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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