Bobcat 324 Excavator Repair Service Manual - 6989593

(S/N: AKY511001 & Above) 
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This workshop repair service manual PDF download for the 324 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 Compact Excavator 324
S/N: AKY511001 & Above


TABLE OF CONTENTS :

SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM 
UNDERCARRIAGE 
UPPERSTRUCTURE & SWING 
ELECTRICAL SYSTEM 
ENGINE 
SPECIFICATIONS 
ALPHABETICAL INDEX 


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6989593 (2-10)
Total Pages : 647


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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Excavator Serial Number
        Engine Serial Number
    DELIVERY REPORT
    EXCAVATOR IDENTIFICATION
    
SAFETY & MAINTENANCE
    LIFTING AND BLOCKING THE EXCAVATOR
        Procedure
    UPPERSTRUCTURE SLEW LOCK
    LIFTING THE EXCAVATOR
        Procedure
    OPERATOR CAB (ROPS / TOPS)
        Description
        Cab Door
        Front Window
        Front Wiper
        Window Washer Reservoir
        Right Side Windows
        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 The Filter Elements
    CAB FILTER
        Cleaning And Maintenance
    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 Hydraulic Oil
        Hydraulic / Hydrostatic Fluid Chart
        Removing And Replacing The Hydraulic Filter
        Removing And Replacing The Hydraulic Fluid
    LUBRICATING THE EXCAVATOR
        Lubrication Locations
    TRAVEL MOTOR
        Checking Oil Level
        Draining The Drive Motor
    SPARK ARRESTER MUFFLER
        Cleaning Procedure
    ALTERNATOR BELT
        Belt Adjustment
        Belt Replacement
    SEAT BELT
        Inspection And Maintenance
    CONTROL CONSOLE LOCKOUTS
        Inspection And Maintenance
    PIVOT PINS
        Inspection And Maintenance
    EXCAVATOR STORAGE AND RETURN TO SERVICE
        Storage
        Return to Service
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
        Procedure
    EMERGENCY EXIT
        Right Side Rear Window
        Front Window
        
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
        Parts Identification
        Disassembly
        Right Travel Valve Section Disassembly And Assembly
        Boom Swing Valve Section Disassembly And Assembly
        Arm Valve Section Disassembly and Assembly
        Bucket Valve Section Disassembly And Assembly
        Auxiliary Valve Section Disassembly And Assembly
        Boom Valve Section Disassembly And Assembly
        Left Travel Valve Section Disassembly And Assembly
        Swing (Slew) Valve Section Disassembly And Assembly
        Blade Valve Section Disassembly And Assembly
        Assembly
    HYDRAULIC PUMP
        Description
        Torque Adjustment
        Testing The Piston Pump
        Testing The Gear Pump
        Testing Auxiliary Hydraulic Flow
        Removal And Installation
        Parts Identification
        Disassembly
        Gear Pump Disassembly
        Piston Pump Disassembly
        Piston Pump Assembly
        Gear Pump Assembly
        Assembly
    MANIFOLD ASSEMBLY / ACCUMULATOR
        Description
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    ACCUMULATORS
        Removal And Installation
    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 MOUNT
        Description
        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
    SLEW LOCK VALVE
        Description
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        
UNDERCARRIAGE
    BLADE
        Description
        Extension Removal And Installation
        Blade Removal And Installation
    TRACKS
        Track Lug Height
        Track Tension Adjustment
        Removal And Installation
    TRACK FRAME
        Disassembly And Assembly
        Removal And Installation Of Expandable Track Frame
    TRACK DAMAGE IDENTIFICATION
        Cutting Of The Steel Cords
        Causes Of The Damage
        Abrasion Of Embedded Metals
        Separation Of Embedded Metals
        Separation Of Embedded Metals Due To Corrosion
        Cuts On The Lug Side Rubber
        Cracks On The Lug Side Rubber Due To Fatigue
        Lug Abrasion
        Cracks And Cuts On The Lug Side Rubber
        Abrasion Of The Track Roller Side
        Cuts On The Edges Of The Track Roller Side
    TRACK IDLER
        Parts Identification
        Disassembly
        Assembly
    TRACK ROLLER
        Parts Identification
        Disassembly
        Assembly
    SWING CIRCLE GEAR
        Removal and Installation
        
UPPERSTRUCTURE & SWING
    UPPERSTRUCTURE
        Description
        Removal
        Installation
    ROPS CANOPY
        Removal And Installation
    CAB
        Removal And Installation
        Door Removal And Installation
        Front Window Removal And Installation
        Right Side Rear Sliding Window Removal And Installation
        Right Side Front Sliding Window Removal And Installation
        Glass Removal
        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
    ENGINE SPEED CONTROL
        Removal and Installation
        Cable Removal and Installation
    BLADE CONTROL
        Removal and Installation
        Disassembly And Assembly
        Cable Removal and Installation
    UPPERSTRUCTURE SLEW LOCK
        Removal And Installation
        Disassembly And Assembly
    RIGHT PEDAL
        Removal And Installation
        Disassembly And Assembly
    TRAVEL CONTROLS
        Removal And Installation
        Disassembly And Assembly
    LEFT PEDAL
        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
        Removal And Installation
    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
    ELECTRICAL SCHEMATIC
    ELECTRICAL SYSTEM INFORMATION
        Glossary Of Electrical Symbols
        Troubleshooting
        Description
        Fuse And Relay Location / Identification
        Fuel Timer And Diode Location / Identification
    BATTERY
        Servicing
        Removal And Installation
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Description
        Tests
        Alternator Output Test
        Full Field Test
        Alternator Regulator Test
        Alternator Regulator Test With Voltmeter
        Removal And Installation
        Belt Adjustment
        Charging System Inspection
        Parts Identification
    STARTER
        Removal And Installation
        Parts Identification
        Cleaning And Inspection
    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
    TWO-SPEED BOOST SWITCH
        Description
        Removal And Installation
    FUEL LEVEL SENDER
        Removal And Installation
        Testing
        
ENGINE
    TROUBLESHOOTING
        Chart
    SPARK ARRESTOR MUFFLER
        Removal And Installation
    AIR CLEANER
        Removal And Installation
    RADIATOR
        Removal And Installation
    ENGINE COMPONENTS AND TESTING
        Valve Clearance Adjustment
        Engine Compression Checking
        Fuel Shutoff Solenoid - Checking
        Fuel Shutoff Solenoid Removal And Installation
        Fuel Shutoff Timer Removal And Installation
        Fuel Injection Pump Check
        Fuel Injection Pump Removal And Installation
        Fuel Injection Pump Timing
        Fuel Injector Removal And Installation
        Fuel Injector Checking
        Glow Plug Removal And Installation
    ENGINE
        Description
        Engine Removal and Installation
        Engine Mount Replacement
    FLYWHEEL AND HOUSING
        Flywheel Housing Removal And Installation
        Hydraulic Pump Coupler Removal And Installation
        Flywheel Removal
        Flywheel Installation
        Rear End Plate Removal And Installation
    RECONDITIONING THE ENGINE
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head, Servicing
        Cylinder Head Top Clearance
        Valve Guide, Checking
        Valve Timing, Checking
        Valve And Valve Seat Reconditioning
        Valve Seat Tightness
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft, Checking
        Timing Gearcase Cover Removal And Installation
        Idler Gear And Camshaft Removal And Installation
        Idler Gear and Shaft, Servicing
        Timing Gears Checking Backlash
        Fuel Camshaft Removal And Installation
        Fuel Camshaft Governor
        Crankshaft Gear Removal And Installation
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump, Service
        Engine Oil Pressure, Checking
        Relief Valve
        Piston And Connecting Rod Removal And Installation
        Piston And Connecting Rod, Servicing
        Connecting Rod Alignment
        Crankshaft And Bearings Removal And Installation
        Crankshaft And Bearings, Servicing
        Cylinder Bore, Checking
        Water Pump Removal And Installation
        Water Pump Disassembly And Assembly
        Thermostat Removal And Installation
        Testing The Thermostat
    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
    EXCAVATOR SPECIFICATIONS
        324 Excavator Machine Dimensions
        324 Excavator Machine Dimensions - Standard Arm
        324 Excavator Machine Dimensions - Long Arm
        Performance
        Controls
        Engine
        Hydraulic System
        Hydraulic Cylinders
        Hydraulic Cycle Times
        Electrical
        Drive System
        Slew System
        Undercarriage
        Capacities
        Tracks
        Ground Pressure
    ENGINE 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
        Engine Bolt Torque
    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
        
ALPHABETICAL INDEX

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