Service manual Bobcat 319 Compact Excavator | 6904188 (2-06)

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 / TOPS)
— 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/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
— 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/ACCUMULATOR
— 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/TRACK EXPANSION SOLENOID BLOCK
— 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 / Identification
— Fuel Timer And Diode Location / Identification
– 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