Bobcat 324 Compact Excavator Service Manual 6989593 (02-16) – PDF DOWNLOAD
FILE DETAILS:
Bobcat 324 Compact Excavator Service Manual 6989593 (02-16) – PDF DOWNLOAD
Language : English
Pages :737
Downloadable : Yes
File Type : PDF
Size:20.4 MB
DESCRIPTION:
Bobcat 324 Compact Excavator Service Manual 6989593 (02-16) – PDF DOWNLOAD
FOREWORD
This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc
A general inspection of the following items must be made after the excavator has had service or repair:
TABLE OF CONTENTS:
Bobcat 324 Compact Excavator Service Manual 6989593 (02-16) – PDF DOWNLOAD
MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
UPPERSTRUCTURE SLEW LOCK 25
LIFTING THE EXCAVATOR 27
Procedure 27
OPERATOR Canopy (ROPS / TOPS) 29
Description 29
OPERATOR CAB (ROPS / TOPS) 31
Description 31
Cab Door 32
Front Window 33
Front Wiper 34
Window Washer Reservoir 34
Right Side Windows 35
Heater 36
TRANSPORTING THE EXCAVATOR ON A TRAILER 37
Loading And Unloading 37
Fastening 37
TAILGATE 39
Opening And Closing 39
Adjusting The Bumper 39
Adjusting The Latch 39
SERVICE SCHEDULE 41
Chart 41
AIR CLEANER SERVICE 43
Daily Check 43
Replacing The Filter Elements 43
CAB FILTER 45
Cleaning And Maintenance (Early Models Only) 45
ENGINE COOLING SYSTEM 47
Cleaning 47
Checking Level 47
Removing And Replacing Coolant 48
FUEL SYSTEM 49
Fuel Specifications 49
Biodiesel Blend Fuel 49
Filling The Fuel Tank 50
Fuel Filters 50
Draining The Fuel Tank 51
Removing Air From The Fuel System 51
ENGINE LUBRICATION SYSTEM 53
Checking And Adding Engine Oil 53
Engine Oil Chart 53
Removing And Replacing Oil And Filter 54
HYDRAULIC SYSTEM 55
Checking And Adding Hydraulic Oil 55
Hydraulic / Hydrostatic Fluid Chart 56
Removing And Replacing The Hydraulic Filter 56
Removing And Replacing The Hydraulic Fluid 57
LUBRICATING THE EXCAVATOR 59
Lubrication Locations 59
TRAVEL MOTOR 63
Checking And Adding Oil 63
Removing And Replacing Oil 63
SPARK ARRESTER MUFFLER 65
Cleaning Procedure 65
ALTERNATOR BELT 67
Belt Adjustment (S/N AKY511001 – AKY511934) 67
Belt Adjustment (S/N AKY511935 & Above) 68
Belt Replacement 69
SEAT BELT 71
Inspection And Maintenance 71
CONTROL CONSOLE LOCKOUTS 73
Inspection And Maintenance 73
PIVOT PINS 75
Inspection And Maintenance 75
EXCAVATOR STORAGE AND RETURN TO SERVICE 77
Storage 77
Return To Service 77
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 79
Procedure 79
EMERGENCY EXIT 81
Right Side Rear Window 81
Front Window 81
REMOTE START TOOL KIT – MEL1563 83
Remote Start Tool – MEL1563 83
Service Tool Harness Communicator – MEL1566 85
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031 87
Description 87
Remote Start Tool (Service Tool) – 7003030 88
Excavator Service Tool Harness – 6689747 89
Computer Service Tool Harness – 6689746 90
HYDRAULIC SYSTEM 91
HYDRAULIC/HYDROSTATIC SCHEMATICS 97
HYDRAULIC SYSTEM INFORMATION 99
Glossary Of Hydraulic / Hydrostatic Symbols 99
Troubleshooting The Hydraulic Circuit 102
Troubleshooting The Cylinder Circuit 103
Troubleshooting The Swing (Upperstructure Slew) Circuit 104
Troubleshooting The Travel Circuit 105
CYLINDER (BOOM) 107
Testing 107
Removal And Installation 108
Parts Identification 111
Disassembly 112
Assembly 114
CYLINDER (ARM) 117
Testing 117
Removal And Installation 119
Parts Identification 121
Disassembly 122
Assembly 124
CYLINDER (BOOM SWING) 127
Testing 127
Removal And Installation 128
Parts Identification 130
Disassembly 131
Assembly 133
CYLINDER (BUCKET) 137
Testing 137
Removal And Installation 138
Parts Identification 140
Disassembly 141
Assembly 143
CYLINDER (BLADE) 147
Testing 147
Removal And Installation 148
Parts Identification 150
Disassembly 151
Assembly 153
CYLINDER (TRACK FRAME EXPANSION) 157
Testing 157
Removal And Installation 158
Parts Identification 162
Disassembly 163
Assembly 165
VALVE (MAIN RELIEF) 169
Testing And Adjusting 169
VALVES (PORT RELIEF) 173
Testing And Adjusting 173
VALVES (CROSSPORT RELIEF) 175
Testing And Adjusting 175
VALVE (PRESSURE REDUCING) 179
Testing And Adjusting 179
HYDRAULIC CONTROL VALVE 181
Description 181
Removal And Installation 181
Parts Identification 183
Disassembly 184
Right Travel Valve Section Disassembly And Assembly 185
Boom Swing Valve Section Disassembly And Assembly 189
Arm Valve Section Disassembly And Assembly 192
Bucket Valve Section Disassembly And Assembly 195
Auxiliary Valve Section Disassembly And Assembly 198
Boom Valve Section Disassembly And Assembly 203
Left Travel Valve Section Disassembly And Assembly 206
Swing (Slew) Valve Section Disassembly And Assembly 210
Blade Valve Section Disassembly And Assembly 213
Assembly 217
HYDRAULIC PUMP 223
Description 223
Torque Adjustment 223
Testing The Piston Pump 224
Testing The Gear Pump 226
Testing Auxiliary Hydraulic Flow 227
Removal And Installation 228
Parts Identification 231
Disassembly 232
Gear Pump Disassembly 233
Piston Pump Disassembly 235
Piston Pump Assembly 244
Gear Pump Assembly 253
Assembly 255
MANIFOLD ASSEMBLY / ACCUMULATOR 257
Description 257
Removal And Installation 257
Parts Identification 260
Disassembly 261
Assembly 272
ACCUMULATORS 283
Removal And Installation 283
TRAVEL MOTOR 285
Description 285
Removal And Installation 285
Parts Identification 286
Disassembly 287
Assembly 294
SWIVEL JOINT 303
Description 303
Removal And Installation 303
Parts Identification (S/N AKY511001 – AKY522000) 306
Parts Identification (S/N AKY522001- AKY523425) 307
Parts Identification (S/N AKY523426 & Above) 308
Disassembly 309
Assembly 311
SWING MOTOR 315
Description 315
Removal And Installation 315
Parts Identification 316
Disassembly 317
Assembly 323
CONTROL LEVER (JOYSTICK) (RIGHT) (S/N AKY511001 – AKY522621) 331
Description 331
Testing 331
Handle Removal And Installation 333
Removal And Installation 334
Parts Identification 336
Disassembly 337
Assembly 342
CONTROL LEVER (JOYSTICK) (RIGHT) (S/N AKY522622 & Above) 347
Description 347
Testing 347
Handle Removal And Installation 349
Removal And Installation 350
Parts Identification 352
Disassembly 353
Assembly 357
CONTROL LEVER (JOYSTICK) (LEFT) (S/N AKY511001 – AKY522621) 361
Description 361
Testing 361
Handle Removal And Installation 363
Removal And Installation 365
Parts Identification 366
Disassembly 367
Assembly 372
CONTROL LEVER (JOYSTICK) (LEFT) (S/N AKY522622 & Above) 377
Description 377
Testing 377
Handle Removal And Installation 379
Removal And Installation 381
Parts Identification 382
Disassembly 383
Assembly 387
HYDRAULIC FILTER MOUNT 391
Description 391
Removal And Installation 391
HYDRAULIC RESERVOIR 393
Description 393
Removal And Installation 393
OIL COOLER 395
Description 395
Removal And Installation 395
BLADE / TRACK EXPANSION SOLENOID BLOCK (S/N AKY511001 – AKY22000) 397
Description 397
Block Removal And Installation 397
Solenoid Removal And Installation 398
Block Disassembly And Assembly 399
BLADE / TRACK EXPANSION SOLENOID BLOCK (S/N AKY522001 & ABOVE) 401
Description 401
Block Removal And Installation 401
Solenoid Removal And Installation 402
Block Disassembly And Assembly 403
SLEW LOCK VALVE 405
Description 405
Removal And Installation 405
Parts Identification 407
Disassembly And Assembly 408
UNDERCARRIAGE 413
BLADE 415
Description 415
Extension Removal And Installation 415
Blade Removal And Installation 416
TRACKS 417
Track Lug Height 417
Track Tension Adjustment 417
Removal And Installation 420
TRACK FRAME 421
Disassembly And Assembly 421
Removal And Installation Of Expandable Track Frame 422
TRACK DAMAGE IDENTIFICATION 425
Cutting Of The Steel Cords 425
Causes Of The Damage 425
Abrasion Of Embedded Metals 426
Separation Of Embedded Metals 427
Separation Of Embedded Metals Due To Corrosion 428
Cuts On The Lug Side Rubber 429
Cracks On The Lug Side Rubber Due To Fatigue 430
Lug Abrasion 431
Cracks And Cuts On The Lug Side Rubber 432
Abrasion Of The Track Roller Side 433
Cuts On The Edges Of The Track Roller Side 434
TRACK IDLER 437
Parts Identification 437
Disassembly 438
Assembly 440
TRACK ROLLER 443
Parts Identification 443
Disassembly 444
Assembly 446
SWING CIRCLE GEAR 449
Removal And Installation 449
UPPERSTRUCTURE & SWING 451
UPPERSTRUCTURE 455
Description 455
Removal 455
Installation 457
ROPS CANOPY 459
Removal And Installation 459
CAB 463
Removal And Installation 463
Door Removal And Installation 467
Front Window Removal And Installation 468
Right Side Rear Sliding Window Removal And Installation 471
Right Side Front Sliding Window Removal And Installation 472
Glass Removal 472
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 473
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 473
Glass Installation 474
SEAT AND SEAT MOUNT (AKY511001 – AKY11934) 477
Seat Mount Removal And Installation 477
SEAT AND SEAT MOUNT (S/N AKY511935 & ABOVE) 479
Seat Mount Removal And Installation 479
RIGHT CONSOLE 481
Description 481
Joystick Console Cover (Bottom) Removal And Installation 481
Joystick Console Cover (Top) Removal And Installation 482
Joystick Console Cover (Top) Disassembly And Assembly 483
Compression Spring Removal And Installation (Canopy Only) 484
Compression Spring Disassembly And Assembly (Canopy Only) 485
Lever Removal And Installation (Canopy Only) 486
Joystick Console Frame Removal And Installation 488
Joystick Console Frame Disassembly And Assembly 489
Right Rear Console Cover Removal And Installation 490
Right Rear Console Cover Disassembly And Assembly 491
Right Rear Console Frame Removal And Installation 492
LEFT CONSOLE 495
Description 495
Joystick Console Cover (Bottom) Removal And Installation 495
Joystick Console Cover (Top) Removal And Installation 496
Compression Spring Removal And Installation 497
Compression Spring Disassembly And Assembly 498
Lever Removal And Installation 500
Joystick Console Frame Removal And Installation 501
Joystick Console Frame Disassembly And Assembly 502
Left Rear Console Cover Removal And Installation 502
Left Rear Console Frame Removal And Installation 503
ENGINE SPEED CONTROL 505
Removal And Installation 505
Cable Removal And Installation 506
BLADE CONTROL 509
Removal And Installation 509
Disassembly And Assembly 510
Cable Removal And Installation 512
UPPERSTRUCTURE SLEW LOCK 513
Removal And Installation 513
Disassembly And Assembly 513
RIGHT PEDAL 515
Removal And Installation 515
Disassembly And Assembly 515
TRAVEL CONTROLS 517
Removal And Installation 517
Disassembly And Assembly 517
LEFT PEDAL 519
Removal And Installation 519
Disassembly And Assembly 519
CONTROL LINKAGE ASSEMBLY 521
Description 521
Removal And Installation 521
Right Half Of Control Linkage Disassembly And Assembly 523
Left Half Of Control Linkage Disassembly And Assembly 525
Bracket Of Control Linkage Disassembly And Assembly 528
FLOOR MAT AND FLOOR PANELS 529
Description 529
Removal And Installation 529
FUEL TANK 531
Removal And Installation 531
HORN 533
Removal And Installation 533
SWING FRAME 535
Description 535
Removal And Installation 535
Bushing Removal And Installation 537
Swing Frame Bushing Removal 537
Swing Frame Bushing Installation 538
Boom Pivot Bushing Removal 539
Boom Pivot Bushing Installation 539
BOOM 541
Description 541
Removal And Installation 541
Boom Bushing Removal And Installation 543
ARM 545
Description 545
Removal And Installation 545
Arm To Boom Bushing Removal And Installation 546
Arm To Bucket And Bucket Link Bushing Removal And Installation 547
BUCKET 549
Removal And Installation 549
TAILGATE 551
Removal And Installation 551
Latch Removal And Installation 552
QUICK COUPLER (KLAC™ SYSTEM) 553
Troubleshooting 553
Daily Inspection 554
Removal And Installation 554
Parts Identification 556
Disassembly 557
Assembly 559
QUICK COUPLER (LEHNHOFF® SYSTEM) 561
Troubleshooting 561
Daily Inspection 561
Removal (MS03 And MS08) 562
Installation (MS03 And MS08) 563
Parts Identification (MS03) 564
Disassembly And Assembly (MS03) 565
Parts Identification (MS08) 566
Disassembly (MS08) 567
Assembly (MS08) 570
ELECTRICAL SYSTEM 575
ELECTRICAL SCHEMATICS 577
ELECTRICAL SYSTEM INFORMATION 578
Glossary Of Electrical Symbols 578
Troubleshooting 581
Description 582
Fuse And Relay Location / Identification 582
Fuel Timer And Diode Location / Identification 583
BATTERY 584
Servicing 584
Removal And Installation 585
Using A Booster Battery (Jump Starting) 586
ALTERNATOR 588
Description 588
Tests 588
Alternator Output Test 589
Full Field Test 589
Alternator Regulator Test 590
Alternator Regulator Test With Voltmeter 590
Removal And Installation 591
Belt Adjustment 592
Charging System Inspection 594
Parts Identification 595
STARTER 596
Removal And Installation 596
Parts Identification 597
Cleaning And Inspection 598
LIGHTS 600
Upperstructure Light Removal And Installation 600
Upperstructure Light Disassembly And Assembly 600
Boom Light Removal And Installation 601
Boom Light Disassembly And Assembly 601
Light Switch Removal And Installation 602
MICROSWITCH 604
Testing Left Console Microswitch 604
Left Console Microswitch Removal And Installation 605
Testing Right Console Microswitch 605
Right Console Microswitch Removal And Installation 607
TWO-SPEED BOOST SWITCH 608
Description 608
Removal And Installation 608
FUEL LEVEL SENDER 610
Removal And Installation 610
Testing 610
ENGINE 612
ENGINE INFORMATION 614
Description 614
Specifications 615
Crankshaft Re-Grind Data 619
Torque Values 620
Troubleshooting 621
Removal And Installation 622
Engine Mount Replacement 630
Engine Compression – Checking 631
SPARK ARRESTER MUFFLER 632
Removal And Installation 632
AIR CLEANER 634
Removal And Installation 634
ENGINE COOLING SYSTEM 636
Radiator Removal And Installation 636
Water Pump Removal And Installation 641
Water Pump Disassembly And Assembly 641
Thermostat Removal And Installation 642
Thermostat – Checking 642
LUBRICATION SYSTEM 644
Oil Pan Removal And Installation 644
Oil Pump Removal And Installation 645
Oil Pump – Service 645
Engine Oil Pressure – Testing 646
FUEL SYSTEM 648
Fuel Shutoff Solenoid Removal And Installation 648
Fuel Shutoff Timer Removal And Installation 648
Fuel Injection Pump – Checking 649
Fuel Injection Pump Removal And Installation 650
Fuel Injection Pump – Timing 652
Fuel Camshaft Removal And Installation 653
Fuel Camshaft Governor 654
Fuel Injector Removal And Installation 654
Fuel Injector Nozzle Pressure – Checking 655
CYLINDER HEAD 658
Glow Plug Removal And Installation 658
Valve Clearance Adjustment 659
Valve Timing – Checking 660
Cylinder Head Removal And Installation 660
Cylinder Head Disassembly And Assembly 662
Cylinder Head – Servicing 663
Cylinder Head Top Clearance 664
Valve Guide – Checking 664
Valve And Valve Seat Reconditioning 666
Valve Seat Tightness 667
Valve Spring 667
Valve Tappets 668
Rocker Arm And Shaft – Checking 669
CRANKSHAFT AND PISTONS 670
Piston And Connecting Rod Removal And Installation 670
Piston And Connecting Rod – Servicing 672
Cylinder Bore – Checking 674
Connecting Rod Alignment 675
Crankshaft Gear Removal And Installation 675
Crankshaft And Bearings Removal And Installation 676
Crankshaft And Bearings – Servicing 678
CAMSHAFT AND TIMING GEARS 682
Timing Gearcase Cover Removal And Installation 682
Timing Gears Checking Backlash 684
Idler Gear And Camshaft Removal And Installation 684
Idler Gear and Shaft – Servicing 687
FLYWHEEL AND HOUSING 688
Flywheel Housing Removal And Installation 688
Hydraulic Pump Coupler Removal And Installation 689
Flywheel Removal 690
Flywheel Installation 690
Rear End Plate Removal And Installation 691
HEATING, VENTILATION, AIR CONDITIONING 692
HEATER SYSTEM 694
Description 694
Components 694
REGULATORY MAINTENANCE 696
Filter Element Removal And Installation 696
Heater Coil 696
HEATER UNIT 698
Removal And Installation 698
Louver Removal And Installation 699
Threaded Insert Removal And Installation 699
HEATER COIL 700
Removal And Installation 700
HEATER FAN 704
Removal And Installation 704
HEATER VALVE 708
Removal And Installation 708
SPECIFICATIONS 710
324 SPECIFICATIONS 712
Machine Dimensions 712
Performance 714
Controls 714
Engine 715
Hydraulic System 715
Hydraulic Cylinders 716
Hydraulic Cycle Times 716
Electrical 716
Drive System 716
Slew System 716
Undercarriage 717
Capacities 717
Fuel Tank 717
Tracks 717
Ground Pressure 717
TECHNICAL SERVICE GUIDE SPECIFICATIONS 718
Engine 718
Engine Torques 718
Cooling System 718
Excavator Torques 718
TORQUE SPECIFICATIONS FOR BOLTS 720
Torque For General SAE Bolts 720
Torque For General Metric Bolts 721
HYDRAULIC CONNECTION SPECIFICATIONS 722
O-ring Face Seal Connection 722
Straight Thread O-ring Fitting 723
Tubelines And Hoses 723
Flare Fitting 724
Port Seal Fitting 725
HYDRAULIC FLUID SPECIFICATIONS 726
Specifications 726
CONVERSIONS 728
Decimal And Millimeter Equivalents 728
U S To Metric Conversion Chart 728
SERVICE TOOLS REQUIRED 730
Remote Start Tools 730
Hydraulic Tools 731
Engine Tools 733
HVAC Tools 735
ALPHABETICAL INDEX 736
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.M