEC-40-6 1
P13573
Copper Bonnet Orifice Always remove the O-ring (Item 1) [Figure SPEC-40-7]
from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-40-7] is added to the

flat boss of the fitting to seal the connection in this
application.
P13572
Use a standard flare fitting (Item 1) [Figure SPEC-40-6]

as shown.
When a O-ring flare fitting is used as a straight thread

port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.
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HYDRAULIC CONNECTION SPECIFICATIONS Do not over tighten the port seal fitting.
(CONT'D)
Port Seal Fitting PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
Figure SPEC-40-8 FITTING NUT THREAD SIZE TORQUE FT.-
WRENCH SIZE (NM) LBS. (NM)
11/16" 9/16" - 18 22 (30)
15/16" 3/4" - 16 40 (54)
1-1/8" 7/8" - 14 60 (81)
1-1/4" 1-1/16" - 12 84 (114)
1-1/2" 1-5/16" - 12 118 (160)
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
Nut Seals to
Fitting NOTE: Port seal fittings are not recommended in all
applications. Use O-ring boss fittings in these
applications.
Nut Seals to Figure SPEC-40-9

Port
Secondary
O-Ring Seal
P13008
1
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-8].
P13571
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Do not use port seal fittings when a thread in orifice (Item
Use the following procedure to tighten the port seal 1) [Figure SPEC-40-9] is used in the port. The orifice
fitting: may interfere with the fitting and prevent it from sealing.
Port seal and nut, washer and O-ring (O-ring Boss) Use an O-ring boss fitting (Item 1) [Figure SPEC-40-9]
fittings use the same tightening torque chart. as shown.
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
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HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the Excavator must be kept in a warm building.
Specifications Extra warm-up time must be used each time the
Excavator is started during cold temperature conditions.
Use Bobcat hydraulic fluid (P/N 6563328). If this fluid is Cold fluid will not flow easily and it makes action of the
not available, use 10W-30 or 10W-40 SAE Motor Oil hydraulic function slower. Loss of fluid flow to the
(5W-30 for 0°F [-18°C] and Below). hydraulic system can cause damage in less than 60
seconds.
DO NOT use automatic transmission fluids in the
Excavator or permanent damage to the hydraulic system
will result.
WARNING
WARNING During cold weather 32°F (0°C) and below, do not
operate machine until the engine has run for at least
five (5) minutes at less than half throttle. This warm-
Diesel fuel or hydraulic fluid under pressure can up period is necessary for foot pedal operation and
penetrate skin or eyes, causing serious injury or safe stopping. Do not operate controls during warm-
death. Fluid leaks under pressure may not be visible. up period. When temperatures are below -20°F
Use a piece or cardboard or wood to find leaks. Do (30°C), the hydrostatic oil must be heated or kept
not use your bare hand. Wear safety goggles. If fluid warm. The hydrostatic system will not get enough oil
enters skin or eyes, get immediate medical attention at low temperatures. Park the machine in an area
from a physician familiar with this injury. where the temperature will be above 0°F (-18°C), if
W-2072-0496 possible.
W-2027-1285
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320/322 Excavator
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FUEL, COOLANT AND LUBRICANTS
Chart
Use this chart for correct selection of Fuel, Coolant and Lubricants.
RESERVOIR KIND OF FLUID RECOMMENDED FLUID CAPACITY

Engine oil w/ filter *Use SAE 3.4 qts. (3,2 L)
Viscosity Number
as Listed With
API Classification
CD or Better
Fuel Diesel Fuel Temp. F° No. 2 No.1 7.3 gal.

+15° (9°) 100% 0% (27,3 L)
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
Coolant Propylene 6 qts.
Glycol (5,7 L)
Hydraulic Bobcat Fluid Tank Capacity
6563328* 6.8 qts. (6,5 L)
Drive Motor Gear Lube SAE-90W 0.42 qts.
(each side) (0,4 L)
* Engine Oil Change Interval Relating to Diesel Fuel Sulfur Content
Sulfur Content Change Interval

0.5% or Less Change engine oil and filter. (See SERVICE SCHEDULE on Page 10-50-1)
0.5 - 1.0% Use 1/2 of Service Schedule interval.
Above 1.0% Use 1/4 of Service Schedule interval.
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CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart
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ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 320/322-1

Date: 12 Aug 2004
Product: Bobcat Excavator
Model: 320/322
Manual No: 6902668 (02-04)
The following sections are a revision to the above Service Manual.
Take out existing sections and put in the new sections as listed below:
TAKE OUT PUT IN REVISION DESCRIPTION

ALPHABETICAL INDEX ALPHABETICAL INDEX Revised Text
10-01 10-01 Revised Text


Printed in U.S.A.
700 of 705
TAKE OUT PUT IN REVISION DESCRIPTION
40-91 Added Text
40-220 Section moved to 40-91


SPEC-01 SPEC-01 Revised Text
2
701 of 705
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 24 March 2006
Model: 320/322
Manual No: 6902668 (2-04)
320/322 Service Manual (P/N 6902668) Dated (3-06) contains updated service information
which replaces the previous 320/322 Service Manual (P/N 6902668) Dated (2-04)
Printed in U.S.A.
702 of 705
2
703 of 705
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 29 July 2006
Model: 320/322
Manual No: 6902668 (3-06)
The following Sections are a revision to the above Service Manual.
Cover
ALPHABETICAL INDEX
HYDRAULIC SCHEMATIC
20-01
20-30
20-31
20-32
20-40
20-41
20-50
20-60
30-30
30-70
ELECTRICAL SCHEMATIC
60-01
60-50
60-51
60-80
60-81
SPEC-10
Printed in U.S.A.
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2
705 of 705

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What safety precautions should be taken when servicing equipment?

What safety precautions should be taken when servicing equipment?

What maintenance procedures can be performed by the owner/operator?

What maintenance procedures can be performed by the owner/operator?

320

6902668 (7-06) Printed in U.S.A. ©Bobcat Company 2006

CORRECT CORRECT CORRECT

B-10731A B-19964 B-19959

B-19965 B-19960 B-19966

WRONG WRONG WRONG

B-19962 B-19958 B-19798

AIR CLEANER ........................................................ 60-01 LEFT CONSOLE .....................................................40-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE

320/ 322 Excavator

2. Check that ROPS/TOPS 10. Check for correct function of

3. The seat belt must be 11. Check hydraulic fluid level,

4. Inspect for loose or broken 12. Inspect for fuel, oil or

5. Machine signs must be 13. Lubricate the Excavator.

6. Steering levers, control levers 14. Check the condition of the

8. Check the electrical charging

320/ 322 Excavator

• The Compact Excavator Operator Training Course is

• The Bobcat Compact Excavator Safety Video is

320/ 322 Excavator

The dealer and owner/operator review the recommended

Call Before You Dig

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

320/ 322 Excavator

Always use the serial number of the Excavator when Figure 2

Excavator Serial Number

The Excavator serial number plate (Item 1) is located on

Explanation of Excavator Serial Number:

1. The four digit Model/Engine Combination Module

2. The five digit Production Sequence Number identifies

320/ 322 Excavator

The delivery report must be filled out by the dealer and

ARM LIFT POINT

BUCKET LINK BLADE

320/ 322 Excavator

CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . 10-160-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 DRIVE

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1

HEATER AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1 SPECIFICATIONS

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . 10-10-1

LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1

LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . 10-110-1

Continued On Next Page

OPERATOR CAB ROPS/TOPS . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-130-1