Bobcat Excavators 325 328 6986940 Service Manual 2 08-21416B320072.pdf -Bookmark created by https://wimanual.com 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 LIFTING THE EXCAVATOR Procedure OPERATOR CAB (ROPS 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 HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic 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 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 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 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 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 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 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 Disassembly And Assembly RIGHT SIDE COVER Removal And Installation ELECTRICAL SYSTEM AND ANALYSIS ELECTRICAL SCHEMATICS 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 Boom Light Bulb Replacement 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 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 Removal And Installation HEATER COIL Removal And Installation BLOWER FAN Removal And Installation Disassembly And Assembly Resistor Removal And Installation HEATER VALVE Removal And Installation SPECIFICATIONS SPECIFICATIONS 325 325 Excavator Machine Dimensions 325 With Long Arm Option And 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 . 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