Bobcat 325, 328 G-Series Excavator Repair Service Manual – 6902745

325 (S/N: 234111001 & Above) – 328 (S/N: 234211001 & Above) – (G 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
325 – S/N: 234111001 & Above
328 – S/N: 234211001 & Above
(G 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 REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902745 (10-09)
Total Pages : 830

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
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
Operation (Early Models)
Operation (Later Models)
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS/TOPS)
Emergency Exit
Front Window
Right Side Windows
Cab Door
TRANSPORTING THE EXCAVATOR
Procedure
TAILGATE
Opening And Closing The Tailgate
Adjusting The Bumper
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SERVICE SCHEDULE
Chart
AIR CLEANER
Daily Check
Replacing The Filters
HEATER AIR FILTER (WITH CAB OPTION ONLY)
Removal And Installation
COOLING SYSTEM
Cleaning The Cooling System
Checking Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Removing Water From The Fuel Filter
Draining The Fuel Tank
Fuel Filter
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
Replacing The Hydraulic Oil
Replacing The Hydraulic Filter
Replacing The Case Drain Filter
Diagnostic Couplers
LUBRICATION OF THE HYDRAULIC EXCAVATOR
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
SPARK ARRESTOR MUFFLER
ENGINE ACCESSORY DRIVE BELT
Belt Tension
Belt Adjustment
SEAT BELT
Inspection And Maintenance

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATIC
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting Chart
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
CLAMP CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVES
Testing And Adjusting The Main Relief Valves
PORT RELIEF VALVES
Testing And Adjusting The Port Relief Valves
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valves
PRESSURE REDUCING VALVE
Testing And Adjusting The Pressure Reducing Valve
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Control Valve Identification
Disassembly
Right Travel Valve Section Disassembly And Assembly
Boom Swing 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
Slew Valve Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP (S/N 234111001-23412473) & (S/N 234211001-234212268)
Description
Torque Adjustment
Testing The Piston Pump
Testing The Gear Pump
Testing Auxiliary Hydraulic Flow
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Start Up
Gear Pump Parts Identification
Piston Pump Parts Identification
Disassembly
Gear Pump Disassembly
Gear Pump Assembly
Piston Pump Disassembly
Piston Pump Assembly
Assembly
HYDRAULIC PUMP (S/N 234112474 & Above) & (S/N 234212269 & Above)
Description
Torque Adjustment
Testing The Piston Pump
Testing The Gear Pump
Testing Auxiliary Hydraulic Flow
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Start Up
Gear Pump Parts Identification
Piston Pump Parts Identification
Disassembly
Gear Pump Disassembly
Gear Pump Assembly
Piston Pump Disassembly
Piston Pump Assembly
MANIFOLD ASSEMBLY/ ACCUMULATOR
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly
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)
Testing
Handle Removal And Installation
Joystick Assembly, Removal And Installation
Parts Identification
Disassembly
Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER MOUNT
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
Parts Identification
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 Cylinder Disassembly And Assembly
Recoil Spring Cylinder Parts Identification (with Replaceable Shaft)
Recoil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)
TRACK DAMAGE IDENTIFICATION
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
Disassembly
Assembly
TRACK ROLLER
Parts Identification
Disassembly
Assembly
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing Installation

UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
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
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 Removal
Glass 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
Compression Spring Disassembly And Assembly
Lock Lever Removal And Installation
Console Removal And Installation
Disassembly And Assembly
Console Switch Removal And Installation
Console Base Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
Adjustment (Later Models)
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
Pedal Disassembly And Assembly
Linkage Removal And Installation
TRAVEL CONTROLS
Removal And Installation
Disassembly And Assembly
Adjustment
FLOOR MAT AND FLOOR PLATE
Removal And Installation (Canopy Equipped Excavators)
Removal And Installation (Cab Equipped Excavators)
FUEL TANK
Removal And Installation
HORN
Removal And Installation (Early Models)
Removal And Installation (Later Models)
SWING FRAME
Boom Swing Bracket Removal And Installation
Boom Swing Bracket Hose Installation
Bushing Removal
Bushing Installation
BOOM
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
CLAMP
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
X-CHANGE
Removal And Installation
Disassembly
Assembly
Check Proper Latch Engagement
UPPERSTRUCTURE SLEW LOCK
Removal And Installation (Early Models)
Removal And Installation (Later Models)
Disassembly And Assembly (Later Models)
RIGHT SIDE COVER
Removal And Installation

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATIC
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location
BATTERY
Servicing
Removing And Installing The Battery
Using A Booster Battery (Jump Starting)
ALTERNATOR
Engine Accessory Drive Belt
Engine Accessory Drive Belt Tensioner Removal And Installation
Removal And Installation
Bracket Removal And Installation
Description
Tests
Alternator Output Test
Full Field Test
Alternator Regulator Test
Parts Identification
Disassembly And Assembly
Rotor Continuity Test
Rotor Continuity Test
Rectifier Continuity (Diode) Test
STARTER
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
LIGHTS
Removal And Installation
Boom Light Removal And Installation (Early Models)
Boom Light Disassembly And Assembly (Early Models)
Boom Light Removal And Installation (Later Models)
Boom Light Bulb Replacement (Later Models)
TWO SPEED SWITCH
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTICS SERVICE CODE
Number Codes List
DELUXE INSTRUMENT PANEL SETUP
Passwords
Password Entry (For Starting And Operating The Machine)
Changing The Owner or Operator Password
Password Lockout Feature
Job Clock
RPM

ENGINE SERVICE
TROUBLESHOOTING
Chart
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
ENGINE COMPONENTS AND TESTING
Engine Compression Checking
Glow Plugs Removal And Installation
Checking The Glow Plug
Fuel Shut-Off Solenoid Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Nozzles Removal And Installation
Fuel Injector Nozzle Check
Valve Clearance Adjustment
ENGINE
Removal And Installation
ENGINE FLYWHEEL (EARLY MODELS)
Flywheel Removal And Installation
Hydraulic Pump Coupler
Flywheel Ring Gear
ENGINE FLYWHEEL (LATER MODELS)
Flywheel Removal And Installation
Hydraulic Pump Coupler
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
Camshaft Servicing
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
Checking Engine Oil Pressure
Valve Tappets
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 SYSTEM
Description
Components
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
HEATER UNIT (EARLY MODELS)
Removal And Installation
HEATER UNIT (LATER MODELS)
Removal And Installation
HEATER COIL (EARLY MODELS)
Removal And Installation
HEATER COIL (LATER MODELS)
Removal And Installation
BLOWER FAN (EARLY MODELS)
Removal And Installation
Disassembly And Assembly
Resistor Removal And Installation
Wire Connector Removal And Installation
BLOWER FAN (LATER MODELS)
Removal And Installation
Disassembly And Assembly
Resistor Removal And Installation
HEATER VALVE (EARLY MODELS)
Removal And Installation
HEATER VALVE (LATER MODELS)
Removal And Installation

SPECIFICATIONS
SPECIFICATIONS
325/328 Excavator Machine Dimensions
325 Excavator Machine Dimensions
328 Excavator Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Drive System
Undercarriage
Track
Electrical
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
Timing Gear
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

SERVICE MANUAL REVISIONS
Revision No: 325/328-1
Revision No: 325/328-2
Revision No: 325/328-3
Revision No: 325/328-4
Revision No: 325/328-5
Revision No: 325/328-6
Revision No: 325/328-7
Revision No: 325/328-8
Revision No: 325/328-9

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