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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