Bobcat 323 Compact Excavator Service Manual 6986958 – PDF DOWNLOAD
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Bobcat 323 Compact Excavator Service Manual 6986958 – PDF DOWNLOAD
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Description
Bobcat 323 Compact Excavator Service Manual 6986958 – PDF DOWNLOAD
FILE DETAILS:
Bobcat 323 Compact Excavator Service Manual 6986958 – PDF DOWNLOAD
Language : English
Pages : 697
Downloadable : Yes
File Type : PDF
Size: 20.4 MB
DESCRIPTION:
Bobcat 323 Compact Excavator Service Manual 6986958 – PDF DOWNLOAD
FOREWORD
This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing an d
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:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the excavator gives operating information as well as routin e
maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sol d.
Replacement Operation & Maintenance Manuals can be ordered from your Bobcat Excavator dealer.
• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations
are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator dealer.
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow
the safety message to avoid personal injury or death.
• The Bobcat Hydraulic Excavator has a plastic Operator’s Handbook fastened to the operator cab. It’s brief instructions
are convenient to the operator. The handbook is available from your dealer in an English, French, German, Dutch, Italian,
Spanish, Portugese, Finnish, Danish, and Swedish editions.
• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Bobcat compact Excavator Operator Training Course is available through your local dealer. This course is intended
to provide rules and practices of correct operation of the Hydraulic Excavator.
TABLE OF CONTENTS:
Bobcat 323 Compact Excavator Service Manual 6986958 – PDF DOWNLOAD
MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
UPPERSTRUCTURE SLEW LOCK 25
LIFTING THE EXCAVATOR 27
OPERATOR CAB (ROPS / TOPS) 29
Description 29
Cab Door 30
Front Window Wiper 30
Window Washer Reservoir 30
Front Window 31
Right Side Windows 32
Heater (If Equipped) 33
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TAILGATE 37
Opening And Closing The Tailgate 37
Adjusting The Bumper 37
Adjusting The Latch 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Daily Check 41
Replacing The Filter Elements 41
HEATER AIR FILTERS 43
Recirculation Filter 43
Fresh Air Filter 43
ENGINE COOLING SYSTEM 45
Cleaning 45
Checking Level 45
Removing And Replacing The Coolant 46
FUEL SYSTEM 49
Fuel Specifications 49
Biodiesel Blend Fuel 49
Filling The Fuel Tank 50
Fuel Filters 51
Replacing Elements 51
Draining The Fuel Tank 52
Removing Air From The Fuel System 52
ENGINE LUBRICATION SYSTEM 53
Checking And Adding Engine Oil 53
Engine Oil Chart 53
Replacing Oil And Filter 54
HYDRAULIC SYSTEM 55
Checking And Adding Fluid 55
Hydraulic / Hydrostatic Fluid Chart 55
Diagnostic Couplers 56
Removing And Replacing The Hydraulic Filter 56
Removing And Replacing Hydraulic Fluid 56
LUBRICATING OF THE EXCAVATOR 59
Lubrication Locations 59
TRAVEL MOTOR 63
Checking And Adding Oil 63
Removing and Replacing Oil 63
SPARK ARRESTOR MUFFLER 65
Cleaning Process 65
ALTERNATOR BELT 67
Belt Adjustment 67
Belt Replacement 68
SEAT BELT 69
Inspection And Maintenance 69
CONTROL CONSOLE LOCKOUTS 71
Inspection And Maintenance 71
PIVOT PINS 73
Inspection And Maintenance 73
EXCAVATOR STORAGE AND RETURN TO SERVICE 75
Storage 75
Return To Service 75
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 77
Procedure 77
EMERGENCY EXITS 79
Right Side Rear Window 79
Front Window 79
MOTION ALARM SYSTEM (IF EQUIPPED) 81
Description 81
Inspecting 81
Adjusting Switch Position 81
REMOTE START TOOL KIT – MEL1563 83
Remote Start Tool – MEL1563 83
Service Tool Harness Communicator – MEL1566 85
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031 87
Description 87
Remote Start Tool (Service Tool) – 7003030 88
Excavator Service Tool Harness – 6689747 89
Computer Service Tool Harness – 6689746 90
HYDRAULIC SYSTEM 91
HYDRAULIC/HYDROSTATIC SCHEMATICS 95
HYDRAULIC SYSTEM INFORMATION 97
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators 97
Troubleshooting The Hydraulic Circuit 100
Troubleshooting The Cylinder Circuit 101
Troubleshooting The Swing (Upperstructure Slew) Circuit 102
Troubleshooting The Travel Circuit 103
CYLINDER (BOOM) 105
Testing 105
Removal And Installation 108
Parts Identification 110
Disassembly 111
Assembly 113
CYLINDER (ARM) 117
Testing 117
Removal And Installation 118
Parts Identification 120
Disassembly 121
Assembly 123
CYLINDER (BOOM SWING) 127
Testing 127
Removal And Installation 128
Parts Identification 131
Disassembly 132
Assembly 134
CYLINDER (BUCKET) 137
Testing 137
Removal And Installation 138
Parts Identification 140
Disassembly 141
Assembly 143
CYLINDER (BLADE) 147
Testing 147
Removal And Installation 149
Parts Identification 151
Disassembly 152
Assembly 154
CYLINDER (TRACK FRAME EXPANSION) 157
Testing 157
Removal And Installation 158
Parts Identification 162
Disassembly 163
Assembly 165
VALVE (Main Relief) 169
Testing And Adjusting The Main Relief Valve 169
VALVES (PORT RELIEF) 171
Testing And Adjusting The Port Relief Valve Pressure 171
VALVES (CROSSPORT RELIEF) 173
Testing And Adjusting The Crossport Relief Valve 173
VALVE (PRESSURE REDUCING) 177
Testing And Adjusting The Pressure Reducing Valve 177
HYDRAULIC CONTROL VALVE 179
Description 179
Removal And Installation 179
Parts Identification 182
Disassembly 183
Right Travel Valve Section Disassembly And Assembly 184
Boom Swing Valve Section Disassembly And Assembly 189
Arm Valve Section Disassembly and Assembly 192
Bucket Valve Section Disassembly And Assembly 195
Auxiliary Valve Section Disassembly And Assembly 198
Boom Valve Section Disassembly And Assembly 203
Left Travel Valve Section Disassembly And Assembly 206
Swing Valve Section Disassembly And Assembly 211
Blade Valve Section Disassembly And Assembly 214
Assembly 218
HYDRAULIC PUMP 223
Description 223
Torque Adjustment 224
Testing The Piston Pump 224
Testing The Gear Pump 226
Testing Auxiliary Hydraulic Flow 227
Removal And Installation 228
Hydraulic Pump Start Up 232
Parts Identification 233
Disassembly 234
Gear Pump Disassembly 235
Piston Pump Disassembly 237
Piston Pump Assembly 246
Gear Pump Assembly 255
Assembly 257
MANIFOLD ASSEMBLY / ACCUMULATOR 259
Description 259
Removal And Installation 259
Parts Identification 262
Disassembly 263
Assembly 276
TRAVEL MOTOR 289
Description 289
Removal And Installation 289
Parts Identification 290
Disassembly 291
Assembly 298
SWIVEL JOINT 307
Description 307
Removal And Installation 307
Parts Identification 310
Disassembly 311
Assembly 313
SWING MOTOR 317
Description 317
Removal And Installation 317
Parts Identification 318
Disassembly 319
Assembly 325
CONTROL PATTERN SELECTOR VALVE 333
Description 333
Removal And Installation 333
Parts Identification 335
Disassembly 336
Assembly 337
CONTROL LEVER (JOYSTICK) (RIGHT) 339
Description 339
Testing 339
Handle Removal And Installation 341
Removal And Installation 342
Parts Identification 343
Disassembly 344
Assembly 348
CONTROL LEVER (JOYSTICK) (LEFT) 353
Description 353
Testing 353
Handle Removal And Installation 355
Removal And Installation 357
Parts Identification 358
Disassembly 359
Assembly 363
HYDRAULIC FILTER MOUNT 367
Removal And Installation 367
HYDRAULIC RESERVOIR 369
Removal And Installation 369
OIL COOLER 371
Description 371
Removal And Installation 371
BLADE / TRACK EXPANSION SOLENOID BLOCK 373
Block Removal And Installation 373
Solenoid Removal And Installation 374
Block Disassembly And Assembly 376
UNDERCARRIAGE 379
BLADE 381
Extension Removal And Installation 381
Blade Removal And Installation 381
TRACKS 383
Track Lug Height 383
Track Tension Adjustment 384
Removal And Installation 386
TRACK FRAME 387
Disassembly And Assembly 387
Removal And Installation Of Expandable Track Frame 388
TRACK DAMAGE IDENTIFICATION 391
Cutting Of The Steel Cords 391
Causes Of The Damage 391
Abrasion Of Embedded Metals 392
Separation Of Embedded Metals 393
Separation Of Embedded Metals Due To Corrosion 394
Cuts On The Lug Side Rubber 395
Cracks On The Lug Side Rubber Due To Fatigue 396
Lug Abrasion 397
Cracks And Cuts On The Lug Side Rubber 398
Abrasion Of The Track Roller Side 399
Cuts On The Edges Of The Track Roller Side 400
TRACK IDLER 403
Parts Identification 403
Disassembly 404
Assembly 406
TRACK ROLLER 409
Parts Identification 409
Disassembly 410
Assembly 412
SWING CIRCLE GEAR 415
Removal and Installation 415
UPPERSTRUCTURE AND SWING SECTION 417
UPPERSTRUCTURE 421
Description 421
Removal 421
Installation 423
ROPS CANOPY 427
Removal And Installation 427
CAB 431
Removal And Installation 431
Door Removal And Installation 435
Front Window Removal And Installation 436
Right Side Rear Sliding Window Removal And Installation 439
Right Side Front Sliding Window Removal And Installation 440
Glass Removal 440
Glass Installation 441
SEAT AND SEAT MOUNT 443
Removal And Installation 443
RIGHT CONSOLE 445
Description 445
Console Cover Removal And Installation (Cab) 445
Console Cover Removal And Installation (ROPS Canopy) 447
Gas Spring Removal And Installation (ROPS Canopy) 450
Lock Lever Removal And Installation (ROPS Canopy) 451
Adjustment (ROPS Canopy Models) 453
Latch Hook Removal And Installation (ROPS Canopy) 453
Latch Hook Disassembly And Assembly (ROPS Canopy) 454
Cab Models 455
Upper Console Removal And Installation 456
Console Base Removal And Installation 457
LEFT CONSOLE 461
Description 461
Console Cover Removal And Installation 461
Gas Spring Removal And Installation 463
Lock Lever Removal And Installation 464
Adjustment 466
Latch Hook Removal And Installation 467
Latch Hook Disassembly And Assembly 468
Upper Console Removal And Installation 469
Console Base Removal And Installation 470
ENGINE SPEED CONTROL 473
Removal And Installation 473
Engine Speed Control Cable Removal And Installation 474
BLADE CONTROL 477
Removal And Installation 477
Disassembly And Assembly 478
SWING LOCK 481
Removal And Installation 481
RIGHT PEDAL AND LINKAGE 483
Description 483
Right Pedal Removal And Installation 483
Disassembly And Assembly 484
Linkage Removal And Installation 485
Linkage Disassembly And Assembly 485
TRAVEL CONTROLS 487
Description 487
Removal And Installation 487
Disassembly And Assembly 487
LEFT PEDAL 489
Removal And Installation 489
Disassembly And Assembly 490
CONTROL LINKAGE ASSEMBLY 491
Removal And Installation 491
Left Pedal Linkage Disassembly And Assembly 492
Right Travel Control Linkage Disassembly And Assembly 493
Left Travel Control Linkage Disassembly And Assembly 494
Left Pedal Bellcrank Disassembly And Assembly 495
Linkage Rod Removal And Installation 497
Linkage Rod Adjustment 498
FLOOR MAT AND FLOOR PANELS 499
Description 499
Removal And Installation 499
BLADE EXTENSION TRAY 503
Removal And Installation 503
FUEL TANK 505
Removal And Installation 505
HORN 507
Removal And Installation 507
SWING FRAME 509
Description 509
Removal And Installation 509
Bushing Replacement 511
Swing Frame Bushing Removal 512
Swing Frame Bushing Installation 512
Boom Pivot Bushing Removal And Installation 513
BOOM 515
Description 515
Removal And Installation 515
Boom Bushing Removal And Installation 517
ARM 519
Description 519
Removal And Installation 519
Arm To Boom Bushing Removal And Installation 520
Arm To Bucket And Bucket Link Bushing Removal And Installation 521
BUCKET 523
Removal And Installation 523
TAILGATE 525
Removal And Installation 525
Latch Removal And Installation 526
QUICK COUPLER (KLAC SYSTEM) 527
Troubleshooting 527
Daily Inspection 527
Removal And Installation 528
Parts Identification 530
Disassembly 531
Assembly 532
QUICK COUPLER (LEHNHOFF SYSTEM) 535
Troubleshooting 535
Daily Inspection 535
Removal (MS03 And MS08) 536
Installation (MS03 And MS08) 537
Parts Identification (MS03) 538
Disassembly And Assembly (MS03) 539
Parts Identification (MS08) 540
Disassembly (MS08) 541
Assembly (MS08) 544
ELECTRICAL SYSTEM & ANALYSIS 549
ELECTRICAL SCHEMATICS 551
ELECTRICAL SYSTEM 552
Troubleshooting Chart 552
ELECTRICAL SYSTEM 553
Description 553
Fuses And Relay Location / Identification 553
Fuel Timer And Diode Location / Identification 553
BATTERY 554
Servicing 554
Removing And Installing The Battery 555
Using A Booster Battery (Jump Starting) 556
ALTERNATOR 558
Description 558
Tests 558
Alternator Output Test 559
Full Field Test 559
Alternator Regulator Test 560
Alternator Regulator Test With Voltmeter 560
Removal And Installation 561
Parts Identification 563
Disassembly And Assembly 563
STARTER 564
Removal And Installation 564
Parts Identification 565
Disassembly And Assembly 565
Cleaning And Inspection 565
LIGHTS 566
Uppestructure Light Removal And Installation 566
Uppestructure Light Disassembly And Assembly 566
Boom Light Removal And Installation 567
Boom Light Bulb Replacement 567
Light Switch Removal And Installation 568
MICROSWITCH 570
Adjustment 570
Testing 571
Removal And Installation 572
TWO-SPEED SWITCH 574
Removal And Installation 574
FUEL LEVEL SENDER 576
Removal And Installation 576
Testing 576
TWO-SPEED BOOST SWITCH 578
Description 578
Removal And Installation 578
ENGINE SERVICE 580
ENGINE INFORMATION 582
Description 582
Specifications 583
Crankshaft Re-Grind Data 588
Torque Valves 589
Torque Values 590
Troubleshooting 592
Removal And Installation 593
Engine Compression Checking 600
SPARK ARRESTOR MUFFLER 602
Removal And Installation 602
AIR CLEANER 604
Removal And Installation 604
ENGINE COOLING SYSTEM 606
Radiator Removal And Installation 606
Water Pump Removal And Installation 611
Water Pump Disassembly And Assembly 611
Thermostat Removal And Installation 612
Testing The Thermostat 612
LUBRICATION SYSTEM 614
Oil Pump Removal And Installation 614
Oil Pump, Service 614
Engine Oil Pressure, Testing 615
Relief Valve 616
FUEL SYSTEM 618
Fuel Shutoff Solenoid Removal And Installation 618
Fuel Shutoff Timer Removal And Installation 618
Fuel Injection Pump Checking 619
Fuel Tightness of Pump Element 619
Fuel Tightness of Delivery Valve 619
Fuel Injection Pump Removal And Installation 620
Fuel Injection Pump Timing 621
Fuel Camshaft Removal And Installation 623
Fuel Camshaft Governor 623
Fuel Injector Removal And Installation 624
Fuel Injector Nozzle Checking 625
CYLINDER HEAD 628
Glow Plug Removal And Installation 628
Valve Clearance Adjustment 629
Cylinder Head Removal And Installation 630
Cylinder Head Disassembly And Assembly 632
Cylinder Head, Servicing 633
Cylinder Head Top Clearance 633
Valve Guide, Checking 634
Valve And Valve Seat Reconditioning 636
Valve Seat Tightness 637
Valve Spring 638
Rocker Arm And Shaft, Checking 639
CRANKSHAFT AND PISTONS 640
Piston And Connecting Rod Removal And Installation 640
Piston And Connecting Rod, Servicing 642
Cylinder Bore, Checking 644
Connecting Rod Alignment 645
Crankshaft Gear Removal And Installation 645
CRANKSHAFT AND PISTONS 646
Crankshaft And Bearings Removal And Installation 646
Crankshaft And Bearings, Servicing 649
CAMSHAFT AND TIMING GEARS 652
Timing Gearcase Cover Removal And Installation 652
Timing Gears Checking Backlash 654
Idler Gear And Camshaft Removal And Installation 655
Idler Gear and Shaft, Servicing 658
FLYWHEEL AND HOUSING 660
Removal And Installation 660
Hydraulic Pump Coupler Removal And Installation 661
Hydraulic Pump Coupler Disassembly And Assembly 662
Flywheel Ring Gear 662
HEATER 664
HEATER 666
Description 666
Removal And Installation 666
SPECIFICATIONS 668
323 EXCAVATOR SPECIFICATIONS 670
Machine Dimensions 670
Performance 672
Controls 672
Engine 672
Hydraulic System 673
Hydraulic Cylinders 673
Hydraulic Cycle Times 674
Electrical System 674
Instrumentation 674
Drive System 674
Slew System 674
Capacities 674
Fuel Tank 674
Undercarriage 675
Crawler Track Design 675
Ground Pressure 675
TORQUE SPECIFICATIONS 676
Torque For General SAE Bolts 676
Torque For General Metric Bolts 677
HYDRAULIC CONNECTION SPECIFICATIONS 678
O-ring Face Seal Connection 678
Straight Thread O-ring Fitting 678
Tubelines And Hoses 678
Flare Fitting 679
O-ring Flare Fitting 680
Port Seal Fitting 682
HYDRAULIC FLUID SPECIFICATIONS 684
Specifications 684
CONVERSIONS 686
Decimal And Millimeter Equivalents Chart 686
U S To Metric Conversion Chart 687
SERVICE TOOLS REQUIRED 688
Remote Start Tools 688
Hydraulic Tools 689
Engine Tools 691
HVAC Tools 693
FUEL, COOLANT AND LUBRICANTS 694
Chart 694
ALPHABETICAL INDEX 696
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M
