Bobcat 319 Compact Excavator Repair Service Manual - 6904188

(S/N: 563311001 & Above) 
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This workshop repair service manual PDF download for the 319 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Excavator 319
S/N: 563311001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT
EXCAVATOR IDENTIFICATION 
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM 
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION 
ELECTRICAL SYSTEM AND ANALYSIS 
ENGINE SERVICE 
HEATER 
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6904188 (2-06)
Total Pages : 602


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
        Fire Prevention
    SERIAL NUMBER LOCATIONS
        Excavator Serial Number
        Engine Serial Number
    DELIVERY REPORT
    EXCAVATOR IDENTIFICATION
    
SAFETY AND MAINTENANCE
    LIFTING AND BLOCKING THE EXCAVATOR
        Procedure
    UPPERSTRUCTURE SLEW LOCK
        Operation
    LIFTING THE EXCAVATOR
        Procedure
    OPERATOR CAB (ROPS / TOPS)
        Description
        Cab Door
        Front Window
        Front Wiper
        Window Washer Reservoir
        Right Side Window
        Heater
    TRANSPORTING THE EXCAVATOR ON A TRAILER
        Loading And Unloading
        Fastening
    TAILGATE
        Opening And Closing
        Adjusting The Bumper
        Adjusting The Latch
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Daily Check
        Replacing Filter Elements
    ENGINE COOLING SYSTEM
        Cleaning
        Checking Level
        Removing And Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filters
        Draining The Fuel Tank
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking And Adding Engine Oil
        Engine Oil Chart
        Removing And Replacing Oil And Filter
    HYDRAULIC SYSTEM
        Checking And Adding Fluid
        Hydraulic Fluid Chart
        Removing And Replacing Hydraulic Filter
        Removing And Replacing Hydraulic Fluid
    LUBRICATING THE EXCAVATOR
        Lubrication Locations
    TRAVEL MOTOR
        Checking And Adding Oil
        Removing And Replacing Oil
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    ALTERNATOR BELT
        Belt Adjustment
        Belt Replacement
    SEAT BELT
        Inspection And Maintenance
    PIVOT PINS
        Inspection And Maintenance
    EXCAVATOR STORAGE AND RETURN TO SERVICE
        Storage
        Return to Service
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
        Procedure
        Emergency Exits
        
HYDRAULIC SYSTEM
    HYDRAULIC/HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary Of Hydraulic / Hydrostatic Symbols
        Troubleshooting The Hydraulic Circuit
        Troubleshooting The Cylinder Circuit
        Troubleshooting The Swing (Upperstructure Slew) Circuit
        Troubleshooting The Travel Circuit
    BOOM CYLINDER
        Testing
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    ARM CYLINDER
        Testing
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    BOOM SWING CYLINDER
        Testing
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    BUCKET CYLINDER
        Testing
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    BLADE CYLINDER
        Testing
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    TRACK FRAME EXPANSION CYLINDER
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE
        Testing And Adjusting The Main Relief Valve
    PORT RELIEF VALVES
        Testing And Adjusting The Port Relief Valve Pressure
    CROSSPORT RELIEF VALVES
        Testing And Adjusting The Crossport Relief Valve
    PRESSURE REDUCING VALVE
        Testing And Adjusting The Pressure Reducing Valve
    HYDRAULIC CONTROL VALVE
        Description
        Removal and Installation
        Identification Chart
        Disassembly
        Blade Valve Section Disassembly And Assembly
        Slew Valve Section Disassembly And Assembly
        Left Travel Valve Section Disassembly and Assembly
        Boom Valve Section Disassembly and Assembly
        Auxiliary Valve Section Disassembly And Assembly
        Bucket Valve Section Disassembly and Assembly
        Arm Valve Section Disassembly and Assembly
        Boom Swing Valve Section Disassembly And Assembly
        Right Travel Valve Section Disassembly And Assembly
        Assembly
    HYDRAULIC PUMP
        Description
        Testing The Hydraulic Pump
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    MANIFOLD ASSEMBLY/ACCUMULATOR
        Description
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    TRAVEL MOTOR
        Description
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    SWIVEL JOINT
        Description
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    SWING MOTOR
        Description
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    RIGHT CONTROL LEVER (JOYSTICK)
        Description
        Testing
        Handle Removal And Installation
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    LEFT CONTROL LEVER (JOYSTICK)
        Description
        Testing
        Handle Removal And Installation
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    HYDRAULIC FILTER
        Description
        Housing Removal and Installation
    HYDRAULIC RESERVOIR
        Description
        Removal and Installation
    OIL COOLER
        Description
        Removal And Installation
    BLADE/TRACK EXPANSION SOLENOID BLOCK
        Description
        Block Removal and Installation
        Solenoid Removal and Installation
        Block Disassembly And Assembly
        
UNDERCARRIAGE
    BLADE
        Description
        Extension Removal And Installation
        Blade Removal And Installation
    TRACK FRAME COMPONENTS
        Description
        Track Lug Height
        Checking Tension
        Adjusting Tension
        Track Removal And Installation
        Idler (Front) Removal And Installation
        Idler (Front) Parts Identification
        Idler (Front) Disassembly
        Idler (Front) Assembly
        Track Tension Grease Cylinder Parts Identification
        Track Tension Grease Cylinder Disassembly And Assembly
        Roller Removal And Installation
        Roller Parts Identification
        Roller Disassembly
        Roller Assembly
        Track Guide Removal And Installation
        Sprocket Removal And Installation
        Frame Removal And Installation
        Track Damage Identification
    SWING CIRCLE GEAR
        Removal and Installation
        
UPPERSTRUCTURE & SWING SECTION
    UPPERSTRUCTURE
        Description
        Removal
        Installation
    CANOPY
        Removal And Installation
    CAB
        Removal And Installation
        Door Removal And Installation
        Front Window Removal And Installation
        Right Side Rear Sliding Window Removal And Installation
        Right Side Front Sliding Window Removal And Installation
        Glass Removal
        Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
        Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
        Glass Installation
    SEAT AND SEAT MOUNT
        Seat Mount Removal And Installation
    RIGHT CONSOLE
        Description
        Joystick Console Cover (Bottom) Removal And Installation
        Joystick Console Cover (Top) Removal And Installation
        Joystick Console Cover (Top) Disassembly And Assembly
        Compression Spring Removal And Installation (Canopy Only)
        Compression Spring Disassembly And Assembly (Canopy Only)
        Lever Removal And Installation (Canopy Only)
        Joystick Console Frame Removal And Installation
        Joystick Console Frame Disassembly And Assembly
        Right Rear Console Cover Removal And Installation
        Right Rear Console Cover Disassembly and Assembly
        Right Rear Console Frame Removal And Installation
    LEFT CONSOLE
        Description
        Joystick Console Cover (Bottom) Removal And Installation
        Joystick Console Cover (Top) Removal And Installation
        Compression Spring Removal And Installation
        Compression Spring Disassembly And Assembly
        Lever Removal And Installation
        Joystick Console Frame Removal And Installation
        Joystick Console Frame Disassembly And Assembly
        Left Rear Console Cover Removal And Installation
        Left Rear Console Frame Removal And Installation
    BLADE CONTROL
        Removal and Installation
        Disassembly And Assembly
        Cable Removal and Installation
    UPPERSTRUCTURE SLEW LOCK
        Removal and Installation
        Disassembly And Assembly
    CONTROL LINKAGE ASSEMBLY
        Description
        Removal And Installation
        Right Half of Control Linkage Disassembly And Assembly
        Left Half of Control Linkage Disassembly And Assembly
        Bracket of Control Linkage Disassembly And Assembly
    FLOOR MAT AND FLOOR PANELS
        Description
        Rear Floor Panel Removal and Installation
        Front Floor Panel Removal and Installation
        Linkage Rod Removal And Installation
        Linkage Rod Adjustment
        Boom Swing Pedal Removal And Installation
        Boom Swing Pedal Disassembly And Assembly
        Right Travel Lever Removal And Installation
        Right Travel Lever Disassembly And Assembly
        Left Travel Lever Removal And Installation
        Left Travel Lever Disassembly And Assembly
        Auxiliary Pedal Removal And Installation (If Equipped)
        Auxiliary Pedal Disassembly And Assembly (If Equipped)
        Auxiliary Pedal Disassembly And Assembly (If Equipped)
    FUEL TANK
        Removal and Installation
    HORN
        Removal and Installation
    SWING FRAME
        Description
        Removal And Installation
        Bushing Removal and Installation
        Swing Frame Bushing Removal
        Swing Frame Bushing Installation
        Boom Pivot Bushing Removal
        Boom Pivot Bushing Installation
    BOOM
        Description
        Removal And Installation
        Boom Bushing Removal And Installation
    ARM
        Description
        Removal And Installation
        Arm To Boom Bushing Removal And Installation
        Arm To Bucket And Bucket Link Bushing Removal And Installation
    BUCKET
        Removal And Installation
    TAILGATE
        Removal And Installation
        Latch Removal And Installation
        
ELECTRICAL SYSTEM AND ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Glossary Of Electrical Symbols
        Troubleshooting
        Description
        Fuse And Relay Location / Identification
        Fuel Timer And Diode Location / Identification
    BATTERY
        Removal and Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Belt Adjustment
        Charging System Inspection
        Description
        Tests
        Alternator Output Test
        Full Field Test
        Alternator Regulator Test
        Alternator Regulator Test With Voltmeter
        Removal And Installation
        Parts Identification
    STARTER
        Removal And Installation
        Parts Identification
    LIGHTS
        UpperStructure Light Removal And Installation
        UpperStructure Light Disassembly and Assembly
        Boom Light Removal And Installation
        Boom Light Disassembly And Assembly
        Light Switch Removal And Installation
    MICROSWITCH
        Testing Left Console Microswitch
        Left Console Microswitch Removal And Installation
        Testing Right Console Microswitch
        Right Console Microswitch Removal And Installation
    FUEL LEVEL SENDER
        Testing
        Removal and Installation
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Specifications
        Engine
        Fuel Injector Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Rocker Arms
        Camshaft
        Cylinders
        Piston Rings
        Pistons
        Connecting Rods
        Crankshaft
        Oil Pump
        Thermostat
        Torque Values
        Troubleshooting
        Engine Removal and Installation
        Engine Mount Replacement
        Compression - Checking
    ENGINE SPEED CONTROL
        Removal and Installation
        Cable Removal and Installation
    SPARK ARRESTOR MUFFLER
        Removal And Installation
    AIR CLEANER
        Housing Removal And Installation
    ENGINE COOLING SYSTEM
        Radiator Removal And Installation
        Water Pump Removal And Installation
        Water Pump Disassembly And Assembly
        Thermostat Removal And Installation
        Testing The Thermostat
    LUBRICATION SYSTEM
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Inspection
        Engine Oil Pressure - Testing
        Relief Valve
    FUEL SYSTEM
        Fuel Camshaft Removal And Installation
        Fuel Camshaft Governor Disassembly And Assembly
        Fuel Shutoff Solenoid - Checking
        Fuel Shutoff Solenoid - Removal And Installation
        Fuel Shutoff Timer Removal And Installation
        Fuel Injection Pump - Checking
        Fuel Injection Pump Removal And Installation
        Injection Pump - Timing
        Fuel Injector Removal And Installation
        Fuel Injector Nozzle Pressure - Checking
        Nozzle Spray Condition
        Valve Seat Tightness
    CYLINDER HEAD
        Glow Plug Removal And Installation
        Glow Plugs - Testing
        Valve Clearance Adjustment
        Valve Timing, Checking
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head - Servicing
        Cylinder Head Top Clearance
        Valve Guide - Checking
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft - Checking
    CRANKSHAFT AND PISTONS
        Piston And Connecting Rod Removal And Installation
        Piston And Connecting Rod - Servicing
        Cylinder Bore Checking
        Connecting Rod Alignment
        Crankshaft Gear Removal And Installation
        Crankshaft And Bearings Removal And Installation
        Crankshaft And Bearings - Servicing
    CAMSHAFT AND TIMING GEARS
        Timing Gearcase Cover Removal And Installation
        Timing Gears Backlash - Checking
        Idler Gear And Shaft Removal And Installation
        Camshaft - Servicing
        Idler Gear And Shaft Servicing
    FLYWHEEL AND HOUSING
        Flywheel Housing Removal And Installation
        Hydraulic Pump Coupler Removal And Installation
        Flywheel Removal
        Flywheel Installation
        Rear End Plate Removal And Installation
        
HEATER
    HEATER SYSTEM
        Description
        Components
    REGULATOR MAINTENANCE
        Filter Element Removal And Installation
        Heater Coil
    HEATER UNIT
        Removal And Installation
        Louver Removal and Installation
        Threaded Insert Removal And Installation
    HEATER COIL
        Removal And Installation
    HEATER FAN
        Removal And Installation
    HEATER VALVE
        Removal And Installation
        
SPECIFICATIONS
    319 EXCAVATOR SPECIFICATIONS
        Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Hydraulic Cylinders
        Hydraulic Cycle Times
        Electrical
        Instrumentation
        Drive System
        Slew System
        Undercarriage
        Crawler Track Design
        Capacities
        Fuel Tank
        Tracks
        Type
        Ground Pressure
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O-ring Face Seal Connection
        Straight Thread O-ring Fitting
        Tubelines And Hoses
        Flare Fitting
        Port Seal Fitting
    HYDRAULIC FLUID SPECIFICATIONS
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalents
        U.S. To Metric Conversion Chart
        
SERVICE MANUAL REVISION
    319-1
    
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