Bobcat Excavators 323 6986958 Service Manual 2 08-21416B320069.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Before Operation Safe Operation Is The Operator�s Responsibility Safe Operation Needs A Qualified Operator Avoid Silica Dust 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 BOBCAT EXCAVATOR IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE EXCAVATOR Procedure UPPERSTRUCTURE SLEW LOCK LIFTING THE EXCAVATOR OPERATOR CAB ROPS Emergency Exits Cab Door Front Window Wiper Window Washer Reservoir Front Window Right Side Windows TRANSPORTING THE EXCAVATOR TAILGATE Opening And Closing The Tailgate Adjusting The Bumper Adjusting The Tailgate Latch SERVICE SCHEDULE Chart AIR CLEANER SERVICE Daily Check Replacing The Filters HEATER AIR FILTERS Recirculation Filter Fresh Air Filter ENGINE COOLING SYSTEM Cleaning The Cooling System Checking Coolant Level Replacing The Coolant FUEL SYSTEM Fuel Specifications Biodiesel Blend Fuel Filling The Fuel Tank Removing Water From The Fuel Filter Replacing The Fuel Filter Draining The Fuel Tank Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking Engine Oil Oil Chart Replacing Oil And Filter HYDRAULIC SYSTEM Checking And Adding Hydraulic Oil Hydraulic Fluid Chart Diagnostic Couplers Replacing The Hydraulic Filter Replacing Hydraulic Oil LUBRICATION OF THE HYDRAULIC EXCAVATOR TRAVEL MOTOR Checking Oil Level Draining The Travel Motor SPARK ARRESTOR MUFFLER ALTERNATOR BELT Adjusting The Alternator Belt SEAT BELT Inspection And Maintenance CONTROL CONSOLE LOCKOUTS Inspection And Maintenance EXCAVATOR STORAGE AND RETURN TO SERVICE Storage Return to Service STOPPING THE ENGINE AND LEAVING THE EXCAVATOR Procedure Emergency Exits MOTION ALARM SYSTEM (IF EQUIPPED) Description Inspecting Adjusting Switch Position 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 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 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 Hydraulic Pump Start Up Parts Identification Disassembly Gear Pump Disassembly Piston Pump Disassembly Piston Pump Assembly Gear Pump Assembly 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 CONTROL PATTERN SELECTOR VALVE 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 Removal And Installation HYDRAULIC RESERVOIR Removal And Installation OIL COOLER Description Removal And Installation BLADE Block Removal And Installation Solenoid Removal And Installation Block Disassembly And Assembly UNDERCARRIAGE BLADE 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 SECTION 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 Glass Installation SEAT AND SEAT MOUNT Removal And Installation RIGHT CONSOLE Description Console Cover Removal And Installation (Cab) Console Cover Removal And Installation (ROPS Canopy) Gas Spring Removal And Installation (ROPS Canopy) Lock Lever Removal And Installation (ROPS Canopy) Adjustment (ROPS Canopy Models) Latch Hook Removal And Installation (ROPS Canopy) Latch Hook Disassembly And Assembly (ROPS Canopy) Cab Models Upper Console Removal And Installation Console Base Removal And Installation LEFT CONSOLE Description Console Cover Removal And Installation Gas Spring Removal And Installation Lock Lever Removal And Installation Adjustment Latch Hook Removal And Installation Latch Hook Disassembly And Assembly Upper Console Removal And Installation Console Base Removal And Installation ENGINE SPEED CONTROL Removal And Installation Engine Speed Control Cable Removal And Installation BLADE CONTROL Removal And Installation Disassembly And Assembly SWING LOCK Removal and Installation RIGHT PEDAL AND LINKAGE Description Right Pedal Removal And Installation Disassembly And Assembly Linkage Removal And Installation Linkage Disassembly And Assembly TRAVEL CONTROLS Description Removal And Installation Disassembly And Assembly LEFT PEDAL Removal And Installation Disassembly And Assembly CONTROL LINKAGE ASSEMBLY Removal And Installation Left Pedal Linkage Disassembly And Assembly Right Travel Control Linkage Disassembly And Assembly Left Travel Control Linkage Disassembly And Assembly Left Pedal Bellcrank Disassembly And Assembly Linkage Rod Removal And Installation Linkage Rod Adjustment FLOOR MAT AND FLOOR PANELS Description Removal And Installation BLADE EXTENSION TRAY Removal And Installation FUEL TANK Removal And Installation HORN Removal And Installation SWING FRAME Description Removal And Installation Bushing Replacement Swing Frame Bushing Removal Swing Frame Bushing Installation Boom Pivot Bushing Removal And 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 Troubleshooting Chart Description Fuses Relays And Diodes BATTERY Servicing Removing And Installing The Battery 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 Parts Identification Disassembly And Assembly STARTER Removal And Installation Parts Identification Disassembly And Assembly Cleaning And Inspection LIGHTS Uppestructure Light Removal And Installation Uppestructure Light Disassembly And Assembly Boom Light Removal And Installation Boom Light Bulb Replacement Light Switch Removal And Installation MICROSWITCH Adjustment Testing Removal And Installation TWO-SPEED SWITCH Removal And Installation FUEL LEVEL SENDER Removal And Installation Testing TWO-SPEED BOOST SWITCH Description Removal And Installation ENGINE SERVICE 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 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 Removal And Installation ENGINE FLYWHEEL Removal And Installation Hydraulic Pump Coupler Removal And Installation Hydraulic Pump Coupler Disassembly And Assembly Flywheel Ring Gear RECONDITIONING THE ENGINE Cylinder Head Removal And Installation Cylinder Head Disassembly And Assembly Cylinder Head, Servicing Cylinder Head Top Clearance Valve Guide, Checking Valve And Valve Seat Reconditioning Valve Spring 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 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 HEATER HEATER Description Removal And Installation SPECIFICATIONS SPECIFICATIONS 323 Excavator Machine Dimensions Performance Controls Engine Hydraulic System Hydraulic Cylinders Hydraulic Cycle Times Electrical System Instrumentation Drive System Slew System Undercarriage Crawler Track Design 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 Crankshaft Re-Grind Data TORQUE SPECIFICATIONS 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 O-Ring Flare Fitting Port Seal Fitting HYDRAULIC FLUID SPECIFICATIONS Specifications FUEL, COOLANT AND LUBRICANTS Chart CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion . 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