A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Excavator Serial Number
• Engine Serial Number
• DELIVERY REPORT
• EXCAVATOR IDENTIFICATION
• SAFETY & MAINTENANCE
• LIFTING AND BLOCKING THE EXCAVATOR
• Procedure
• UPPERSTRUCTURE SLEW LOCK
• LIFTING THE EXCAVATOR
• Procedure
• OPERATOR CAB (ROPS / TOPS)
• Description
• Cab Door
• Front Window
• Front Wiper
• Window Washer Reservoir
• Right Side Windows
• Heater
• TRANSPORTING THE EXCAVATOR ON A TRAILER
• Loading And Unloading
• Fastening
• TAILGATE
• Opening And Closing
• Adjusting The Bumper
• Adjusting The Latch
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Daily Check
• Replacing The Filter Elements
• CAB FILTER
• Cleaning And Maintenance
• ENGINE COOLING SYSTEM
• Cleaning
• Checking Level
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filters
• Draining The Fuel Tank
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil Chart
• Removing And Replacing Oil And Filter
• HYDRAULIC SYSTEM
• Checking And Adding Hydraulic Oil
• Hydraulic / Hydrostatic Fluid Chart
• Removing And Replacing The Hydraulic Filter
• Removing And Replacing The Hydraulic Fluid
• LUBRICATING THE EXCAVATOR
• Lubrication Locations
• TRAVEL MOTOR
• Checking Oil Level
• Draining The Drive Motor
• SPARK ARRESTER MUFFLER
• Cleaning Procedure
• ALTERNATOR BELT
• Belt Adjustment
• Belt Replacement
• SEAT BELT
• Inspection And Maintenance
• CONTROL CONSOLE LOCKOUTS
• Inspection And Maintenance
• PIVOT PINS
• Inspection And Maintenance
• EXCAVATOR STORAGE AND RETURN TO SERVICE
• Storage
• Return to Service
• STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
• Procedure
• EMERGENCY EXIT
• Right Side Rear Window
• Front Window
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting The Hydraulic Circuit
• Troubleshooting The Cylinder Circuit
• Troubleshooting The Swing (Upperstructure Slew) Circuit
• Troubleshooting The Travel Circuit
• BOOM CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• ARM CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BOOM SWING CYLINDER
• Testing
• Removal and Installation
• Parts Identification
• Disassembly
• Assembly
• BUCKET CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BLADE CYLINDER
• Testing
• Removal and Installation
• Parts Identification
• Disassembly
• Assembly
• TRACK FRAME EXPANSION CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Testing And Adjusting The Main Relief Valve
• PORT RELIEF VALVES
• Testing And Adjusting The Port Relief Valve Pressure
• CROSSPORT RELIEF VALVES
• Testing And Adjusting The Crossport Relief Valve
• PRESSURE REDUCING VALVE
• Testing And Adjusting The Pressure Reducing Valve
• HYDRAULIC CONTROL VALVE
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Right Travel Valve Section Disassembly And Assembly
• Boom Swing Valve Section Disassembly And Assembly
• Arm Valve Section Disassembly and Assembly
• Bucket Valve Section Disassembly And Assembly
• Auxiliary Valve Section Disassembly And Assembly
• Boom Valve Section Disassembly And Assembly
• Left Travel Valve Section Disassembly And Assembly
• Swing (Slew) Valve Section Disassembly And Assembly
• Blade Valve Section Disassembly And Assembly
• Assembly
• HYDRAULIC PUMP
• Description
• Torque Adjustment
• Testing The Piston Pump
• Testing The Gear Pump
• Testing Auxiliary Hydraulic Flow
• Removal And Installation
• Parts Identification
• Disassembly
• Gear Pump Disassembly
• Piston Pump Disassembly
• Piston Pump Assembly
• Gear Pump Assembly
• Assembly
• MANIFOLD ASSEMBLY / ACCUMULATOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• ACCUMULATORS
• Removal And Installation
• TRAVEL MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• SWIVEL JOINT
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• SWING MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• RIGHT CONTROL LEVER (JOYSTICK)
• Description
• Testing
• Handle Removal And Installation
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• LEFT CONTROL LEVER (JOYSTICK)
• Description
• Testing
• Handle Removal And Installation
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• HYDRAULIC FILTER MOUNT
• Description
• Removal And Installation
• HYDRAULIC RESERVOIR
• Description
• Removal And Installation
• OIL COOLER
• Description
• Removal And Installation
• BLADE / TRACK EXPANSION SOLENOID BLOCK
• Description
• Block Removal and Installation
• Solenoid Removal and Installation
• Block Disassembly And Assembly
• SLEW LOCK VALVE
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• UNDERCARRIAGE
• BLADE
• Description
• Extension Removal And Installation
• Blade Removal And Installation
• TRACKS
• Track Lug Height
• Track Tension Adjustment
• Removal And Installation
• TRACK FRAME
• Disassembly And Assembly
• Removal And Installation Of Expandable Track Frame
• TRACK DAMAGE IDENTIFICATION
• Cutting Of The Steel Cords
• Causes Of The Damage
• Abrasion Of Embedded Metals
• Separation Of Embedded Metals
• Separation Of Embedded Metals Due To Corrosion
• Cuts On The Lug Side Rubber
• Cracks On The Lug Side Rubber Due To Fatigue
• Lug Abrasion
• Cracks And Cuts On The Lug Side Rubber
• Abrasion Of The Track Roller Side
• Cuts On The Edges Of The Track Roller Side
• TRACK IDLER
• Parts Identification
• Disassembly
• Assembly
• TRACK ROLLER
• Parts Identification
• Disassembly
• Assembly
• SWING CIRCLE GEAR
• Removal and Installation
• UPPERSTRUCTURE & SWING
• UPPERSTRUCTURE
• Description
• Removal
• Installation
• ROPS CANOPY
• Removal And Installation
• CAB
• Removal And Installation
• Door Removal And Installation
• Front Window Removal And Installation
• Right Side Rear Sliding Window Removal And Installation
• Right Side Front Sliding Window Removal And Installation
• Glass Removal
• Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
• Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
• Glass Installation
• SEAT AND SEAT MOUNT
• Seat Mount Removal And Installation
• RIGHT CONSOLE
• Description
• Joystick Console Cover (Bottom) Removal And Installation
• Joystick Console Cover (Top) Removal And Installation
• Joystick Console Cover (Top) Disassembly And Assembly
• Compression Spring Removal And Installation (Canopy Only)
• Compression Spring Disassembly And Assembly (Canopy Only)
• Lever Removal And Installation (Canopy Only)
• Joystick Console Frame Removal And Installation
• Joystick Console Frame Disassembly And Assembly
• Right Rear Console Cover Removal And Installation
• Right Rear Console Cover Disassembly and Assembly
• Right Rear Console Frame Removal And Installation
• LEFT CONSOLE
• Description
• Joystick Console Cover (Bottom) Removal And Installation
• Joystick Console Cover (Top) Removal And Installation
• Compression Spring Removal And Installation
• Compression Spring Disassembly And Assembly
• Lever Removal And Installation
• Joystick Console Frame Removal And Installation
• Joystick Console Frame Disassembly And Assembly
• Left Rear Console Cover Removal And Installation
• Left Rear Console Frame Removal And Installation
• ENGINE SPEED CONTROL
• Removal and Installation
• Cable Removal and Installation
• BLADE CONTROL
• Removal and Installation
• Disassembly And Assembly
• Cable Removal and Installation
• UPPERSTRUCTURE SLEW LOCK
• Removal And Installation
• Disassembly And Assembly
• RIGHT PEDAL
• Removal And Installation
• Disassembly And Assembly
• TRAVEL CONTROLS
• Removal And Installation
• Disassembly And Assembly
• LEFT PEDAL
• Removal And Installation
• Disassembly And Assembly
• CONTROL LINKAGE ASSEMBLY
• Description
• Removal And Installation
• Right Half of Control Linkage Disassembly And Assembly
• Left Half of Control Linkage Disassembly And Assembly
• Bracket of Control Linkage Disassembly And Assembly
• FLOOR MAT AND FLOOR PANELS
• Description
• Removal And Installation
• FUEL TANK
• Removal and Installation
• HORN
• Removal And Installation
• SWING FRAME
• Description
• Removal And Installation
• Bushing Removal and Installation
• Swing Frame Bushing Removal
• Swing Frame Bushing Installation
• Boom Pivot Bushing Removal
• Boom Pivot Bushing Installation
• BOOM
• Description
• Removal And Installation
• Boom Bushing Removal And Installation
• ARM
• Description
• Removal And Installation
• Arm To Boom Bushing Removal And Installation
• Arm To Bucket And Bucket Link Bushing Removal And Installation
• BUCKET
• Removal And Installation
• TAILGATE
• Removal And Installation
• Latch Removal And Installation
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATIC
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Troubleshooting
• Description
• Fuse And Relay Location / Identification
• Fuel Timer And Diode Location / Identification
• BATTERY
• Servicing
• Removal And Installation
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Description
• Tests
• Alternator Output Test
• Full Field Test
• Alternator Regulator Test
• Alternator Regulator Test With Voltmeter
• Removal And Installation
• Belt Adjustment
• Charging System Inspection
• Parts Identification
• STARTER
• Removal And Installation
• Parts Identification
• Cleaning And Inspection
• LIGHTS
• Upperstructure Light Removal And Installation
• Upperstructure Light Disassembly and Assembly
• Boom Light Removal And Installation
• Boom Light Disassembly And Assembly
• Light Switch Removal And Installation
• MICROSWITCH
• Testing Left Console Microswitch
• Left Console Microswitch Removal And Installation
• Testing Right Console Microswitch
• Right Console Microswitch Removal And Installation
• TWO-SPEED BOOST SWITCH
• Description
• Removal And Installation
• FUEL LEVEL SENDER
• Removal And Installation
• Testing
• ENGINE
• TROUBLESHOOTING
• Chart
• SPARK ARRESTOR MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• RADIATOR
• Removal And Installation
• ENGINE COMPONENTS AND TESTING
• Valve Clearance Adjustment
• Engine Compression Checking
• Fuel Shutoff Solenoid – Checking
• Fuel Shutoff Solenoid Removal And Installation
• Fuel Shutoff Timer Removal And Installation
• Fuel Injection Pump Check
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump Timing
• Fuel Injector Removal And Installation
• Fuel Injector Checking
• Glow Plug Removal And Installation
• ENGINE
• Description
• Engine Removal and Installation
• Engine Mount Replacement
• FLYWHEEL AND HOUSING
• Flywheel Housing Removal And Installation
• Hydraulic Pump Coupler Removal And Installation
• Flywheel Removal
• Flywheel Installation
• Rear End Plate Removal And Installation
• RECONDITIONING THE ENGINE
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head, Servicing
• Cylinder Head Top Clearance
• Valve Guide, Checking
• Valve Timing, Checking
• Valve And Valve Seat Reconditioning
• Valve Seat Tightness
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft, Checking
• Timing Gearcase Cover Removal And Installation
• Idler Gear And Camshaft Removal And Installation
• Idler Gear and Shaft, Servicing
• Timing Gears Checking Backlash
• Fuel Camshaft Removal And Installation
• Fuel Camshaft Governor
• Crankshaft Gear Removal And Installation
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump, Service
• Engine Oil Pressure, Checking
• Relief Valve
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod, Servicing
• Connecting Rod Alignment
• Crankshaft And Bearings Removal And Installation
• Crankshaft And Bearings, Servicing
• Cylinder Bore, Checking
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Removal And Installation
• Testing The Thermostat
• HEATER SYSTEM
• Description
• Components
• REGULATOR MAINTENANCE
• Filter Element Removal And Installation
• Heater Coil
• HEATER UNIT
• Removal And Installation
• Louver Removal and Installation
• Threaded Insert Removal And Installation
• HEATER COIL
• Removal And Installation
• HEATER FAN
• Removal And Installation
• HEATER VALVE
• Removal And Installation
• SPECIFICATIONS
• EXCAVATOR SPECIFICATIONS
• 324 Excavator Machine Dimensions
• 324 Excavator Machine Dimensions – Standard Arm
• 324 Excavator Machine Dimensions – Long Arm
• Performance
• Controls
• Engine
• Hydraulic System
• Hydraulic Cylinders
• Hydraulic Cycle Times
• Electrical
• Drive System
• Slew System
• Undercarriage
• Capacities
• Tracks
• Ground Pressure
• ENGINE SPECIFICATIONS
• Engine
• Fuel Injector Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Rocker Arms
• Camshaft
• Cylinders
• Piston Rings
• Pistons
• Connecting Rods
• Crankshaft
• Oil Pump
• Thermostat
• Engine Bolt Torque
• TORQUE SPECIFICATIONS FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• HYDRAULIC CONNECTION SPECIFICATIONS
• O-ring Face Seal Connection
• Straight Thread O-ring Fitting
• Tubelines And Hoses
• Flare Fitting
• Port Seal Fitting
• HYDRAULIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion Chart
• ALPHABETICAL INDEX