Bobcat 325, 328 D-Series Excavator Repair Service Manual – 6901138

(S/N: 232511001 & Above – S/N: 232411001 & Above) – (D Series)
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This workshop repair service manual PDF download for the 325 & 328 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 Excavator 325 / 328
S/N: 232511001 & Above
S/N: 232411001 & Above
(D Series)

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM AND ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901138 (2-06)
Total Pages : 798

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 !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
Fire Prevention
SERIAL NUMBER LOCATIONS
Bobcat Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
SWING LOCK
Operation
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS) (IF EQUIPPED)
Emergency Exit
Cab Door
Front Window
TRANSPORTING THE EXCAVATOR
Procedure
TAILGATE
Opening And Closing The Tailgate (Early Models)
Adjusting The Bumper (Early Models)
Adjusting The Tailgate Latch (Early Models)
Opening And Closing The Tailgate (Later Models)
Adjusting The Tailgate Latch (Later Models)
Adjusting The Bumper (Later Models)
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing The Filters
HEATER AIR FILTERS (WITH CAB OPTION ONLY)
Recirculation Filter
Fresh Air Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specification
Filling The Fuel Tank
Removing Water From The Fuel Filter
Fuel Filter
Removing Air From The Fuel System
Draining The Fuel Tank
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Fluid
Replacing the Hydraulic Filter
Replacing the Case Drain Filter
Replacing the Hydraulic Fluid
Diagnostic Couplers
LUBRICATING THE EXCAVATOR
Procedure
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
SPARK ARRESTOR MUFFLER (IF EQUIPPED)
Cleaning The Spark Arrestor Muffler

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting Chart
BOOM CYLINDER
Checking The Boom Cylinder
Removal And Installation
Parts Identification
Disassembly
Assembly
ARM CYLINDER
Checking The Arm Cylinder
Removal And Installation
Parts Identification
Disassembly
Assembly
BOOM OFFSET CYLINDER
Checking The Boom Offset Cylinder
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET CYLINDER
Checking The Bucket Cylinder
Removal And Installation
Parts Identification
Disassembly
Assembly
BLADE CYLINDER
Checking The Blade Cylinder
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVES
Testing And Adjusting The Main Relief Valves (S/N 232312386 & Below, 232412117 & Below, 232412128 And 232412129)
Testing And Adjusting The Main Relief Valves (S/N 232312387 & Above, 232412118-232412127 And 232412130 & Above)
PORT RELIEF VALVES
Testing And Adjusting Port Relief Valve Pressure (S/ N 232312386 & Below And 232412117 & Below, 232412128 And 232412129)
Testing Port Relief Valve Pressure (S/N 232312387 & Above And 232412118-232412127 And 232412130 & Above)
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valves
SYSTEM PRESSURES AT GAUGE PORT SPECIFICATIONS
PRESSURE REDUCING VALVE (S/N 232312386 & BELOW AND 232412117 & BELOW, 232412128 AND 232412129)
Testing And Adjusting The Pressure Reducing Valve
PRESSURE REDUCING VALVE (S/N 232312387 & ABOVE AND 232412118-232412127 AND 232412130 & ABOVE)
Testing And Adjusting The Pressure Reducing Valve
HYDRAULIC CONTROL VALVE (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)
Description
Removal And Installation
Control Valve Identification
Disassembly
Right Travel Valve Section Disassembly And Assembly
Boom Offset Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Boost Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Swing Valve Section Disassembly And Assembly
Assembly
HYDRAULIC CONTROL VALVE (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)
Description
Removal And Installation
Control Valve Identification
Disassembly
Right Travel Valve Section Disassembly And Assembly
Boom Offset Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Boost Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Swing Valve Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Description
Torque Adjustment
Testing The Piston Pump
Testing The Gear Pump
Testing The Auxiliary Hydraulic Flow
Removal And Installation
Coupler Removal And Installation
Gear Pump Parts Identification
Piston Pump Parts Identification
Disassembly
Gear Pump Disassembly
Gear Pump Assembly
Piston Pump Disassembly
Piston Pump Assembly
Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311950 & BELOW AND 232411763 & BELOW)
Manifold Description
Removal And Installation
MANIFOLD ASSEMBLY (S/N 232311950 & BELOW AND 232411763 & BELOW)
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311951 & ABOVE AND 232411764 & ABOVE)
Manifold Description
Removal And Installation
MANIFOLD ASSEMBLY (S/N 232311951 & ABOVE AND 232411764 & ABOVE)
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation (With The Upperstructure Removed)
Removal And Installation (Through Bottom Access Cover)
Parts Identification
Description
Disassembly
Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
Cross Port Relief Valve Parts Identification
Cross Port Relief Valve Disassembly
Cross Port Relief Valve Assembly
SWING MOTOR DRIVE CARRIER
Removal And Installation
Parts Identification
Disassembly
Assembly
CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)
Testing
Handle Removal And Installation
Joystick Assembly, Removal And Installation
Parts Identification
Disassembly
LEFT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
LEFT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER
Removal And Installation
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
DIRECT TO TANK VALVE
Removal And Installation
Disassembly And Assembly
BUILD UP VALVE
Description
Removal And Installation
Disassembly And Assembly
CASE DRAIN FILTER
Removal And Installation

UNDERCARRIAGE
BLADE
Removal And Installation
TRACKS
Track Lug Height
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
TRACK FRAME
Disassembly And Assembly
Recoil Spring Disassembly And Assembly
TRACK DAMAGE IDENTIFICATIONS
Cutting Of Steel Cords
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 Track Roller Side
TRACK IDLER
Parts Identification (S/N 232311036 & Below And 232411019 & Below)
Disassembly (S/N 232311036 & Below And 232411019 & Below)
Assembly (S/N 232311036 & Below And 232411019 & Below)
Parts Identification (S/N 232311037 & Above And 232411020 & Above)
Disassembly (S/N 232311037 & Above And 232411020 & Above)
Assembly (S/N 232311037 & Above And 232411020 & Above)
TRACK ROLLER
Parts Identification (S/N 232311036 & Below And 232411019 & Below)
Disassembly (S/N 232311036 & Below And 232411019 & Below)
Assembly (S/N 232311036 & Below And 232411019 & Below)
Parts Identification (S/N 232311037 & Above And 232411020 & Above)
Disassembly (S/N 232311037 & Above And 232411020 & Above)
Assembly (S/N 232311037 & Above And 232411020 & Above)
SWING CIRCLE GEAR
Removal And Installation
Swing Bearing Removal
Swing Bearing Installation
Alignment Pins (Not Threaded)

UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Removal And Installation
Swing Bearing Removal
Swing Bearing Installation
Alignment Pins (Not Threaded)
ROPS CANOPY
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Lower Front Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
Right Side Front Sliding Window Removal And Installation
Right Side Panel And Window Assembly Removal And Installation
Door, Left Side, Rear And Upper Front Window Removal And Installation
STANDARD SEAT AND SEAT MOUNT
Removal And Installation
SUSPENSION SEAT AND SEAT MOUNT
Removal And Installation
RIGHT CONSOLE
Console Cover Removal And Installation
Console Base Removal And Installation
LEFT CONSOLE
Lower Console Cover Removal And Installation
Upper Console Cover Removal And Installation
Compression Spring Removal And Installation
Lock Lever Removal And Installation
Upper Console Removal And Installation
Console Switch Removal And Installation
Disassembly And Assembly
Console Base Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
BLADE CONTROL
Lever Removal And Installation
Linkage Removal And Installation
Linkage Bar Removal And Installation
Lower Linkage Removal And Installation
RIGHT PEDAL AND LINKAGE
Pedal Removal And Installation
Right Pedal Disassembly And Assembly
Linkage Removal And Installation
Adjustment
TRAVEL CONTROLS
Removal And Installation
Disassembly And Assembly
Adjustment
FLOOR MAT AND FLOOR PANELS
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Boom Swing Bracket Removal And Installation
Boom Swing Bracket Hose Installation
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
Boom Bushing Removal And Installation
ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
TAILGATE
Removal And Installation
Release Rod Removal And Installation
Latch Removal And Installation
Release Rod Removal And Installation (Early Models)
Latch Removal And Installation (Early Models)
Latch Removal And Installation (Later Models)
X-CHANGE™
Removal And Installation
Disassembly
Assembly
RIGHT SIDE COVER
Removal And Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATIC
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting Chart
Description
Fuse Location
BATTERY
Servicing
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Adjusting The Alternator Belt
Description
Tests
Alternator Output Test
Full Field Test
Alternator Regulator Test
Removal And Installation
Disassembly And Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
LIGHTS
Removal And Installation
Disassembly And Assembly
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTICS SERVICE CODE
Number Codes List

ENGINE SERVICE
TROUBLESHOOTING
Chart
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 Adjustment
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Nozzles Removal And Installation
Checking The Injector Nozzle
Glow Plug Removal And Installation
Glow Plug Checking
ENGINE
Removal And Installation
ENGINE FLYWHEEL
Removal And Installation
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
Reconditioning The Valve And Valve Seat
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
Fan Removal And Installation

HEATER
HEATER UNIT
Removal And Installation
Disassembly And Assembly
HEATER COIL
Removal And Installation
HEATER FAN
Removal And Installation
Disassembly And Assembly
Resistor Removal And Installation
Wire Connector Removal And Installation
HEATER VALVE
Removal And Installation

SPECIFICATIONS
HYDRAULIC EXCAVATOR SPECIFICATIONS (325)
Machine Dimensions
Lifting Capacity
Weights
Controls
Engine
Electrical
Hydraulic System
Swing System
Hydraulic Cylinders
Drive System
Brakes
Undercarriage
STD Track
Capacities
Digging Force
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 W/LONG ARM KIT & 328)
Machine Dimensions
Lifting Capacities
Weights
Controls
Engine
Electrical
Hydraulic System
Swing System
Hydraulic Cylinders
Drive System
Brakes
Undercarriage
STD Track
Capacities
Digging Force
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinders
Piston Rings
Pistons
Connecting Rods
Oil Pump
Crankshaft
Thermostat
Timing Gear
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

SERVICE MANUAL REVISION
325/328-1
325/328-2
325/328-3

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