Bobcat 323 562411001+ Factory Service & Work Shop Manual

©Bobcat Company 2006 6903380 (11-06) 323 Printed in U.S.A. Service Manual S/N 562411001 & Above

MAINTENANCE SAFETY Never service the Bobcat Compact Excavator without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking, or when near open flame. Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Bobcat Company. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protections approved for type of welding. Keep tailgate closed except for service. Close and latch tailgate before operating the excavator. Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust fumes can kill without warning. Cleaning and maintenance are required daily. MSW28-0805 Use the correct procedure to lift and support the excavator. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. WARNING 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. W-2003-0903 Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. B-10731A CORRECT B-19964 CORRECT CORRECT B-19959 B-19965 WRONG WRONG B-19960 B-19966 WRONG WRONG B-19962 B-19958 WRONG B-19798 WRONG

323 Excavator Service Manual ALPHABETICAL INDEX AIR CLEANER ........................................................ 60-01 AIRCLEANER SERVICE ........................................ 10-01 ALTERNATOR ....................................................... 50-01 ALTERNATOR BELT ............................................. 10-01 ARM ....................................................................... 40-01 ARM CYLINDER .................................................... 20-01 BATTERY ............................................................... 50-01 BLADE ................................................................... 30-01 BLADE CONTROL .................................................. 40-01 BLADE CYLINDER ................................................. 20-01 BLADE EXTENSION TRAY .................................... 40-01 BLADE/TRACK EXPANSION SOLENOID BLOCK 20-01 BOOM ..................................................................... 40-01 BOOM CYLINDER .................................................. 20-01 BOOM SWING CYLINDER..................................... 20-01 BUCKET ................................................................. 40-01 BUCKET CYLINDER .............................................. 20-01 CAB......................................................................... 40-01 CONTROL CONSOLE LOCKOUTS ....................... 10-01 CONTROL LINKAGE ASSEMBLY ......................... 40-01 CONTROL PATTERN SELECTOR VALVE ............ 20-01 CONVERSIONS ............................................... SPEC-01 CROSSPORT RELIEF VALVES............................. 20-01 ELECTRICAL SYSTEM .......................................... 50-01 ENGINE .................................................................. 60-01 ENGINE COMPONENTS AND TESTING .............. 60-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE FLYWHEEL .............................................. 60-01 ENGINE LUBRICATION SYSTEM ......................... 10-01 ENGINE SPECIFICATIONS .............................. SPEC-01 ENGINE SPEED CONTROL .................................. 40-01 FLOORMAT AND FLOORPLATES ........................ 40-01 FUEL, COOLANT AND LUBRICANTS ............. SPEC-01 FUEL LEVEL SENDER........................................... 50-01 FUEL SYSTEM ....................................................... 10-01 FUEL TANK ............................................................ 40-01 HEATER AIR FILTERS .......................................... 10-01 HEATER ................................................................. 70-01 HORN .................................................................... 40-01 HYDRAULIC CONNECTION SPECIFICATIONS ........................................................................... SPEC-01 HYDRAULIC CONTROL VALVE ........................... 20-01 HYDRAULIC FILTER MOUNT................................ 20-01 HYDRAULIC FLUID SPECIFICATIONS ........... SPEC-01 HYDRAULIC PUMP ................................................ 20-01 HYDRAULIC RESERVOIR ..................................... 20-01 HYDRAULIC SYSTEM ........................................... 10-01 HYDRAULIC SYSTEM INFORMATION ................ 20-01 LEFT CONSOLE ..................................................... 40-01 LEFT CONTROL LEVER (JOYSTICK) .................. 20-01 LEFT PEDAL ........................................................... 40-01 LIFTING AND BLOCKING THE EXCAVATOR ....... 10-01 LIFTING THE EXCAVATOR ................................... 10-01 LIGHTS.................................................................... 50-01 LUBRICATION OF THE HYD. EXCAVATOR ......... 10-01 MAIN RELIEF VALVE ............................................. 20-01 MANIFOLD ASSEMBLY/ACCUMULATOR ............. 20-01 MICROSWITCH ...................................................... 50-01 OIL COOLER........................................................... 20-01 OPERATOR CAB (ROPS/TOPS) ............................ 10-01 PORT RELIEF VALVES .......................................... 20-01 PRESSURE REDUCING VALVE ............................ 20-01 RADIATOR ............................................................. 60-01 RECONDITIONING THE ENGINE .........................60-01 RIGHT CONSOLE ................................................... 40-01 RIGHT CONTROL LEVER (JOYSTICK) ................. 20-01 RIGHT PEDAL AND LINKAGE ............................... 40-01 ROPS CANOPY.......................................................40-01 SEAT AND SEAT MOUNT ..................................... 40-01 SEAT BELT ............................................................ 10-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTOR MUFFLER ............... 10-01 & 60-01 SPECIFICATIONS............................................. SPEC-01 STARTER ................................................................ 50-01 SWING CIRCLE GEAR ........................................... 30-01 SWING FRAME ....................................................... 40-01 SLEW LOCK............................................................ 40-01 SWING MOTOR ..................................................... 20-01 SWIVEL JOINT .......................................................20-01 TAILGATE ............................................................... 40-01 TORQUE SPECIFICATIONS ............................SPEC-01 TRACK DAMAGE IDENTIFICATION ...................... 30-01 TRACK FRAME ...................................................... 30-01 TRACK IDLER ......................................................... 30-01 TRACK FRAME EXPANSION CYLINDER.............. 20-01 TRACK ROLLER ..................................................... 30-01 TRACKS .................................................................. 30-01 TRANSPORTING THE EXCAVATOR..................... 10-01 TRAVEL CONTROLS.............................................. 40-01 TRAVEL MOTOR ...................................... 10-01 & 20-01 TROUBLESHOOTING ............................................ 60-01 TWO SPEED SWITCH ............................................ 50-01 TWO-SPEED BOOST SWITCH .............................. 50-01 UPPERSTRUCTURE .............................................. 40-01 UPPERSTRUCTURE SLEW LOCK ........................ 10-01

323 Excavator Service Manual

323 Excavator I Service Manual CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01 ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SAFETY AND MAINTENANCE HYDRAULIC SYSTEM UNDER- CARRIAGE UPPER- STRUCTURE & SWING SECTION eELECTRICAL sSYSTEM AND AANALYSISRI ENGINE SERVICE SPECIFICATIONS HEATER

323 Excavator II Service Manual

323 Excavator III Service Manual FOREWORD This manual is for the Bobcat Hydraulic Excavator mechanic. It provides necessary servicing and 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: 1. Check that the ROPS/TOPS/ FOGS is in good condition and is not modified. 9. Safety treads must be in good condition. 2. Check that ROPS/TOPS mounting hardware is tightened and is Bobcat approved. 10. Check for correct function of indicator lamps (Optional on some models). 3. The seat belt must be correctly installed, functional and in good condition. 11. Check hydraulic fluid level, engine oil level and fuel supply. 4. Inspect for loose or broken parts or connections. 12. Inspect for fuel, oil or hydraulic fluid leaks. 5. Machine signs must be legible and in the correct location. 13. Lubricate the excavator. 6. Steering levers, control levers and foot pedals must return to neutral. Check that foot pedals lock and control lever locks are in working order. 14. Check the condition of the battery and cables. 7. Inspect the air cleaner for damage or leaks. Check the condition of the element. Recommend to the owner that all necessary corrections be made before the machine is returned to service. 8. Check the electrical charging system. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

323 Excavator IV Service Manual

Bobcat 323 562411001+ Factory Service & Work Shop Manual

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