Bobcat 323 Excavator Service Manual 6903380 (6-11) – PDF DOWNLOAD

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Bobcat 323 Excavator Service Manual 6903380 (6-11) – PDF DOWNLOAD

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Bobcat 323 Excavator Service Manual 6903380 (6-11) – PDF DOWNLOAD

Language : English
Pages : 673
Downloadable : Yes
File Type : PDF
Size:24.8 MB

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Bobcat 323 Excavator Service Manual 6903380 (6-11) – PDF DOWNLOAD

S/N 562411001 Above

FOREWORD
This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS

Instructions are necessary before operating or 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.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat 323 Excavator Service Manual 6903380 (6-11) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 12
FIRE PREVENTION 14
Maintenance 14
Operation 14
Electrical 14
Hydraulic System 14
Fueling 14
Starting 14
Spark Arrester Exhaust System 14
Welding And Grinding 15
Fire Extinguishers 15
SERIAL NUMBER LOCATIONS 16
Excavator Serial Number 16
Engine Serial Number 16
DELIVERY REPORT 17
BOBCAT EXCAVATOR IDENTIFICATION 18
SAFETY MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
UPPERSTRUCTURE SLEW LOCK 23
LIFTING THE EXCAVATOR 25
OPERATOR CAB ROPS / TOPS (IF EQUIPPED) 27
Emergency Exits 27
Cab Door 27
Front Window Wiper 28
Window Washer Reservoir 29
Front Window 29
Right Side Windows 31
TRANSPORTING THE EXCAVATOR 33
TAILGATE 35
Opening And Closing The Tailgate 35
Adjusting The Bumper 35
Adjusting The Tailgate Latch 35
SERVICE SCHEDULE 37
Chart 37
AIR CLEANER SERVICE 39
Daily Check 39
Replacing The Filters 39
HEATER AIR FILTERS 41
Recirculation Filter 41
Fresh Air Filter 41
ENGINE COOLING SYSTEM 43
Cleaning The Cooling System 43
Checking Coolant Level 43
Replacing The Coolant 44
FUEL SYSTEM 47
Fuel Specifications 47
Filling The Fuel Tank 47
Removing Water From The Fuel Filter 48
Replacing The Fuel Filter 48
Draining The Fuel Tank 49
Removing Air From The Fuel System 49
ENGINE LUBRICATION SYSTEM 51
Checking Engine Oil 51
Oil Chart 51
Replacing Oil And Filter 52
HYDRAULIC SYSTEM 53
Checking And Adding Hydraulic Oil 53
Diagnostic Couplers 53
Replacing The Hydraulic Filter 54
Replacing Hydraulic Oil 54
LUBRICATION OF THE HYDRAULIC EXCAVATOR 57
TRAVEL MOTOR 59
Checking Oil Level 59
Draining The Travel Motor 59
SPARK ARRESTER MUFFLER 61
ALTERNATOR BELT 63
Adjusting The Alternator Belt 63
SEAT BELT 65
Inspection And Maintenance 65
CONTROL CONSOLE LOCKOUTS 67
Inspection And Maintenance 67
HYDRAULIC SYSTEM 69
HYDRAULIC / HYDROSTATIC SCHEMATIC 73
HYDRAULIC SYSTEM INFORMATION 75
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators 75
Troubleshooting The Hydraulic Circuit 78
Troubleshooting The Cylinder Circuit 79
Troubleshooting The Swing (Upperstructure Slew) Circuit 80
Troubleshooting The Travel Circuit 81
CYLINDER (BOOM) 83
Testing 83
Removal And Installation 86
Parts Identification 89
Disassembly 90
Assembly 92
CYLINDER (ARM) 95
Testing 95
Removal And Installation 96
Parts Identification 98
Disassembly 99
Assembly 101
CYLINDER (BOOM SWING) 105
Testing 105
Removal And Installation 106
Parts Identification 109
Disassembly 110
Assembly 112
CYLINDER (BUCKET) 115
Testing 115
Removal And Installation 116
Parts Identification 118
Disassembly 119
Assembly 121
CYLINDER (BLADE) 125
Testing 125
Removal And Installation 127
Parts Identification 129
Disassembly 130
Assembly 132
CYLINDER (TRACK FRAME EXPANSION) 135
Testing 135
Removal And Installation 136
Parts Identification 140
Disassembly 141
Assembly 142
VALVE (MAIN RELIEF) 147
Testing And Adjusting The Main Relief Valve 147
VALVES (PORT RELIEF) 149
Testing And Adjusting The Port Relief Valve Pressure 149
VALVES (CROSSPORT RELIEF) 151
Testing And Adjusting The Crossport Relief Valve 151
VALVE (PRESSURE REDUCING) 155
Testing And Adjusting The Pressure Reducing Valve 155
HYDRAULIC CONTROL VALVE 157
Description 157
Removal And Installation 157
Parts Identification 160
Disassembly 161
Right Travel Valve Section Disassembly And Assembly 162
Boom Swing Valve Section Disassembly And Assembly 167
Arm Valve Section Disassembly And Assembly 170
Bucket Valve Section Disassembly And Assembly 173
Auxiliary Valve Section Disassembly And Assembly 176
Boom Valve Section Disassembly And Assembly 181
Left Travel Valve Section Disassembly And Assembly 184
Swing Valve Section Disassembly And Assembly 189
Blade Valve Section Disassembly And Assembly 192
Assembly 196
HYDRAULIC PUMP 201
Description 201
Torque Adjustment 201
Testing The Piston Pump 202
Testing The Gear Pump 204
Testing Auxiliary Hydraulic Flow 205
Removal And Installation 206
Parts Identification 210
Disassembly 211
Gear Pump Disassembly 212
Piston Pump Disassembly 214
Piston Pump Assembly 223
Gear Pump Assembly 232
Assembly 234
MANIFOLD ASSEMBLY / ACCUMULATOR 237
Description 237
Removal And Installation 237
Parts Identification 240
Disassembly 241
Assembly 254
TRAVEL MOTOR 267
Removal And Installation 267
Parts Identification 268
Disassembly 269
Assembly 276
SWIVEL JOINT 285
Removal And Installation 285
Parts Identification 288
Disassembly 289
Assembly 291
SWING MOTOR 295
Removal And Installation 295
Parts Identification 296
Disassembly 297
Assembly 303
CONTROL PATTERN SELECTOR VALVE 311
Removal And Installation 311
Parts Identification 313
Disassembly 314
Assembly 315
CONTROL LEVER (JOYSTICK) (RIGHT) 317
Testing 317
Handle Removal And Installation 319
Removal And Installation 320
Parts Identification 321
Disassembly 322
Assembly 327
CONTROL LEVER (JOYSTICK) (LEFT) 333
Testing 333
Handle Removal And Installation 335
Removal And Installation 337
Parts Identification 338
Disassembly 339
Assembly 344
HYDRAULIC FILTER MOUNT 349
Removal And Installation 349
HYDRAULIC RESERVOIR 351
Removal And Installation 351
OIL COOLER 353
Removal And Installation 353
BLADE / TRACK EXPANSION SOLENOID BLOCK 355
Block Removal And Installation 355
Solenoid Removal And Installation 356
Block Disassembly And Assembly 358
UNDERCARRIAGE 361
BLADE 363
Extension Removal And Installation 363
Blade Removal And Installation 363
TRACKS 365
Track Lug Height 365
Track Tension Adjustment 366
Removal And Installation 368
TRACK FRAME 369
Disassembly And Assembly 369
Removal And Installation Of Expandable Track Frame 370
TRACK DAMAGE IDENTIFICATION 373
Cutting Of The Steel Cords 373
Causes Of The Damage 373
Abrasion Of Embedded Metals 374
Separation Of Embedded Metals 375
Separation Of Embedded Metals Due To Corrosion 376
Cuts On The Lug Side Rubber 377
Cracks On The Lug Side Rubber Due To Fatigue 378
Lug Abrasion 379
Cracks And Cuts On The Lug Side Rubber 380
Abrasion Of The Track Roller Side 381
Cuts On The Edges Of The Track Roller Side 382
TRACK IDLER 385
Parts Identification 385
Disassembly 386
Assembly 388
TRACK ROLLER 391
Parts Identification 391
Disassembly 392
Assembly 394
SWING CIRCLE GEAR 397
Removal And Installation 397
UPPERSTRUCTURE SWING SECTION 399
UPPERSTRUCTURE 403
Removal 403
Installation 405
ROPS CANOPY 409
Removal And Installation 409
CAB 413
Removal And Installation 413
Door Removal And Installation 417
Front Window Removal And Installation 418
Right Side Rear Sliding Window Removal And Installation 421
Right Side Front Sliding Window Removal And Installation 422
Glass Removal 422
Glass Installation 423
SEAT AND SEAT MOUNT 425
Removal And Installation 425
RIGHT CONSOLE 427
Console Cover Removal And Installation (Cab) 427
Console Cover Removal And Installation (ROPS Canopy) 430
Gas Spring Removal And Installation (ROPS Canopy) 433
Lock Lever Removal And Installation (ROPS Canopy) 434
Adjustment (ROPS Canopy Models) 436
Latch Hook Removal And Installation (ROPS Canopy) 436
Latch Hook Disassembly And Assembly (ROPS Canopy) 437
Cab Models 438
Upper Console Removal And Installation 439
Console Base Removal And Installation 440
LEFT CONSOLE 443
Console Cover Removal And Installation 443
Gas Spring Removal And Installation 445
Lock Lever Removal And Installation 446
Adjustment 448
Latch Hook Removal And Installation 449
Latch Hook Disassembly And Assembly 450
Upper Console Removal And Installation 451
Console Base Removal And Installation 452
ENGINE SPEED CONTROL 455
Removal And Installation 455
Engine Speed Control Cable Removal And Installation 456
BLADE CONTROL 459
Removal And Installation 459
Disassembly And Assembly 460
SWING LOCK 463
Removal And Installation 463
RIGHT PEDAL AND LINKAGE 465
Right Pedal Removal And Installation 465
Disassembly And Assembly 466
Linkage Removal And Installation 467
Linkage Disassembly And Assembly 467
TRAVEL CONTROLS 469
Removal And Installation 469
Disassembly And Assembly 469
LEFT PEDAL 471
Removal And Installation 471
Disassembly And Assembly 472
CONTROL LINKAGE ASSEMBLY 473
Removal And Installation 473
Left Pedal Linkage Disassembly And Assembly 474
Right Travel Control Linkage Disassembly And Assembly 475
Left Travel Control Linkage Disassembly And Assembly 476
Left Pedal Bellcrank Disassembly And Assembly 477
Linkage Rod Removal And Installation 478
Linkage Rod Adjustment 480
FLOOR MAT AND FLOOR PANELS 481
Removal And Installation 481
BLADE EXTENSION TRAY 485
Removal And Installation 485
FUEL TANK 487
Removal And Installation 487
HORN 489
Removal And Installation (Earlier Models) 489
Removal And Installation (Later Models) 489
SWING FRAME 491
Removal And Installation 491
Bushing Replacement 493
Swing Frame Bushing Removal 494
Swing Frame Bushing Installation 494
Boom Pivot Bushing Removal And Installation 495
BOOM 497
Removal And Installation 497
Boom Bushing Removal And Installation 499
ARM 501
Removal And Installation 501
Arm To Boom Bushing Removal And Installation 502
Arm To Bucket And Bucket Link Bushing Removal And Installation 503
BUCKET 505
Removal And Installation 505
TAILGATE 507
Removal And Installation 507
Latch Removal And Installation 508
QUICK COUPLER (KLAC™ SYSTEM) 509
Troubleshooting 509
Daily Inspection 509
Removal And Installation 510
Parts Identification 512
Disassembly 513
Assembly 514
QUICK COUPLER (LEHNHOFF® SYSTEM) 517
Troubleshooting 517
Daily Inspection 517
Removal (MS03 And MS08) 518
Installation (MS03 And MS08) 519
Parts Identification (MS03) 520
Disassembly And Assembly (MS03) 521
Parts Identification (MS08) 522
Disassembly (MS08) 523
Assembly (MS08) 526
ELECTRICAL SYSTEM AND ANALYSIS 531
ELECTRICAL SCHEMATICS 533
ELECTRICAL SYSTEM 534
Troubleshooting Chart 534
Description 535
Fuses 535
Relays And Diodes 535
BATTERY 538
Servicing 538
Removing And Installing The Battery 539
Using A Booster Battery (Jump Starting) 540
ALTERNATOR 542
Description 542
Tests 542
Alternator Output Test 543
Full Field Test 543
Alternator Regulator Test 544
Alternator Regulator Test With Voltmeter 544
Removal And Installation 545
Parts Identification 547
Disassembly And Assembly 547
STARTER 548
Removal And Installation 548
Parts Identification 549
Disassembly And Assembly 549
Cleaning And Inspection 549
LIGHTS 550
Uppestructure Light Removal And Installation 550
Uppestructure Light Disassembly And Assembly 550
Boom Light Removal And Installation (Earlier Models) 551
Boom Light Disassembly And Assembly (Earlier Models) 551
Boom Light Removal And Installation (Later Models) 552
Boom Light Bulb Replacement (Later Models) 552
Light Switch Removal And Installation 553
MICROSWITCH 554
Adjustment 554
Testing 556
Removal And Installation 557
TWO-SPEED SWITCH 558
Removal And Installation 558
FUEL LEVEL SENDER 560
Removal And Installation 560
Testing 560
TWO-SPEED BOOST SWITCH 562
Description 562
Removal And Installation 562
ENGINE SERVICE 564
TROUBLESHOOTING 566
Chart 566
SPARK ARRESTER MUFFLER 568
Removal And Installation 568
AIR CLEANER 570
Removal And Installation 570
RADIATOR 572
Removal And Installation 572
ENGINE COMPONENTS AND TESTING 578
Valve Clearance Adjustment 578
Engine Compression Checking 579
Fuel Shutoff Solenoid Removal And Installation 579
Fuel Shutoff Timer Removal And Installation 580
Fuel Injection Pump Check 580
Fuel Injection Pump Removal And Installation 581
Fuel Injection Pump Timing 583
Fuel Injector Removal And Installation 584
Fuel Injector Checking 586
Glow Plug Removal And Installation 588
ENGINE 590
Removal And Installation 590
ENGINE FLYWHEEL 598
Removal And Installation 598
Hydraulic Pump Coupler Removal And Installation 599
Hydraulic Pump Coupler Disassembly And Assembly 600
Flywheel Ring Gear 600
RECONDITIONING THE ENGINE 602
Cylinder Head Removal And Installation 602
Cylinder Head Disassembly And Assembly 603
Cylinder Head, Servicing 604
Cylinder Head Top Clearance 605
Valve Guide, Checking 605
Valve And Valve Seat Reconditioning 607
Valve Spring 608
Rocker Arm And Shaft, Checking 608
Timing Gearcase Cover Removal And Installation 609
Idler Gear And Camshaft Removal And Installation 610
Idler Gear And Shaft, Servicing 613
Timing Gears Checking Backlash 614
Fuel Camshaft Removal And Installation 614
Fuel Camshaft Governor 615
Crankshaft Gear Removal And Installation 615
Oil Pump Removal And Installation 616
Oil Pump, Service 616
Engine Oil Pressure, Checking 617
Relief Valve 618
Piston And Connecting Rod Removal And Installation 619
Piston And Connecting Rod, Servicing 621
Connecting Rod Alignment 623
Crankshaft And Bearings Removal And Installation 623
Crankshaft And Bearings, Servicing 625
Cylinder Bore, Checking 627
Water Pump Removal And Installation 628
Water Pump Disassembly And Assembly 628
HEATER 630
HEATER 632
Removal And Installation 632
SPECIFICATIONS 634
SPECIFICATIONS 636
323 Excavator Machine Dimensions 636
Performance 638
Controls 638
Engine 638
Hydraulic System 639
Hydraulic Cylinders 639
Hydraulic Cycle Times 640
Drive System 640
Undercarriage 640
Track 640
Electrical 641
ENGINE SPECIFICATIONS 642
Specifications 642
Crankshaft Re-Grind Data 647
TORQUE SPECIFICATIONS 648
Torque For General SAE Bolts 648
Torque For General Metric Bolts 649
HYDRAULIC CONNECTION SPECIFICATIONS 650
O-ring Face Seal Connection 650
Straight Thread O-ring Fitting 650
Tubelines And Hoses 650
Flare Fitting 651
O-ring Flare Fitting 652
Port Seal Fitting 654
HYDRAULIC FLUID SPECIFICATIONS 656
Specifications 656
FUEL, COOLANT AND LUBRICANTS 658
Chart 658
CONVERSIONS 660
Decimal And Millimeter Equivalents Chart 660
U S To Metric Conversion Chart 661
ALPHABETICAL INDEX 662
SERVICE MANUAL REVISIONS 664
Revision No: 323-1 664
Revision No: 323-2 666
Revision No: 323-3 668
Revision No: 323-4 670
Revision No: 323 – 5 672

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