A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• ALPHABETICAL INDEX
• CONTENTS
• FOREWORD
• SAFETY INSTRUCTIONS
• Before Operation
• Safe Operation Is The Operator’s Responsibility
• Safe Operation Needs A Qualified Operator
• Avoid Silica Dust
• 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
• BOBCAT EXCAVATOR IDENTIFICATION
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE EXCAVATOR
• Procedure
• UPPERSTRUCTURE SLEW LOCK
• LIFTING THE EXCAVATOR
• OPERATOR CAB ROPS/TOPS (IF EQUIPPED)
• Emergency Exits
• Cab Door
• Front Window Wiper
• Window Washer Reservoir
• Front Window
• Right Side Windows
• TRANSPORTING THE EXCAVATOR
• TAILGATE
• Opening And Closing The Tailgate
• Adjusting The Bumper
• Adjusting The Tailgate Latch
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Daily Check
• Replacing The Filters
• HEATER AIR FILTERS
• Recirculation Filter
• Fresh Air Filter
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking Coolant Level
• Replacing The Coolant
• FUEL SYSTEM
• Fuel Specifications
• Biodiesel Blend Fuel
• Filling The Fuel Tank
• Removing Water From The Fuel Filter
• Replacing The Fuel Filter
• Draining The Fuel Tank
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Oil Chart
• Replacing Oil And Filter
• HYDRAULIC SYSTEM
• Checking And Adding Hydraulic Oil
• Hydraulic Fluid Chart
• Diagnostic Couplers
• Replacing The Hydraulic Filter
• Replacing Hydraulic Oil
• LUBRICATION OF THE HYDRAULIC EXCAVATOR
• TRAVEL MOTOR
• Checking Oil Level
• Draining The Travel Motor
• SPARK ARRESTOR MUFFLER
• ALTERNATOR BELT
• Adjusting The Alternator Belt
• SEAT BELT
• Inspection And Maintenance
• CONTROL CONSOLE LOCKOUTS
• Inspection And Maintenance
• EXCAVATOR STORAGE AND RETURN TO SERVICE
• Storage
• Return to Service
• STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
• Procedure
• Emergency Exits
• MOTION ALARM SYSTEM (IF EQUIPPED)
• Description
• Inspecting
• Adjusting Switch Position
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
• 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 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
• Hydraulic Pump Start Up
• 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
• 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
• CONTROL PATTERN SELECTOR VALVE
• 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
• Removal And Installation
• HYDRAULIC RESERVOIR
• Removal And Installation
• OIL COOLER
• Description
• Removal And Installation
• BLADE/TRACK EXPANSION SOLENOID BLOCK
• Block Removal And Installation
• Solenoid Removal And Installation
• Block Disassembly And Assembly
• UNDERCARRIAGE
• BLADE
• 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 SECTION
• 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
• Glass Installation
• SEAT AND SEAT MOUNT
• Removal And Installation
• RIGHT CONSOLE
• Description
• Console Cover Removal And Installation (Cab)
• Console Cover Removal And Installation (ROPS Canopy)
• Gas Spring Removal And Installation (ROPS Canopy)
• Lock Lever Removal And Installation (ROPS Canopy)
• Adjustment (ROPS Canopy Models)
• Latch Hook Removal And Installation (ROPS Canopy)
• Latch Hook Disassembly And Assembly (ROPS Canopy)
• Cab Models
• Upper Console Removal And Installation
• Console Base Removal And Installation
• LEFT CONSOLE
• Description
• Console Cover Removal And Installation
• Gas Spring Removal And Installation
• Lock Lever Removal And Installation
• Adjustment
• Latch Hook Removal And Installation
• Latch Hook Disassembly And Assembly
• Upper Console Removal And Installation
• Console Base Removal And Installation
• ENGINE SPEED CONTROL
• Removal And Installation
• Engine Speed Control Cable Removal And Installation
• BLADE CONTROL
• Removal And Installation
• Disassembly And Assembly
• SWING LOCK
• Removal and Installation
• RIGHT PEDAL AND LINKAGE
• Description
• Right Pedal Removal And Installation
• Disassembly And Assembly
• Linkage Removal And Installation
• Linkage Disassembly And Assembly
• TRAVEL CONTROLS
• Description
• Removal And Installation
• Disassembly And Assembly
• LEFT PEDAL
• Removal And Installation
• Disassembly And Assembly
• CONTROL LINKAGE ASSEMBLY
• Removal And Installation
• Left Pedal Linkage Disassembly And Assembly
• Right Travel Control Linkage Disassembly And Assembly
• Left Travel Control Linkage Disassembly And Assembly
• Left Pedal Bellcrank Disassembly And Assembly
• Linkage Rod Removal And Installation
• Linkage Rod Adjustment
• FLOOR MAT AND FLOOR PANELS
• Description
• Removal And Installation
• BLADE EXTENSION TRAY
• Removal And Installation
• FUEL TANK
• Removal And Installation
• HORN
• Removal And Installation
• SWING FRAME
• Description
• Removal And Installation
• Bushing Replacement
• Swing Frame Bushing Removal
• Swing Frame Bushing Installation
• Boom Pivot Bushing Removal And 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
• Troubleshooting Chart
• Description
• Fuses
• Relays And Diodes
• BATTERY
• Servicing
• Removing And Installing The Battery
• 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
• Parts Identification
• Disassembly And Assembly
• STARTER
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Cleaning And Inspection
• LIGHTS
• Uppestructure Light Removal And Installation
• Uppestructure Light Disassembly And Assembly
• Boom Light Removal And Installation
• Boom Light Bulb Replacement
• Light Switch Removal And Installation
• MICROSWITCH
• Adjustment
• Testing
• Removal And Installation
• TWO-SPEED SWITCH
• Removal And Installation
• FUEL LEVEL SENDER
• Removal And Installation
• Testing
• TWO-SPEED BOOST SWITCH
• Description
• Removal And Installation
• ENGINE SERVICE
• 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 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
• Removal And Installation
• ENGINE FLYWHEEL
• Removal And Installation
• Hydraulic Pump Coupler Removal And Installation
• Hydraulic Pump Coupler Disassembly And Assembly
• Flywheel Ring Gear
• RECONDITIONING THE ENGINE
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head, Servicing
• Cylinder Head Top Clearance
• Valve Guide, Checking
• Valve And Valve Seat Reconditioning
• Valve Spring
• 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 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
• HEATER
• HEATER
• Description
• Removal And Installation
• SPECIFICATIONS
• SPECIFICATIONS
• 323 Excavator Machine Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Hydraulic Cylinders
• Hydraulic Cycle Times
• Electrical System
• Instrumentation
• Drive System
• Slew System
• Undercarriage
• Crawler Track Design
• 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
• Crankshaft Re-Grind Data
• TORQUE SPECIFICATIONS
• 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
• O-Ring Flare Fitting
• Port Seal Fitting
• HYDRAULIC FLUID SPECIFICATIONS
• Specifications
• FUEL, COOLANT AND LUBRICANTS
• Chart
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion