Bobcat Excavators 325, 328, X325, X328 Repair Service Manuals
Catalog:
Model:
Complete repair service manual with Electrical Wiring Diagrams for Bobcat Excavators 325, 328, X325, X328, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Bobcat Excavators 325, 328, X325, X328 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
6722714 (9-97) - X 325 Excavator Operation & Maintenance Manual.pdf
6722849 (4–94) - X 325 Excavator Service Manual.pdf
6722849 (6–12) - X 325 Excavator Service Manual.pdf
6724322 (6-95) - X 325 Excavator Operation & Maintenance Manual.pdf
6724480 (6–12) - X 325 Excavator Service Manual.pdf
6724480 (11–95) - X 325 Excavator Service Manual.pdf
6724546 (5-97) - X 325 Excavator Operation & Maintenance Manual.pdf
6900462 (3–98) - X 325, X 328 Excavator Service Manual.pdf
6900462 (6–12) - X 325, X 328 Excavator Service Manual.pdf
6900556 (4-00) - X 325, X 328 Compact Excavator Operation & Maintenance Manual.pdf
6901018 (5-03) - 325, 328 Operation & Maintenance Manual.pdf
6901138 (2-06) - 325, 328 Service Manual.pdf
6901138 (6-12) - 325, 328 Service Manual.pdf
6902610 (5-07) - 325, 328 Compact Excavator Operation & Maintenance Manual.pdf
6902745 (10-09) - 325, 328 Service Manual.pdf
6986939 (10-09) - 325, 328 Compact Excavator Operation & Maintenance Manual.pdf
6986940 (7-11) - 325, 328 Compact Excavator Service Manual.pdf
6986940 (10-09) - 325, 328 Compact Excavator Service Manual.pdf
Total Pages: 6,252 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
6722714 (9-97) - X 325 Excavator Operation & Maintenance Manual...1
OPERATOR SAFETY WARNINGS...3
CONTENTS...5
REGULAR MAINTENANCE ITEMS...6
FOREWORD...7
SERIAL NUMBER LOCATIONS...9
HYDRAULIC EXCAVATOR SERIAL NUMBER...9
ENGINE SERIAL NUMBER...9
DELIVERY REPORT...9
HYDRAULIC EXCAVATOR IDENTIFICATION...10
SAFETY...11
SAFETY INSTRUCTIONS...13
FIRE PREVENTION...15
MACHINE SIGNS (DECALS)...16
OPERATING INSTRUCTIONS...19
GETTING ON AND OFF THE MACHINE...21
SEAT...22
CONTROL CONSOLE LEVER LOCK...22
INSTRUMENT PANEL...23
FUSES...23
AUDIBLE ALARM...24
KEY SWITCH...24
LIGHT SWITCH...24
AUXILIARY POWER OUTLET...24
CAB ELECTRICAL (Cab Option)...25
HEATER CONTROL...25
WASHER...25
CONTROL LEVERS...26
Operation Of Left Control Lever (ISO)...26
Operation Of Right Control Lever (ISO)...26
Operation Of Left Control Lever (STANDARD)...27
Operation Of Right Control Lever (STANDARD)...27
SWING LOCKING LEVER...28
HORN BUTTON...28
SPEED CONTROL LEVER...29
ENGINE STOP CONTROL...29
STEERING LEVERS/FOOT PEDALS...30
Forward and Reverse Travel...30
Turning...30
Making A Counter–Rotation Turn...30
BOOM SWING PEDAL...31
AUXILIARY OPERATION PEDAL LOCK/FOOTREST...31
BLADE CONTROL LEVER...31
DAILY INSPECTION...32
STARTING/STOPPING THE ENGINE...32
Normal Starting Procedure (With Engine Warm)...32
Cold Temperature Starting Condition...33
OPERATING PROCEDURE...34
Breaking In A New Machine...34
Operating On Slopes...35
Operating in Water...36
PARKING THE HYDRAULIC EXCAVATOR...36
TRANSPORTING THE HYDRAULIC EXCAVATOR...37
LIFTING THE EXCAVATOR...38
LIFTING A LOAD...38
BUCKET...39
Removal...39
Installation...39
OPERATOR’S HANDBOOK (If Equipped)...40
STORAGE COMPARTMENT (If Equipped)...40
CAB OPTION...41
Opening the Front Window...41
Closing the Front Window...41
PREVENTIVE MAINTENANCE...43
MAINTENANCE SAFETY...44
SERVICE SCHEDULE...45
ENGINE COVER...46
AIR CLEANER SERVICE...46
FUEL SYSTEM...48
Fuel Specifications...48
Fuel System Service...48
Fuel Filter...49
Removing Air From The Fuel System...49
ENGINE LUBRICATION SYSTEM...50
Engine Oil And Filter Replacement...50
COOLING SYSTEM...51
Coolant Level...51
Coolant Replacement...51
Ethylene Glycol...51
Propylene Glycol...51
ALTERNATOR/FAN BELT ADJUSTMENT...52
ELECTRICAL SYSTEM...53
Fuses...53
Service The Electrical System...53
Using A Booster Battery (Jump Starting)...54
Removal and Installation of the Battery (S/N 511820001–511820294)...55
Removal and Installation of the Battery (S/N 511820295 & Above)...56
HYDRAULIC SYSTEM...57
Checking and Adding Fluid...57
Replacement of the Hydraulic Filter...57
Hydraulic Reservoir...58
Case Drain Line Filter...58
Diagnostic Couplers...58
LUBRICATION OF THE HYDRAULIC EXCAVATOR...59
FINAL DRIVE CASE...61
Checking Oil Level...61
Draining Final Drive Case...61
TRACK TENSION...62
Adjustment...62
Rubber Tracks...62
Steel Tracks...63
JOYSTICK CONTROL CHANGE...64
SPECIFICATIONS...65
HYDRAULIC EXCAVATOR SPECIFICATIONS...67
Machine Dimensions...67
Lifting Capacity...68
OPERATION & PERFORMANCE...68
ENGINE...68
HYDRAULIC SYSTEM...69
SWING SYSTEM...69
CYLINDER CYCLE TIMES...69
HYDRAULIC CYLINDERS...69
DRIVE SYSTEM...69
UNDERCARRIAGE...69
BRAKES...69
TRACKS...69
CAPACITIES...69
DIGGING FORCE...69
FUEL, COOLANT AND LUBRICANTS...70
ENGINE OIL SPECIFICATIONS...70
Description...70
Ethylene Glycol...70
Propylene Glycol...70
BUCKET SPECIFICATIONS...71
ADDITIONAL PUBLICATIONS...72
WARRANTY...73
6722849 (4–94) - X 325 Excavator Service Manual...75
MAINTENANCE SAFETY...77
ALPHABETICAL INDEX...79
FOREWORD...81
CONTENTS...83
SAFETY INSTRUCTIONS...85
HYDRAULIC EXCAVATOR SERIAL NUMBER...86
ENGINE SERIAL NUMBER...86
DELIVERY REPORT...86
HYDRAULIC EXCAVATOR IDENTIFICATION...87
PREVENTIVE MAINTENANCE...89
SERVICE SCHEDULE...91
ENGINE COVER...92
Procedure...92
AIR CLEANER SERVICE...92
Replacing The Filter Element...92
FUEL SYSTEM...94
Fuel Specification...94
Fuel System Service...94
Fuel Filter...95
Maintenance...95
Removal And Installation...95
Removing Air From The Fuel System...95
ENGINE LUBRICATION SYSTEM...96
Checking The Engine Oil...96
Engine Oil And Filter Replacement...96
COOLING SYSTEM...97
Coolant Level...97
Coolant Replacement...97
HYDRAULIC SYSTEM...98
Checking And Adding Fluid...98
Replacement Of The Hydraulic Filter...98
Hydraulic Reservoir...99
USING A BOOSTER BATTERY (Jump Starting)...100
Procedure...100
LUBRICATION OF THE HYDRAULIC EXCAVATOR...101
Procedure...101
FINAL DRIVE CASE...103
Checking Oil Level...103
Draining Final Drive Case...103
HYDRAULIC SECTION...105
HYDRAULIC SCHEMATIC...109
HYDRAULIC SERVICE INFORMATION...114
Checking The Main Relief Valve...114
Checking The Hydraulic Pump...115
Removal And Installation...116
Parts Identification (S/N 51182001 – 511820408)...116
Disassembly And Assembly (S/N 511820001–511820408)...117
Parts Identification (S/N 511820409 & Above)...121
Disassembly (S/N 511820409 & Above)...122
Assembly (S/N 511820409 & Above)...124
HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511820001–511820519)...127
Removal And Installation...127
Parts Identification...128
Disassembly...129
Inlet Section (R.H. and L.H. Travel)...130
Disassembly...130
Assembly...131
Valve Sections (Boom, Bucket & Arm)...132
Disassembly...132
Assembly...133
Valve Sections (Auxiliary)...134
Disassembly...134
Assembly...135
Port Relief Valve...137
Disassembly...137
Assembly...137
Adjustment...138
Main Relief Valve...139
Disassembly...139
Assembly...139
Adjustment...139
HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511820001–511820519)...140
Removal And Installation...140
Parts Identification...141
Disassembly...142
Inlet Section (Housing Swing)...143
Disassembly...143
Assembly...143
End Cover (Boom Swing) And Valve Section (Blade)...144
Disassembly...144
Assembly...146
Load Check Block...148
Disassembly...148
Assembly...149
Build–up Valve...150
Disassembly...150
Assembly...150
Disassembly...151
Assembly...151
Adjustment...151
HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE (S/N 511820520 & Above)...152
Description...152
Removal And Installation...152
Parts Identification...153
Disassembly...154
Inlet Section Disassembly And Assembly...155
Right Hand And Left Hand Travel Section...156
Disassembly...156
Assembly...157
Boom, Bucket And Arm Section...159
Disassembly...159
Assembly...160
Auxiliary Valve Section...162
Disassembly...162
Assembly...163
PORT RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above)...166
Parts Identification...166
Disassembly...167
Assembly...168
Adjustment...168
MAIN RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above)...169
Parts Identification...169
Disassembly...170
Assembly...170
Adjusting The Main Relief Valves...171
HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511820520 & Above)...172
Removal And Installation...172
Parts Identification...173
Disassembly...174
Blade And Boom Swing Section...175
Disassembly...175
Assembly...177
Lockout Valve Disassembly...178
Lockout Valve Assembly...179
Swing Motor Section...180
Disassembly...180
Assembly...181
Build Up Valve Disassembly...184
Build Up Valve Assembly...184
Build Up Valve Test Procedure...185
ACCUMULATOR...186
Pressure Reducing Valve...186
Removal And Installation...186
Parts Identification...186
Disassembly...187
Assembly...191
Setting The Safety Relief Valve...195
Charging...196
PORT BLOCK...197
Removal And Installation...197
OIL COOLER...198
Removal And Installation...198
HYDRAULIC RESERVOIR...199
Removal And Installation...199
HYDRAULIC FILTER ASSEMBLY...201
Removal And Installation...201
BOOM CYLINDER...202
Removal And Installation...202
Boom Cylinder Shield...202
ARM CYLINDER...203
Removal And Installation...203
BUCKET CYLINDER...204
Removal And Installation...204
BLADE CYLINDER...205
Removal And Installation...205
BOOM SWING CYLINDER...206
Removal And Installation...206
HYDRAULIC CYLINDER...207
Disassembly...207
Assembly...209
JOYSTICK CONTROL CHANGE...214
DRIVE SECTION...216
LEFT CONSOLE...218
Lockout Valve Removal And Installation...218
Cylinder Removal And Installation...218
Removal And Installation...219
LEFT JOYSTICK...220
Removal And Installation...220
JOYSTICK...221
Disassembly And Assembly...221
CONTROL LEVERS...225
Removal And Installation...225
Speed Control Lever...227
Blade Lever...228
RIGHT CONSOLE...229
Removal And Installation...229
RIGHT JOYSTICK...231
Removal And Installation...231
FOOT PEDALS AND STEERING LEVERS...232
Removal And Installation...232
Bushing Removal And Installation...233
UPPER WORKS AND SWING SECTION...234
ENGINE COVER...236
Removal And Installation...236
SEAT AND MOUNTING FRAME...236
Removal And Installation...236
CENTER FLOOR PANEL...237
Removal And Installation...237
SWING MOTOR COVER...238
Removal And Installation...238
REAR FLOOR PANEL...238
Removal And Installation...238
INSPECTION COVER...239
Removal And Installation...239
TOOL BOX...239
Removal And Installation...239
LEFT HAND SIDE COVER...239
Removal And Installation...239
CORNER POST...240
Removal And Installation...240
COUNTERWEIGHTS...241
Removal And Installation...241
FRONT ENGINE COVER...242
Removal And Installation...242
FUEL TANK...243
Removal And Installation...243
BUCKET...245
Removal And Installation...245
BUCKET TEETH...245
Removal And Installation...245
ARM...246
Removal And Installation...246
BOOM...247
Removal And Installation...247
BOOM SWING BRACKET...248
Removal And Installation...248
Replacing Boom Swing Bracket Bushings...248
SWING MOTOR...250
Removal And Installation...250
Parts Identification...251
Disassembly...252
Assembly...254
CROSS PORT RELIEF VALVE (S/N 511820001–511820519)...259
Disassembly...259
Assembly...260
Description...261
COUNTER BALANCE VALVE (S/N 511820520 &Above)...262
Removal And Installation...262
Disassembly...262
Assembly...263
SWING GEAR BOX ASSEMBLY...265
Parts Identification...265
Disassembly...266
Assembly...272
UPPERSTRUCTURE AND SWING CIRCLE GEAR...282
Removal And Installation...282
Swing Bearing Removal...283
Swing Bearing Installation...285
Alignment Pins (Threaded)...285
Alignment Pins (Not Threaded)...286
CENTER SWIVEL JOINT...287
Removal And Installation (Through Upper Access Cover)...287
Removal And Installation (Through Bottom Access Cover)...287
Parts Identification (S/N 511820001–511820197)...289
Parts Identification (S/N 511820198 & Above)...290
Description...291
Disassembly (S/N 511820198 & Above)...291
Assembly (S/N 511820198 & Above)...292
ROPS CANOPY...295
Removal And Installation...295
CAB...297
Removal And Installation...297
Door Removal And Installation...300
Front Window Removal And Installation...301
Front Lower Glass Removal And Installation...303
Front Upper Plexiglass Removal And Installation...303
Door Glass Removal And Installation...304
Left Hand Side Glass Removal And Installation...304
Rear Glass Removal And Installation...305
Right Hand Side Glass Removal And Installation...305
CAB/CANOPY REAR COVER...306
Removal And Installation...306
MAIN FRAME AND TRACKS...308
BLADE...310
Removal And Installation...310
TRACK...311
Track Tension Adjustment...311
Rubber Tracks...311
Steel Tracks...312
Removal And Installation...313
TRACK FRAME...317
Disassembly And Assembly...317
TRACK IDLER...318
Parts Identification...318
Disassembly...319
Assembly...321
TRACK ROLLER...327
Parts Identification...327
Disassembly...328
Assembly...330
FINAL DRIVE...335
Removal And Installation...335
Parts Identification...336
FINAL DRIVE...337
Parts Identification...337
TRAVEL MOTOR...338
Disassembly...338
Assembly...349
FINAL DRIVE CASE...359
Check Oil Level...359
Draining Final Drive Case...359
TRACK...360
Damage Identification And Causes...360
ELECTRICAL SYSTEM...370
ELECTRICAL SCHEMATICS...372
TROUBLESHOOTING...374
ELECTRICAL SYSTEM...374
Description...374
Fuses...375
Electrical System Service...375
BATTERY (S/N 20001–20294)...376
Checking The Battery...376
Removal And Installation...376
BATTERY(S/N 20295 and up)...377
Checking The Battery...377
Removal And Installation...377
ALTERNATOR...378
Belt Adjustment...378
Removal And Installation...378
STARTER...379
Removal And Installation...379
Disassembly And Assembly...380
Cleaning And Inspection...380
FUEL LEVEL SENDER...381
Removal And Installation...381
Checking...381
INSTRUMENT PANEL...382
Removal And Installation...382
CAB ELECTRICAL (Cab Option)...383
ENGINE SERVICE...384
TROUBLESHOOTING...386
VALVE CLEARANCE...387
Adjustment...387
ENGINE COMPRESSION...388
Checking...388
ELECTRIC FUEL PUMP...389
Remove Air From The Fuel System...389
Removal And Installation...389
FUEL FILTER...389
Removal And Installation...389
FUEL INJECTION PUMP...390
Checking The Injection Pump...390
Removal And Installation...391
Timing The Injection Pump...392
FUEL INJECTOR NOZZLES...393
Removal And Installation...393
Checking The Injector Nozzle...394
GLOW PLUGS...395
Removal And Installation...395
Checking The Glow Plug...395
RADIATOR...396
Removal And Installation...396
MUFFLER...400
Removal And Installation...400
AIR CLEANER...401
Removal And Installation...401
ENGINE...402
Removal And Installation...402
ENGINE FLYWHEEL...404
Removal And Installation...404
Flywheel Ring Gear...405
CYLINDER HEAD...406
Removal...406
Disassembly Of The Cylinder Head...407
Servicing The Cylinder Head And Valves...408
Checking Valve Springs...409
Checking Rocker Arm And Shaft...410
Assembling The Cylinder Head...410
Installing The Cylinder Head...410
TIMING GEAR COVER...412
Removal And Installation...412
TIMING GEAR, CAMSHAFT AND OIL PUMP...414
Removal And Installation...414
Oil Pump Service...416
Servicing The Camshaft...417
CRANKSHAFT & PISTONS...419
Removal And Installation...419
Crankshaft Service...421
Servicing The Connecting Rods And Pistons...422
Checking The Cylinder Liners...424
Cylinder Liner Installation...424
WATER PUMP...425
Removal And Installation...425
Disassembly And Assembly...425
SPECIFICATIONS...426
EXCAVATOR SPECIFICATIONS...428
Machine Dimensions...428
Lifting Capacity...429
PERFORMANCE & OPERATION...429
ENGINE...429
HYDRAULIC SYSTEM...430
SWING SYSTEM...430
HYDRAULIC CYLINDERS...430
CYLINDER CYCLE TIMES...430
DRIVE SYSTEM...430
BRAKES...430
UNDERCARRIAGE...430
TRACK...430
CAPACITIES...430
DIGGING FORCE...430
ENGINE SPECIFICATIONS...431
Fuel Injection Nozzles...431
Fuel Injection Pump...431
Cylinder Head...431
Valves...431
Valve Springs...431
Rocker Arms...431
Camshaft...431
Cylinders...432
Piston Rings...432
Pistons...432
Crankshaft...432
Oil Pump...432
Engine Oil...432
Specifications...432
ENGINE BOLT TORQUE...433
FUEL, COOLANT AND LUBRICANTS...434
CHART...434
ENGINE OIL SPECIFICATIONS...434
Description...434
Ethylene Glycol...434
Propylene Glycol...434
Re–Grinding The Crankshaft...435
BUCKET SPECIFICATIONS...436
DECIMAL AND MILLIMETER EQUIVALENTS...437
U.S. TO METRIC CONVERSION...437
SERVICE MANUAL REVISION...438
325-1...438
325-2...440
325-3...442
6722849 (6–12) - X 325 Excavator Service Manual...444
MAINTENANCE SAFETY...446
ALPHABETICAL INDEX...448
FOREWORD...450
CONTENTS...452
SAFETY INSTRUCTIONS...454
HYDRAULIC EXCAVATOR SERIAL NUMBER...455
ENGINE SERIAL NUMBER...455
DELIVERY REPORT...455
HYDRAULIC EXCAVATOR IDENTIFICATION...456
PREVENTIVE MAINTENANCE...458
SERVICE SCHEDULE...460
ENGINE COVER...461
Procedure...461
AIR CLEANER SERVICE...461
Replacing The Filter Element...461
FUEL SYSTEM...463
Fuel Specification...463
Fuel System Service...463
Fuel Filter...464
Maintenance...464
Removal And Installation...464
Removing Air From The Fuel System...464
ENGINE LUBRICATION SYSTEM...465
Checking The Engine Oil...465
Engine Oil And Filter Replacement...465
COOLING SYSTEM...466
Coolant Level...466
Coolant Replacement...466
HYDRAULIC SYSTEM...467
Checking And Adding Fluid...467
Replacement Of The Hydraulic Filter...467
Hydraulic Reservoir...468
USING A BOOSTER BATTERY (Jump Starting)...469
Procedure...469
LUBRICATION OF THE HYDRAULIC EXCAVATOR...470
Procedure...470
FINAL DRIVE CASE...472
Checking Oil Level...472
Draining Final Drive Case...472
HYDRAULIC SECTION...474
HYDRAULIC SCHEMATIC...478
HYDRAULIC SERVICE INFORMATION...484
Checking The Main Relief Valve...484
Checking The Hydraulic Pump...485
Removal And Installation...486
Parts Identification (S/N 51182001 – 511820408)...486
Disassembly And Assembly (S/N 511820001–511820408)...487
Parts Identification (S/N 511820409 & Above)...491
Disassembly (S/N 511820409 & Above)...492
Assembly (S/N 511820409 & Above)...494
HYDRAULIC CONTROL VALVE (6–Spool) DUKES VALVE (S/N 511820001–511820519)...497
Removal And Installation...497
Parts Identification...498
Disassembly...499
Inlet Section (R.H. and L.H. Travel)...500
Disassembly...500
Assembly...501
Valve Sections (Boom, Bucket & Arm)...502
Disassembly...502
Assembly...503
Valve Sections (Auxiliary)...504
Disassembly...504
Assembly...505
Port Relief Valve...507
Disassembly...507
Assembly...507
Adjustment...508
Main Relief Valve...509
Disassembly...509
Assembly...509
Adjustment...509
HYDRAULIC CONTROL VALVE (3–Spool) DUKES VALVE (S/N 511820001–511820519)...510
Removal And Installation...510
Parts Identification...511
Disassembly...512
Inlet Section (Housing Swing)...513
Disassembly...513
Assembly...513
End Cover (Boom Swing) And Valve Section (Blade)...514
Disassembly...514
Assembly...516
Load Check Block...518
Disassembly...518
Assembly...519
Build–up Valve...520
Disassembly...520
Assembly...520
Disassembly...521
Assembly...521
Adjustment...521
HYDRAULIC CONTROL VALVE (6–Spool) HUSCO VALVE (S/N 511820520 & Above)...522
Description...522
Removal And Installation...522
Parts Identification...523
Disassembly...524
Inlet Section Disassembly And Assembly...525
Right Hand And Left Hand Travel Section...526
Disassembly...526
Assembly...527
Boom, Bucket And Arm Section...529
Disassembly...529
Assembly...530
Auxiliary Valve Section...532
Disassembly...532
Assembly...533
PORT RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above)...536
Parts Identification...536
Disassembly...537
Assembly...538
Adjustment...538
MAIN RELIEF VALVES HUSCO VALVE (S/N 511820520 & Above)...539
Parts Identification...539
Disassembly...540
Assembly...540
Adjusting The Main Relief Valves...541
HYDRAULIC CONTROL VALVE (3–Spool) HUSCO VALVE (S/N 511820520 & Above)...542
Removal And Installation...542
Parts Identification...543
Disassembly...544
Blade And Boom Swing Section...545
Disassembly...545
Assembly...547
Lockout Valve Disassembly...548
Lockout Valve Assembly...549
Swing Motor Section...550
Disassembly...550
Assembly...551
Build Up Valve Disassembly...554
Build Up Valve Assembly...554
Build Up Valve Test Procedure...555
ACCUMULATOR...556
Pressure Reducing Valve...556
Removal And Installation...556
Parts Identification...556
Disassembly...557
Assembly...561
Setting The Safety Relief Valve...565
Charging...566
PORT BLOCK...567
Removal And Installation...567
OIL COOLER...568
Removal And Installation...568
HYDRAULIC RESERVOIR...569
Removal And Installation...569
HYDRAULIC FILTER ASSEMBLY...571
Removal And Installation...571
BOOM CYLINDER...572
Removal And Installation...572
Boom Cylinder Shield...572
ARM CYLINDER...573
Removal And Installation...573
BUCKET CYLINDER...574
Removal And Installation...574
BLADE CYLINDER...575
Removal And Installation...575
BOOM SWING CYLINDER...576
Removal And Installation...576
HYDRAULIC CYLINDER...577
Disassembly...577
Assembly...579
JOYSTICK CONTROL CHANGE...584
DRIVE SECTION...586
LEFT CONSOLE...588
Lockout Valve Removal And Installation...588
Cylinder Removal And Installation...588
Removal And Installation...589
LEFT JOYSTICK...590
Removal And Installation...590
JOYSTICK...591
Disassembly And Assembly...591
CONTROL LEVERS...595
Removal And Installation...595
Speed Control Lever...597
Blade Lever...598
RIGHT CONSOLE...599
Removal And Installation...599
RIGHT JOYSTICK...601
Removal And Installation...601
FOOT PEDALS AND STEERING LEVERS...602
Removal And Installation...602
Bushing Removal And Installation...603
UPPER WORKS AND SWING SECTION...604
ENGINE COVER...606
Removal And Installation...606
SEAT AND MOUNTING FRAME...606
Removal And Installation...606
CENTER FLOOR PANEL...607
Removal And Installation...607
SWING MOTOR COVER...608
Removal And Installation...608
REAR FLOOR PANEL...608
Removal And Installation...608
INSPECTION COVER...609
Removal And Installation...609
TOOL BOX...609
Removal And Installation...609
LEFT HAND SIDE COVER...609
Removal And Installation...609
CORNER POST...610
Removal And Installation...610
COUNTERWEIGHTS...611
Removal And Installation...611
FRONT ENGINE COVER...612
Removal And Installation...612
FUEL TANK...613
Removal And Installation...613
BUCKET...615
Removal And Installation...615
BUCKET TEETH...615
Removal And Installation...615
ARM...616
Removal And Installation...616
BOOM...617
Removal And Installation...617
BOOM SWING BRACKET...618
Removal And Installation...618
Replacing Boom Swing Bracket Bushings...618
SWING MOTOR...620
Removal And Installation...620
Parts Identification...621
Disassembly...622
Assembly...624
CROSS PORT RELIEF VALVE (S/N 511820001–511820519)...629
Disassembly...629
Assembly...630
Description...631
COUNTER BALANCE VALVE (S/N 511820520 &Above)...632
Removal And Installation...632
Disassembly...632
Assembly...633
SWING GEAR BOX ASSEMBLY...635
Parts Identification...635
Disassembly...636
Assembly...642
UPPERSTRUCTURE AND SWING CIRCLE GEAR...652
Removal And Installation...652
Swing Bearing Removal...653
Swing Bearing Installation...655
Alignment Pins (Threaded)...655
Alignment Pins (Not Threaded)...656
CENTER SWIVEL JOINT...657
Removal And Installation (Through Upper Access Cover)...657
Removal And Installation (Through Bottom Access Cover)...657
Parts Identification (S/N 511820001–511820197)...659
Parts Identification (S/N 511820198 & Above)...660
Description...661
Disassembly (S/N 511820198 & Above)...661
Assembly (S/N 511820198 & Above)...662
ROPS CANOPY...665
Removal And Installation...665
CAB...667
Removal And Installation...667
Door Removal And Installation...670
Front Window Removal And Installation...671
Front Lower Glass Removal And Installation...673
Front Upper Plexiglass Removal And Installation...673
Door Glass Removal And Installation...674
Left Hand Side Glass Removal And Installation...674
Rear Glass Removal And Installation...675
Right Hand Side Glass Removal And Installation...675
CAB/CANOPY REAR COVER...676
Removal And Installation...676
MAIN FRAME AND TRACKS...678
BLADE...680
Removal And Installation...680
TRACK...681
Track Tension Adjustment...681
Rubber Tracks...681
Steel Tracks...682
Removal And Installation...683
TRACK FRAME...687
Disassembly And Assembly...687
TRACK IDLER...688
Parts Identification...688
Disassembly...689
Assembly...691
TRACK ROLLER...697
Parts Identification...697
Disassembly...698
Assembly...700
FINAL DRIVE...705
Removal And Installation...705
Parts Identification...706
FINAL DRIVE...707
Parts Identification...707
TRAVEL MOTOR...708
Disassembly...708
Assembly...719
FINAL DRIVE CASE...729
Check Oil Level...729
Draining Final Drive Case...729
TRACK...730
Damage Identification And Causes...730
ELECTRICAL SYSTEM...740
ELECTRICAL SCHEMATICS...742
TROUBLESHOOTING...744
ELECTRICAL SYSTEM...744
Description...744
Fuses...745
Electrical System Service...745
BATTERY (S/N 20001–20294)...746
Checking The Battery...746
Removal And Installation...746
BATTERY(S/N 20295 and up)...747
Checking The Battery...747
Removal And Installation...747
ALTERNATOR...748
Belt Adjustment...748
Removal And Installation...748
STARTER...749
Removal And Installation...749
Disassembly And Assembly...750
Cleaning And Inspection...750
FUEL LEVEL SENDER...751
Removal And Installation...751
Checking...751
INSTRUMENT PANEL...752
Removal And Installation...752
CAB ELECTRICAL (Cab Option)...753
ENGINE SERVICE...754
TROUBLESHOOTING...756
VALVE CLEARANCE...757
Adjustment...757
ENGINE COMPRESSION...758
Checking...758
ELECTRIC FUEL PUMP...759
Remove Air From The Fuel System...759
Removal And Installation...759
FUEL FILTER...759
Removal And Installation...759
FUEL INJECTION PUMP...760
Checking The Injection Pump...760
Removal And Installation...761
Timing The Injection Pump...762
FUEL INJECTOR NOZZLES...763
Removal And Installation...763
Checking The Injector Nozzle...764
GLOW PLUGS...765
Removal And Installation...765
Checking The Glow Plug...765
RADIATOR...766
Removal And Installation...766
MUFFLER...770
Removal And Installation...770
AIR CLEANER...771
Removal And Installation...771
ENGINE...772
Removal And Installation...772
ENGINE FLYWHEEL...774
Removal And Installation...774
Flywheel Ring Gear...775
CYLINDER HEAD...776
Removal...776
Disassembly Of The Cylinder Head...777
Servicing The Cylinder Head And Valves...778
Checking Valve Springs...779
Checking Rocker Arm And Shaft...780
Assembling The Cylinder Head...780
Installing The Cylinder Head...780
TIMING GEAR COVER...782
Removal And Installation...782
TIMING GEAR, CAMSHAFT AND OIL PUMP...784
Removal And Installation...784
Oil Pump Service...786
Servicing The Camshaft...787
CRANKSHAFT & PISTONS...789
Removal And Installation...789
Crankshaft Service...791
Servicing The Connecting Rods And Pistons...792
Checking The Cylinder Liners...794
Cylinder Liner Installation...794
WATER PUMP...795
Removal And Installation...795
Disassembly And Assembly...795
SPECIFICATIONS...796
EXCAVATOR SPECIFICATIONS...798
Machine Dimensions...798
Lifting Capacity...799
PERFORMANCE & OPERATION...799
ENGINE...799
HYDRAULIC SYSTEM...800
SWING SYSTEM...800
HYDRAULIC CYLINDERS...800
CYLINDER CYCLE TIMES...800
DRIVE SYSTEM...800
BRAKES...800
UNDERCARRIAGE...800
TRACK...800
CAPACITIES...800
DIGGING FORCE...800
ENGINE SPECIFICATIONS...801
Fuel Injection Nozzles...801
Fuel Injection Pump...801
Cylinder Head...801
Valves...801
Valve Springs...801
Rocker Arms...801
Camshaft...801
Cylinders...802
Piston Rings...802
Pistons...802
Crankshaft...802
Oil Pump...802
Engine Oil...802
Specifications...802
ENGINE BOLT TORQUE...803
FUEL, COOLANT AND LUBRICANTS...804
CHART...804
ENGINE OIL SPECIFICATIONS...804
Description...804
Ethylene Glycol...804
Propylene Glycol...804
Re–Grinding The Crankshaft...805
BUCKET SPECIFICATIONS...806
DECIMAL AND MILLIMETER EQUIVALENTS...807
U.S. TO METRIC CONVERSION...807
SERVICE MANUAL REVISION...808
325-1...808
325-2...810
325-3...812
325-4...814
6724322 (6-95) - X 325 Excavator Operation & Maintenance Manual...816
OPERATOR SAFETY WARNINGS...818
CONTENTS...820
REGULAR MAINTENANCE ITEMS...821
FOREWORD...822
SERIAL NUMBER LOCATIONS...824
HYDRAULIC EXCAVATOR SERIAL NUMBER...824
ENGINE SERIAL NUMBER...824
DELIVERY REPORT...824
HYDRAULIC EXCAVATOR IDENTIFICATION...825
SAFETY...826
SAFETY INSTRUCTIONS...828
FIRE PREVENTION...830
MACHINE SIGNS (DECALS)...831
OPERATING INSTRUCTIONS...834
GETTING ON AND OFF THE MACHINE...836
SEAT...837
CONTROL CONSOLE LEVER LOCK...837
INSTRUMENT PANEL...838
FUSES...838
OPERATOR'S HANDBOOK...839
STORAGE COMPARTMENT...839
AUDIBLE ALARM...840
KEY SWITCH...840
LIGHT SWITCH...840
AUXILIARY POWER OUTLET...840
CAB ELECTRICAL (Cab Option)...841
HEATER CONTROL...841
WASHER...841
CONTROL LEVERS...842
Operation Of Left Control Lever (ISO)...842
Operation Of Right Control Lever (ISO)...842
Operation Of Left Control Lever (STANDARD)...843
Operation Of Right Control Lever (STANDARD)...843
SWING LOCKING LEVER...844
HORN BUTTON...844
SPEED CONTROL LEVER...845
STEERING LEVERS/FOOT PEDALS...846
Forward And Reverse Travel...846
Turning...846
BOOM SWING PEDAL...847
AUXILIARY OPERATION PEDAL...847
BLADE CONTROL LEVER...847
DAILY INSPECTION...848
STARTING/STOPPING THE ENGINE...848
Normal Starting Procedure (With Engine Warm)...848
Cold Temperature Starting Condition...849
OPERATING PROCEDURE...850
Breaking In A New Machine...850
General Operation Suggestions...850
Operating In Water...852
PARKING THE HYDRAULIC EXCAVATOR...852
LIFTING THE EXCAVATOR...853
LIFTING A LOAD...853
TRANSPORTING THE HYDRAULIC EXCAVATOR...854
BUCKET...855
Removal...855
Installation...855
CAB OPTION...856
Opening The Front Window...856
Closing The Front Window...856
CAB/CANOPY FOPS (Falling Object Protective Structure)...856
PREVENTIVE MAINTENANCE...858
MAINTENANCE SAFETY...859
SERVICE SCHEDULE...861
ENGINE COVER...862
AIR CLEANER SERVICE...862
FUEL SYSTEM...864
Fuel Specifications...864
Filling The Fuel Tank...864
Fuel System Maintenance...865
Fuel Filter...865
Removing Air Fron The Fuel System...865
ENGINE LUBRICATION SYSTEM...866
Engine Oil And Filter Replacement...866
COOLING SYSTEM...867
Coolant Level...867
Coolant Replacement...867
Propylene Glycol (Factory Installed)...867
ALTERNATOR/FAN BELT ADJUSTMENT...868
ELECTRICAL RELAYS AND DIODES...868
ELECTRICAL SYSTEM...869
Fuses...869
Service The Electrical System (And Battery)...869
Using A Booster Battery (Jump Starting)...870
Removal And Installation Of The Battery...871
Electric Solenoid (Engine Stop)...871
HYDRAULIC SYSTEM...872
Checking And Adding Fluid...872
Return Line Filter Service...872
Replacement Of The Hydraulic Filter...872
Hydraulic Reservoir...873
Diagnostic Couplers...873
SPARK ARRESTOR MUFFLER...874
LUBRICATION OF THE HYDRAULIC EXCAVATOR...875
FINAL DRIVE CASE...877
Checking Oil Level...877
Draining Final Drive Case...877
TRACK TENSION...878
Adjustment...878
Rubber Tracks...878
Steel Tracks...879
JOYSTICK CONTROL CHANGE...880
SPECIFICATIONS...882
HYDRAULIC EXCAVATOR SPECIFICATIONS...884
Machine Dimensions...884
Lifting Capacity...885
OPERATION & PERFORMANCE...885
ENGINE...885
HYDRAULIC SYSTEM...886
SWING SYSTEM...886
CYLINDER CYCLE TIMES...886
HYDRAULIC CYLINDERS...886
DRIVE SYSTEM...886
UNDERCARRIAGE...886
BRAKES...886
TRACKS...886
CAPACITIES...886
DIGGING FORCE...886
VIBRATION DATA...886
FUEL, COOLANT AND LUBRICANTS...887
ENGINE OIL SPECIFICATIONS...887
Description...887
Propylene Glycol (Factory Installed)...887
BUCKET SPECIFICATIONS...888
WARRANTY...890
6724480 (11–95) - X 325 Excavator Service Manual...892
MAINTENANCE SAFETY...894
ALPHABETICAL INDEX...896
CONTENTS...898
FOREWORD...900
SAFETY INSTRUCTIONS...902
SERIAL NUMBER LOCATIONS...903
HYDRAULIC EXCAVATOR SERIAL NUMBER...903
ENGINE SERIAL NUMBER...903
DELIVERY REPORT...903
HYDRAULIC EXCAVATOR IDENTIFICATION...904
PREVENTIVE MAINTENANCE...906
SERVICE SCHEDULE...908
LIFTING AND BLOCKING THE EXCAVATOR...910
Procedure...910
TRANSPORTING THE HYDRAULIC EXCAVATOR...911
Procedure...911
ENGINE COVER...912
Procedure...912
AIR CLEANER SERVICE...912
Replacing the Filter Element...912
FUEL SYSTEM...914
Fuel Specifications...914
Filling the Fuel Tank...914
Fuel System Maintenance...915
Fuel Filter...915
Removing Air From the Fuel System...915
ENGINE LUBRICATION SYSTEM...916
Checking Engine Oil...916
Engine Oil and Filter Replacement...916
COOLING SYSTEM...917
Coolant Level...917
Coolant Replacement...917
Propylene Glycol (Factory Installed)...917
HYDRAULIC SYSTEM...918
Checking and Adding Fluid...918
Return Line Filter Service...918
Replacement of the Hydraulic Filter...918
Hydraulic Reservoir...919
USING A BOOSTER BATTERY (Jump Starting)...920
Procedure...920
LUBRICATION OF THE HYDRAULIC EXCAVATOR...921
FINAL DRIVE CASE...924
Checking Oil Level (S/N 12999 & Below)...924
Draining Final Drive Case (S/N 12999 & Below)...924
Checking Oil Level (S/N 13001 & Above)...925
Draining Final Drive Case (S/N 13001 & Above)...925
HEATER AIR FILTER SERVICE...925
SPARK ARRESTOR MUFFLER...926
Cleaning Spark Arrestor Muffler...926
HYDRAULIC SECTION...928
HYDRAULIC SCHEMATICS...931
HYDRAULIC SYSTEM TROUBLESHOOTING...939
HYDRAULIC SERVICE INFORMATION...944
Checking the Main Relief Valves (S/N 11001–12999)...944
Checking the Main Relief Valves (S/N 13001 & Above)...945
Testing the 4050 PSI (27925 kPa) Circuit Relief Valve...946
Testing the Auxiliary and Bucket Circuit Relief Valve...947
Testing the Left Hand Travel Circuit Relief Valve...948
Testing the Right Hand Travel Circuit Relief Valve...949
Testing the Boom Circuit Relief Valve...950
Checking the Hydraulic Pump...951
HYDRAULIC PUMP...952
Removal and Installation...952
Parts Identification...953
Disassembly...954
Assembly...956
HYDRAULIC CONTROL VALVE (6 Spool) HUSCO VALVE (S/N 11001–12999)...959
Removal and Installation...959
Parts Identification...960
Disassembly...961
Inlet Section...962
Right Hand & Left Hand Travel...963
Disassembly...963
Assembly...964
Boom, Bucket & Arm...966
Disassembly...966
Assembly...967
Port Relief Valves (Adjustable)...973
Auxiliary...969
Disassembly...969
Assembly...970
Port Relief Valves (Adjustable)...973
Parts Identification...973
Port Relief Valve Pressure Setting...974
Disassembly...974
Assembly...975
Adjustment Procedure...975
Main Relief Valves...976
Parts Identification...976
Disassembly...977
Assembly...977
Adjusting the Main Relief Valves...978
HYDRAULIC CONTROL VALVE (3 Spool) HUSCO VALVE (S/N 11001 –12999)...979
Description...979
Removal and Installation...979
Parts Identification...980
Disassembly...981
Blade and Boom Swing...982
Disassembly...982
Assembly...984
Lockout Valve Assembly...985
Disassembly...985
Assembly...986
Swing Motor Valve...987
Disassembly...987
Assembly...988
Build–Up Valve...991
Disassembly...991
Assembly...991
Test Procedure...992
HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)...993
Left Travel, Right Travel, Boom, Bucket and Auxiliary...993
Description...993
Removal and Installation...993
Parts Identification...994
Disassembly...995
Outlet Sections Disassembly...996
Outlet Sections Assembly...996
Mid Inlet Section Disassembly...996
Mid Inlet Section Assembly...996
Left Travel, Right Travel and Auxiliary Disassembly...997
Left Travel, Right Travel and Auxiliary Assembly...999
Boom and Bucket Disassembly...1001
Boom and Bucket Assembly...1003
Assembly...1005
PORT RELIEF VALVES AND MAIN RELIEF VALVES (S/N 13001 & Above)...1006
Parts Identification...1006
Port Relief Valve Pressure Setting...1007
Disassembly...1007
Assembly...1008
MAIN RELIEF VALVES (Adjustable) (S/N 13001 & Above)...1009
Parts Identification...1009
Assembly...1010
Disassembly...1011
Assembly...1011
Adjusting the Main Relief Valves...1012
HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)...1013
Boost, Arm, Boom Swing, Blade and Swing Section...1013
Description...1013
Removal and Installation...1013
Parts Identification...1014
Disassembly...1015
Inlet Section...1016
Arm, Boost and Swing Motor Disassembly...1017
Arm, Boost and Swing Motor Assembly...1019
Boom Swing Disassembly...1021
Boom Swing Assembly...1023
Blade Disassembly...1026
Blade Assembly...1028
Assembly...1030
ACCUMULATOR (S/N 11001 – 12999)...1031
Pressure Reducing Valve...1031
Description...1031
Test Procedure...1031
Removal and Installation...1031
Parts Identification...1032
Disassembly...1033
Assembly...1037
Charging...1041
Setting the Safety Relief Valve...1042
ACCUMULATOR (S/N 13001 & Above)...1043
Removal and Installation...1043
Parts Identification...1044
PORT BLOCK...1045
Removal and Installation (S/N 11001–12999)...1045
Removal and Installation (S/N 13001 & Above)...1045
AUXILIARY SELECTOR VALVE...1046
Removal and Installation (S/N 11001–12999)...1046
Removal and Installation (S/N 13001 & Above)...1046
Disassembly and Assembly...1046
TWO SPEED VALVE (S/N 13001 & Above)...1047
Removal and Installation...1047
OIL COOLER...1048
Removal and Installation...1048
HYDRAULIC RESERVOIR...1049
Removal and Installation...1049
HYDRAULIC FILTER ASSEMBLY...1051
Removal and Installation...1051
RETURN LINE FILTER...1051
Removal and Installation...1051
BOOM CYLINDER...1052
Removal and Installation...1052
BOOM CYLINDER SHIELD...1052
Removal and Installation...1052
ARM CYLINDER...1053
Removal and Installation...1053
BUCKET CYLINDER...1054
Removal and Installation...1054
BLADE CYLINDER...1055
Removal and Installation...1055
BOOM SWING CYLINDER...1056
Removal and Installation...1056
HYDRAULIC CYLINDERS...1057
Disassembly...1057
Assembly...1059
JOYSTICK CONTROL CHANGE...1064
ISO to STANDARD Control Pattern (S/N 12999 & Below)...1064
STANDARD to ISO Control Pattern (S/N 12999 & Below)...1064
ISO to STANDARD Control Pattern (S/N 13001 & Above)...1065
STANDARD to ISO Control Pattern (S/N 13001 & Above)...1065
DRIVE SECTION...1066
LEFT CONSOLE (S/N 11001 – 12999)...1068
Lockout Valve Removal and Installation...1068
Cylinder Removal and Installation...1068
Removal and Installation...1069
LEFT CONSOLE (S/N 13001 & Above)...1070
Control Lock Micro–Switch...1070
Removal and Installation...1070
Cylinder Removal and Installation...1071
Removal and Installation...1072
Release Handle...1073
Removal and Installation...1073
Disassembly and Assembly...1074
Adjustment...1074
Latch Plate ...1074
Adjustment...1074
JOYSTICK (S/N 11001 –12999)...1075
Left Joystick...1075
Removal and Installation...1075
Parts Identification...1076
Right Joystick...1077
Removal and Installation...1077
Troubleshooting...1077
Parts Identification...1078
Disassembly and Assembly...1079
JOYSTICK (S/N 13001 & Above )...1083
Removal and Installation...1083
Parts Identification...1084
Disassembly...1086
Assembly...1089
Troubleshooting...1094
CONTROL LEVERS...1095
Removal and Installation...1095
Low Idle Adjustment...1097
High Idle Adjustment...1097
Speed Control Lever...1097
Blade Lever...1098
RIGHT CONSOLE...1099
Removal and Installation (S/N 11001 –12999)...1099
Removal and Installation (S/N 13001 & Above)...1101
FOOT PEDALS AND STEERING LEVERS...1103
Removal and Installation...1103
Bushing Removal and Installation...1104
UPPER WORKS AND SWING SECTION...1106
REAR ENGINE COVER...1108
Removal and Installation...1108
SEAT AND MOUNTING FRAME...1108
Removal and Installation...1108
CENTER FLOOR PANEL...1109
Removal and Installation...1109
S/N 12999 & Below...1110
S/N 13001 & Above...1110
SWING MOTOR COVER...1111
Removal and Installation...1111
REAR FLOOR PANEL...1111
Removal and Installation...1111
TOOL BOX...1111
Removal and Installation...1111
LEFT SIDE COVER...1111
Removal and Installation...1111
CORNER POST...1112
Removal and Installation...1112
COUNTERWEIGHTS...1113
Removal and Installation...1113
FRONT ENGINE COVER...1114
Removal and Installation...1114
FUEL TANK...1115
Removal and Installation...1115
BUCKET...1117
Removal and Installation...1117
ARM...1118
Removal and Installation...1118
BOOM...1119
Removal and Installation...1119
BOOM SWING BRACKET...1120
Removal...1120
Installation...1121
Hose Installation...1122
SWING BRACKET BUSHING...1123
Bushing Removal...1123
Bushing Installation...1123
SWING MOTOR...1124
Removal and Installation...1124
Parts Identification...1125
Disassembly...1126
Assembly ...1128
CROSS PORT RELIEF VALVE...1133
Disassembly...1133
Assembly...1134
Description...1135
Testing...1135
SWING MOTOR DRIVE CARRIER...1136
Removal and Installation...1136
Parts Identification...1136
Disassembly...1137
Assembly...1138
UPPERSTRUCTURE AND SWING CIRCLE GEAR...1142
Removal and Installation...1142
Swing Bearing Removal...1143
Swing Bearing Installation...1144
Alignment Pins (Threaded)...1145
Alignment Pins (Not Threaded)...1146
CENTER SWIVEL JOINT...1147
Removal and Installation (Through Upper AccessCover)...1147
Removal and Installation (Through Bottom Access Cover) (S/N 11001–12999)...1147
Removal and Installation (Through Bottom Access Cover) (S/N 13001 & Above)...1149
Parts Identification...1150
Description...1151
Disassembly...1151
Assembly...1152
ROPS CANOPY...1155
Removal and Installation...1155
CAB...1157
Removal and Installation...1157
Two Piece Side Window...1159
Three Piece Side Windows...1160
Door Removal and Installation...1160
Front Window Removal and Installation...1161
Front Lower Glass Removal and Installation...1163
Front Upper Plexiglass Removal and Installation...1163
Left Hand Side Glass Removal and Installation...1163
Door Glass Removal and Installation...1164
Rear Glass Removal and Installation...1164
Right Hand Side Glass Removal and Installation...1165
Two Piece Side Window...1165
Three Piece Side Window...1165
CAB/CANOPY REAR COVER...1167
Removal...1167
Installation...1167
MAIN FRAME AND TRACKS...1168
BLADE...1170
Removal and Installation...1170
TRACK...1170
Track Lug Height...1170
Track Tension...1171
Rubber Tracks...1171
Steel Tracks...1172
Adjustment (S/N 11001–12999)...1172
Adjustment (S/N 13001 & Above)...1173
Removal and Installation...1174
TRACK FRAME...1178
Disassembly and Assembly (S/N 11001–12999)...1178
Disassembly and Assembly (S/N 13001 & Above)...1179
TRAVEL MOTOR...1181
Testing...1181
Removal and Installation (S/N 11001–12999)...1182
Removal and Installation (S/N 13001 & Above)...1183
Parts Identification (S/N 11001–12999)...1185
Disassembly (S/N 11001–12999)...1187
Assembly (S/N 11001–12999)...1198
Check Oil Level (S/N 11001–12999)...1208
Draining Final Drive Case (S/N 11001–12999)...1208
TRAVEL MOTOR (SOM)...1208
Checking Oil Level (S/N 13001 & Above)...1209
Draining Final Drive Case (S/N 13001 & Above)...1209
Parts Identification (S/N 13001 & Above)...1210
Disassembly (S/N 13001 & Above)...1211
Assembly (S/N 13001 & Above)...1218
TRACK DAMAGE IDENTIFICATION...1227
Cutting of Steel Cords...1227
Abrasion of Embedded Metals...1228
Separation of Embedded Metals...1229
Separation of Embedded Metals Due To Corrosion...1230
Cuts On The Lug Side Rubber...1231
Cracks Of The Lug Side Rubber Due To Fatigue...1232
Lug Abrasion...1233
Cracks And Cuts On The Lug Side Rubber...1233
Abrasion Of The Track Roller Side...1234
Cuts On The Edges Of Track Roller Side...1235
ELECTRICAL SYSTEM...1236
ELECTRICAL SCHEMATICS...1239
TROUBLESHOOTING...1243
Chart...1243
ELECTRICAL SYSTEM...1243
Description...1243
Fuses...1244
Electrical System Service...1244
BATTERY...1245
Checking the Battery...1245
Removal and Installation...1245
ALTERNATOR...1246
Belt Adjustment...1246
Removal and Installation...1246
Disassembly and Inspection...1247
Stator Continuity Test...1247
Stator Ground Test...1247
Rotor Continuity Test...1248
Rotor Ground Test...1248
Rectifier Continuity (Diode) Test...1248
Assembly...1249
STARTER...1250
Removal and Installation...1250
Parts Identification...1250
Disassembly and Assembly...1251
Cleaning and Inspection...1252
FUEL LEVEL SENDER...1254
Removal and Installation...1254
Checking...1254
INSTRUMENT PANEL...1255
Removal and Installation...1255
GAUGES...1255
Removal and Installation...1255
GAUGE LIGHTS...1256
Removal and Installation...1256
CAB ELECTRICAL (Cab Option)...1256
ENGINE SYSTEM...1257
TROUBLESHOOTING...1259
VALVE CLEARANCE...1260
Adjustment...1260
ENGINE COMPRESSION...1260
Checking...1260
FUEL SHUTOFF SOLENOID...1262
Adjustment...1262
Removal and Installation...1262
Timer Module Removal and Installation...1262
FUEL INJECTION PUMP...1263
Checking the Injection Pump...1263
Removal and Installation...1263
Timing the Injection Pump...1265
FUEL INJECTOR NOZZLES...1267
Removal and Installation...1267
Checking the Injector Nozzle...1268
GLOW PLUGS...1269
Removal and Installation...1269
Checking the Glow Plug...1269
FAN GUARD...1270
Removal and Installation...1270
RADIATOR...1271
Removal and Installation...1271
MUFFLER...1272
Removal and Installation...1272
AIR CLEANER...1273
Removal and Installation...1273
ENGINE...1274
Removal and Installation...1274
ENGINE FLYWHEEL...1278
Removal and Installation...1278
FLYWHEEL RING GEAR...1279
CYLINDER HEAD...1280
Removal and Installation...1280
Disassembly and Assembly of the Cylinder Head...1281
Servicing the Cylinder Head...1282
Top Clearance...1282
VALVE, VALVE SEAT AND GUIDE...1283
Checking the Valve Guide...1283
Reconditioning the Valve and Valve Seat...1284
Valve Spring...1285
ROCKER ARM AND SHAFT...1285
Checking...1285
TIMING GEARCASE COVER...1286
Removal and Installation...1286
IDLER GEAR AND CAMSHAFT...1288
Removal and Installation...1288
Servicing the Idler Gear and Shaft...1290
TIMING GEARS...1290
Checking Backlash...1290
FUEL CAMSHAFT...1291
Removal and Installation...1291
Governor...1291
CRANKSHAFT GEAR...1292
Removal and Installation...1292
OIL PUMP...1292
Removal and Installation...1292
Oil Pump Service...1292
Checking Engine Oil Pressure...1293
Relief Valve...1293
PISTON AND CONNECTING ROD...1294
Removal and Installation...1294
Servicing the Piston and Connecting Rod...1295
Connecting Rod Alignment...1297
CRANKSHAFT AND BEARINGS...1298
Removal and Installation...1298
Servicing the Crankshaft and Bearings...1299
CYLINDER BORE...1302
Checking the Cylinder Bore...1302
WATER PUMP...1303
Disassembly and Assembly...1303
SPECIFICATIONS...1305
HYDRAULIC EXCAVATOR SPECIFICATIONS...1307
Machine Dimensions...1307
Lifting Capacity...1308
HYDRAULIC SYSTEM...1309
SWING SYSTEM...1309
HYDRAULIC CYLINDERS...1309
DRIVE SYSTEM...1309
BRAKES...1309
UNDERCARRIAGE...1309
STD TRACK SHOES...1309
CAPACITIES...1309
DIGGING FORCE...1309
ENGINE SPECIFICATIONS...1310
Fuel Injection Nozzles...1310
Fuel Injection Pump...1310
Cylinder Head...1310
Valves...1310
Valve Springs...1310
Valve Timing...1310
Rocker Arms...1310
Camshaft...1311
Tappet...1311
Cylinders...1311
Piston Rings...1311
Pistons...1311
Connecting Rod...1311
Oil Pump...1311
Crankshaft...1311
Timing Gear...1312
Thermostat...1312
Engine Bolt Torque...1312
Re–Grinding The Crankshaft...1313
FUEL, COOLANT AND LUBRICANTS CHART...1314
ENGINE OIL SPECIFICATIONS...1314
Description...1314
Ethylene Glycol...1314
Propylene Glycol...1314
BUCKET SPECIFICATIONS...1315
DECIMAL AND MILLIMETER EQUIVALENTS...1316
U.S. TO METRIC CONVERSION...1316
SERVICE MANUAL REVISION...1317
325-1...1317
325-2...1319
325-3...1321
325-4...1323
325-5...1325
6724480 (6–12) - X 325 Excavator Service Manual...1327
MAINTENANCE SAFETY...1329
ALPHABETICAL INDEX...1331
CONTENTS...1333
FOREWORD...1335
SAFETY INSTRUCTIONS...1337
SERIAL NUMBER LOCATIONS...1338
HYDRAULIC EXCAVATOR SERIAL NUMBER...1338
ENGINE SERIAL NUMBER...1338
DELIVERY REPORT...1338
HYDRAULIC EXCAVATOR IDENTIFICATION...1339
PREVENTIVE MAINTENANCE...1341
SERVICE SCHEDULE...1343
LIFTING AND BLOCKING THE EXCAVATOR...1345
Procedure...1345
TRANSPORTING THE HYDRAULIC EXCAVATOR...1346
Procedure...1346
ENGINE COVER...1347
Procedure...1347
AIR CLEANER SERVICE...1347
Replacing the Filter Element...1347
FUEL SYSTEM...1349
Fuel Specifications...1349
Filling the Fuel Tank...1349
Fuel System Maintenance...1350
Fuel Filter...1350
Removing Air From the Fuel System...1350
ENGINE LUBRICATION SYSTEM...1351
Checking Engine Oil...1351
Engine Oil and Filter Replacement...1351
COOLING SYSTEM...1352
Coolant Level...1352
Coolant Replacement...1352
Propylene Glycol (Factory Installed)...1352
HYDRAULIC SYSTEM...1353
Checking and Adding Fluid...1353
Return Line Filter Service...1353
Replacement of the Hydraulic Filter...1353
Hydraulic Reservoir...1354
USING A BOOSTER BATTERY (Jump Starting)...1355
Procedure...1355
LUBRICATION OF THE HYDRAULIC EXCAVATOR...1356
FINAL DRIVE CASE...1359
Checking Oil Level (S/N 12999 & Below)...1359
Draining Final Drive Case (S/N 12999 & Below)...1359
Checking Oil Level (S/N 13001 & Above)...1360
Draining Final Drive Case (S/N 13001 & Above)...1360
HEATER AIR FILTER SERVICE...1360
SPARK ARRESTOR MUFFLER...1361
Cleaning Spark Arrestor Muffler...1361
HYDRAULIC SECTION...1363
HYDRAULIC SCHEMATICS...1367
HYDRAULIC SYSTEM TROUBLESHOOTING...1375
HYDRAULIC SERVICE INFORMATION...1380
Checking the Main Relief Valves (S/N 11001–12999)...1380
Checking the Main Relief Valves (S/N 13001 & Above)...1381
Testing the 4050 PSI (27925 kPa) Circuit Relief Valve...1382
Testing the Auxiliary and Bucket Circuit Relief Valve...1383
Testing the Left Hand Travel Circuit Relief Valve...1384
Testing the Right Hand Travel Circuit Relief Valve...1385
Testing the Boom Circuit Relief Valve...1386
Checking the Hydraulic Pump...1387
HYDRAULIC PUMP...1388
Removal and Installation...1388
Parts Identification...1389
Disassembly...1390
Assembly...1392
HYDRAULIC CONTROL VALVE (6 Spool) HUSCO VALVE (S/N 11001–12999)...1395
Removal and Installation...1395
Parts Identification...1396
Disassembly...1397
Inlet Section...1398
Right Hand & Left Hand Travel...1399
Disassembly...1399
Assembly...1400
Boom, Bucket & Arm...1402
Disassembly...1402
Assembly...1403
Port Relief Valves (Adjustable)...1409
Auxiliary...1405
Disassembly...1405
Assembly...1406
Port Relief Valves (Adjustable)...1409
Parts Identification...1409
Port Relief Valve Pressure Setting...1410
Disassembly...1410
Assembly...1411
Adjustment Procedure...1411
Main Relief Valves...1412
Parts Identification...1412
Disassembly...1413
Assembly...1413
Adjusting the Main Relief Valves...1414
HYDRAULIC CONTROL VALVE (3 Spool) HUSCO VALVE (S/N 11001 –12999)...1415
Description...1415
Removal and Installation...1415
Parts Identification...1416
Disassembly...1417
Blade and Boom Swing...1418
Disassembly...1418
Assembly...1420
Lockout Valve Assembly...1421
Disassembly...1421
Assembly...1422
Swing Motor Valve...1423
Disassembly...1423
Assembly...1424
Build–Up Valve...1427
Disassembly...1427
Assembly...1427
Test Procedure...1428
HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)...1429
Left Travel, Right Travel, Boom, Bucket and Auxiliary...1429
Description...1429
Removal and Installation...1429
Parts Identification...1430
Disassembly...1431
Outlet Sections Disassembly...1432
Outlet Sections Assembly...1432
Mid Inlet Section Disassembly...1432
Mid Inlet Section Assembly...1432
Left Travel, Right Travel and Auxiliary Disassembly...1433
Left Travel, Right Travel and Auxiliary Assembly...1435
Boom and Bucket Disassembly...1437
Boom and Bucket Assembly...1439
Assembly...1441
PORT RELIEF VALVES AND MAIN RELIEF VALVES (S/N 13001 & Above)...1442
Parts Identification...1442
Port Relief Valve Pressure Setting...1443
Disassembly...1443
Assembly...1444
MAIN RELIEF VALVES (Adjustable) (S/N 13001 & Above)...1445
Parts Identification...1445
Assembly...1446
Disassembly...1447
Assembly...1447
Adjusting the Main Relief Valves...1448
HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)...1449
Boost, Arm, Boom Swing, Blade and Swing Section...1449
Description...1449
Removal and Installation...1449
Parts Identification...1450
Disassembly...1451
Inlet Section...1452
Arm, Boost and Swing Motor Disassembly...1453
Arm, Boost and Swing Motor Assembly...1455
Boom Swing Disassembly...1457
Boom Swing Assembly...1459
Blade Disassembly...1462
Blade Assembly...1464
Assembly...1466
ACCUMULATOR (S/N 11001 – 12999)...1467
Pressure Reducing Valve...1467
Description...1467
Test Procedure...1467
Removal and Installation...1467
Parts Identification...1468
Disassembly...1469
Assembly...1473
Charging...1477
Setting the Safety Relief Valve...1478
ACCUMULATOR (S/N 13001 & Above)...1479
Removal and Installation...1479
Parts Identification...1480
PORT BLOCK...1481
Removal and Installation (S/N 11001–12999)...1481
Removal and Installation (S/N 13001 & Above)...1481
AUXILIARY SELECTOR VALVE...1482
Removal and Installation (S/N 11001–12999)...1482
Removal and Installation (S/N 13001 & Above)...1482
Disassembly and Assembly...1482
TWO SPEED VALVE (S/N 13001 & Above)...1483
Removal and Installation...1483
OIL COOLER...1484
Removal and Installation...1484
HYDRAULIC RESERVOIR...1485
Removal and Installation...1485
HYDRAULIC FILTER ASSEMBLY...1487
Removal and Installation...1487
RETURN LINE FILTER...1487
Removal and Installation...1487
BOOM CYLINDER...1488
Removal and Installation...1488
BOOM CYLINDER SHIELD...1488
Removal and Installation...1488
ARM CYLINDER...1489
Removal and Installation...1489
BUCKET CYLINDER...1490
Removal and Installation...1490
BLADE CYLINDER...1491
Removal and Installation...1491
BOOM SWING CYLINDER...1492
Removal and Installation...1492
HYDRAULIC CYLINDERS...1493
Disassembly...1493
Assembly...1495
JOYSTICK CONTROL CHANGE...1500
ISO to STANDARD Control Pattern (S/N 12999 & Below)...1500
STANDARD to ISO Control Pattern (S/N 12999 & Below)...1500
ISO to STANDARD Control Pattern (S/N 13001 & Above)...1501
STANDARD to ISO Control Pattern (S/N 13001 & Above)...1501
DRIVE SECTION...1502
LEFT CONSOLE (S/N 11001 – 12999)...1504
Lockout Valve Removal and Installation...1504
Cylinder Removal and Installation...1504
Removal and Installation...1505
LEFT CONSOLE (S/N 13001 & Above)...1506
Control Lock Micro–Switch...1506
Removal and Installation...1506
Cylinder Removal and Installation...1507
Removal and Installation...1508
Release Handle...1509
Removal and Installation...1509
Disassembly and Assembly...1510
Adjustment...1510
Latch Plate ...1510
Adjustment...1510
JOYSTICK (S/N 11001 –12999)...1511
Left Joystick...1511
Removal and Installation...1511
Parts Identification...1512
Right Joystick...1513
Removal and Installation...1513
Troubleshooting...1513
Parts Identification...1514
Disassembly and Assembly...1515
JOYSTICK (S/N 13001 & Above )...1519
Removal and Installation...1519
Parts Identification...1520
Disassembly...1522
Assembly...1525
Troubleshooting...1530
CONTROL LEVERS...1531
Removal and Installation...1531
Low Idle Adjustment...1533
High Idle Adjustment...1533
Speed Control Lever...1533
Blade Lever...1534
RIGHT CONSOLE...1535
Removal and Installation (S/N 11001 –12999)...1535
Removal and Installation (S/N 13001 & Above)...1537
FOOT PEDALS AND STEERING LEVERS...1539
Removal and Installation...1539
Bushing Removal and Installation...1540
UPPER WORKS AND SWING SECTION...1542
REAR ENGINE COVER...1544
Removal and Installation...1544
SEAT AND MOUNTING FRAME...1544
Removal and Installation...1544
CENTER FLOOR PANEL...1545
Removal and Installation...1545
S/N 12999 & Below...1546
S/N 13001 & Above...1546
SWING MOTOR COVER...1547
Removal and Installation...1547
REAR FLOOR PANEL...1547
Removal and Installation...1547
TOOL BOX...1547
Removal and Installation...1547
LEFT SIDE COVER...1547
Removal and Installation...1547
CORNER POST...1548
Removal and Installation...1548
COUNTERWEIGHTS...1549
Removal and Installation...1549
FRONT ENGINE COVER...1550
Removal and Installation...1550
FUEL TANK...1551
Removal and Installation...1551
BUCKET...1553
Removal and Installation...1553
ARM...1554
Removal and Installation...1554
BOOM...1555
Removal and Installation...1555
BOOM SWING BRACKET...1556
Removal...1556
Installation...1557
Hose Installation...1558
SWING BRACKET BUSHING...1559
Bushing Removal...1559
Bushing Installation...1559
SWING MOTOR...1560
Removal and Installation...1560
Parts Identification...1561
Disassembly...1562
Assembly ...1564
CROSS PORT RELIEF VALVE...1569
Disassembly...1569
Assembly...1570
Description...1571
Testing...1571
SWING MOTOR DRIVE CARRIER...1572
Removal and Installation...1572
Parts Identification...1572
Disassembly...1573
Assembly...1574
UPPERSTRUCTURE AND SWING CIRCLE GEAR...1578
Removal and Installation...1578
Swing Bearing Removal...1579
Swing Bearing Installation...1580
Alignment Pins (Threaded)...1581
Alignment Pins (Not Threaded)...1582
CENTER SWIVEL JOINT...1583
Removal and Installation (Through Upper AccessCover)...1583
Removal and Installation (Through Bottom Access Cover) (S/N 11001–12999)...1583
Removal and Installation (Through Bottom Access Cover) (S/N 13001 & Above)...1585
Parts Identification...1586
Description...1587
Disassembly...1587
Assembly...1588
ROPS CANOPY...1591
Removal and Installation...1591
CAB...1593
Removal and Installation...1593
Two Piece Side Window...1595
Three Piece Side Windows...1596
Door Removal and Installation...1596
Front Window Removal and Installation...1597
Front Lower Glass Removal and Installation...1599
Front Upper Plexiglass Removal and Installation...1599
Left Hand Side Glass Removal and Installation...1599
Door Glass Removal and Installation...1600
Rear Glass Removal and Installation...1600
Right Hand Side Glass Removal and Installation...1601
Two Piece Side Window...1601
Three Piece Side Window...1601
CAB/CANOPY REAR COVER...1603
Removal...1603
Installation...1603
MAIN FRAME AND TRACKS...1604
BLADE...1606
Removal and Installation...1606
TRACK...1606
Track Lug Height...1606
Track Tension...1607
Rubber Tracks...1607
Steel Tracks...1608
Adjustment (S/N 11001–12999)...1608
Adjustment (S/N 13001 & Above)...1609
Removal and Installation...1610
TRACK FRAME...1614
Disassembly and Assembly (S/N 11001–12999)...1614
Disassembly and Assembly (S/N 13001 & Above)...1615
TRAVEL MOTOR...1617
Testing...1617
Removal and Installation (S/N 11001–12999)...1618
Removal and Installation (S/N 13001 & Above)...1619
Parts Identification (S/N 11001–12999)...1621
Disassembly (S/N 11001–12999)...1623
Assembly (S/N 11001–12999)...1634
Check Oil Level (S/N 11001–12999)...1644
Draining Final Drive Case (S/N 11001–12999)...1644
TRAVEL MOTOR (SOM)...1644
Checking Oil Level (S/N 13001 & Above)...1645
Draining Final Drive Case (S/N 13001 & Above)...1645
Parts Identification (S/N 13001 & Above)...1646
Disassembly (S/N 13001 & Above)...1647
Assembly (S/N 13001 & Above)...1654
TRACK DAMAGE IDENTIFICATION...1663
Cutting of Steel Cords...1663
Abrasion of Embedded Metals...1664
Separation of Embedded Metals...1665
Separation of Embedded Metals Due To Corrosion...1666
Cuts On The Lug Side Rubber...1667
Cracks Of The Lug Side Rubber Due To Fatigue...1668
Lug Abrasion...1669
Cracks And Cuts On The Lug Side Rubber...1669
Abrasion Of The Track Roller Side...1670
Cuts On The Edges Of Track Roller Side...1671
ELECTRICAL SYSTEM...1672
ELECTRICAL SCHEMATICS...1675
TROUBLESHOOTING...1679
Chart...1679
ELECTRICAL SYSTEM...1679
Description...1679
Fuses...1680
Electrical System Service...1680
BATTERY...1681
Checking the Battery...1681
Removal and Installation...1681
ALTERNATOR...1682
Belt Adjustment...1682
Removal and Installation...1682
Disassembly and Inspection...1683
Stator Continuity Test...1683
Stator Ground Test...1683
Rotor Continuity Test...1684
Rotor Ground Test...1684
Rectifier Continuity (Diode) Test...1684
Assembly...1685
STARTER...1686
Removal and Installation...1686
Parts Identification...1686
Disassembly and Assembly...1687
Cleaning and Inspection...1688
FUEL LEVEL SENDER...1690
Removal and Installation...1690
Checking...1690
INSTRUMENT PANEL...1691
Removal and Installation...1691
GAUGES...1691
Removal and Installation...1691
GAUGE LIGHTS...1692
Removal and Installation...1692
CAB ELECTRICAL (Cab Option)...1692
ENGINE SYSTEM...1693
TROUBLESHOOTING...1695
VALVE CLEARANCE...1696
Adjustment...1696
ENGINE COMPRESSION...1696
Checking...1696
FUEL SHUTOFF SOLENOID...1698
Adjustment...1698
Removal and Installation...1698
Timer Module Removal and Installation...1698
FUEL INJECTION PUMP...1699
Checking the Injection Pump...1699
Removal and Installation...1699
Timing the Injection Pump...1701
FUEL INJECTOR NOZZLES...1703
Removal and Installation...1703
Checking the Injector Nozzle...1704
GLOW PLUGS...1705
Removal and Installation...1705
Checking the Glow Plug...1705
FAN GUARD...1706
Removal and Installation...1706
RADIATOR...1707
Removal and Installation...1707
MUFFLER...1708
Removal and Installation...1708
AIR CLEANER...1709
Removal and Installation...1709
ENGINE...1710
Removal and Installation...1710
ENGINE FLYWHEEL...1714
Removal and Installation...1714
FLYWHEEL RING GEAR...1715
CYLINDER HEAD...1716
Removal and Installation...1716
Disassembly and Assembly of the Cylinder Head...1717
Servicing the Cylinder Head...1718
Top Clearance...1718
VALVE, VALVE SEAT AND GUIDE...1719
Checking the Valve Guide...1719
Reconditioning the Valve and Valve Seat...1720
Valve Spring...1721
ROCKER ARM AND SHAFT...1721
Checking...1721
TIMING GEARCASE COVER...1722
Removal and Installation...1722
IDLER GEAR AND CAMSHAFT...1724
Removal and Installation...1724
Servicing the Idler Gear and Shaft...1726
TIMING GEARS...1726
Checking Backlash...1726
FUEL CAMSHAFT...1727
Removal and Installation...1727
Governor...1727
CRANKSHAFT GEAR...1728
Removal and Installation...1728
OIL PUMP...1728
Removal and Installation...1728
Oil Pump Service...1728
Checking Engine Oil Pressure...1729
Relief Valve...1729
PISTON AND CONNECTING ROD...1730
Removal and Installation...1730
Servicing the Piston and Connecting Rod...1731
Connecting Rod Alignment...1733
CRANKSHAFT AND BEARINGS...1734
Removal and Installation...1734
Servicing the Crankshaft and Bearings...1735
CYLINDER BORE...1738
Checking the Cylinder Bore...1738
WATER PUMP...1739
Disassembly and Assembly...1739
SPECIFICATIONS...1741
HYDRAULIC EXCAVATOR SPECIFICATIONS...1743
Machine Dimensions...1743
Lifting Capacity...1744
HYDRAULIC SYSTEM...1745
SWING SYSTEM...1745
HYDRAULIC CYLINDERS...1745
DRIVE SYSTEM...1745
BRAKES...1745
UNDERCARRIAGE...1745
STD TRACK SHOES...1745
CAPACITIES...1745
DIGGING FORCE...1745
ENGINE SPECIFICATIONS...1746
Fuel Injection Nozzles...1746
Fuel Injection Pump...1746
Cylinder Head...1746
Valves...1746
Valve Springs...1746
Valve Timing...1746
Rocker Arms...1746
Camshaft...1747
Tappet...1747
Cylinders...1747
Piston Rings...1747
Pistons...1747
Connecting Rod...1747
Oil Pump...1747
Crankshaft...1747
Timing Gear...1748
Thermostat...1748
Engine Bolt Torque...1748
Re–Grinding The Crankshaft...1749
FUEL, COOLANT AND LUBRICANTS CHART...1750
ENGINE OIL SPECIFICATIONS...1750
Description...1750
Ethylene Glycol...1750
Propylene Glycol...1750
BUCKET SPECIFICATIONS...1751
DECIMAL AND MILLIMETER EQUIVALENTS...1752
U.S. TO METRIC CONVERSION...1752
SERVICE MANUAL REVISION...1753
325-1...1753
325-2...1755
325-3...1757
325-4...1759
325-5...1761
325-6...1763
6724546 (5-97) - X 325 Excavator Operation & Maintenance Manual...1765
OPERATOR SAFETY WARNINGS...1767
CONTENTS...1769
REGULAR MAINTENANCE ITEMS...1770
FOREWORD...1771
SERIAL NUMBER LOCATIONS...1773
HYDRAULIC EXCAVATOR SERIAL NUMBER...1773
ENGINE SERIAL NUMBER...1773
DELIVERY REPORT...1773
HYDRAULIC EXCAVATOR IDENTIFICATION...1774
SAFETY...1775
SAFETY INSTRUCTIONS...1777
FIRE PREVENTION...1779
MACHINE SIGNS (DECALS)...1780
OPERATING INSTRUCTIONS...1783
INSTRUMENT PANEL...1785
KEY SWITCH...1785
STEERING LEVERS/FOOT PEDALS...1786
Forward And Reverse Travel...1786
Turning...1786
Right Turn...1786
Left Turn...1786
AUXILIARY POWER OUTLET...1787
CAB/CANOPY...1787
CAB/CANOPY FOPS (Falling Object Protective Structure)...1787
Front Window...1787
Emergency Exit...1787
CAB OPTION...1788
Opening The Front Window...1788
Closing The Front Window...1788
ELECTRICAL...1788
WINDSHIELD WASHER TANK (If Equipped)...1789
HEATER CONTROL...1789
LIGHT SWITCH (Cab/Canopy)...1789
FUSES...1789
AUDIBLE ALARM...1790
HORN BUTTON...1790
SEAT...1790
SPEED CONTROL LEVER...1791
OPERATOR'S HANDBOOK...1791
STORAGE COMPARTMENT...1791
ENGINE COVER...1791
AUXILIARY OPERATION PEDAL...1792
Flush Face Couplers...1792
BLADE CONTROL LEVER...1792
SWING LOCK...1793
BOOM SWING PEDAL...1793
CONTROL LEVERS (JOYSTICKS)...1794
Operation Of Left Control Lever (ISO)...1794
Operation Of Right Control Lever (ISO)...1794
Operation Of Left Control Lever (Standard)...1795
Operation Of Right Control Lever (Standard)...1795
CONTROL LEVER (JOYSTICK) LOCK...1796
TWO SPEED FOOT PEDAL...1796
GETTING ON AND OFF THE MACHINE...1797
DAILY INSPECTION...1798
STARTING THE ENGINE...1798
Normal Starting Procedure (With Engine Warm)...1798
Cold Temperature Starting Procedure...1799
BUCKET...1800
Removal...1800
Installation...1800
OPERATING PROCEDURE...1801
Breaking In A New Machine...1801
General Operation Suggestons...1801
Operating On Slopes...1802
Operating In Water...1803
PARKING THE HYDRAULIC EXCAVATOR...1803
TRANSPORTING THE HYDRAULIC EXCAVATOR...1804
LIFTING THE HYDRAULIC EXCAVATOR...1805
LIFTING A LOAD...1805
PREVENTIVE MAINTENANCE...1807
MAINTENANCE SAFETY...1808
SERVICE SCHEDULE...1809
ENGINE COVER...1810
Adjustment Of The Engine Cover Latch...1810
AIR CLEANER SERVICE...1810
FUEL SYSTEM...1812
Filling The Fuel Tank...1812
Fuel Filter...1812
Fuel System Maintenance...1813
Removing Air From The Fuel System...1813
Fuel Specification...1813
ENGINE LUBRICATON SYSTEM...1814
Checking Engine Oil...1814
Replacement Of Oil And Filter...1814
COOLING SYSTEM...1815
Coolant Level...1815
Coolant Replacement...1815
Propylene Glycol (Factory Installed)...1815
ALTERNATOR BELT ADJUSTMENT...1816
ELECTRICAL SYSTEM...1816
Electrical Relays And Diodes...1816
Fuses...1817
Service The Electrical System (And Battery)...1817
Using A Booster Battery (Jump Starting)...1818
Removal And Installation Of The Battery...1819
Electric Solenoid (Engine Stop)...1819
HYDRAULIC SYSTEM...1820
Checking And Adding Fluid...1820
Diagnostic Couplers...1820
Hydraulic Reservoir...1821
Replacement Of The Hydraulic Filter...1821
Drain Return Line Filter Service...1821
SPARK ARRESTOR MUFFLER...1822
TRACK TENSION...1823
Adjustment...1823
Rubber Tracks...1823
Steel Tracks...1824
FINAL DRIVE CASE...1825
Checking Oil Level...1825
Draining Final Drive Case...1825
JOYSTICK CONTROL CHANGE...1826
ISO To STANDARD Control Pattern...1826
STANDARD To ISO Control Pattern...1826
LUBRICATION OF THE HYDRAULIC EXCAVATOR...1827
HEATER AIR FILTER (With Cab Option Only)...1829
MACHINE SIGN TRANSLATIONS...1831
SPECIFICATIONS...1839
HYDRAULIC EXCAVATOR SPECIFICATIONS...1841
Machine Dimensions (S/N 13001 & Above)...1841
Lifting Capacity...1842
OPERATION & PERFORMANCE...1842
WEIGHTS...1842
CONTROLS...1842
ELECTRICAL...1842
HYDRAULIC SYSTEM...1843
SWING SYSTEM...1843
HYDRAULIC CYLINDERS...1843
DRIVE SYSTEM...1843
BRAKES...1843
UNDERCARRIAGE...1843
STD TRACK SHOES...1843
CAPACITIES...1843
DIGGING FORCE...1843
FUEL, COOLANT AND LUBRICANTS...1844
ENGINE OIL SPECIFICATIONS...1844
Description...1844
Propylene Glycol (Factory Installed)...1844
BUCKET SPECIFICATIONS...1845
ADDITIONAL PUBLICATIONS...1846
WARRANTY...1847
6900462 (3–98) - X 325, X 328 Excavator Service Manual...1849
MAINTENANCE SAFETY...1851
ALPHABETICAL INDEX...1853
CONTENTS...1855
FOREWORD...1857
SAFETY INSTRUCTIONS...1859
SERIAL NUMBER LOCATIONS...1861
HYDRAULIC EXCAVATOR SERIAL NUMBER...1861
ENGINE SERIAL NUMBER...1861
DELIVERY REPORT...1861
HYDRAULIC EXCAVATOR IDENTIFICATION...1862
PREVENTIVE MAINTENANCE...1863
SERVICE SCHEDULE...1865
LIFTING AND BLOCKING THE EXCAVATOR...1866
Procedure...1866
TRANSPORTING THE HYDRAULIC EXCAVATOR...1867
ENGINE COVER...1868
Opening The Engine Cover...1868
Adjustment Of The Engine Cover Latch...1868
AIR CLEANER SERVICE...1869
Replacing The Filter Element (325 S/N 514013001–514014899)...1869
Replacing The Filter Element (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...1871
FUEL SYSTEM...1872
Fuel Specifications...1872
Filling The Fuel Tank...1872
Fuel System Maintenance...1873
Fuel Filter (325 S/N 514013001–514014899)...1873
Fuel Filter (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...1873
Removing Air From The Fuel System (325 S/N514013001–514014899)...1874
ENGINE LUBRICATION SYSTEM...1875
Checking Engine Oil...1875
Replacement Of Oil And Filter...1875
COOLING SYSTEM...1876
Coolant Level...1876
Coolant Replacement...1876
ALTERNATOR BELT...1877
Adjustment...1877
ELECTRICAL SYSTEM...1878
Using A Booster Battery (Jump Starting)...1878
HYDRAULIC SYSTEM...1879
Checking And Adding Fluid...1879
Replacing The Hydraulic Oil...1880
Replacing The Hydraulic Filter...1880
Replacing The Drain Line Filter...1880
SPARK ARRESTOR MUFFLER (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...1881
Cleaning The Spark Arrestor Muffler...1881
SPARK ARRESTOR MUFFLER (325 S/N 514013001–514014899)...1882
Cleaning The Spark Arrestor Muffler...1882
TRAVEL MOTOR...1883
Checking The Oil Level...1883
Draining And Refilling...1883
LUBRICATION OF THE HYDRAULIC EXCAVATOR...1884
HEATER AIR FILTER (With Cab Option Only) (325 S/N514013001–514014899)...1887
HEATER AIR FILTER (With Cab Option Only) (325 S/N514014900 & Above) & (328 S/N 516611001 & Above)...1887
HYDRAULIC SECTION...1889
HYDRAULIC SCHEMATICS...1892
HYDRAULIC SYSTEM TROUBLESHOOTING...1915
HYDRAULIC SERVICE INFORMATION...1920
Description...1920
Checking The Main Relief Valves...1921
Testing The Swing Circuit Relief Valve...1922
Testing The Auxiliary And Bucket Circuit Relief Valve...1924
Testing The Left Hand Travel Circuit Relief Valve...1926
Testing The Right Hand Travel Circuit Relief Valve...1928
Testing The Boom Circuit Relief Valve...1930
CROSS PORT RELIEF VALVE...1931
Description...1931
Testing...1931
HYDRAULIC PUMP...1932
Checking the Hydraulic Pump...1932
Removal And Installation (325 S/N 514013001–514014899)...1933
Parts Identification (325 S/N 514013001– 514014899)...1934
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...1935
Disassembly (325 S/N 514013001–514014899)...1937
Assembly (325 S/N 514013001–514014899)...1939
HYDRAULIC CONTROL VALVE (5–Spool)...1942
Left Travel, Right Travel, Boom, Bucket and Auxiliary...1942
Description...1942
Removal And Installation (325 S/N 514013001–514014899)...1942
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...1943
Left Travel, Right Travel, Boom, Bucket and Auxiliary...1946
Parts Identification...1946
Disassembly...1947
Outlet Sections Disassembly...1948
Mid Inlet Section Disassembly...1948
Mid Inlet Section Assembly...1948
Left Travel, Right Travel and Auxiliary Disassembly...1949
Left Travel, Right Travel and Auxiliary Assembly...1951
Boom And Bucket Disassembly...1953
Boom And Bucket Assembly...1955
Assembly...1957
PORT RELIEF VALVES AND MID INLET MAIN RELIEF VALVES...1958
Parts Identification...1958
Port Relief Valve Pressure Setting...1959
Disassembly...1959
Assembly...1960
MAIN RELIEF VALVES (Adjustable)...1961
Parts Identification...1961
Pressure Settings...1962
Disassembly...1963
Assembly...1963
Adjusting The Main Relief Valves...1964
HYDRAULIC CONTROL VALVE (5–Spool)...1965
Boost, Arm, Boom Swing, Blade And Swing Section...1965
Description...1965
Removal And Installation...1965
Parts Identification...1966
Disassembly...1967
Inlet Section Disassembly...1968
Inlet Section Assembly...1968
Arm, Boost And Swing Motor Disassembly...1969
Arm, Boost And Swing Motor Assembly...1971
Boom Swing Disassembly...1973
Boom Swing Assembly...1975
Blade Disassembly...1978
Blade Assembly...1980
Assembly...1982
ACCUMULATOR...1983
Removal And Installation...1983
Parts Identification (S/N 514013001 – 514017331& 516611001 – 516611918)...1984
Disassembly (S/N 514013001 – 514017331& 516611001 – 516611918)...1985
Assembly...1987
Parts Identification (S/N 514017312 & Above &516611919 & Above)...1990
Disassembly (S/N 514017312 & Above &516611919 & Above)...1991
Assembly (S/N 514017312 & Above &516611919 & Above)...1993
Testing (All Models)...1996
PORT BLOCK...1998
Removal And Installation...1998
BUILD UP VALVE...1999
Description...1999
Removal And Installation...1999
Disassembly And Assembly...1999
AUXILIARY SELECTOR VALVE...2000
Removal And Installation (325 S/N 514013001–514014899)...2000
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2000
Disassembly And Assembly...2001
OIL COOLER...2002
Removal And Installation...2002
HYDRAULIC RESERVOIR...2003
Removal And Installation...2003
HYDRAULIC FILTER ASSEMBLY...2005
Removal And Installation...2005
CASE DRAIN FILTER...2005
BOOM CYLINDER SHIELD...2006
Removal And Installation...2006
BOOM CYLINDER...2006
Removal And Installation...2006
BOOM CYLINDER...2007
Parts Identification...2007
ARM CYLINDER...2008
Removal And Installation...2008
Parts Identification...2009
BUCKET CYLINDER...2010
Removal And Installation...2010
Parts Identification...2011
BLADE CYLINDER...2012
Removal And Installation...2012
Parts Identification...2012
BOOM SWING CYLINDER ...2013
Removal And Installation...2013
Parts Identification...2014
HYDRAULIC CYLINDER...2015
Disassembly...2015
Assembly...2017
JOYSTICK CONTROL CHANGE...2022
ISO to STANDARD Control Pattern...2022
STANDARD To ISO Control Pattern...2023
DRIVE SECTION...2024
RIGHT CONSOLE COVER (325 S/N 514013001–514014899)...2026
Removal And Installation...2026
RIGHT CONSOLE...2028
Speed Control Lever Removal And Installation...2030
Speed Control Lever Adjustment...2030
Low Speed Position...2030
High Speed Position...2030
Blade Control Lever And Cable Removal And Installation...2031
LEFT CONSOLE (325 S/N 514013001–514014899)...2032
Control Lock Micro–Switch Removal And Installation...2032
Gas Spring Removal And Installation...2033
Removal And Installation...2034
Lock Lever Removal And Installation...2035
Lock Lever Disassembly And Assembly...2036
Lock Lever Adjustment...2036
Latch Plate Adjustment...2036
RIGHT CONSOLE COVER (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2037
Removal And Installation...2037
Arm Rest Removal And Installation...2038
Gauge Removal And Installation...2038
RIGHT CONSOLE (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)...2039
Swing Lock Lever Removal And Installation...2039
Blade Lever Removal And Installation...2041
Speed Control Lever Removal And Installation...2042
Speed Control Lever Adjustment...2044
Low Speed Position...2044
High Speed Position...2044
LEFT CONSOLE COVER (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2045
Removal And Installation...2045
Arm Rest Removal And Installation...2046
Switch Removal And Installation...2046
Switch Description...2046
Rear Cover Removal And Installation...2047
LEFT CONSOLE (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above...2048
Console And Mount Removal And Installation...2048
Control Lock Micro–switch Removal And Installation...2049
Lock Lever Removal And Installation...2050
Gas Spring Removal And Installation...2052
Console Removal And Installation...2053
JOYSTICK...2055
Removal And Installation (325 S/N 514013001–514014899)...2055
Removal And Installation Of Right Hand Joystick(325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2056
Removal And Installation Of Left Hand Joystick (325S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2056
Troubleshooting...2057
Parts Identification...2058
Disassembly...2059
Assembly...2063
STEERING LEVERS AND PEDALS...2069
Removal And Installation...2069
UPPER WORKS AND SWING SECTION...2072
REAR ENGINE COVER...2074
Removal And Installation...2074
SEAT AND SEAT MOUNT...2074
Removal And Installation (325 S/N 514013001–514014899)...2074
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2075
FLOOR MAT AND FLOOR PLATE...2076
Removal And Installation...2076
REAR FLOOR PLATE...2077
Removal And Installation (325 S/N 514013001–514014899)...2077
SWING MOTOR COVER...2078
Removal And Installation...2078
TOOL BOX...2078
Removal And Installation (325 S/N 514013001–514014899)...2078
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2078
LEFT SIDE COVER...2079
Removal And Installation (325 S/N 514013001–514014899)...2079
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2079
RIGHT SIDE COVER...2079
Removal And Installation...2079
CORNER POST...2080
Removal And Installation...2080
COUNTERWEIGHTS...2081
Removal And Installation...2081
FRONT ENGINE COVER...2082
Removal And Installation...2082
FUEL TANK...2083
Removal And Installation...2083
BUCKET...2085
Removal And Installation...2085
ARM...2086
Removal And Installation...2086
ARM BUSHINGS...2086
Arm To Boom Bushing Removal And Installation...2086
Arm To Bucket And Bucket Link Bushing RemovalAnd Installation...2087
BOOM...2088
Removal And Installation...2088
BOOM BUSHING...2089
Removal And Installation...2089
BOOM SWING BRACKET...2090
Removal...2090
Installation...2091
Hose Installation...2092
SWING BRACKET BUSHING...2093
Bushing Removal...2093
Bushing Installation...2093
SWING MOTOR...2094
Removal And Installation...2094
Parts Identification...2095
Disassembly...2096
Assembly...2098
CROSS PORT RELIEF VALVE...2103
Disassembly...2103
Assembly...2104
SWING MOTOR DRIVE CARRIER...2106
Removal And Installation...2106
Parts Identification...2106
Disassembly...2107
Assembly...2108
UPPERSTRUCTURE AND SWING CIRCLE GEAR...2112
Removal And Installation...2112
Swing Bearing Removal...2113
Swing Bearing Installation...2114
Alignment Pins (Not Threaded)...2116
CENTER SWIVEL JOINT...2117
Removal And Installation...2117
Removal And Installation (Through Bottom AccessCover)...2118
Parts Identification...2119
Description...2120
Disassembly...2120
Assembly...2121
ROPS CANOPY...2124
Removal And Installation...2124
CAB...2126
Removal And Installation...2126
Heater Removal And Installation (325 S/N514013001– 514014899)...2128
Heater Removal And Installation (325 S/N 514014900& Above) & (328 S/N 516611001 & Above)...2129
Heater Disassembly And Assembly (325 S/N514014900 & Above) & (328 S/N 516611001 & Above)...2131
Front Window Removal And Installation...2134
Front Lower Window Removal And Installation...2135
Front Upper Window Removal And Installation (325S/N 514013001–514014899)...2136
Front Upper Window Removal And Installation (325S/N 514014900 & Above) & (328 S/N 516611001 &Above)...2136
Door Window Removal And Installation...2137
Left Hand Side Window Removal And Installation...2137
Right Hand Side Window Removal And Installation...2138
Right Hand Window Assembly Removal AndInstallation...2139
Rear Window Removal And Installation...2139
CAB/CANOPY REAR COVER...2140
Removal...2140
Installation...2140
MAIN FRAME AND TRACKS...2142
BLADE...2144
Removal And Installation...2144
TRACK...2144
Track Lug Height...2144
Track Tension Adjustment...2145
Rubber Track Clearance...2145
Steel Track Clearance...2146
Adjustment...2147
Rubber Track Removal And Installation...2148
Steel Track Removal And Installation...2150
Disassembly And Assembly...2152
Recoil Spring Disassembly And Assembly...2154
TRACK IDLER...2155
Parts Identification...2155
Disassembly...2156
Assembly...2158
TRACK ROLLER...2162
Parts Identification...2162
Disassembly...2163
Assembly...2165
TRAVEL MOTOR...2169
Removal And Installation...2169
Parts Identification...2170
Disassembly...2171
Assembly...2178
TRACK DAMAGE IDENTIFICATION...2187
Cutting Of Steel Cords...2187
Abrasion Of Embedded Metals...2188
Separation Of Embedded Metals...2189
Separation Of Embedded Metals Due To Corrosion...2190
Cuts On The Lug Side Rubber...2191
Cracks Of The Lug Side Rubber Due To Fatigue...2192
Lug Abrasion...2193
Cracks And Cuts On The Lug Side Rubber...2193
Abrasion Of The Track Roller Side...2194
Cuts On The Edges Of Track Roller Side...2195
ELECTRICAL SYSTEM...2196
ELECTRICAL SCHEMATICS...2198
TROUBLESHOOTING...2204
ELECTRICAL SYSTEM...2204
Description...2204
Fuses (325 S/N 514013001–514014899)...2205
Fuse Arrangement (325 S/N 514013001–514014899)...2205
Electrical Relays And Diodes (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2205
Fuse Arrangement (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)...2206
BATTERY...2207
Removal And Installation...2207
Servicing The Battery...2208
ALTERNATOR...2209
Belt Adjustment...2209
Removal And Installation...2209
ALTERNATOR...2210
Alternator Output Test...2210
Rectifier (Diode) Test...2210
Alternator Regulator Test...2211
Parts Identification...2212
Disassembly And Inspection...2212
Stator Continuity Test...2212
Stator Ground Test...2212
Rotor Continuity Test...2213
Rotor Ground Test...2213
Rectifier Continuity (Diode) Test...2213
Assembly...2214
STARTER...2215
Removal And Installation (325 S/N 514013001–514014899)...2215
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2215
Disassembly And Assembly...2216
Cleaning And Inspection (325 S/N 514013001–514014899)...2217
Parts Identification (325 S/N 514013001– 514014899)...2218
Parts Identification (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2219
Disassembly (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2220
Inspection And Repair (325 S/N 514014900 & Above)& (328 S/N 516611001 & Above)...2225
Assembly (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2228
FUEL LEVEL SENDER...2233
Removal And Installation...2233
Testing...2233
INSTRUMENT PANEL (325 S/N 514013001–514014899)...2234
Removal And Installation...2234
GAUGES...2234
Removal And Installation (325 S/N 514013001–514014899)...2234
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2236
Bulb Replacement (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)...2236
TIMER (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2237
Removal And Installation...2237
DIODES (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2237
Diode Location...2237
Diode Replacement...2237
Diode Testing...2237
CAB ELECTRICAL...2238
Cab Option (325 S/N 514013001–514014899)...2238
Cab Option (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2238
HORN...2239
Removal And Installation...2239
BUZZER...2239
Removal And Installation...2239
TWO SPEED SWITCH...2239
Removal And Installation...2239
ENGINE SYSTEM...2240
TROUBLESHOOTING...2242
VALVE CLEARANCE...2243
Adjustment...2243
ENGINE COMPRESSION...2243
Checking...2243
FUEL SHUTOFF SOLENOID...2245
Adjustment...2245
Removal And Installation...2245
Timer Module Removal And Installation...2245
FUEL INJECTION PUMP...2246
Checking The Injection Pump...2246
Removal And Installation...2246
Timing The Injection Pump...2247
FUEL INJECTOR NOZZLES...2249
Checking The Injector Nozzle...2250
GLOW PLUGS...2251
Removal And Installation...2251
Checking The Glow Plug...2251
FAN GUARD...2252
Removal And Installation...2252
RADIATOR...2253
Removal And Installation...2253
MUFFLER...2254
Removal And Installation (325 S/N 514013001–514014899)...2254
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2255
AIR CLEANER...2256
Removal And Installation (325 S/N 514013001–514014899)...2256
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2257
ENGINE...2258
Removal And Installation...2258
ENGINE FLYWHEEL...2264
Removal And Installation (325 S/N 514013001–514014899)...2264
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2265
FLYWHEEL RING GEAR...2266
CYLINDER HEAD...2267
Removal And Installation...2267
Disassembly And Assembly Of The Cylinder Head...2268
Servicing The Cylinder Head...2269
Top Clearance...2269
VALVE, VALVE SEAT AND GUIDE...2270
Checking The Valve Guide...2270
Reconditioning The Valve And Valve Seat...2271
Valve Spring...2272
ROCKER ARM AND SHAFT...2272
Checking...2272
TIMING GEARCASE COVER...2273
Removal And Installation...2273
IDLER GEAR AND CAMSHAFT...2275
Removal And Installation...2275
Servicing The Idler Gear And Shaft...2277
TIMING GEARS...2277
Checking Backlash...2277
FUEL CAMSHAFT...2278
Removal And Installation...2278
Governor...2278
CRANKSHAFT GEAR...2279
Removal And Installation...2279
OIL PUMP...2279
Removal And Installation...2279
Oil Pump Service...2279
Checking Engine Oil Pressure...2280
Relief Valve...2280
PISTON AND CONNECTING ROD...2281
Removal And Installation...2281
Servicing The Piston And Connecting Rod...2282
Connecting Rod Alignment...2284
CRANKSHAFT AND BEARINGS...2285
Removal And Installation...2285
Servicing The Crankshaft And Bearings...2286
CYLINDER BORE...2289
Checking The Cylinder Bore...2289
WATER PUMP...2290
Disassembly And Assembly...2290
SPECIFICATIONS...2292
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 S/N 514013001–514014899)...2294
Machine Dimensions...2294
Lifting Capacity...2295
WEIGHTS...2295
CONTROLS...2295
ENGINE...2295
ELECTRICAL...2295
HYDRAULIC SYSTEM...2296
SWING SYSTEM...2296
HYDRAULIC CYLINDERS...2296
DRIVE SYSTEM...2296
BRAKES...2296
UNDERCARRIAGE...2296
STD TRACK...2296
CAPACITIES...2296
DIGGING FORCE...2296
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above...2297
Machine Dimensions...2297
Lifting Capacity...2298
WEIGHTS...2298
CONTROLS...2298
ENGINE...2298
ELECTRICAL...2298
HYDRAULIC SYSTEM...2299
SWING SYSTEM...2299
HYDRAULIC CYLINDERS...2299
DRIVE SYSTEM...2299
BRAKES...2299
UNDERCARRIAGE...2299
STD TRACK...2299
CAPACITIES...2299
DIGGING FORCE...2299
ENGINE SPECIFICATIONS...2300
Fuel Injection Nozzles...2300
Fuel Injection Pump...2300
Cylinder Head...2300
Valves...2300
Valve Springs...2300
Valve Timing...2300
Rocker Arms...2300
Camshaft...2301
Tappet...2301
Cylinders...2301
Piston Rings...2301
Pistons...2301
Connecting Rod...2301
Oil Pump...2301
Crankshaft...2301
Timing Gear...2302
Thermostat...2302
Engine Bolt Torque...2302
Re–Grinding The Crankshaft...2303
TORQUE FOR GENERAL METRIC BOLTS...2303
FUEL, COOLANT AND LUBRICANTS...2304
Chart...2304
ENGINE OIL AND COOLING SPECIFICATIONS...2304
Description...2304
Anti–Freeze Solution...2304
Propylene Glycol...2304
BUCKET SPECIFICATIONS...2305
DECIMAL AND MILLIMETER EQUIVALENTS...2306
U.S. TO METRIC CONVERSION...2306
SERVICE MANUAL REVISON...2308
325-1...2308
325-2...2310
6900462 (6–12) - X 325, X 328 Excavator Service Manual...2312
MAINTENANCE SAFETY...2314
ALPHABETICAL INDEX...2316
CONTENTS...2318
FOREWORD...2320
SAFETY INSTRUCTIONS...2322
SERIAL NUMBER LOCATIONS...2324
HYDRAULIC EXCAVATOR SERIAL NUMBER...2324
ENGINE SERIAL NUMBER...2324
DELIVERY REPORT...2324
HYDRAULIC EXCAVATOR IDENTIFICATION...2325
PREVENTIVE MAINTENANCE...2326
SERVICE SCHEDULE...2328
LIFTING AND BLOCKING THE EXCAVATOR...2329
Procedure...2329
TRANSPORTING THE HYDRAULIC EXCAVATOR...2330
ENGINE COVER...2331
Opening The Engine Cover...2331
Adjustment Of The Engine Cover Latch...2331
AIR CLEANER SERVICE...2332
Replacing The Filter Element (325 S/N 514013001–514014899)...2332
Replacing The Filter Element (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2334
FUEL SYSTEM...2335
Fuel Specifications...2335
Filling The Fuel Tank...2335
Fuel System Maintenance...2336
Fuel Filter (325 S/N 514013001–514014899)...2336
Fuel Filter (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2336
Removing Air From The Fuel System (325 S/N514013001–514014899)...2337
ENGINE LUBRICATION SYSTEM...2338
Checking Engine Oil...2338
Replacement Of Oil And Filter...2338
COOLING SYSTEM...2339
Coolant Level...2339
Coolant Replacement...2339
ALTERNATOR BELT...2340
Adjustment...2340
ELECTRICAL SYSTEM...2341
Using A Booster Battery (Jump Starting)...2341
HYDRAULIC SYSTEM...2342
Checking And Adding Fluid...2342
Replacing The Hydraulic Oil...2343
Replacing The Hydraulic Filter...2343
Replacing The Drain Line Filter...2343
SPARK ARRESTOR MUFFLER (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2344
Cleaning The Spark Arrestor Muffler...2344
SPARK ARRESTOR MUFFLER (325 S/N 514013001–514014899)...2345
Cleaning The Spark Arrestor Muffler...2345
TRAVEL MOTOR...2346
Checking The Oil Level...2346
Draining And Refilling...2346
LUBRICATION OF THE HYDRAULIC EXCAVATOR...2347
HEATER AIR FILTER (With Cab Option Only) (325 S/N514013001–514014899)...2350
HEATER AIR FILTER (With Cab Option Only) (325 S/N514014900 & Above) & (328 S/N 516611001 & Above)...2350
HYDRAULIC SECTION...2352
HYDRAULIC SCHEMATICS...2356
HYDRAULIC SYSTEM TROUBLESHOOTING...2381
HYDRAULIC SERVICE INFORMATION...2386
Description...2386
Checking The Main Relief Valves...2387
Testing The Swing Circuit Relief Valve...2388
Testing The Auxiliary And Bucket Circuit Relief Valve...2390
Testing The Left Hand Travel Circuit Relief Valve...2392
Testing The Right Hand Travel Circuit Relief Valve...2394
Testing The Boom Circuit Relief Valve...2396
CROSS PORT RELIEF VALVE...2397
Description...2397
Testing...2397
HYDRAULIC PUMP...2398
Checking the Hydraulic Pump...2398
Removal And Installation (325 S/N 514013001–514014899)...2399
Parts Identification (325 S/N 514013001– 514014899)...2400
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2401
Disassembly (325 S/N 514013001–514014899)...2403
Assembly (325 S/N 514013001–514014899)...2405
HYDRAULIC CONTROL VALVE (5–Spool)...2408
Left Travel, Right Travel, Boom, Bucket and Auxiliary...2408
Description...2408
Removal And Installation (325 S/N 514013001–514014899)...2408
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2409
Left Travel, Right Travel, Boom, Bucket and Auxiliary...2412
Parts Identification...2412
Disassembly...2413
Outlet Sections Disassembly...2414
Mid Inlet Section Disassembly...2414
Mid Inlet Section Assembly...2414
Left Travel, Right Travel and Auxiliary Disassembly...2415
Left Travel, Right Travel and Auxiliary Assembly...2417
Boom And Bucket Disassembly...2419
Boom And Bucket Assembly...2421
Assembly...2423
PORT RELIEF VALVES AND MID INLET MAIN RELIEF VALVES...2424
Parts Identification...2424
Port Relief Valve Pressure Setting...2425
Disassembly...2425
Assembly...2426
MAIN RELIEF VALVES (Adjustable)...2427
Parts Identification...2427
Pressure Settings...2428
Disassembly...2429
Assembly...2429
Adjusting The Main Relief Valves...2430
HYDRAULIC CONTROL VALVE (5–Spool)...2431
Boost, Arm, Boom Swing, Blade And Swing Section...2431
Description...2431
Removal And Installation...2431
Parts Identification...2432
Disassembly...2433
Inlet Section Disassembly...2434
Inlet Section Assembly...2434
Arm, Boost And Swing Motor Disassembly...2435
Arm, Boost And Swing Motor Assembly...2437
Boom Swing Disassembly...2439
Boom Swing Assembly...2441
Blade Disassembly...2444
Blade Assembly...2446
Assembly...2448
ACCUMULATOR...2449
Removal And Installation...2449
Parts Identification (S/N 514013001 – 514017331& 516611001 – 516611918)...2450
Disassembly (S/N 514013001 – 514017331& 516611001 – 516611918)...2451
Assembly...2453
Parts Identification (S/N 514017312 & Above &516611919 & Above)...2456
Disassembly (S/N 514017312 & Above &516611919 & Above)...2457
Assembly (S/N 514017312 & Above &516611919 & Above)...2459
Testing (All Models)...2462
PORT BLOCK...2464
Removal And Installation...2464
BUILD UP VALVE...2465
Description...2465
Removal And Installation...2465
Disassembly And Assembly...2465
AUXILIARY SELECTOR VALVE...2466
Removal And Installation (325 S/N 514013001–514014899)...2466
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2466
Disassembly And Assembly...2467
OIL COOLER...2468
Removal And Installation...2468
HYDRAULIC RESERVOIR...2469
Removal And Installation...2469
HYDRAULIC FILTER ASSEMBLY...2471
Removal And Installation...2471
CASE DRAIN FILTER...2471
BOOM CYLINDER SHIELD...2472
Removal And Installation...2472
BOOM CYLINDER...2472
Removal And Installation...2472
BOOM CYLINDER...2473
Parts Identification...2473
ARM CYLINDER...2474
Removal And Installation...2474
Parts Identification...2475
BUCKET CYLINDER...2476
Removal And Installation...2476
Parts Identification...2477
BLADE CYLINDER...2478
Removal And Installation...2478
Parts Identification...2478
BOOM SWING CYLINDER ...2479
Removal And Installation...2479
Parts Identification...2480
HYDRAULIC CYLINDER...2481
Disassembly...2481
Assembly...2483
JOYSTICK CONTROL CHANGE...2488
ISO to STANDARD Control Pattern...2488
STANDARD To ISO Control Pattern...2489
DRIVE SECTION...2490
RIGHT CONSOLE COVER (325 S/N 514013001–514014899)...2492
Removal And Installation...2492
RIGHT CONSOLE...2494
Speed Control Lever Removal And Installation...2496
Speed Control Lever Adjustment...2496
Low Speed Position...2496
High Speed Position...2496
Blade Control Lever And Cable Removal And Installation...2497
LEFT CONSOLE (325 S/N 514013001–514014899)...2498
Control Lock Micro–Switch Removal And Installation...2498
Gas Spring Removal And Installation...2499
Removal And Installation...2500
Lock Lever Removal And Installation...2501
Lock Lever Disassembly And Assembly...2502
Lock Lever Adjustment...2502
Latch Plate Adjustment...2502
RIGHT CONSOLE COVER (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2503
Removal And Installation...2503
Arm Rest Removal And Installation...2504
Gauge Removal And Installation...2504
RIGHT CONSOLE (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)...2505
Swing Lock Lever Removal And Installation...2505
Blade Lever Removal And Installation...2507
Speed Control Lever Removal And Installation...2508
Speed Control Lever Adjustment...2510
Low Speed Position...2510
High Speed Position...2510
LEFT CONSOLE COVER (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2511
Removal And Installation...2511
Arm Rest Removal And Installation...2512
Switch Removal And Installation...2512
Switch Description...2512
Rear Cover Removal And Installation...2513
LEFT CONSOLE (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above...2514
Console And Mount Removal And Installation...2514
Control Lock Micro–switch Removal And Installation...2515
Lock Lever Removal And Installation...2516
Gas Spring Removal And Installation...2518
Console Removal And Installation...2519
JOYSTICK...2521
Removal And Installation (325 S/N 514013001–514014899)...2521
Removal And Installation Of Right Hand Joystick(325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2522
Removal And Installation Of Left Hand Joystick (325S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2522
Troubleshooting...2523
Parts Identification...2524
Disassembly...2525
Assembly...2529
STEERING LEVERS AND PEDALS...2535
Removal And Installation...2535
UPPER WORKS AND SWING SECTION...2538
REAR ENGINE COVER...2540
Removal And Installation...2540
SEAT AND SEAT MOUNT...2540
Removal And Installation (325 S/N 514013001–514014899)...2540
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2541
FLOOR MAT AND FLOOR PLATE...2542
Removal And Installation...2542
REAR FLOOR PLATE...2543
Removal And Installation (325 S/N 514013001–514014899)...2543
SWING MOTOR COVER...2544
Removal And Installation...2544
TOOL BOX...2544
Removal And Installation (325 S/N 514013001–514014899)...2544
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2544
LEFT SIDE COVER...2545
Removal And Installation (325 S/N 514013001–514014899)...2545
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2545
RIGHT SIDE COVER...2545
Removal And Installation...2545
CORNER POST...2546
Removal And Installation...2546
COUNTERWEIGHTS...2547
Removal And Installation...2547
FRONT ENGINE COVER...2548
Removal And Installation...2548
FUEL TANK...2549
Removal And Installation...2549
BUCKET...2551
Removal And Installation...2551
ARM...2552
Removal And Installation...2552
ARM BUSHINGS...2552
Arm To Boom Bushing Removal And Installation...2552
Arm To Bucket And Bucket Link Bushing RemovalAnd Installation...2553
BOOM...2554
Removal And Installation...2554
BOOM BUSHING...2555
Removal And Installation...2555
BOOM SWING BRACKET...2556
Removal...2556
Installation...2557
Hose Installation...2558
SWING BRACKET BUSHING...2559
Bushing Removal...2559
Bushing Installation...2559
SWING MOTOR...2560
Removal And Installation...2560
Parts Identification...2561
Disassembly...2562
Assembly...2564
CROSS PORT RELIEF VALVE...2569
Disassembly...2569
Assembly...2570
SWING MOTOR DRIVE CARRIER...2572
Removal And Installation...2572
Parts Identification...2572
Disassembly...2573
Assembly...2574
UPPERSTRUCTURE AND SWING CIRCLE GEAR...2578
Removal And Installation...2578
Swing Bearing Removal...2579
Swing Bearing Installation...2580
Alignment Pins (Not Threaded)...2582
CENTER SWIVEL JOINT...2583
Removal And Installation...2583
Removal And Installation (Through Bottom AccessCover)...2584
Parts Identification...2585
Description...2586
Disassembly...2586
Assembly...2587
ROPS CANOPY...2590
Removal And Installation...2590
CAB...2592
Removal And Installation...2592
Heater Removal And Installation (325 S/N514013001– 514014899)...2594
Heater Removal And Installation (325 S/N 514014900& Above) & (328 S/N 516611001 & Above)...2595
Heater Disassembly And Assembly (325 S/N514014900 & Above) & (328 S/N 516611001 & Above)...2597
Front Window Removal And Installation...2600
Front Lower Window Removal And Installation...2601
Front Upper Window Removal And Installation (325S/N 514013001–514014899)...2602
Front Upper Window Removal And Installation (325S/N 514014900 & Above) & (328 S/N 516611001 &Above)...2602
Door Window Removal And Installation...2603
Left Hand Side Window Removal And Installation...2603
Right Hand Side Window Removal And Installation...2604
Right Hand Window Assembly Removal AndInstallation...2605
Rear Window Removal And Installation...2605
CAB/CANOPY REAR COVER...2606
Removal...2606
Installation...2606
MAIN FRAME AND TRACKS...2608
BLADE...2610
Removal And Installation...2610
TRACK...2610
Track Lug Height...2610
Track Tension Adjustment...2611
Rubber Track Clearance...2611
Steel Track Clearance...2612
Adjustment...2613
Rubber Track Removal And Installation...2614
Steel Track Removal And Installation...2616
Disassembly And Assembly...2618
Recoil Spring Disassembly And Assembly...2620
TRACK IDLER...2621
Parts Identification...2621
Disassembly...2622
Assembly...2624
TRACK ROLLER...2628
Parts Identification...2628
Disassembly...2629
Assembly...2631
TRAVEL MOTOR...2635
Removal And Installation...2635
Parts Identification...2636
Disassembly...2637
Assembly...2644
TRACK DAMAGE IDENTIFICATION...2653
Cutting Of Steel Cords...2653
Abrasion Of Embedded Metals...2654
Separation Of Embedded Metals...2655
Separation Of Embedded Metals Due To Corrosion...2656
Cuts On The Lug Side Rubber...2657
Cracks Of The Lug Side Rubber Due To Fatigue...2658
Lug Abrasion...2659
Cracks And Cuts On The Lug Side Rubber...2659
Abrasion Of The Track Roller Side...2660
Cuts On The Edges Of Track Roller Side...2661
ELECTRICAL SYSTEM...2662
ELECTRICAL SCHEMATICS...2664
TROUBLESHOOTING...2674
ELECTRICAL SYSTEM...2674
Description...2674
Fuses (325 S/N 514013001–514014899)...2675
Fuse Arrangement (325 S/N 514013001–514014899)...2675
Electrical Relays And Diodes (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2675
Fuse Arrangement (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)...2676
BATTERY...2677
Removal And Installation...2677
Servicing The Battery...2678
ALTERNATOR...2679
Belt Adjustment...2679
Removal And Installation...2679
ALTERNATOR...2680
Alternator Output Test...2680
Rectifier (Diode) Test...2680
Alternator Regulator Test...2681
Parts Identification...2682
Disassembly And Inspection...2682
Stator Continuity Test...2682
Stator Ground Test...2682
Rotor Continuity Test...2683
Rotor Ground Test...2683
Rectifier Continuity (Diode) Test...2683
Assembly...2684
STARTER...2685
Removal And Installation (325 S/N 514013001–514014899)...2685
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2685
Disassembly And Assembly...2686
Cleaning And Inspection (325 S/N 514013001–514014899)...2687
Parts Identification (325 S/N 514013001– 514014899)...2688
Parts Identification (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above)...2689
Disassembly (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2690
Inspection And Repair (325 S/N 514014900 & Above)& (328 S/N 516611001 & Above)...2695
Assembly (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2698
FUEL LEVEL SENDER...2703
Removal And Installation...2703
Testing...2703
INSTRUMENT PANEL (325 S/N 514013001–514014899)...2704
Removal And Installation...2704
GAUGES...2704
Removal And Installation (325 S/N 514013001–514014899)...2704
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2706
Bulb Replacement (325 S/N 514014900 & Above) &(328 S/N 516611001 & Above)...2706
TIMER (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2707
Removal And Installation...2707
DIODES (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2707
Diode Location...2707
Diode Replacement...2707
Diode Testing...2707
CAB ELECTRICAL...2708
Cab Option (325 S/N 514013001–514014899)...2708
Cab Option (325 S/N 514014900 & Above) & (328 S/N516611001 & Above)...2708
HORN...2709
Removal And Installation...2709
BUZZER...2709
Removal And Installation...2709
TWO SPEED SWITCH...2709
Removal And Installation...2709
ENGINE SYSTEM...2710
TROUBLESHOOTING...2712
VALVE CLEARANCE...2713
Adjustment...2713
ENGINE COMPRESSION...2713
Checking...2713
FUEL SHUTOFF SOLENOID...2715
Adjustment...2715
Removal And Installation...2715
Timer Module Removal And Installation...2715
FUEL INJECTION PUMP...2716
Checking The Injection Pump...2716
Removal And Installation...2716
Timing The Injection Pump...2717
FUEL INJECTOR NOZZLES...2719
Checking The Injector Nozzle...2720
GLOW PLUGS...2721
Removal And Installation...2721
Checking The Glow Plug...2721
FAN GUARD...2722
Removal And Installation...2722
RADIATOR...2723
Removal And Installation...2723
MUFFLER...2724
Removal And Installation (325 S/N 514013001–514014899)...2724
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2725
AIR CLEANER...2726
Removal And Installation (325 S/N 514013001–514014899)...2726
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2727
ENGINE...2728
Removal And Installation...2728
ENGINE FLYWHEEL...2734
Removal And Installation (325 S/N 514013001–514014899)...2734
Removal And Installation (325 S/N 514014900 &Above) & (328 S/N 516611001 & Above)...2735
FLYWHEEL RING GEAR...2736
CYLINDER HEAD...2737
Removal And Installation...2737
Disassembly And Assembly Of The Cylinder Head...2738
Servicing The Cylinder Head...2739
Top Clearance...2739
VALVE, VALVE SEAT AND GUIDE...2740
Checking The Valve Guide...2740
Reconditioning The Valve And Valve Seat...2741
Valve Spring...2742
ROCKER ARM AND SHAFT...2742
Checking...2742
TIMING GEARCASE COVER...2743
Removal And Installation...2743
IDLER GEAR AND CAMSHAFT...2745
Removal And Installation...2745
Servicing The Idler Gear And Shaft...2747
TIMING GEARS...2747
Checking Backlash...2747
FUEL CAMSHAFT...2748
Removal And Installation...2748
Governor...2748
CRANKSHAFT GEAR...2749
Removal And Installation...2749
OIL PUMP...2749
Removal And Installation...2749
Oil Pump Service...2749
Checking Engine Oil Pressure...2750
Relief Valve...2750
PISTON AND CONNECTING ROD...2751
Removal And Installation...2751
Servicing The Piston And Connecting Rod...2752
Connecting Rod Alignment...2754
CRANKSHAFT AND BEARINGS...2755
Removal And Installation...2755
Servicing The Crankshaft And Bearings...2756
CYLINDER BORE...2759
Checking The Cylinder Bore...2759
WATER PUMP...2760
Disassembly And Assembly...2760
SPECIFICATIONS...2762
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 S/N 514013001–514014899)...2764
Machine Dimensions...2764
Lifting Capacity...2765
WEIGHTS...2765
CONTROLS...2765
ENGINE...2765
ELECTRICAL...2765
HYDRAULIC SYSTEM...2766
SWING SYSTEM...2766
HYDRAULIC CYLINDERS...2766
DRIVE SYSTEM...2766
BRAKES...2766
UNDERCARRIAGE...2766
STD TRACK...2766
CAPACITIES...2766
DIGGING FORCE...2766
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above...2767
Machine Dimensions...2767
Lifting Capacity...2768
WEIGHTS...2768
CONTROLS...2768
ENGINE...2768
ELECTRICAL...2768
HYDRAULIC SYSTEM...2769
SWING SYSTEM...2769
HYDRAULIC CYLINDERS...2769
DRIVE SYSTEM...2769
BRAKES...2769
UNDERCARRIAGE...2769
STD TRACK...2769
CAPACITIES...2769
DIGGING FORCE...2769
ENGINE SPECIFICATIONS...2770
Fuel Injection Nozzles...2770
Fuel Injection Pump...2770
Cylinder Head...2770
Valves...2770
Valve Springs...2770
Valve Timing...2770
Rocker Arms...2770
Camshaft...2771
Tappet...2771
Cylinders...2771
Piston Rings...2771
Pistons...2771
Connecting Rod...2771
Oil Pump...2771
Crankshaft...2771
Timing Gear...2772
Thermostat...2772
Engine Bolt Torque...2772
Re–Grinding The Crankshaft...2773
TORQUE FOR GENERAL METRIC BOLTS...2773
FUEL, COOLANT AND LUBRICANTS...2774
Chart...2774
ENGINE OIL AND COOLING SPECIFICATIONS...2774
Description...2774
Anti–Freeze Solution...2774
Propylene Glycol...2774
BUCKET SPECIFICATIONS...2775
DECIMAL AND MILLIMETER EQUIVALENTS...2776
U.S. TO METRIC CONVERSION...2776
SERVICE MANUAL REVISON...2778
325-1...2778
325-2...2780
325/328-3...2782
6900556 (4-00) - X 325, X 328 Compact Excavator Operation & Maintenance Manual...2784
OPERATOR SAFETY WARNINGS...2786
CONTENTS...2788
REGULAR MAINTENANCE ITEMS...2789
FOREWORD...2790
SERIAL NUMBER LOCATIONS...2792
HYDRAULIC EXCAVATOR SERIAL NUMBER...2792
ENGINE SERIAL NUMBER...2792
DELIVERY REPORT...2792
HYDRAULIC EXCAVATOR IDENTIFICATION...2793
SAFETY...2794
SAFETY INSTRUCTIONS...2796
FIRE PREVENTION...2798
MACHINE SIGNS (DECALS)...2799
OPERATING INSTRUCTIONS...2802
INSTRUMENT PANEL...2804
KEY SWITCH...2804
STEERING LEVERS / FOOT PEDALS...2805
Forward And Reverse Travel...2805
Turning...2805
Right Turn...2805
Counter-Rotation Turn Right...2805
Left Turn...2805
Counter-Rotation Turn Left...2805
AUXILIARY POWER OUTLET...2806
CAB / CANOPY...2806
CAB / CANOPY FOGS (Falling Object Guards)...2806
CAB OPTION...2807
Emergency Exit...2807
Cab Door...2807
Front Window...2807
Opening The Front Window...2808
Closing The Front Window...2808
Interior Light...2809
Wiper Washer Switch...2809
Windshield Washer Tank...2809
Heater Control...2810
CONSOLE SWITCHES...2810
SPEED CONTROL LEVER...2810
FUSES...2811
AUDIBLE ALARM...2812
HORN BUTTON...2812
SEAT...2813
OPERATOR'S HANDBOOK...2813
STORAGE COMPARTMENT...2813
ENGINE COVER...2813
AUXILIARY HYDRAULIC PEDAL...2814
Operation...2814
DIRECT TO TANK VALVE (If Equipped)...2814
Breaker Operation:...2814
Auger And Other Attachment Operation:...2814
AUXILIARY HYDRAULIC COUPLERS...2815
Quick Couplers...2815
CONTROL LEVERS (JOYSTICKS)...2816
Operation Of Left Control Lever (ISO)...2816
Operation Of Right Control Lever (ISO)...2816
Operation Of Left Control Lever (Standard)...2817
Operation Of Right Control Lever (Standard)...2817
SWING LOCK...2818
BOOM SWING PEDAL...2818
BLADE CONTROL LEVER...2819
CONTROL LEVER (JOYSTICK) LOCK...2819
TWO-SPEED FOOT SWITCH...2819
GETTING ON AND OFF THE MACHINE...2820
DAILY INSPECTION...2821
STARTING THE ENGINE...2821
Normal Starting Procedure (With Engine Warm)...2821
Cold Temperature Starting Procedure...2822
ATTACHMENTS (Pin On)...2823
Removal...2823
Installation...2823
ATTACHMENTS (Using The X-Change™ System) (If Equipped)...2824
Removal...2824
Installation...2825
OPERATING PROCEDURE...2826
Operating On Public Roads...2826
Lifting A Load...2826
Excavating...2827
Boom Offset...2828
Backfilling...2829
Driving The Excavator...2829
Operating On Slopes...2830
Operating In Water...2832
PARKING THE HYDRAULIC EXCAVATOR...2832
TRANSPORTING THE HYDRAULIC EXCAVATOR...2833
LIFTING THE HYDRAULIC EXCAVATOR...2834
PREVENTIVE MAINTENANCE...2836
MAINTENANCE SAFETY...2837
SERVICE SCHEDULE...2838
ENGINE COVER...2839
Opening The Engine Cover...2839
Adjustment Of The Engine Cover Latch...2839
AIR CLEANER SERVICE...2839
FUEL SYSTEM...2841
Filling The Fuel Tank...2841
Fuel Filter...2841
Fuel System Maintenance...2842
Removing Air From The Fuel System...2842
Fuel Specifications...2842
ENGINE LUBRICATION SYSTEM...2843
Checking Engine Oil...2843
Replacement Of Oil And Filter...2843
COOLING SYSTEM...2844
Coolant Level...2844
Coolant Replacement...2844
ALTERNATOR BELT ADJUSTMENT...2845
ELECTRICAL SYSTEM...2845
Electrical Relays And Diodes...2845
Fuses...2845
Service The Electrical System (And Battery)...2846
Using A Booster Battery (Jump Starting)...2848
Removal And Installation Of The Battery...2849
Electrical Solenoid (Engine Stop)...2849
HYDRAULIC SYSTEM...2850
Checking And Adding Fluid...2850
Diagnostic Couplers...2850
Replacing The Hydraulic Oil...2851
Replacing The Hydraulic Filter...2851
Cleaning The Case Drain Filter...2851
SPARK ARRESTOR MUFFLER...2852
TRACK TENSION...2853
Adjustment...2853
Rubber Tracks...2853
Steel Tracks...2854
TRAVEL MOTOR...2855
Checking Oil Level...2855
Draining And Refilling...2855
JOYSTICK CONTROL CHANGE For 325 (S/N 514011001 - 514016282) And 328 (S/N 516611001 - 516611315)...2856
ISO To Standard Control Pattern...2856
Standard To ISO Control Pattern...2856
JOYSTICK CONTROL CHANGE (With ISO/Standard Control Valve) For 325 (S/N 514016283 & Above), 328 (S/N 516611316 & Above)...2857
LUBRICATION OF THE HYDRAULIC EXCAVATOR...2858
HEATER AIR FILTER (With Cab Option Only)...2861
MACHINE SIGN TRANSLATIONS...2862
SPECIFICATIONS...2872
HYDRAULIC EXCAVATOR SPECIFICATIONS 325 (S/N 514014900 & Above)...2874
Machine Dimensions...2874
Lifting Capacity 325 (S/N 514014900 - 514016149)...2875
Lifting Capacity 325 (S/N 514016150 & Above)...2875
WEIGHTS...2876
CONTROLS...2876
ENGINE...2876
ELECTRICAL...2876
HYDRAULIC SYSTEM...2876
SWING SYSTEM...2876
HYDRAULIC CYLINDERS...2877
DRIVE SYSTEM...2877
BRAKES...2877
UNDERCARRIAGE...2877
STD TRACK...2877
CAPACITIES...2877
DIGGING FORCE...2877
HYDRAULIC EXCAVATOR SPECIFICATIONS 328 (S/N 516611001 & Above)...2878
Machine Dimensions...2878
Lifting Capacity 328 (S/N 516611001 - 516611219)...2879
Lifting Capacity 328 (S/N 516611220 & Above)...2879
WEIGHTS...2880
CONTROLS...2880
ENGINE...2880
ELECTRICAL...2880
HYDRAULIC SYSTEM...2880
SWING SYSTEM...2880
HYDRAULIC CYLINDERS...2881
DRIVE SYSTEM...2881
BRAKES...2881
UNDERCARRIAGE...2881
STD TRACK...2881
CAPACITIES...2881
DIGGING FORCE...2881
FUEL, COOLANT AND LUBRICANTS...2882
Chart...2882
ENGINE OIL SPECIFICATIONS...2882
Description...2882
Propylene Glycol (Factory Installed)...2882
BUCKET SPECIFICATIONS...2883
Pin On ...2883
X-Change™...2883
BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...2884
BUCKETS AVALIABLE...2884
ATTACHMENTS...2884
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...2886
WARRANTY...2888
6901018 (5-03) - 325, 328 Operation & Maintenance Manual...2890
OPERATOR SAFETY WARNINGS...2892
CONTENTS...2894
REGULAR MAINTENANCE ITEMS...2895
FOREWORD...2896
SERIAL NUMBER LOCATIONS...2898
Bobcat Excavator Serial Number...2898
Engine Serial Number...2898
DELIVERY REPORT...2898
BOBCAT EXCAVATOR IDENTIFICATION...2899
FEATURES AND ACCESSORIES...2900
SAFETY...2902
SAFETY INSTRUCTIONS FOR BOBCAT COMPACT EXCAVATORS AND ATTACHMENTS...2904
FIRE PREVENTION...2906
MACHINE SIGNS (DECALS)...2907
OPERATING INSTRUCTIONS...2910
INSTRUMENTS AND CONSOLES...2912
Cab Interior Light (If Equipped)...2912
Left Console...2912
Wiper / Washer Fluid Reservoir (If Equipped)...2912
Right Console...2913
STD / ISO SELECTOR VALVE...2913
Function Icons...2914
Raising And Lowering The Console...2915
TWO–SPEED TRAVEL...2915
TAILGATE...2915
Opening And Closing...2915
OPERATOR CANOPY (ROPS / TOPS)...2916
FALLING OBJECT GUARDS (FOGS)...2916
CANOPY ENCLOSURE...2916
SLEW LOCK...2917
OPERATOR CAB (ROPS / TOPS) (If Equipped)...2917
Emergency Exit...2917
Cab Door...2917
Front Window...2917
STEERING LEVERS / FOOT PEDALS...2919
Forward And Reverse Travel...2919
Turning...2919
HYDRAULIC CONTROLS...2920
ISO Control Pattern...2920
Left Control Lever...2920
Right Control Lever...2920
Standard Control Pattern...2921
Left Control Lever...2921
Right Control Lever...2921
Quick Couplers...2922
Auxiliary Hydraulics...2922
Relieving Hydraulic Pressure...2922
Two–Way Flow / One–Way Flow (Breaker Operation)(Field Accessory)...2923
BLADE CONTROL LEVER...2923
BOOM SWING PEDAL...2923
DAILY INSPECTION...2924
PRE–STARTING PROCEDURE...2925
STARTING THE ENGINE...2927
Key Switch...2927
Keyless Start...2928
Cold Temperature Starting Procedure...2929
ATTACHMENTS (Using the X–Change™ System)...2930
Removing Bucket or Attachment...2930
Installing Bucket or Attachment...2931
OPERATING PROCEDURE...2932
Operating On Public Roads...2932
Lifting A Load...2932
Excavating...2933
Boom Offset...2934
Backfilling...2935
Driving The Excavator...2935
Operating On Slopes...2936
Operating In Water...2938
PARKING THE EXCAVATOR...2938
TRANSPORTING THE EXCAVATOR...2939
LIFTING THE EXCAVATOR...2940
PREVENTIVE MAINTENANCE...2942
MAINTENANCE SAFETY...2943
SERVICE SCHEDULE...2944
TAILGATE...2945
Opening And Closing The Tailgate...2945
Adjusting The Bumper...2945
Adjusting The Tailgate Latch...2945
AIR CLEANER...2945
Daily Check...2945
Replacing The Filters...2945
HEATER AIR FILTERS (With Cab Option Only)...2946
Recirculation Filter...2946
Fresh Air Filter...2946
FUEL SYSTEM...2947
Fuel Specifications...2947
Filling The Fuel Tank...2947
Removing Water From The Fuel Filter...2947
Fuel Filter...2947
Removing Air From The Fuel System...2948
Draining The Fuel Tank...2948
ENGINE LUBRICATION SYSTEM...2949
Checking Engine Oil...2949
Replacing Oil And Filter...2949
COOLING SYSTEM...2950
Cleaning The Cooling System...2950
Checking Coolant Level...2950
Replacing The Coolant...2951
ELECTRICAL SYSTEM...2952
Description...2952
Fuse Location...2952
Removing And Installing The Battery...2953
ALTERNATOR...2953
Adjusting The Alternator Belt...2953
Removing And Installing The Battery...2954
HYDRAULIC SYSTEM...2955
Checking And Adding Fluid...2955
Replacing The Hydraulic Oil...2956
Replacing the Hydraulic Filter...2957
Replacing the Case Drain Filter...2957
Diagnostic Couplers...2958
SPARK ARRESTOR MUFFLER (If Equipped)...2959
TRACK TENSION...2960
Adjustment...2961
TRAVEL MOTOR...2962
Checking Oil Level...2962
Draining Final Drive Case...2962
LUBRICATION OF THE HYDRAULIC EXCAVATOR...2963
SYSTEM SETUP AND ANALYSIS...2966
SERVICE CODES...2968
DELUXE INSTRUMENT PANEL SETUP...2969
Passwords...2969
Password Entry (For Starting and Operating the Machine)...2969
Changing The Operator Password...2969
Password Lockout Feature...2970
Job Clock...2970
RPM...2970
MACHINE SIGN TRANSLATIONS...2972
SPECIFICATIONS...2984
325 EXCAVATOR SPECIFICATIONS...2986
328 (and 325 with Long Arm Kit) EXCAVATOR SPECIFICATIONS...2987
325 Lifting Capacity...2988
328 Lifting Capacity (Also 325 when equipped with long arm.)...2988
FUEL, COOLANT AND LUBRICANTS...2989
Chart...2989
BOBCAT APPROVED ATTACHMENTS & ACCESSORIES...2990
BUCKETS AVAILABLE ...2990
ATTACHMENTS...2990
ADDITIONAL PUBLICATIONS and TRAINING MATERIALS...2991
WARRANTY...2992
6901138 (2-06) - 325, 328 Service Manual...2994
MAINTENANCE SAFETY...2996
ALPHABETICAL INDEX...2998
CONTENTS...3002
FOREWORD...3004
SAFETY INSTRUCTIONS...3006
Fire Prevention...3008
SERIAL NUMBER LOCATIONS...3010
Bobcat Excavator Serial Number...3010
Engine Serial Number...3010
DELIVERY REPORT...3010
BOBCAT EXCAVATOR IDENTIFICATION...3011
SAFETY AND MAINTENANCE...3012
LIFTING AND BLOCKING THE EXCAVATOR...3014
Procedure...3014
SWING LOCK...3016
Operation...3016
LIFTING THE EXCAVATOR...3018
Procedure...3018
OPERATOR CAB (ROPS / TOPS) (IF EQUIPPED)...3020
Emergency Exit...3020
Cab Door...3020
Front Window...3020
TRANSPORTING THE EXCAVATOR...3022
Procedure...3022
TAILGATE...3024
Opening And Closing The Tailgate (Early Models)...3024
Adjusting The Bumper (Early Models)...3024
Adjusting The Tailgate Latch (Early Models)...3025
Opening And Closing The Tailgate (Later Models)...3025
Adjusting The Tailgate Latch (Later Models)...3026
Adjusting The Bumper (Later Models)...3026
SERVICE SCHEDULE...3028
Chart...3028
AIR CLEANER SERVICE...3030
Daily Check...3030
Replacing The Filters...3030
HEATER AIR FILTERS (WITH CAB OPTION ONLY)...3032
Recirculation Filter...3032
Fresh Air Filter...3032
ENGINE COOLING SYSTEM...3034
Cleaning The Cooling System...3034
Checking The Coolant Level...3034
Replacing The Coolant...3035
FUEL SYSTEM...3038
Fuel Specification...3038
Filling The Fuel Tank...3038
Removing Water From The Fuel Filter...3038
Fuel Filter...3038
Removing Air From The Fuel System...3039
Draining The Fuel Tank...3039
ENGINE LUBRICATION SYSTEM...3040
Checking Engine Oil...3040
Replacing Oil And Filter...3040
HYDRAULIC SYSTEM...3042
Checking And Adding Fluid...3042
Replacing the Hydraulic Filter...3042
Replacing the Case Drain Filter...3043
Replacing the Hydraulic Fluid...3043
Diagnostic Couplers...3044
LUBRICATING THE EXCAVATOR...3046
Procedure...3046
TRAVEL MOTOR...3048
Checking Oil Level...3048
Draining The Travel Motor...3048
SPARK ARRESTOR MUFFLER (IF EQUIPPED)...3050
Cleaning The Spark Arrestor Muffler...3050
HYDRAULIC SYSTEM...3052
HYDRAULIC/HYDROSTATIC SCHEMATICS...3058
HYDRAULIC SYSTEM INFORMATION...3063
Glossary Of Hydraulic / Hydrostatic Symbols...3063
Troubleshooting Chart...3067
BOOM CYLINDER...3071
Checking The Boom Cylinder...3071
Removal And Installation...3073
Parts Identification...3075
Disassembly...3076
Assembly...3078
ARM CYLINDER...3081
Checking The Arm Cylinder...3081
Removal And Installation...3083
Parts Identification...3084
Disassembly...3085
Assembly...3087
BOOM OFFSET CYLINDER...3091
Checking The Boom Offset Cylinder...3091
Removal And Installation...3093
Parts Identification...3095
Disassembly...3096
Assembly...3098
BUCKET CYLINDER...3101
Checking The Bucket Cylinder...3101
Removal And Installation...3103
Parts Identification...3104
Disassembly...3105
Assembly...3107
BLADE CYLINDER...3111
Checking The Blade Cylinder...3111
Removal And Installation...3113
Parts Identification...3114
Disassembly...3115
Assembly...3117
MAIN RELIEF VALVES...3121
Testing And Adjusting The Main Relief Valves (S/N 232312386 & Below, 232412117 & Below, 232412128 And 232412129)...3121
Testing And Adjusting The Main Relief Valves (S/N 232312387 & Above, 232412118-232412127 And 232412130 & Above)...3125
PORT RELIEF VALVES...3129
Testing And Adjusting Port Relief Valve Pressure (S/ N 232312386 & Below And 232412117 & Below, 232412128 And 232412129)...3129
Testing Port Relief Valve Pressure (S/N 232312387 & Above And 232412118-232412127 And 232412130 & Above)...3130
CROSSPORT RELIEF VALVES...3133
Testing And Adjusting The Crossport Relief Valves...3133
SYSTEM PRESSURES AT GAUGE PORT SPECIFICATIONS...3133
PRESSURE REDUCING VALVE (S/N 232312386 & BELOW AND 232412117 & BELOW, 232412128 AND 232412129)...3135
Testing And Adjusting The Pressure Reducing Valve...3135
PRESSURE REDUCING VALVE (S/N 232312387 & ABOVE AND 232412118-232412127 AND 232412130 & ABOVE)...3137
Testing And Adjusting The Pressure Reducing Valve...3137
HYDRAULIC CONTROL VALVE (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)...3141
Description...3141
Removal And Installation...3141
Control Valve Identification...3145
Disassembly...3146
Right Travel Valve Section Disassembly And Assembly...3147
Boom Offset Valve Section Disassembly And Assembly...3150
Boom Valve Section Disassembly And Assembly...3153
Left Travel Valve Section Disassembly And Assembly...3156
Arm Valve Section Disassembly And Assembly...3158
Bucket Valve Section Disassembly And Assembly...3161
Auxiliary Valve Section Disassembly And Assembly...3163
Boost Valve Section Disassembly And Assembly...3166
Blade Valve Section Disassembly And Assembly...3168
Swing Valve Section Disassembly And Assembly...3170
Assembly...3172
HYDRAULIC CONTROL VALVE (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)...3179
Description...3179
Removal And Installation...3179
Control Valve Identification...3185
Disassembly...3186
Right Travel Valve Section Disassembly And Assembly...3187
Boom Offset Valve Section Disassembly And Assembly...3193
Boom Valve Section Disassembly And Assembly...3199
Left Travel Valve Section Disassembly And Assembly...3203
Arm Valve Section Disassembly And Assembly...3208
Bucket Valve Section Disassembly And Assembly...3212
Auxiliary Valve Section Disassembly And Assembly...3216
Boost Valve Section Disassembly And Assembly...3220
Blade Valve Section Disassembly And Assembly...3224
Swing Valve Section Disassembly And Assembly...3229
Assembly...3233
HYDRAULIC PUMP...3241
Description...3241
Torque Adjustment...3241
Testing The Piston Pump...3242
Testing The Gear Pump...3244
Testing The Auxiliary Hydraulic Flow...3246
Removal And Installation...3247
Coupler Removal And Installation...3248
Gear Pump Parts Identification...3249
Piston Pump Parts Identification...3250
Disassembly...3251
Gear Pump Disassembly...3252
Gear Pump Assembly...3255
Piston Pump Disassembly...3257
Piston Pump Assembly...3265
Assembly...3274
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311950 & BELOW AND 232411763 & BELOW)...3275
Manifold Description...3275
Removal And Installation...3275
MANIFOLD ASSEMBLY (S/N 232311950 & BELOW AND 232411763 & BELOW)...3279
Parts Identification...3279
Disassembly...3280
Assembly...3288
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311951 & ABOVE AND 232411764 & ABOVE)...3297
Manifold Description...3297
Removal And Installation...3297
MANIFOLD ASSEMBLY (S/N 232311951 & ABOVE AND 232411764 & ABOVE)...3301
Parts Identification...3301
Disassembly...3302
Assembly...3312
TRAVEL MOTOR...3325
Removal And Installation...3325
Parts Identification...3327
Disassembly...3328
Assembly...3335
SWIVEL JOINT...3345
Removal And Installation (With The Upperstructure Removed)...3345
Removal And Installation (Through Bottom Access Cover)...3345
Parts Identification...3347
Description...3348
Disassembly...3348
Assembly...3349
SWING MOTOR...3353
Removal And Installation...3353
Parts Identification...3356
Disassembly...3357
Assembly...3359
Cross Port Relief Valve Parts Identification...3364
Cross Port Relief Valve Disassembly...3365
Cross Port Relief Valve Assembly...3367
SWING MOTOR DRIVE CARRIER...3369
Removal And Installation...3369
Parts Identification...3370
Disassembly...3371
Assembly...3373
CONTROL PATTERN SELECTOR VALVE...3377
Removal And Installation...3377
Parts Identification...3377
Disassembly...3378
Assembly...3379
RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)...3381
Testing...3381
Handle Removal And Installation...3382
Joystick Assembly, Removal And Installation...3386
Parts Identification...3388
Disassembly...3389
LEFT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)...3393
Testing...3393
Handle Removal And Installation...3394
Joystick Assembly Removal And Installation...3397
Parts Identification...3400
Disassembly...3401
LEFT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)...3405
Testing...3405
Handle Removal And Installation...3406
Joystick Assembly Removal And Installation...3409
Parts Identification...3411
Disassembly...3412
Assembly...3416
RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)...3423
Testing...3423
Handle Removal And Installation...3424
Joystick Assembly Removal And Installation...3428
Parts Identification...3430
Disassembly...3431
Assembly...3435
HYDRAULIC FILTER...3441
Removal And Installation...3441
HYDRAULIC RESERVOIR...3443
Removal And Installation...3443
OIL COOLER...3445
Removal And Installation...3445
DIRECT TO TANK VALVE...3447
Removal And Installation...3447
Disassembly And Assembly...3448
BUILD UP VALVE...3449
Description...3449
Removal And Installation...3449
Disassembly And Assembly...3449
CASE DRAIN FILTER...3451
Removal And Installation...3451
UNDERCARRIAGE...3453
BLADE...3455
Removal And Installation...3455
TRACKS...3457
Track Lug Height...3457
Adjustment...3457
Rubber Track Removal And Installation...3460
Steel Track Removal And Installation...3462
TRACK FRAME...3465
Disassembly And Assembly...3465
Recoil Spring Disassembly And Assembly...3467
TRACK DAMAGE IDENTIFICATIONS...3471
Cutting Of Steel Cords...3471
Abrasion Of Embedded Metals...3472
Separation Of Embedded Metals...3473
Separation Of Embedded Metals Due To Corrosion...3474
Cuts On The Lug Side Rubber...3475
Cracks On The Lug Side Rubber Due To Fatigue...3476
Lug Abrasion...3477
Cracks And Cuts On The Lug Side Rubber...3478
Abrasion Of The Track Roller Side...3479
Cuts On The Edges Of Track Roller Side...3480
TRACK IDLER...3483
Parts Identification (S/N 232311036 & Below And 232411019 & Below)...3483
Disassembly (S/N 232311036 & Below And 232411019 & Below)...3484
Assembly (S/N 232311036 & Below And 232411019 & Below)...3486
Parts Identification (S/N 232311037 & Above And 232411020 & Above)...3490
Disassembly (S/N 232311037 & Above And 232411020 & Above)...3491
Assembly (S/N 232311037 & Above And 232411020 & Above)...3493
TRACK ROLLER...3497
Parts Identification (S/N 232311036 & Below And 232411019 & Below)...3497
Disassembly (S/N 232311036 & Below And 232411019 & Below)...3498
Assembly (S/N 232311036 & Below And 232411019 & Below)...3500
Parts Identification (S/N 232311037 & Above And 232411020 & Above)...3504
Disassembly (S/N 232311037 & Above And 232411020 & Above)...3505
Assembly (S/N 232311037 & Above And 232411020 & Above)...3506
SWING CIRCLE GEAR...3509
Removal And Installation...3509
Swing Bearing Removal...3511
Swing Bearing Installation...3512
Alignment Pins (Not Threaded)...3514
UPPERSTRUCTURE & SWING SECTION...3515
UPPERSTRUCTURE...3519
Removal And Installation...3519
Swing Bearing Removal...3521
Swing Bearing Installation...3522
Alignment Pins (Not Threaded)...3524
ROPS CANOPY...3527
Removal And Installation...3527
CAB...3531
Removal And Installation...3531
Door Removal And Installation...3534
Front Window Removal And Installation...3535
Lower Front Window Removal And Installation...3537
Right Side Rear Sliding Window Removal And Installation...3538
Right Side Front Sliding Window Removal And Installation...3539
Right Side Panel And Window Assembly Removal And Installation...3540
Door, Left Side, Rear And Upper Front Window Removal And Installation...3543
STANDARD SEAT AND SEAT MOUNT...3545
Removal And Installation...3545
SUSPENSION SEAT AND SEAT MOUNT...3547
Removal And Installation...3547
RIGHT CONSOLE...3549
Console Cover Removal And Installation...3549
Console Base Removal And Installation...3550
LEFT CONSOLE...3555
Lower Console Cover Removal And Installation...3555
Upper Console Cover Removal And Installation...3557
Compression Spring Removal And Installation...3558
Lock Lever Removal And Installation...3559
Upper Console Removal And Installation...3560
Console Switch Removal And Installation...3562
Disassembly And Assembly...3563
Console Base Removal And Installation...3565
ENGINE SPEED CONTROL...3567
Removal And Installation...3567
BLADE CONTROL...3569
Lever Removal And Installation...3569
Linkage Removal And Installation...3570
Linkage Bar Removal And Installation...3572
Lower Linkage Removal And Installation...3573
RIGHT PEDAL AND LINKAGE...3577
Pedal Removal And Installation...3577
Right Pedal Disassembly And Assembly...3578
Linkage Removal And Installation...3580
Adjustment...3583
TRAVEL CONTROLS...3585
Removal And Installation...3585
Disassembly And Assembly...3586
Adjustment...3589
FLOOR MAT AND FLOOR PANELS...3591
Removal And Installation...3591
FUEL TANK...3593
Removal And Installation...3593
HORN...3599
Removal And Installation...3599
SWING FRAME...3601
Boom Swing Bracket Removal And Installation...3601
Boom Swing Bracket Hose Installation...3605
Bushing Removal...3606
Bushing Installation...3607
BOOM...3609
Removal And Installation...3609
Boom Bushing Removal And Installation...3610
ARM...3611
Removal And Installation...3611
Arm To Boom Bushing Removal And Installation...3611
Arm To Bucket And Bucket Link Bushing Removal And Installation...3612
BUCKET...3613
Bucket Teeth Removal And Installation...3613
Bucket Side Cutting Edge Removal And Installation...3614
TAILGATE...3615
Removal And Installation...3615
Release Rod Removal And Installation...3616
Latch Removal And Installation...3617
Release Rod Removal And Installation (Early Models)...3617
Latch Removal And Installation (Early Models)...3618
Latch Removal And Installation (Later Models)...3619
X-CHANGE™...3621
Removal And Installation...3621
Disassembly...3623
Assembly...3628
RIGHT SIDE COVER...3635
Removal And Installation...3635
ELECTRICAL SYSTEM & ANALYSIS...3637
ELECTRICAL SCHEMATIC...3639
ELECTRICAL SYSTEM INFORMATION...3640
Glossary Of Electrical Symbols...3640
Troubleshooting Chart...3644
Description...3645
Fuse Location...3645
BATTERY...3646
Servicing...3646
Removal And Installation...3647
Using A Booster Battery (Jump Starting)...3648
ALTERNATOR...3650
Adjusting The Alternator Belt...3650
Description...3650
Tests...3651
Alternator Output Test...3651
Full Field Test...3652
Alternator Regulator Test...3652
Removal And Installation...3653
Disassembly And Assembly...3655
STARTER...3656
Removal And Installation...3656
Parts Identification...3657
Disassembly...3658
Inspection And Repair...3663
Assembly...3666
LIGHTS...3672
Removal And Installation...3672
Disassembly And Assembly...3673
FUEL LEVEL SENDER...3674
Removal And Installation...3674
Testing...3674
DIAGNOSTICS SERVICE CODE...3676
Number Codes List...3676
ENGINE SERVICE...3678
TROUBLESHOOTING...3680
Chart...3680
MUFFLER...3682
Removal And Installation...3682
AIR CLEANER...3684
Removal And Installation...3684
RADIATOR...3686
Removal And Installation...3686
ENGINE COMPONENTS AND TESTING...3690
Valve Clearance Adjustment...3690
Engine Compression Checking...3690
Fuel Shutoff Solenoid Adjustment...3692
Fuel Shutoff Solenoid Removal And Installation...3692
Fuel Injection Pump Check...3693
Fuel Injection Pump Removal And Installation...3694
Fuel Injection Pump Timing...3695
Fuel Injector Nozzles Removal And Installation...3696
Checking The Injector Nozzle...3698
Glow Plug Removal And Installation...3699
Glow Plug Checking...3700
ENGINE...3702
Removal And Installation...3702
ENGINE FLYWHEEL...3708
Removal And Installation...3708
Flywheel Ring Gear...3710
RECONDITIONING THE ENGINE...3712
Cylinder Head Removal And Installation...3712
Cylinder Head Disassembly And Assembly...3713
Cylinder Head Servicing...3714
Cylinder Head Top Clearance...3715
Valve Guide, Checking...3715
Reconditioning The Valve And Valve Seat...3717
Valve Spring...3718
Rocker Arm And Shaft Checking...3719
Timing Gearcase Cover Removal And Installation...3719
Idler Gear And Camshaft Removal And Installation...3722
Idler Gear And Shaft Servicing...3724
Timing Gears Checking Backlash...3725
Fuel Camshaft Removal And Installation...3725
Fuel Camshaft Governor...3726
Crankshaft Gear Removal And Installation...3726
Oil Pump Removal And Installation...3727
Oil Pump Service...3727
Engine Oil Pressure, Checking...3728
Relief Valve...3729
Piston And Connecting Rod Removal And Installation...3729
Piston And Connecting Rod Servicing...3731
Connecting Rod Alignment...3733
Crankshaft And Bearings Removal And Installation...3734
Crankshaft And Bearings, Servicing...3736
Cylinder Bore, Checking...3738
Water Pump Removal And Installation...3738
Water Pump Disassembly And Assembly...3739
Fan Removal And Installation...3739
HEATER...3742
HEATER UNIT...3744
Removal And Installation...3744
Disassembly And Assembly...3745
HEATER COIL...3746
Removal And Installation...3746
HEATER FAN...3748
Removal And Installation...3748
Disassembly And Assembly...3749
Resistor Removal And Installation...3750
Wire Connector Removal And Installation...3751
HEATER VALVE...3754
Removal And Installation...3754
SPECIFICATIONS...3756
HYDRAULIC EXCAVATOR SPECIFICATIONS (325)...3758
Machine Dimensions...3758
Lifting Capacity...3759
Weights...3759
Controls...3759
Engine...3760
Electrical...3760
Hydraulic System...3760
Swing System...3761
Hydraulic Cylinders...3761
Drive System...3761
Brakes...3761
Undercarriage...3761
STD Track...3762
Capacities...3762
Digging Force...3762
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 W/LONG ARM KIT & 328)...3763
Machine Dimensions...3763
Lifting Capacities...3764
Weights...3764
Controls...3764
Engine...3765
Electrical...3765
Hydraulic System...3765
Swing System...3766
Hydraulic Cylinders...3766
Drive System...3766
Brakes...3766
Undercarriage...3766
STD Track...3767
Capacities...3767
Digging Force...3767
ENGINE SPECIFICATIONS...3768
Fuel Injection Nozzles...3768
Fuel Injection Pump...3768
Cylinder Head...3768
Valves...3768
Valve Springs...3769
Valve Timing...3769
Rocker Arms...3769
Camshaft...3769
Tappet...3769
Cylinders...3770
Piston Rings...3770
Pistons...3770
Connecting Rods...3770
Oil Pump...3770
Crankshaft...3771
Thermostat...3771
Timing Gear...3772
Engine Bolt Torque...3772
Crankshaft Re-Grind Data...3773
TORQUE SPECIFICATIONS...3774
Torque For General SAE Bolts...3774
Torque For General Metric Bolts...3775
HYDRAULIC CONNECTION SPECIFICATIONS...3776
O-Ring Face Seal Connection...3776
Straight Thread O-Ring Fitting...3776
Tubelines And Hoses...3776
Flare Fitting...3776
O-Ring Flare Fitting...3777
Port Seal Fitting...3779
HYDRAULIC FLUID SPECIFICATIONS...3780
Specifications...3780
FUEL, COOLANT AND LUBRICANTS...3782
Chart...3782
CONVERSIONS...3784
Decimal And Millimeter Equivalents...3784
U.S. To Metric Conversion...3785
SMR...3786
325/328-1...3786
325/328-2...3788
325/328-3...3790
6901138 (6-12) - 325, 328 Service Manual...3792
MAINTENANCE SAFETY...3794
ALPHABETICAL INDEX...3796
CONTENTS...3800
FOREWORD...3802
SAFETY INSTRUCTIONS...3804
Fire Prevention...3806
SERIAL NUMBER LOCATIONS...3808
Bobcat Excavator Serial Number...3808
Engine Serial Number...3808
DELIVERY REPORT...3808
BOBCAT EXCAVATOR IDENTIFICATION...3809
SAFETY AND MAINTENANCE...3810
LIFTING AND BLOCKING THE EXCAVATOR...3812
Procedure...3812
SWING LOCK...3814
Operation...3814
LIFTING THE EXCAVATOR...3816
Procedure...3816
OPERATOR CAB (ROPS / TOPS) (IF EQUIPPED)...3818
Emergency Exit...3818
Cab Door...3818
Front Window...3818
TRANSPORTING THE EXCAVATOR...3820
Procedure...3820
TAILGATE...3822
Opening And Closing The Tailgate (Early Models)...3822
Adjusting The Bumper (Early Models)...3822
Adjusting The Tailgate Latch (Early Models)...3823
Opening And Closing The Tailgate (Later Models)...3823
Adjusting The Tailgate Latch (Later Models)...3824
Adjusting The Bumper (Later Models)...3824
SERVICE SCHEDULE...3826
Chart...3826
AIR CLEANER SERVICE...3828
Daily Check...3828
Replacing The Filters...3828
HEATER AIR FILTERS (WITH CAB OPTION ONLY)...3830
Recirculation Filter...3830
Fresh Air Filter...3830
ENGINE COOLING SYSTEM...3832
Cleaning The Cooling System...3832
Checking The Coolant Level...3832
Replacing The Coolant...3833
FUEL SYSTEM...3836
Fuel Specification...3836
Filling The Fuel Tank...3836
Removing Water From The Fuel Filter...3836
Fuel Filter...3836
Removing Air From The Fuel System...3837
Draining The Fuel Tank...3837
ENGINE LUBRICATION SYSTEM...3838
Checking Engine Oil...3838
Replacing Oil And Filter...3838
HYDRAULIC SYSTEM...3840
Checking And Adding Fluid...3840
Replacing the Hydraulic Filter...3840
Replacing the Case Drain Filter...3841
Replacing the Hydraulic Fluid...3841
Diagnostic Couplers...3842
LUBRICATING THE EXCAVATOR...3844
Procedure...3844
TRAVEL MOTOR...3846
Checking Oil Level...3846
Draining The Travel Motor...3846
SPARK ARRESTOR MUFFLER (IF EQUIPPED)...3848
Cleaning The Spark Arrestor Muffler...3848
HYDRAULIC SYSTEM...3850
HYDRAULIC/HYDROSTATIC SCHEMATICS...3856
HYDRAULIC SYSTEM INFORMATION...3861
Glossary Of Hydraulic / Hydrostatic Symbols...3861
Troubleshooting Chart...3865
BOOM CYLINDER...3869
Checking The Boom Cylinder...3869
Removal And Installation...3871
Parts Identification...3873
Disassembly...3874
Assembly...3876
ARM CYLINDER...3879
Checking The Arm Cylinder...3879
Removal And Installation...3881
Parts Identification...3882
Disassembly...3883
Assembly...3885
BOOM OFFSET CYLINDER...3889
Checking The Boom Offset Cylinder...3889
Removal And Installation...3891
Parts Identification...3893
Disassembly...3894
Assembly...3896
BUCKET CYLINDER...3899
Checking The Bucket Cylinder...3899
Removal And Installation...3901
Parts Identification...3902
Disassembly...3903
Assembly...3905
BLADE CYLINDER...3909
Checking The Blade Cylinder...3909
Removal And Installation...3911
Parts Identification...3912
Disassembly...3913
Assembly...3915
MAIN RELIEF VALVES...3919
Testing And Adjusting The Main Relief Valves (S/N 232312386 & Below, 232412117 & Below, 232412128 And 232412129)...3919
Testing And Adjusting The Main Relief Valves (S/N 232312387 & Above, 232412118-232412127 And 232412130 & Above)...3923
PORT RELIEF VALVES...3927
Testing And Adjusting Port Relief Valve Pressure (S/ N 232312386 & Below And 232412117 & Below, 232412128 And 232412129)...3927
Testing Port Relief Valve Pressure (S/N 232312387 & Above And 232412118-232412127 And 232412130 & Above)...3928
CROSSPORT RELIEF VALVES...3931
Testing And Adjusting The Crossport Relief Valves...3931
SYSTEM PRESSURES AT GAUGE PORT SPECIFICATIONS...3931
PRESSURE REDUCING VALVE (S/N 232312386 & BELOW AND 232412117 & BELOW, 232412128 AND 232412129)...3933
Testing And Adjusting The Pressure Reducing Valve...3933
PRESSURE REDUCING VALVE (S/N 232312387 & ABOVE AND 232412118-232412127 AND 232412130 & ABOVE)...3935
Testing And Adjusting The Pressure Reducing Valve...3935
HYDRAULIC CONTROL VALVE (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)...3939
Description...3939
Removal And Installation...3939
Control Valve Identification...3943
Disassembly...3944
Right Travel Valve Section Disassembly And Assembly...3945
Boom Offset Valve Section Disassembly And Assembly...3948
Boom Valve Section Disassembly And Assembly...3951
Left Travel Valve Section Disassembly And Assembly...3954
Arm Valve Section Disassembly And Assembly...3956
Bucket Valve Section Disassembly And Assembly...3959
Auxiliary Valve Section Disassembly And Assembly...3961
Boost Valve Section Disassembly And Assembly...3964
Blade Valve Section Disassembly And Assembly...3966
Swing Valve Section Disassembly And Assembly...3968
Assembly...3970
HYDRAULIC CONTROL VALVE (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)...3977
Description...3977
Removal And Installation...3977
Control Valve Identification...3983
Disassembly...3984
Right Travel Valve Section Disassembly And Assembly...3985
Boom Offset Valve Section Disassembly And Assembly...3991
Boom Valve Section Disassembly And Assembly...3997
Left Travel Valve Section Disassembly And Assembly...4001
Arm Valve Section Disassembly And Assembly...4006
Bucket Valve Section Disassembly And Assembly...4010
Auxiliary Valve Section Disassembly And Assembly...4014
Boost Valve Section Disassembly And Assembly...4018
Blade Valve Section Disassembly And Assembly...4022
Swing Valve Section Disassembly And Assembly...4027
Assembly...4031
HYDRAULIC PUMP...4039
Description...4039
Torque Adjustment...4039
Testing The Piston Pump...4040
Testing The Gear Pump...4042
Testing The Auxiliary Hydraulic Flow...4044
Removal And Installation...4045
Coupler Removal And Installation...4046
Gear Pump Parts Identification...4047
Piston Pump Parts Identification...4048
Disassembly...4049
Gear Pump Disassembly...4050
Gear Pump Assembly...4053
Piston Pump Disassembly...4055
Piston Pump Assembly...4063
Assembly...4072
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311950 & BELOW AND 232411763 & BELOW)...4073
Manifold Description...4073
Removal And Installation...4073
MANIFOLD ASSEMBLY (S/N 232311950 & BELOW AND 232411763 & BELOW)...4077
Parts Identification...4077
Disassembly...4078
Assembly...4086
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 232311951 & ABOVE AND 232411764 & ABOVE)...4095
Manifold Description...4095
Removal And Installation...4095
MANIFOLD ASSEMBLY (S/N 232311951 & ABOVE AND 232411764 & ABOVE)...4099
Parts Identification...4099
Disassembly...4100
Assembly...4110
TRAVEL MOTOR...4123
Removal And Installation...4123
Parts Identification...4125
Disassembly...4126
Assembly...4133
SWIVEL JOINT...4143
Removal And Installation (With The Upperstructure Removed)...4143
Removal And Installation (Through Bottom Access Cover)...4143
Parts Identification...4145
Description...4146
Disassembly...4146
Assembly...4147
SWING MOTOR...4151
Removal And Installation...4151
Parts Identification...4154
Disassembly...4155
Assembly...4157
Cross Port Relief Valve Parts Identification...4162
Cross Port Relief Valve Disassembly...4163
Cross Port Relief Valve Assembly...4165
SWING MOTOR DRIVE CARRIER...4167
Removal And Installation...4167
Parts Identification...4168
Disassembly...4169
Assembly...4171
CONTROL PATTERN SELECTOR VALVE...4175
Removal And Installation...4175
Parts Identification...4175
Disassembly...4176
Assembly...4177
RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)...4179
Testing...4179
Handle Removal And Installation...4180
Joystick Assembly, Removal And Installation...4184
Parts Identification...4186
Disassembly...4187
LEFT CONTROL LEVER (JOYSTICK) (S/N 232312386 & BELOW, 232412117 & BELOW, 232412128 AND 232412129)...4191
Testing...4191
Handle Removal And Installation...4192
Joystick Assembly Removal And Installation...4195
Parts Identification...4198
Disassembly...4199
LEFT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)...4203
Testing...4203
Handle Removal And Installation...4204
Joystick Assembly Removal And Installation...4207
Parts Identification...4209
Disassembly...4210
Assembly...4214
RIGHT CONTROL LEVER (JOYSTICK) (S/N 232312387 & ABOVE, 232412118-232412127 AND 232412130 & ABOVE)...4221
Testing...4221
Handle Removal And Installation...4222
Joystick Assembly Removal And Installation...4226
Parts Identification...4228
Disassembly...4229
Assembly...4233
HYDRAULIC FILTER...4239
Removal And Installation...4239
HYDRAULIC RESERVOIR...4241
Removal And Installation...4241
OIL COOLER...4243
Removal And Installation...4243
DIRECT TO TANK VALVE...4245
Removal And Installation...4245
Disassembly And Assembly...4246
BUILD UP VALVE...4247
Description...4247
Removal And Installation...4247
Disassembly And Assembly...4247
CASE DRAIN FILTER...4249
Removal And Installation...4249
UNDERCARRIAGE...4251
BLADE...4253
Removal And Installation...4253
TRACKS...4255
Track Lug Height...4255
Adjustment...4255
Rubber Track Removal And Installation...4258
Steel Track Removal And Installation...4260
TRACK FRAME...4263
Disassembly And Assembly...4263
Recoil Spring Disassembly And Assembly...4265
TRACK DAMAGE IDENTIFICATIONS...4269
Cutting Of Steel Cords...4269
Abrasion Of Embedded Metals...4270
Separation Of Embedded Metals...4271
Separation Of Embedded Metals Due To Corrosion...4272
Cuts On The Lug Side Rubber...4273
Cracks On The Lug Side Rubber Due To Fatigue...4274
Lug Abrasion...4275
Cracks And Cuts On The Lug Side Rubber...4276
Abrasion Of The Track Roller Side...4277
Cuts On The Edges Of Track Roller Side...4278
TRACK IDLER...4281
Parts Identification (S/N 232311036 & Below And 232411019 & Below)...4281
Disassembly (S/N 232311036 & Below And 232411019 & Below)...4282
Assembly (S/N 232311036 & Below And 232411019 & Below)...4284
Parts Identification (S/N 232311037 & Above And 232411020 & Above)...4288
Disassembly (S/N 232311037 & Above And 232411020 & Above)...4289
Assembly (S/N 232311037 & Above And 232411020 & Above)...4291
TRACK ROLLER...4295
Parts Identification (S/N 232311036 & Below And 232411019 & Below)...4295
Disassembly (S/N 232311036 & Below And 232411019 & Below)...4296
Assembly (S/N 232311036 & Below And 232411019 & Below)...4298
Parts Identification (S/N 232311037 & Above And 232411020 & Above)...4302
Disassembly (S/N 232311037 & Above And 232411020 & Above)...4303
Assembly (S/N 232311037 & Above And 232411020 & Above)...4304
SWING CIRCLE GEAR...4307
Removal And Installation...4307
Swing Bearing Removal...4309
Swing Bearing Installation...4310
Alignment Pins (Not Threaded)...4312
UPPERSTRUCTURE & SWING SECTION...4313
UPPERSTRUCTURE...4317
Removal And Installation...4317
Swing Bearing Removal...4319
Swing Bearing Installation...4320
Alignment Pins (Not Threaded)...4322
ROPS CANOPY...4325
Removal And Installation...4325
CAB...4329
Removal And Installation...4329
Door Removal And Installation...4332
Front Window Removal And Installation...4333
Lower Front Window Removal And Installation...4335
Right Side Rear Sliding Window Removal And Installation...4336
Right Side Front Sliding Window Removal And Installation...4337
Right Side Panel And Window Assembly Removal And Installation...4338
Door, Left Side, Rear And Upper Front Window Removal And Installation...4341
STANDARD SEAT AND SEAT MOUNT...4343
Removal And Installation...4343
SUSPENSION SEAT AND SEAT MOUNT...4345
Removal And Installation...4345
RIGHT CONSOLE...4347
Console Cover Removal And Installation...4347
Console Base Removal And Installation...4348
LEFT CONSOLE...4353
Lower Console Cover Removal And Installation...4353
Upper Console Cover Removal And Installation...4355
Compression Spring Removal And Installation...4356
Lock Lever Removal And Installation...4357
Upper Console Removal And Installation...4358
Console Switch Removal And Installation...4360
Disassembly And Assembly...4361
Console Base Removal And Installation...4363
ENGINE SPEED CONTROL...4365
Removal And Installation...4365
BLADE CONTROL...4367
Lever Removal And Installation...4367
Linkage Removal And Installation...4368
Linkage Bar Removal And Installation...4370
Lower Linkage Removal And Installation...4371
RIGHT PEDAL AND LINKAGE...4375
Pedal Removal And Installation...4375
Right Pedal Disassembly And Assembly...4376
Linkage Removal And Installation...4378
Adjustment...4381
TRAVEL CONTROLS...4383
Removal And Installation...4383
Disassembly And Assembly...4384
Adjustment...4387
FLOOR MAT AND FLOOR PANELS...4389
Removal And Installation...4389
FUEL TANK...4391
Removal And Installation...4391
HORN...4397
Removal And Installation...4397
SWING FRAME...4399
Boom Swing Bracket Removal And Installation...4399
Boom Swing Bracket Hose Installation...4403
Bushing Removal...4404
Bushing Installation...4405
BOOM...4407
Removal And Installation...4407
Boom Bushing Removal And Installation...4408
ARM...4409
Removal And Installation...4409
Arm To Boom Bushing Removal And Installation...4409
Arm To Bucket And Bucket Link Bushing Removal And Installation...4410
BUCKET...4411
Bucket Teeth Removal And Installation...4411
Bucket Side Cutting Edge Removal And Installation...4412
TAILGATE...4413
Removal And Installation...4413
Release Rod Removal And Installation...4414
Latch Removal And Installation...4415
Release Rod Removal And Installation (Early Models)...4415
Latch Removal And Installation (Early Models)...4416
Latch Removal And Installation (Later Models)...4417
X-CHANGE™...4419
Removal And Installation...4419
Disassembly...4421
Assembly...4426
RIGHT SIDE COVER...4433
Removal And Installation...4433
ELECTRICAL SYSTEM & ANALYSIS...4435
ELECTRICAL SCHEMATIC...4437
ELECTRICAL SYSTEM INFORMATION...4438
Glossary Of Electrical Symbols...4438
Troubleshooting Chart...4442
Description...4443
Fuse Location...4443
BATTERY...4444
Servicing...4444
Removal And Installation...4445
Using A Booster Battery (Jump Starting)...4446
ALTERNATOR...4448
Adjusting The Alternator Belt...4448
Description...4448
Tests...4449
Alternator Output Test...4449
Full Field Test...4450
Alternator Regulator Test...4450
Removal And Installation...4451
Disassembly And Assembly...4453
STARTER...4454
Removal And Installation...4454
Parts Identification...4455
Disassembly...4456
Inspection And Repair...4461
Assembly...4464
LIGHTS...4470
Removal And Installation...4470
Disassembly And Assembly...4471
FUEL LEVEL SENDER...4472
Removal And Installation...4472
Testing...4472
DIAGNOSTICS SERVICE CODE...4474
Number Codes List...4474
ENGINE SERVICE...4476
TROUBLESHOOTING...4478
Chart...4478
MUFFLER...4480
Removal And Installation...4480
AIR CLEANER...4482
Removal And Installation...4482
RADIATOR...4484
Removal And Installation...4484
ENGINE COMPONENTS AND TESTING...4488
Valve Clearance Adjustment...4488
Engine Compression Checking...4488
Fuel Shutoff Solenoid Adjustment...4490
Fuel Shutoff Solenoid Removal And Installation...4490
Fuel Injection Pump Check...4491
Fuel Injection Pump Removal And Installation...4492
Fuel Injection Pump Timing...4493
Fuel Injector Nozzles Removal And Installation...4494
Checking The Injector Nozzle...4496
Glow Plug Removal And Installation...4497
Glow Plug Checking...4498
ENGINE...4500
Removal And Installation...4500
ENGINE FLYWHEEL...4506
Removal And Installation...4506
Flywheel Ring Gear...4508
RECONDITIONING THE ENGINE...4510
Cylinder Head Removal And Installation...4510
Cylinder Head Disassembly And Assembly...4511
Cylinder Head Servicing...4512
Cylinder Head Top Clearance...4513
Valve Guide, Checking...4513
Reconditioning The Valve And Valve Seat...4515
Valve Spring...4516
Rocker Arm And Shaft Checking...4517
Timing Gearcase Cover Removal And Installation...4517
Idler Gear And Camshaft Removal And Installation...4520
Idler Gear And Shaft Servicing...4522
Timing Gears Checking Backlash...4523
Fuel Camshaft Removal And Installation...4523
Fuel Camshaft Governor...4524
Crankshaft Gear Removal And Installation...4524
Oil Pump Removal And Installation...4525
Oil Pump Service...4525
Engine Oil Pressure, Checking...4526
Relief Valve...4527
Piston And Connecting Rod Removal And Installation...4527
Piston And Connecting Rod Servicing...4529
Connecting Rod Alignment...4531
Crankshaft And Bearings Removal And Installation...4532
Crankshaft And Bearings, Servicing...4534
Cylinder Bore, Checking...4536
Water Pump Removal And Installation...4536
Water Pump Disassembly And Assembly...4537
Fan Removal And Installation...4537
HEATER...4540
HEATER UNIT...4542
Removal And Installation...4542
Disassembly And Assembly...4543
HEATER COIL...4544
Removal And Installation...4544
HEATER FAN...4546
Removal And Installation...4546
Disassembly And Assembly...4547
Resistor Removal And Installation...4548
Wire Connector Removal And Installation...4549
HEATER VALVE...4552
Removal And Installation...4552
SPECIFICATIONS...4554
HYDRAULIC EXCAVATOR SPECIFICATIONS (325)...4556
Machine Dimensions...4556
Lifting Capacity...4557
Weights...4557
Controls...4557
Engine...4558
Electrical...4558
Hydraulic System...4558
Swing System...4559
Hydraulic Cylinders...4559
Drive System...4559
Brakes...4559
Undercarriage...4559
STD Track...4560
Capacities...4560
Digging Force...4560
HYDRAULIC EXCAVATOR SPECIFICATIONS (325 W/LONG ARM KIT & 328)...4561
Machine Dimensions...4561
Lifting Capacities...4562
Weights...4562
Controls...4562
Engine...4563
Electrical...4563
Hydraulic System...4563
Swing System...4564
Hydraulic Cylinders...4564
Drive System...4564
Brakes...4564
Undercarriage...4564
STD Track...4565
Capacities...4565
Digging Force...4565
ENGINE SPECIFICATIONS...4566
Fuel Injection Nozzles...4566
Fuel Injection Pump...4566
Cylinder Head...4566
Valves...4566
Valve Springs...4567
Valve Timing...4567
Rocker Arms...4567
Camshaft...4567
Tappet...4567
Cylinders...4568
Piston Rings...4568
Pistons...4568
Connecting Rods...4568
Oil Pump...4568
Crankshaft...4569
Thermostat...4569
Timing Gear...4570
Engine Bolt Torque...4570
Crankshaft Re-Grind Data...4571
TORQUE SPECIFICATIONS...4572
Torque For General SAE Bolts...4572
Torque For General Metric Bolts...4573
HYDRAULIC CONNECTION SPECIFICATIONS...4574
O-Ring Face Seal Connection...4574
Straight Thread O-Ring Fitting...4574
Tubelines And Hoses...4574
Flare Fitting...4574
O-Ring Flare Fitting...4575
Port Seal Fitting...4577
HYDRAULIC FLUID SPECIFICATIONS...4578
Specifications...4578
FUEL, COOLANT AND LUBRICANTS...4580
Chart...4580
CONVERSIONS...4582
Decimal And Millimeter Equivalents...4582
U.S. To Metric Conversion...4583
SMR...4584
325/328-1...4584
325/328-2...4586
325/328-3...4588
325/328-4...4590
6902610 (5-07) - 325, 328 Compact Excavator Operation & Maintenance Manual...4592
CONTENTS...4596
FOREWORD...4598
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...4600
REGULAR MAINTENANCE ITEMS...4600
SERIAL NUMBER LOCATIONS...4602
Excavator Serial Number...4602
Engine Serial Number...4602
DELIVERY REPORT...4602
EXCAVATOR IDENTIFICATION...4603
FEATURES, ACCESSORIES AND ATTACHMENTS...4604
Standard Items...4604
Options and Accessories...4604
Attachments...4604
Buckets Available...4604
Falling Object Guards (FOGS)...4605
Special Applications Kit...4605
Special Applications Kit Inspection And Maintenance...4605
SAFETY & TRAINING RESOURCES...4606
SAFETY INSTRUCTIONS...4608
Before Operation...4608
Safe Operation Is The Operator’s Responsibility...4609
Safe Operation Needs A Qualified Operator...4609
Fire Prevention...4610
MACHINE SIGNS (DECALS)...4611
PUBLICATIONS AND TRAINING RESOURCES...4613
OPERATING INSTRUCTIONS...4614
INSTRUMENTS AND CONSOLES...4616
Cab Interior Light (If Equipped)...4616
Left Console...4616
Right Console...4617
Function Icons...4618
STD / ISO Selector Valve...4619
Upperstructure Slew Lock...4619
Raising And Lowering The Console...4620
Two-Speed Travel...4620
OPERATOR CANOPY (ROPS / TOPS)...4621
Description...4621
OPERATOR CAB (ROPS / TOPS)...4621
Description...4621
Cab Door...4622
Front Window...4623
Front Wiper...4624
Window Washer Reservoir...4624
Right Side Windows...4625
Heating, Ventilation, and Air Conditioning Duct...4626
TRAVEL CONTROLS...4627
Description...4627
Forward And Reverse Travel...4627
Turning...4627
HYDRAULIC CONTROLS...4629
Description...4629
STANDARD Control Pattern...4629
ISO Control Pattern...4630
Quick Couplers...4631
Auxiliary Hydraulics...4632
Relieve Hydraulic Pressure (Excavator And Attachment)...4632
Return To Tank Valve (If Equipped)...4632
BLADE CONTROL LEVER...4633
Operation...4633
BOOM SWING PEDAL...4633
Operation...4633
DAILY INSPECTION...4634
Daily Inspection And Maintenance...4635
PRE-STARTING PROCEDURE...4636
Operation & Maintenance Manual And Operator’s Handbook Locations...4636
Entering The Excavator...4636
Seat Adjustment...4637
Seat Belt Adjustment...4637
Control Console...4637
STARTING THE ENGINE...4638
Key Switch...4638
Keyless...4639
Cold Temperature Starting...4640
Warming The Hydraulic System...4641
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...4642
Procedure...4642
Emergency Exit...4643
ATTACHMENTS...4644
Installing And Removing The Attachment (Pin-On X- Change)...4644
Installing And Removing The Attachment (Bolt-On X- Change)...4650
Installing And Removing The Attachment (Latching X-Change System)...4656
Installing And Removing The Attachment (Pin-On Attachment)...4659
OPERATING PROCEDURE...4660
Inspect The Work Area...4660
Lowering The Work Equipment (Engine STOPPED)...4660
Operating On Public Roads...4660
Lifting A Load...4661
Excavating...4662
Boom Swing...4664
Backfilling...4665
Driving The Excavator...4665
Operating On Slopes...4666
Operating In Water...4668
Avoiding Track Damage...4668
TOWING THE EXCAVATOR...4668
Procedure...4668
LIFTING THE EXCAVATOR...4669
Procedure...4669
TRANSPORTING THE EXCAVATOR ON A TRAILER...4670
Loading And Unloading...4670
Fastening...4670
PREVENTIVE MAINTENANCE...4672
MAINTENANCE SAFETY...4674
SERVICE SCHEDULE...4676
Chart...4676
CONTROL CONSOLE LOCKOUTS...4677
Inspection And Maintenance...4677
SEAT BELT...4678
Inspection And Maintenance...4678
TAILGATE...4679
Opening And Closing...4679
Adjusting The Bumper...4679
Adjusting The Latch...4679
RIGHT SIDE COVER...4680
Opening And Closing...4680
Adjusting The Latch...4680
CAB FILTERS...4681
Cleaning And Maintenance...4681
AIR CLEANER SERVICE...4683
Daily Check...4683
Replacing The Filters...4683
FUEL SYSTEM...4685
Fuel Specifications...4685
Filling The Fuel Tank...4685
Fuel Filters...4686
Draining The Fuel Tank...4686
Removing Air From The Fuel System...4687
ENGINE LUBRICATION SYSTEM...4688
Checking And Adding Engine Oil...4688
Engine Oil Chart...4688
Removing And Replacing Oil And Filter...4689
ENGINE COOLING SYSTEM...4690
Cleaning...4690
Checking Level...4690
Removing And Replacing The Coolant...4691
ELECTRICAL SYSTEM...4692
Description...4692
Fuse And Relay Location / Identification...4692
Battery Maintenance...4693
Using A Booster Battery (Jump Starting)...4694
Removing And Installing The Battery...4695
HYDRAULIC SYSTEM...4696
Checking And Adding Fluid...4696
Hydraulic Fluid Chart...4696
Removing And Replacing The Hydraulic Filters...4697
Removing And Replacing The Case Drain Filter...4697
Removing And Replacing The Hydraulic Fluid...4698
SPARK ARRESTOR MUFFLER...4699
Cleaning Procedure...4699
TRACK TENSION...4700
Adjusting...4700
TRAVEL MOTOR...4702
Checking And Adding Oil...4702
Removing And Replacing Oil...4702
ALTERNATOR BELT...4703
Belt Adjustment...4703
Belt Replacement...4703
X-CHANGE...4704
Inspection And Maintenance...4704
TRACK ROLLER AND IDLER LUBRICATION...4704
Procedure...4704
BUCKET...4705
Bucket Teeth Removal And Installation...4705
LUBRICATION OF THE EXCAVATOR...4706
Lubrication Locations...4706
PIVOT PINS...4708
Inspection And Maintenance...4708
EXCAVATOR STORAGE AND RETURN TO SERVICE...4709
Storage...4709
Return to Service...4709
SYSTEM SETUP AND ANALYSIS...4710
DIAGNOSTICS SERVICE CODES...4712
Service Codes List...4712
DISPLAY CONTROLLER PANEL SETUP...4713
Passwords...4713
Password Entry (For Starting and Operating the Machine)...4713
Changing The Operator Password...4713
Password Lockout Feature...4714
Job Clock...4714
RPM...4714
Viewing Service Codes (Key Switch)...4715
Viewing Service Codes (Keyless)...4715
MACHINE SIGN TRANSLATIONS...4716
WARNING (6808185)...4718
LIFT CHART...4719
325 (6809677)...4719
325 W/ Long Arm And 328 (6809678)...4722
325 W/ Long Arm And 328 (6809678)...4723
SERVICE SCHEDULE (7130456)...4725
WARNING (6807776)...4728
WARNING(6804114)...4731
WARNING (6804232)...4731
WARNING (6577754)...4731
WARNING (6804233)...4731
WARNING (6817815)...4732
WARNING 6808474)...4732
WARNING (6815915)...4733
USING THE X-CHANGE SYSTEM (6817816)...4734
USING THE X-CHANGE SYSTEM (7102651)...4737
WARNING (6809829)...4740
JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...4741
SPECIFICATIONS...4742
SPECIFICATIONS...4744
325 Excavator Machine Dimensions...4744
325 W/ Long Arm And 328 Excavator Machine Dimensions...4745
325 / 328 Excavator Machine Dimensions...4746
Performance...4747
Controls...4747
Engine...4747
Hydraulic System...4748
Hydraulic Cylinders...4748
Hydraulic Cycle Times...4749
Electrical...4749
Instrumentation...4749
Drive System...4749
Slew System...4749
Undercarriage...4749
Crawler Track Design...4749
Capacities...4750
Fuel Tank...4750
Tracks...4750
Type...4750
Ground Pressure...4750
WARRANTY...4752
ALPHABETICAL INDEX...4756
6902745 (10-09) - 325, 328 Service Manual...4758
MAINTENANCE SAFETY...4760
ALPHABETICAL INDEX...4762
CONTENTS...4764
FOREWORD...4765
SAFETY INSTRUCTIONS...4768
FIRE PREVENTION...4770
Maintenance...4770
Operation...4770
Electrical...4770
Hydraulic System...4770
Fueling...4770
Starting...4770
Spark Arrestor Exhaust System...4770
Welding And Grinding...4771
Fire Extinguishers...4771
SERIAL NUMBER LOCATIONS...4772
Excavator Serial Number...4772
Engine Serial Number...4772
DELIVERY REPORT...4773
BOBCAT EXCAVATOR IDENTIFICATION...4774
SAFETY AND MAINTENANCE...4776
LIFTING AND BLOCKING THE EXCAVATOR...4778
Procedure...4778
UPPERSTRUCTURE SLEW LOCK...4780
Operation (Early Models)...4780
Operation (Later Models)...4780
LIFTING THE EXCAVATOR...4782
Procedure...4782
OPERATOR CAB (ROPS/TOPS)...4784
Emergency Exit...4784
Front Window...4785
Right Side Windows...4787
Cab Door...4788
TRANSPORTING THE EXCAVATOR...4790
Procedure...4790
TAILGATE...4792
Opening And Closing The Tailgate...4792
Adjusting The Bumper...4792
Adjusting The Latch...4792
RIGHT SIDE COVER...4794
Opening And Closing The Right Side Cover...4794
SERVICE SCHEDULE...4796
Chart...4796
AIR CLEANER...4798
Daily Check...4798
Replacing The Filters...4798
HEATER AIR FILTER (WITH CAB OPTION ONLY)...4800
Removal And Installation...4800
COOLING SYSTEM...4802
Cleaning The Cooling System...4802
Checking Coolant Level...4803
Replacing The Coolant...4804
FUEL SYSTEM...4806
Fuel Specifications...4806
Filling The Fuel Tank...4806
Removing Water From The Fuel Filter...4807
Draining The Fuel Tank...4807
Fuel Filter...4808
Removing Air From The Fuel System...4808
ENGINE LUBRICATION SYSTEM...4810
Checking Engine Oil...4810
Oil Chart...4810
Replacing Oil And Filter...4811
HYDRAULIC SYSTEM...4812
Checking And Adding Hydraulic Oil...4812
Replacing The Hydraulic Oil...4813
Replacing The Hydraulic Filter...4814
Replacing The Case Drain Filter...4815
Diagnostic Couplers...4815
LUBRICATION OF THE HYDRAULIC EXCAVATOR...4818
TRAVEL MOTOR...4822
Checking Oil Level...4822
Draining The Travel Motor...4822
SPARK ARRESTOR MUFFLER...4824
ENGINE ACCESSORY DRIVE BELT...4826
Belt Tension...4826
Belt Adjustment...4826
SEAT BELT...4828
Inspection And Maintenance...4828
HYDRAULIC SYSTEM...4830
HYDRAULIC / HYDROSTATIC SCHEMATIC...4836
HYDRAULIC SYSTEM INFORMATION...4838
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...4838
Troubleshooting Chart...4841
Troubleshooting The Hydraulic Circuit...4841
Troubleshooting The Cylinder Circuit...4842
Troubleshooting The Swing (Upperstructure Slew) Circuit...4843
Troubleshooting The Travel Circuit...4844
BOOM CYLINDER...4846
Testing...4846
Removal And Installation...4849
Parts Identification...4852
Disassembly...4853
Assembly...4855
ARM CYLINDER...4858
Testing...4858
Removal And Installation...4860
Parts Identification...4862
Disassembly...4863
Assembly...4865
BOOM SWING CYLINDER...4868
Testing...4868
Removal And Installation...4870
Parts Identification...4872
Disassembly...4873
Assembly...4875
BUCKET CYLINDER...4878
Testing...4878
Removal And Installation...4880
Parts Identification...4881
Disassembly...4882
Assembly...4884
BLADE CYLINDER...4888
Testing...4888
Removal And Installation...4890
Parts Identification...4891
Disassembly...4892
Assembly...4894
CLAMP CYLINDER...4898
Testing...4898
Removal And Installation...4899
Parts Identification...4900
Disassembly...4901
Assembly...4904
MAIN RELIEF VALVES...4910
Testing And Adjusting The Main Relief Valves...4910
PORT RELIEF VALVES...4914
Testing And Adjusting The Port Relief Valves...4914
CROSSPORT RELIEF VALVES...4916
Testing And Adjusting The Crossport Relief Valves...4916
PRESSURE REDUCING VALVE...4920
Testing And Adjusting The Pressure Reducing Valve...4920
HYDRAULIC CONTROL VALVE...4922
Description...4922
Removal And Installation...4923
Control Valve Identification...4930
Disassembly...4931
Right Travel Valve Section Disassembly And Assembly...4933
Boom Swing Valve Section Disassembly And Assembly...4939
Boom Valve Section Disassembly And Assembly...4946
Left Travel Valve Section Disassembly And Assembly...4950
Arm Valve Section Disassembly And Assembly...4955
Bucket Valve Section Disassembly And Assembly...4959
Auxiliary Valve Section Disassembly And Assembly...4963
Boost Valve Section Disassembly And Assembly...4967
Blade Valve Section Disassembly And Assembly...4971
Slew Valve Section Disassembly And Assembly...4976
Assembly...4980
HYDRAULIC PUMP (S/N 234111001-23412473) & (S/N 234211001-234212268)...4988
Description...4988
Torque Adjustment...4989
Testing The Piston Pump...4990
Testing The Gear Pump...4992
Testing Auxiliary Hydraulic Flow...4993
Removal And Installation...4994
Coupler Removal And Installation...4996
Hydraulic Pump Start Up...4997
Gear Pump Parts Identification...4998
Piston Pump Parts Identification...4999
Disassembly...5000
Gear Pump Disassembly...5001
Gear Pump Assembly...5004
Piston Pump Disassembly...5007
Piston Pump Assembly...5015
Assembly...5023
HYDRAULIC PUMP (S/N 234112474 & Above) & (S/N 234212269 & Above)...5026
Description...5026
Torque Adjustment...5027
Testing The Piston Pump...5028
Testing The Gear Pump...5030
Testing Auxiliary Hydraulic Flow...5032
Removal And Installation...5033
Coupler Removal And Installation...5034
Hydraulic Pump Start Up...5035
Gear Pump Parts Identification...5036
Piston Pump Parts Identification...5037
Disassembly...5038
Gear Pump Disassembly...5039
Gear Pump Assembly...5042
Piston Pump Disassembly...5045
Piston Pump Assembly...5051
MANIFOLD ASSEMBLY/ ACCUMULATOR...5058
Description...5058
Removal And Installation...5058
Parts Identification...5062
Disassembly...5063
Assembly...5073
MANIFOLD ASSEMBLY...5084
Parts Identification...5084
Disassembly...5085
Assembly...5095
TRAVEL MOTOR...5108
Removal And Installation...5108
Parts Identification...5109
Disassembly...5110
Assembly...5118
SWIVEL JOINT...5128
Description...5128
Removal And Installation...5128
Parts Identification...5130
Disassembly...5131
Assembly...5132
SWING MOTOR...5136
Removal And Installation...5136
Parts Identification...5139
Disassembly...5140
Assembly...5145
SWING MOTOR DRIVE CARRIER...5152
Removal And Installation...5152
Parts Identification...5153
Disassembly...5154
Assembly...5156
CONTROL PATTERN SELECTOR VALVE...5160
Removal And Installation...5160
Parts Identification...5161
Disassembly...5162
Assembly...5163
RIGHT CONTROL LEVER (JOYSTICK)...5164
Testing...5164
Handle Removal And Installation...5165
Joystick Assembly, Removal And Installation...5169
Parts Identification...5172
Disassembly...5173
Assembly...5178
LEFT CONTROL LEVER (JOYSTICK)...5182
Testing...5182
Handle Removal And Installation...5183
Joystick Assembly Removal And Installation...5186
Parts Identification...5188
Disassembly...5189
Assembly...5194
HYDRAULIC FILTER MOUNT...5200
Removal And Installation...5200
HYDRAULIC RESERVOIR...5202
Removal And Installation...5202
OIL COOLER...5204
Removal And Installation...5204
DIRECT TO TANK VALVE...5206
Removal And Installation...5206
Disassembly And Assembly...5207
BUILD UP VALVE...5208
Description...5208
Removal And Installation...5208
Parts Identification...5209
Disassembly And Assembly...5210
CASE DRAIN FILTER...5212
Removal And Installation...5212
UNDERCARRIAGE...5214
BLADE...5216
Removal And Installation...5216
TRACKS...5218
Track Lug Height...5218
Adjustment...5218
Rubber Track Removal And Installation...5221
Steel Track Removal And Installation...5223
TRACK FRAME...5226
Disassembly And Assembly...5226
Recoil Spring Cylinder Disassembly And Assembly...5228
Recoil Spring Cylinder Parts Identification (with Replaceable Shaft)...5229
Recoil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)...5230
TRACK DAMAGE IDENTIFICATION...5232
Cutting Of Steel Cords...5232
Abrasion Of Embedded Metals...5233
Separation Of Embedded Metals...5234
Separation Of Embedded Metals Due To Corrosion...5235
Cuts On The Lug Side Rubber...5236
Cracks On The Lug Side Rubber Due To Fatigue...5237
Lug Abrasion...5238
Cracks And Cuts On The Lug Side Rubber...5239
Abrasion Of The Track Roller Side...5240
Cuts On The Edges Of Track Roller Side...5241
TRACK IDLER...5244
Parts Identification...5244
Disassembly...5245
Assembly...5247
TRACK ROLLER...5250
Parts Identification...5250
Disassembly...5251
Assembly...5253
SWING CIRCLE GEAR...5256
Swing Bearing Removal...5256
Swing Bearing Installation...5257
UPPERSTRUCTURE & SWING SECTION...5258
UPPERSTRUCTURE...5262
Removal...5262
Installation...5265
ROPS CANOPY...5268
Removal And Installation...5268
CAB...5272
Removal And Installation...5272
Door Removal And Installation...5277
Front Window Removal And Installation...5278
Right Side Rear Sliding Window Removal And Installation...5281
Right Side Front Sliding Window Removal And Installation...5281
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...5282
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...5282
Glass Removal...5283
Glass Installation...5284
STANDARD SEAT AND SEAT MOUNT...5286
Removal And Installation...5286
SUSPENSION SEAT AND SEAT MOUNT...5288
Removal And Installation...5288
RIGHT CONSOLE...5290
Console Cover Removal And Installation...5290
Console Base Removal And Installation...5291
LEFT CONSOLE...5294
Lower Console Cover Removal And Installation...5294
Upper Console Cover Removal And Installation...5296
Compression Spring Removal And Installation...5297
Compression Spring Disassembly And Assembly...5298
Lock Lever Removal And Installation...5300
Console Removal And Installation...5301
Disassembly And Assembly...5305
Console Switch Removal And Installation...5308
Console Base Removal And Installation...5309
ENGINE SPEED CONTROL...5310
Removal And Installation...5310
Adjustment (Later Models)...5311
BLADE CONTROL...5312
Lever Removal And Installation...5312
Linkage Removal And Installation...5313
Linkage Bar Removal And Installation...5315
Lower Linkage Removal And Installation...5317
RIGHT PEDAL AND LINKAGE...5320
Pedal Removal And Installation...5320
Pedal Disassembly And Assembly...5321
Linkage Removal And Installation...5323
TRAVEL CONTROLS...5324
Removal And Installation...5324
Disassembly And Assembly...5325
Adjustment...5328
FLOOR MAT AND FLOOR PLATE...5332
Removal And Installation (Canopy Equipped Excavators)...5332
Removal And Installation (Cab Equipped Excavators)...5333
FUEL TANK...5334
Removal And Installation...5334
HORN...5338
Removal And Installation (Early Models)...5338
Removal And Installation (Later Models)...5339
SWING FRAME...5340
Boom Swing Bracket Removal And Installation...5340
Boom Swing Bracket Hose Installation...5344
Bushing Removal...5345
Bushing Installation...5346
BOOM...5348
Removal And Installation...5348
ARM...5350
Removal And Installation...5350
Arm To Boom Bushing Removal And Installation...5350
Arm To Bucket And Bucket Link Bushing Removal And Installation...5351
BUCKET...5352
Bucket Teeth Removal And Installation...5352
Bucket Side Cutting Edge Removal And Installation...5353
CLAMP...5354
Removal And Installation...5354
TAILGATE...5356
Removal And Installation...5356
Latch Removal And Installation...5357
X-CHANGE...5358
Removal And Installation...5358
Disassembly...5360
Assembly...5364
Check Proper Latch Engagement...5370
UPPERSTRUCTURE SLEW LOCK...5374
Removal And Installation (Early Models)...5374
Removal And Installation (Later Models)...5375
Disassembly And Assembly (Later Models)...5375
RIGHT SIDE COVER...5378
Removal And Installation...5378
ELECTRICAL SYSTEM AND ANALYSIS...5380
ELECTRICAL SCHEMATIC...5382
ELECTRICAL SYSTEM INFORMATION...5384
Troubleshooting Chart...5384
Description...5385
Fuse And Relay Location...5385
BATTERY...5386
Servicing...5386
Removing And Installing The Battery...5387
Using A Booster Battery (Jump Starting)...5388
ALTERNATOR...5390
Engine Accessory Drive Belt...5390
Engine Accessory Drive Belt Tensioner Removal And Installation...5391
Removal And Installation...5392
Bracket Removal And Installation...5393
Description...5394
Tests...5394
Alternator Output Test...5395
Full Field Test...5395
Alternator Regulator Test...5396
Parts Identification...5397
Disassembly And Assembly...5398
Rotor Continuity Test...5402
Rotor Continuity Test...5403
Rectifier Continuity (Diode) Test...5403
STARTER...5404
Removal And Installation...5404
Parts Identification...5405
Disassembly...5406
Inspection And Repair...5411
Assembly...5414
LIGHTS...5420
Removal And Installation...5420
Boom Light Removal And Installation (Early Models)...5421
Boom Light Disassembly And Assembly (Early Models)...5421
Boom Light Removal And Installation (Later Models)...5422
Boom Light Bulb Replacement (Later Models)...5422
TWO SPEED SWITCH...5424
Removal And Installation...5424
FUEL LEVEL SENDER...5426
Removal And Installation...5426
Testing...5426
DIAGNOSTICS SERVICE CODE...5428
Number Codes List...5428
DELUXE INSTRUMENT PANEL SETUP...5430
Passwords...5430
Password Entry (For Starting And Operating The Machine)...5430
Changing The Owner or Operator Password...5430
Password Lockout Feature...5431
Job Clock...5431
RPM...5431
ENGINE SERVICE...5432
TROUBLESHOOTING...5434
Chart...5434
MUFFLER...5436
Removal And Installation...5436
AIR CLEANER...5438
Removal And Installation...5438
RADIATOR...5440
Removal And Installation...5440
ENGINE COMPONENTS AND TESTING...5442
Engine Compression Checking...5442
Glow Plugs Removal And Installation...5443
Checking The Glow Plug...5444
Fuel Shut-Off Solenoid Removal And Installation...5445
Fuel Injection Pump Check...5447
Fuel Injection Pump Removal And Installation...5448
Fuel Injection Pump Timing...5451
Fuel Injector Nozzles Removal And Installation...5453
Fuel Injector Nozzle Check...5455
Valve Clearance Adjustment...5456
ENGINE...5458
Removal And Installation...5458
ENGINE FLYWHEEL (EARLY MODELS)...5464
Flywheel Removal And Installation...5464
Hydraulic Pump Coupler...5466
Flywheel Ring Gear...5466
ENGINE FLYWHEEL (LATER MODELS)...5468
Flywheel Removal And Installation...5468
Hydraulic Pump Coupler...5470
Flywheel Ring Gear...5471
RECONDITIONING THE ENGINE...5472
Cylinder Head Removal And Installation...5472
Cylinder Head Disassembly And Assembly...5475
Cylinder Head Servicing...5476
Cylinder Head Top Clearance...5476
Valve Guide Checking...5477
Reconditioning The Valve And Valve Seat...5479
Valve Spring...5480
Rocker Arm And Shaft Checking...5481
Timing Gearcase Cover Removal And Installation...5481
Idler Gear And Camshaft Removal And Installation...5484
Camshaft Servicing...5485
Idler Gear And Shaft Servicing...5486
Timing Gears Checking Backlash...5487
Fuel Camshaft Removal And Installation...5487
Fuel Camshaft Governor...5488
Crankshaft Gear Removal And Installation...5488
Oil Pump Removal And Installation...5489
Oil Pump Service...5489
Checking Engine Oil Pressure...5490
Valve Tappets...5491
Piston And Connecting Rod Removal And Installation...5491
Piston And Connecting Rod Servicing...5493
Connecting Rod Alignment...5495
Crankshaft And Bearings Removal And Installation...5496
Crankshaft And Bearings, Servicing...5498
Cylinder Bore, Checking...5502
Water Pump Removal And Installation...5502
Water Pump Disassembly And Assembly...5503
HEATER...5504
HEATER SYSTEM...5506
Description...5506
Components...5506
REGULAR MAINTENANCE...5508
Filter Element Removal And Installation...5508
Heater Coil...5509
TROUBLESHOOTING...5510
Blower Motor Does Not Operate...5510
Blower Motor Operates Normally, But Air Flow Is Insufficient...5510
Electrical System...5511
HEATER UNIT (EARLY MODELS)...5516
Removal And Installation...5516
HEATER UNIT (LATER MODELS)...5518
Removal And Installation...5518
HEATER COIL (EARLY MODELS)...5520
Removal And Installation...5520
HEATER COIL (LATER MODELS)...5522
Removal And Installation...5522
BLOWER FAN (EARLY MODELS)...5524
Removal And Installation...5524
Disassembly And Assembly...5525
Resistor Removal And Installation...5526
Wire Connector Removal And Installation...5527
BLOWER FAN (LATER MODELS)...5530
Removal And Installation...5530
Disassembly And Assembly...5531
Resistor Removal And Installation...5532
HEATER VALVE (EARLY MODELS)...5534
Removal And Installation...5534
HEATER VALVE (LATER MODELS)...5536
Removal And Installation...5536
SPECIFICATIONS...5538
SPECIFICATIONS...5540
325/328 Excavator Machine Dimensions...5540
325 Excavator Machine Dimensions...5541
328 Excavator Machine Dimensions...5542
Performance...5543
Controls...5543
Engine...5543
Hydraulic System...5544
Hydraulic Cylinders...5544
Hydraulic Cycle Times...5545
Drive System...5545
Undercarriage...5545
Track...5546
Electrical...5546
ENGINE SPECIFICATIONS...5548
Fuel Injection Nozzles...5548
Fuel Injection Pump...5548
Cylinder Head...5548
Valves...5548
Valve Springs...5549
Valve Timing...5549
Rocker Arms...5549
Camshaft...5549
Tappet...5549
Cylinders...5550
Piston Rings...5550
Pistons...5550
Connecting Rods...5550
Oil Pump...5550
Crankshaft...5551
Timing Gear...5551
Thermostat...5552
Engine Bolt Torque...5552
Crankshaft Re-Grind Data...5553
TORQUE SPECIFICATIONS...5554
Torque for General SAE Bolts...5554
Torque For General Metric Bolts...5555
HYDRAULIC CONNECTION SPECIFICATIONS...5556
O-ring Face Seal Connection...5556
Straight Thread O-ring Fitting...5556
Tubelines And Hoses...5556
Flare Fitting...5557
O-ring Flare Fitting...5558
Port Seal Fitting...5560
HYDRAULIC FLUID SPECIFICATIONS...5564
Specifications...5564
FUEL, COOLANT AND LUBRICANTS...5566
Chart...5566
CONVERSIONS...5568
Decimal And Millimeter Equivalents...5568
U.S. To Metric Conversion...5569
SERVICE MANUAL REVISIONS...5570
Revision No: 325/328-1...5570
Revision No: 325/328-2...5572
Revision No: 325/328-3...5574
Revision No: 325/328-4...5576
Revision No: 325/328-5...5578
Revision No: 325/328-6...5580
Revision No: 325/328-7...5582
Revision No: 325/328-8...5584
Revision No: 325/328-9...5586
6986939 (10-09) - 325, 328 Compact Excavator Operation & Maintenance Manual...5588
OPERATOR SAFETY WARNING...5590
CONTENTS...5592
FOREWORD...5594
BOBCAT COMPANY IS IS0 9001 CERTIFIED...5596
REGULAR MAINTENANCE ITEMS...5596
SERIAL NUMBER LOCATIONS...5598
Excavator Serial Number...5598
Engine Serial Number...5598
DELIVERY REPORT...5598
EXCAVATOR IDENTIFICATION...5599
FEATURES, ACCESSORIES AND ATTACHMENTS...5600
Standard Items...5600
Options and Accessories...5600
Attachments...5600
Buckets Available...5600
Falling Object Guards (FOGS)...5601
Special Applications Kit...5601
Special Applications Kit Inspection And Maintenance...5601
SAFETY & TRAINING RESOURCES...5602
SAFETY INSTRUCTIONS...5604
Before Operation...5604
Safe Operation Is The Operator’s Responsibility...5605
Safe Operation Needs A Qualified Operator...5605
Avoid Silica Dust...5606
FIRE PREVENTION...5606
Maintenance...5606
Operation...5606
Electrical...5606
Hydraulic System...5607
Fueling...5607
Starting...5607
Spark Arrestor Exhaust System...5607
Welding And Grinding...5607
Fire Extinguishers...5607
MACHINE SIGNS (DECALS)...5608
PUBLICATIONS AND TRAINING RESOURCES...5610
OPERATING INSTRUCTIONS...5612
INSTRUMENTS AND CONSOLES...5614
Cab Interior Light (If Equipped)...5614
Left Console...5614
Right Console...5615
Function Icons...5616
STD / ISO Selector Valve...5617
Upperstructure Slew Lock...5617
Raising And Lowering The Console...5618
Two-Speed Travel...5618
OPERATOR CANOPY (ROPS / TOPS)...5619
Description...5619
OPERATOR CAB (ROPS / TOPS)...5619
Description...5619
Cab Door...5620
Front Window...5621
Front Wiper...5622
Window Washer Reservoir...5622
Right Side Windows...5623
Heating, Ventilation, and Air Conditioning Duct...5624
TRAVEL CONTROLS...5625
Description...5625
Forward And Reverse Travel...5625
Turning...5625
MOTION ALARM SYSTEM (IF EQUIPPED)...5627
Operation...5627
HYDRAULIC CONTROLS...5628
Description...5628
STANDARD Control Pattern...5628
ISO Control Pattern...5629
Quick Couplers...5630
Auxiliary Hydraulics...5631
Relieve Hydraulic Pressure (Excavator And Attachment)...5631
Return To Tank Valve (If Equipped)...5631
BLADE CONTROL LEVER...5632
Operation...5632
BOOM SWING PEDAL...5632
Operation...5632
DAILY INSPECTION...5633
Daily Inspection And Maintenance...5634
PRE-STARTING PROCEDURE...5635
Operation & Maintenance Manual And Operator’s Handbook Locations...5635
Entering The Excavator...5635
Seat Adjustment...5636
Seat Belt Adjustment...5636
Control Console...5636
STARTING THE ENGINE...5637
Key Switch...5637
Keyless...5638
Cold Temperature Starting...5639
Warming The Hydraulic System...5640
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...5641
Procedure...5641
Emergency Exit...5642
ATTACHMENTS...5643
Installing And Removing The Attachment (Pin-On X- Change)...5643
Installing And Removing The Attachment (Bolt-On X- Change)...5649
Installing And Removing The Attachment (Pin-On Attachment)...5655
OPERATING PROCEDURE...5656
Inspect The Work Area...5656
Basic Operating Instructions...5656
Lowering The Work Equipment (Engine STOPPED)...5656
Lifting A Load...5657
Excavating...5658
Boom Swing...5660
Backfilling...5661
Driving The Excavator...5661
Operating On Slopes...5662
Operating In Water...5664
Avoiding Track Damage...5665
TOWING THE EXCAVATOR...5666
Procedure...5666
LIFTING THE EXCAVATOR...5667
Procedure...5667
TRANSPORTING THE EXCAVATOR ON A TRAILER...5668
Loading And Unloading...5668
Fastening...5668
PREVENTIVE MAINTENANCE...5670
MAINTENANCE SAFETY...5672
SERVICE SCHEDULE...5674
Chart...5674
CONTROL CONSOLE LOCKOUTS...5675
Inspection And Maintenance...5675
SEAT BELT...5676
Inspection And Maintenance...5676
MOTION ALARM SYSTEM (IF EQUIPPED)...5677
Description...5677
Inspecting...5677
Adjusting Switch Position...5677
TAILGATE...5678
Opening And Closing...5678
Adjusting The Bumper...5678
Adjusting The Latch...5678
RIGHT SIDE COVER...5679
Opening And Closing...5679
Adjusting The Latch...5679
CAB FILTERS...5680
Cleaning And Maintenance...5680
AIR CLEANER SERVICE...5681
Daily Check...5681
Replacing The Filters...5681
FUEL SYSTEM...5683
Fuel Specifications...5683
Biodiesel Blend Fuel...5683
Filling The Fuel Tank...5684
Fuel Filters...5685
Draining The Fuel Tank...5685
Removing Air From The Fuel System...5686
ENGINE LUBRICATION SYSTEM...5687
Checking And Adding Engine Oil...5687
Engine Oil Chart...5687
Removing And Replacing Oil And Filter...5688
ENGINE COOLING SYSTEM...5690
Cleaning...5690
Checking Level...5690
Removing And Replacing The Coolant...5691
ELECTRICAL SYSTEM...5692
Description...5692
Fuse And Relay Location / Identification...5692
Battery Maintenance...5693
Using A Booster Battery (Jump Starting)...5694
Removing And Installing The Battery...5695
HYDRAULIC SYSTEM...5696
Checking And Adding Fluid...5696
Hydraulic / Hydrostatic Fluid Chart...5696
Removing And Replacing The Hydraulic Filters...5697
Removing And Replacing The Case Drain Filter...5697
Removing And Replacing The Hydraulic Fluid...5698
SPARK ARRESTOR MUFFLER...5699
Cleaning Procedure...5699
TRACK TENSION...5700
Adjusting...5700
TRAVEL MOTOR...5702
Checking And Adding Oil...5702
Removing And Replacing Oil...5702
ALTERNATOR BELT...5703
Belt Adjustment...5703
Belt Replacement...5703
X-CHANGE...5704
Inspection And Maintenance...5704
TRACK ROLLER AND IDLER LUBRICATION...5704
Procedure...5704
BUCKET...5705
Bucket Teeth Removal And Installation...5705
LUBRICATION OF THE EXCAVATOR...5706
Lubrication Locations...5706
PIVOT PINS...5708
Inspection And Maintenance...5708
EXCAVATOR STORAGE AND RETURN TO SERVICE...5709
Storage...5709
Return to Service...5709
SYSTEM SETUP AND ANALYSIS...5710
DIAGNOSTICS SERVICE CODES...5712
Service Codes List...5712
DISPLAY CONTROLLER PANEL SETUP...5713
Passwords...5713
Password Entry (For Starting and Operating the Machine)...5713
Changing The Operator Password...5713
Password Lockout Feature...5714
Job Clock...5714
RPM...5714
Viewing Service Codes (Key Switch)...5715
Viewing Service Codes (Keyless)...5715
MAINTENANCE CLOCK...5716
Description...5716
Setup...5716
Reset...5716
MACHINE SIGN TRANSLATIONS...5718
WARNING (6808185)...5720
LIFT CHART...5721
325 (6809677)...5721
325 W/ Long Arm And 328 (6809678)...5724
325 W/ Long Arm And 328 (6809678)...5725
SERVICE SCHEDULE (7158257)...5727
WARNING (6807776)...5730
WARNING(6804114)...5733
WARNING (6804232)...5733
WARNING (6577754)...5733
WARNING (6804233)...5733
WARNING (6817815)...5734
WARNING 6808474)...5734
WARNING (6815915)...5735
USING THE X-CHANGE SYSTEM (7102651)...5736
WARNING (6809829)...5739
JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...5740
SPECIFICATIONS...5742
SPECIFICATIONS...5744
325 Excavator Machine Dimensions...5744
325 W/ Long Arm And 328 Excavator Machine Dimensions...5745
325 / 328 Excavator Machine Dimensions...5746
Performance...5747
Controls...5747
Engine...5747
Hydraulic System...5748
Hydraulic Cylinders...5748
Hydraulic Cycle Times...5749
Electrical...5749
Instrumentation...5749
Drive System...5749
Slew System...5749
Undercarriage...5749
Crawler Track Design...5749
Capacities...5750
Fuel Tank...5750
Tracks...5750
Type...5750
Ground Pressure...5750
WARRANTY...5752
WARRANTY...5754
ALPHABETICAL INDEX...5755
6986940 (10-09) - 325, 328 Compact Excavator Service Manual...5757
MAINTENANCE SAFETY...5759
ALPHABETICAL INDEX...5761
CONTENTS...5763
FOREWORD...5764
SAFETY INSTRUCTIONS...5766
FIRE PREVENTION...5768
Maintenance...5768
Operation...5768
Electrical...5768
Hydraulic System...5768
Fueling...5768
Starting...5768
Spark Arrestor Exhaust System...5768
Welding And Grinding...5769
Fire Extinguishers...5769
SERIAL NUMBER LOCATIONS...5770
Excavator Serial Number...5770
Engine Serial Number...5770
DELIVERY REPORT...5771
BOBCAT EXCAVATOR IDENTIFICATION...5772
SAFETY AND MAINTENANCE...5773
LIFTING AND BLOCKING THE EXCAVATOR...5775
Procedure...5775
UPPERSTRUCTURE SLEW LOCK...5777
Operation...5777
LIFTING THE EXCAVATOR...5779
Procedure...5779
OPERATOR CAB (ROPS/TOPS)...5781
Emergency Exit...5781
Front Window...5782
Right Side Windows...5784
Cab Door...5785
TRANSPORTING THE EXCAVATOR...5787
Procedure...5787
TAILGATE...5789
Opening And Closing The Tailgate...5789
Adjusting The Bumper...5789
Adjusting The Latch...5789
RIGHT SIDE COVER...5791
Opening And Closing The Right Side Cover...5791
SERVICE SCHEDULE...5793
Chart...5793
AIR CLEANER...5795
Daily Check...5795
Replacing The Filters...5795
HEATER AIR FILTER (WITH CAB OPTION ONLY)...5797
Removal And Installation...5797
COOLING SYSTEM...5799
Cleaning The Cooling System...5799
Checking Coolant Level...5800
Replacing The Coolant...5801
FUEL SYSTEM...5803
Fuel Specifications...5803
Biodiesel Blend Fuel...5803
Filling The Fuel Tank...5804
Removing Water From The Fuel Filter...5804
Draining The Fuel Tank...5805
Fuel Filter...5805
Removing Air From The Fuel System...5806
ENGINE LUBRICATION SYSTEM...5807
Checking Engine Oil...5807
Oil Chart...5807
Replacing Oil And Filter...5808
HYDRAULIC SYSTEM...5809
Checking And Adding Hydraulic Oil...5809
Replacing The Hydraulic Oil...5810
Replacing The Hydraulic Filter...5811
Replacing The Case Drain Filter...5811
Diagnostic Couplers...5811
LUBRICATION OF THE HYDRAULIC EXCAVATOR...5813
TRAVEL MOTOR...5817
Checking Oil Level...5817
Draining The Travel Motor...5817
SPARK ARRESTOR MUFFLER...5819
ENGINE ACCESSORY DRIVE BELT...5821
Belt Tension...5821
Belt Adjustment...5821
SEAT BELT...5823
Inspection And Maintenance...5823
MOTION ALARM SYSTEM (IF EQUIPPED)...5825
Description...5825
Adjusting Switch Position...5825
HYDRAULIC SYSTEM...5827
HYDRAULIC / HYDROSTATIC SCHEMATIC...5831
HYDRAULIC SYSTEM INFORMATION...5833
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...5833
Troubleshooting The Hydraulic Circuit...5836
Troubleshooting The Cylinder Circuit...5837
Troubleshooting The Swing (Upperstructure Slew) Circuit...5838
Troubleshooting The Travel Circuit...5839
BOOM CYLINDER...5841
Testing...5841
Removal And Installation...5844
Parts Identification...5847
Disassembly...5848
Assembly...5850
ARM CYLINDER...5853
Testing...5853
Removal And Installation...5855
Parts Identification...5857
Disassembly...5858
Assembly...5860
BOOM SWING CYLINDER...5863
Testing...5863
Removal And Installation...5865
Parts Identification...5867
Disassembly...5868
Assembly...5870
BUCKET CYLINDER...5873
Testing...5873
Removal And Installation...5875
Parts Identification...5876
Disassembly...5877
Assembly...5879
BLADE CYLINDER...5883
Testing...5883
Removal And Installation...5885
Parts Identification...5886
Disassembly...5887
Assembly...5889
CLAMP CYLINDER...5893
Testing...5893
Removal And Installation...5894
Parts Identification...5895
Disassembly...5896
Assembly...5899
MAIN RELIEF VALVES...5905
Testing And Adjusting The Main Relief Valves...5905
PORT RELIEF VALVES...5909
Testing And Adjusting The Port Relief Valves...5909
CROSSPORT RELIEF VALVES...5911
Testing And Adjusting The Crossport Relief Valves...5911
PRESSURE REDUCING VALVE...5915
Testing And Adjusting The Pressure Reducing Valve...5915
HYDRAULIC CONTROL VALVE...5917
Description...5917
Removal And Installation...5917
Control Valve Identification...5925
Disassembly...5926
Right Travel Valve Section Disassembly And Assembly...5928
Boom Swing Valve Section Disassembly And Assembly...5934
Boom Valve Section Disassembly And Assembly...5941
Left Travel Valve Section Disassembly And Assembly...5945
Arm Valve Section Disassembly And Assembly...5950
Bucket Valve Section Disassembly And Assembly...5954
Auxiliary Valve Section Disassembly And Assembly...5958
Boost Valve Section Disassembly And Assembly...5962
Blade Valve Section Disassembly And Assembly...5966
Slew Valve Section Disassembly And Assembly...5971
Assembly...5975
HYDRAULIC PUMP...5983
Description...5983
Torque Adjustment...5984
Testing The Piston Pump...5985
Testing The Gear Pump...5987
Testing Auxiliary Hydraulic Flow...5989
Removal And Installation...5990
Coupler Removal And Installation...5991
Hydraulic Pump Start Up...5992
Gear Pump Parts Identification...5993
Piston Pump Parts Identification...5994
Disassembly...5995
Gear Pump Disassembly...5996
Gear Pump Assembly...5999
Piston Pump Disassembly...6002
Piston Pump Assembly...6008
MANIFOLD ASSEMBLY/ ACCUMULATOR...6017
Description...6017
Removal And Installation...6017
Parts Identification...6021
Disassembly...6022
Assembly...6033
MANIFOLD ASSEMBLY...6045
Parts Identification...6045
Disassembly...6046
Assembly...6057
TRAVEL MOTOR...6069
Removal And Installation...6069
Parts Identification...6070
Disassembly...6071
Assembly...6079
SWIVEL JOINT...6089
Description...6089
Removal And Installation...6089
Parts Identification...6091
Disassembly...6092
Assembly...6093
SWING MOTOR...6097
Removal And Installation...6097
Parts Identification...6100
Disassembly...6101
Assembly...6106
SWING MOTOR DRIVE CARRIER...6113
Removal And Installation...6113
Parts Identification...6114
Disassembly...6115
Assembly...6117
CONTROL PATTERN SELECTOR VALVE...6121
Removal And Installation...6121
Parts Identification...6122
Disassembly...6123
Assembly...6124
RIGHT CONTROL LEVER (JOYSTICK)...6125
Testing...6125
Handle Removal And Installation...6126
Joystick Assembly, Removal And Installation...6130
Parts Identification...6133
Disassembly...6134
Assembly...6139
LEFT CONTROL LEVER (JOYSTICK)...6143
Testing...6143
Handle Removal And Installation...6144
Joystick Assembly Removal And Installation...6147
Parts Identification...6149
Disassembly...6150
Assembly...6155
HYDRAULIC FILTER MOUNT...6161
Removal And Installation...6161
HYDRAULIC RESERVOIR...6163
Removal And Installation...6163
OIL COOLER...6165
Removal And Installation...6165
DIRECT TO TANK VALVE...6167
Removal And Installation...6167
Disassembly And Assembly...6168
BUILD UP VALVE...6169
Description...6169
Removal And Installation...6169
Parts Identification...6170
Disassembly And Assembly...6171
CASE DRAIN FILTER...6173
Removal And Installation...6173
SLEW LOCK VALVE...6175
Description...6175
Removal And Installation...6175
Parts Identification...6176
Disassembly And Assembly...6177
UNDERCARRIAGE...6181
BLADE...6183
Removal And Installation...6183
TRACKS...6185
Track Lug Height...6185
Adjustment...6185
Rubber Track Removal And Installation...6188
Steel Track Removal And Installation...6190
TRACK FRAME...6193
Disassembly And Assembly...6193
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511315 & Below, A9KO11108 & Below And A9K111109 & Below)...6195
Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above)...6196
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above)...6197
TRACK DAMAGE IDENTIFICATION...6199
Cutting Of Steel Cords...6199
Abrasion Of Embedded Metals...6200
Separation Of Embedded Metals...6201
Separation Of Embedded Metals Due To Corrosion...6202
Cuts On The Lug Side Rubber...6203
Cracks On The Lug Side Rubber Due To Fatigue...6204
Lug Abrasion...6205
Cracks And Cuts On The Lug Side Rubber...6206
Abrasion Of The Track Roller Side...6207
Cuts On The Edges Of Track Roller Side...6208
TRACK IDLER...6211
Parts Identification...6211
Disassembly...6212
Assembly...6214
TRACK ROLLER...6217
Parts Identification...6217
Disassembly...6218
Assembly...6220
SWING CIRCLE GEAR...6223
Swing Bearing Removal...6223
Swing Bearing Installation...6224
UPPERSTRUCTURE & SWING SECTION...6225
UPPERSTRUCTURE...6229
Removal...6229
Installation...6232
ROPS CANOPY...6235
Removal And Installation...6235
CAB...6239
Removal And Installation...6239
Door Removal And Installation...6244
Front Window Removal And Installation...6245
Right Side Rear Sliding Window Removal And Installation...6248
Right Side Front Sliding Window Removal And Installation...6248
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...6249
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...6249
Glass Removal...6250
Glass Installation...6251
STANDARD SEAT AND SEAT MOUNT...6253
Removal And Installation...6253
SUSPENSION SEAT AND SEAT MOUNT...6255
Removal And Installation...6255
RIGHT CONSOLE...6257
Console Cover Removal And Installation...6257
Console Base Removal And Installation...6258
LEFT CONSOLE...6261
Lower Console Cover Removal And Installation...6261
Upper Console Cover Removal And Installation...6263
Compression Spring Removal And Installation...6264
Compression Spring Disassembly And Assembly...6265
Lock Lever Removal And Installation...6267
Console Removal And Installation...6268
Disassembly And Assembly...6272
Console Switch Removal And Installation...6275
Console Base Removal And Installation...6276
ENGINE SPEED CONTROL...6277
Removal And Installation...6277
Adjustment...6278
BLADE CONTROL...6279
Lever Removal And Installation...6279
Linkage Removal And Installation...6280
Linkage Bar Removal And Installation...6282
Lower Linkage Removal And Installation...6284
RIGHT PEDAL AND LINKAGE...6287
Pedal Removal And Installation...6287
Pedal Disassembly And Assembly...6288
Linkage Removal And Installation...6290
TRAVEL CONTROLS...6291
Removal And Installation...6291
Disassembly And Assembly...6292
Adjustment...6295
FLOOR MAT AND FLOOR PLATE...6299
Removal And Installation (Canopy Equipped Excavators)...6299
Removal And Installation (Cab Equipped Excavators)...6300
FUEL TANK...6301
Removal And Installation...6301
HORN...6305
Removal And Installation...6305
SWING FRAME...6307
Boom Swing Bracket Removal And Installation...6307
Boom Swing Bracket Hose Installation...6311
Bushing Removal...6312
Bushing Installation...6313
BOOM...6315
Removal And Installation...6315
ARM...6317
Removal And Installation...6317
Arm To Boom Bushing Removal And Installation...6317
Arm To Bucket And Bucket Link Bushing Removal And Installation...6318
BUCKET...6319
Bucket Teeth Removal And Installation...6319
Bucket Side Cutting Edge Removal And Installation...6320
CLAMP...6321
Removal And Installation...6321
TAILGATE...6323
Removal And Installation...6323
Latch Removal And Installation...6324
X-CHANGE...6325
Removal And Installation...6325
Disassembly...6327
Assembly...6331
Check Proper Latch Engagement...6337
UPPERSTRUCTURE SLEW LOCK...6341
Removal And Installation...6341
Disassembly And Assembly...6341
RIGHT SIDE COVER...6343
Removal And Installation...6343
ELECTRICAL SYSTEM AND ANALYSIS...6345
ELECTRICAL SCHEMATICS...6347
ELECTRICAL SYSTEM INFORMATION...6349
Troubleshooting Chart...6349
Description...6350
Fuse And Relay Location...6350
BATTERY...6351
Servicing...6351
Removing And Installing The Battery...6352
Using A Booster Battery (Jump Starting)...6352
ALTERNATOR...6355
Engine Accessory Drive Belt...6355
Engine Accessory Drive Belt Tensioner Removal And Installation...6356
Removal And Installation...6357
Bracket Removal And Installation...6358
Description...6359
Tests...6359
Alternator Output Test...6360
Full Field Test...6360
Alternator Regulator Test...6361
Parts Identification...6362
Disassembly And Assembly...6363
Rotor Continuity Test...6367
Rectifier Continuity (Diode) Test...6368
STARTER...6369
Removal And Installation...6369
Parts Identification...6370
Disassembly...6371
Inspection And Repair...6376
Assembly...6379
LIGHTS...6385
Removal And Installation...6385
Boom Light Removal And Installation...6386
Boom Light Bulb Replacement...6386
TWO SPEED SWITCH...6387
Removal And Installation...6387
FUEL LEVEL SENDER...6389
Removal And Installation...6389
Testing...6389
DIAGNOSTICS SERVICE CODE...6391
Number Codes List...6391
DELUXE INSTRUMENT PANEL SETUP...6393
Passwords...6393
Password Entry (For Starting And Operating The Machine)...6393
Changing The Owner or Operator Password...6393
Password Lockout Feature...6394
Job Clock...6394
RPM...6394
ENGINE SERVICE...6395
TROUBLESHOOTING...6397
Chart...6397
MUFFLER...6399
Removal And Installation...6399
AIR CLEANER...6401
Removal And Installation...6401
RADIATOR...6403
Removal And Installation...6403
ENGINE COMPONENTS AND TESTING...6405
Engine Compression Checking...6405
Glow Plugs Removal And Installation...6406
Checking The Glow Plug...6407
Fuel Shut-Off Solenoid Removal And Installation...6408
Fuel Injection Pump Check...6410
Fuel Injection Pump Removal And Installation...6411
Fuel Injection Pump Timing...6414
Fuel Injector Nozzles Removal And Installation...6416
Fuel Injector Nozzle Check...6418
Valve Seat Tightness...6419
Valve Clearance Adjustment...6419
ENGINE...6421
Removal And Installation...6421
ENGINE FLYWHEEL...6427
Flywheel Removal And Installation...6427
Hydraulic Pump Coupler...6429
Flywheel Ring Gear...6430
RECONDITIONING THE ENGINE...6431
Cylinder Head Removal And Installation...6431
Cylinder Head Disassembly And Assembly...6434
Cylinder Head Servicing...6435
Cylinder Head Top Clearance...6435
Valve Guide Checking...6436
Reconditioning The Valve And Valve Seat...6438
Valve Spring...6439
Rocker Arm And Shaft Checking...6440
Timing Gearcase Cover Removal And Installation...6440
Idler Gear And Camshaft Removal And Installation...6443
Camshaft Servicing...6444
Idler Gear And Shaft Servicing...6445
Timing Gears Checking Backlash...6446
Fuel Camshaft Removal And Installation...6446
Fuel Camshaft Governor...6447
Crankshaft Gear Removal And Installation...6447
Oil Pump Removal And Installation...6448
Oil Pump Service...6448
Checking Engine Oil Pressure...6449
Valve Tappets...6450
Piston And Connecting Rod Removal And Installation...6450
Piston And Connecting Rod Servicing...6452
Connecting Rod Alignment...6454
Crankshaft And Bearings Removal And Installation...6455
Crankshaft And Bearings, Servicing...6457
Cylinder Bore, Checking...6461
Water Pump Removal And Installation...6461
Water Pump Disassembly And Assembly...6462
HEATER...6463
HEATER SYSTEM...6465
Description...6465
Components...6465
REGULAR MAINTENANCE...6467
Filter Element Removal And Installation...6467
Heater Coil...6468
TROUBLESHOOTING...6469
Blower Motor Does Not Operate...6469
Blower Motor Operates Normally, But Air Flow Is Insufficient...6469
Electrical System...6470
HEATER UNIT...6475
Removal And Installation...6475
HEATER COIL...6477
Removal And Installation...6477
BLOWER FAN...6479
Removal And Installation...6479
Disassembly And Assembly...6480
Resistor Removal And Installation...6481
HEATER VALVE...6483
Removal And Installation...6483
SPECIFICATIONS...6485
SPECIFICATIONS...6487
325/328 Excavator Machine Dimensions...6487
325 Excavator Machine Dimensions...6488
325 With Long Arm Option And 328 Excavator Machine Dimensions...6489
Performance...6490
Controls...6490
Engine...6490
Hydraulic System...6491
Hydraulic Cylinders...6491
Hydraulic Cycle Times...6492
Drive System...6492
Undercarriage...6492
Track...6493
Electrical...6493
ENGINE SPECIFICATIONS...6495
Fuel Injection Nozzles...6495
Fuel Injection Pump...6495
Cylinder Head...6495
Valves...6495
Valve Springs...6496
Valve Timing...6496
Rocker Arms...6496
Camshaft...6496
Tappet...6496
Cylinders...6497
Piston Rings...6497
Pistons...6497
Connecting Rods...6497
Oil Pump...6497
Crankshaft...6498
Timing Gear...6498
Thermostat...6499
Engine Bolt Torque...6499
Crankshaft Re-Grind Data...6500
TORQUE SPECIFICATIONS...6501
Torque for General SAE Bolts...6501
Torque For General Metric Bolts...6502
HYDRAULIC CONNECTION SPECIFICATIONS...6503
O-ring Face Seal Connection...6503
Straight Thread O-Ring Fitting...6503
Tubelines And Hoses...6503
Flare Fitting...6504
O-ring Flare Fitting...6505
Port Seal Fitting...6507
HYDRAULIC FLUID SPECIFICATIONS...6509
Specifications...6509
FUEL, COOLANT AND LUBRICANTS...6511
Chart...6511
CONVERSIONS...6513
Decimal And Millimeter Equivalents...6513
U.S. To Metric Conversion...6514
SERVICE MANUAL REVISION...6517
SERVICE MANUAL REVISION...6515
Revision No: 325 / 328 - 1...6515
Revision No: 325 / 328 - 2...6517
6986940 (7-11) - 325, 328 Compact Excavator Service Manual...6519
MAINTENANCE SAFETY...6521
CONTENTS...6523
FOREWORD...6525
FOREWORD...6527
SAFETY INSTRUCTIONS...6529
FIRE PREVENTION...6531
Maintenance...6531
Operation...6531
Electrical...6531
Hydraulic System...6531
Fueling...6531
Starting...6531
Spark Arrester Exhaust System...6531
Welding And Grinding...6532
Fire Extinguishers...6532
SERIAL NUMBER LOCATIONS...6533
Excavator Serial Number...6533
Engine Serial Number...6533
DELIVERY REPORT...6534
BOBCAT EXCAVATOR IDENTIFICATION...6535
SAFETY & MAINTENANCE...6537
LIFTING AND BLOCKING THE EXCAVATOR...6539
Procedure...6539
UPPERSTRUCTURE SLEW LOCK...6541
Operation...6541
LIFTING THE EXCAVATOR...6543
Procedure...6543
OPERATOR CAB (ROPS / TOPS)...6545
Emergency Exit...6545
Front Window...6546
Right Side Windows...6548
Cab Door...6549
TRANSPORTING THE EXCAVATOR ON A TRAILER...6551
Loading And Unloading...6551
Fastening...6552
TAILGATE...6553
Opening And Closing The Tailgate...6553
Adjusting The Bumper...6553
Adjusting The Latch...6553
RIGHT SIDE COVER...6555
Opening And Closing The Right Side Cover...6555
Adjusting The Latch...6555
SERVICE SCHEDULE...6557
Chart...6557
AIR CLEANER SERVICE...6559
Daily Check...6559
Replacing The Filters...6559
CAB FILTERS...6561
Cleaning And Maintenance...6561
ENGINE COOLING SYSTEM...6563
Cleaning...6563
Checking Coolant Level...6564
Removing And Replacing The Coolant...6565
FUEL SYSTEM...6567
Fuel Specifications...6567
Biodiesel Blend Fuel...6567
Filling The Fuel Tank...6568
Removing Water...6568
Draining The Fuel Tank...6569
Fuel Filter...6569
Removing Air From The Fuel System...6570
ENGINE LUBRICATION SYSTEM...6571
Checking And Adding Engine Oil...6571
Engine Oil Chart...6571
Removing And Replacing Oil And Filter...6572
HYDRAULIC SYSTEM...6575
Checking And Adding Fluid...6575
Hydraulic / Hydrostatic Fluid Chart...6576
Removing And Replacing The Hydraulic Filters...6576
Removing And Replacing The Case Drain Filter...6577
Removing And Replacing The Hydraulic Fluid...6577
LUBRICATION OF THE HYDRAULIC EXCAVATOR...6579
TRAVEL MOTOR...6583
Checking And Adding Oil...6583
Removing And Replacing Oil...6583
SPARK ARRESTER MUFFLER...6585
Cleaning Procedure...6585
ALTERNATOR BELT...6587
Belt Adjustment...6587
Belt Replacement...6587
SEAT BELT...6589
Inspection And Maintenance...6589
MOTION ALARM SYSTEM (IF EQUIPPED)...6591
Description...6591
Adjusting Switch Position...6591
REMOTE START TOOL KIT - MEL1563...6593
Remote Start Tool - MEL1563...6593
Service Tool Harness Communicator - MEL1566...6595
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...6597
Description...6597
Remote Start Tool (Service Tool) - 7003030...6598
Excavator Service Tool Harness - 6689747...6599
Computer Service Tool Harness - 6689746...6600
HYDRAULIC SYSTEM...6601
HYDRAULIC / HYDROSTATIC SCHEMATICS...6605
HYDRAULIC SYSTEM INFORMATION...6607
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators...6607
Troubleshooting The Hydraulic Circuit...6610
Troubleshooting The Cylinder Circuit...6611
Troubleshooting The Swing (Upperstructure Slew) Circuit...6612
Troubleshooting The Travel Circuit...6613
CYLINDER (BOOM)...6615
Testing...6615
Removal And Installation...6618
Parts Identification...6621
Disassembly...6622
Assembly...6624
CYLINDER (ARM)...6627
Testing...6627
Removal And Installation...6629
Parts Identification...6631
Disassembly...6632
Assembly...6634
CYLINDER (BOOM SWING)...6637
Testing...6637
Removal And Installation...6639
Parts Identification...6641
Disassembly...6642
Assembly...6644
CYLINDER (BUCKET)...6647
Testing...6647
Removal And Installation...6649
Parts Identification...6650
Disassembly...6651
Assembly...6653
CYLINDER (BLADE)...6657
Testing...6657
Removal And Installation...6659
Parts Identification...6660
Disassembly...6661
Assembly...6663
CYLINDER (CLAMP)...6667
Testing...6667
Removal And Installation...6668
Parts Identification...6669
Disassembly...6670
Assembly...6673
VALVES (MAIN RELIEF)...6677
Testing And Adjusting The Main Relief Valves...6677
VALVES (PORT RELIEF)...6681
Testing And Adjusting The Port Relief Valves...6681
VALVES (CROSSPORT RELIEF)...6683
Testing And Adjusting The Crossport Relief Valves...6683
VALVE (PRESSURE REDUCING)...6687
Testing And Adjusting The Pressure Reducing Valve...6687
HYDRAULIC CONTROL VALVE...6689
Description...6689
Removal And Installation...6689
Control Valve Identification...6697
Disassembly...6698
Right Travel Valve Section Disassembly And Assembly...6700
Boom Swing Valve Section Disassembly And Assembly...6706
Boom Valve Section Disassembly And Assembly...6713
Left Travel Valve Section Disassembly And Assembly...6718
Arm Valve Section Disassembly And Assembly...6723
Bucket Valve Section Disassembly And Assembly...6727
Auxiliary Valve Section Disassembly And Assembly...6731
Boost Valve Section Disassembly And Assembly...6735
Blade Valve Section Disassembly And Assembly...6740
Slew Valve Section Disassembly And Assembly...6745
Assembly...6749
HYDRAULIC PUMP...6757
Description...6757
Torque Adjustment...6758
Testing The Piston Pump...6759
Testing The Gear Pump...6761
Testing Auxiliary Hydraulic Flow...6763
Removal And Installation...6764
Coupler Removal And Installation...6765
Hydraulic Pump Start Up...6766
Gear Pump Parts Identification...6767
Piston Pump Parts Identification...6768
Disassembly...6769
Gear Pump Disassembly...6770
Gear Pump Assembly...6773
Piston Pump Disassembly...6776
Piston Pump Assembly...6782
MANIFOLD ASSEMBLY / ACCUMULATOR...6791
Description...6791
Removal And Installation...6791
Parts Identification...6795
Disassembly...6796
Assembly...6807
MANIFOLD ASSEMBLY...6819
Parts Identification...6819
Disassembly...6820
Assembly...6831
TRAVEL MOTOR...6843
Removal And Installation...6843
Parts Identification...6844
Disassembly...6845
Assembly...6853
SWIVEL JOINT...6863
Description...6863
Removal And Installation...6863
Parts Identification...6865
Disassembly...6866
Assembly...6867
SWING MOTOR...6871
Removal And Installation...6871
Parts Identification...6874
Disassembly...6875
Assembly...6880
SWING MOTOR DRIVE CARRIER...6887
Removal And Installation...6887
Parts Identification...6888
Disassembly...6889
Assembly...6891
CONTROL PATTERN SELECTOR VALVE...6895
Removal And Installation...6895
Parts Identification...6896
Disassembly...6897
Assembly...6898
RIGHT CONTROL LEVER (JOYSTICK)...6899
Testing...6899
Handle Removal And Installation...6900
Joystick Assembly, Removal And Installation...6904
Parts Identification...6907
Disassembly...6908
Assembly...6913
LEFT CONTROL LEVER (JOYSTICK)...6917
Testing...6917
Handle Removal And Installation...6918
Joystick Assembly Removal And Installation...6921
Parts Identification...6923
Disassembly...6924
Assembly...6929
HYDRAULIC FILTER MOUNT...6935
Removal And Installation...6935
HYDRAULIC RESERVOIR...6937
Removal And Installation...6937
OIL COOLER...6939
Removal And Installation...6939
DIRECT TO TANK VALVE...6941
Removal And Installation...6941
Disassembly And Assembly...6942
BUILD UP VALVE...6943
Description...6943
Removal And Installation...6943
Parts Identification...6944
Disassembly And Assembly...6945
CASE DRAIN FILTER...6947
Removal And Installation...6947
SLEW LOCK VALVE...6949
Description...6949
Removal And Installation...6949
Parts Identification...6950
Disassembly And Assembly...6951
UNDERCARRIAGE...6955
BLADE...6957
Removal And Installation...6957
TRACKS...6959
Track Lug Height...6959
Adjustment...6959
Rubber Track Removal And Installation...6962
Steel Track Removal And Installation...6964
TRACK FRAME...6967
Disassembly And Assembly...6967
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511315 & Below, A9KO11108 & Below And A9K111109 & Below)...6970
Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above)...6971
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above)...6972
TRACK DAMAGE IDENTIFICATION...6975
Cutting Of Steel Cords...6975
Abrasion Of Embedded Metals...6976
Separation Of Embedded Metals...6977
Separation Of Embedded Metals Due To Corrosion...6978
Cuts On The Lug Side Rubber...6979
Cracks On The Lug Side Rubber Due To Fatigue...6980
Lug Abrasion...6981
Cracks And Cuts On The Lug Side Rubber...6982
Abrasion Of The Track Roller Side...6983
Cuts On The Edges Of Track Roller Side...6984
TRACK IDLER...6987
Parts Identification...6987
Disassembly...6988
Assembly...6990
TRACK ROLLER (AAC513024 & BELOW, A9K013003 & BELOW AND a9K113001 & BELOW)...6993
Parts Identification...6993
Disassembly...6994
Assembly...6996
SWING CIRCLE GEAR...6999
Swing Bearing Removal...6999
Swing Bearing Installation...7000
UPPERSTRUCTURE AND SWING SECTION...7001
UPPERSTRUCTURE...7005
Removal...7005
Installation...7008
ROPS CANOPY...7011
Removal And Installation...7011
CAB...7015
Removal And Installation...7015
Door Removal And Installation...7020
Front Window Removal And Installation...7021
Right Side Rear Sliding Window Removal And Installation...7024
Right Side Front Sliding Window Removal And Installation...7024
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...7025
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...7025
Glass Removal...7026
Glass Installation...7027
SEAT AND SEAT MOUNT (STANDARD)...7029
Removal And Installation...7029
SEAT AND SEAT MOUNT (SUSPENSION)...7031
Removal And Installation...7031
RIGHT CONSOLE...7033
Console Cover Removal And Installation...7033
Console Base Removal And Installation...7034
LEFT CONSOLE...7037
Lower Console Cover Removal And Installation...7037
Upper Console Cover Removal And Installation...7039
Compression Spring Removal And Installation...7040
Compression Spring Disassembly And Assembly...7041
Lock Lever Removal And Installation...7043
Console Removal And Installation...7044
Disassembly And Assembly...7048
Console Switch Removal And Installation...7051
Console Base Removal And Installation...7052
ENGINE SPEED CONTROL...7053
Removal And Installation...7053
Adjustment...7054
BLADE CONTROL...7055
Lever Removal And Installation...7055
Linkage Removal And Installation...7056
Linkage Bar Removal And Installation...7058
Lower Linkage Removal And Installation...7060
RIGHT PEDAL AND LINKAGE...7063
Pedal Removal And Installation...7063
Pedal Disassembly And Assembly...7064
Linkage Removal And Installation...7066
TRAVEL CONTROLS...7067
Removal And Installation...7067
Disassembly And Assembly...7068
Adjustment...7071
FLOOR MAT AND FLOOR PLATE...7075
Removal And Installation (Canopy Equipped Excavators)...7075
Removal And Installation (Cab Equipped Excavators)...7076
FUEL TANK...7077
Removal And Installation...7077
HORN...7081
Removal And Installation...7081
SWING FRAME...7083
Boom Swing Bracket Removal And Installation...7083
Boom Swing Bracket Hose Installation...7087
Bushing Removal...7088
Bushing Installation...7089
BOOM...7091
Removal And Installation...7091
ARM...7093
Removal And Installation...7093
Arm To Boom Bushing Removal And Installation...7093
Arm To Bucket And Bucket Link Bushing Removal And Installation...7094
BUCKET...7095
Bucket Teeth Removal And Installation...7095
Bucket Side Cutting Edge Removal And Installation...7096
CLAMP...7097
Removal And Installation...7097
TAILGATE...7099
Removal And Installation...7099
Latch Removal And Installation...7100
X-CHANGE...7101
Removal And Installation...7101
Disassembly...7103
Assembly...7107
Check Proper Latch Engagement...7113
UPPERSTRUCTURE SLEW LOCK...7117
Removal And Installation...7117
Disassembly And Assembly...7117
RIGHT SIDE COVER...7119
Removal And Installation...7119
QUICK COUPLER (KLAC™ SYSTEM)...7121
Troubleshooting...7121
Daily Inspection...7121
Removal And Installation...7122
Parts Identification...7124
Disassembly...7125
Assembly...7126
QUICK COUPLER (LEHNHOFF® SYSTEM)...7129
Troubleshooting...7129
Daily Inspection...7129
Removal (MS03 And MS08)...7130
Installation (MS03 And MS08)...7131
Parts Identification (MS03)...7132
Disassembly And Assembly (MS03)...7133
Parts Identification (MS08)...7134
Disassembly (MS08)...7135
Assembly (MS08)...7138
ELECTRICAL SYSTEM & ANALYSIS...7143
ELECTRICAL SCHEMATICS...7145
ELECTRICAL SYSTEM INFORMATION...7147
Troubleshooting Chart...7147
Description...7148
Fuse And Relay Location...7148
BATTERY...7149
Servicing...7149
Removing And Installing The Battery...7150
Using A Booster Battery (Jump Starting)...7150
ALTERNATOR...7153
Engine Accessory Drive Belt...7153
Engine Accessory Drive Belt Tensioner Removal And Installation...7154
Removal And Installation...7155
Bracket Removal And Installation...7156
Description...7157
Tests...7157
Alternator Output Test...7158
Full Field Test...7158
Alternator Regulator Test...7159
Parts Identification...7160
Disassembly And Assembly...7161
Rotor Continuity Test...7165
Rectifier Continuity (Diode) Test...7166
STARTER...7167
Removal And Installation...7167
Parts Identification...7168
Disassembly...7169
Inspection And Repair...7174
Assembly...7177
LIGHTS...7183
Removal And Installation...7183
Boom Light Removal And Installation...7184
Boom Light Bulb Replacement...7184
TWO-SPEED SWITCH...7185
Removal And Installation...7185
FUEL LEVEL SENDER...7187
Removal And Installation...7187
Testing...7187
DIAGNOSTICS SERVICE CODE...7189
Number Codes List...7189
DELUXE INSTRUMENT PANEL SETUP...7191
Passwords...7191
Password Entry (For Starting And Operating The Machine)...7191
Changing The Owner or Operator Password...7191
Password Lockout Feature...7192
Job Clock...7192
RPM...7192
ENGINE SERVICE...7193
TROUBLESHOOTING...7195
Chart...7195
MUFFLER...7197
Removal And Installation...7197
AIR CLEANER...7199
Removal And Installation...7199
RADIATOR...7201
Removal And Installation...7201
ENGINE COMPONENTS AND TESTING...7203
Engine Compression Checking...7203
Glow Plugs Removal And Installation...7204
Checking The Glow Plug...7205
Fuel Shut-Off Solenoid Removal And Installation...7206
Fuel Injection Pump Check...7208
Fuel Injection Pump Removal And Installation...7209
Fuel Injection Pump Timing...7212
Fuel Injector Nozzles Removal And Installation...7214
Fuel Injector Nozzle Check...7216
Valve Seat Tightness...7217
Valve Clearance Adjustment...7217
ENGINE...7219
Removal And Installation...7219
ENGINE FLYWHEEL...7225
Flywheel Removal And Installation...7225
Hydraulic Pump Coupler...7227
Flywheel Ring Gear...7228
RECONDITIONING THE ENGINE...7229
Cylinder Head Removal And Installation...7229
Cylinder Head Disassembly And Assembly...7232
Cylinder Head Servicing...7233
Cylinder Head Top Clearance...7233
Valve Guide Checking...7234
Reconditioning The Valve And Valve Seat...7236
Valve Spring...7237
Rocker Arm And Shaft Checking...7238
Timing Gearcase Cover Removal And Installation...7238
Idler Gear And Camshaft Removal And Installation...7241
Camshaft Servicing...7242
Idler Gear And Shaft Servicing...7243
Timing Gears Checking Backlash...7244
Fuel Camshaft Removal And Installation...7244
Fuel Camshaft Governor...7245
Crankshaft Gear Removal And Installation...7245
Oil Pump Removal And Installation...7246
Oil Pump Service...7246
Checking Engine Oil Pressure...7247
Valve Tappets...7248
Piston And Connecting Rod Removal And Installation...7248
Piston And Connecting Rod Servicing...7250
Connecting Rod Alignment...7252
Crankshaft And Bearings Removal And Installation...7253
Crankshaft And Bearings, Servicing...7255
Cylinder Bore, Checking...7259
Water Pump Removal And Installation...7259
Water Pump Disassembly And Assembly...7260
HEATING, VENTILATION & AIR CONDITIONING...7261
HEATER SYSTEM...7263
Description...7263
Components...7263
REGULAR MAINTENANCE...7265
Filter Element Removal And Installation...7265
Heater Coil...7266
TROUBLESHOOTING...7267
Blower Motor Does Not Operate...7267
Blower Motor Operates Normally, But Air Flow Is Insufficient...7267
Electrical System...7268
HEATER UNIT...7273
Removal And Installation...7273
HEATER COIL...7275
Removal And Installation...7275
BLOWER FAN...7277
Removal And Installation...7277
Disassembly And Assembly...7278
Resistor Removal And Installation...7279
HEATER VALVE...7281
Removal And Installation...7281
SPECIFICATIONS...7283
SPECIFICATIONS...7285
325, 328 Excavator Machine Dimensions...7285
325 Excavator Machine Dimensions...7286
325 With Long Arm Option And 328 Excavator Machine Dimensions...7287
Performance...7288
Controls...7288
Engine...7288
Hydraulic System...7289
Hydraulic Cylinders...7289
Hydraulic Cycle Times...7290
Drive System...7290
Undercarriage...7290
Track...7290
Electrical...7290
ENGINE SPECIFICATIONS...7291
Fuel Injection Nozzles...7291
Fuel Injection Pump...7291
Cylinder Head...7291
Valves...7291
Valve Springs...7292
Valve Timing...7292
Rocker Arms...7292
Camshaft...7292
Tappet...7292
Cylinders...7293
Piston Rings...7293
Pistons...7293
Connecting Rods...7293
Oil Pump...7293
Crankshaft...7294
Timing Gear...7294
Thermostat...7295
Engine Bolt Torque...7295
Crankshaft Re-Grind Data...7296
TORQUE SPECIFICATIONS...7299
Torque for General SAE Bolts...7299
Torque For General Metric Bolts...7300
HYDRAULIC CONNECTION SPECIFICATIONS...7301
O-ring Face Seal Connection...7301
Straight Thread O-ring Fitting...7301
Tubelines And Hoses...7301
Flare Fitting...7302
O-ring Flare Fitting...7303
Port Seal Fitting...7305
HYDRAULIC FLUID SPECIFICATIONS...7307
Specifications...7307
FUEL, COOLANT AND LUBRICANTS...7309
Chart...7309
CONVERSIONS...7311
Decimal And Millimeter Equivalents...7311
U.S. To Metric Conversion...7312
ALPHABETICAL INDEX...7313
SERVICE MANUAL REVISION...7315
Revision No: 325 / 328 - 1...7315
Revision No: 325 / 328 - 2...7317
Revision No: 325, 328 - 3...7319
Bobcat Excavators 325, 328, X325, X328 Repair Service Manuals
