Bobcat 325, 328 D Series Excavator Service Manual
798 pages · Publication 6901138_2_06
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- Models
- 325, 328 D Series
- Serial coverage
- SN 232511001 & above, SN 232411001 & above
- Manual type
- Service Manual
- Pages
- 798
- Publication
- 6901138_2_06
- Condition
- Brand new
What's inside
From the manual's own table of contents: 19 sections, 510 entries. See sample pages (PDF, 382 KB)
MAINTENANCE SAFETY
ALPHABETICAL INDEX
FOREWORD7 topics
- 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 EXCAVATOR53 topics
- 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 SCHEMATICS163 topics
- 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
- PORT RELIEF VALVES
- CROSSPORT RELIEF VALVES
- Testing And Adjusting The Crossport Relief Valves
- SYSTEM PRESSURES AT GAUGE PORT SPECIFICATIONS
- Testing And Adjusting The Pressure Reducing Valve
- 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
- 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
- Parts Identification
- Disassembly
- Assembly
- MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311951 & ABOVE AND 232411764 & ABOVE)
- Manifold Description
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- 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
- Testing
- Handle Removal And Installation
- Joystick Assembly, Removal And Installation
- Parts Identification
- Disassembly
- Testing
- Handle Removal And Installation
- Joystick Assembly Removal And Installation
- Parts Identification
- Disassembly
- Testing
- Handle Removal And Installation
- Joystick Assembly Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- 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
BLADE27 topics
- 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
- TRACK ROLLER
- SWING CIRCLE GEAR
- Removal And Installation
- Swing Bearing Removal
- Swing Bearing Installation
- Alignment Pins (Not Threaded)
UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE77 topics
- Removal And Installation
- Swing Bearing Removal
- Swing Bearing Installation
- Alignment Pins (Not Threaded)
- ROPS CANOPY
- 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
- 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
- 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 SCHEMATIC32 topics
- 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
TROUBLESHOOTING53 topics
- 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 UNIT11 topics
- 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)68 topics
- 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
Inside this manual
Real pages from this service manual (798 pages). Open the sample pages (PDF, 381 KB)
- Diagram, page 70: HYDRAULIC SYSTEM INFORMATION
- Repair procedure, page 574: ENGINE SPEED CONTROL
- Specifications, page 766: HYDRAULIC EXCAVATOR SPECIFICATIONS (325) (CONT’D)
- Foldout diagram, page 646: BATTERY FEED 1000-1999 RED, RED/WHT, RNG
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 325 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 6901138_2_06$79.55
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 798 pages
Quantity one is the manual described above.
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Other editions and similar models
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