Bobcat X325 Excavator Repair Service Manual – 6724480

(S/N: 514011001 – 514012999)
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This workshop repair service manual PDF download for the X-325 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 X-325
S/N: 514011001 – 514012999

TABLE OF CONTENTS :

SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
HYDRAULIC EXCAVATOR IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
DRIVE SYSTEM
UPPER WORKS & SWING SECTION
MAIN FRAME & TRACKS
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724480 (11–95)
Total Pages : 435

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
SERIAL NUMBER LOCATIONS
HYDRAULIC EXCAVATOR SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
HYDRAULIC EXCAVATOR IDENTIFICATION

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
TRANSPORTING THE HYDRAULIC EXCAVATOR
Procedure
ENGINE COVER
Procedure
AIR CLEANER SERVICE
Replacing the Filter Element
FUEL SYSTEM
Fuel Specifications
Filling the Fuel Tank
Fuel System Maintenance
Fuel Filter
Removing Air From the Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Engine Oil and Filter Replacement
COOLING SYSTEM
Coolant Level
Coolant Replacement
Propylene Glycol (Factory Installed)
HYDRAULIC SYSTEM
Checking and Adding Fluid
Return Line Filter Service
Replacement of the Hydraulic Filter
Hydraulic Reservoir
USING A BOOSTER BATTERY (Jump Starting)
Procedure
LUBRICATION OF THE HYDRAULIC EXCAVATOR
FINAL DRIVE CASE
Checking Oil Level (S/N 12999 & Below)
Draining Final Drive Case (S/N 12999 & Below)
Checking Oil Level (S/N 13001 & Above)
Draining Final Drive Case (S/N 13001 & Above)
HEATER AIR FILTER SERVICE
SPARK ARRESTOR MUFFLER
Cleaning Spark Arrestor Muffler

HYDRAULIC SECTION
HYDRAULIC SCHEMATICS
HYDRAULIC SYSTEM TROUBLESHOOTING
HYDRAULIC SERVICE INFORMATION
Checking the Main Relief Valves (S/N 11001–12999)
Checking the Main Relief Valves (S/N 13001 & Above)
Testing the 4050 PSI (27925 kPa) Circuit Relief Valve
Testing the Auxiliary and Bucket Circuit Relief Valve
Testing the Left Hand Travel Circuit Relief Valve
Testing the Right Hand Travel Circuit Relief Valve
Testing the Boom Circuit Relief Valve
Checking the Hydraulic Pump
HYDRAULIC PUMP
Removal and Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC CONTROL VALVE (6 Spool) HUSCO VALVE (S/N 11001–12999)
Removal and Installation
Parts Identification
Disassembly
Inlet Section
Right Hand & Left Hand Travel
Disassembly
Assembly
Boom, Bucket & Arm
Disassembly
Assembly
Port Relief Valves (Adjustable)
Auxiliary
Disassembly
Assembly
Port Relief Valves (Adjustable)
Parts Identification
Port Relief Valve Pressure Setting
Disassembly
Assembly
Adjustment Procedure
Main Relief Valves
Parts Identification
Disassembly
Assembly
Adjusting the Main Relief Valves
HYDRAULIC CONTROL VALVE (3 Spool) HUSCO VALVE (S/N 11001 –12999)
Description
Removal and Installation
Parts Identification
Disassembly
Blade and Boom Swing
Disassembly
Assembly
Lockout Valve Assembly
Disassembly
Assembly
Swing Motor Valve
Disassembly
Assembly
Build–Up Valve
Disassembly
Assembly
Test Procedure
HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)
Left Travel, Right Travel, Boom, Bucket and Auxiliary
Description
Removal and Installation
Parts Identification
Disassembly
Outlet Sections Disassembly
Outlet Sections Assembly
Mid Inlet Section Disassembly
Mid Inlet Section Assembly
Left Travel, Right Travel and Auxiliary Disassembly
Left Travel, Right Travel and Auxiliary Assembly
Boom and Bucket Disassembly
Boom and Bucket Assembly
Assembly
PORT RELIEF VALVES AND MAIN RELIEF VALVES (S/N 13001 & Above)
Parts Identification
Port Relief Valve Pressure Setting
Disassembly
Assembly
MAIN RELIEF VALVES (Adjustable) (S/N 13001 & Above)
Parts Identification
Assembly
Disassembly
Assembly
Adjusting the Main Relief Valves
HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)
Boost, Arm, Boom Swing, Blade and Swing Section
Description
Removal and Installation
Parts Identification
Disassembly
Inlet Section
Arm, Boost and Swing Motor Disassembly
Arm, Boost and Swing Motor Assembly
Boom Swing Disassembly
Boom Swing Assembly
Blade Disassembly
Blade Assembly
Assembly
ACCUMULATOR (S/N 11001 – 12999)
Pressure Reducing Valve
Description
Test Procedure
Removal and Installation
Parts Identification
Disassembly
Assembly
Charging
Setting the Safety Relief Valve
ACCUMULATOR (S/N 13001 & Above)
Removal and Installation
Parts Identification
PORT BLOCK
Removal and Installation (S/N 11001–12999)
Removal and Installation (S/N 13001 & Above)
AUXILIARY SELECTOR VALVE
Removal and Installation (S/N 11001–12999)
Removal and Installation (S/N 13001 & Above)
Disassembly and Assembly
TWO SPEED VALVE (S/N 13001 & Above)
Removal and Installation
OIL COOLER
Removal and Installation
HYDRAULIC RESERVOIR
Removal and Installation
HYDRAULIC FILTER ASSEMBLY
Removal and Installation
RETURN LINE FILTER
Removal and Installation
BOOM CYLINDER
Removal and Installation
BOOM CYLINDER SHIELD
Removal and Installation
ARM CYLINDER
Removal and Installation
BUCKET CYLINDER
Removal and Installation
BLADE CYLINDER
Removal and Installation
BOOM SWING CYLINDER
Removal and Installation
HYDRAULIC CYLINDERS
Disassembly
Assembly
JOYSTICK CONTROL CHANGE
ISO to STANDARD Control Pattern (S/N 12999 & Below)
STANDARD to ISO Control Pattern (S/N 12999 & Below)
ISO to STANDARD Control Pattern (S/N 13001 & Above)
STANDARD to ISO Control Pattern (S/N 13001 & Above)

DRIVE SECTION
LEFT CONSOLE (S/N 11001 – 12999)
Lockout Valve Removal and Installation
Cylinder Removal and Installation
Removal and Installation
LEFT CONSOLE (S/N 13001 & Above)
Control Lock Micro–Switch
Removal and Installation
Cylinder Removal and Installation
Removal and Installation
Release Handle
Removal and Installation
Disassembly and Assembly
Adjustment
Latch Plate
Adjustment
JOYSTICK (S/N 11001 –12999)
Left Joystick
Removal and Installation
Parts Identification
Right Joystick
Removal and Installation
Troubleshooting
Parts Identification
Disassembly and Assembly
JOYSTICK (S/N 13001 & Above )
Removal and Installation
Parts Identification
Disassembly
Assembly
Troubleshooting
CONTROL LEVERS
Removal and Installation
Low Idle Adjustment
High Idle Adjustment
Speed Control Lever
Blade Lever
RIGHT CONSOLE
Removal and Installation (S/N 11001 –12999)
Removal and Installation (S/N 13001 & Above)
FOOT PEDALS AND STEERING LEVERS
Removal and Installation
Bushing Removal and Installation

UPPER WORKS AND SWING SECTION
REAR ENGINE COVER
Removal and Installation
SEAT AND MOUNTING FRAME
Removal and Installation
CENTER FLOOR PANEL
Removal and Installation
S/N 12999 & Below
S/N 13001 & Above
SWING MOTOR COVER
Removal and Installation
REAR FLOOR PANEL
Removal and Installation
TOOL BOX
Removal and Installation
LEFT SIDE COVER
Removal and Installation
CORNER POST
Removal and Installation
COUNTERWEIGHTS
Removal and Installation
FRONT ENGINE COVER
Removal and Installation
FUEL TANK
Removal and Installation
BUCKET
Removal and Installation
ARM
Removal and Installation
BOOM
Removal and Installation
BOOM SWING BRACKET
Removal
Installation
Hose Installation
SWING BRACKET BUSHING
Bushing Removal
Bushing Installation
SWING MOTOR
Removal and Installation
Parts Identification
Disassembly
Assembly
CROSS PORT RELIEF VALVE
Disassembly
Assembly
Description
Testing
SWING MOTOR DRIVE CARRIER
Removal and Installation
Parts Identification
Disassembly
Assembly
UPPERSTRUCTURE AND SWING CIRCLE GEAR
Removal and Installation
Swing Bearing Removal
Swing Bearing Installation
Alignment Pins (Threaded)
Alignment Pins (Not Threaded)
CENTER SWIVEL JOINT
Removal and Installation (Through Upper AccessCover)
Removal and Installation (Through Bottom Access Cover) (S/N 11001–12999)
Removal and Installation (Through Bottom Access Cover) (S/N 13001 & Above)
Parts Identification
Description
Disassembly
Assembly
ROPS CANOPY
Removal and Installation
CAB
Removal and Installation
Two Piece Side Window
Three Piece Side Windows
Door Removal and Installation
Front Window Removal and Installation
Front Lower Glass Removal and Installation
Front Upper Plexiglass Removal and Installation
Left Hand Side Glass Removal and Installation
Door Glass Removal and Installation
Rear Glass Removal and Installation
Right Hand Side Glass Removal and Installation
Two Piece Side Window
Three Piece Side Window
CAB/CANOPY REAR COVER
Removal
Installation

MAIN FRAME AND TRACKS
BLADE
Removal and Installation
TRACK
Track Lug Height
Track Tension
Rubber Tracks
Steel Tracks
Adjustment (S/N 11001–12999)
Adjustment (S/N 13001 & Above)
Removal and Installation
TRACK FRAME
Disassembly and Assembly (S/N 11001–12999)
Disassembly and Assembly (S/N 13001 & Above)
TRAVEL MOTOR
Testing
Removal and Installation (S/N 11001–12999)
Removal and Installation (S/N 13001 & Above)
Parts Identification (S/N 11001–12999)
Disassembly (S/N 11001–12999)
Assembly (S/N 11001–12999)
Check Oil Level (S/N 11001–12999)
Draining Final Drive Case (S/N 11001–12999)
TRAVEL MOTOR (SOM)
Checking Oil Level (S/N 13001 & Above)
Draining Final Drive Case (S/N 13001 & Above)
Parts Identification (S/N 13001 & Above)
Disassembly (S/N 13001 & Above)
Assembly (S/N 13001 & Above)
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 Of 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

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
Chart
ELECTRICAL SYSTEM
Description
Fuses
Electrical System Service
BATTERY
Checking the Battery
Removal and Installation
ALTERNATOR
Belt Adjustment
Removal and Installation
Disassembly and Inspection
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER
Removal and Installation
Parts Identification
Disassembly and Assembly
Cleaning and Inspection
FUEL LEVEL SENDER
Removal and Installation
Checking
INSTRUMENT PANEL
Removal and Installation
GAUGES
Removal and Installation
GAUGE LIGHTS
Removal and Installation
CAB ELECTRICAL (Cab Option)

ENGINE SYSTEM
TROUBLESHOOTING
VALVE CLEARANCE
Adjustment
ENGINE COMPRESSION
Checking
FUEL SHUTOFF SOLENOID
Adjustment
Removal and Installation
Timer Module Removal and Installation
FUEL INJECTION PUMP
Checking the Injection Pump
Removal and Installation
Timing the Injection Pump
FUEL INJECTOR NOZZLES
Removal and Installation
Checking the Injector Nozzle
GLOW PLUGS
Removal and Installation
Checking the Glow Plug
FAN GUARD
Removal and Installation
RADIATOR
Removal and Installation
MUFFLER
Removal and Installation
AIR CLEANER
Removal and Installation
ENGINE
Removal and Installation
ENGINE FLYWHEEL
Removal and Installation
FLYWHEEL RING GEAR
CYLINDER HEAD
Removal and Installation
Disassembly and Assembly of the Cylinder Head
Servicing the Cylinder Head
Top Clearance
VALVE, VALVE SEAT AND GUIDE
Checking the Valve Guide
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
Servicing the Idler Gear and Shaft
TIMING GEARS
Checking Backlash
FUEL CAMSHAFT
Removal and Installation
Governor
CRANKSHAFT GEAR
Removal and Installation
OIL PUMP
Removal and Installation
Oil Pump Service
Checking Engine Oil Pressure
Relief Valve
PISTON AND CONNECTING ROD
Removal and Installation
Servicing the Piston and Connecting Rod
Connecting Rod Alignment
CRANKSHAFT AND BEARINGS
Removal and Installation
Servicing the Crankshaft and Bearings
CYLINDER BORE
Checking the Cylinder Bore
WATER PUMP
Disassembly and Assembly

SPECIFICATIONS
HYDRAULIC EXCAVATOR SPECIFICATIONS
Machine Dimensions
Lifting Capacity
HYDRAULIC SYSTEM
SWING SYSTEM
HYDRAULIC CYLINDERS
DRIVE SYSTEM
BRAKES
UNDERCARRIAGE
STD TRACK SHOES
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 Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Bolt Torque
Re–Grinding The Crankshaft
FUEL, COOLANT AND LUBRICANTS CHART
ENGINE OIL SPECIFICATIONS
Description
Ethylene Glycol
Propylene Glycol
BUCKET SPECIFICATIONS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION

SERVICE MANUAL REVISION
325-1
325-2
325-3
325-4
325-5

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