Bobcat X325, X328 Excavator Repair Service Manual – 6900462

325 (S/N: 514013001 & Above) – 328 (S/N: 516611001 & Above)
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This workshop repair service manual PDF download for the X-325 & X-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 Compact Excavator
X325 (S/N: 514013001 & Above)
X328 (S/N: 516611001 & Above)

TABLE OF CONTENTS :

FOREWORD
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 : 6900462 (3–98)
Total Pages : 463

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
ENGINE COVER
Opening The Engine Cover
Adjustment Of The Engine Cover Latch
AIR CLEANER SERVICE
Replacing The Filter Element (325 S/N 514013001–514014899)
Replacing The Filter Element (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel System Maintenance
Fuel Filter (325 S/N 514013001–514014899)
Fuel Filter (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)
Removing Air From The Fuel System (325 S/N514013001–514014899)
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacement Of Oil And Filter
COOLING SYSTEM
Coolant Level
Coolant Replacement
ALTERNATOR BELT
Adjustment
ELECTRICAL SYSTEM
Using A Booster Battery (Jump Starting)
HYDRAULIC SYSTEM
Checking And Adding Fluid
Replacing The Hydraulic Oil
Replacing The Hydraulic Filter
Replacing The Drain Line Filter
SPARK ARRESTOR MUFFLER (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Cleaning The Spark Arrestor Muffler
SPARK ARRESTOR MUFFLER (325 S/N 514013001–514014899)
Cleaning The Spark Arrestor Muffler
TRAVEL MOTOR
Checking The Oil Level
Draining And Refilling
LUBRICATION OF THE HYDRAULIC EXCAVATOR
HEATER AIR FILTER (With Cab Option Only) (325 S/N514013001–514014899)
HEATER AIR FILTER (With Cab Option Only) (325 S/N514014900 & Above) & (328 S/N 516611001 & Above)

HYDRAULIC SECTION
HYDRAULIC SCHEMATICS
HYDRAULIC SYSTEM TROUBLESHOOTING
HYDRAULIC SERVICE INFORMATION
Description
Checking The Main Relief Valves
Testing The Swing 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
CROSS PORT RELIEF VALVE
Description
Testing
HYDRAULIC PUMP
Checking the Hydraulic Pump
Removal And Installation (325 S/N 514013001–514014899)
Parts Identification (325 S/N 514013001– 514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Disassembly (325 S/N 514013001–514014899)
Assembly (325 S/N 514013001–514014899)
HYDRAULIC CONTROL VALVE (5–Spool)
Left Travel, Right Travel, Boom, Bucket and Auxiliary
Description
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Left Travel, Right Travel, Boom, Bucket and Auxiliary
Parts Identification
Disassembly
Outlet Sections Disassembly
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 MID INLET MAIN RELIEF VALVES
Parts Identification
Port Relief Valve Pressure Setting
Disassembly
Assembly
MAIN RELIEF VALVES (Adjustable)
Parts Identification
Pressure Settings
Disassembly
Assembly
Adjusting The Main Relief Valves
HYDRAULIC CONTROL VALVE (5–Spool)
Boost, Arm, Boom Swing, Blade And Swing Section
Description
Removal And Installation
Parts Identification
Disassembly
Inlet Section Disassembly
Inlet Section Assembly
Arm, Boost And Swing Motor Disassembly
Arm, Boost And Swing Motor Assembly
Boom Swing Disassembly
Boom Swing Assembly
Blade Disassembly
Blade Assembly
Assembly
ACCUMULATOR
Removal And Installation
Parts Identification (S/N 514013001 – 514017331& 516611001 – 516611918)
Disassembly (S/N 514013001 – 514017331& 516611001 – 516611918)
Assembly
Parts Identification (S/N 514017312 & Above &516611919 & Above)
Disassembly (S/N 514017312 & Above &516611919 & Above)
Assembly (S/N 514017312 & Above &516611919 & Above)
Testing (All Models)
PORT BLOCK
Removal And Installation
BUILD UP VALVE
Description
Removal And Installation
Disassembly And Assembly
AUXILIARY SELECTOR VALVE
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Disassembly And Assembly
OIL COOLER
Removal And Installation
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC FILTER ASSEMBLY
Removal And Installation
CASE DRAIN FILTER
BOOM CYLINDER SHIELD
Removal And Installation
BOOM CYLINDER
Removal And Installation
BOOM CYLINDER
Parts Identification
ARM CYLINDER
Removal And Installation
Parts Identification
BUCKET CYLINDER
Removal And Installation
Parts Identification
BLADE CYLINDER
Removal And Installation
Parts Identification
BOOM SWING CYLINDER
Removal And Installation
Parts Identification
HYDRAULIC CYLINDER
Disassembly
Assembly
JOYSTICK CONTROL CHANGE
ISO to STANDARD Control Pattern
STANDARD To ISO Control Pattern

DRIVE SECTION
RIGHT CONSOLE COVER (325 S/N 514013001–514014899)
Removal And Installation
RIGHT CONSOLE
Speed Control Lever Removal And Installation
Speed Control Lever Adjustment
Low Speed Position
High Speed Position
Blade Control Lever And Cable Removal And Installation
LEFT CONSOLE (325 S/N 514013001–514014899)
Control Lock Micro–Switch Removal And Installation
Gas Spring Removal And Installation
Removal And Installation
Lock Lever Removal And Installation
Lock Lever Disassembly And Assembly
Lock Lever Adjustment
Latch Plate Adjustment
RIGHT CONSOLE COVER (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Removal And Installation
Arm Rest Removal And Installation
Gauge Removal And Installation
RIGHT CONSOLE (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)
Swing Lock Lever Removal And Installation
Blade Lever Removal And Installation
Speed Control Lever Removal And Installation
Speed Control Lever Adjustment
Low Speed Position
High Speed Position
LEFT CONSOLE COVER (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)
Removal And Installation
Arm Rest Removal And Installation
Switch Removal And Installation
Switch Description
Rear Cover Removal And Installation
LEFT CONSOLE (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above
Console And Mount Removal And Installation
Control Lock Micro–switch Removal And Installation
Lock Lever Removal And Installation
Gas Spring Removal And Installation
Console Removal And Installation
JOYSTICK
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation Of Right Hand Joystick(325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)
Removal And Installation Of Left Hand Joystick (325S/N 514014900 & Above) & (328 S/N 516611001 & Above)
Troubleshooting
Parts Identification
Disassembly
Assembly
STEERING LEVERS AND PEDALS
Removal And Installation

UPPER WORKS AND SWING SECTION
REAR ENGINE COVER
Removal And Installation
SEAT AND SEAT MOUNT
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
FLOOR MAT AND FLOOR PLATE
Removal And Installation
REAR FLOOR PLATE
Removal And Installation (325 S/N 514013001–514014899)
SWING MOTOR COVER
Removal And Installation
TOOL BOX
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
LEFT SIDE COVER
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
RIGHT 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
ARM BUSHINGS
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing RemovalAnd Installation
BOOM
Removal And Installation
BOOM BUSHING
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
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 (Not Threaded)
CENTER SWIVEL JOINT
Removal And Installation
Removal And Installation (Through Bottom AccessCover)
Parts Identification
Description
Disassembly
Assembly
ROPS CANOPY
Removal And Installation
CAB
Removal And Installation
Heater Removal And Installation (325 S/N514013001– 514014899)
Heater Removal And Installation (325 S/N 514014900& Above) & (328 S/N 516611001 & Above)
Heater Disassembly And Assembly (325 S/N514014900 & Above) & (328 S/N 516611001 & Above)
Front Window Removal And Installation
Front Lower Window Removal And Installation
Front Upper Window Removal And Installation (325S/N 514013001–514014899)
Front Upper Window Removal And Installation (325S/N 514014900 & Above) & (328 S/N 516611001 &Above)
Door Window Removal And Installation
Left Hand Side Window Removal And Installation
Right Hand Side Window Removal And Installation
Right Hand Window Assembly Removal AndInstallation
Rear Window Removal And Installation
CAB/CANOPY REAR COVER
Removal
Installation

MAIN FRAME AND TRACKS
BLADE
Removal And Installation
TRACK
Track Lug Height
Track Tension Adjustment
Rubber Track Clearance
Steel Track Clearance
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
Disassembly And Assembly
Recoil Spring Disassembly And Assembly
TRACK IDLER
Parts Identification
Disassembly
Assembly
TRACK ROLLER
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
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
ELECTRICAL SYSTEM
Description
Fuses (325 S/N 514013001–514014899)
Fuse Arrangement (325 S/N 514013001–514014899)
Electrical Relays And Diodes (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Fuse Arrangement (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)
BATTERY
Removal And Installation
Servicing The Battery
ALTERNATOR
Belt Adjustment
Removal And Installation
ALTERNATOR
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Parts Identification
Disassembly And Inspection
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Disassembly And Assembly
Cleaning And Inspection (325 S/N 514013001–514014899)
Parts Identification (325 S/N 514013001– 514014899)
Parts Identification (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)
Disassembly (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)
Inspection And Repair (325 S/N 514014900 & Above)& (328 S/N 516611001 & Above)
Assembly (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)
FUEL LEVEL SENDER
Removal And Installation
Testing
INSTRUMENT PANEL (325 S/N 514013001–514014899)
Removal And Installation
GAUGES
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
Bulb Replacement (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)
TIMER (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)
Removal And Installation
DIODES (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)
Diode Location
Diode Replacement
Diode Testing
CAB ELECTRICAL
Cab Option (325 S/N 514013001–514014899)
Cab Option (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)
HORN
Removal And Installation
BUZZER
Removal And Installation
TWO SPEED SWITCH
Removal And Installation

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
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 (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
AIR CLEANER
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
ENGINE
Removal And Installation
ENGINE FLYWHEEL
Removal And Installation (325 S/N 514013001–514014899)
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)
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 (325 S/N 514013001–514014899)
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 S/N 514014900 & Above) & (328 S/N 516611001 & Above
Machine Dimensions
Lifting Capacity
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 Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Bolt Torque
Re–Grinding The Crankshaft
TORQUE FOR GENERAL METRIC BOLTS
FUEL, COOLANT AND LUBRICANTS
Chart
ENGINE OIL AND COOLING SPECIFICATIONS
Description
Anti–Freeze Solution
Propylene Glycol
BUCKET SPECIFICATIONS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION

SERVICE MANUAL REVISION
325-1
325-2

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