Bobcat X325, X328 Excavator Repair Service Manual - 6900462

325 (S/N: 514013001 & Above) - 328 (S/N: 516611001 & Above) 
- 
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 !!!! 

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
    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
    
    -