Bobcat X325 Excavator Repair Service Manual - 6724480

(S/N: 514011001 – 514012999) 
- 
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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

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
    
    -