Bobcat 325, 328 Compact Excavator Service Manual 6986940 (7-11) – PDF DOWNLOAD

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Bobcat 325, 328 Compact Excavator Service Manual 6986940 (7-11) – PDF DOWNLOAD

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Bobcat 325 328 Compact Excavator Service Manual 6986940 (7-11) – PDF DOWNLOAD

Language : English
Pages : 802
Downloadable : Yes
File Type : PDF
Size: 32.3 mb

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Bobcat 325 328 Compact Excavator Service Manual 6986940 (7-11) – PDF DOWNLOAD

FOREWORD

This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc

A general inspection of the following items must be made after the excavator has had service or repair:

Maintenance

• The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.
• Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.
• The operator’s area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating. All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.

TABLE OF CONTENTS:

Bobcat 325 328 Compact Excavator Service Manual 6986940 (7-11) – PDF DOWNLOAD’

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
UPPERSTRUCTURE SLEW LOCK 23
Operation 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS / TOPS) 27
Emergency Exit 27
Front Window 28
Right Side Windows 30
Cab Door 31
TRANSPORTING THE EXCAVATOR ON A TRAILER 33
Loading And Unloading 33
Fastening 34
TAILGATE 35
Opening And Closing The Tailgate 35
Adjusting The Bumper 35
Adjusting The Latch 35
RIGHT SIDE COVER 37
Opening And Closing The Right Side Cover 37
Adjusting The Latch 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Daily Check 41
Replacing The Filters 41
CAB FILTERS 43
Cleaning And Maintenance 43
ENGINE COOLING SYSTEM 45
Cleaning 45
Checking Coolant Level 46
Removing And Replacing The Coolant 47
FUEL SYSTEM 49
Fuel Specifications 49
Biodiesel Blend Fuel 49
Filling The Fuel Tank 50
Removing Water 50
Draining The Fuel Tank 51
Fuel Filter 51
Removing Air From The Fuel System 52
ENGINE LUBRICATION SYSTEM 53
Checking And Adding Engine Oil 53
Engine Oil Chart 53
Removing And Replacing Oil And Filter 54
HYDRAULIC SYSTEM 57
Checking And Adding Fluid 57
Hydraulic / Hydrostatic Fluid Chart 58
Removing And Replacing The Hydraulic Filters 58
Removing And Replacing The Case Drain Filter 59
Removing And Replacing The Hydraulic Fluid 59
LUBRICATION OF THE HYDRAULIC EXCAVATOR 61
TRAVEL MOTOR 65
Checking And Adding Oil 65
Removing And Replacing Oil 65
SPARK ARRESTER MUFFLER 67
Cleaning Procedure 67
ALTERNATOR BELT 69
Belt Adjustment 69
Belt Replacement 69
SEAT BELT 71
Inspection And Maintenance 71
MOTION ALARM SYSTEM (IF EQUIPPED) 73
Description 73
Adjusting Switch Position 73
REMOTE START TOOL KIT – MEL1563 75
Remote Start Tool – MEL1563 75
Service Tool Harness Communicator – MEL1566 77
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031 79
Description 79
Remote Start Tool (Service Tool) – 7003030 80
Excavator Service Tool Harness – 6689747 81
Computer Service Tool Harness – 6689746 82
HYDRAULIC SYSTEM 83
HYDRAULIC / HYDROSTATIC SCHEMATICS 87
HYDRAULIC SYSTEM INFORMATION 89
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators 89
Troubleshooting The Hydraulic Circuit 92
Troubleshooting The Cylinder Circuit 93
Troubleshooting The Swing (Upperstructure Slew) Circuit 94
Troubleshooting The Travel Circuit 95
CYLINDER (BOOM) 97
Testing 97
Removal And Installation 100
Parts Identification 103
Disassembly 104
Assembly 106
CYLINDER (ARM) 109
Testing 109
Removal And Installation 111
Parts Identification 113
Disassembly 114
Assembly 116
CYLINDER (BOOM SWING) 119
Testing 119
Removal And Installation 121
Parts Identification 123
Disassembly 124
Assembly 126
CYLINDER (BUCKET) 129
Testing 129
Removal And Installation 131
Parts Identification 132
Disassembly 133
Assembly 135
CYLINDER (BLADE) 139
Testing 139
Removal And Installation 141
Parts Identification 142
Disassembly 143
Assembly 145
CYLINDER (CLAMP) 149
Testing 149
Removal And Installation 150
Parts Identification 151
Disassembly 152
Assembly 155
VALVES (MAIN RELIEF) 159
Testing And Adjusting The Main Relief Valves 159
VALVES (PORT RELIEF) 163
Testing And Adjusting The Port Relief Valves 163
VALVES (CROSSPORT RELIEF) 165
Testing And Adjusting The Crossport Relief Valves 165
VALVE (PRESSURE REDUCING) 169
Testing And Adjusting The Pressure Reducing Valve 169
HYDRAULIC CONTROL VALVE 171
Description 171
Removal And Installation 171
Control Valve Identification 179
Disassembly 180
Right Travel Valve Section Disassembly And Assembly 182
Boom Swing Valve Section Disassembly And Assembly 188
Boom Valve Section Disassembly And Assembly 195
Left Travel Valve Section Disassembly And Assembly 200
Arm Valve Section Disassembly And Assembly 205
Bucket Valve Section Disassembly And Assembly 209
Auxiliary Valve Section Disassembly And Assembly 213
Boost Valve Section Disassembly And Assembly 217
Blade Valve Section Disassembly And Assembly 222
Slew Valve Section Disassembly And Assembly 227
Assembly 231
HYDRAULIC PUMP 239
Description 239
Torque Adjustment 240
Testing The Piston Pump 241
Testing The Gear Pump 243
Testing Auxiliary Hydraulic Flow 245
Removal And Installation 246
Coupler Removal And Installation 247
Hydraulic Pump Start Up 248
Gear Pump Parts Identification 249
Piston Pump Parts Identification 250
Disassembly 251
Gear Pump Disassembly 252
Gear Pump Assembly 255
Piston Pump Disassembly 258
Piston Pump Assembly 264
MANIFOLD ASSEMBLY / ACCUMULATOR 273
Description 273
Removal And Installation 273
Parts Identification 277
Disassembly 278
Assembly 289
MANIFOLD ASSEMBLY 301
Parts Identification 301
Disassembly 302
Assembly 313
TRAVEL MOTOR 325
Removal And Installation 325
Parts Identification 326
Disassembly 327
Assembly 335
SWIVEL JOINT 345
Description 345
Removal And Installation 345
Parts Identification 347
Disassembly 348
Assembly 349
SWING MOTOR 353
Removal And Installation 353
Parts Identification 356
Disassembly 357
Assembly 362
SWING MOTOR DRIVE CARRIER 369
Removal And Installation 369
Parts Identification 370
Disassembly 371
Assembly 373
CONTROL PATTERN SELECTOR VALVE 377
Removal And Installation 377
Parts Identification 378
Disassembly 379
Assembly 380
RIGHT CONTROL LEVER (JOYSTICK) 381
Testing 381
Handle Removal And Installation 382
Joystick Assembly, Removal And Installation 386
Parts Identification 389
Disassembly 390
Assembly 395
LEFT CONTROL LEVER (JOYSTICK) 399
Testing 399
Handle Removal And Installation 400
Joystick Assembly Removal And Installation 403
Parts Identification 405
Disassembly 406
Assembly 411
HYDRAULIC FILTER MOUNT 417
Removal And Installation 417
HYDRAULIC RESERVOIR 419
Removal And Installation 419
OIL COOLER 421
Removal And Installation 421
DIRECT TO TANK VALVE 423
Removal And Installation 423
Disassembly And Assembly 424
BUILD UP VALVE 425
Description 425
Removal And Installation 425
Parts Identification 426
Disassembly And Assembly 427
CASE DRAIN FILTER 429
Removal And Installation 429
SLEW LOCK VALVE 431
Description 431
Removal And Installation 431
Parts Identification 432
Disassembly And Assembly 433
UNDERCARRIAGE 437
BLADE 439
Removal And Installation 439
TRACKS 441
Track Lug Height 441
Adjustment 441
Rubber Track Removal And Installation 444
Steel Track Removal And Installation 446
TRACK FRAME 449
Disassembly And Assembly 449
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511315 & Below, A9KO11108 & Below And A9K111109 & Below) 452
Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above) 453
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above) 454
TRACK DAMAGE IDENTIFICATION 457
Cutting Of Steel Cords 457
Abrasion Of Embedded Metals 458
Separation Of Embedded Metals 459
Separation Of Embedded Metals Due To Corrosion 460
Cuts On The Lug Side Rubber 461
Cracks On The Lug Side Rubber Due To Fatigue 462
Lug Abrasion 463
Cracks And Cuts On The Lug Side Rubber 464
Abrasion Of The Track Roller Side 465
Cuts On The Edges Of Track Roller Side 466
TRACK IDLER 469
Parts Identification 469
Disassembly 470
Assembly 472
TRACK ROLLER (AAC513024 & BELOW, A9K013003 & BELOW AND a9K113001 & BELOW) 475
Parts Identification 475
Disassembly 476
Assembly 478
SWING CIRCLE GEAR 481
Swing Bearing Removal 481
Swing Bearing Installation 482
UPPERSTRUCTURE AND SWING SECTION 483
UPPERSTRUCTURE 487
Removal 487
Installation 490
ROPS CANOPY 493
Removal And Installation 493
CAB 497
Removal And Installation 497
Door Removal And Installation 502
Front Window Removal And Installation 503
Right Side Rear Sliding Window Removal And Installation 506
Right Side Front Sliding Window Removal And Installation 506
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 507
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 507
Glass Removal 508
Glass Installation 509
SEAT AND SEAT MOUNT (STANDARD) 511
Removal And Installation 511
SEAT AND SEAT MOUNT (SUSPENSION) 513
Removal And Installation 513
RIGHT CONSOLE 515
Console Cover Removal And Installation 515
Console Base Removal And Installation 516
LEFT CONSOLE 519
Lower Console Cover Removal And Installation 519
Upper Console Cover Removal And Installation 521
Compression Spring Removal And Installation 522
Compression Spring Disassembly And Assembly 523
Lock Lever Removal And Installation 525
Console Removal And Installation 526
Disassembly And Assembly 530
Console Switch Removal And Installation 533
Console Base Removal And Installation 534
ENGINE SPEED CONTROL 535
Removal And Installation 535
Adjustment 536
BLADE CONTROL 537
Lever Removal And Installation 537
Linkage Removal And Installation 538
Linkage Bar Removal And Installation 540
Lower Linkage Removal And Installation 542
RIGHT PEDAL AND LINKAGE 545
Pedal Removal And Installation 545
Pedal Disassembly And Assembly 546
Linkage Removal And Installation 548
TRAVEL CONTROLS 549
Removal And Installation 549
Disassembly And Assembly 550
Adjustment 553
FLOOR MAT AND FLOOR PLATE 557
Removal And Installation (Canopy Equipped Excavators) 557
Removal And Installation (Cab Equipped Excavators) 558
FUEL TANK 559
Removal And Installation 559
HORN 563
Removal And Installation 563
SWING FRAME 565
Boom Swing Bracket Removal And Installation 565
Boom Swing Bracket Hose Installation 569
Bushing Removal 570
Bushing Installation 571
BOOM 573
Removal And Installation 573
ARM 575
Removal And Installation 575
Arm To Boom Bushing Removal And Installation 575
Arm To Bucket And Bucket Link Bushing Removal And Installation 576
BUCKET 577
Bucket Teeth Removal And Installation 577
Bucket Side Cutting Edge Removal And Installation 578
CLAMP 579
Removal And Installation 579
TAILGATE 581
Removal And Installation 581
Latch Removal And Installation 582
X-CHANGE 583
Removal And Installation 583
Disassembly 585
Assembly 589
Check Proper Latch Engagement 595
UPPERSTRUCTURE SLEW LOCK 599
Removal And Installation 599
Disassembly And Assembly 599
RIGHT SIDE COVER 601
Removal And Installation 601
QUICK COUPLER (KLAC™ SYSTEM) 603
Troubleshooting 603
Daily Inspection 603
Removal And Installation 604
Parts Identification 606
Disassembly 607
Assembly 608
QUICK COUPLER (LEHNHOFF® SYSTEM) 611
Troubleshooting 611
Daily Inspection 611
Removal (MS03 And MS08) 612
Installation (MS03 And MS08) 613
Parts Identification (MS03) 614
Disassembly And Assembly (MS03) 615
Parts Identification (MS08) 616
Disassembly (MS08) 617
Assembly (MS08) 620
ELECTRICAL SYSTEM & ANALYSIS 625
ELECTRICAL SCHEMATICS 627
ELECTRICAL SYSTEM INFORMATION 629
Troubleshooting Chart 629
Description 630
Fuse And Relay Location 630
BATTERY 631
Servicing 631
Removing And Installing The Battery 632
Using A Booster Battery (Jump Starting) 632
ALTERNATOR 635
Engine Accessory Drive Belt 635
Engine Accessory Drive Belt Tensioner Removal And Installation 636
Removal And Installation 637
Bracket Removal And Installation 638
Description 639
Tests 639
Alternator Output Test 640
Full Field Test 640
Alternator Regulator Test 641
Parts Identification 642
Disassembly And Assembly 643
Rotor Continuity Test 647
Rectifier Continuity (Diode) Test 648
STARTER 649
Removal And Installation 649
Parts Identification 650
Disassembly 651
Inspection And Repair 656
Assembly 659
LIGHTS 665
Removal And Installation 665
Boom Light Removal And Installation 666
Boom Light Bulb Replacement 666
TWO-SPEED SWITCH 667
Removal And Installation 667
FUEL LEVEL SENDER 669
Removal And Installation 669
Testing 669
DIAGNOSTICS SERVICE CODE 671
Number Codes List 671
DELUXE INSTRUMENT PANEL SETUP 673
Passwords 673
Password Entry (For Starting And Operating The Machine) 673
Changing The Owner or Operator Password 673
Password Lockout Feature 674
Job Clock 674
RPM 674
ENGINE SERVICE 675
TROUBLESHOOTING 677
Chart 677
MUFFLER 679
Removal And Installation 679
AIR CLEANER 681
Removal And Installation 681
RADIATOR 683
Removal And Installation 683
ENGINE COMPONENTS AND TESTING 685
Engine Compression Checking 685
Glow Plugs Removal And Installation 686
Checking The Glow Plug 687
Fuel Shut-Off Solenoid Removal And Installation 688
Fuel Injection Pump Check 690
Fuel Injection Pump Removal And Installation 691
Fuel Injection Pump Timing 694
Fuel Injector Nozzles Removal And Installation 696
Fuel Injector Nozzle Check 698
Valve Seat Tightness 699
Valve Clearance Adjustment 699
ENGINE 701
Removal And Installation 701
ENGINE FLYWHEEL 707
Flywheel Removal And Installation 707
Hydraulic Pump Coupler 709
Flywheel Ring Gear 710
RECONDITIONING THE ENGINE 711
Cylinder Head Removal And Installation 711
Cylinder Head Disassembly And Assembly 714
Cylinder Head Servicing 715
Cylinder Head Top Clearance 715
Valve Guide Checking 716
Reconditioning The Valve And Valve Seat 718
Valve Spring 719
Rocker Arm And Shaft Checking 720
Timing Gearcase Cover Removal And Installation 720
Idler Gear And Camshaft Removal And Installation 723
Camshaft Servicing 724
Idler Gear And Shaft Servicing 725
Timing Gears Checking Backlash 726
Fuel Camshaft Removal And Installation 726
Fuel Camshaft Governor 727
Crankshaft Gear Removal And Installation 727
Oil Pump Removal And Installation 728
Oil Pump Service 728
Checking Engine Oil Pressure 729
Valve Tappets 730
Piston And Connecting Rod Removal And Installation 730
Piston And Connecting Rod Servicing 732
Connecting Rod Alignment 734
Crankshaft And Bearings Removal And Installation 735
Crankshaft And Bearings, Servicing 737
Cylinder Bore, Checking 741
Water Pump Removal And Installation 741
Water Pump Disassembly And Assembly 742
HEATING, VENTILATION & AIR CONDITIONING 743
HEATER SYSTEM 745
Description 745
Components 745
REGULAR MAINTENANCE 747
Filter Element Removal And Installation 747
Heater Coil 748
TROUBLESHOOTING 749
Blower Motor Does Not Operate 749
Blower Motor Operates Normally, But Air Flow Is Insufficient 749
Electrical System 750
HEATER UNIT 755
Removal And Installation 755
HEATER COIL 757
Removal And Installation 757
BLOWER FAN 759
Removal And Installation 759
Disassembly And Assembly 760
Resistor Removal And Installation 761
HEATER VALVE 763
Removal And Installation 763
SPECIFICATIONS 765
SPECIFICATIONS 767
325, 328 Excavator Machine Dimensions 767
325 Excavator Machine Dimensions 768
325 With Long Arm Option And 328 Excavator Machine Dimensions 769
Performance 770
Controls 770
Engine 770
Hydraulic System 771
Hydraulic Cylinders 771
Hydraulic Cycle Times 772
Drive System 772
Undercarriage 772
Track 772
Electrical 772
ENGINE SPECIFICATIONS 773
Fuel Injection Nozzles 773
Fuel Injection Pump 773
Cylinder Head 773
Valves 773
Valve Springs 774
Valve Timing 774
Rocker Arms 774
Camshaft 774
Tappet 774
Cylinders 775
Piston Rings 775
Pistons 775
Connecting Rods 775
Oil Pump 775
Crankshaft 776
Timing Gear 776
Thermostat 777
Engine Bolt Torque 777
Crankshaft Re-Grind Data 778
TORQUE SPECIFICATIONS 781
Torque for General SAE Bolts 781
Torque For General Metric Bolts 782
HYDRAULIC CONNECTION SPECIFICATIONS 783
O-ring Face Seal Connection 783
Straight Thread O-ring Fitting 783
Tubelines And Hoses 783
Flare Fitting 784
O-ring Flare Fitting 785
Port Seal Fitting 787
HYDRAULIC FLUID SPECIFICATIONS 789
Specifications 789
FUEL, COOLANT AND LUBRICANTS 791
Chart 791
CONVERSIONS 793
Decimal And Millimeter Equivalents 793
U S To Metric Conversion 794
ALPHABETICAL INDEX 795
SERVICE MANUAL REVISION 797
Revision No: 325 / 328 – 1 797
Revision No: 325 / 328 – 2 799
Revision No: 325, 328 – 3 801

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