Complete service repair manual with Electrical Wiring Diagrams for Bobcat 321, 323, 324, 329 Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat 321, 323, 324, 329 Excavators workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6903380 (6-11) - 323 Excavator Service Manual.pdf
6903380 (11-06) - 323 Excavator Service Manual.pdf
6904770 (10-07) - 329 Compact Excavator Operation & Maintenance Manual.pdf
6904771 (7-12) - 329 Compact Excavator Service Manual.pdf
6904771 (10-09) - 329 Compact Excavator Service Manual.pdf
6986731 (05-10) - 321-323 Compact Excavator Service Manual.pdf
6986945 (2-08) - 329 Compact Excavator Operation & Maintenance Manual.pdf
6986946 (10-09) - 329 Compact Excavator Service Manual.pdf
6986958 (2-08) - 323 Compact Excavator Service Manual.pdf
6986958 (7-14) - 323 Compact Excavator Service Manual.pdf
6989592 (1-10) - 324 Compact Excavator Operation & Maintenance Manual.pdf
6989593 (1-12) - 323 Compact Excavator Service Manual.pdf
6989593 (2-10) - 323 Compact Excavator Service Manual.pdf

Total Pages: 3,112 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
6903380 (11-06) - 323 Excavator Service Manual...1
  MAINTENANCE SAFETY...3
  ALPHABETICAL INDEX...5
  CONTENTS...7
    FOREWORD...9
    SAFETY INSTRUCTIONS...11
      Fire Prevention...13
    SERIAL NUMBER LOCATIONS...15
      Excavator Serial Number...15
      Engine Serial Number...15
    DELIVERY REPORT...16
    BOBCAT EXCAVATOR IDENTIFICATION...17
  SAFETY AND 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 ARRESTOR 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 SCHEMATICS...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
    BOOM CYLINDER...83
      Testing...83
      Removal and Installation...86
      Parts Identification...89
      Disassembly...90
      Assembly...92
    ARM CYLINDER...95
      Testing...95
      Removal And Installation...96
      Parts Identification...98
      Disassembly...99
      Assembly...101
    BOOM SWING CYLINDER...105
      Testing...105
      Removal And Installation...106
      Parts Identification...109
      Disassembly...110
      Assembly...112
    BUCKET CYLINDER...115
      Testing...115
      Removal And Installation...116
      Parts Identification...118
      Disassembly...119
      Assembly...121
    BLADE CYLINDER...125
      Testing...125
      Removal And Installation...127
      Parts Identification...129
      Disassembly...130
      Assembly...132
    TRACK FRAME EXPANSION CYLINDER...135
      Testing...135
      Removal And Installation...136
      Parts Identification...140
      Disassembly...141
      Assembly...142
    MAIN RELIEF VALVE...147
      Testing And Adjusting The Main Relief Valve...147
    PORT RELIEF VALVES...149
      Testing And Adjusting The Port Relief Valve Pressure...149
    CROSSPORT RELIEF VALVES...151
      Testing And Adjusting The Crossport Relief Valve...151
    PRESSURE REDUCING VALVE...153
      Testing And Adjusting The Pressure Reducing Valve...153
    HYDRAULIC CONTROL VALVE...155
      Description...155
      Removal And Installation...155
      Parts Identification...158
      Disassembly...159
      Right Travel Valve Section Disassembly And Assembly...160
      Boom Swing Valve Section Disassembly And Assembly...165
      Arm Valve Section Disassembly and Assembly...168
      Bucket Valve Section Disassembly And Assembly...171
      Auxiliary Valve Section Disassembly And Assembly...174
      Boom Valve Section Disassembly And Assembly...179
      Left Travel Valve Section Disassembly And Assembly...182
      Swing Valve Section Disassembly And Assembly...187
      Blade Valve Section Disassembly And Assembly...190
      Assembly...194
    HYDRAULIC PUMP...199
      Description...199
      Torque Adjustment...199
      Testing The Piston Pump...200
      Testing The Gear Pump...202
      Testing Auxiliary Hydraulic Flow...203
      Removal And Installation...204
      Parts Identification...208
      Disassembly...209
      Gear Pump Disassembly...210
      Piston Pump Disassembly...212
      Piston Pump Assembly...221
      Gear Pump Assembly...230
      Assembly...232
    MANIFOLD ASSEMBLY/ACCUMULATOR...235
      Description...235
      Removal And Installation...235
      Parts Identification...238
      Disassembly...239
      Assembly...252
    TRAVEL MOTOR...265
      Removal And Installation...265
      Parts Identification...266
      Disassembly...267
      Assembly...274
    SWIVEL JOINT...283
      Removal And Installation...283
      Parts Identification...286
      Disassembly...287
      Assembly...289
    SWING MOTOR...293
      Removal And Installation...293
      Parts Identification...294
      Disassembly...295
      Assembly...301
    CONTROL PATTERN SELECTOR VALVE...309
      Removal And Installation...309
      Parts Identification...311
      Disassembly...312
      Assembly...313
    RIGHT CONTROL LEVER (JOYSTICK)...315
      Testing...315
      Handle Removal And Installation...317
      Removal And Installation...318
      Parts Identification...319
      Disassembly...320
      Assembly...325
    LEFT CONTROL LEVER (JOYSTICK)...331
      Testing...331
      Handle Removal And Installation...333
      Removal And Installation...335
      Parts Identification...336
      Disassembly...337
      Assembly...342
    HYDRAULIC FILTER MOUNT...347
      Removal And Installation...347
    HYDRAULIC RESERVOIR...349
      Removal And Installation...349
    OIL COOLER...351
      Removal And Installation...351
    BLADE/TRACK EXPANSION SOLENOID BLOCK...353
      Block Removal And Installation...353
      Solenoid Removal And Installation...354
      Block Disassembly And Assembly...356
  UNDERCARRIAGE...359
    BLADE...361
      Extension Removal And Installation...361
      Blade Removal And Installation...361
    TRACKS...363
      Track Lug Height...363
      Track Tension Adjustment...364
      Removal And Installation...366
    TRACK FRAME...367
      Disassembly And Assembly...367
      Removal And Installation Of Expandable Track Frame...368
    TRACK DAMAGE IDENTIFICATION...371
      Cutting Of The Steel Cords...371
      Causes Of The Damage...371
      Abrasion Of Embedded Metals...372
      Separation Of Embedded Metals...373
      Separation Of Embedded Metals Due To Corrosion...374
      Cuts On The Lug Side Rubber...375
      Cracks On The Lug Side Rubber Due To Fatigue...376
      Lug Abrasion...377
      Cracks And Cuts On The Lug Side Rubber...378
      Abrasion Of The Track Roller Side...379
      Cuts On The Edges Of The Track Roller Side...380
    TRACK IDLER...383
      Parts Identification...383
      Disassembly...384
      Assembly...386
    TRACK ROLLER...389
      Parts Identification...389
      Disassembly...390
      Assembly...392
    SWING CIRCLE GEAR...395
      Removal and Installation...395
  UPPERSTRUCTURE & SWING SECTION...397
    UPPERSTRUCTURE...401
      Removal...401
      Installation...403
    ROPS CANOPY...407
      Removal And Installation...407
    CAB...411
      Removal And Installation...411
      Door Removal And Installation...415
      Front Window Removal And Installation...416
      Right Side Rear Sliding Window Removal And Installation...419
      Right Side Front Sliding Window Removal And Installation...420
      Glass Removal...420
      Glass Installation...421
    SEAT AND SEAT MOUNT...423
      Removal And Installation...423
    RIGHT CONSOLE...425
      Console Cover Removal And Installation (Cab)...425
      Console Cover Removal And Installation (ROPS Canopy)...428
      Gas Spring Removal And Installation (ROPS Canopy)...431
      Lock Lever Removal And Installation (ROPS Canopy)...432
      Adjustment (ROPS Canopy Models)...434
      Latch Hook Removal And Installation (ROPS Canopy)...434
      Latch Hook Disassembly And Assembly (ROPS Canopy)...435
      Cab Models...436
      Upper Console Removal And Installation...437
      Console Base Removal And Installation...438
    LEFT CONSOLE...441
      Console Cover Removal And Installation...441
      Gas Spring Removal And Installation...443
      Lock Lever Removal And Installation...444
      Adjustment...446
      Latch Hook Removal And Installation...447
      Latch Hook Disassembly And Assembly...448
      Upper Console Removal And Installation...449
      Console Base Removal And Installation...450
    ENGINE SPEED CONTROL...453
      Removal And Installation...453
      Engine Speed Control Cable Removal And Installation...454
    BLADE CONTROL...457
      Removal And Installation...457
      Disassembly And Assembly...458
    SWING LOCK...461
      Removal and Installation...461
    RIGHT PEDAL AND LINKAGE...463
      Right Pedal Removal And Installation...463
      Disassembly And Assembly...464
      Linkage Removal And Installation...465
      Linkage Disassembly And Assembly...465
    TRAVEL CONTROLS...467
      Removal And Installation...467
      Disassembly And Assembly...467
    LEFT PEDAL...469
      Removal And Installation...469
      Disassembly And Assembly...470
    CONTROL LINKAGE ASSEMBLY...471
      Removal And Installation...471
      Left Pedal Linkage Disassembly And Assembly...472
      Right Travel Control Linkage Disassembly And Assembly...473
      Left Travel Control Linkage Disassembly And Assembly...474
      Left Pedal Bellcrank Disassembly And Assembly...475
      Linkage Rod Removal And Installation...476
      Linkage Rod Adjustment...478
    FLOOR MAT AND FLOOR PANELS...479
      Removal And Installation...479
    BLADE EXTENSION TRAY...483
      Removal And Installation...483
    FUEL TANK...485
      Removal And Installation...485
    HORN...487
      Removal And Installation (Earlier Models)...487
      Removal And Installation (Later Models)...487
    SWING FRAME...489
      Removal And Installation...489
      Bushing Replacement...491
      Swing Frame Bushing Removal...492
      Swing Frame Bushing Installation...492
      Boom Pivot Bushing Removal And Installation...493
    BOOM...495
      Removal And Installation...495
      Boom Bushing Removal And Installation...497
    ARM...499
      Removal And Installation...499
      Arm To Boom Bushing Removal And Installation...500
      Arm To Bucket And Bucket Link Bushing Removal And Installation...501
    BUCKET...503
      Removal And Installation...503
    TAILGATE...505
      Removal And Installation...505
      Latch Removal And Installation...506
  ELECTRICAL SYSTEM AND ANALYSIS...507
    ELECTRICAL SCHEMATICS...509
    ELECTRICAL SYSTEM...510
      Troubleshooting Chart...510
      Description...511
      Fuses...511
      Relays And Diodes...511
    BATTERY...514
      Servicing...514
      Removing And Installing The Battery...515
      Using A Booster Battery (Jump Starting)...516
    ALTERNATOR...518
      Description...518
      Tests...518
      Alternator Output Test...519
      Full Field Test...519
      Alternator Regulator Test...520
      Alternator Regulator Test With Voltmeter...520
      Removal And Installation...521
      Parts Identification...523
      Disassembly And Assembly...523
    STARTER...524
      Removal And Installation...524
      Parts Identification...525
      Disassembly And Assembly...525
      Cleaning And Inspection...525
    LIGHTS...526
      Uppestructure Light Removal And Installation...526
      Uppestructure Light Disassembly And Assembly...526
      Boom Light Removal And Installation (Earlier Models)...527
      Boom Light Disassembly And Assembly (Earlier Models)...527
      Boom Light Removal And Installation (Later Models)...528
      Boom Light Bulb Replacement (Later Models)...528
      Light Switch Removal And Installation...529
    MICROSWITCH...530
      Adjustment...530
      Testing...532
      Removal And Installation...533
    TWO-SPEED SWITCH...534
      Removal And Installation...534
    FUEL LEVEL SENDER...536
      Removal And Installation...536
      Testing...536
    TWO-SPEED BOOST SWITCH...538
      Description...538
      Removal And Installation...538
  ENGINE SERVICE...540
    TROUBLESHOOTING...542
      Chart...542
    SPARK ARRESTOR MUFFLER...544
      Removal And Installation...544
    AIR CLEANER...546
      Removal And Installation...546
    RADIATOR...548
      Removal And Installation...548
    ENGINE COMPONENTS AND TESTING...554
      Valve Clearance Adjustment...554
      Engine Compression Checking...555
      Fuel Shutoff Solenoid Removal And Installation...555
      Fuel Shutoff Timer Removal And Installation...556
      Fuel Injection Pump Check...556
      Fuel Injection Pump Removal And Installation...557
      Fuel Injection Pump Timing...559
      Fuel Injector Removal And Installation...560
      Fuel Injector Checking...561
      Glow Plug Removal And Installation...563
    ENGINE...564
      Removal And Installation...564
    ENGINE FLYWHEEL...572
      Removal And Installation...572
      Hydraulic Pump Coupler Removal And Installation...573
      Hydraulic Pump Coupler Disassembly And Assembly...574
      Flywheel Ring Gear...574
    RECONDITIONING THE ENGINE...576
      Cylinder Head Removal And Installation...576
      Cylinder Head Disassembly And Assembly...577
      Cylinder Head, Servicing...578
      Cylinder Head Top Clearance...579
      Valve Guide, Checking...579
      Valve And Valve Seat Reconditioning...581
      Valve Spring...582
      Rocker Arm And Shaft, Checking...582
      Timing Gearcase Cover Removal And Installation...583
      Idler Gear And Camshaft Removal And Installation...584
      Idler Gear and Shaft, Servicing...587
      Timing Gears Checking Backlash...588
      Fuel Camshaft Removal And Installation...588
      Fuel Camshaft Governor...589
      Crankshaft Gear Removal And Installation...589
      Oil Pump Removal And Installation...590
      Oil Pump, Service...590
      Engine Oil Pressure, Checking...591
      Relief Valve...592
      Piston And Connecting Rod Removal And Installation...592
      Piston And Connecting Rod, Servicing...594
      Connecting Rod Alignment...596
      Crankshaft And Bearings Removal And Installation...597
      Crankshaft And Bearings, Servicing...599
      Cylinder Bore, Checking...601
      Water Pump Removal And Installation...601
      Water Pump Disassembly And Assembly...601
  HEATER...602
    HEATER...604
      Removal And Installation...604
  SPECIFICATIONS...606
    SPECIFICATIONS...608
      323 Excavator Machine Dimensions...608
      Performance...610
      Controls...610
      Engine...610
      Hydraulic System...611
      Hydraulic Cylinders...611
      Hydraulic Cycle Times...612
      Drive System...612
      Undercarriage...612
      Track...612
      Electrical...613
    ENGINE SPECIFICATIONS...614
      Engine...614
      Fuel Injector Nozzles...614
      Fuel Injection Pump...614
      Cylinder Head...614
      Valves...614
      Valve Springs...614
      Rocker Arms...615
      Camshaft...615
      Cylinders...615
      Piston Rings...615
      Pistons...616
      Connecting Rods...616
      Crankshaft...616
      Oil Pump...616
      Thermostat...617
      Engine Bolt Torque...617
      Crankshaft Re-Grind Data...619
    TORQUE SPECIFICATIONS...620
      Torque For General SAE Bolts...620
      Torque For General Metric Bolts...621
    HYDRAULIC CONNECTION SPECIFICATIONS...622
      O-ring Face Seal Connection...622
      Straight Thread O-ring Fitting...622
      Tubelines And Hoses...622
      Flare Fitting...623
      O-ring Flare Fitting...624
      Port Seal Fitting...626
    HYDRAULIC FLUID SPECIFICATIONS...628
      Specifications...628
    FUEL, COOLANT AND LUBRICANTS...630
      Chart...630
    CONVERSIONS...632
      Decimal And Millimeter Equivalents...632
      U.S. To Metric Conversion...633
  SMR...634
    Revision No: 323-1...634
    Revision No: 323-2...636
    Revision No: 323-3...638
    Revision No: 323-4...640
6903380 (6-11) - 323 Excavator Service Manual...642
  MAINTENANCE SAFETY...644
  CONTENTS...646
  FOREWORD...648
    FOREWORD...650
    SAFETY INSTRUCTIONS...653
    FIRE PREVENTION...655
      Maintenance...655
      Operation...655
      Electrical...655
      Hydraulic System...655
      Fueling...655
      Starting...655
      Spark Arrester Exhaust System...655
      Welding And Grinding...656
      Fire Extinguishers...656
    SERIAL NUMBER LOCATIONS...657
      Excavator Serial Number...657
      Engine Serial Number...657
    DELIVERY REPORT...658
    BOBCAT EXCAVATOR IDENTIFICATION...659
  SAFETY MAINTENANCE...660
    LIFTING AND BLOCKING THE EXCAVATOR...662
      Procedure...662
    UPPERSTRUCTURE SLEW LOCK...664
    LIFTING THE EXCAVATOR...666
    OPERATOR CAB ROPS / TOPS (IF EQUIPPED)...668
      Emergency Exits...668
      Cab Door...668
      Front Window Wiper...669
      Window Washer Reservoir...670
      Front Window...670
      Right Side Windows...672
    TRANSPORTING THE EXCAVATOR...674
    TAILGATE...676
      Opening And Closing The Tailgate...676
      Adjusting The Bumper...676
      Adjusting The Tailgate Latch...676
    SERVICE SCHEDULE...678
      Chart...678
    AIR CLEANER SERVICE...680
      Daily Check...680
      Replacing The Filters...680
    HEATER AIR FILTERS...682
      Recirculation Filter...682
      Fresh Air Filter...682
    ENGINE COOLING SYSTEM...684
      Cleaning The Cooling System...684
      Checking Coolant Level...684
      Replacing The Coolant...685
    FUEL SYSTEM...688
      Fuel Specifications...688
      Filling The Fuel Tank...688
      Removing Water From The Fuel Filter...689
      Replacing The Fuel Filter...689
      Draining The Fuel Tank...690
      Removing Air From The Fuel System...690
    ENGINE LUBRICATION SYSTEM...692
      Checking Engine Oil...692
      Oil Chart...692
      Replacing Oil And Filter...693
    HYDRAULIC SYSTEM...694
      Checking And Adding Hydraulic Oil...694
      Diagnostic Couplers...694
      Replacing The Hydraulic Filter...695
      Replacing Hydraulic Oil...695
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...698
    TRAVEL MOTOR...700
      Checking Oil Level...700
      Draining The Travel Motor...700
    SPARK ARRESTER MUFFLER...702
    ALTERNATOR BELT...704
      Adjusting The Alternator Belt...704
    SEAT BELT...706
      Inspection And Maintenance...706
    CONTROL CONSOLE LOCKOUTS...708
      Inspection And Maintenance...708
  HYDRAULIC SYSTEM...710
    HYDRAULIC / HYDROSTATIC SCHEMATIC...714
    HYDRAULIC SYSTEM INFORMATION...716
      Glossary Of Hydraulic / Hydrostatic Symbols For Excavators...716
      Troubleshooting The Hydraulic Circuit...719
      Troubleshooting The Cylinder Circuit...720
      Troubleshooting The Swing (Upperstructure Slew) Circuit...721
      Troubleshooting The Travel Circuit...722
    CYLINDER (BOOM)...724
      Testing...724
      Removal And Installation...727
      Parts Identification...730
      Disassembly...731
      Assembly...733
    CYLINDER (ARM)...736
      Testing...736
      Removal And Installation...737
      Parts Identification...739
      Disassembly...740
      Assembly...742
    CYLINDER (BOOM SWING)...746
      Testing...746
      Removal And Installation...747
      Parts Identification...750
      Disassembly...751
      Assembly...753
    CYLINDER (BUCKET)...756
      Testing...756
      Removal And Installation...757
      Parts Identification...759
      Disassembly...760
      Assembly...762
    CYLINDER (BLADE)...766
      Testing...766
      Removal And Installation...768
      Parts Identification...770
      Disassembly...771
      Assembly...773
    CYLINDER (TRACK FRAME EXPANSION)...776
      Testing...776
      Removal And Installation...777
      Parts Identification...781
      Disassembly...782
      Assembly...783
    VALVE (MAIN RELIEF)...788
      Testing And Adjusting The Main Relief Valve...788
    VALVES (PORT RELIEF)...790
      Testing And Adjusting The Port Relief Valve Pressure...790
    VALVES (CROSSPORT RELIEF)...792
      Testing And Adjusting The Crossport Relief Valve...792
    VALVE (PRESSURE REDUCING)...796
      Testing And Adjusting The Pressure Reducing Valve...796
    HYDRAULIC CONTROL VALVE...798
      Description...798
      Removal And Installation...798
      Parts Identification...801
      Disassembly...802
      Right Travel Valve Section Disassembly And Assembly...803
      Boom Swing Valve Section Disassembly And Assembly...808
      Arm Valve Section Disassembly And Assembly...811
      Bucket Valve Section Disassembly And Assembly...814
      Auxiliary Valve Section Disassembly And Assembly...817
      Boom Valve Section Disassembly And Assembly...822
      Left Travel Valve Section Disassembly And Assembly...825
      Swing Valve Section Disassembly And Assembly...830
      Blade Valve Section Disassembly And Assembly...833
      Assembly...837
    HYDRAULIC PUMP...842
      Description...842
      Torque Adjustment...842
      Testing The Piston Pump...843
      Testing The Gear Pump...845
      Testing Auxiliary Hydraulic Flow...846
      Removal And Installation...847
      Parts Identification...851
      Disassembly...852
      Gear Pump Disassembly...853
      Piston Pump Disassembly...855
      Piston Pump Assembly...864
      Gear Pump Assembly...873
      Assembly...875
    MANIFOLD ASSEMBLY / ACCUMULATOR...878
      Description...878
      Removal And Installation...878
      Parts Identification...881
      Disassembly...882
      Assembly...895
    TRAVEL MOTOR...908
      Removal And Installation...908
      Parts Identification...909
      Disassembly...910
      Assembly...917
    SWIVEL JOINT...926
      Removal And Installation...926
      Parts Identification...929
      Disassembly...930
      Assembly...932
    SWING MOTOR...936
      Removal And Installation...936
      Parts Identification...937
      Disassembly...938
      Assembly...944
    CONTROL PATTERN SELECTOR VALVE...952
      Removal And Installation...952
      Parts Identification...954
      Disassembly...955
      Assembly...956
    CONTROL LEVER (JOYSTICK) (RIGHT)...958
      Testing...958
      Handle Removal And Installation...960
      Removal And Installation...961
      Parts Identification...962
      Disassembly...963
      Assembly...968
    CONTROL LEVER (JOYSTICK) (LEFT)...974
      Testing...974
      Handle Removal And Installation...976
      Removal And Installation...978
      Parts Identification...979
      Disassembly...980
      Assembly...985
    HYDRAULIC FILTER MOUNT...990
      Removal And Installation...990
    HYDRAULIC RESERVOIR...992
      Removal And Installation...992
    OIL COOLER...994
      Removal And Installation...994
    BLADE / TRACK EXPANSION SOLENOID BLOCK...996
      Block Removal And Installation...996
      Solenoid Removal And Installation...997
      Block Disassembly And Assembly...999
  UNDERCARRIAGE...1002
    BLADE...1004
      Extension Removal And Installation...1004
      Blade Removal And Installation...1004
    TRACKS...1006
      Track Lug Height...1006
      Track Tension Adjustment...1007
      Removal And Installation...1009
    TRACK FRAME...1010
      Disassembly And Assembly...1010
      Removal And Installation Of Expandable Track Frame...1011
    TRACK DAMAGE IDENTIFICATION...1014
      Cutting Of The Steel Cords...1014
      Causes Of The Damage...1014
      Abrasion Of Embedded Metals...1015
      Separation Of Embedded Metals...1016
      Separation Of Embedded Metals Due To Corrosion...1017
      Cuts On The Lug Side Rubber...1018
      Cracks On The Lug Side Rubber Due To Fatigue...1019
      Lug Abrasion...1020
      Cracks And Cuts On The Lug Side Rubber...1021
      Abrasion Of The Track Roller Side...1022
      Cuts On The Edges Of The Track Roller Side...1023
    TRACK IDLER...1026
      Parts Identification...1026
      Disassembly...1027
      Assembly...1029
    TRACK ROLLER...1032
      Parts Identification...1032
      Disassembly...1033
      Assembly...1035
    SWING CIRCLE GEAR...1038
      Removal And Installation...1038
  UPPERSTRUCTURE SWING SECTION...1040
    UPPERSTRUCTURE...1044
      Removal...1044
      Installation...1046
    ROPS CANOPY...1050
      Removal And Installation...1050
    CAB...1054
      Removal And Installation...1054
      Door Removal And Installation...1058
      Front Window Removal And Installation...1059
      Right Side Rear Sliding Window Removal And Installation...1062
      Right Side Front Sliding Window Removal And Installation...1063
      Glass Removal...1063
      Glass Installation...1064
    SEAT AND SEAT MOUNT...1066
      Removal And Installation...1066
    RIGHT CONSOLE...1068
      Console Cover Removal And Installation (Cab)...1068
      Console Cover Removal And Installation (ROPS Canopy)...1071
      Gas Spring Removal And Installation (ROPS Canopy)...1074
      Lock Lever Removal And Installation (ROPS Canopy)...1075
      Adjustment (ROPS Canopy Models)...1077
      Latch Hook Removal And Installation (ROPS Canopy)...1077
      Latch Hook Disassembly And Assembly (ROPS Canopy)...1078
      Cab Models...1079
      Upper Console Removal And Installation...1080
      Console Base Removal And Installation...1081
    LEFT CONSOLE...1084
      Console Cover Removal And Installation...1084
      Gas Spring Removal And Installation...1086
      Lock Lever Removal And Installation...1087
      Adjustment...1089
      Latch Hook Removal And Installation...1090
      Latch Hook Disassembly And Assembly...1091
      Upper Console Removal And Installation...1092
      Console Base Removal And Installation...1093
    ENGINE SPEED CONTROL...1096
      Removal And Installation...1096
      Engine Speed Control Cable Removal And Installation...1097
    BLADE CONTROL...1100
      Removal And Installation...1100
      Disassembly And Assembly...1101
    SWING LOCK...1104
      Removal And Installation...1104
    RIGHT PEDAL AND LINKAGE...1106
      Right Pedal Removal And Installation...1106
      Disassembly And Assembly...1107
      Linkage Removal And Installation...1108
      Linkage Disassembly And Assembly...1108
    TRAVEL CONTROLS...1110
      Removal And Installation...1110
      Disassembly And Assembly...1110
    LEFT PEDAL...1112
      Removal And Installation...1112
      Disassembly And Assembly...1113
    CONTROL LINKAGE ASSEMBLY...1114
      Removal And Installation...1114
      Left Pedal Linkage Disassembly And Assembly...1115
      Right Travel Control Linkage Disassembly And Assembly...1116
      Left Travel Control Linkage Disassembly And Assembly...1117
      Left Pedal Bellcrank Disassembly And Assembly...1118
      Linkage Rod Removal And Installation...1119
      Linkage Rod Adjustment...1121
    FLOOR MAT AND FLOOR PANELS...1122
      Removal And Installation...1122
    BLADE EXTENSION TRAY...1126
      Removal And Installation...1126
    FUEL TANK...1128
      Removal And Installation...1128
    HORN...1130
      Removal And Installation (Earlier Models)...1130
      Removal And Installation (Later Models)...1130
    SWING FRAME...1132
      Removal And Installation...1132
      Bushing Replacement...1134
      Swing Frame Bushing Removal...1135
      Swing Frame Bushing Installation...1135
      Boom Pivot Bushing Removal And Installation...1136
    BOOM...1138
      Removal And Installation...1138
      Boom Bushing Removal And Installation...1140
    ARM...1142
      Removal And Installation...1142
      Arm To Boom Bushing Removal And Installation...1143
      Arm To Bucket And Bucket Link Bushing Removal And Installation...1144
    BUCKET...1146
      Removal And Installation...1146
    TAILGATE...1148
      Removal And Installation...1148
      Latch Removal And Installation...1149
    QUICK COUPLER (KLAC™ SYSTEM)...1150
      Troubleshooting...1150
      Daily Inspection...1150
      Removal And Installation...1151
      Parts Identification...1153
      Disassembly...1154
      Assembly...1155
    QUICK COUPLER (LEHNHOFF® SYSTEM)...1158
      Troubleshooting...1158
      Daily Inspection...1158
      Removal (MS03 And MS08)...1159
      Installation (MS03 And MS08)...1160
      Parts Identification (MS03)...1161
      Disassembly And Assembly (MS03)...1162
      Parts Identification (MS08)...1163
      Disassembly (MS08)...1164
      Assembly (MS08)...1167
  ELECTRICAL SYSTEM AND ANALYSIS...1172
    ELECTRICAL SCHEMATICS...1174
    ELECTRICAL SYSTEM...1175
      Troubleshooting Chart...1175
      Description...1176
      Fuses...1176
      Relays And Diodes...1176
    BATTERY...1179
      Servicing...1179
      Removing And Installing The Battery...1180
      Using A Booster Battery (Jump Starting)...1181
    ALTERNATOR...1183
      Description...1183
      Tests...1183
      Alternator Output Test...1184
      Full Field Test...1184
      Alternator Regulator Test...1185
      Alternator Regulator Test With Voltmeter...1185
      Removal And Installation...1186
      Parts Identification...1188
      Disassembly And Assembly...1188
    STARTER...1189
      Removal And Installation...1189
      Parts Identification...1190
      Disassembly And Assembly...1190
      Cleaning And Inspection...1190
    LIGHTS...1191
      Uppestructure Light Removal And Installation...1191
      Uppestructure Light Disassembly And Assembly...1191
      Boom Light Removal And Installation (Earlier Models)...1192
      Boom Light Disassembly And Assembly (Earlier Models)...1192
      Boom Light Removal And Installation (Later Models)...1193
      Boom Light Bulb Replacement (Later Models)...1193
      Light Switch Removal And Installation...1194
    MICROSWITCH...1195
      Adjustment...1195
      Testing...1197
      Removal And Installation...1198
    TWO-SPEED SWITCH...1199
      Removal And Installation...1199
    FUEL LEVEL SENDER...1201
      Removal And Installation...1201
      Testing...1201
    TWO-SPEED BOOST SWITCH...1203
      Description...1203
      Removal And Installation...1203
  ENGINE SERVICE...1205
    TROUBLESHOOTING...1207
      Chart...1207
    SPARK ARRESTER MUFFLER...1209
      Removal And Installation...1209
    AIR CLEANER...1211
      Removal And Installation...1211
    RADIATOR...1213
      Removal And Installation...1213
    ENGINE COMPONENTS AND TESTING...1219
      Valve Clearance Adjustment...1219
      Engine Compression Checking...1220
      Fuel Shutoff Solenoid Removal And Installation...1220
      Fuel Shutoff Timer Removal And Installation...1221
      Fuel Injection Pump Check...1221
      Fuel Injection Pump Removal And Installation...1222
      Fuel Injection Pump Timing...1224
      Fuel Injector Removal And Installation...1225
      Fuel Injector Checking...1227
      Glow Plug Removal And Installation...1229
    ENGINE...1231
      Removal And Installation...1231
    ENGINE FLYWHEEL...1239
      Removal And Installation...1239
      Hydraulic Pump Coupler Removal And Installation...1240
      Hydraulic Pump Coupler Disassembly And Assembly...1241
      Flywheel Ring Gear...1241
    RECONDITIONING THE ENGINE...1243
      Cylinder Head Removal And Installation...1243
      Cylinder Head Disassembly And Assembly...1244
      Cylinder Head, Servicing...1245
      Cylinder Head Top Clearance...1246
      Valve Guide, Checking...1246
      Valve And Valve Seat Reconditioning...1248
      Valve Spring...1249
      Rocker Arm And Shaft, Checking...1249
      Timing Gearcase Cover Removal And Installation...1250
      Idler Gear And Camshaft Removal And Installation...1251
      Idler Gear And Shaft, Servicing...1254
      Timing Gears Checking Backlash...1255
      Fuel Camshaft Removal And Installation...1255
      Fuel Camshaft Governor...1256
      Crankshaft Gear Removal And Installation...1256
      Oil Pump Removal And Installation...1257
      Oil Pump, Service...1257
      Engine Oil Pressure, Checking...1258
      Relief Valve...1259
      Piston And Connecting Rod Removal And Installation...1260
      Piston And Connecting Rod, Servicing...1262
      Connecting Rod Alignment...1264
      Crankshaft And Bearings Removal And Installation...1264
      Crankshaft And Bearings, Servicing...1266
      Cylinder Bore, Checking...1268
      Water Pump Removal And Installation...1269
      Water Pump Disassembly And Assembly...1269
  HEATER...1271
    HEATER...1273
      Removal And Installation...1273
  SPECIFICATIONS...1275
    SPECIFICATIONS...1277
      323 Excavator Machine Dimensions...1277
      Performance...1279
      Controls...1279
      Engine...1279
      Hydraulic System...1280
      Hydraulic Cylinders...1280
      Hydraulic Cycle Times...1281
      Drive System...1281
      Undercarriage...1281
      Track...1281
      Electrical...1282
    ENGINE SPECIFICATIONS...1283
      Specifications...1283
      Crankshaft Re-Grind Data...1288
    TORQUE SPECIFICATIONS...1289
      Torque For General SAE Bolts...1289
      Torque For General Metric Bolts...1290
    HYDRAULIC CONNECTION SPECIFICATIONS...1291
      O-ring Face Seal Connection...1291
      Straight Thread O-ring Fitting...1291
      Tubelines And Hoses...1291
      Flare Fitting...1292
      O-ring Flare Fitting...1293
      Port Seal Fitting...1295
    HYDRAULIC FLUID SPECIFICATIONS...1297
      Specifications...1297
    FUEL, COOLANT AND LUBRICANTS...1299
      Chart...1299
    CONVERSIONS...1301
      Decimal And Millimeter Equivalents Chart...1301
      U.S. To Metric Conversion Chart...1302
  ALPHABETICAL INDEX...1303
  SERVICE MANUAL REVISIONS...1305
    Revision No: 323-1...1305
    Revision No: 323-2...1307
    Revision No: 323-3...1309
    Revision No: 323-4...1311
    Revision No: 323 - 5...1313
6904770 (10-07) - 329 Compact Excavator Operation & Maintenance Manual...1315
  CONTENTS...1319
  FOREWORD...1321
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...1323
    REGULAR MAINTENANCE ITEMS...1323
    SERIAL NUMBER LOCATIONS...1325
      Excavator Serial Number...1325
      Engine Serial Number...1325
    DELIVERY REPORT...1325
    EXCAVATOR IDENTIFICATION...1326
    FEATURES, ACCESSORIES AND ATTACHMENTS...1327
      Standard Items...1327
      Options and Accessories...1327
      Attachments...1327
      Buckets Available...1327
      Falling Object Guards (FOGS)...1328
      Special Applications Kit...1328
      Special Applications Kit Inspection And Maintenance...1328
  SAFETY & TRAINING RESOURCES...1329
    SAFETY INSTRUCTIONS...1331
      Before Operation...1331
      Safe Operation Is The Operator’s Responsibility...1332
      Safe Operation Needs A Qualified Operator...1332
      Avoid Silica Dust...1333
    FIRE PREVENTION...1333
      Maintenance...1333
      Operation...1333
      Electrical...1333
      Hydraulic System...1334
      Fueling...1334
      Starting...1334
      Spark Arrestor Exhaust System...1334
      Welding And Grinding...1334
      Fire Extinguishers...1334
    MACHINE SIGNS (DECALS)...1335
    PUBLICATIONS AND TRAINING RESOURCES...1337
  OPERATING INSTRUCTIONS...1339
    INSTRUMENTS AND CONSOLES...1341
      Cab Interior Light (If Equipped)...1341
      Left Console...1341
      Right Console...1342
      Function Icons...1343
      STD / ISO Selector Valve...1344
      Upperstructure Slew Lock...1344
      Raising And Lowering The Console...1345
      Two-Speed Travel...1345
    OPERATOR CANOPY (ROPS / TOPS)...1346
      Description...1346
    OPERATOR CAB (ROPS / TOPS)...1346
      Description...1346
      Cab Door...1347
      Front Window...1348
      Front Wiper...1349
      Window Washer Reservoir...1349
      Right Side Window...1350
      Heating, Ventilation And Air Conditioning Duct...1351
    TRAVEL CONTROLS...1352
      Description...1352
      Forward And Reverse Travel...1352
      Turning...1352
    HYDRAULIC CONTROLS...1354
      Description...1354
      STANDARD Control Pattern...1354
      ISO Control Pattern...1355
      Quick Couplers (If Equipped)...1356
      Auxiliary Hydraulics...1357
      Relieve Hydraulic Pressure (Excavator And Attachment)...1357
      Return To Tank Valve (If Equipped)...1357
    BLADE CONTROL LEVER...1358
      Operation...1358
    BOOM SWING PEDAL...1358
      Operation...1358
    DAILY INSPECTION...1359
      Daily Inspection And Maintenance...1360
    PRE-STARTING PROCEDURE...1361
      Operation & Maintenance Manual And Operator’s Handbook Locations...1361
      Entering The Excavator...1361
      Seat Adjustment...1362
      Seat Belt Adjustment...1362
      Control Console...1363
    STARTING THE ENGINE...1364
      Key Switch...1364
      Keyless...1365
      Cold Temperature Starting...1366
      Warming The Hydraulic System...1367
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...1368
      Procedure...1368
      Emergency Exits...1369
    ATTACHMENTS...1370
      Installing And Removing The Attachment (Pin-On X- Change)...1370
      Installing And Removing The Attachment (Bolt-On X- Change)...1376
      Installing And Removing The Attachment (Pin-On Attachment)...1382
    OPERATING PROCEDURE...1383
      Inspect The Work Area...1383
      Lowering The Work Equipment (Engine STOPPED)...1383
      Operating On Public Roads...1383
      Lifting A Load...1384
      Excavating...1385
      Boom Swing...1387
      Backfilling...1388
      Driving The Excavator...1388
      Operating On Slopes...1389
      Operating In Water...1391
      Avoiding Track Damage...1391
    TOWING THE EXCAVATOR...1391
      Procedure...1391
    LIFTING THE EXCAVATOR...1392
      Procedure...1392
    TRANSPORTING THE EXCAVATOR ON A TRAILER...1393
      Loading And Unloading...1393
      Fastening...1393
  PREVENTIVE MAINTENANCE...1395
    MAINTENANCE SAFETY...1397
    SERVICE SCHEDULE...1399
      Chart...1399
    CONTROL CONSOLE LOCKOUTS...1400
      Inspection And Maintenance...1400
    SEAT BELT...1401
      Inspection And Maintenance...1401
    MOTION ALARM SYSTEM (IF EQUIPPED)...1402
      Description...1402
      Inspecting...1402
      Adjusting Switch Position...1402
    TAILGATE...1403
      Opening And Closing...1403
      Adjusting The Bumper...1403
      Adjusting The Latch...1403
    RIGHT SIDE COVER...1404
      Opening And Closing...1404
      Adjusting The Latch...1404
    CAB FILTERS...1405
      Cleaning And Maintenance...1405
    AIR CLEANER SERVICE...1407
      Daily Check...1407
      Replacing Filter Elements...1407
    FUEL SYSTEM...1409
      Fuel Specifications...1409
      Filling The Fuel Tank...1409
      Fuel Filters...1410
      Draining The Fuel Tank...1410
      Removing Air From The Fuel System...1411
    ENGINE LUBRICATION SYSTEM...1412
      Checking And Adding Engine Oil...1412
      Engine Oil Chart...1412
      Removing And Replacing Oil And Filter...1413
    ENGINE COOLING SYSTEM...1414
      Cleaning...1414
      Checking Level...1414
      Removing And Replacing Coolant...1415
    ELECTRICAL SYSTEM...1416
      Description...1416
      Fuse And Relay Location / Identification...1416
      Battery Maintenance...1417
      Using A Booster Battery (Jump Starting)...1418
      Removing And Installing Battery...1419
    HYDRAULIC SYSTEM...1420
      Checking And Adding Fluid...1420
      Hydraulic Fluid Chart...1420
      Removing And Replacing Hydraulic Filters...1421
      Removing And Replacing Hydraulic Fluid...1422
    SPARK ARRESTOR MUFFLER...1423
      Cleaning Procedure...1423
    TRACK TENSION...1424
      Adjusting...1424
    TRAVEL MOTOR...1426
      Checking And Adding Oil...1426
      Removing And Replacing Oil...1426
    ALTERNATOR BELT...1427
      Belt Adjustment...1427
      Belt Replacement...1427
    X-CHANGE...1428
      Inspection And Maintenance...1428
    TRACK ROLLER AND IDLER LUBRICATION...1428
      Procedure...1428
    BUCKET...1429
      Bucket Teeth Removal And Installation...1429
    LUBRICATING THE EXCAVATOR...1430
      Lubrication Locations...1430
    PIVOT PINS...1432
      Inspection And Maintenance...1432
    EXCAVATOR STORAGE AND RETURN TO SERVICE...1433
      Storage...1433
      Return to Service...1433
  SYSTEM SETUP AND ANALYSIS...1435
    DIAGNOSTIC SERVICE CODE...1437
      Service Codes List...1437
    DISPLAY CONTROLLER PANEL SETUP...1438
      Passwords...1438
      Password Entry (For Starting and Operating the Machine)...1438
      Changing The Owner or Operator Password...1438
      Password Lockout Feature...1439
      Job Clock...1439
      RPM...1439
      Viewing Service Codes (Key Switch)...1440
      Viewing Service Codes (Keyless)...1440
  MACHINE SIGN TRANSLATIONS...1441
    WARNING (6808185)...1443
    LIFT CHART (7125436)...1444
    SERVICE SCHEDULE (7151799)...1447
    WARNING (6807776)...1450
    WARNING (6804114, 6577754, 6809832, 6804233)...1452
    WARNING (6815945)...1453
      WARNING (6808474)...1453
    WARNING (6815915)...1454
    USING THE X-CHANGE SYSTEM (7102651)...1455
    WARNING (6809829)...1458
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...1458
  SPECIFICATIONS...1459
    EXCAVATOR SPECIFICATIONS...1461
      Dimensions...1461
      Performance...1463
      Controls...1463
      Engine...1463
      Hydraulic System...1464
      Hydraulic Cylinders...1464
      Hydraulic Cycle Times...1464
      Electrical...1464
      Instrumentation...1464
      Drive System...1465
      Slew System...1465
      Undercarriage...1465
      Crawler Track Design...1465
      Capacities...1465
      Fuel Tank...1465
      Tracks...1465
      Type...1465
      Ground Pressure...1465
  WARRANTY...1467
  ALPHABETICAL INDEX...1471
6904771 (10-09) - 329 Compact Excavator Service Manual...1473
  MAINTENANCE SAFETY...1475
  ALPHABETICAL INDEX...1477
  CONTENTS...1479
    FOREWORD...1480
    SAFETY INSTRUCTIONS...1482
    FIRE PREVENTION...1484
      Maintenance...1484
      Operation...1484
      Electrical...1484
      Hydraulic System...1484
      Fueling...1484
      Starting...1484
      Spark Arrestor Exhaust System...1484
      Welding And Grinding...1485
      Fire Extinguishers...1485
    SERIAL NUMBER LOCATIONS...1486
      Excavator Serial Number...1486
      Engine Serial Number...1486
    DELIVERY REPORT...1487
    EXCAVATOR IDENTIFICATION...1488
  SAFETY AND MAINTENANCE...1489
    LIFTING AND BLOCKING THE EXCAVATOR...1491
      Procedure...1491
    UPPERSTRUCTURE SLEW LOCK...1493
      Operation...1493
    LIFTING THE EXCAVATOR...1495
      Procedure...1495
    OPERATOR CAB (ROPS / TOPS)...1497
      Description...1497
      Cab Door...1497
      Front Window...1498
      Front Wiper...1499
      Window Washer Reservoir...1499
      Right Side Window...1500
      Heating, Ventilation And Air Conditioning Duct...1501
    TRANSPORTING THE EXCAVATOR ON A TRAILER...1503
      Loading And Unloading...1503
      Fastening...1503
    TAILGATE...1505
      Opening And Closing...1505
      Adjusting The Bumper...1505
      Adjusting The Latch...1505
    RIGHT SIDE COVER...1507
      Opening And Closing...1507
      Adjusting The Latch...1507
    SERVICE SCHEDULE...1509
      Chart...1509
    AIR CLEANER SERVICE...1511
      Daily Check...1511
      Replacing Filter Elements...1511
    ENGINE COOLING SYSTEM...1513
      Cleaning...1513
      Checking Level...1513
      Removing And Replacing Coolant...1514
    FUEL SYSTEM...1517
      Fuel Specifications...1517
      Filling The Fuel Tank...1517
      Fuel Filter...1518
      Draining The Fuel Tank...1518
      Removing Air From The Fuel System...1519
    ENGINE LUBRICATION SYSTEM...1521
      Checking And Adding Engine Oil...1521
      Engine Oil Chart...1521
      Removing And Replacing Oil And Filter...1522
    HYDRAULIC SYSTEM...1523
      Checking And Adding Fluid...1523
      Hydraulic Fluid Chart...1523
      Removing And Replacing Hydraulic Filters...1524
      Removing And Replacing Hydraulic Fluid...1525
    LUBRICATING THE EXCAVATOR...1527
      Lubrication Locations...1527
    TRAVEL MOTOR...1531
      Checking And Adding Oil...1531
      Removing And Replacing Oil...1531
    SPARK ARRESTOR MUFFLER...1533
      Cleaning Procedure...1533
    ALTERNATOR BELT...1535
      Belt Adjustment...1535
      Belt Replacement...1535
    SEAT BELT...1537
      Inspection And Maintenance...1537
    PIVOT PINS...1539
      Inspection And Maintenance...1539
    EXCAVATOR STORAGE AND RETURN TO SERVICE...1541
      Storage...1541
      Return to Service...1541
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...1543
      Procedure...1543
      Emergency Exits...1544
  HYDRAULIC SYSTEM...1545
    HYDRAULC / HYDROSTATIC SCHEMATICS...1551
    HYDRAULIC SYSTEM INFORMATION...1553
      Glossary Of Hydraulic / Hydrostatic Symbols...1553
      Troubleshooting The Hydraulic Circuit...1557
      Troubleshooting The Cylinder Circuit...1558
      Troubleshooting The Swing (Upperstructure Slew) Circuit...1559
      Troubleshooting The Travel Circuit...1560
    BOOM CYLINDER...1561
      Testing...1561
      Removal And Installation...1563
      Parts Identification...1565
      Disassembly...1566
      Assembly...1568
    ARM CYLINDER...1571
      Testing...1571
      Removal And Installation...1573
      Parts Identification...1575
      Disassembly...1576
      Assembly...1578
    BOOM SWING CYLINDER...1581
      Testing...1581
      Removal And Installation...1583
      Parts Identification...1585
      Disassembly...1586
      Assembly...1588
    BUCKET CYLINDER...1591
      Testing...1591
      Removal And Installation...1593
      Parts Identification...1595
      Disassembly...1596
      Assembly...1598
    BLADE CYLINDER...1601
      Testing...1601
      Removal And Installation...1603
      Parts Identification...1604
      Disassembly...1605
      Assembly...1607
    CLAMP CYLINDER...1611
      Testing...1611
      Removal And Installation...1612
      Parts Identification...1613
      Disassembly...1614
      Assembly...1617
    MAIN RELIEF VALVE...1623
      Testing And Adjusting The Main Relief Valve...1623
    PORT RELIEF VALVES...1627
      Testing And Adjusting Port Relief Valve Pressure...1627
    CROSSPORT RELIEF VALVES...1629
      Testing And Adjusting The Crossport Relief Valves...1629
    PRESSURE REDUCING VALVE...1633
      Testing And Adjusting The Pressure Reducing Valve...1633
    HYDRAULIC CONTROL VALVE...1635
      Description...1635
      Removal And Installation...1636
      Control Valve Identification...1643
      Disassembly...1644
      Right Travel Valve Section Disassembly And Assembly...1646
      Boom Swing Valve Section Disassembly And Assembly...1651
      Boom Valve Section Disassembly And Assembly...1658
      Left Travel Valve Section Disassembly And Assembly...1662
      Arm Valve Section Disassembly And Assembly...1667
      Bucket Valve Section Disassembly And Assembly...1671
      Auxiliary Valve Section Disassembly And Assembly...1675
      Boost Valve Section Disassembly And Assembly...1679
      Blade Valve Section Disassembly And Assembly...1683
      Slew Valve Section Disassembly And Assembly...1688
      Assembly...1692
    HYDRAULIC PUMP...1699
      Description...1699
      Torque Adjustment...1700
      Testing The Piston Pump...1701
      Testing The Gear Pump...1703
      Testing Auxiliary Hydraulic Flow...1704
      Removal And Installation...1705
      Coupler Removal And Installation...1707
      Parts Identification (Gear Pump)...1708
      Parts Identification (Piston Pump)...1709
      Disassembly...1710
      Gear Pump Disassembly...1711
      Gear Pump Assembly...1714
      Piston Pump Disassembly...1717
      Piston Pump Assembly...1723
      Assembly...1729
    MANIFOLD ASSEMBLY / ACCUMULATOR...1731
      Description...1731
      Removal And Installation...1731
      Parts Identification...1735
      Disassembly...1736
      Assembly...1746
    TRAVEL MOTOR...1757
      Description...1757
      Removal and installation...1757
      Parts Identification...1759
      Disassembly...1760
      Assembly...1770
    SWIVEL JOINT...1781
      Description...1781
      Removal And Installation...1781
      Parts Identification...1783
      Disassembly...1784
      Assembly...1785
    SWING MOTOR...1789
      Description...1789
      Removal And Installation...1789
      Parts Identification...1792
      Disassembly...1793
      Assembly...1798
    SWING MOTOR DRIVE CARRIER...1805
      Description...1805
      Removal And Installation...1805
      Parts Identification...1806
      Disassembly...1807
      Assembly...1809
    CONTROL PATTERN SELECTOR VALVE...1813
      Description...1813
      Removal And Installation...1813
      Parts Identification...1814
      Disassembly...1815
      Assembly...1816
    RIGHT CONTROL LEVER (JOYSTICK)...1817
      Description...1817
      Testing...1817
      Handle Removal And Installation...1818
      Removal And Installation...1822
      Parts Identification...1825
      Disassembly...1826
      Assembly...1831
    LEFT CONTROL LEVER (JOYSTICK)...1837
      Description...1837
      Testing...1837
      Handle Removal And Installation...1838
      Removal And Installation...1841
      Parts Identification...1843
      Disassembly...1844
      Assembly...1849
    HYDRAULIC FILTER...1855
      Description...1855
      Housing Removal and Installation...1855
    CASE DRAIN FILTER...1857
      Description...1857
      Housing Removal And Installation...1857
    HYDRAULIC RESERVOIR...1859
      Description...1859
      Removal And Installation...1859
    OIL COOLER...1861
      Description...1861
      Removal And Installation...1861
    DIRECT TO TANK VALVE...1863
      Description...1863
      Removal And Installation...1863
      Parts Identification...1865
      Disassembly And Assembly...1866
    BUILDUP VALVE...1869
      Description...1869
      Removal And Installation...1869
      Parts Identification...1870
      Disassembly And Assembly...1871
  UNDERCARRIAGE...1873
    BLADE...1875
      Description...1875
      Removal And Installation...1875
    TRACK FRAME COMPONENTS...1877
      Description...1877
      Track Lug Height...1877
      Checking Tension...1878
      Adjusting Tension...1879
      Rubber Track Removal And Installation...1881
      Steel Track Removal And Installation...1884
      Idler (Front) Removal And Installation...1887
      Idler (Front) Parts Identification...1888
      Idler (Front) Disassembly...1889
      Idler (Front) Assembly...1891
      Coil Spring Assembly And Cylinder Disassembly And Assembly (W/O Replaceable Shaft)...1894
      Cylinder Parts Identification (With Replaceable Shaft)...1895
      Coil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)...1896
      Roller Removal and Installation...1897
      Roller Parts Identification...1898
      Roller Disassembly...1899
      Roller Assembly...1901
      Track Guide Removal And Installation...1903
      Sprocket Removal And Installation...1903
      Track Damage Identification...1904
    SWING CIRCLE GEAR...1915
      Removal And Installation...1915
  UPPERSTRUCTURE & SWING SECTION...1917
    UPPERSTRUCTURE...1921
      Description...1921
      Removal...1921
      Installation...1924
    CANOPY...1927
      Removal And Installation...1927
    CAB...1931
      Removal And Installation...1931
      Door Removal And Installation...1936
      Front Window Removal And Installation...1937
      Right Side Rear Sliding Window Removal And Installation...1940
      Right Side Front Sliding Window Removal And Installation...1940
      Glass Removal...1941
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...1942
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...1942
      Glass Installation...1943
    SEAT AND SEAT MOUNT...1949
      Seat Mount Removal And Installation...1949
      Seat Removal And Installation...1950
    RIGHT CONSOLE...1951
      Description...1951
      Console Cover Removal And Installation...1951
      Console Frame Removal And Installation...1952
    LEFT CONSOLE...1955
      Description...1955
      Joystick Console Cover (Bottom) Removal And Installation...1955
      Joystick Console Cover (Top) Removal And Installation...1956
      Compression Spring Removal And Installation...1957
      Compression Spring Disassembly And Assembly...1957
      Lever Removal And Installation...1959
      Joystick Console Frame Removal And Installation...1960
      Joystick Console Frame Disassembly And Installation...1961
      Left Rear Console Cover Removal And Installation...1962
      Left Rear Console Frame Removal And Installation...1963
      Left Rear Console Frame Disassembly And Assembly...1965
    BLADE CONTROL...1967
      Removal And Installation...1967
      Disassembly And Assembly...1967
      Linkage Removal And Installation...1968
      Linkage Disassembly And Assembly...1970
    UPPERSTRUCTURE SLEW LOCK...1973
      Removal and Installation (S/N A2PG11001 - A2PG11093)...1973
      Removal And Installation (S/N A2PG11094 & Above)...1974
      Disassembly And Assembly (S/N A2PG11094 & Above)...1974
    FLOOR MAT AND FLOOR PANEL...1977
      Description...1977
      Removal And Installation...1977
    BOOM SWING PEDAL...1981
      Description...1981
      Removal And Installation...1981
      Disassembly And Assembly...1982
      Linkage Removal And Installation...1984
    TRAVEL LEVERS / PEDALS...1985
      Description...1985
      Adjustment...1985
      Removal And Installation...1988
      Disassembly And Assembly...1988
    FUEL TANK...1991
      Removal And Installation...1991
    HORN...1995
      Removal And Installation (Earlier Models)...1995
      Removal And Installation (Later Models)...1996
    SWING FRAME...1997
      Description...1997
      Removal And Installation...1997
      Hose Routing...2001
      Bushing Removal And Installation...2002
      Swing Frame Bushing Removal And Installation...2002
    BOOM...2005
      Description...2005
      Removal And Installation...2005
    ARM...2009
      Description...2009
      Removal And Installation...2009
      Arm To Boom Bushing Removal And Installation...2010
      Arm To Bucket And Bucket Link Bushing Removal And Installation...2011
    BUCKET...2013
      Removal And Installation (Pin-On X-Change)...2013
      Removal And Installation (Bolt-On X-Change)...2019
      Removal And Installation (Pin-On Attachment)...2025
      Bucket Teeth Removal And Installation...2026
      Bucket Side Cutting Edge Removal And Installation...2027
    CLAMP...2029
      Removal And Installation...2029
    TAILGATE...2031
      Removal And Installation...2031
      Latch Removal And Installation...2032
    X-CHANGE...2033
      Pin-On Removal And Installation...2033
      Pin-On Disassembly and Assembly...2034
    RIGHT SIDE COVER...2035
      Removal And Installation...2035
  ELECTRICAL SYSTEM AND ANALYSIS...2037
    ELECTRICAL SCHEMATICS...2039
    ELECTRICAL SYSTEM INFORMATION...2041
      Glossary Of Electrical Symbols...2041
      Harness Connectors...2044
      Troubleshooting...2046
      Description...2047
      Fuse And Relay Locations / Identification...2047
    BATTERY...2049
      Removal And Installation...2049
      Servicing...2050
      Using A Booster Battery (Jump Starting)...2051
    ALTERNATOR...2053
      Belt Adjustment...2053
      Belt Replacement...2053
      Charging System Inspection...2054
      Description...2055
      Tests...2055
      Alternator Output Test...2056
      Full Field Test...2056
      Alternator Regulator Test...2057
      Alternator Regulator Test With Voltmeter...2057
      Removal And Installation...2058
      Parts Identification...2059
    STARTER...2061
      Testing...2061
      Removal And Installation...2062
      Parts Identification...2063
    LIGHTS...2065
      Upperstructure Light Removal And Installation...2065
      Upperstructure Light Disassembly And Assembly...2065
      Boom Light Removal And Installation (Earlier Models)...2066
      Boom Light Disassembly And Assembly (Earlier Models)...2066
      Boom Light Removal And Installation (Later Models)...2067
      Boom Light Bulb Replacement (Later Models)...2067
    MAGNETIC LOCKOUT SENSOR...2069
      Testing Left Console Magnetic Lockout Sensor...2069
      Left Console Magnetic Lockout Sensor Removal And Installation...2070
    FUEL LEVEL SENDER...2073
      Removal And Installation...2073
      Testing...2074
    DIAGNOSTICS SERVICE CODES...2075
      Description...2075
      Service Codes List...2076
  ENGINE SERVICE...2077
    ENGINE INFORMATION...2079
      Description...2079
      Specifications...2080
      Torque Values...2084
      Troubleshooting...2085
      Removal And Installation...2086
      Engine Mount Replacement...2092
      Compression - Checking...2093
    ENGINE SPEED CONTROL...2095
      Removal And Installation...2095
    SPARK ARRESTOR MUFFLER...2097
      Removal And Installation...2097
    AIR CLEANER...2099
      Removal And Installation...2099
    ENGINE COOLING SYSTEM...2101
      Radiator Removal And Installation...2101
      Water Pump Removal And Installation...2102
      Water Pump Disassembly And Assembly...2103
      Thermostat Housing Removal And Installation...2104
      Testing The Thermostat...2105
    LUBRICATION SYSTEM...2107
      Oil Pan Removal And Installation...2107
      Oil Pump Removal And Installation...2107
      Oil Pump Inspection...2108
      Engine Oil Pressure - Testing...2109
    FUEL SYSTEM...2111
      Fuel Camshaft Removal And Installation...2111
      Fuel Camshaft Governor Disassembly And Assembly...2112
      Fuel Shutoff Solenoid - Checking...2113
      Fuel Shutoff Solenoid Removal And Installation...2113
      Fuel Injection Pump Removal And Installation...2114
      Injection Pump - Timing...2116
      Fuel Injector Removal And Installation...2118
      Fuel Injector Nozzle Pressure - Checking...2120
      Nozzle Spray Condition...2121
      Valve Seat Tightness...2122
    CYLINDER HEAD...2123
      Glow Plug - Testing...2123
      Glow Plug Removal And Installation...2124
      Valve Clearance Adjustment...2124
      Valve Timing - Checking...2125
      Cylinder Head Removal And Installation...2126
      Cylinder Head Disassembly and Assembly...2129
      Cylinder Head - Servicing...2129
      Cylinder Head Top Clearance...2130
      Valve Guide - Checking...2130
      Reconditioning The Valve And Valve Seat...2131
      Valve Spring...2133
      Valve Tappets...2134
      Rocker Arm And Shaft - Checking...2134
    CRANKSHAFT AND PISTONS...2135
      Piston And Connecting Rod Removal And Installation...2135
      Piston And Connecting Rod - Servicing...2137
      Cylinder Bore Checking...2139
      Connecting Rod Alignment...2140
      Crankshaft And Bearings Removal And Installation...2140
      Crankshaft And Bearings - Servicing...2142
    CAMSHAFT AND TIMING GEARS...2147
      Timing Gearcase Cover Removal And Installation...2147
      Timing Gears Backlash - Checking...2149
      Idler Gear And Shaft Removal And Installation...2150
      Camshaft - Servicing...2151
      Idler Gear And Shaft Servicing...2152
    FLYWHEEL AND HOUSING...2153
      Flywheel Housing Removal And Installation...2153
      Hydraulic Pump Coupler Removal And Installation...2154
      Flywheel Removal And Installation...2155
      Rear End Plate Removal And Installation...2155
  HEATER...2157
    HEATER SYSTEM (EARLIER MODELS)...2159
      Description...2159
      Components...2159
    HEATER SYSTEM (LATER MODELS)...2161
      Description...2161
      Components...2161
    REGULAR MAINTENANCE (EARLIER MODELS)...2163
      Filter Element Removal And Installation...2163
      Heater Coil...2164
    REGULAR MAINTENANCE (LATER MODELS)...2165
      Filter Element Removal And Installation...2165
      Heater Coil...2166
    TROUBLESHOOTING (EARLIER MODELS)...2167
      Blower Motor Does Not Operate...2167
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2167
      Electrical System...2168
    TROUBLESHOOTING (LATER MODELS)...2175
      Blower Motor Does Not Operate...2175
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2175
      Electrical System...2176
    HEATER UNIT (EARLIER MODELS)...2181
      Removal And Installation...2181
    HEATER UNIT (LATER MODELS)...2183
      Removal And Installation...2183
    HEATER COIL (EARLIER MODELS)...2185
      Removal And Installation...2185
    HEATER COIL (LATER MODELS)...2187
      Removal And Installation...2187
    BLOWER FAN (EARLIER MODELS)...2189
      Removal And Installation...2189
    BLOWER FAN (LATER MODELS)...2191
      Removal And Installation...2191
    HEATER VALVE (EARLIER MODELS)...2193
      Removal And Installation...2193
    HEATER VALVE (LATER MODELS)...2195
      Removal And Installation...2195
  SPECIFICATIONS...2197
    329 EXCAVATOR SPECIFICATIONS...2199
      Dimensions...2199
      Performance...2201
      Controls...2201
      Engine...2201
      Hydraulic System...2202
      Hydraulic Cylinders...2202
      Hydraulic Cycle Times...2202
      Electrical...2203
      Drive System...2203
      Slew System...2203
      Undercarriage...2203
      Capacities...2203
      Tracks...2203
      Ground Pressure...2203
    TORQUE SPECIFICATIONS FOR BOLTS...2205
      Torque For General SAE Bolts...2205
      Torque For General Metric Bolts...2206
    HYDRAULIC CONNECTION SPECIFICATIONS...2207
      O-Ring Face Seal Connection...2207
      Straight Thread O-ring Fitting...2208
      Tubelines And Hoses...2208
      Flare Fitting...2209
      Port Seal Fitting...2210
    HYDRAULIC FLUID SPECIFICATIONS...2211
      Specifications...2211
    CONVERSIONS...2213
      Decimal And Millimeter Equivalents...2213
      U.S. To Metric Conversion Chart...2213
  SERVICE MANUAL REVISION...2215
    Revision No: 329 - 1...2215
    Revision No: 329 - 2...2217
    Revision No: 329 - 3...2219
    Revision No: 329 - 4...2221
6904771 (7-12) - 329 Compact Excavator Service Manual...2223
  MAINTENANCE SAFETY...2225
  CONTENTS...2227
  FOREWORD...2229
    FOREWORD...2231
    SAFETY INSTRUCTIONS...2233
    FIRE PREVENTION...2235
      Maintenance...2235
      Operation...2235
      Electrical...2235
      Hydraulic System...2235
      Fueling...2235
      Starting...2235
      Spark Arrester Exhaust System...2235
      Welding And Grinding...2236
      Fire Extinguishers...2236
    SERIAL NUMBER LOCATIONS...2237
      Excavator Serial Number...2237
      Engine Serial Number...2237
    DELIVERY REPORT...2238
    EXCAVATOR IDENTIFICATION...2239
  SAFETY AND MAINTENANCE...2241
    LIFTING AND BLOCKING THE EXCAVATOR...2245
      Procedure...2245
    UPPERSTRUCTURE SLEW LOCK...2247
      Operation...2247
    LIFTING THE EXCAVATOR...2249
      Procedure...2249
    OPERATOR CAB (ROPS / TOPS)...2251
      Description...2251
      Cab Door...2251
      Front Window...2252
      Front Wiper...2253
      Window Washer Reservoir...2253
      Right Side Window...2254
      Heating, Ventilation And Air Conditioning Duct...2255
    TRANSPORTING THE EXCAVATOR ON A TRAILER...2257
      Loading And Unloading...2257
      Fastening...2257
    TAILGATE...2259
      Opening And Closing...2259
      Adjusting The Bumper...2259
      Adjusting The Latch...2259
    RIGHT SIDE COVER...2261
      Opening And Closing...2261
      Adjusting The Latch...2261
    SERVICE SCHEDULE...2263
      Chart...2263
    AIR CLEANER SERVICE...2265
      Daily Check...2265
      Replacing Filter Elements...2265
    ENGINE COOLING SYSTEM...2267
      Cleaning...2267
      Checking Level...2267
      Removing And Replacing Coolant...2268
    FUEL SYSTEM...2271
      Fuel Specifications...2271
      Filling The Fuel Tank...2271
      Fuel Filter...2272
      Draining The Fuel Tank...2272
      Removing Air From The Fuel System...2273
    ENGINE LUBRICATION SYSTEM...2275
      Checking And Adding Engine Oil...2275
      Engine Oil Chart...2275
      Removing And Replacing Oil And Filter...2276
    HYDRAULIC SYSTEM...2277
      Checking And Adding Fluid...2277
      Hydraulic Fluid Chart...2277
      Removing And Replacing Hydraulic Filters...2278
      Removing And Replacing Hydraulic Fluid...2279
    LUBRICATING THE EXCAVATOR...2281
      Lubrication Locations...2281
    TRAVEL MOTOR...2285
      Checking And Adding Oil...2285
      Removing And Replacing Oil...2285
    SPARK ARRESTER MUFFLER...2287
      Cleaning Procedure...2287
    ALTERNATOR BELT...2289
      Belt Adjustment...2289
      Belt Replacement...2289
    SEAT BELT...2291
      Inspection And Maintenance...2291
    PIVOT PINS...2293
      Inspection And Maintenance...2293
    EXCAVATOR STORAGE AND RETURN TO SERVICE...2295
      Storage...2295
      Return To Service...2295
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...2297
      Procedure...2297
      Emergency Exits...2298
    REMOTE START TOOL KIT - MEL1563...2299
      Remote Start Tool - MEL1563...2299
      Service Tool Harness Communicator - MEL1566...2301
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...2303
      Description...2303
      Remote Start Tool (Service Tool) - 7003030...2304
      Excavator Service Tool Harness - 6689747...2305
      Computer Service Tool Harness - 6689746...2306
  HYDRAULIC SYSTEM...2307
    HYDRAULIC / HYDROSTATIC SCHEMATICS...2311
    HYDRAULIC SYSTEM INFORMATION...2313
      Glossary Of Hydraulic / Hydrostatic Symbols...2313
      Troubleshooting The Hydraulic Circuit...2317
      Troubleshooting The Cylinder Circuit...2318
      Troubleshooting The Swing (Upperstructure Slew) Circuit...2319
      Troubleshooting The Travel Circuit...2320
    CYLINDER (BOOM)...2321
      Testing...2321
      Removal And Installation...2323
      Parts Identification...2325
      Disassembly...2326
      Assembly...2328
    CYLINDER (ARM)...2333
      Testing...2333
      Removal And Installation...2335
      Parts Identification...2337
      Disassembly...2338
      Assembly...2340
    CYLINDER (BOOM SWING)...2345
      Testing...2345
      Removal And Installation...2347
      Parts Identification...2349
      Disassembly...2350
      Assembly...2352
    CYLINDER (BUCKET)...2355
      Testing...2355
      Removal And Installation...2357
      Parts Identification...2359
      Disassembly...2360
      Assembly...2362
    CYLINDER (BLADE)...2365
      Testing...2365
      Removal And Installation...2367
      Parts Identification...2368
      Disassembly...2369
      Assembly...2371
    CYLINDER (CLAMP)...2375
      Testing...2375
      Removal And Installation...2376
      Parts Identification...2377
      Disassembly...2378
      Assembly...2381
    VALVE (MAIN RELIEF)...2387
      Testing And Adjusting The Main Relief Valve...2387
    VALVES (PORT RELIEF)...2393
      Testing And Adjusting Port Relief Valve Pressure...2393
    VALVES (CROSSPORT RELIEF)...2395
      Testing And Adjusting The Crossport Relief Valves...2395
    VALVE (PRESSURE REDUCING)...2401
      Testing And Adjusting The Pressure Reducing Valve...2401
    HYDRAULIC CONTROL VALVE...2403
      Description...2403
      Removal And Installation...2404
      Control Valve Identification...2411
      Disassembly...2412
      Right Travel Valve Section Disassembly And Assembly...2414
      Boom Swing Valve Section Disassembly And Assembly...2419
      Boom Valve Section Disassembly And Assembly...2426
      Left Travel Valve Section Disassembly And Assembly...2430
      Arm Valve Section Disassembly And Assembly...2435
      Bucket Valve Section Disassembly And Assembly...2439
      Auxiliary Valve Section Disassembly And Assembly...2443
      Boost Valve Section Disassembly And Assembly...2447
      Blade Valve Section Disassembly And Assembly...2451
      Slew Valve Section Disassembly And Assembly...2456
      Assembly...2460
    HYDRAULIC PUMP...2467
      Description...2467
      Torque Adjustment...2468
      Testing The Piston Pump...2469
      Testing The Gear Pump...2471
      Testing Auxiliary Hydraulic Flow...2472
      Removal And Installation...2473
      Coupler Removal And Installation...2475
      Parts Identification (Gear Pump)...2476
      Parts Identification (Piston Pump)...2477
      Disassembly...2478
      Gear Pump Disassembly...2479
      Gear Pump Assembly...2482
      Piston Pump Disassembly...2485
      Piston Pump Assembly...2491
      Assembly...2497
    MANIFOLD ASSEMBLY / ACCUMULATOR ASSEMBLY...2499
      Description...2499
      Removal And Installation...2499
      Parts Identification...2503
      Disassembly...2504
      Assembly...2514
    TRAVEL MOTOR...2525
      Description...2525
      Removal And Installation...2525
      Parts Identification...2527
      Disassembly...2528
      Assembly...2538
    SWIVEL JOINT...2549
      Description...2549
      Removal And Installation...2549
      Parts Identification...2551
      Disassembly...2552
      Assembly...2553
    SWING MOTOR...2557
      Description...2557
      Removal And Installation...2557
      Parts Identification...2560
      Disassembly...2561
      Assembly...2566
    SWING MOTOR (DRIVE CARRIER)...2573
      Description...2573
      Removal And Installation...2573
      Parts Identification...2574
      Disassembly...2575
      Assembly...2577
    CONTROL PATTERN SELECTOR VALVE...2581
      Description...2581
      Removal And Installation...2581
      Parts Identification...2582
      Disassembly...2583
      Assembly...2584
    RIGHT CONTROL LEVER (JOYSTICK)...2585
      Description...2585
      Testing...2585
      Handle Removal And Installation...2586
      Removal And Installation...2590
      Parts Identification...2593
      Disassembly...2594
      Assembly...2599
    LEFT CONTROL LEVER (JOYSTICK)...2605
      Description...2605
      Testing...2605
      Handle Removal And Installation...2606
      Removal And Installation...2609
      Parts Identification...2611
      Disassembly...2612
      Assembly...2617
    HYDRAULIC FILTER...2623
      Description...2623
      Housing Removal And Installation...2623
    CASE DRAIN FILTER...2625
      Description...2625
      Housing Removal And Installation...2625
    HYDRAULIC RESERVOIR...2627
      Description...2627
      Removal And Installation...2627
    OIL COOLER...2629
      Description...2629
      Removal And Installation...2629
    DIRECT TO TANK VALVE...2631
      Description...2631
      Removal And Installation...2631
      Parts Identification...2633
      Disassembly And Assembly...2634
    BUILDUP VALVE...2637
      Description...2637
      Removal And Installation...2637
      Parts Identification...2638
      Disassembly And Assembly...2639
  UNDERCARRIAGE...2641
    BLADE...2643
      Description...2643
      Removal And Installation...2643
    TRACK FRAME COMPONENTS...2645
      Description...2645
      Track Lug Height...2645
      Checking Tension...2646
      Adjusting Tension...2647
      Rubber Track Removal And Installation...2649
      Steel Track Removal And Installation...2652
      Idler (Front) Removal And Installation...2655
      Idler (Front) Parts Identification...2656
      Idler (Front) Disassembly...2657
      Idler (Front) Assembly...2659
      Coil Spring Assembly And Cylinder Disassembly And Assembly (W/O Replaceable Shaft)...2662
      Cylinder Parts Identification (With Replaceable Shaft)...2663
      Coil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)...2664
      Roller Removal And Installation...2665
      Roller Parts Identification...2666
      Roller Disassembly...2667
      Roller Assembly...2669
      Track Guide Removal And Installation...2671
      Sprocket Removal And Installation...2671
      Track Damage Identification...2672
    SWING CIRCLE GEAR...2683
      Removal And Installation...2683
  UPPERSTRUCTURE AND SWING SECTION...2685
    UPPERSTRUCTURE...2689
      Description...2689
      Removal...2689
      Installation...2692
    CANOPY...2695
      Removal And Installation...2695
    CAB...2699
      Removal And Installation...2699
      Door Removal And Installation...2704
      Front Window Removal And Installation...2705
      Right Side Rear Sliding Window Removal And Installation...2708
      Right Side Front Sliding Window Removal And Installation...2708
      Glass Removal...2709
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...2710
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...2710
      Glass Installation...2711
    SEAT AND SEAT MOUNT...2717
      Seat Mount Removal And Installation...2717
      Seat Removal And Installation...2718
    RIGHT CONSOLE...2719
      Description...2719
      Console Cover Removal And Installation...2719
      Console Frame Removal And Installation...2720
    LEFT CONSOLE...2723
      Description...2723
      Joystick Console Cover (Bottom) Removal And Installation...2723
      Joystick Console Cover (Top) Removal And Installation...2724
      Compression Spring Removal And Installation...2725
      Compression Spring Disassembly And Assembly...2725
      Lever Removal And Installation...2727
      Joystick Console Frame Removal And Installation...2728
      Joystick Console Frame Disassembly And Installation...2729
      Left Rear Console Cover Removal And Installation...2730
      Left Rear Console Frame Removal And Installation...2731
      Left Rear Console Frame Disassembly And Assembly...2733
    BLADE CONTROL...2735
      Removal And Installation...2735
      Disassembly And Assembly...2735
      Linkage Removal And Installation...2736
      Linkage Disassembly And Assembly...2738
    UPPERSTRUCTURE SLEW LOCK...2741
      Removal And Installation (S/N A2PG11001 - A2PG11093)...2741
      Removal And Installation (S/N A2PG11094 & Above)...2742
      Disassembly And Assembly (S/N A2PG11094 & Above)...2742
    FLOOR MAT AND FLOOR PANEL...2745
      Description...2745
      Removal And Installation...2745
    BOOM SWING PEDAL...2749
      Description...2749
      Removal And Installation...2749
      Disassembly And Assembly...2750
      Linkage Removal And Installation...2752
    TRAVEL LEVERS / PEDALS...2753
      Description...2753
      Adjustment...2753
      Removal And Installation...2756
      Disassembly And Assembly...2756
    FUEL TANK...2759
      Removal And Installation...2759
    HORN...2763
      Removal And Installation (Earlier Models)...2763
      Removal And Installation (Later Models)...2764
    SWING FRAME...2765
      Description...2765
      Removal And Installation...2765
      Hose Routing...2769
      Bushing Removal And Installation...2770
      Swing Frame Bushing Removal And Installation...2770
    BOOM...2773
      Description...2773
      Removal And Installation...2773
    ARM...2777
      Description...2777
      Removal And Installation...2777
      Arm To Boom Bushing Removal And Installation...2778
      Arm To Bucket And Bucket Link Bushing Removal And Installation...2779
    BUCKET...2781
      Removal And Installation (Pin-On X-Change™)...2781
      Removal And Installation (Bolt-On X-Change™)...2787
      Removal And Installation (Pin-On Attachment)...2793
      Bucket Teeth Removal And Installation...2794
      Bucket Side Cutting Edge Removal And Installation...2795
    CLAMP...2797
      Removal And Installation...2797
    TAILGATE...2799
      Removal And Installation...2799
      Latch Removal And Installation...2800
    X-CHANGE...2801
      Pin-On Removal And Installation...2801
      Pin-On Disassembly And Assembly...2802
    RIGHT SIDE COVER...2803
      Removal And Installation...2803
    QUICK COUPLER (KLAC™ SYSTEM)...2805
      Troubleshooting...2805
      Daily Inspection...2805
      Removal And Installation...2806
      Parts Identification...2808
      Disassembly...2809
      Assembly...2810
    QUICK COUPLER (LEHNHOFF® SYSTEM)...2813
      Troubleshooting...2813
      Daily Inspection...2813
      Removal (MS03 And MS08)...2814
      Installation (MS03 And MS08)...2815
      Parts Identification (MS03)...2816
      Disassembly And Assembly (MS03)...2817
      Parts Identification (MS08)...2818
      Disassembly (MS08)...2819
      Assembly (MS08)...2822
  ELECTRICAL SYSTEM AND ANALYSIS...2827
    ELECTRICAL SCHEMATICS...2829
    ELECTRICAL SYSTEM INFORMATION...2831
      Glossary Of Electrical Symbols...2831
      Harness Connectors...2834
      Troubleshooting...2836
      Description...2837
      Fuse And Relay Locations / Identification...2837
    BATTERY...2839
      Removal And Installation...2839
      Servicing...2840
      Using A Booster Battery (Jump Starting)...2841
    ALTERNATOR...2843
      Belt Adjustment...2843
      Belt Replacement...2843
      Charging System Inspection...2844
      Description...2845
      Tests...2845
      Alternator Output Test...2846
      Full Field Test...2846
      Alternator Regulator Test...2847
      Alternator Regulator Test With Voltmeter...2847
      Removal And Installation...2848
      Parts Identification...2849
    STARTER...2851
      Testing...2851
      Removal And Installation...2852
      Parts Identification...2853
    LIGHTS...2855
      Upperstructure Light Removal And Installation...2855
      Upperstructure Light Disassembly And Assembly...2855
      Boom Light Removal And Installation (Earlier Models)...2856
      Boom Light Disassembly And Assembly (Earlier Models)...2856
      Boom Light Removal And Installation (Later Models)...2857
      Boom Light Bulb Replacement (Later Models)...2857
    MAGNETIC LOCKOUT SENSOR...2859
      Testing Left Console Magnetic Lockout Sensor...2859
      Left Console Magnetic Lockout Sensor Removal And Installation...2860
    FUEL LEVEL SENDER...2863
      Removal And Installation...2863
      Testing...2864
    DIAGNOSTICS SERVICE CODES...2865
      Description...2865
  ENGINE SERVICE...2867
    ENGINE INFORMATION...2869
      Description...2869
      Specifications...2870
      Torque Values...2874
      Troubleshooting...2875
      Removal And Installation...2876
      Engine Mount Replacement...2882
      Compression - Checking...2883
    ENGINE SPEED CONTROL...2885
      Removal And Installation...2885
    SPARK ARRESTER MUFFLER...2887
      Removal And Installation...2887
    AIR CLEANER...2889
      Removal And Installation...2889
    ENGINE COOLING SYSTEM...2891
      Radiator Removal And Installation...2891
      Water Pump Removal And Installation...2892
      Water Pump Disassembly And Assembly...2893
      Thermostat Housing Removal And Installation...2894
      Testing The Thermostat...2895
    LUBRICATION SYSTEM...2897
      Oil Pan Removal And Installation...2897
      Oil Pump Removal And Installation...2897
      Oil Pump Inspection...2898
      Engine Oil Pressure - Testing...2899
    FUEL SYSTEM...2901
      Fuel Camshaft Removal And Installation...2901
      Fuel Camshaft Governor Disassembly And Assembly...2902
      Fuel Shutoff Solenoid - Checking...2903
      Fuel Shutoff Solenoid Removal And Installation...2903
      Fuel Injection Pump Removal And Installation...2904
      Injection Pump - Timing...2906
      Fuel Injector Removal And Installation...2908
      Fuel Injector Nozzle Pressure - Checking...2910
      Nozzle Spray Condition...2911
      Valve Seat Tightness...2912
    CYLINDER HEAD...2913
      Glow Plug - Testing...2913
      Glow Plug Removal And Installation...2914
      Valve Clearance Adjustment...2914
      Valve Timing - Checking...2915
      Cylinder Head Removal And Installation...2916
      Cylinder Head Disassembly And Assembly...2919
      Cylinder Head - Servicing...2919
      Cylinder Head Top Clearance...2920
      Valve Guide - Checking...2920
      Reconditioning The Valve And Valve Seat...2921
      Valve Spring...2923
      Valve Tappets...2924
      Rocker Arm And Shaft - Checking...2924
    CRANKSHAFT AND PISTONS...2925
      Piston And Connecting Rod Removal And Installation...2925
      Piston And Connecting Rod - Servicing...2927
      Cylinder Bore Checking...2929
      Connecting Rod Alignment...2930
      Crankshaft And Bearings Removal And Installation...2930
      Crankshaft And Bearings - Servicing...2932
    CAMSHAFT AND TIMING GEARS...2937
      Timing Gearcase Cover Removal And Installation...2937
      Timing Gears Backlash - Checking...2939
      Idler Gear And Shaft Removal And Installation...2940
      Camshaft - Servicing...2941
      Idler Gear And Shaft Servicing...2942
    FLYWHEEL AND HOUSING...2943
      Flywheel Housing Removal And Installation...2943
      Hydraulic Pump Coupler Removal And Installation...2944
      Flywheel Removal And Installation...2945
      Rear End Plate Removal And Installation...2945
  HEATER...2947
    HEATER SYSTEM (EARLIER MODELS)...2949
      Description...2949
      Components...2949
    HEATER SYSTEM (LATER MODELS)...2951
      Description...2951
      Components...2951
    REGULAR MAINTENANCE (EARLIER MODELS)...2953
      Filter Element Removal And Installation...2953
      Heater Coil...2954
    REGULAR MAINTENANCE (LATER MODELS)...2955
      Filter Element Removal And Installation...2955
      Heater Coil...2956
    TROUBLESHOOTING (EARLIER MODELS)...2957
      Blower Motor Does Not Operate...2957
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2957
      Electrical System...2958
    TROUBLESHOOTING (LATER MODELS)...2965
      Blower Motor Does Not Operate...2965
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2965
      Electrical System...2966
    HEATER UNIT (EARLIER MODELS)...2971
      Removal And Installation...2971
    HEATER UNIT (LATER MODELS)...2973
      Removal And Installation...2973
    HEATER COIL (EARLIER MODELS)...2975
      Removal And Installation...2975
    HEATER COIL (LATER MODELS)...2977
      Removal And Installation...2977
    BLOWER FAN (EARLIER MODELS)...2979
      Removal And Installation...2979
    BLOWER FAN (LATER MODELS)...2981
      Removal And Installation...2981
    HEATER VALVE (EARLIER MODELS)...2983
      Removal And Installation...2983
    HEATER VALVE (LATER MODELS)...2985
      Removal And Installation...2985
  SPECIFICATIONS...2987
    329 EXCAVATOR SPECIFICATIONS...2989
      Dimensions...2989
      Performance...2991
      Controls...2991
      Engine...2991
      Hydraulic System...2992
      Hydraulic Cylinders...2992
      Hydraulic Cycle Times...2992
      Electrical...2993
      Drive System...2993
      Slew System...2993
      Undercarriage...2993
      Capacities...2993
      Tracks...2993
      Ground Pressure...2993
    TORQUE SPECIFICATIONS FOR BOLTS...2995
      Torque For General SAE Bolts...2995
      Torque For General Metric Bolts...2996
    HYDRAULIC CONNECTION SPECIFICATIONS...2997
      O-ring Face Seal Connection...2997
      Straight Thread O-ring Fitting...2998
      Tubelines And Hoses...2998
      Flare Fitting...2999
      Port Seal Fitting...3000
    HYDRAULIC FLUID SPECIFICATIONS...3001
      Specifications...3001
    CONVERSIONS...3003
      Decimal And Millimeter Equivalents Charts...3003
      U.S. To Metric Conversion Chart...3003
  ALPHABETICAL INDEX...3005
  SERVICE MANUAL REVISION...3007
    Revision No: 329 - 1...3007
    Revision No: 329 - 2...3009
    Revision No: 329 - 3...3011
    Revision No: 329 - 4...3013
    Revision No: 329 - 5...3015
6986731 (05-10) - 321-323 Compact Excavator Service Manual...3017
  ALPHABETICAL INDEX...3021
  CONTENTS...3023
    FOREWORD...3025
    SAFETY INSTRUCTIONS...3027
    FIRE PREVENTION...3028
      Maintenance...3028
      Operation...3028
      Electrical...3028
      Hydraulic System...3029
      Fueling...3029
      Starting...3029
      Spark Arrestor Exhaust System...3029
      Welding And Grinding...3029
      Fire Extinguishers...3029
    SERIAL NUMBER LOCATIONS...3031
      Excavator Serial Number...3031
      Engine Serial Number...3031
    DELIVERY REPORT...3032
    BOBCAT EXCAVATOR IDENTIFICATION...3033
  SAFETY AND MAINTENANCE...3035
    LIFTING AND BLOCKING THE EXCAVATOR...3037
      Procedure...3037
    UPPERSTRUCTURE SLEW LOCK...3039
    LIFTING THE EXCAVATOR...3041
    OPERATOR CAB (ROPS / TOPS) (If Equipped)...3043
      Emergency Exits...3043
      Cab Door...3043
      Front Window...3044
      Front Window Wiper...3045
      Window Washer Reservoir...3045
      Right Side Windows...3045
    TRANSPORTING THE EXCAVATOR...3047
    TAILGATE...3049
      Opening And Closing The Tailgate...3049
      Adjusting the Bumper...3049
      Adjusting The Tailgate Catch...3049
    SERVICE SCHEDULE...3051
      Chart...3051
    AIR CLEANER SERVICE...3053
      Daily Check...3053
      Replacing The Filters...3053
    CAB FILTER...3055
      Cleaning And Maintenance...3055
    ENGINE COOLING SYSTEM...3057
      Cleaning The Cooling System...3057
      Checking The Coolant Level...3057
      Replacing The Coolant...3057
    FUEL SYSTEM...3059
      Fuel Specifications...3059
      Filling The Fuel Tank...3059
      Removing Water From The Fuel Filter...3059
      Replacing The Fuel Filter...3059
      Draining The Fuel Tank...3060
      Removing Air From The Fuel System...3060
    ENGINE LUBRICATION SYSTEM...3061
      Checking Engine Oil...3061
      Replacing Oil And Filter...3061
    HYDRAULIC SYSTEM...3063
      Checking And Adding Hydraulic Oil...3063
      Diagnostic Connectors...3063
      Replacing The Hydraulic Filter...3064
      Replacing Hydraulic Oil...3064
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...3065
      Rear Door Hinges...3065
      Blade...3065
      Boom Swing And Boom Base...3066
      Boom, Middle...3067
      Boom And Arm...3067
      Frame Fittings...3068
      Track Expansion Tube...3068
    TRAVEL MOTOR...3069
      Checking Oil Level...3069
      Draining The Drive Motor...3069
    SPARK ARRESTER MUFFLER...3071
      Cleaning Procedure...3071
    ALTERNATOR BELT...3073
      Adjusting The Alternator Belt...3073
    SEAT BELT...3075
      Inspection And Maintenance...3075
    CONTROL CONSOLE LOCKOUTS...3077
      Inspection And Maintenance...3077
    DE-AERATION...3079
      Procedure...3079
  HYDRAULIC SYSTEM...3083
    HYDRAULIC SCHEMATIC...3087
    HYDRAULIC SYSTEM INFORMATION...3089
      Glossary Of Hydraulic / Hydrostatic Symbols...3089
      Troubleshooting The Hydraulic Circuit...3093
      Troubleshooting The Cylinder Circuit...3094
      Troubleshooting The Swing (Upperstructure Slew) Circuit...3095
      Troubleshooting The Travel Circuit...3096
    BOOM CYLINDER...3097
      Testing...3097
      Removal and Installation...3098
      Parts Identification...3100
      Disassembly...3101
      Assembly...3103
    ARM CYLINDER...3107
      Testing...3107
      Removal and Installation...3109
      Parts Identification...3110
      Disassembly...3111
      Assembly...3113
    BOOM SWING CYLINDER...3117
      Testing...3117
      Removal and Installation...3118
      Parts Identification...3120
      Disassembly...3121
      Assembly...3123
    BUCKET CYLINDER...3127
      Testing...3127
      Removal and Installation...3128
      Parts Identification...3130
      Disassembly...3131
      Assembly...3133
    BLADE CYLINDER...3137
      Testing...3137
      Removal and Installation...3138
      Parts Identification...3140
      Disassembly...3141
      Assembly...3143
    TRACK FRAME EXPANSION CYLINDER...3147
      Testing...3147
      Removal And Installation...3148
      Parts Identification...3152
      Disassembly...3153
      Assembly...3155
    MAIN RELIEF VALVE...3159
      Testing And Adjusting The Main Relief Valve...3159
    PORT RELIEF VALVES...3161
      Testing And Adjusting The Port Relief Valve Pressure...3161
    CROSSPORT RELIEF VALVES...3163
      Testing And Adjusting The Crossport Relief Valve...3163
    PRESSURE REDUCING VALVE...3165
      Testing And Adjusting The Pressure Reducing Valve...3165
    HYDRAULIC CONTROL VALVE...3167
      Description...3167
      Removal And Installation...3167
      Parts Identification...3169
      Disassembly...3170
      Right Travel Valve Section Disassembly And Assembly...3171
      Boom Swing Valve Section Disassembly And Assembly...3175
      Arm Valve Section Disassembly and Assembly...3178
      Bucket Valve Section Disassembly And Assembly...3181
      Auxiliary Valve Section Disassembly And Assembly...3184
      Boom Valve Section Disassembly And Assembly...3189
      Left Travel Valve Section Disassembly And Assembly...3192
      Swing (Slew) Valve Section Disassembly And Assembly...3196
      Blade Valve Section Disassembly And Assembly...3199
      Assembly...3203
    HYDRAULIC PUMP...3209
      Description...3209
      Torque Adjustment...3209
      Testing The Piston Pump...3210
      Testing The Gear Pump...3212
      Testing Auxiliary Hydraulic Flow...3213
      Removal And Installation...3214
      Parts Identification...3217
      Disassembly...3218
      Gear Pump Disassembly...3219
      Piston Pump Disassembly...3221
      Piston Pump Assembly...3230
      Gear Pump Assembly...3239
      Assembly...3241
    MANIFOLD ASSEMBLY / ACCUMULATOR...3243
      Description...3243
      Removal And Installation...3243
      Parts Identification...3246
      Disassembly...3247
      Assembly...3258
    ACCUMULATORS...3269
      Removal And Installation...3269
    TRAVEL MOTOR...3271
      Description...3271
      Removal And Installation...3271
      Parts Identification...3272
      Disassembly...3273
      Assembly...3280
    SWIVEL JOINT...3289
      Description...3289
      Removal And Installation...3289
      Parts Identification...3292
      Disassembly...3293
      Assembly...3295
    SWING MOTOR...3299
      Description...3299
      Removal And Installation...3299
      Parts Identification...3300
      Disassembly...3301
      Assembly...3307
    RIGHT CONTROL LEVER (JOYSTICK)...3315
      Description...3315
      Testing...3315
      Handle Removal And Installation...3317
      Removal And Installation...3318
      Parts Identification...3319
      Disassembly...3320
      Assembly...3325
    LEFT CONTROL LEVER (JOYSTICK)...3329
      Description...3329
      Testing...3329
      Handle Removal And Installation...3331
      Removal And Installation...3333
      Parts Identification...3334
      Disassembly...3335
      Assembly...3340
    HYDRAULIC FILTER MOUNT...3345
      Description...3345
      Removal And Installation...3345
    HYDRAULIC RESERVOIR...3347
      Description...3347
      Removal And Installation...3347
    OIL COOLER...3349
      Description...3349
      Removal And Installation...3349
    BLADE / TRACK EXPANSION SOLENOID BLOCK...3351
      Description...3351
      Block Removal and Installation...3351
      Solenoid Removal and Installation...3352
      Block Disassembly And Assembly...3353
    SLEW LOCK VALVE (FOR S/N A76511001 & ABOVE, A01711001 & ABOVE)...3355
      Description...3355
      Removal And Installation...3355
      Parts Identification...3357
      Disassembly And Assembly...3358
  UNDERCARRIAGE...3363
    BLADE...3365
      Description...3365
      Extension Removal And Installation...3365
      Blade Removal And Installation...3366
    TRACKS...3367
      Track Lug Height...3367
      Track Tension Adjustment...3367
      Removal And Installation...3370
    TRACK FRAME...3371
      Disassembly And Assembly...3371
      Removal And Installation Of Expandable Track Frame...3372
    TRACK DAMAGE IDENTIFICATION...3375
      Cutting Of The Steel Cords...3375
      Causes Of The Damage...3375
      Abrasion Of Embedded Metals...3376
      Separation Of Embedded Metals...3377
      Separation Of Embedded Metals Due To Corrosion...3378
      Cuts On The Lug Side Rubber...3379
      Cracks On The Lug Side Rubber Due To Fatigue...3380
      Lug Abrasion...3381
      Cracks And Cuts On The Lug Side Rubber...3382
      Abrasion Of The Track Roller Side...3383
      Cuts On The Edges Of The Track Roller Side...3384
    TRACK IDLER...3387
      Parts Identification...3387
      Disassembly...3388
      Assembly...3390
    TRACK ROLLER...3393
      Parts Identification...3393
      Disassembly...3394
      Assembly...3396
    SWING CIRCLE GEAR...3399
      Removal and Installation...3399
  UPPERSTRUCTURE AND SWING SECTION...3401
    UPPERSTRUCTURE...3405
      Description...3405
      Removal...3405
      Installation...3407
    ROPS CANOPY...3409
      Removal And Installation...3409
    CAB...3413
      Removal And Installation...3413
      Door Removal And Installation...3417
      Front Window Removal And Installation...3418
      Right Side Rear Sliding Window Removal And Installation...3421
      Right Side Front Sliding Window Removal And Installation...3422
      Glass Removal...3422
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...3423
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...3423
      Glass Installation...3424
    SEAT AND SEAT MOUNT...3427
      Removal And Installation...3427
    RIGHT CONSOLE...3429
      Description...3429
      Joystick Console Cover (Bottom) Removal And Installation...3429
      Joystick Console Cover (Top) Removal And Installation...3430
      Joystick Console Cover (Top) Disassembly And Assembly...3431
      Compression Spring Removal And Installation (Canopy Only)...3432
      Compression Spring Disassembly And Assembly (Canopy Only)...3433
      Lever Removal And Installation (Canopy Only)...3434
      Joystick Console Frame Removal And Installation...3436
      Joystick Console Frame Disassembly And Assembly...3437
      Right Rear Console Cover Removal And Installation...3438
      Right Rear Console Cover Disassembly and Assembly...3439
      Right Rear Console Frame Removal And Installation...3440
    LEFT CONSOLE...3443
      Description...3443
      Joystick Console Cover (Bottom) Removal And Installation...3443
      Joystick Console Cover (Top) Removal And Installation...3444
      Compression Spring Removal And Installation...3445
      Compression Spring Disassembly And Assembly...3446
      Lever Removal And Installation...3448
      Joystick Console Frame Removal And Installation...3449
      Joystick Console Frame Disassembly And Assembly...3450
      Left Rear Console Cover Removal And Installation...3450
      Left Rear Console Frame Removal And Installation...3451
    ENGINE SPEED CONTROL...3453
      Removal and Installation...3453
      Cable Removal and Installation...3454
    BLADE CONTROL...3457
      Removal and Installation...3457
      Disassembly And Assembly...3458
      Cable Removal and Installation...3460
    UPPERSTRUCTURE SLEW LOCK...3461
      Removal and Installation...3461
      Disassembly And Assembly...3461
    RIGHT PEDAL...3463
      Removal And Installation...3463
      Disassembly And Assembly...3463
    TRAVEL CONTROLS...3465
      Removal And Installation...3465
      Disassembly And Assembly...3465
    LEFT PEDAL...3467
      Removal And Installation...3467
      Disassembly And Assembly...3467
    CONTROL LINKAGE ASSEMBLY...3469
      Description...3469
      Removal And Installation...3469
      Right Half of Control Linkage Disassembly And Assembly...3471
      Left Half of Control Linkage Disassembly And Assembly...3473
      Bracket of Control Linkage Disassembly And Assembly...3476
    FLOOR MAT AND FLOOR PANELS...3477
      Description...3477
      Removal and Installation...3477
    FUEL TANK...3479
      Removal and Installation...3479
    HORN...3481
      Removal And Installation...3481
    SWING FRAME...3483
      Description...3483
      Removal And Installation...3483
      Bushing Removal and Installation...3484
      Swing Frame Bushing Removal...3485
      Swing Frame Bushing Installation...3486
      Boom Pivot Bushing Removal...3486
      Boom Pivot Bushing Installation...3487
    BOOM...3489
      Description...3489
      Removal And Installation...3489
      Boom Bushing Removal And Installation...3490
    ARM...3491
      Description...3491
      Removal And Installation...3491
      Arm To Boom Bushing Removal And Installation...3492
      Arm To Bucket And Bucket Link Bushing Removal And Installation...3493
    BUCKET...3495
      Removal And Installation...3495
    TAILGATE...3497
      Removal And Installation...3497
      Latch Removal And Installation...3498
  ELECTRICAL SYSTEM AND ANALYSIS...3499
    ELECTRICAL SCHEMATIC...3501
    ELECTRICAL SYSTEM INFORMATION...3502
      Glossary Of Electrical Symbols...3502
      Troubleshooting...3505
      Description...3506
      Fuse And Relay Location / Identification...3506
      Fuel Timer And Diode Location / Identification...3507
    BATTERY...3508
      Servicing...3508
      Removal and Installation...3509
      Using A Booster Battery (Jump Starting)...3510
    ALTERNATOR...3512
      Description...3512
      Tests...3512
      Alternator Output Test...3513
      Full Field Test...3513
      Alternator Regulator Test...3514
      Alternator Regulator Test With Voltmeter...3514
      Removal And Installation...3515
      Belt Adjustment...3516
      Charging System Inspection...3518
      Parts Identification...3519
    STARTER...3520
      Removal And Installation...3520
      Parts Identification...3521
      Cleaning And Inspection...3522
    LIGHTS...3524
      UpperStructure Light Removal And Installation...3524
      UpperStructure Light Disassembly and Assembly...3524
      Boom Light Removal And Installation...3525
      Boom Light Disassembly And Assembly...3525
      Light Switch Removal And Installation...3526
    MICROSWITCH...3528
      Testing Left Console Microswitch...3528
      Left Console Microswitch Removal And Installation...3529
      Testing Right Console Microswitch...3529
      Right Console Microswitch Removal And Installation...3531
    TWO-SPEED BOOST SWITCH...3532
      Description...3532
      Removal And Installation...3532
    FUEL LEVEL SENDER...3534
      Removal And Installation...3534
      Testing...3534
  ENGINE SERVICE...3536
    TROUBLESHOOTING...3538
      Chart...3538
    SPARK ARRESTOR MUFFLER...3540
      Removal And Installation...3540
    AIR CLEANER...3542
      Removal And Installation...3542
    RADIATOR...3544
      Removal And Installation...3544
    ENGINE COMPONENTS AND TESTING...3550
      Valve Clearance Adjustment...3550
      Engine Compression Checking...3551
      Fuel Shutoff Solenoid - Checking...3551
      Fuel Shutoff Solenoid Removal And Installation...3552
      Fuel Shutoff Timer Removal And Installation...3552
      Fuel Injection Pump Check...3552
      Fuel Injection Pump Removal And Installation...3553
      Fuel Injection Pump Timing...3555
      Fuel Injector Removal And Installation...3556
      Fuel Injector Checking...3557
      Glow Plug Removal And Installation...3559
    ENGINE...3560
      Description...3560
      Specifications...3561
      Engine...3561
      Fuel Injector Nozzles...3561
      Fuel Injection Pump...3561
      Cylinder Head...3561
      Valves...3561
      Valve Springs...3561
      Rocker Arms...3562
      Camshaft...3562
      Cylinders...3562
      Piston Rings...3562
      Pistons...3563
      Connecting Rods...3563
      Crankshaft...3563
      Oil Pump...3563
      Thermostat...3564
      Torque Values...3565
      Engine Removal and Installation...3566
      Engine Mount Replacement...3573
    FLYWHEEL AND HOUSING...3574
      Flywheel Housing Removal And Installation...3574
      Hydraulic Pump Coupler Removal And Installation...3575
      Flywheel Removal...3575
      Flywheel Installation...3576
      Rear End Plate Removal And Installation...3576
    RECONDITIONING THE ENGINE...3578
      Cylinder Head Removal And Installation...3578
      Cylinder Head Disassembly And Assembly...3579
      Cylinder Head, Servicing...3580
      Cylinder Head Top Clearance...3581
      Valve Guide, Checking...3581
      Valve Timing, Checking...3583
      Valve And Valve Seat Reconditioning...3583
      Valve Seat Tightness...3584
      Valve Spring...3585
      Valve Tappets...3586
      Rocker Arm And Shaft, Checking...3587
      Timing Gearcase Cover Removal And Installation...3587
      Idler Gear And Camshaft Removal And Installation...3589
      Idler Gear and Shaft, Servicing...3592
      Timing Gears Checking Backlash...3593
      Fuel Camshaft Removal And Installation...3593
      Fuel Camshaft Governor...3594
      Crankshaft Gear Removal And Installation...3594
      Oil Pan Removal And Installation...3595
      Oil Pump Removal And Installation...3596
      Oil Pump, Service...3596
      Engine Oil Pressure, Checking...3597
      Relief Valve...3598
      Piston And Connecting Rod Removal And Installation...3598
      Piston And Connecting Rod, Servicing...3600
      Connecting Rod Alignment...3602
      Crankshaft And Bearings Removal And Installation...3602
      Crankshaft And Bearings, Servicing...3604
      Cylinder Bore, Checking...3606
      Water Pump Removal And Installation...3607
      Water Pump Disassembly And Assembly...3607
      Thermostat Removal And Installation...3608
      Testing The Thermostat...3608
  HEATER...3610
    HEATER SYSTEM...3612
      Description...3612
      Components...3612
    REGULATOR MAINTENANCE...3614
      Filter Element Removal And Installation...3614
      Heater Coil...3614
    HEATER UNIT...3616
      Removal And Installation...3616
      Louver Removal and Installation...3617
      Threaded Insert Removal And Installation...3617
    HEATER COIL...3618
      Removal And Installation...3618
    HEATER FAN...3622
      Removal And Installation...3622
    HEATER VALVE...3626
      Removal And Installation...3626
  SPECIFICATIONS...3628
    SPECIFICATIONS 321 EXCAVATOR...3630
      Machine dimensions...3630
      Working range...3631
      Lift Capacity (Object handling applications excluded)...3632
      Performance...3633
      Function Time...3633
      Weights...3633
      Controls...3633
      Engine...3634
      Electrical...3634
      Hydraulic system...3634
      Hydraulic cylinders...3635
      Drive system...3635
      Traction...3635
      Brakes...3636
      Slew system...3636
      Serviceability...3636
      Fluid capacities...3637
      Fluid specifications...3637
      Environmental...3638
      Instrumentation...3638
      Safety...3638
      Standard features...3639
      Options...3639
      Attachments...3639
      Bucket...3639
    SPECIFICATIONS 323 EXCAVATOR...3640
      Machine dimensions...3640
      Working range...3641
      Lift Capacity (Object handling applications excluded)...3642
      Performance...3643
      Function time...3643
      Weights...3643
      Controls...3643
      Engine...3644
      Electrical...3644
      Hydraulic system...3644
      Hydraulic cylinders...3645
      Drive system...3645
      Traction...3645
      Brakes...3646
      Slew system...3646
      Serviceability...3646
      Fluid capacities...3647
      Fluid specifications...3647
      Environmental...3648
      Instrumentation...3648
      Safety...3648
      Standard features...3649
      Options...3649
      Attachments...3649
      Buckets...3649
    TORQUE SPECIFICATIONS FOR BOLTS...3650
      Torque For General SAE Bolts...3650
      Torque For General Metric Bolts...3651
    HYDRAULIC CONNECTION SPECIFICATIONS...3652
      O-ring Face Seal Connection...3652
      Straight Thread O-ring Fitting...3653
      Tubelines And Hoses...3653
      Flare Fitting...3654
      Port Seal Fitting...3655
    HYDRAULIC FLUID SPECIFICATIONS...3656
      Specifications...3656
    CONVERSIONS...3658
      Decimal And Millimeter Equivalents...3658
      U.S. To Metric Conversion Chart...3658
6986945 (2-08) - 329 Compact Excavator Operation & Maintenance Manual...3660
  CONTENTS...3664
  FOREWORD...3666
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...3668
    REGULAR MAINTENANCE ITEMS...3668
    SERIAL NUMBER LOCATIONS...3670
      Excavator Serial Number...3670
      Engine Serial Number...3670
    DELIVERY REPORT...3670
    EXCAVATOR IDENTIFICATION...3671
    FEATURES, ACCESSORIES AND ATTACHMENTS...3672
      Standard Items...3672
      Options and Accessories...3672
      Attachments...3672
      Buckets Available...3672
      Falling Object Guards (FOGS)...3673
      Special Applications Kit...3673
      Special Applications Kit Inspection And Maintenance...3673
  SAFETY & TRAINING RESOURCES...3674
    SAFETY INSTRUCTIONS...3676
      Before Operation...3676
      Safe Operation Is The Operator’s Responsibility...3677
      Safe Operation Needs A Qualified Operator...3677
      Avoid Silica Dust...3678
    FIRE PREVENTION...3678
      Maintenance...3678
      Operation...3678
      Electrical...3678
      Hydraulic System...3679
      Fueling...3679
      Starting...3679
      Spark Arrestor Exhaust System...3679
      Welding And Grinding...3679
      Fire Extinguishers...3679
    MACHINE SIGNS (DECALS)...3680
    PUBLICATIONS AND TRAINING RESOURCES...3682
  OPERATING INSTRUCTIONS...3684
    INSTRUMENTS AND CONSOLES...3686
      Cab Interior Light (If Equipped)...3686
      Left Console...3686
      Right Console...3687
      Function Icons...3688
      STD / ISO Selector Valve...3689
      Upperstructure Slew Lock...3689
      Raising And Lowering The Console...3690
      Two-Speed Travel...3690
    OPERATOR CANOPY (ROPS / TOPS)...3691
      Description...3691
    OPERATOR CAB (ROPS / TOPS)...3691
      Description...3691
      Cab Door...3692
      Front Window...3693
      Front Wiper...3694
      Window Washer Reservoir...3694
      Right Side Window...3695
      Heating, Ventilation And Air Conditioning Duct...3696
    TRAVEL CONTROLS...3697
      Description...3697
      Forward And Reverse Travel...3697
      Turning...3697
    HYDRAULIC CONTROLS...3699
      Description...3699
      STANDARD Control Pattern...3699
      ISO Control Pattern...3700
      Quick Couplers (If Equipped)...3701
      Auxiliary Hydraulics...3702
      Relieve Hydraulic Pressure (Excavator And Attachment)...3702
      Return To Tank Valve (If Equipped)...3702
    BLADE CONTROL LEVER...3703
      Operation...3703
    BOOM SWING PEDAL...3703
      Operation...3703
    DAILY INSPECTION...3704
      Daily Inspection And Maintenance...3705
    PRE-STARTING PROCEDURE...3706
      Operation & Maintenance Manual And Operator’s Handbook Locations...3706
      Entering The Excavator...3706
      Seat Adjustment...3707
      Seat Belt Adjustment...3707
      Control Console...3708
    STARTING THE ENGINE...3709
      Key Switch...3709
      Keyless...3710
      Cold Temperature Starting...3711
      Warming The Hydraulic System...3712
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...3713
      Procedure...3713
      Emergency Exits...3714
    ATTACHMENTS...3715
      Installing And Removing The Attachment (Pin-On X- Change)...3715
      Installing And Removing The Attachment (Bolt-On X- Change)...3721
      Installing And Removing The Attachment (Pin-On Attachment)...3727
    OPERATING PROCEDURE...3728
      Inspect The Work Area...3728
      Lowering The Work Equipment (Engine STOPPED)...3728
      Operating On Public Roads...3728
      Lifting A Load...3729
      Excavating...3730
      Boom Swing...3732
      Backfilling...3733
      Driving The Excavator...3733
      Operating On Slopes...3734
      Operating In Water...3736
      Avoiding Track Damage...3736
    TOWING THE EXCAVATOR...3736
      Procedure...3736
    LIFTING THE EXCAVATOR...3737
      Procedure...3737
    TRANSPORTING THE EXCAVATOR ON A TRAILER...3738
      Loading And Unloading...3738
      Fastening...3738
  PREVENTIVE MAINTENANCE...3740
    MAINTENANCE SAFETY...3742
    SERVICE SCHEDULE...3744
      Chart...3744
    CONTROL CONSOLE LOCKOUTS...3745
      Inspection And Maintenance...3745
    SEAT BELT...3746
      Inspection And Maintenance...3746
    MOTION ALARM SYSTEM (IF EQUIPPED)...3747
      Description...3747
      Inspecting...3747
      Adjusting Switch Position...3747
    TAILGATE...3748
      Opening And Closing...3748
      Adjusting The Bumper...3748
      Adjusting The Latch...3748
    RIGHT SIDE COVER...3749
      Opening And Closing...3749
      Adjusting The Latch...3749
    CAB FILTERS...3750
      Cleaning And Maintenance...3750
    AIR CLEANER SERVICE...3751
      Daily Check...3751
      Replacing Filter Elements...3751
    FUEL SYSTEM...3753
      Fuel Specifications...3753
      Biodiesel Blend Fuel...3753
      Filling The Fuel Tank...3754
      Fuel Filters...3755
      Draining The Fuel Tank...3755
      Removing Air From The Fuel System...3756
    ENGINE LUBRICATION SYSTEM...3757
      Checking And Adding Engine Oil...3757
      Engine Oil Chart...3757
      Removing And Replacing Oil And Filter...3758
    ENGINE COOLING SYSTEM...3759
      Cleaning...3759
      Checking Level...3759
      Removing And Replacing Coolant...3760
    ELECTRICAL SYSTEM...3761
      Description...3761
      Fuse And Relay Location / Identification...3761
      Battery Maintenance...3762
      Using A Booster Battery (Jump Starting)...3763
      Removing And Installing Battery...3764
    HYDRAULIC SYSTEM...3765
      Checking And Adding Fluid...3765
      Hydraulic Fluid Chart...3765
      Removing And Replacing Hydraulic Filters...3766
      Removing And Replacing Hydraulic Fluid...3767
    SPARK ARRESTOR MUFFLER...3768
      Cleaning Procedure...3768
    TRACK TENSION...3769
      Adjusting...3769
    TRAVEL MOTOR...3771
      Checking And Adding Oil...3771
      Removing And Replacing Oil...3771
    ALTERNATOR BELT...3772
      Belt Adjustment...3772
      Belt Replacement...3772
    X-CHANGE...3773
      Inspection And Maintenance...3773
    TRACK ROLLER AND IDLER LUBRICATION...3773
      Procedure...3773
    BUCKET...3774
      Bucket Teeth Removal And Installation...3774
    LUBRICATING THE EXCAVATOR...3775
      Lubrication Locations...3775
    PIVOT PINS...3777
      Inspection And Maintenance...3777
    EXCAVATOR STORAGE AND RETURN TO SERVICE...3778
      Storage...3778
      Return to Service...3778
  SYSTEM SETUP AND ANALYSIS...3780
    DIAGNOSTIC SERVICE CODE...3782
      Service Codes List...3782
    DISPLAY CONTROLLER PANEL SETUP...3783
      Passwords...3783
      Password Entry (For Starting and Operating the Machine)...3783
      Changing The Owner or Operator Password...3783
      Password Lockout Feature...3784
      Job Clock...3784
      RPM...3784
      Viewing Service Codes (Key Switch)...3785
      Viewing Service Codes (Keyless)...3785
  MACHINE SIGN TRANSLATIONS...3786
    WARNING (6808185)...3788
    LIFT CHART (7125436)...3789
    SERVICE SCHEDULE (7151799)...3792
    WARNING (6807776)...3795
    WARNING (6804114, 6577754, 6809832, 6804233)...3797
    WARNING (6815945)...3798
      WARNING (6808474)...3798
    WARNING (6815915)...3799
    USING THE X-CHANGE SYSTEM (7102651)...3800
    WARNING (6809829)...3803
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...3803
  SPECIFICATIONS...3804
    EXCAVATOR SPECIFICATIONS...3806
      Dimensions...3806
      Performance...3808
      Controls...3808
      Engine...3808
      Hydraulic System...3809
      Hydraulic Cylinders...3809
      Hydraulic Cycle Times...3809
      Electrical...3809
      Instrumentation...3809
      Drive System...3810
      Slew System...3810
      Undercarriage...3810
      Crawler Track Design...3810
      Capacities...3810
      Fuel Tank...3810
      Tracks...3810
      Type...3810
      Ground Pressure...3810
  WARRANTY...3812
  ALPHABETICAL INDEX...3816
6986946 (10-09) - 329 Compact Excavator Service Manual...3818
  ALPHABETICAL INDEX...3820
  MAINTENANCE SAFETY...3822
  CONTENTS...3824
    FOREWORD...3825
    SAFETY INSTRUCTIONS...3827
    FIRE PREVENTION...3829
      Maintenance...3829
      Operation...3829
      Electrical...3829
      Hydraulic System...3829
      Fueling...3829
      Starting...3829
      Spark Arrestor Exhaust System...3829
      Welding And Grinding...3830
      Fire Extinguishers...3830
    SERIAL NUMBER LOCATIONS...3832
      Excavator Serial Number...3832
      Engine Serial Number...3832
    DELIVERY REPORT...3833
    EXCAVATOR IDENTIFICATION...3834
  SAFETY AND MAINTENANCE...3836
    LIFTING AND BLOCKING THE EXCAVATOR...3840
      Procedure...3840
    UPPERSTRUCTURE SLEW LOCK...3842
      Operation...3842
    LIFTING THE EXCAVATOR...3844
      Procedure...3844
    OPERATOR CAB (ROPS / TOPS)...3846
      Description...3846
      Cab Door...3846
      Front Window...3847
      Front Wiper...3848
      Window Washer Reservoir...3848
      Right Side Window...3849
      Heating, Ventilation And Air Conditioning Duct...3850
    TRANSPORTING THE EXCAVATOR ON A TRAILER...3852
      Loading And Unloading...3852
      Fastening...3852
    TAILGATE...3854
      Opening And Closing...3854
      Adjusting The Bumper...3854
      Adjusting The Latch...3854
    RIGHT SIDE COVER...3856
      Opening And Closing...3856
      Adjusting The Latch...3856
    SERVICE SCHEDULE...3858
      Chart...3858
    AIR CLEANER SERVICE...3860
      Daily Check...3860
      Replacing Filter Elements...3860
    ENGINE COOLING SYSTEM...3862
      Cleaning...3862
      Checking Level...3862
      Removing And Replacing Coolant...3863
    FUEL SYSTEM...3866
      Fuel Specifications...3866
      Biodiesel Blend Fuel...3866
      Filling The Fuel Tank...3867
      Fuel Filter...3868
      Draining The Fuel Tank...3868
      Removing Air From The Fuel System...3869
    ENGINE LUBRICATION SYSTEM...3870
      Checking And Adding Engine Oil...3870
      Engine Oil Chart...3870
      Removing And Replacing Oil And Filter...3871
    HYDRAULIC SYSTEM...3872
      Checking And Adding Fluid...3872
      Hydraulic Fluid Chart...3873
      Removing And Replacing Hydraulic Filters...3873
      Removing And Replacing Hydraulic Fluid...3874
    LUBRICATING THE EXCAVATOR...3876
      Lubrication Locations...3876
    TRAVEL MOTOR...3880
      Checking And Adding Oil...3880
      Removing And Replacing Oil...3880
    SPARK ARRESTOR MUFFLER...3882
      Cleaning Procedure...3882
    ALTERNATOR BELT...3884
      Belt Adjustment...3884
      Belt Replacement...3884
    SEAT BELT...3886
      Inspection And Maintenance...3886
    PIVOT PINS...3888
      Inspection And Maintenance...3888
    EXCAVATOR STORAGE AND RETURN TO SERVICE...3890
      Storage...3890
      Return to Service...3890
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...3892
      Procedure...3892
      Emergency Exits...3893
    MOTION ALARM SYSTEM (IF EQUIPPED)...3894
      Description...3894
      Inspecting...3894
      Adjusting Switch Position...3894
  HYDRAULIC SYSTEM...3896
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3901
    HYDRAULIC SYSTEM INFORMATION...3904
      Glossary Of Hydraulic / Hydrostatic Symbols...3904
      Troubleshooting The Hydraulic Circuit...3908
      Troubleshooting The Cylinder Circuit...3909
      Troubleshooting The Swing (Upperstructure Slew) Circuit...3910
      Troubleshooting The Travel Circuit...3911
    BOOM CYLINDER...3912
      Testing...3912
      Removal And Installation...3914
      Parts Identification...3916
      Disassembly...3917
      Assembly...3919
    ARM CYLINDER...3924
      Testing...3924
      Removal And Installation...3926
      Parts Identification...3928
      Disassembly...3929
      Assembly...3931
    BOOM SWING CYLINDER...3936
      Testing...3936
      Removal And Installation...3938
      Parts Identification...3940
      Disassembly...3941
      Assembly...3943
    BUCKET CYLINDER...3946
      Testing...3946
      Removal And Installation...3948
      Parts Identification...3950
      Disassembly...3951
      Assembly...3953
    BLADE CYLINDER...3956
      Testing...3956
      Removal And Installation...3958
      Parts Identification...3959
      Disassembly...3960
      Assembly...3962
    CLAMP CYLINDER...3966
      Testing...3966
      Removal And Installation...3967
      Parts Identification...3968
      Disassembly...3969
      Assembly...3972
    MAIN RELIEF VALVE...3978
      Testing And Adjusting The Main Relief Valve...3978
    PORT RELIEF VALVES...3982
      Testing And Adjusting Port Relief Valve Pressure...3982
    CROSSPORT RELIEF VALVES...3984
      Testing And Adjusting The Crossport Relief Valves...3984
    PRESSURE REDUCING VALVE...3988
      Testing And Adjusting The Pressure Reducing Valve...3988
    HYDRAULIC CONTROL VALVE...3990
      Description...3990
      Removal And Installation...3990
      Disassembly...3998
      Right Travel Valve Section Disassembly And Assembly...4000
      Boom Swing Valve Section Disassembly And Assembly...4005
      Boom Valve Section Disassembly And Assembly...4012
      Left Travel Valve Section Disassembly And Assembly...4016
      Arm Valve Section Disassembly And Assembly...4021
      Bucket Valve Section Disassembly And Assembly...4025
      Auxiliary Valve Section Disassembly And Assembly...4029
      Boost Valve Section Disassembly And Assembly...4033
      Blade Valve Section Disassembly And Assembly...4037
      Slew Valve Section Disassembly And Assembly...4042
      Assembly...4046
    HYDRAULIC PUMP...4054
      Description...4054
      Torque Adjustment...4055
      Testing The Piston Pump...4056
      Testing The Gear Pump...4058
      Testing Auxiliary Hydraulic Flow...4059
      Removal And Installation...4060
      Coupler Removal And Installation...4062
      Hydraulic Pump Start Up...4063
      Parts Identification (Gear Pump)...4064
      Parts Identification (Piston Pump)...4065
      Disassembly...4066
      Gear Pump Disassembly...4067
      Gear Pump Assembly...4070
      Piston Pump Disassembly...4073
      Piston Pump Assembly...4079
      Assembly...4085
    MANIFOLD ASSEMBLY / ACCUMULATOR...4088
      Description...4088
      Removal And Installation...4088
      Parts Identification...4092
      Disassembly...4093
      Assembly...4103
    TRAVEL MOTOR...4114
      Description...4114
      Removal and installation...4114
      Parts Identification...4116
      Disassembly...4117
      Assembly...4127
    SWIVEL JOINT...4138
      Description...4138
      Removal And Installation...4138
      Parts Identification...4140
      Disassembly...4141
      Assembly...4142
    SWING MOTOR...4146
      Description...4146
      Removal And Installation...4146
      Parts Identification...4149
      Disassembly...4150
      Assembly...4155
    SWING MOTOR DRIVE CARRIER...4162
      Description...4162
      Removal And Installation...4162
      Parts Identification...4163
      Disassembly...4164
      Assembly...4166
    CONTROL PATTERN SELECTOR VALVE...4170
      Description...4170
      Removal And Installation...4170
      Parts Identification...4171
      Disassembly...4172
      Assembly...4173
    RIGHT CONTROL LEVER (JOYSTICK)...4174
      Description...4174
      Testing...4174
      Handle Removal And Installation...4175
      Removal And Installation...4179
      Parts Identification...4182
      Disassembly...4183
      Assembly...4188
    LEFT CONTROL LEVER (JOYSTICK)...4194
      Description...4194
      Testing...4194
      Handle Removal And Installation...4195
      Removal And Installation...4198
      Parts Identification...4200
      Disassembly...4201
      Assembly...4206
    HYDRAULIC FILTER...4212
      Description...4212
      Housing Removal And Installation...4212
    CASE DRAIN FILTER...4214
      Description...4214
      Housing Removal And Installation...4214
    HYDRAULIC RESERVOIR...4216
      Description...4216
      Removal And Installation...4216
    OIL COOLER...4218
      Description...4218
      Removal And Installation...4218
    DIRECT TO TANK VALVE...4220
      Description...4220
      Removal And Installation...4220
      Parts Identification...4221
      Disassembly And Assembly...4222
    BUILDUP VALVE...4224
      Description...4224
      Removal And Installation...4224
      Parts Identification...4225
      Disassembly And Assembly...4226
  UNDERCARRIAGE...4228
    BLADE...4230
      Description...4230
      Removal And Installation...4230
    TRACK FRAME COMPONENTS...4232
      Description...4232
      Track Lug Height...4232
      Checking Tension...4233
      Adjusting Tension...4234
      Rubber Track Removal And Installation...4236
      Steel Track Removal And Installation...4239
      Idler (Front) Removal And Installation...4242
      Idler (Front) Parts Identification...4243
      Idler (Front) Disassembly...4244
      Idler (Front) Assembly...4246
      Coil Spring Assembly And Cylinder Disassembly And Assembly (W/o Replaceable Shaft)...4249
      Coil Spring Cylinder Parts Identification (W/ Replaceable Shaft)...4250
      Coil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)...4251
      Roller Removal and Installation...4253
      Roller Parts Identification...4254
      Roller Disassembly...4255
      Roller Assembly...4257
      Track Guide Removal And Installation...4259
      Sprocket Removal And Installation...4259
      Track Damage Identification...4260
    SWING CIRCLE GEAR...4270
      Removal And Installation...4270
  UPPERSTRUCTURE & SWING SECTION...4272
    UPPERSTRUCTURE...4276
      Description...4276
      Removal...4276
      Installation...4278
    CANOPY...4282
      Removal And Installation...4282
    CAB...4286
      Removal And Installation...4286
      Door Removal And Installation...4291
      Front Window Removal And Installation...4292
      Right Side Rear Sliding Window Removal And Installation...4295
      Right Side Front Sliding Window Removal And Installation...4295
      Glass Removal...4296
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...4297
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...4297
      Glass Installation...4298
    SEAT AND SEAT MOUNT...4304
      Seat Mount Removal And Installation...4304
      Seat Removal And Installation...4305
    RIGHT CONSOLE...4306
      Description...4306
      Console Cover Removal And Installation...4306
      Console Frame Removal And Installation...4307
    LEFT CONSOLE...4310
      Description...4310
      Joystick Console Cover (Bottom) Removal And Installation...4310
      Joystick Console Cover (Top) Removal And Installation...4311
      Compression Spring Removal And Installation...4312
      Compression Spring Disassembly And Assembly...4312
      Lever Removal And Installation...4314
      Joystick Console Frame Removal And Installation...4315
      Joystick Console Frame Disassembly And Installation...4316
      Left Rear Console Cover Removal And Installation...4317
      Left Rear Console Frame Removal And Installation...4318
      Left Rear Console Frame Disassembly And Assembly...4321
    BLADE CONTROL...4322
      Removal And Installation...4322
      Disassembly And Assembly...4322
      Linkage Removal And Installation...4323
      Linkage Disassembly And Assembly...4325
    UPPERSTRUCTURE SLEW LOCK...4328
      Removal And Installation...4328
      Disassembly And Assembly...4328
    FLOOR MAT AND FLOOR PANEL...4330
      Description...4330
      Removal And Installation...4330
    BOOM SWING PEDAL...4334
      Description...4334
      Removal And Installation...4334
      Disassembly And Assembly...4334
      Linkage Removal And Installation...4336
    TRAVEL LEVERS / PEDALS...4338
      Description...4338
      Adjustment...4338
      Removal And Installation...4341
      Disassembly And Assembly...4341
    FUEL TANK...4344
      Removal And Installation...4344
    HORN...4348
      Removal And Installation...4348
    SWING FRAME...4350
      Description...4350
      Removal And Installation...4350
      Hose Routing...4354
      Bushing Removal And Installation...4355
      Swing Frame Bushing Removal And Installation...4355
    BOOM...4358
      Description...4358
      Removal And Installation...4358
    ARM...4360
      Description...4360
      Removal And Installation...4360
      Arm To Boom Bushing Removal And Installation...4361
      Arm To Bucket And Bucket Link Bushing Removal And Installation...4362
    BUCKET...4364
      Removal And Installation (Pin-On X-Change)...4364
      Removal And Installation (Bolt-On X-Change)...4370
      Removal And Installation (Pin-On Attachment)...4376
      Bucket Teeth Removal And Installation...4377
      Bucket Side Cutting Edge Removal And Installation...4378
    TAILGATE...4380
      Removal And Installation...4380
      Latch Removal And Installation...4381
    X-CHANGE...4382
      Pin-On Removal And Installation...4382
      Pin-On Disassembly and Assembly...4383
    RIGHT SIDE COVER...4384
      Removal And Installation...4384
  ELECTRICAL SYSTEM AND ANALYSIS...4386
    ELECTRICAL SCHEMATICS...4388
    ELECTRICAL SYSTEM INFORMATION...4390
      Glossary Of Electrical Symbols...4390
      Harness Connectors...4393
      Troubleshooting...4395
      Description...4396
      Fuse And Relay Locations / Identification...4396
    BATTERY...4398
      Removal And Installation...4398
      Servicing...4399
      Using A Booster Battery (Jump Starting)...4400
    ALTERNATOR...4402
      Belt Adjustment...4402
      Belt Replacement...4402
      Charging System Inspection...4403
      Description...4404
      Tests...4404
      Alternator Output Test...4405
      Full Field Test...4405
      Alternator Regulator Test...4406
      Alternator Regulator Test With Voltmeter...4406
      Removal And Installation...4407
      Parts Identification...4408
    STARTER...4410
      Testing...4410
      Removal And Installation...4411
      Parts Identification...4412
    LIGHTS...4414
      Upperstructure Light Removal And Installation...4414
      Upperstructure Light Disassembly And Assembly...4414
      Boom Light Removal And Installation...4415
      Boom Light Bulb Replacement...4415
    MAGNETIC LOCKOUT SENSOR...4416
      Testing Left Console Magnetic Lockout Sensor...4416
      Left Console Magnetic Lockout Sensor Removal And Installation...4417
    FUEL LEVEL SENDER...4420
      Removal And Installation...4420
      Testing...4421
    DIAGNOSTICS SERVICE CODES...4422
      Description...4422
      Service Codes List...4423
  ENGINE SERVICE...4424
    ENGINE INFORMATION...4426
      Description...4426
      Specifications...4427
      Torque Values...4431
      Troubleshooting...4432
      Removal And Installation...4433
      Engine Mount Replacement...4439
      Compression - Checking...4440
    ENGINE SPEED CONTROL...4442
      Removal And Installation...4442
    SPARK ARRESTOR MUFFLER...4444
      Removal And Installation...4444
    AIR CLEANER...4446
      Removal And Installation...4446
    ENGINE COOLING SYSTEM...4448
      Radiator Removal And Installation...4448
      Water Pump Removal And Installation...4449
      Water Pump Disassembly And Assembly...4450
      Thermostat Housing Removal And Installation...4451
      Testing The Thermostat...4452
    LUBRICATION SYSTEM...4454
      Oil Pan Removal And Installation...4454
      Oil Pump Removal And Installation...4454
      Oil Pump Inspection...4455
      Engine Oil Pressure - Testing...4456
    FUEL SYSTEM...4458
      Fuel Camshaft Removal And Installation...4458
      Fuel Camshaft Governor Disassembly And Assembly...4459
      Fuel Shutoff Solenoid - Checking...4460
      Fuel Shutoff Solenoid Removal And Installation...4460
      Fuel Injection Pump Removal And Installation...4461
      Injection Pump - Timing...4463
      Fuel Injector Removal And Installation...4465
      Fuel Injector Nozzle Pressure - Checking...4467
      Nozzle Spray Condition...4468
      Valve Seat Tightness...4468
    CYLINDER HEAD...4470
      Glow Plug - Testing...4470
      Glow Plug Removal And Installation...4471
      Valve Clearance Adjustment...4471
      Valve Timing - Checking...4472
      Cylinder Head Removal And Installation...4473
      Cylinder Head Disassembly and Assembly...4476
      Cylinder Head - Servicing...4476
      Cylinder Head Top Clearance...4477
      Valve Guide - Checking...4477
      Reconditioning The Valve And Valve Seat...4478
      Valve Spring...4480
      Valve Tappets...4481
      Rocker Arm And Shaft - Checking...4481
    CRANKSHAFT AND PISTONS...4482
      Piston And Connecting Rod Removal And Installation...4482
      Piston And Connecting Rod - Servicing...4484
      Cylinder Bore Checking...4486
      Connecting Rod Alignment...4487
      Crankshaft And Bearings Removal And Installation...4487
      Crankshaft And Bearings - Servicing...4489
    CAMSHAFT AND TIMING GEARS...4494
      Timing Gearcase Cover Removal And Installation...4494
      Timing Gears Backlash - Checking...4496
      Idler Gear And Shaft Removal And Installation...4497
      Camshaft - Servicing...4498
      Idler Gear And Shaft Servicing...4499
    FLYWHEEL AND HOUSING...4500
      Flywheel Housing Removal And Installation...4500
      Hydraulic Pump Coupler Removal And Installation...4501
      Flywheel Removal And Installation...4502
      Rear End Plate Removal And Installation...4502
  HEATER...4504
    HEATER SYSTEM...4506
      Description...4506
      Components...4506
    REGULAR MAINTENANCE...4508
      Filter Element Removal And Installation...4508
      Heater Coil...4509
    TROUBLESHOOTING...4510
      Blower Motor Does Not Operate...4510
      Blower Motor Operates Normally, But Air Flow Is Insufficient...4510
      Electrical System...4511
    HEATER UNIT...4516
      Removal And Installation...4516
    HEATER COIL...4518
      Removal And Installation...4518
    BLOWER FAN...4520
      Removal And Installation...4520
    HEATER VALVE...4522
      Removal And Installation...4522
  SPECIFICATIONS...4524
    329 EXCAVATOR SPECIFICATIONS...4526
      Dimensions...4526
      Performance...4528
      Controls...4528
      Engine...4528
      Hydraulic System...4529
      Hydraulic Cylinders...4529
      Hydraulic Cycle Times...4529
      Electrical...4530
      Drive System...4530
      Slew System...4530
      Undercarriage...4530
      Capacities...4530
      Type...4530
      Ground Pressure...4530
    TORQUE SPECIFICATIONS FOR BOLTS...4532
      Torque For General SAE Bolts...4532
      Torque For General Metric Bolts...4533
    HYDRAULIC CONNECTION SPECIFICATIONS...4534
      O-Ring Face Seal Connection...4534
      Straight Thread O-Ring Fitting...4535
      Tubelines And Hoses...4535
      Flare Fitting...4536
      Port Seal Fitting...4537
    HYDRAULIC FLUID SPECIFICATIONS...4538
      Specifications...4538
    CONVERSIONS...4540
      Decimal And Millimeter Equivalents...4540
      U.S. To Metric Conversion Chart...4540
  SERVICE MANUAL REVISION...4542
    Revision No: 329-1...4542
6986958 (2-08) - 323 Compact Excavator Service Manual...4544
  MAINTENANCE SAFETY...4546
  ALPHABETICAL INDEX...4548
  CONTENTS...4550
    FOREWORD...4552
    SAFETY INSTRUCTIONS...4554
      Before Operation...4554
      Safe Operation Is The Operator’s Responsibility...4555
      Safe Operation Needs A Qualified Operator...4555
      Avoid Silica Dust...4556
    FIRE PREVENTION...4556
      Maintenance...4556
      Operation...4556
      Electrical...4556
      Hydraulic System...4557
      Fueling...4557
      Starting...4557
      Spark Arrestor Exhaust System...4557
      Welding And Grinding...4557
      Fire Extinguishers...4557
    SERIAL NUMBER LOCATIONS...4558
      Excavator Serial Number...4558
      Engine Serial Number...4558
    DELIVERY REPORT...4559
    BOBCAT EXCAVATOR IDENTIFICATION...4560
  SAFETY AND MAINTENANCE...4562
    LIFTING AND BLOCKING THE EXCAVATOR...4564
      Procedure...4564
    UPPERSTRUCTURE SLEW LOCK...4566
    LIFTING THE EXCAVATOR...4568
    OPERATOR CAB ROPS/TOPS (IF EQUIPPED)...4570
      Emergency Exits...4570
      Cab Door...4570
      Front Window Wiper...4571
      Window Washer Reservoir...4571
      Front Window...4571
      Right Side Windows...4573
    TRANSPORTING THE EXCAVATOR...4574
    TAILGATE...4576
      Opening And Closing The Tailgate...4576
      Adjusting The Bumper...4576
      Adjusting The Tailgate Latch...4576
    SERVICE SCHEDULE...4578
      Chart...4578
    AIR CLEANER SERVICE...4580
      Daily Check...4580
      Replacing The Filters...4580
    HEATER AIR FILTERS...4582
      Recirculation Filter...4582
      Fresh Air Filter...4582
    ENGINE COOLING SYSTEM...4584
      Cleaning The Cooling System...4584
      Checking Coolant Level...4584
      Replacing The Coolant...4585
    FUEL SYSTEM...4588
      Fuel Specifications...4588
      Biodiesel Blend Fuel...4588
      Filling The Fuel Tank...4589
      Removing Water From The Fuel Filter...4590
      Replacing The Fuel Filter...4590
      Draining The Fuel Tank...4591
      Removing Air From The Fuel System...4591
    ENGINE LUBRICATION SYSTEM...4592
      Checking Engine Oil...4592
      Oil Chart...4592
      Replacing Oil And Filter...4593
    HYDRAULIC SYSTEM...4594
      Checking And Adding Hydraulic Oil...4594
      Hydraulic Fluid Chart...4594
      Diagnostic Couplers...4595
      Replacing The Hydraulic Filter...4595
      Replacing Hydraulic Oil...4595
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...4598
    TRAVEL MOTOR...4600
      Checking Oil Level...4600
      Draining The Travel Motor...4600
    SPARK ARRESTOR MUFFLER...4602
    ALTERNATOR BELT...4604
      Adjusting The Alternator Belt...4604
    SEAT BELT...4606
      Inspection And Maintenance...4606
    CONTROL CONSOLE LOCKOUTS...4608
      Inspection And Maintenance...4608
    EXCAVATOR STORAGE AND RETURN TO SERVICE...4610
      Storage...4610
      Return to Service...4610
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...4612
      Procedure...4612
      Emergency Exits...4613
    MOTION ALARM SYSTEM (IF EQUIPPED)...4614
      Description...4614
      Inspecting...4614
      Adjusting Switch Position...4614
  HYDRAULIC SYSTEM...4616
    HYDRAULIC/HYDROSTATIC SCHEMATICS...4620
    HYDRAULIC SYSTEM INFORMATION...4622
      Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...4622
      Troubleshooting The Hydraulic Circuit...4625
      Troubleshooting The Cylinder Circuit...4626
      Troubleshooting The Swing (Upperstructure Slew) Circuit...4627
      Troubleshooting The Travel Circuit...4628
    BOOM CYLINDER...4630
      Testing...4630
      Removal and Installation...4633
      Parts Identification...4635
      Disassembly...4636
      Assembly...4638
    ARM CYLINDER...4642
      Testing...4642
      Removal And Installation...4643
      Parts Identification...4645
      Disassembly...4646
      Assembly...4648
    BOOM SWING CYLINDER...4652
      Testing...4652
      Removal And Installation...4653
      Parts Identification...4656
      Disassembly...4657
      Assembly...4659
    BUCKET CYLINDER...4662
      Testing...4662
      Removal And Installation...4663
      Parts Identification...4665
      Disassembly...4666
      Assembly...4668
    BLADE CYLINDER...4672
      Testing...4672
      Removal And Installation...4674
      Parts Identification...4676
      Disassembly...4677
      Assembly...4679
    TRACK FRAME EXPANSION CYLINDER...4682
      Testing...4682
      Removal And Installation...4683
      Parts Identification...4687
      Disassembly...4688
      Assembly...4690
    MAIN RELIEF VALVE...4694
      Testing And Adjusting The Main Relief Valve...4694
    PORT RELIEF VALVES...4696
      Testing And Adjusting The Port Relief Valve Pressure...4696
    CROSSPORT RELIEF VALVES...4698
      Testing And Adjusting The Crossport Relief Valve...4698
    PRESSURE REDUCING VALVE...4700
      Testing And Adjusting The Pressure Reducing Valve...4700
    HYDRAULIC CONTROL VALVE...4702
      Description...4702
      Removal And Installation...4702
      Parts Identification...4705
      Disassembly...4706
      Right Travel Valve Section Disassembly And Assembly...4707
      Boom Swing Valve Section Disassembly And Assembly...4712
      Arm Valve Section Disassembly and Assembly...4715
      Bucket Valve Section Disassembly And Assembly...4718
      Auxiliary Valve Section Disassembly And Assembly...4721
      Boom Valve Section Disassembly And Assembly...4726
      Left Travel Valve Section Disassembly And Assembly...4729
      Swing Valve Section Disassembly And Assembly...4734
      Blade Valve Section Disassembly And Assembly...4737
      Assembly...4741
    HYDRAULIC PUMP...4746
      Description...4746
      Torque Adjustment...4747
      Testing The Piston Pump...4747
      Testing The Gear Pump...4749
      Testing Auxiliary Hydraulic Flow...4750
      Removal And Installation...4751
      Hydraulic Pump Start Up...4755
      Parts Identification...4756
      Disassembly...4757
      Gear Pump Disassembly...4758
      Piston Pump Disassembly...4760
      Piston Pump Assembly...4769
      Gear Pump Assembly...4778
      Assembly...4781
    MANIFOLD ASSEMBLY/ACCUMULATOR...4782
      Description...4782
      Removal And Installation...4782
      Parts Identification...4785
      Disassembly...4786
      Assembly...4799
    TRAVEL MOTOR...4812
      Description...4812
      Removal And Installation...4812
      Parts Identification...4813
      Disassembly...4814
      Assembly...4821
    SWIVEL JOINT...4830
      Description...4830
      Removal And Installation...4830
      Parts Identification...4833
      Disassembly...4834
      Assembly...4836
    SWING MOTOR...4840
      Description...4840
      Removal And Installation...4840
      Parts Identification...4841
      Disassembly...4842
      Assembly...4848
    CONTROL PATTERN SELECTOR VALVE...4856
      Description...4856
      Removal And Installation...4856
      Parts Identification...4858
      Disassembly...4859
      Assembly...4860
    RIGHT CONTROL LEVER (JOYSTICK)...4862
      Description...4862
      Testing...4862
      Handle Removal And Installation...4864
      Removal And Installation...4865
      Parts Identification...4866
      Disassembly...4867
      Assembly...4872
    LEFT CONTROL LEVER (JOYSTICK)...4878
      Description...4878
      Testing...4878
      Handle Removal And Installation...4880
      Removal And Installation...4882
      Parts Identification...4883
      Disassembly...4884
      Assembly...4889
    HYDRAULIC FILTER MOUNT...4894
      Removal And Installation...4894
    HYDRAULIC RESERVOIR...4896
      Removal And Installation...4896
    OIL COOLER...4898
      Description...4898
      Removal And Installation...4898
    BLADE/TRACK EXPANSION SOLENOID BLOCK...4900
      Block Removal And Installation...4900
      Solenoid Removal And Installation...4901
      Block Disassembly And Assembly...4903
  UNDERCARRIAGE...4906
    BLADE...4908
      Extension Removal And Installation...4908
      Blade Removal And Installation...4908
    TRACKS...4910
      Track Lug Height...4910
      Track Tension Adjustment...4911
      Removal And Installation...4913
    TRACK FRAME...4914
      Disassembly And Assembly...4914
      Removal And Installation Of Expandable Track Frame...4915
    TRACK DAMAGE IDENTIFICATION...4918
      Cutting Of The Steel Cords...4918
      Causes Of The Damage...4918
      Abrasion Of Embedded Metals...4919
      Separation Of Embedded Metals...4920
      Separation Of Embedded Metals Due To Corrosion...4921
      Cuts On The Lug Side Rubber...4922
      Cracks On The Lug Side Rubber Due To Fatigue...4923
      Lug Abrasion...4924
      Cracks And Cuts On The Lug Side Rubber...4925
      Abrasion Of The Track Roller Side...4926
      Cuts On The Edges Of The Track Roller Side...4927
    TRACK IDLER...4930
      Parts Identification...4930
      Disassembly...4931
      Assembly...4933
    TRACK ROLLER...4936
      Parts Identification...4936
      Disassembly...4937
      Assembly...4939
    SWING CIRCLE GEAR...4942
      Removal and Installation...4942
  UPPERSTRUCTURE & SWING SECTION...4944
    UPPERSTRUCTURE...4948
      Description...4948
      Removal...4948
      Installation...4950
    ROPS CANOPY...4954
      Removal And Installation...4954
    CAB...4958
      Removal And Installation...4958
      Door Removal And Installation...4962
      Front Window Removal And Installation...4963
      Right Side Rear Sliding Window Removal And Installation...4966
      Right Side Front Sliding Window Removal And Installation...4967
      Glass Removal...4967
      Glass Installation...4968
    SEAT AND SEAT MOUNT...4970
      Removal And Installation...4970
    RIGHT CONSOLE...4972
      Description...4972
      Console Cover Removal And Installation (Cab)...4972
      Console Cover Removal And Installation (ROPS Canopy)...4974
      Gas Spring Removal And Installation (ROPS Canopy)...4977
      Lock Lever Removal And Installation (ROPS Canopy)...4978
      Adjustment (ROPS Canopy Models)...4980
      Latch Hook Removal And Installation (ROPS Canopy)...4980
      Latch Hook Disassembly And Assembly (ROPS Canopy)...4981
      Cab Models...4982
      Upper Console Removal And Installation...4983
      Console Base Removal And Installation...4984
    LEFT CONSOLE...4988
      Description...4988
      Console Cover Removal And Installation...4988
      Gas Spring Removal And Installation...4990
      Lock Lever Removal And Installation...4991
      Adjustment...4993
      Latch Hook Removal And Installation...4994
      Latch Hook Disassembly And Assembly...4995
      Upper Console Removal And Installation...4996
      Console Base Removal And Installation...4997
    ENGINE SPEED CONTROL...5000
      Removal And Installation...5000
      Engine Speed Control Cable Removal And Installation...5001
    BLADE CONTROL...5004
      Removal And Installation...5004
      Disassembly And Assembly...5005
    SWING LOCK...5008
      Removal and Installation...5008
    RIGHT PEDAL AND LINKAGE...5010
      Description...5010
      Right Pedal Removal And Installation...5010
      Disassembly And Assembly...5011
      Linkage Removal And Installation...5012
      Linkage Disassembly And Assembly...5012
    TRAVEL CONTROLS...5014
      Description...5014
      Removal And Installation...5014
      Disassembly And Assembly...5014
    LEFT PEDAL...5016
      Removal And Installation...5016
      Disassembly And Assembly...5017
    CONTROL LINKAGE ASSEMBLY...5018
      Removal And Installation...5018
      Left Pedal Linkage Disassembly And Assembly...5019
      Right Travel Control Linkage Disassembly And Assembly...5020
      Left Travel Control Linkage Disassembly And Assembly...5021
      Left Pedal Bellcrank Disassembly And Assembly...5022
      Linkage Rod Removal And Installation...5024
      Linkage Rod Adjustment...5025
    FLOOR MAT AND FLOOR PANELS...5026
      Description...5026
      Removal And Installation...5026
    BLADE EXTENSION TRAY...5030
      Removal And Installation...5030
    FUEL TANK...5032
      Removal And Installation...5032
    HORN...5034
      Removal And Installation...5034
    SWING FRAME...5036
      Description...5036
      Removal And Installation...5036
      Bushing Replacement...5038
      Swing Frame Bushing Removal...5039
      Swing Frame Bushing Installation...5039
      Boom Pivot Bushing Removal And Installation...5040
    BOOM...5042
      Description...5042
      Removal And Installation...5042
      Boom Bushing Removal And Installation...5044
    ARM...5046
      Description...5046
      Removal And Installation...5046
      Arm To Boom Bushing Removal And Installation...5047
      Arm To Bucket And Bucket Link Bushing Removal And Installation...5048
    BUCKET...5050
      Removal And Installation...5050
    TAILGATE...5052
      Removal And Installation...5052
      Latch Removal And Installation...5053
  ELECTRICAL SYSTEM AND ANALYSIS...5054
    ELECTRICAL SCHEMATICS...5056
    ELECTRICAL SYSTEM...5057
      Troubleshooting Chart...5057
      Description...5058
      Fuses...5058
      Relays And Diodes...5058
    BATTERY...5061
      Servicing...5061
      Removing And Installing The Battery...5062
      Using A Booster Battery (Jump Starting)...5063
    ALTERNATOR...5065
      Description...5065
      Tests...5065
      Alternator Output Test...5066
      Full Field Test...5066
      Alternator Regulator Test...5067
      Alternator Regulator Test With Voltmeter...5067
      Removal And Installation...5068
      Parts Identification...5070
      Disassembly And Assembly...5070
    STARTER...5071
      Removal And Installation...5071
      Parts Identification...5072
      Disassembly And Assembly...5072
      Cleaning And Inspection...5072
    LIGHTS...5073
      Uppestructure Light Removal And Installation...5073
      Uppestructure Light Disassembly And Assembly...5073
      Boom Light Removal And Installation...5074
      Boom Light Bulb Replacement...5074
      Light Switch Removal And Installation...5075
    MICROSWITCH...5077
      Adjustment...5077
      Testing...5078
      Removal And Installation...5079
    TWO-SPEED SWITCH...5081
      Removal And Installation...5081
    FUEL LEVEL SENDER...5083
      Removal And Installation...5083
      Testing...5083
    TWO-SPEED BOOST SWITCH...5085
      Description...5085
      Removal And Installation...5085
  ENGINE SERVICE...5087
    TROUBLESHOOTING...5089
      Chart...5089
    SPARK ARRESTOR MUFFLER...5091
      Removal And Installation...5091
    AIR CLEANER...5093
      Removal And Installation...5093
    RADIATOR...5095
      Removal And Installation...5095
    ENGINE COMPONENTS AND TESTING...5101
      Valve Clearance Adjustment...5101
      Engine Compression Checking...5102
      Fuel Shutoff Solenoid Removal And Installation...5102
      Fuel Shutoff Timer Removal And Installation...5103
      Fuel Injection Pump Check...5103
      Fuel Injection Pump Removal And Installation...5104
      Fuel Injection Pump Timing...5106
      Fuel Injector Removal And Installation...5108
      Fuel Injector Checking...5109
      Glow Plug Removal And Installation...5111
    ENGINE...5113
      Removal And Installation...5113
    ENGINE FLYWHEEL...5121
      Removal And Installation...5121
      Hydraulic Pump Coupler Removal And Installation...5122
      Hydraulic Pump Coupler Disassembly And Assembly...5123
      Flywheel Ring Gear...5123
    RECONDITIONING THE ENGINE...5125
      Cylinder Head Removal And Installation...5125
      Cylinder Head Disassembly And Assembly...5127
      Cylinder Head, Servicing...5128
      Cylinder Head Top Clearance...5128
      Valve Guide, Checking...5129
      Valve And Valve Seat Reconditioning...5131
      Valve Spring...5132
      Rocker Arm And Shaft, Checking...5133
      Timing Gearcase Cover Removal And Installation...5133
      Idler Gear And Camshaft Removal And Installation...5135
      Idler Gear and Shaft, Servicing...5138
      Timing Gears Checking Backlash...5139
      Fuel Camshaft Removal And Installation...5139
      Fuel Camshaft Governor...5140
      Crankshaft Gear Removal And Installation...5140
      Oil Pump Removal And Installation...5141
      Oil Pump, Service...5141
      Engine Oil Pressure, Checking...5142
      Relief Valve...5143
      Piston And Connecting Rod Removal And Installation...5144
      Piston And Connecting Rod, Servicing...5146
      Connecting Rod Alignment...5148
      Crankshaft And Bearings Removal And Installation...5148
      Crankshaft And Bearings, Servicing...5151
      Cylinder Bore, Checking...5153
      Water Pump Removal And Installation...5153
      Water Pump Disassembly And Assembly...5153
  HEATER...5155
    HEATER...5157
      Description...5157
      Removal And Installation...5157
  SPECIFICATIONS...5159
    SPECIFICATIONS...5161
      323 Excavator Machine Dimensions...5161
      Performance...5163
      Controls...5163
      Engine...5163
      Hydraulic System...5164
      Hydraulic Cylinders...5164
      Hydraulic Cycle Times...5165
      Electrical System...5165
      Instrumentation...5165
      Drive System...5165
      Slew System...5165
      Undercarriage...5165
      Crawler Track Design...5165
      Ground Pressure...5165
    ENGINE SPECIFICATIONS...5167
      Engine...5167
      Fuel Injector Nozzles...5167
      Fuel Injection Pump...5167
      Cylinder Head...5167
      Valves...5167
      Valve Springs...5167
      Rocker Arms...5168
      Camshaft...5168
      Cylinders...5168
      Piston Rings...5168
      Pistons...5169
      Connecting Rods...5169
      Crankshaft...5169
      Oil Pump...5169
      Thermostat...5170
      Engine Bolt Torque...5170
      Crankshaft Re-Grind Data...5172
    TORQUE SPECIFICATIONS...5173
      Torque For General SAE Bolts...5173
      Torque For General Metric Bolts...5174
    HYDRAULIC CONNECTION SPECIFICATIONS...5175
      O-Ring Face Seal Connection...5175
      Straight Thread O-Ring Fitting...5175
      Tubelines And Hoses...5175
      Flare Fitting...5176
      O-Ring Flare Fitting...5177
      Port Seal Fitting...5179
    HYDRAULIC FLUID SPECIFICATIONS...5181
      Specifications...5181
    FUEL, COOLANT AND LUBRICANTS...5183
      Chart...5183
    CONVERSIONS...5185
      Decimal And Millimeter Equivalents...5185
      U.S. To Metric Conversion...5186
6986958 (7-14) - 323 Compact Excavator Service Manual...5187
  MAINTENANCE SAFETY...5189
  CONTENTS...5191
  FOREWORD...5193
    FOREWORD...5195
    SAFETY INSTRUCTIONS...5197
    FIRE PREVENTION...5199
      Maintenance...5199
      Operation...5199
      Electrical...5199
      Hydraulic System...5199
      Fueling...5199
      Starting...5199
      Spark Arrester Exhaust System...5199
      Welding And Grinding...5200
      Fire Extinguishers...5200
    SERIAL NUMBER LOCATIONS...5201
      Excavator Serial Number...5201
      Engine Serial Number...5201
    DELIVERY REPORT...5202
    BOBCAT EXCAVATOR IDENTIFICATION...5203
  SAFETY & MAINTENANCE...5205
    LIFTING AND BLOCKING THE EXCAVATOR...5209
      Procedure...5209
    UPPERSTRUCTURE SLEW LOCK...5211
    LIFTING THE EXCAVATOR...5213
    OPERATOR CAB (ROPS / TOPS)...5215
      Description...5215
      Cab Door...5216
      Front Window Wiper...5216
      Window Washer Reservoir...5216
      Front Window...5217
      Right Side Windows...5218
      Heater (If Equipped)...5219
    TRANSPORTING THE EXCAVATOR ON A TRAILER...5221
      Loading And Unloading...5221
      Fastening...5221
    TAILGATE...5223
      Opening And Closing The Tailgate...5223
      Adjusting The Bumper...5223
      Adjusting The Latch...5223
    SERVICE SCHEDULE...5225
      Chart...5225
    AIR CLEANER SERVICE...5227
      Daily Check...5227
      Replacing The Filter Elements...5227
    HEATER AIR FILTERS...5229
      Recirculation Filter...5229
      Fresh Air Filter...5229
    ENGINE COOLING SYSTEM...5231
      Cleaning...5231
      Checking Level...5231
      Removing And Replacing The Coolant...5232
    FUEL SYSTEM...5235
      Fuel Specifications...5235
      Biodiesel Blend Fuel...5235
      Filling The Fuel Tank...5236
      Fuel Filters...5237
      Replacing Elements...5237
      Draining The Fuel Tank...5238
      Removing Air From The Fuel System...5238
    ENGINE LUBRICATION SYSTEM...5239
      Checking And Adding Engine Oil...5239
      Engine Oil Chart...5239
      Replacing Oil And Filter...5240
    HYDRAULIC SYSTEM...5241
      Checking And Adding Fluid...5241
      Hydraulic / Hydrostatic Fluid Chart...5241
      Diagnostic Couplers...5242
      Removing And Replacing The Hydraulic Filter...5242
      Removing And Replacing Hydraulic Fluid...5242
    LUBRICATING OF THE EXCAVATOR...5245
      Lubrication Locations...5245
    TRAVEL MOTOR...5249
      Checking And Adding Oil...5249
      Removing and Replacing Oil...5249
    SPARK ARRESTOR MUFFLER...5251
      Cleaning Process...5251
    ALTERNATOR BELT...5253
      Belt Adjustment...5253
      Belt Replacement...5254
    SEAT BELT...5255
      Inspection And Maintenance...5255
    CONTROL CONSOLE LOCKOUTS...5257
      Inspection And Maintenance...5257
    PIVOT PINS...5259
      Inspection And Maintenance...5259
    EXCAVATOR STORAGE AND RETURN TO SERVICE...5261
      Storage...5261
      Return To Service...5261
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...5263
      Procedure...5263
    EMERGENCY EXITS...5265
      Right Side Rear Window...5265
      Front Window...5265
    MOTION ALARM SYSTEM (IF EQUIPPED)...5267
      Description...5267
      Inspecting...5267
      Adjusting Switch Position...5267
    REMOTE START TOOL KIT - MEL1563...5269
      Remote Start Tool - MEL1563...5269
      Service Tool Harness Communicator - MEL1566...5271
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...5273
      Description...5273
      Remote Start Tool (Service Tool) - 7003030...5274
      Excavator Service Tool Harness - 6689747...5275
      Computer Service Tool Harness - 6689746...5276
  HYDRAULIC SYSTEM...5277
    HYDRAULIC/HYDROSTATIC SCHEMATICS...5281
    HYDRAULIC SYSTEM INFORMATION...5283
      Glossary Of Hydraulic / Hydrostatic Symbols For Excavators...5283
      Troubleshooting The Hydraulic Circuit...5286
      Troubleshooting The Cylinder Circuit...5287
      Troubleshooting The Swing (Upperstructure Slew) Circuit...5288
      Troubleshooting The Travel Circuit...5289
    CYLINDER (BOOM)...5291
      Testing...5291
      Removal And Installation...5294
      Parts Identification...5296
      Disassembly...5297
      Assembly...5299
    CYLINDER (ARM)...5303
      Testing...5303
      Removal And Installation...5304
      Parts Identification...5306
      Disassembly...5307
      Assembly...5309
    CYLINDER (BOOM SWING)...5313
      Testing...5313
      Removal And Installation...5314
      Parts Identification...5317
      Disassembly...5318
      Assembly...5320
    CYLINDER (BUCKET)...5323
      Testing...5323
      Removal And Installation...5324
      Parts Identification...5326
      Disassembly...5327
      Assembly...5329
    CYLINDER (BLADE)...5333
      Testing...5333
      Removal And Installation...5335
      Parts Identification...5337
      Disassembly...5338
      Assembly...5340
    CYLINDER (TRACK FRAME EXPANSION)...5343
      Testing...5343
      Removal And Installation...5344
      Parts Identification...5348
      Disassembly...5349
      Assembly...5351
    VALVE (Main Relief)...5355
      Testing And Adjusting The Main Relief Valve...5355
    VALVES (PORT RELIEF)...5357
      Testing And Adjusting The Port Relief Valve Pressure...5357
    VALVES (CROSSPORT RELIEF)...5359
      Testing And Adjusting The Crossport Relief Valve...5359
    VALVE (PRESSURE REDUCING)...5363
      Testing And Adjusting The Pressure Reducing Valve...5363
    HYDRAULIC CONTROL VALVE...5365
      Description...5365
      Removal And Installation...5365
      Parts Identification...5368
      Disassembly...5369
      Right Travel Valve Section Disassembly And Assembly...5370
      Boom Swing Valve Section Disassembly And Assembly...5375
      Arm Valve Section Disassembly and Assembly...5378
      Bucket Valve Section Disassembly And Assembly...5381
      Auxiliary Valve Section Disassembly And Assembly...5384
      Boom Valve Section Disassembly And Assembly...5389
      Left Travel Valve Section Disassembly And Assembly...5392
      Swing Valve Section Disassembly And Assembly...5397
      Blade Valve Section Disassembly And Assembly...5400
      Assembly...5404
    HYDRAULIC PUMP...5409
      Description...5409
      Torque Adjustment...5410
      Testing The Piston Pump...5410
      Testing The Gear Pump...5412
      Testing Auxiliary Hydraulic Flow...5413
      Removal And Installation...5414
      Hydraulic Pump Start Up...5418
      Parts Identification...5419
      Disassembly...5420
      Gear Pump Disassembly...5421
      Piston Pump Disassembly...5423
      Piston Pump Assembly...5432
      Gear Pump Assembly...5441
      Assembly...5443
    MANIFOLD ASSEMBLY / ACCUMULATOR...5445
      Description...5445
      Removal And Installation...5445
      Parts Identification...5448
      Disassembly...5449
      Assembly...5462
    TRAVEL MOTOR...5475
      Description...5475
      Removal And Installation...5475
      Parts Identification...5476
      Disassembly...5477
      Assembly...5484
    SWIVEL JOINT...5493
      Description...5493
      Removal And Installation...5493
      Parts Identification...5496
      Disassembly...5497
      Assembly...5499
    SWING MOTOR...5503
      Description...5503
      Removal And Installation...5503
      Parts Identification...5504
      Disassembly...5505
      Assembly...5511
    CONTROL PATTERN SELECTOR VALVE...5519
      Description...5519
      Removal And Installation...5519
      Parts Identification...5521
      Disassembly...5522
      Assembly...5523
    CONTROL LEVER (JOYSTICK) (RIGHT)...5525
      Description...5525
      Testing...5525
      Handle Removal And Installation...5527
      Removal And Installation...5528
      Parts Identification...5529
      Disassembly...5530
      Assembly...5534
    CONTROL LEVER (JOYSTICK) (LEFT)...5539
      Description...5539
      Testing...5539
      Handle Removal And Installation...5541
      Removal And Installation...5543
      Parts Identification...5544
      Disassembly...5545
      Assembly...5549
    HYDRAULIC FILTER MOUNT...5553
      Removal And Installation...5553
    HYDRAULIC RESERVOIR...5555
      Removal And Installation...5555
    OIL COOLER...5557
      Description...5557
      Removal And Installation...5557
    BLADE / TRACK EXPANSION SOLENOID BLOCK...5559
      Block Removal And Installation...5559
      Solenoid Removal And Installation...5560
      Block Disassembly And Assembly...5562
  UNDERCARRIAGE...5565
    BLADE...5567
      Extension Removal And Installation...5567
      Blade Removal And Installation...5567
    TRACKS...5569
      Track Lug Height...5569
      Track Tension Adjustment...5570
      Removal And Installation...5572
    TRACK FRAME...5573
      Disassembly And Assembly...5573
      Removal And Installation Of Expandable Track Frame...5574
    TRACK DAMAGE IDENTIFICATION...5577
      Cutting Of The Steel Cords...5577
      Causes Of The Damage...5577
      Abrasion Of Embedded Metals...5578
      Separation Of Embedded Metals...5579
      Separation Of Embedded Metals Due To Corrosion...5580
      Cuts On The Lug Side Rubber...5581
      Cracks On The Lug Side Rubber Due To Fatigue...5582
      Lug Abrasion...5583
      Cracks And Cuts On The Lug Side Rubber...5584
      Abrasion Of The Track Roller Side...5585
      Cuts On The Edges Of The Track Roller Side...5586
    TRACK IDLER...5589
      Parts Identification...5589
      Disassembly...5590
      Assembly...5592
    TRACK ROLLER...5595
      Parts Identification...5595
      Disassembly...5596
      Assembly...5598
    SWING CIRCLE GEAR...5601
      Removal and Installation...5601
  UPPERSTRUCTURE AND SWING SECTION...5603
    UPPERSTRUCTURE...5607
      Description...5607
      Removal...5607
      Installation...5609
    ROPS CANOPY...5613
      Removal And Installation...5613
    CAB...5617
      Removal And Installation...5617
      Door Removal And Installation...5621
      Front Window Removal And Installation...5622
      Right Side Rear Sliding Window Removal And Installation...5625
      Right Side Front Sliding Window Removal And Installation...5626
      Glass Removal...5626
      Glass Installation...5627
    SEAT AND SEAT MOUNT...5629
      Removal And Installation...5629
    RIGHT CONSOLE...5631
      Description...5631
      Console Cover Removal And Installation (Cab)...5631
      Console Cover Removal And Installation (ROPS Canopy)...5633
      Gas Spring Removal And Installation (ROPS Canopy)...5636
      Lock Lever Removal And Installation (ROPS Canopy)...5637
      Adjustment (ROPS Canopy Models)...5639
      Latch Hook Removal And Installation (ROPS Canopy)...5639
      Latch Hook Disassembly And Assembly (ROPS Canopy)...5640
      Cab Models...5641
      Upper Console Removal And Installation...5642
      Console Base Removal And Installation...5643
    LEFT CONSOLE...5647
      Description...5647
      Console Cover Removal And Installation...5647
      Gas Spring Removal And Installation...5649
      Lock Lever Removal And Installation...5650
      Adjustment...5652
      Latch Hook Removal And Installation...5653
      Latch Hook Disassembly And Assembly...5654
      Upper Console Removal And Installation...5655
      Console Base Removal And Installation...5656
    ENGINE SPEED CONTROL...5659
      Removal And Installation...5659
      Engine Speed Control Cable Removal And Installation...5660
    BLADE CONTROL...5663
      Removal And Installation...5663
      Disassembly And Assembly...5664
    SWING LOCK...5667
      Removal And Installation...5667
    RIGHT PEDAL AND LINKAGE...5669
      Description...5669
      Right Pedal Removal And Installation...5669
      Disassembly And Assembly...5670
      Linkage Removal And Installation...5671
      Linkage Disassembly And Assembly...5671
    TRAVEL CONTROLS...5673
      Description...5673
      Removal And Installation...5673
      Disassembly And Assembly...5673
    LEFT PEDAL...5675
      Removal And Installation...5675
      Disassembly And Assembly...5676
    CONTROL LINKAGE ASSEMBLY...5677
      Removal And Installation...5677
      Left Pedal Linkage Disassembly And Assembly...5678
      Right Travel Control Linkage Disassembly And Assembly...5679
      Left Travel Control Linkage Disassembly And Assembly...5680
      Left Pedal Bellcrank Disassembly And Assembly...5681
      Linkage Rod Removal And Installation...5683
      Linkage Rod Adjustment...5684
    FLOOR MAT AND FLOOR PANELS...5685
      Description...5685
      Removal And Installation...5685
    BLADE EXTENSION TRAY...5689
      Removal And Installation...5689
    FUEL TANK...5691
      Removal And Installation...5691
    HORN...5693
      Removal And Installation...5693
    SWING FRAME...5695
      Description...5695
      Removal And Installation...5695
      Bushing Replacement...5697
      Swing Frame Bushing Removal...5698
      Swing Frame Bushing Installation...5698
      Boom Pivot Bushing Removal And Installation...5699
    BOOM...5701
      Description...5701
      Removal And Installation...5701
      Boom Bushing Removal And Installation...5703
    ARM...5705
      Description...5705
      Removal And Installation...5705
      Arm To Boom Bushing Removal And Installation...5706
      Arm To Bucket And Bucket Link Bushing Removal And Installation...5707
    BUCKET...5709
      Removal And Installation...5709
    TAILGATE...5711
      Removal And Installation...5711
      Latch Removal And Installation...5712
    QUICK COUPLER (KLAC SYSTEM)...5713
      Troubleshooting...5713
      Daily Inspection...5713
      Removal And Installation...5714
      Parts Identification...5716
      Disassembly...5717
      Assembly...5718
    QUICK COUPLER (LEHNHOFF SYSTEM)...5721
      Troubleshooting...5721
      Daily Inspection...5721
      Removal (MS03 And MS08)...5722
      Installation (MS03 And MS08)...5723
      Parts Identification (MS03)...5724
      Disassembly And Assembly (MS03)...5725
      Parts Identification (MS08)...5726
      Disassembly (MS08)...5727
      Assembly (MS08)...5730
  ELECTRICAL SYSTEM & ANALYSIS...5735
    ELECTRICAL SCHEMATICS...5737
    ELECTRICAL SYSTEM...5738
      Troubleshooting Chart...5738
    ELECTRICAL SYSTEM...5739
      Description...5739
      Fuses And Relay Location / Identification...5739
      Fuel Timer And Diode Location / Identification...5739
    BATTERY...5740
      Servicing...5740
      Removing And Installing The Battery...5741
      Using A Booster Battery (Jump Starting)...5742
    ALTERNATOR...5744
      Description...5744
      Tests...5744
      Alternator Output Test...5745
      Full Field Test...5745
      Alternator Regulator Test...5746
      Alternator Regulator Test With Voltmeter...5746
      Removal And Installation...5747
      Parts Identification...5749
      Disassembly And Assembly...5749
    STARTER...5750
      Removal And Installation...5750
      Parts Identification...5751
      Disassembly And Assembly...5751
      Cleaning And Inspection...5751
    LIGHTS...5752
      Uppestructure Light Removal And Installation...5752
      Uppestructure Light Disassembly And Assembly...5752
      Boom Light Removal And Installation...5753
      Boom Light Bulb Replacement...5753
      Light Switch Removal And Installation...5754
    MICROSWITCH...5756
      Adjustment...5756
      Testing...5757
      Removal And Installation...5758
    TWO-SPEED SWITCH...5760
      Removal And Installation...5760
    FUEL LEVEL SENDER...5762
      Removal And Installation...5762
      Testing...5762
    TWO-SPEED BOOST SWITCH...5764
      Description...5764
      Removal And Installation...5764
  ENGINE SERVICE...5766
    ENGINE INFORMATION...5768
      Description...5768
      Specifications...5769
      Crankshaft Re-Grind Data...5774
      Torque Valves...5775
      Torque Values...5776
      Troubleshooting...5778
      Removal And Installation...5779
      Engine Compression Checking...5786
    SPARK ARRESTOR MUFFLER...5788
      Removal And Installation...5788
    AIR CLEANER...5790
      Removal And Installation...5790
    ENGINE COOLING SYSTEM...5792
      Radiator Removal And Installation...5792
      Water Pump Removal And Installation...5797
      Water Pump Disassembly And Assembly...5797
      Thermostat Removal And Installation...5798
      Testing The Thermostat...5798
    LUBRICATION SYSTEM...5800
      Oil Pump Removal And Installation...5800
      Oil Pump, Service...5800
      Engine Oil Pressure, Testing...5801
      Relief Valve...5802
    FUEL SYSTEM...5804
      Fuel Shutoff Solenoid Removal And Installation...5804
      Fuel Shutoff Timer Removal And Installation...5804
      Fuel Injection Pump Checking...5805
      Fuel Tightness of Pump Element...5805
      Fuel Tightness of Delivery Valve...5805
      Fuel Injection Pump Removal And Installation...5806
      Fuel Injection Pump Timing...5807
      Fuel Camshaft Removal And Installation...5809
      Fuel Camshaft Governor...5809
      Fuel Injector Removal And Installation...5810
      Fuel Injector Nozzle Checking...5811
    CYLINDER HEAD...5814
      Glow Plug Removal And Installation...5814
      Valve Clearance Adjustment...5815
      Cylinder Head Removal And Installation...5816
      Cylinder Head Disassembly And Assembly...5818
      Cylinder Head, Servicing...5819
      Cylinder Head Top Clearance...5819
      Valve Guide, Checking...5820
      Valve And Valve Seat Reconditioning...5822
      Valve Seat Tightness...5823
      Valve Spring...5824
      Rocker Arm And Shaft, Checking...5825
    CRANKSHAFT AND PISTONS...5826
      Piston And Connecting Rod Removal And Installation...5826
      Piston And Connecting Rod, Servicing...5828
      Cylinder Bore, Checking...5830
      Connecting Rod Alignment...5831
      Crankshaft Gear Removal And Installation...5831
    CRANKSHAFT AND PISTONS...5832
      Crankshaft And Bearings Removal And Installation...5832
      Crankshaft And Bearings, Servicing...5835
    CAMSHAFT AND TIMING GEARS...5838
      Timing Gearcase Cover Removal And Installation...5838
      Timing Gears Checking Backlash...5840
      Idler Gear And Camshaft Removal And Installation...5841
      Idler Gear and Shaft, Servicing...5844
    FLYWHEEL AND HOUSING...5846
      Removal And Installation...5846
      Hydraulic Pump Coupler Removal And Installation...5847
      Hydraulic Pump Coupler Disassembly And Assembly...5848
      Flywheel Ring Gear...5848
  HEATER...5850
    HEATER...5852
      Description...5852
      Removal And Installation...5852
  SPECIFICATIONS...5854
    323 EXCAVATOR SPECIFICATIONS...5856
      Machine Dimensions...5856
      Performance...5858
      Controls...5858
      Engine...5858
      Hydraulic System...5859
      Hydraulic Cylinders...5859
      Hydraulic Cycle Times...5860
      Electrical System...5860
      Instrumentation...5860
      Drive System...5860
      Slew System...5860
      Capacities...5860
      Fuel Tank...5860
      Undercarriage...5861
      Crawler Track Design...5861
      Ground Pressure...5861
    TORQUE SPECIFICATIONS...5862
      Torque For General SAE Bolts...5862
      Torque For General Metric Bolts...5863
    HYDRAULIC CONNECTION SPECIFICATIONS...5864
      O-ring Face Seal Connection...5864
      Straight Thread O-ring Fitting...5864
      Tubelines And Hoses...5864
      Flare Fitting...5865
      O-ring Flare Fitting...5866
      Port Seal Fitting...5868
    HYDRAULIC FLUID SPECIFICATIONS...5870
      Specifications...5870
    CONVERSIONS...5872
      Decimal And Millimeter Equivalents Chart...5872
      U.S. To Metric Conversion Chart...5873
    SERVICE TOOLS REQUIRED...5874
      Remote Start Tools...5874
      Hydraulic Tools...5875
      Engine Tools...5877
      HVAC Tools...5879
    FUEL, COOLANT AND LUBRICANTS...5880
      Chart...5880
  ALPHABETICAL INDEX...5882
6989592 (1-10) - 324 Compact Excavator Operation & Maintenance Manual...5884
  OPERATOR SAFETY WARNING...5886
  CONTENTS...5888
  FOREWORD...5890
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...5892
    REGULAR MAINTENANCE ITEMS...5892
    SERIAL NUMBER LOCATIONS...5893
      Excavator Serial Number...5893
      Engine Serial Number...5893
    DELIVERY REPORT...5893
    EXCAVATOR IDENTIFICATION...5894
    FEATURES, ACCESSORIES AND ATTACHMENTS...5895
      Standard Items...5895
      Options And Accessories...5895
      Attachments...5895
      Buckets Available...5895
      Falling Object Guards (FOGS)...5896
      Special Applications Kit...5896
      Special Applications Kit Inspection And Maintenance...5896
  SAFETY & TRAINING RESOURCES...5898
    SAFETY INSTRUCTIONS...5900
      Before Operation...5900
      Safe Operation Is The Operator’s Responsibility...5901
      Safe Operation Needs A Qualified Operator...5901
      Avoid Silica Dust...5902
    FIRE PREVENTION...5902
      Maintenance...5902
      Operation...5902
      Electrical...5902
      Hydraulic System...5903
      Fueling...5903
      Starting...5903
      Spark Arrester Exhaust System...5903
      Welding And Grinding...5903
      Fire Extinguishers...5903
    PUBLICATIONS AND TRAINING RESOURCES...5904
    MACHINE SIGNS (DECALS)...5905
  OPERATING INSTRUCTIONS...5908
    INSTRUMENTS AND CONSOLES...5910
      Cab Interior Light (If Equipped)...5910
      Left Console...5910
      Right Console...5911
      STD / ISO Selector Valve...5912
      Upperstructure Slew Lock...5912
      Raising And Lowering The Console...5913
      Two-Speed Travel...5913
    OPERATOR CANOPY (ROPS / TOPS)...5914
      Description...5914
    OPERATOR CAB (ROPS / TOPS)...5914
      Description...5914
      Cab Door...5915
      Front Window...5915
      Front Wiper...5916
      Window Washer Reservoir...5916
      Right Side Windows...5917
      Heater...5918
    EMERGENCY EXIT...5918
      Right Side Rear Window...5918
      Front Window...5918
    MOTION ALARM SYSTEM (IF EQUIPPED)...5919
      Operation...5919
    TRAVEL CONTROLS...5920
      Forward And Reverse Travel...5920
      Turning...5920
    HYDRAULIC CONTROLS...5922
      Description...5922
      STANDARD Control Pattern...5922
      ISO Control Pattern...5923
      Quick Couplers...5924
      Auxiliary Hydraulics (If Equipped)...5925
      Relieve Hydraulic Pressure (Excavator And Attachment)...5925
    BLADE CONTROL LEVER...5926
      Raising And Lowering Blade...5926
    TRACK FRAME EXPANSION...5927
      Operation...5927
    BOOM SWING...5929
      Operation...5929
    DAILY INSPECTION...5930
      Daily Inspection And Maintenance...5930
    PRE-STARTING PROCEDURE...5931
      Operation & Maintenance Manual And Operator’s Handbook Locations...5931
      Entering The Excavator...5932
      Seat Adjustment...5932
      Seat Belt...5932
      Control Console...5933
    STARTING THE ENGINE...5934
      Key Switch...5934
      Keyless...5935
      Cold Temperature Starting...5936
      Warming The Hydraulic System...5937
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...5938
      Procedure...5938
    ATTACHMENTS...5939
      Installing And Removing The Attachment (Pin-On Attachment)...5939
    OPERATING PROCEDURE...5940
      Inspect The Work Area...5940
      Basic Operating Instructions...5940
      Lowering The Work Equipment (Engine STOPPED)...5940
      Lifting A Load...5941
      Excavating...5942
      Boom Swing...5944
      Backfilling...5945
      Driving The Excavator...5945
      Operating On Slopes...5946
      Operating In Water...5948
      Avoiding Track Damage...5949
    TOWING THE EXCAVATOR...5950
      Procedure...5950
    LIFTING THE EXCAVATOR...5951
      Procedure...5951
    TRANSPORTING THE EXCAVATOR ON A TRAILER...5952
      Loading And Unloading...5952
      Fastening...5952
  PREVENTIVE MAINTENANCE...5954
    MAINTENANCE SAFETY...5956
    SERVICE SCHEDULE...5958
      Chart...5958
    CONTROL CONSOLE LOCKOUTS...5959
      Inspection And Maintenance...5959
    SEAT BELT...5960
      Inspection And Maintenance...5960
    MOTION ALARM SYSTEM (IF EQUIPPED)...5961
      Description...5961
      Inspecting...5961
      Adjusting Switch Position...5962
    TAILGATE...5963
      Opening And Closing...5963
      Adjusting The Bumper...5963
      Adjusting The Latch...5963
    CAB FILTERS...5964
      Cleaning And Maintenance...5964
    AIR CLEANER SERVICE...5965
      Daily Check...5965
      Replacing The Filter Elements...5965
    FUEL SYSTEM...5967
      Fuel Specifications...5967
      Biodiesel Blend Fuel...5967
      Filling The Fuel Tank...5968
      Fuel Filters...5968
      Draining The Fuel Tank...5969
      Removing Air From The Fuel System...5969
    ENGINE LUBRICATION SYSTEM...5970
      Checking And Adding Engine Oil...5970
      Engine Oil Chart...5970
      Removing And Replacing Oil And Filter...5971
    ENGINE COOLING SYSTEM...5972
      Checking Level...5972
      Removing And Replacing Coolant...5973
    ELECTRICAL SYSTEM...5974
      Fuse And Relay Location / Identification...5974
      Fuel Timer And Diode Location / Identification...5975
      Battery Maintenance...5976
      Using A Booster Battery (Jump Starting)...5977
      Removing And Installing The Battery...5978
    HYDRAULIC SYSTEM...5979
      Checking And Adding Hydraulic Oil...5979
      Hydraulic / Hydrostatic Fluid Chart...5979
      Removing And Replacing The Hydraulic Filters...5980
      Removing And Replacing The Hydraulic Fluid...5981
    SPARK ARRESTER MUFFLER...5982
      Cleaning Procedure...5982
    TRACK TENSION...5983
      Adjusting...5983
    TRAVEL MOTOR...5985
      Checking And Adding Oil...5985
      Removing And Replacing Oil...5985
    ALTERNATOR BELT...5986
      Belt Adjustment...5986
      Belt Replacement...5987
    BLADE EXTENSION...5988
      Description...5988
      Extension Removal And Installation...5988
    TRACK ROLLER AND IDLER LUBRICATION...5989
      Procedure...5989
    BUCKET...5989
      Bucket Teeth Removal And Installation...5989
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...5990
      Lubrication Locations...5990
    PIVOT PINS...5993
      Inspection And Maintenance...5993
    EXCAVATOR STORAGE AND RETURN TO SERVICE...5994
      Storage...5994
      Return To Service...5994
  MACHINE SIGN TRANSLATIONS...5996
    MACHINE SIGN TRANSLATIONS...5998
      Service Schedule (7189301)...5998
      Warning (6808185)...6001
      Lift Chart (7189300)...6002
      Warning (6807776)...6004
      Warning (6809829)...6005
      Warning (6804114)...6006
      Warning (6708929)...6006
      Warning (6809832)...6006
      Warning (6804233)...6006
      Warning (6808474)...6007
      Warning (6808346)...6007
      Joystick Control Pattern Selector Lever (7178179)...6008
      Warning (6810004)...6009
      Warning (7169006)...6009
      Warning (6589058)...6010
      Warning (7152748)...6010
  SPECIFICATIONS...6012
    EXCAVATOR SPECIFICATIONS...6014
      324 Excavator Machine Dimensions...6014
      324 Excavator Machine Dimensions - Standard Arm...6015
      Performance...6016
      Controls...6016
      Engine...6017
      Hydraulic System...6017
      Hydraulic Cylinders...6018
      Hydraulic Cycle Times...6018
      Electrical...6018
      Drive System...6018
      Slew System...6018
      Undercarriage...6019
      Capacities...6019
      Fuel Tank...6019
      Tracks...6019
      Ground Pressure...6019
  WARRANTY...6020
    WARRANTY...6022
  ALPHABETICAL INDEX...6024
6989593 (1-12) - 323 Compact Excavator Service Manual...6026
  MAINTENANCE SAFETY...6028
  CONTENTS...6030
  FOREWORD...6032
    FOREWORD...6034
    SAFETY INSTRUCTIONS...6036
    FIRE PREVENTION...6038
      Maintenance...6038
      Operation...6038
      Electrical...6038
      Hydraulic System...6038
      Fueling...6038
      Starting...6038
      Spark Arrester Exhaust System...6038
      Welding And Grinding...6039
      Fire Extinguishers...6039
    SERIAL NUMBER LOCATIONS...6040
      Excavator Serial Number...6040
      Engine Serial Number...6040
    DELIVERY REPORT...6041
    EXCAVATOR IDENTIFICATION...6042
  SAFETY & MAINTENANCE...6044
    LIFTING AND BLOCKING THE EXCAVATOR...6048
      Procedure...6048
    UPPERSTRUCTURE SLEW LOCK...6050
    LIFTING THE EXCAVATOR...6052
      Procedure...6052
    OPERATOR CAB (ROPS / TOPS)...6054
      Description...6054
      Cab Door...6055
      Front Window...6056
      Front Wiper...6057
      Window Washer Reservoir...6057
      Right Side Windows...6058
      Heater...6059
    TRANSPORTING THE EXCAVATOR ON A TRAILER...6060
      Loading And Unloading...6060
      Fastening...6060
    TAILGATE...6062
      Opening And Closing...6062
      Adjusting The Bumper...6062
      Adjusting The Latch...6062
    SERVICE SCHEDULE...6064
      Chart...6064
    AIR CLEANER SERVICE...6066
      Daily Check...6066
      Replacing The Filter Elements...6066
    CAB FILTER...6068
      Cleaning And Maintenance...6068
    ENGINE COOLING SYSTEM...6070
      Cleaning...6070
      Checking Level...6070
      Removing And Replacing Coolant...6071
    FUEL SYSTEM...6072
      Fuel Specifications...6072
      Biodiesel Blend Fuel...6072
      Filling The Fuel Tank...6073
      Fuel Filters...6073
      Draining The Fuel Tank...6074
      Removing Air From The Fuel System...6074
    ENGINE LUBRICATION SYSTEM...6076
      Checking And Adding Engine Oil...6076
      Engine Oil Chart...6076
      Removing And Replacing Oil And Filter...6077
    HYDRAULIC SYSTEM...6078
      Checking And Adding Hydraulic Oil...6078
      Hydraulic / Hydrostatic Fluid Chart...6078
      Removing And Replacing The Hydraulic Filter...6079
      Removing And Replacing The Hydraulic Fluid...6080
    LUBRICATING THE EXCAVATOR...6082
      Lubrication Locations...6082
    TRAVEL MOTOR...6086
      Checking And Adding Oil...6086
      Removing And Replacing Oil...6086
    SPARK ARRESTER MUFFLER...6088
      Cleaning Procedure...6088
    ALTERNATOR BELT...6090
      Belt Adjustment...6090
      Belt Replacement...6091
    SEAT BELT...6092
      Inspection And Maintenance...6092
    CONTROL CONSOLE LOCKOUTS...6094
      Inspection And Maintenance...6094
    PIVOT PINS...6096
      Inspection And Maintenance...6096
    EXCAVATOR STORAGE AND RETURN TO SERVICE...6098
      Storage...6098
      Return To Service...6098
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...6100
      Procedure...6100
    EMERGENCY EXIT...6102
      Right Side Rear Window...6102
      Front Window...6102
    REMOTE START TOOL KIT - MEL1563...6104
      Remote Start Tool - MEL1563...6104
      Service Tool Harness Communicator - MEL1566...6106
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...6108
      Description...6108
      Remote Start Tool (Service Tool) - 7003030...6109
      Excavator Service Tool Harness - 6689747...6110
      Computer Service Tool Harness - 6689746...6111
  HYDRAULIC SYSTEM...6112
    HYDRAULIC / HYDROSTATIC SCHEMATICS...6116
    HYDRAULIC SYSTEM INFORMATION...6118
      Glossary Of Hydraulic / Hydrostatic Symbols...6118
      Troubleshooting The Hydraulic Circuit...6121
      Troubleshooting The Cylinder Circuit...6122
      Troubleshooting The Swing (Upperstructure Slew) Circuit...6123
      Troubleshooting The Travel Circuit...6124
    CYLINDER (BOOM)...6126
      Testing...6126
      Removal And Installation...6127
      Parts Identification...6130
      Disassembly...6131
      Assembly...6133
    CYLINDER (ARM)...6136
      Testing...6136
      Removal And Installation...6138
      Parts Identification...6140
      Disassembly...6141
      Assembly...6143
    CYLINDER (BOOM SWING)...6146
      Testing...6146
      Removal And Installation...6147
      Parts Identification...6149
      Disassembly...6150
      Assembly...6152
    CYLINDER (BUCKET)...6156
      Testing...6156
      Removal And Installation...6157
      Parts Identification...6159
      Disassembly...6160
      Assembly...6162
    CYLINDER (BLADE)...6166
      Testing...6166
      Removal And Installation...6167
      Parts Identification...6169
      Disassembly...6170
      Assembly...6172
    CYLINDER (TRACK FRAME EXPANSION)...6176
      Testing...6176
      Removal And Installation...6177
      Parts Identification...6181
      Disassembly...6182
      Assembly...6184
    VALVE (MAIN RELIEF)...6188
      Testing And Adjusting...6188
    VALVES (PORT RELIEF)...6192
      Testing And Adjusting...6192
    VALVES (CROSSPORT RELIEF)...6194
      Testing And Adjusting...6194
    VALVE (PRESSURE REDUCING)...6198
      Testing And Adjusting...6198
    HYDRAULIC CONTROL VALVE...6200
      Description...6200
      Removal And Installation...6200
      Parts Identification...6202
      Disassembly...6203
      Right Travel Valve Section Disassembly And Assembly...6204
      Boom Swing Valve Section Disassembly And Assembly...6208
      Arm Valve Section Disassembly And Assembly...6211
      Bucket Valve Section Disassembly And Assembly...6214
      Auxiliary Valve Section Disassembly And Assembly...6217
      Boom Valve Section Disassembly And Assembly...6222
      Left Travel Valve Section Disassembly And Assembly...6225
      Swing (Slew) Valve Section Disassembly And Assembly...6229
      Blade Valve Section Disassembly And Assembly...6232
      Assembly...6236
    HYDRAULIC PUMP...6242
      Description...6242
      Torque Adjustment...6242
      Testing The Piston Pump...6243
      Testing The Gear Pump...6245
      Testing Auxiliary Hydraulic Flow...6246
      Removal And Installation...6247
      Parts Identification...6250
      Disassembly...6251
      Gear Pump Disassembly...6252
      Piston Pump Disassembly...6254
      Piston Pump Assembly...6263
      Gear Pump Assembly...6272
      Assembly...6274
    MANIFOLD ASSEMBLY / ACCUMULATOR...6276
      Description...6276
      Removal And Installation...6276
      Parts Identification...6279
      Disassembly...6280
      Assembly...6291
    ACCUMULATORS...6302
      Removal And Installation...6302
    TRAVEL MOTOR...6304
      Description...6304
      Removal And Installation...6304
      Parts Identification...6305
      Disassembly...6306
      Assembly...6313
    SWIVEL JOINT...6322
      Description...6322
      Removal And Installation...6322
      Parts Identification...6325
      Disassembly...6326
      Assembly...6328
    SWING MOTOR...6332
      Description...6332
      Removal And Installation...6332
      Parts Identification...6333
      Disassembly...6334
      Assembly...6340
    CONTROL LEVER (JOYSTICK) (RIGHT)...6348
      Description...6348
      Testing...6348
      Handle Removal And Installation...6350
      Removal And Installation...6351
      Parts Identification...6353
      Disassembly...6354
      Assembly...6359
    CONTROL LEVER (JOYSTICK) (LEFT)...6364
      Description...6364
      Testing...6364
      Handle Removal And Installation...6366
      Removal And Installation...6368
      Parts Identification...6369
      Disassembly...6370
      Assembly...6375
    HYDRAULIC FILTER MOUNT...6380
      Description...6380
      Removal And Installation...6380
    HYDRAULIC RESERVOIR...6382
      Description...6382
      Removal And Installation...6382
    OIL COOLER...6384
      Description...6384
      Removal And Installation...6384
    BLADE / TRACK EXPANSION SOLENOID BLOCK...6386
      Description...6386
      Block Removal And Installation...6386
      Solenoid Removal And Installation...6387
      Block Disassembly And Assembly...6388
    SLEW LOCK VALVE...6390
      Description...6390
      Removal And Installation...6390
      Parts Identification...6392
      Disassembly And Assembly...6393
  UNDERCARRIAGE...6398
    BLADE...6400
      Description...6400
      Extension Removal And Installation...6400
      Blade Removal And Installation...6401
    TRACKS...6402
      Track Lug Height...6402
      Track Tension Adjustment...6402
      Removal And Installation...6405
    TRACK FRAME...6406
      Disassembly And Assembly...6406
      Removal And Installation Of Expandable Track Frame...6407
    TRACK DAMAGE IDENTIFICATION...6410
      Cutting Of The Steel Cords...6410
      Causes Of The Damage...6410
      Abrasion Of Embedded Metals...6411
      Separation Of Embedded Metals...6412
      Separation Of Embedded Metals Due To Corrosion...6413
      Cuts On The Lug Side Rubber...6414
      Cracks On The Lug Side Rubber Due To Fatigue...6415
      Lug Abrasion...6416
      Cracks And Cuts On The Lug Side Rubber...6417
      Abrasion Of The Track Roller Side...6418
      Cuts On The Edges Of The Track Roller Side...6419
    TRACK IDLER...6422
      Parts Identification...6422
      Disassembly...6423
      Assembly...6425
    TRACK ROLLER...6428
      Parts Identification...6428
      Disassembly...6429
      Assembly...6431
    SWING CIRCLE GEAR...6434
      Removal And Installation...6434
  UPPERSTRUCTURE & SWING...6436
    UPPERSTRUCTURE...6440
      Description...6440
      Removal...6440
      Installation...6442
    ROPS CANOPY...6444
      Removal And Installation...6444
    CAB...6448
      Removal And Installation...6448
      Door Removal And Installation...6452
      Front Window Removal And Installation...6453
      Right Side Rear Sliding Window Removal And Installation...6456
      Right Side Front Sliding Window Removal And Installation...6457
      Glass Removal...6457
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...6458
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...6458
      Glass Installation...6459
    SEAT AND SEAT MOUNT...6462
      Seat Mount Removal And Installation...6462
    RIGHT CONSOLE...6464
      Description...6464
      Joystick Console Cover (Bottom) Removal And Installation...6464
      Joystick Console Cover (Top) Removal And Installation...6465
      Joystick Console Cover (Top) Disassembly And Assembly...6466
      Compression Spring Removal And Installation (Canopy Only)...6467
      Compression Spring Disassembly And Assembly (Canopy Only)...6468
      Lever Removal And Installation (Canopy Only)...6469
      Joystick Console Frame Removal And Installation...6471
      Joystick Console Frame Disassembly And Assembly...6472
      Right Rear Console Cover Removal And Installation...6473
      Right Rear Console Cover Disassembly And Assembly...6474
      Right Rear Console Frame Removal And Installation...6475
    LEFT CONSOLE...6478
      Description...6478
      Joystick Console Cover (Bottom) Removal And Installation...6478
      Joystick Console Cover (Top) Removal And Installation...6479
      Compression Spring Removal And Installation...6480
      Compression Spring Disassembly And Assembly...6481
      Lever Removal And Installation...6483
      Joystick Console Frame Removal And Installation...6484
      Joystick Console Frame Disassembly And Assembly...6485
      Left Rear Console Cover Removal And Installation...6485
      Left Rear Console Frame Removal And Installation...6486
    ENGINE SPEED CONTROL...6488
      Removal And Installation...6488
      Cable Removal And Installation...6489
    BLADE CONTROL...6492
      Removal And Installation...6492
      Disassembly And Assembly...6493
      Cable Removal And Installation...6495
    UPPERSTRUCTURE SLEW LOCK...6496
      Removal And Installation...6496
      Disassembly And Assembly...6496
    RIGHT PEDAL...6498
      Removal And Installation...6498
      Disassembly And Assembly...6498
    TRAVEL CONTROLS...6500
      Removal And Installation...6500
      Disassembly And Assembly...6500
    LEFT PEDAL...6502
      Removal And Installation...6502
      Disassembly And Assembly...6502
    CONTROL LINKAGE ASSEMBLY...6504
      Description...6504
      Removal And Installation...6504
      Right Half of Control Linkage Disassembly And Assembly...6506
      Left Half of Control Linkage Disassembly And Assembly...6508
      Bracket of Control Linkage Disassembly And Assembly...6511
    FLOOR MAT AND FLOOR PANELS...6512
      Description...6512
      Removal And Installation...6512
    FUEL TANK...6514
      Removal And Installation...6514
    HORN...6516
      Removal And Installation...6516
    SWING FRAME...6518
      Description...6518
      Removal And Installation...6518
      Bushing Removal And Installation...6520
      Swing Frame Bushing Removal...6520
      Swing Frame Bushing Installation...6521
      Boom Pivot Bushing Removal...6522
      Boom Pivot Bushing Installation...6522
    BOOM...6524
      Description...6524
      Removal And Installation...6524
      Boom Bushing Removal And Installation...6526
    ARM...6528
      Description...6528
      Removal And Installation...6528
      Arm To Boom Bushing Removal And Installation...6529
      Arm To Bucket And Bucket Link Bushing Removal And Installation...6530
    BUCKET...6532
      Removal And Installation...6532
    TAILGATE...6534
      Removal And Installation...6534
      Latch Removal And Installation...6535
    QUICK COUPLER (KLAC™ SYSTEM)...6536
      Troubleshooting...6536
      Daily Inspection...6536
      Removal And Installation...6537
      Parts Identification...6539
      Disassembly...6540
      Assembly...6541
    QUICK COUPLER (LEHNHOFF® SYSTEM)...6544
      Troubleshooting...6544
      Daily Inspection...6544
      Removal (MS03 And MS08)...6545
      Installation (MS03 And MS08)...6546
      Parts Identification (MS03)...6547
      Disassembly And Assembly (MS03)...6548
      Parts Identification (MS08)...6549
      Disassembly (MS08)...6550
      Assembly (MS08)...6553
  ELECTRICAL SYSTEM...6558
    ELECTRICAL SCHEMATICS...6560
    ELECTRICAL SYSTEM INFORMATION...6561
      Glossary Of Electrical Symbols...6561
      Troubleshooting...6564
      Description...6565
      Fuse And Relay Location / Identification...6565
      Fuel Timer And Diode Location / Identification...6566
    BATTERY...6567
      Servicing...6567
      Removal And Installation...6568
      Using A Booster Battery (Jump Starting)...6569
    ALTERNATOR...6571
      Description...6571
      Tests...6571
      Alternator Output Test...6572
      Full Field Test...6572
      Alternator Regulator Test...6573
      Alternator Regulator Test With Voltmeter...6573
      Removal And Installation...6574
      Belt Adjustment...6575
      Charging System Inspection...6577
      Parts Identification...6578
    STARTER...6579
      Removal And Installation...6579
      Parts Identification...6580
      Cleaning And Inspection...6581
    LIGHTS...6583
      Upperstructure Light Removal And Installation...6583
      Upperstructure Light Disassembly And Assembly...6583
      Boom Light Removal And Installation...6584
      Boom Light Disassembly And Assembly...6584
      Light Switch Removal And Installation...6585
    MICROSWITCH...6587
      Testing Left Console Microswitch...6587
      Left Console Microswitch Removal And Installation...6588
      Testing Right Console Microswitch...6588
      Right Console Microswitch Removal And Installation...6590
    TWO-SPEED BOOST SWITCH...6591
      Description...6591
      Removal And Installation...6591
    FUEL LEVEL SENDER...6593
      Removal And Installation...6593
      Testing...6593
  ENGINE...6595
    ENGINE INFORMATION...6597
      Description...6597
      Specifications...6598
      Crankshaft Re-Grind Data...6602
      Torque Values...6603
      Troubleshooting...6604
      Engine Removal And Installation...6605
      Engine Mount Replacement...6613
      Engine Compression - Checking...6614
    SPARK ARRESTER MUFFLER...6615
      Removal And Installation...6615
    AIR CLEANER...6617
      Removal And Installation...6617
    ENGINE COOLING SYSTEM...6619
      Radiator Removal And Installation...6619
      Water Pump Removal And Installation...6624
      Water Pump Disassembly And Assembly...6624
      Thermostat Removal And Installation...6625
      Thermostat - Checking...6625
    LUBRICATION SYSTEM...6627
      Oil Pan Removal And Installation...6627
      Oil Pump Removal And Installation...6628
      Oil Pump - Service...6628
      Engine Oil Pressure - Testing...6629
    FUEL SYSTEM...6631
      Fuel Shutoff Solenoid Removal And Installation...6631
      Fuel Shutoff Timer Removal And Installation...6631
      Fuel Injection Pump - Checking...6632
      Fuel Injection Pump Removal And Installation...6633
      Fuel Injection Pump - Timing...6635
      Fuel Camshaft Removal And Installation...6636
      Fuel Camshaft Governor...6637
      Fuel Injector Removal And Installation...6637
      Fuel Injector Nozzle Pressure - Checking...6638
    CYLINDER HEAD...6641
      Glow Plug Removal And Installation...6641
      Valve Clearance Adjustment...6642
      Valve Timing - Checking...6643
      Cylinder Head Removal And Installation...6643
      Cylinder Head Disassembly And Assembly...6645
      Cylinder Head - Servicing...6646
      Cylinder Head Top Clearance...6647
      Valve Guide - Checking...6647
      Valve And Valve Seat Reconditioning...6649
      Valve Seat Tightness...6650
      Valve Spring...6650
      Valve Tappets...6651
      Rocker Arm And Shaft - Checking...6652
    CRANKSHAFT AND PISTONS...6653
      Piston And Connecting Rod Removal And Installation...6653
      Piston And Connecting Rod - Servicing...6655
      Cylinder Bore - Checking...6657
      Connecting Rod Alignment...6658
      Crankshaft Gear Removal And Installation...6658
      Crankshaft And Bearings Removal And Installation...6659
      Crankshaft And Bearings - Servicing...6661
    CAMSHAFT AND TIMING GEARS...6665
      Timing Gearcase Cover Removal And Installation...6665
      Timing Gears Checking Backlash...6667
      Idler Gear And Camshaft Removal And Installation...6667
      Idler Gear and Shaft - Servicing...6670
    FLYWHEEL AND HOUSING...6671
      Flywheel Housing Removal And Installation...6671
      Hydraulic Pump Coupler Removal And Installation...6672
      Flywheel Removal...6673
      Flywheel Installation...6673
      Rear End Plate Removal And Installation...6674
  HEATING, VENTILATION, AIR CONDITIONING...6675
    HEATER SYSTEM...6677
      Description...6677
      Components...6677
    REGULATOR MAINTENANCE...6679
      Filter Element Removal And Installation...6679
      Heater Coil...6679
    HEATER UNIT...6681
      Removal And Installation...6681
      Louver Removal And Installation...6682
      Threaded Insert Removal And Installation...6682
    HEATER COIL...6683
      Removal And Installation...6683
    HEATER FAN...6687
      Removal And Installation...6687
    HEATER VALVE...6691
      Removal And Installation...6691
  SPECIFICATIONS...6693
    324 SPECIFICATIONS...6695
      Machine Dimensions...6695
      Performance...6697
      Controls...6697
      Engine...6698
      Hydraulic System...6698
      Hydraulic Cylinders...6699
      Hydraulic Cycle Times...6699
      Electrical...6699
      Drive System...6699
      Slew System...6699
      Undercarriage...6700
      Capacities...6700
      Tracks...6700
      Ground Pressure...6700
    TORQUE SPECIFICATIONS FOR BOLTS...6701
      Torque For General SAE Bolts...6701
      Torque For General Metric Bolts...6702
    HYDRAULIC CONNECTION SPECIFICATIONS...6703
      O-ring Face Seal Connection...6703
      Straight Thread O-ring Fitting...6704
      Tubelines And Hoses...6704
      Flare Fitting...6705
      Port Seal Fitting...6706
    HYDRAULIC FLUID SPECIFICATIONS...6707
      Specifications...6707
    CONVERSIONS...6709
      Decimal And Millimeter Equivalent Chart...6709
      U.S. To Metric Conversion Chart...6709
  ALPHABETICAL INDEX...6711
  SERVICE MANUAL REVISION...6713
    Revision No: 324 - 1...6713
6989593 (2-10) - 323 Compact Excavator Service Manual...6715
  CONTENTS...6719
  FOREWORD...6721
    FOREWORD...6723
    SAFETY INSTRUCTIONS...6725
    FIRE PREVENTION...6727
      Maintenance...6727
      Operation...6727
      Electrical...6727
      Hydraulic System...6727
      Fueling...6727
      Starting...6727
      Spark Arrestor Exhaust System...6727
      Welding And Grinding...6728
      Fire Extinguishers...6728
    SERIAL NUMBER LOCATIONS...6729
      Excavator Serial Number...6729
      Engine Serial Number...6729
    DELIVERY REPORT...6730
    EXCAVATOR IDENTIFICATION...6731
  SAFETY & MAINTENANCE...6733
    LIFTING AND BLOCKING THE EXCAVATOR...6735
      Procedure...6735
    UPPERSTRUCTURE SLEW LOCK...6737
    LIFTING THE EXCAVATOR...6739
      Procedure...6739
    OPERATOR CAB (ROPS / TOPS)...6741
      Description...6741
      Cab Door...6741
      Front Window...6742
      Front Wiper...6743
      Window Washer Reservoir...6743
      Right Side Windows...6744
      Heater...6745
    TRANSPORTING THE EXCAVATOR ON A TRAILER...6747
      Loading And Unloading...6747
      Fastening...6747
    TAILGATE...6749
      Opening And Closing...6749
      Adjusting The Bumper...6749
      Adjusting The Latch...6749
    SERVICE SCHEDULE...6751
      Chart...6751
    AIR CLEANER SERVICE...6753
      Daily Check...6753
      Replacing The Filter Elements...6753
    CAB FILTER...6755
      Cleaning And Maintenance...6755
    ENGINE COOLING SYSTEM...6757
      Cleaning...6757
      Checking Level...6757
      Removing And Replacing Coolant...6758
    FUEL SYSTEM...6759
      Fuel Specifications...6759
      Filling The Fuel Tank...6759
      Fuel Filters...6760
      Draining The Fuel Tank...6760
      Removing Air From The Fuel System...6761
    ENGINE LUBRICATION SYSTEM...6763
      Checking And Adding Engine Oil...6763
      Engine Oil Chart...6763
      Removing And Replacing Oil And Filter...6764
    HYDRAULIC SYSTEM...6765
      Checking And Adding Hydraulic Oil...6765
      Hydraulic / Hydrostatic Fluid Chart...6765
      Removing And Replacing The Hydraulic Filter...6766
      Removing And Replacing The Hydraulic Fluid...6767
    LUBRICATING THE EXCAVATOR...6769
      Lubrication Locations...6769
    TRAVEL MOTOR...6773
      Checking Oil Level...6773
      Draining The Drive Motor...6773
    SPARK ARRESTER MUFFLER...6775
      Cleaning Procedure...6775
    ALTERNATOR BELT...6777
      Belt Adjustment...6777
      Belt Replacement...6778
    SEAT BELT...6779
      Inspection And Maintenance...6779
    CONTROL CONSOLE LOCKOUTS...6781
      Inspection And Maintenance...6781
    PIVOT PINS...6783
      Inspection And Maintenance...6783
    EXCAVATOR STORAGE AND RETURN TO SERVICE...6785
      Storage...6785
      Return to Service...6785
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...6787
      Procedure...6787
    EMERGENCY EXIT...6789
      Right Side Rear Window...6789
      Front Window...6789
  HYDRAULIC SYSTEM...6791
    HYDRAULIC / HYDROSTATIC SCHEMATICS...6795
    HYDRAULIC SYSTEM INFORMATION...6797
      Glossary Of Hydraulic / Hydrostatic Symbols...6797
      Troubleshooting The Hydraulic Circuit...6800
      Troubleshooting The Cylinder Circuit...6801
      Troubleshooting The Swing (Upperstructure Slew) Circuit...6802
      Troubleshooting The Travel Circuit...6803
    BOOM CYLINDER...6805
      Testing...6805
      Removal And Installation...6806
      Parts Identification...6809
      Disassembly...6810
      Assembly...6813
    ARM CYLINDER...6817
      Testing...6817
      Removal And Installation...6819
      Parts Identification...6821
      Disassembly...6822
      Assembly...6824
    BOOM SWING CYLINDER...6827
      Testing...6827
      Removal and Installation...6828
      Parts Identification...6830
      Disassembly...6831
      Assembly...6833
    BUCKET CYLINDER...6837
      Testing...6837
      Removal And Installation...6838
      Parts Identification...6840
      Disassembly...6841
      Assembly...6843
    BLADE CYLINDER...6847
      Testing...6847
      Removal and Installation...6848
      Parts Identification...6850
      Disassembly...6851
      Assembly...6853
    TRACK FRAME EXPANSION CYLINDER...6857
      Testing...6857
      Removal And Installation...6858
      Parts Identification...6862
      Disassembly...6863
      Assembly...6865
    MAIN RELIEF VALVE...6869
      Testing And Adjusting The Main Relief Valve...6869
    PORT RELIEF VALVES...6871
      Testing And Adjusting The Port Relief Valve Pressure...6871
    CROSSPORT RELIEF VALVES...6873
      Testing And Adjusting The Crossport Relief Valve...6873
    PRESSURE REDUCING VALVE...6875
      Testing And Adjusting The Pressure Reducing Valve...6875
    HYDRAULIC CONTROL VALVE...6877
      Description...6877
      Removal And Installation...6877
      Parts Identification...6879
      Disassembly...6880
      Right Travel Valve Section Disassembly And Assembly...6881
      Boom Swing Valve Section Disassembly And Assembly...6885
      Arm Valve Section Disassembly and Assembly...6888
      Bucket Valve Section Disassembly And Assembly...6891
      Auxiliary Valve Section Disassembly And Assembly...6894
      Boom Valve Section Disassembly And Assembly...6899
      Left Travel Valve Section Disassembly And Assembly...6902
      Swing (Slew) Valve Section Disassembly And Assembly...6906
      Blade Valve Section Disassembly And Assembly...6909
      Assembly...6913
    HYDRAULIC PUMP...6919
      Description...6919
      Torque Adjustment...6919
      Testing The Piston Pump...6920
      Testing The Gear Pump...6922
      Testing Auxiliary Hydraulic Flow...6923
      Removal And Installation...6924
      Parts Identification...6927
      Disassembly...6928
      Gear Pump Disassembly...6929
      Piston Pump Disassembly...6931
      Piston Pump Assembly...6940
      Gear Pump Assembly...6949
      Assembly...6951
    MANIFOLD ASSEMBLY / ACCUMULATOR...6953
      Description...6953
      Removal And Installation...6953
      Parts Identification...6956
      Disassembly...6957
      Assembly...6968
    ACCUMULATORS...6979
      Removal And Installation...6979
    TRAVEL MOTOR...6981
      Description...6981
      Removal And Installation...6981
      Parts Identification...6982
      Disassembly...6983
      Assembly...6990
    SWIVEL JOINT...6999
      Description...6999
      Removal And Installation...6999
      Parts Identification...7002
      Disassembly...7003
      Assembly...7005
    SWING MOTOR...7009
      Description...7009
      Removal And Installation...7009
      Parts Identification...7010
      Disassembly...7011
      Assembly...7017
    RIGHT CONTROL LEVER (JOYSTICK)...7025
      Description...7025
      Testing...7025
      Handle Removal And Installation...7027
      Removal And Installation...7028
      Parts Identification...7029
      Disassembly...7030
      Assembly...7035
    LEFT CONTROL LEVER (JOYSTICK)...7039
      Description...7039
      Testing...7039
      Handle Removal And Installation...7041
      Removal And Installation...7043
      Parts Identification...7044
      Disassembly...7045
      Assembly...7050
    HYDRAULIC FILTER MOUNT...7055
      Description...7055
      Removal And Installation...7055
    HYDRAULIC RESERVOIR...7057
      Description...7057
      Removal And Installation...7057
    OIL COOLER...7059
      Description...7059
      Removal And Installation...7059
    BLADE / TRACK EXPANSION SOLENOID BLOCK...7061
      Description...7061
      Block Removal and Installation...7061
      Solenoid Removal and Installation...7062
      Block Disassembly And Assembly...7063
    SLEW LOCK VALVE...7065
      Description...7065
      Removal And Installation...7065
      Parts Identification...7067
      Disassembly And Assembly...7068
  UNDERCARRIAGE...7073
    BLADE...7075
      Description...7075
      Extension Removal And Installation...7075
      Blade Removal And Installation...7076
    TRACKS...7077
      Track Lug Height...7077
      Track Tension Adjustment...7077
      Removal And Installation...7080
    TRACK FRAME...7081
      Disassembly And Assembly...7081
      Removal And Installation Of Expandable Track Frame...7082
    TRACK DAMAGE IDENTIFICATION...7085
      Cutting Of The Steel Cords...7085
      Causes Of The Damage...7085
      Abrasion Of Embedded Metals...7086
      Separation Of Embedded Metals...7087
      Separation Of Embedded Metals Due To Corrosion...7088
      Cuts On The Lug Side Rubber...7089
      Cracks On The Lug Side Rubber Due To Fatigue...7090
      Lug Abrasion...7091
      Cracks And Cuts On The Lug Side Rubber...7092
      Abrasion Of The Track Roller Side...7093
      Cuts On The Edges Of The Track Roller Side...7094
    TRACK IDLER...7097
      Parts Identification...7097
      Disassembly...7098
      Assembly...7100
    TRACK ROLLER...7103
      Parts Identification...7103
      Disassembly...7104
      Assembly...7106
    SWING CIRCLE GEAR...7109
      Removal and Installation...7109
  UPPERSTRUCTURE & SWING...7111
    UPPERSTRUCTURE...7115
      Description...7115
      Removal...7115
      Installation...7117
    ROPS CANOPY...7119
      Removal And Installation...7119
    CAB...7123
      Removal And Installation...7123
      Door Removal And Installation...7127
      Front Window Removal And Installation...7128
      Right Side Rear Sliding Window Removal And Installation...7131
      Right Side Front Sliding Window Removal And Installation...7132
      Glass Removal...7132
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...7133
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...7133
      Glass Installation...7134
    SEAT AND SEAT MOUNT...7137
      Seat Mount Removal And Installation...7137
    RIGHT CONSOLE...7139
      Description...7139
      Joystick Console Cover (Bottom) Removal And Installation...7139
      Joystick Console Cover (Top) Removal And Installation...7140
      Joystick Console Cover (Top) Disassembly And Assembly...7141
      Compression Spring Removal And Installation (Canopy Only)...7142
      Compression Spring Disassembly And Assembly (Canopy Only)...7143
      Lever Removal And Installation (Canopy Only)...7144
      Joystick Console Frame Removal And Installation...7146
      Joystick Console Frame Disassembly And Assembly...7147
      Right Rear Console Cover Removal And Installation...7148
      Right Rear Console Cover Disassembly and Assembly...7149
      Right Rear Console Frame Removal And Installation...7150
    LEFT CONSOLE...7153
      Description...7153
      Joystick Console Cover (Bottom) Removal And Installation...7153
      Joystick Console Cover (Top) Removal And Installation...7154
      Compression Spring Removal And Installation...7155
      Compression Spring Disassembly And Assembly...7156
      Lever Removal And Installation...7158
      Joystick Console Frame Removal And Installation...7159
      Joystick Console Frame Disassembly And Assembly...7160
      Left Rear Console Cover Removal And Installation...7160
      Left Rear Console Frame Removal And Installation...7161
    ENGINE SPEED CONTROL...7163
      Removal and Installation...7163
      Cable Removal and Installation...7164
    BLADE CONTROL...7167
      Removal and Installation...7167
      Disassembly And Assembly...7168
      Cable Removal and Installation...7170
    UPPERSTRUCTURE SLEW LOCK...7171
      Removal And Installation...7171
      Disassembly And Assembly...7171
    RIGHT PEDAL...7173
      Removal And Installation...7173
      Disassembly And Assembly...7173
    TRAVEL CONTROLS...7175
      Removal And Installation...7175
      Disassembly And Assembly...7175
    LEFT PEDAL...7177
      Removal And Installation...7177
      Disassembly And Assembly...7177
    CONTROL LINKAGE ASSEMBLY...7179
      Description...7179
      Removal And Installation...7179
      Right Half of Control Linkage Disassembly And Assembly...7181
      Left Half of Control Linkage Disassembly And Assembly...7183
      Bracket of Control Linkage Disassembly And Assembly...7186
    FLOOR MAT AND FLOOR PANELS...7187
      Description...7187
      Removal And Installation...7187
    FUEL TANK...7189
      Removal and Installation...7189
    HORN...7191
      Removal And Installation...7191
    SWING FRAME...7193
      Description...7193
      Removal And Installation...7193
      Bushing Removal and Installation...7195
      Swing Frame Bushing Removal...7195
      Swing Frame Bushing Installation...7196
      Boom Pivot Bushing Removal...7197
      Boom Pivot Bushing Installation...7197
    BOOM...7199
      Description...7199
      Removal And Installation...7199
      Boom Bushing Removal And Installation...7201
    ARM...7203
      Description...7203
      Removal And Installation...7203
      Arm To Boom Bushing Removal And Installation...7204
      Arm To Bucket And Bucket Link Bushing Removal And Installation...7205
    BUCKET...7207
      Removal And Installation...7207
    TAILGATE...7209
      Removal And Installation...7209
      Latch Removal And Installation...7210
  ELECTRICAL SYSTEM...7211
    ELECTRICAL SCHEMATIC...7213
    ELECTRICAL SYSTEM INFORMATION...7214
      Glossary Of Electrical Symbols...7214
      Troubleshooting...7217
      Description...7218
      Fuse And Relay Location / Identification...7218
      Fuel Timer And Diode Location / Identification...7219
    BATTERY...7220
      Servicing...7220
      Removal And Installation...7221
      Using A Booster Battery (Jump Starting)...7222
    ALTERNATOR...7224
      Description...7224
      Tests...7224
      Alternator Output Test...7225
      Full Field Test...7225
      Alternator Regulator Test...7226
      Alternator Regulator Test With Voltmeter...7226
      Removal And Installation...7227
      Belt Adjustment...7228
      Charging System Inspection...7230
      Parts Identification...7231
    STARTER...7232
      Removal And Installation...7232
      Parts Identification...7233
      Cleaning And Inspection...7234
    LIGHTS...7236
      Upperstructure Light Removal And Installation...7236
      Upperstructure Light Disassembly and Assembly...7236
      Boom Light Removal And Installation...7237
      Boom Light Disassembly And Assembly...7237
      Light Switch Removal And Installation...7238
    MICROSWITCH...7240
      Testing Left Console Microswitch...7240
      Left Console Microswitch Removal And Installation...7241
      Testing Right Console Microswitch...7241
      Right Console Microswitch Removal And Installation...7243
    TWO-SPEED BOOST SWITCH...7244
      Description...7244
      Removal And Installation...7244
    FUEL LEVEL SENDER...7246
      Removal And Installation...7246
      Testing...7246
  ENGINE...7248
    TROUBLESHOOTING...7250
      Chart...7250
    SPARK ARRESTOR MUFFLER...7252
      Removal And Installation...7252
    AIR CLEANER...7254
      Removal And Installation...7254
    RADIATOR...7256
      Removal And Installation...7256
    ENGINE COMPONENTS AND TESTING...7262
      Valve Clearance Adjustment...7262
      Engine Compression Checking...7263
      Fuel Shutoff Solenoid - Checking...7263
      Fuel Shutoff Solenoid Removal And Installation...7264
      Fuel Shutoff Timer Removal And Installation...7264
      Fuel Injection Pump Check...7265
      Fuel Injection Pump Removal And Installation...7266
      Fuel Injection Pump Timing...7268
      Fuel Injector Removal And Installation...7269
      Fuel Injector Checking...7270
      Glow Plug Removal And Installation...7272
    ENGINE...7274
      Description...7274
      Engine Removal and Installation...7274
      Engine Mount Replacement...7282
    FLYWHEEL AND HOUSING...7284
      Flywheel Housing Removal And Installation...7284
      Hydraulic Pump Coupler Removal And Installation...7285
      Flywheel Removal...7286
      Flywheel Installation...7286
      Rear End Plate Removal And Installation...7287
    RECONDITIONING THE ENGINE...7288
      Cylinder Head Removal And Installation...7288
      Cylinder Head Disassembly And Assembly...7289
      Cylinder Head, Servicing...7290
      Cylinder Head Top Clearance...7291
      Valve Guide, Checking...7291
      Valve Timing, Checking...7293
      Valve And Valve Seat Reconditioning...7293
      Valve Seat Tightness...7294
      Valve Spring...7295
      Valve Tappets...7296
      Rocker Arm And Shaft, Checking...7297
      Timing Gearcase Cover Removal And Installation...7297
      Idler Gear And Camshaft Removal And Installation...7299
      Idler Gear and Shaft, Servicing...7302
      Timing Gears Checking Backlash...7303
      Fuel Camshaft Removal And Installation...7303
      Fuel Camshaft Governor...7304
      Crankshaft Gear Removal And Installation...7304
      Oil Pan Removal And Installation...7305
      Oil Pump Removal And Installation...7306
      Oil Pump, Service...7306
      Engine Oil Pressure, Checking...7307
      Relief Valve...7308
      Piston And Connecting Rod Removal And Installation...7308
      Piston And Connecting Rod, Servicing...7310
      Connecting Rod Alignment...7312
      Crankshaft And Bearings Removal And Installation...7312
      Crankshaft And Bearings, Servicing...7314
      Cylinder Bore, Checking...7316
      Water Pump Removal And Installation...7317
      Water Pump Disassembly And Assembly...7317
      Thermostat Removal And Installation...7318
      Testing The Thermostat...7318
    HEATER SYSTEM...7320
      Description...7320
      Components...7320
    REGULATOR MAINTENANCE...7322
      Filter Element Removal And Installation...7322
      Heater Coil...7322
    HEATER UNIT...7324
      Removal And Installation...7324
      Louver Removal and Installation...7325
      Threaded Insert Removal And Installation...7325
    HEATER COIL...7326
      Removal And Installation...7326
    HEATER FAN...7330
      Removal And Installation...7330
    HEATER VALVE...7334
      Removal And Installation...7334
  SPECIFICATIONS...7336
    EXCAVATOR SPECIFICATIONS...7338
      324 Excavator Machine Dimensions...7338
      324 Excavator Machine Dimensions - Standard Arm...7339
      324 Excavator Machine Dimensions - Long Arm...7340
      Performance...7341
      Controls...7341
      Engine...7342
      Hydraulic System...7342
      Hydraulic Cylinders...7343
      Hydraulic Cycle Times...7343
      Electrical...7343
      Drive System...7343
      Slew System...7343
      Undercarriage...7344
      Capacities...7344
      Tracks...7344
      Ground Pressure...7344
    ENGINE SPECIFICATIONS...7346
      Engine...7346
      Fuel Injector Nozzles...7346
      Fuel Injection Pump...7346
      Cylinder Head...7346
      Valves...7346
      Valve Springs...7346
      Rocker Arms...7347
      Camshaft...7347
      Cylinders...7347
      Piston Rings...7347
      Pistons...7347
      Connecting Rods...7348
      Crankshaft...7348
      Oil Pump...7348
      Thermostat...7348
      Engine Bolt Torque...7349
    TORQUE SPECIFICATIONS FOR BOLTS...7350
      Torque For General SAE Bolts...7350
      Torque For General Metric Bolts...7351
    HYDRAULIC CONNECTION SPECIFICATIONS...7352
      O-ring Face Seal Connection...7352
      Straight Thread O-ring Fitting...7353
      Tubelines And Hoses...7353
      Flare Fitting...7354
      Port Seal Fitting...7355
    HYDRAULIC FLUID SPECIFICATIONS...7356
      Specifications...7356
    CONVERSIONS...7358
      Decimal And Millimeter Equivalents...7358
      U.S. To Metric Conversion Chart...7358
  ALPHABETICAL INDEX...7360

Bobcat Excavators 321, 323, 324, 329 Repair Service Manuals