Bobcat Excavators 319 6904188 Service Manual 2 06-21416B320062.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Fire Prevention SERIAL NUMBER LOCATIONS Excavator Serial Number Engine Serial Number DELIVERY REPORT EXCAVATOR IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE EXCAVATOR Procedure UPPERSTRUCTURE SLEW LOCK Operation LIFTING THE EXCAVATOR Procedure OPERATOR CAB (ROPS Description Cab Door Front Window Front Wiper Window Washer Reservoir Right Side Window 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 Filter Elements 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 Fluid Hydraulic Fluid Chart Removing And Replacing Hydraulic Filter Removing And Replacing Hydraulic Fluid LUBRICATING THE EXCAVATOR Lubrication Locations TRAVEL MOTOR Checking And Adding Oil Removing And Replacing Oil SPARK ARRESTOR MUFFLER Cleaning Procedure ALTERNATOR BELT Belt Adjustment Belt Replacement SEAT BELT 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 Exits HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic 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 Identification Chart Disassembly Blade Valve Section Disassembly And Assembly Slew Valve Section Disassembly And Assembly Left Travel Valve Section Disassembly and Assembly Boom Valve Section Disassembly and Assembly Auxiliary Valve Section Disassembly And Assembly Bucket Valve Section Disassembly and Assembly Arm Valve Section Disassembly and Assembly Boom Swing Valve Section Disassembly And Assembly Right Travel Valve Section Disassembly And Assembly Assembly HYDRAULIC PUMP Description Testing The Hydraulic Pump Removal And Installation Parts Identification Disassembly Assembly MANIFOLD ASSEMBLY Description Removal and Installation Parts Identification Disassembly Assembly 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 Description Housing Removal and Installation HYDRAULIC RESERVOIR Description Removal and Installation OIL COOLER Description Removal And Installation BLADE Description Block Removal and Installation Solenoid Removal and Installation Block Disassembly And Assembly UNDERCARRIAGE BLADE Description Extension Removal And Installation Blade Removal And Installation TRACK FRAME COMPONENTS Description Track Lug Height Checking Tension Adjusting Tension Track Removal And Installation Idler (Front) Removal And Installation Idler (Front) Parts Identification Idler (Front) Disassembly Idler (Front) Assembly Track Tension Grease Cylinder Parts Identification Track Tension Grease Cylinder Disassembly And Assembly Roller Removal And Installation Roller Parts Identification Roller Disassembly Roller Assembly Track Guide Removal And Installation Sprocket Removal And Installation Frame Removal And Installation Track Damage Identification SWING CIRCLE GEAR Removal and Installation UPPERSTRUCTURE & SWING SECTION UPPERSTRUCTURE Description Removal Installation 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 BLADE CONTROL Removal and Installation Disassembly And Assembly Cable Removal and Installation UPPERSTRUCTURE SLEW LOCK 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 Rear Floor Panel Removal and Installation Front Floor Panel Removal and Installation Linkage Rod Removal And Installation Linkage Rod Adjustment Boom Swing Pedal Removal And Installation Boom Swing Pedal Disassembly And Assembly Right Travel Lever Removal And Installation Right Travel Lever Disassembly And Assembly Left Travel Lever Removal And Installation Left Travel Lever Disassembly And Assembly Auxiliary Pedal Removal And Installation (If Equipped) Auxiliary Pedal Disassembly And Assembly (If Equipped) Auxiliary Pedal Disassembly And Assembly (If Equipped) 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 AND ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Glossary Of Electrical Symbols Troubleshooting Description Fuse And Relay Location Fuel Timer And Diode Location BATTERY Removal and Installation Servicing Using A Booster Battery (Jump Starting) ALTERNATOR Belt Adjustment Charging System Inspection Description Tests Alternator Output Test Full Field Test Alternator Regulator Test Alternator Regulator Test With Voltmeter Removal And Installation Parts Identification STARTER Removal And Installation Parts Identification 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 FUEL LEVEL SENDER Testing Removal and Installation ENGINE SERVICE ENGINE INFORMATION Description 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 Torque Values Troubleshooting Engine Removal and Installation Engine Mount Replacement Compression - Checking ENGINE SPEED CONTROL Removal and Installation Cable Removal and Installation SPARK ARRESTOR MUFFLER Removal And Installation AIR CLEANER Housing Removal And Installation ENGINE COOLING SYSTEM Radiator Removal And Installation Water Pump Removal And Installation Water Pump Disassembly And Assembly Thermostat Removal And Installation Testing The Thermostat LUBRICATION SYSTEM Oil Pan Removal And Installation Oil Pump Removal And Installation Oil Pump Inspection Engine Oil Pressure - Testing Relief Valve FUEL SYSTEM Fuel Camshaft Removal And Installation Fuel Camshaft Governor Disassembly And Assembly Fuel Shutoff Solenoid - Checking Fuel Shutoff Solenoid - Removal And Installation Fuel Shutoff Timer Removal And Installation Fuel Injection Pump - Checking Fuel Injection Pump Removal And Installation Injection Pump - Timing Fuel Injector Removal And Installation Fuel Injector Nozzle Pressure - Checking Nozzle Spray Condition Valve Seat Tightness CYLINDER HEAD Glow Plug Removal And Installation Glow Plugs - Testing Valve Clearance Adjustment Valve Timing, Checking Cylinder Head Removal And Installation Cylinder Head Disassembly And Assembly Cylinder Head - Servicing Cylinder Head Top Clearance Valve Guide - Checking Reconditioning The Valve And Valve Seat Valve Spring Valve Tappets Rocker Arm And Shaft - Checking CRANKSHAFT AND PISTONS Piston And Connecting Rod Removal And Installation Piston And Connecting Rod - Servicing Cylinder Bore Checking Connecting Rod Alignment Crankshaft Gear Removal And Installation Crankshaft And Bearings Removal And Installation Crankshaft And Bearings - Servicing CAMSHAFT AND TIMING GEARS Timing Gearcase Cover Removal And Installation Timing Gears Backlash - Checking Idler Gear And Shaft Removal And Installation Camshaft - Servicing Idler Gear And Shaft Servicing FLYWHEEL AND HOUSING Flywheel Housing Removal And Installation Hydraulic Pump Coupler Removal And Installation Flywheel Removal Flywheel Installation Rear End Plate Removal And Installation HEATER 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 319 EXCAVATOR SPECIFICATIONS Dimensions Performance Controls Engine Hydraulic System Hydraulic Cylinders Hydraulic Cycle Times Electrical Instrumentation Drive System Slew System Undercarriage Crawler Track Design Capacities Fuel Tank Tracks Type Ground Pressure 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 SMR 319-1 . 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