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Bobcat 324 Excavator Service Manual (SN AKY511001-AKY599999)

Format: PDF (Printable Document)

File Language: English

File Pages: 737

File Size: 20.41 MB (Speed Download Link)

Brand: Bobcat

Model: 324 Excavator

Book No: 6989593

Serial No: SN AKY511001-AKY599999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat 324 Excavator Service Manual (SN AKY511001-AKY599999)

Out on a small place, this 324 is the machine that digs water lines, cleans ditches, and does the tight work around buildings where a big excavator won't fit. The service manual is what you grab when a boom cylinder starts leaking, the travel motor gets weak, or an electrical gremlin kills your workday. Folks who buy it are usually owner-operators, farm mechanics, or small shops that want the same info the dealer techs use. The goal is simple: fix it right over a weekend and get back to work Monday.

What this manual helps you do

  • Diagnose weak digging or travel by checking hydraulic pressures and flow step by step
  • Trace electrical faults using wiring diagrams so you can chase down dead circuits and bad sensors
  • Follow teardown and reassembly procedures for cylinders, swing motor, and drive components
  • Adjust controls, linkages, and track tension so the machine runs smooth and straight
  • Replace engine and hydraulic components with the right sequences and torque references

Who this is for

This is for anyone working on a Bobcat 324 compact excavator with a serial number between AKY511001 and AKY599999. If you just need to learn the controls or basic maintenance, you want the operator's handbook instead, not this shop manual.

FAQ

Q: Is this a searchable PDF and are the wiring diagrams readable?

A: Yes, it's typically a searchable PDF and the wiring diagrams are laid out so you can zoom in and follow circuits.

Q: How do I know if it fits my exact 324?

A: Check your serial plate. If your 324 starts with AKY and falls between AKY511001 and AKY599999, this is the right one.

Q: Is this the right thing for basic service like fluids and grease points?

A: It covers that, but it's aimed at repairs. For simple daily and 50/250-hour service, the operator's manual is easier to use.

Bottom line, if your 324's serial number is in that AKY511001-AKY599999 range and you're planning real repairs, this is the manual you want.

📘 Show Index

Table of Contents:

  • MAINTENANCE SAFETY
  • CONTENTS
  • FOREWORD
    • FOREWORD
    • SAFETY INSTRUCTIONS
    • FIRE PREVENTION
      • Maintenance
      • Operation
      • Electrical
      • Hydraulic System
      • Fueling
      • Starting
      • Spark Arrester 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 Canopy (ROPS / TOPS)
      • Description
    • 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 (Early Models Only)
    • ENGINE COOLING SYSTEM
      • Cleaning
      • Checking Level
      • Removing And Replacing Coolant
    • FUEL SYSTEM
      • Fuel Specifications
      • Biodiesel Blend Fuel
      • 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 And Adding Oil
      • Removing And Replacing Oil
    • SPARK ARRESTER MUFFLER
      • Cleaning Procedure
    • ALTERNATOR BELT
      • Belt Adjustment (S/N AKY511001 – AKY511934)
      • Belt Adjustment (S/N AKY511935 & Above)
      • 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
    • REMOTE START TOOL KIT – MEL1563
      • Remote Start Tool – MEL1563
      • Service Tool Harness Communicator – MEL1566
    • REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
      • Description
      • Remote Start Tool (Service Tool) – 7003030
      • Excavator Service Tool Harness – 6689747
      • Computer Service Tool Harness – 6689746
  • 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
    • CYLINDER (BOOM)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CYLINDER (ARM)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CYLINDER (BOOM SWING)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CYLINDER (BUCKET)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CYLINDER (BLADE)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CYLINDER (TRACK FRAME EXPANSION)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • VALVE (MAIN RELIEF)
      • Testing And Adjusting
    • VALVES (PORT RELIEF)
      • Testing And Adjusting
    • VALVES (CROSSPORT RELIEF)
      • Testing And Adjusting
    • VALVE (PRESSURE REDUCING)
      • Testing And Adjusting
    • 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 (S/N AKY511001 – AKY522000)
      • Parts Identification (S/N AKY522001- AKY523425)
      • Parts Identification (S/N AKY523426 & Above)
      • Disassembly
      • Assembly
    • SWING MOTOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL LEVER (JOYSTICK) (RIGHT) (S/N AKY511001 – AKY522621)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL LEVER (JOYSTICK) (RIGHT) (S/N AKY522622 & Above)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL LEVER (JOYSTICK) (LEFT) (S/N AKY511001 – AKY522621)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL LEVER (JOYSTICK) (LEFT) (S/N AKY522622 & Above)
      • 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 (S/N AKY511001 – AKY22000)
      • Description
      • Block Removal And Installation
      • Solenoid Removal And Installation
      • Block Disassembly And Assembly
    • BLADE / TRACK EXPANSION SOLENOID BLOCK (S/N AKY522001 & ABOVE)
      • 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 (AKY511001 – AKY11934)
      • Seat Mount Removal And Installation
    • SEAT AND SEAT MOUNT (S/N AKY511935 & ABOVE)
      • 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
    • QUICK COUPLER (KLAC™ SYSTEM)
      • Troubleshooting
      • Daily Inspection
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • QUICK COUPLER (LEHNHOFF® SYSTEM)
      • Troubleshooting
      • Daily Inspection
      • Removal (MS03 And MS08)
      • Installation (MS03 And MS08)
      • Parts Identification (MS03)
      • Disassembly And Assembly (MS03)
      • Parts Identification (MS08)
      • Disassembly (MS08)
      • Assembly (MS08)
  • ELECTRICAL SYSTEM
    • ELECTRICAL SCHEMATICS
    • 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
    • ENGINE INFORMATION
      • Description
      • Specifications
      • Crankshaft Re-Grind Data
      • Torque Values
      • Troubleshooting
      • Removal And Installation
      • Engine Mount Replacement
      • Engine Compression – Checking
    • SPARK ARRESTER MUFFLER
      • Removal And Installation
    • AIR CLEANER
      • Removal And Installation
    • ENGINE COOLING SYSTEM
      • Radiator Removal And Installation
      • Water Pump Removal And Installation
      • Water Pump Disassembly And Assembly
      • Thermostat Removal And Installation
      • Thermostat – Checking
    • LUBRICATION SYSTEM
      • Oil Pan Removal And Installation
      • Oil Pump Removal And Installation
      • Oil Pump – Service
      • Engine Oil Pressure – Testing
    • FUEL SYSTEM
      • Fuel Shutoff Solenoid Removal And Installation
      • Fuel Shutoff Timer Removal And Installation
      • Fuel Injection Pump – Checking
      • Fuel Injection Pump Removal And Installation
      • Fuel Injection Pump – Timing
      • Fuel Camshaft Removal And Installation
      • Fuel Camshaft Governor
      • Fuel Injector Removal And Installation
      • Fuel Injector Nozzle Pressure – Checking
    • CYLINDER HEAD
      • Glow Plug Removal And Installation
      • 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
      • Valve And Valve Seat Reconditioning
      • Valve Seat Tightness
      • 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 Checking Backlash
      • Idler Gear And Camshaft Removal And Installation
      • 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
  • HEATING, VENTILATION, AIR CONDITIONING
    • HEATER SYSTEM
      • Description
      • Components
    • REGULATORY 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
    • 324 SPECIFICATIONS
      • Machine Dimensions
      • Performance
      • Controls
      • Engine
      • Hydraulic System
      • Hydraulic Cylinders
      • Hydraulic Cycle Times
      • Electrical
      • Drive System
      • Slew System
      • Undercarriage
      • Capacities
      • Fuel Tank
      • Tracks
      • Ground Pressure
    • TECHNICAL SERVICE GUIDE SPECIFICATIONS
      • Engine
      • Engine Torques
      • Cooling System
      • Excavator Torques
    • 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 TOOLS REQUIRED
      • Remote Start Tools
      • Hydraulic Tools
      • Engine Tools
      • HVAC Tools
  • ALPHABETICAL INDEX

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