325, 328 Mini Excavator Service Repair Manual G Series

6901138 (2-06) Printed in U.S.A. © Bobcat Company 2006 Service Manual S/N 232511001 & Above S/N 232411001 & Above (D Series) 325 328

MAINTENANCE SAFETY Never service the Bobcat Hydraulic Excavator without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. MSW21-0805 Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust fumes can kill without warning. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the excavator. Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Bobcat Company. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Cleaning and maintenance are required daily. B-10731a CORRECT B-15797 CORRECT B-15798 CORRECT WRONG B-15799 WRONG B-15800 WRONG B-15801 WRONG B-15802 WRONG B-16102 B-15780 WRONG B-6589 WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903 Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. Use the correct procedure to lift and support the excavator. Always lift the blade fully before installing jackstands.

325, 328 Excavator Service Manual ALPHABETICAL INDEX AIR CLEANER ........................................................ 60-01 AIR CLEANER SERVICE ....................................... 10-01 ALTERNATOR ....................................................... 50-01 ARM ....................................................................... 40-01 ARM CYLINDER .................................................... 20-01 BATTERY ................................................................ 50-01 BLADE ................................................................... 30-01 BLADE CONTROL .................................................. 40-01 BLADE CYLINDER ................................................. 20-01 BOOM ..................................................................... 40-01 BOOM CYLINDER .................................................. 20-01 BOOM OFFSET CYLINDER................................... 20-01 BUCKET ................................................................. 40-01 BUCKET CYLINDER .............................................. 20-01 CAB......................................................................... 40-01 CASE DRAIN FILTER ............................................ 20-01 CLAMP.................................................................... 40-01 CONVERSIONS ............................................... SPEC-01 CONTROL LINKAGE ASSEMBLY .......................... 40-01 CONTROL PATTERN SELECTOR VALVE ............ 20-01 CROSSPORT RELIEF VALVE ............................... 20-01 DIAGNOSTICS SERVICE CODE ........................... 50-01 DIRECT TO TANK VALVE ...................................... 20-01 ELECTRICAL SYSTEM INFORMATION ................ 50-01 ENGINE .................................................................. 60-01 ENGINE COMPONENTS AND TESTING .............. 60-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE FLYWHEEL .............................................. 60-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPECIFICATIONS............................... SPEC-01 ENGINE SPEED CONTROL .................................. 40-01 FLOORMAT AND FLOOR PANELS ....................... 40-01 FUEL, COOLANT AND LUBRICANTS ............. SPEC-01 FUEL LEVEL SENDER........................................... 50-01 FUEL SYSTEM ....................................................... 10-01 FUEL TANK............................................................. 40-01 HEATER ................................................................ 70-01 HEATER AIR FILTERS .......................................... 10-01 HEATER COIL ....................................................... 70-01 HEATER FAN ......................................................... 70-01 HEATER VALVE ..................................................... 70-01 HORN .................................................................... 40-01 HYDRAULIC CONNECTION SPECS ................ SPEC-01 HYDRAULIC CONTROL VALVE (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 & 232412129 .............................................................. 20-01 HYDRAULIC CONTROL VALVE (S/N 232312387 & ABOVE, 232412118-232412127 & 232412130 & & ABOVE ................................................................ 20-01 HYDRAULIC EXCAVATOR SPECS ................... SPEC-01 HYDRAULIC FLUID SPECIFICATIONS ............ SPEC-01 HYDRAULIC FILTER .............................................. 20-01 HYDRAULIC PUMP ................................................ 20-01 HYDRAULIC RESERVOIR ..................................... 20-01 HYDRAULIC SYSTEM ........................................... 10-01 HYDRAULIC SYSTEM INFORMATION ................. 20-01 LEFT CONTROL LEVER (JOYSTICK)(S/N 232312386 & BELOW, 232412117 & BELOW 232412128 & 232412129) ............................................................. 20-01 LEFT CONTROL LEVER (JOYSTICK)(S/N 232312387 & ABOVE, 232412118-232412127 & 232412130 & ABOVE) ................................................................ 20-01 LEFT CONSOLE ..................................................... 40-01 LIFTING AND BLOCKING THE EXCAVATOR ........ 10-01 LIFTING THE EXCAVATOR .................................... 10-01 LIGHTS.................................................................... 50-01 LUBRICATING THE EXCAVATOR .......................... 10-01 MAIN RELIEF VALVES............................................ 20-01 MANIFOLD ASSEMBLY .......................................... 20-01 MANIFOLD ASSEMBLY/ACCUMULATOR ............. 20-01 MICROSWITCH ..................................................... 50-01 MUFFLER ............................................................... 60-01 OIL COOLER........................................................... 20-01 OPERATOR CAB (ROPS/TOPS) ............................ 10-01 PORT RELIEF VALVES........................................... 20-01 PRESSURE REDUCING VALVE............................. 20-01 RADIATOR...............................................................60-01 RECONDITIONING THE ENGINE .........................60-01 RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW 232412128 AND 232412129) ..................................20-01 RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE) ....................................20-01 RIGHT CONSOLE ................................................... 40-01 RIGHT PEDAL AND LINKAGE ............................... 40-01 RIGHT SIDE COVER..................... .........................40-01 ROPS CANOPY.......................................................40-01 STANDARD SEAT AND MOUNT ........................... 40-01 SUSPENSION SEAT AND SEAT MOUNT ............. 40-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTOR MUFFLER.. ............................10-01 STARTER ................................................................ 50-01 SWING CIRCLE GEAR ........................................... 30-01 SWING FRAME ....................................................... 40-01 SWING LOCK.......................................................... 10-01 SWING MOTOR ..................................................... 20-01 SWING MOTOR DRIVE CARRIER .........................20-01 SWIVEL JOINT .......................................................20-01 TAILGATE ..................................................... 10-01, 40-01 TORQUE SPECIFICATIONS ............................SPEC-01 TRACKS .................................................................. 30-01 TRACK DAMAGE IDENTIFICATION....................... 30-01 TRACK FRAME ...................................................... 30-01 TRACK IDLER ........................................................30-01 TRACK ROLLER .....................................................30-01 TRANSPORTING THE EXCAVATOR...................... 10-01 TRAVEL CONTROLS .............................................. 40-01 TRAVEL MOTOR.......................................... 10-01, 20-01 TROUBLESHOOTING ............................................ 60-01 TWO SPEED SWITCH ............................................ 50-01 UPPERSTRUCTURE .............................................. 40-01 X-CHANGE™ .........................................................40-01

325, 328 Excavator Service Manual

325, 328 Excavator I Service Manual CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . X SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01 ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SAFETY & MAINTENANCE HYDRAULIC SYSTEM UNDERCARRIAGE UPPERSTRUCTURE & SWING SECTION ELECTRICAL SYSTEM & ANALYSIS SERVICE ENGINE HEATER SPECIFICATIONS

325, 328 Excavator II Service Manual

325, 328 Mini Excavator Service Repair Manual G Series

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