Bobcat 325/Bobcat 328 Compact Excavator Service Manual (Ver. October 2009)


Bobcat 325/Bobcat 328 Compact Excavator Service Manual
325 S/N AAC511001 & Above
325 S/N A9K011001 & Above
328 S/N A9K111001 & Above

Type of machine: Excavator
Print No: 6986940, October 2009
Language and Format: English/PDF
Instant Download after payment. Please make sure your email address is correct.

The Service Manual will give you complete information on repair, servicing and preventative maintenance, for your Bobcat 325/Bobcat 328 Compact Excavator.

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Table of contents:
1. SAFETY AND MAINTENANCE
AIR CLEANER
Daily Check
Replacing The Filters
COOLING SYSTEM
Checking Coolant Level
Cleaning The Cooling System
Replacing The Coolant
ENGINE ACCESSORY DRIVE BELT
Belt Adjustment
Belt Tension
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
FUEL SYSTEM
Draining The Fuel Tank
Filling The Fuel Tank
Fuel Filter
Fuel Specifications
Removing Air From The Fuel System
Removing Water From The Fuel Filter
HEATER AIR FILTER (WITH CAB OPTION ONLY)
Removal And Installation
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Oil
Diagnostic Couplers
Replacing The Case Drain Filter
Replacing The Hydraulic Filter
Replacing The Hydraulic Oil
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
LUBRICATION OF THE HYDRAULIC EXCAVATOR
MOTION ALARM SYSTEM (IF EQUIPPED)
Description
Adjusting Switch Position
OPERATOR CAB (ROPS/TOPS)
Cab Door
Emergency Exit
Front Window
Right Side Windows
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SEAT BELT
Inspection And Maintenance
SERVICE SCHEDULE
Chart
SPARK ARRESTOR MUFFLER
TAILGATE
Adjusting The Bumper
Adjusting The Latch
Opening And Closing The Tailgate
TRANSPORTING THE EXCAVATOR
Procedure
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
UPPERSTRUCTURE SLEW LOCK
Operation
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD
TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD
ITEMS MAY VARY.

2. HYDRAULIC SYSTEM
ARM CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BLADE CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM SWING CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BUCKET CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BUILD UP VALVE
Description
Disassembly And Assembly
Parts Identification
Removal And Installation
CASE DRAIN FILTER
Removal And Installation
CLAMP CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
CONTROL PATTERN SELECTOR VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
CROSSPORT RELIEF VALVES
Testing And Adjusting The Port Relief Valves
DIRECT TO TANK VALVE
Disassembly And Assembly
Removal And Installation
HYDRAULIC CONTROL VALVE
Arm Valve Section Disassembly And Assembly
Assembly
Auxiliary Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Boost Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Control Valve Identification
Description
Disassembly
Left Travel Valve Section Disassembly And Assembly
Removal And Installation
Right Travel Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC PUMP
Coupler Removal And Installation
Description
Disassembly
Gear Pump Assembly
Gear Pump Disassembly
Gear Pump Parts Identification
Hydraulic Pump Start Up
Piston Pump Assembly
Piston Pump Disassembly
Piston Pump Parts Identification
Removal And Installation
Testing Auxiliary Hydraulic Flow
Testing The Gear Pump
Testing The Piston Pump
Torque Adjustment
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting The Cylinder Circuit
Troubleshooting The Hydraulic Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
LEFT CONTROL LEVER (JOYSTICK)
Assembly
Disassembly
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Testing
MAIN RELIEF VALVES
Testing And Adjusting The Main Relief Valves
MANIFOLD ASSEMBLY/ ACCUMULATOR
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
OIL COOLER
Removal And Installation
PORT RELIEF VALVES
Testing And Adjusting The Port Relief Valves
PRESSURE REDUCING VALVE
Testing And Adjusting The Pressure Reducing Valve
RIGHT CONTROL LEVER (JOYSTICK)
Assembly
Disassembly
Handle Removal And Installation
Joystick Assembly, Removal And Installation
Parts Identification
Testing
SLEW LOCK VALVE
Description
Disassembly And Assembly
Parts Identification
Removal And Installation
SWING MOTOR DRIVE CARRIER
Assembly
Disassembly
Parts Identification
Removal And Installation
SWIVEL JOINT
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
TRAVEL MOTOR
Assembly
Disassembly
Parts Identification
Removal And Installation
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.

3. UNDERCARRIAGE
BLADE
Removal And Installation
SWING CIRCLE GEAR
Swing Bearing Installation
Swing Bearing Removal
TRACK DAMAGE IDENTIFICATION
Abrasion Of Embedded Metals
Abrasion Of The Track Roller Side
Cracks And Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Cuts On The Edges Of Track Roller Side
Cuts On The Lug Side Rubber
Cutting Of Steel Cords
Lug Abrasion
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
TRACK FRAME
Disassembly And Assembly
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511315 &
Below, A9KO11108 & Below And A9K111109 & Below)
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511316 &
Above, A9K011109 & Above And A9K111110 & Above)
Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above,
A9K011109 & Above And A9K111110 & Above)
TRACK IDLER
Assembly
Disassembly
Parts Identification
TRACK ROLLER
Assembly
Disassembly
Parts Identification
TRACKS
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
Track Lug Height
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD
TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS
MAY VARY.

4. UPPERSTRUCTURE & SWING SECTION
ARM
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation40-160-2
Removal And Installation
BLADE CONTROL
Lever Removal And Installation
Linkage Bar Removal And Installation
Linkage Removal And Installation
Lower Linkage Removal And Installation
BOOM
Removal And Installation
BUCKET
Bucket Side Cutting Edge Removal And Installation
Bucket Teeth Removal And Installation
CAB
Door Removal And Installation
Front Window Removal And Installation
Glass Installation
Glass Removal
Removal And Installation
Right Side Front And Rear Sliding Window Weather Strip Removal And
Installation
Right Side Front And Rear Sliding Window Wiper Strip Removal And
Installation
Right Side Front Sliding Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
CLAMP
Removal And Installation
ENGINE SPEED CONTROL
Adjustment
Removal And Installation
FLOOR MAT AND FLOOR PLATE
Removal And Installation (Cab Equipped Excavators)
Removal And Installation (Canopy Equipped Excavators)
FUEL TANK
Removal And Installation
HORN
Removal And Installation
LEFT CONSOLE
Compression Spring Disassembly And Assembly
Compression Spring Removal And Installation
Console Base Removal And Installation
Console Removal And Installation
Console Switch Removal And Installation
Disassembly And Assembly
Lock Lever Removal And Installation
Lower Console Cover Removal And Installation
Upper Console Cover Removal And Installation
RIGHT CONSOLE
Console Base Removal And Installation
Console Cover Removal And Installation
RIGHT PEDAL AND LINKAGE
Linkage Removal And Installation
Pedal Disassembly And Assembly
Pedal Removal And Installation
RIGHT SIDE COVER
Removal And Installation
ROPS CANOPY
Removal And Installation
STANDARD SEAT AND SEAT MOUNT
Removal And Installation
SUSPENSION SEAT AND SEAT MOUNT
Removal And Installation
SWING FRAME
Boom Swing Bracket Hose Installation
Boom Swing Bracket Removal And Installation
Bushing Installation
Bushing Removal
TAILGATE
Latch Removal And Installation
Removal And Installation
TRAVEL CONTROLS
Adjustment
Disassembly And Assembly
Removal And Installation
UPPERSTRUCTURE
Installation
Removal
UPPERSTRUCTURE SLEW LOCK
Disassembly And Assembly
Removal And Installation
X-CHANGE
Assembly
Check Proper Latch Engagement
Disassembly
Removal And Installation
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS
MAY VARY.

5. ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR
Alternator Output Test
Alternator Regulator Test
Bracket Removal And Installation
Description
Disassembly And Assembly
Engine Accessory Drive Belt
Engine Accessory Drive Belt Tensioner Removal And Installation 50-30-2
Full Field Test
Parts Identification
Rectifier Continuity (Diode) Test
Removal And Installation
Rotor Continuity Test
Tests
BATTERY
Removing And Installing The Battery
Servicing
Using A Booster Battery (Jump Starting)
DELUXE INSTRUMENT PANEL SETUP
Changing The Owner or Operator Password
Job Clock
Password Entry (For Starting And Operating The Machine)
Password Lockout Feature
Passwords
RPM
DIAGNOSTICS SERVICE CODE
Number Codes List
ELECTRICAL SYSTEM INFORMATION
Description
Fuse And Relay Location
Troubleshooting Chart
FUEL LEVEL SENDER
Removal And Installation
Testing
LIGHTS
Boom Light Bulb Replacement
Boom Light Removal And Installation
Removal And Installation
STARTER
Assembly
Disassembly
Inspection And Repair
Parts Identification
Removal And Installation
TWO SPEED SWITCH
Removal And Installation
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD
TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD
ITEMS MAY VARY.

6. ENGINE SERVICE
AIR CLEANER
Removal And Installation
ENGINE
Removal And Installation
ENGINE COMPONENTS AND TESTING
Checking The Glow Plug
Engine Compression Checking
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Nozzle Check
Fuel Injector Nozzles Removal And Installation
Fuel Shut-Off Solenoid Removal And Installation
Glow Plugs Removal And Installation
Valve Clearance Adjustment
Valve Seat Tightness
ENGINE FLYWHEEL
Flywheel Removal And Installation
Flywheel Ring Gear
Hydraulic Pump Coupler
MUFFLER
Removal And Installation
RADIATOR
Removal And Installation
RECONDITIONING THE ENGINE
Camshaft Servicing
Checking Engine Oil Pressure
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings, Servicing
Crankshaft Gear Removal And Installation
Cylinder Bore, Checking
Cylinder Head Disassembly And Assembly
Cylinder Head Removal And Installation
Cylinder Head Servicing
Cylinder Head Top Clearance
Fuel Camshaft Governor
Fuel Camshaft Removal And Installation
Idler Gear And Camshaft Removal And Installation
Idler Gear And Shaft Servicing
Oil Pump Removal And Installation
Oil Pump Service
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Reconditioning The Valve And Valve Seat
Rocker Arm And Shaft Checking
Timing Gearcase Cover Removal And Installation
Timing Gears Checking Backlash
Valve Guide Checking
Valve Spring
Valve Tappets
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
TROUBLESHOOTING
Chart

7. HEATER
BLOWER FAN
Disassembly And Assembly
Removal And Installation
Resistor Removal And Installation
HEATER COIL
Removal And Installation
HEATER SYSTEM
Components
Description
HEATER UNIT
Removal And Installation
HEATER VALVE
Removal And Installation
REGULAR MAINTENANCE
Filter Element Removal And Installation
Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Electrical System

SPECIFICATIONS

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