Bobcat 323 Compact Excavator A9JZ11001 & Up 6986958 (07-14) (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
UPPERSTRUCTURE SLEW LOCK
LIFTING THE EXCAVATOR
OPERATOR CAB (ROPS / TOPS)
Description
Cab Door
Front Window Wiper
Window Washer Reservoir
Front Window
Right Side Windows
Heater (If Equipped)
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
TAILGATE
Opening And Closing The Tailgate
Adjusting The Bumper
Adjusting The Latch
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing The Filter Elements
HEATER AIR FILTERS
Recirculation Filter
Fresh Air Filter
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filters
Replacing Elements
Draining The Fuel Tank
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Diagnostic Couplers
Removing And Replacing The Hydraulic Filter
Removing And Replacing Hydraulic Fluid
LUBRICATING OF THE EXCAVATOR
Lubrication Locations
TRAVEL MOTOR
Checking And Adding Oil
Removing and Replacing Oil
SPARK ARRESTOR MUFFLER
Cleaning Process
ALTERNATOR BELT
Belt Adjustment
Belt Replacement
SEAT BELT
Inspection And Maintenance
CONTROL CONSOLE LOCKOUTS
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
Right Side Rear Window
Front Window
MOTION ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Adjusting Switch Position
REMOTE START TOOL KIT – MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Communicator – MEL1566
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
Description
Remote Start Tool (Service Tool) – 7003030
Excavator Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
CYLINDER (BOOM)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (ARM)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOOM SWING)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BUCKET)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BLADE)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TRACK FRAME EXPANSION)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
VALVE (Main Relief)
Testing And Adjusting The Main Relief Valve
VALVES (PORT RELIEF)
Testing And Adjusting The Port Relief Valve Pressure
VALVES (CROSSPORT RELIEF)
Testing And Adjusting The Crossport Relief Valve
VALVE (PRESSURE REDUCING)
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 / 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
CONTROL PATTERN SELECTOR VALVE
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
CONTROL LEVER (JOYSTICK) (RIGHT)
Description
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
CONTROL LEVER (JOYSTICK) (LEFT)
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 / TRACK EXPANSION SOLENOID BLOCK
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 AND 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
QUICK COUPLER (KLAC SYSTEM)
Troubleshooting
Daily Inspection
Removal And Installation
Parts Identification
Disassembly
Assembly
QUICK COUPLER (LEHNHOFF SYSTEM)
Troubleshooting
Daily Inspection
Removal (MS03 And MS08)
Installation (MS03 And MS08)
Parts Identification (MS03)
Disassembly And Assembly (MS03)
Parts Identification (MS08)
Disassembly (MS08)
Assembly (MS08)
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM
Troubleshooting Chart
ELECTRICAL SYSTEM
Description
Fuses And Relay Location / Identification
Fuel Timer And Diode Location / Identification
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
ENGINE INFORMATION
Description
Specifications
Crankshaft Re-Grind Data
Torque Valves
Torque Values
Troubleshooting
Removal And Installation
Engine Compression Checking
SPARK ARRESTOR MUFFLER
Removal And Installation
AIR CLEANER
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 Pump Removal And Installation
Oil Pump, Service
Engine Oil Pressure, Testing
Relief Valve
FUEL SYSTEM
Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Timer Removal And Installation
Fuel Injection Pump Checking
Fuel Tightness of Pump Element
Fuel Tightness of Delivery Valve
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Fuel Injector Removal And Installation
Fuel Injector Nozzle Checking
CYLINDER HEAD
Glow Plug Removal And Installation
Valve Clearance Adjustment
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 Seat Tightness
Valve Spring
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 PISTONS
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings, Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Checking Backlash
Idler Gear And Camshaft Removal And Installation
Idler Gear and Shaft, Servicing
FLYWHEEL AND HOUSING
Removal And Installation
Hydraulic Pump Coupler Removal And Installation
Hydraulic Pump Coupler Disassembly And Assembly
Flywheel Ring Gear
HEATER
HEATER
Description
Removal And Installation
SPECIFICATIONS
323 EXCAVATOR SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical System
Instrumentation
Drive System
Slew System
Capacities
Fuel Tank
Undercarriage
Crawler Track Design
Ground Pressure
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
CONVERSIONS
Decimal And Millimeter Equivalents Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Engine Tools
HVAC Tools
FUEL, COOLANT AND LUBRICANTS
Chart
ALPHABETICAL INDEX
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