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

Bobcat 325 / 328 Compact Excavator Service Manual 6986940 (7-11)

Fully detailed service manual created directly from the Table of Contents, providing complete diagnostic procedures, removal and installation steps, hydraulic calibration, electrical troubleshooting, engine overhaul instructions and full specifications for the Bobcat 325 and 328 compact excavators.

Model Covers:

Bobcat 325 Compact Excavator - S/N 232311001 & Above
Bobcat 328 Compact Excavator - S/N 232411001 & Above

File Format: PDF

Size: 28.64 MB

No. of pages: 853

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Table of Contents Overview:

Safety Instructions, Identification and Maintenance Schedule

• General safety rules, fire hazards, machine operation precautions and safety signage
• Machine and engine serial number location, model identification and delivery documentation
• Lift and support procedures, upperstructure slew lock, cab safety exit, tailgate adjustments and transport instructions
• Full maintenance interval chart including air cleaner, cooling system, hydraulic filter and fuel system service
• Fuel guidelines, filter element replacement, water drain, tank flushing and air removal procedures
• Hydraulic oil level checks, diagnostic ports, fluid replacement and lubrication service chart
• Travel motor oil servicing, alternator belt tension, spark arrester cleaning and pivot point lubrication
• Seat belt, console interlock, motion alarm checks and storage/return-to-service procedure

Hydraulic System - Schematics, Testing and Component Rebuild

• Hydraulic and hydrostatic circuit diagrams with symbol glossary and troubleshooting logic
• Cylinders: boom, arm, bucket, blade, boom swing and track expansion - testing, removal, teardown and reassembly
• Hydraulic system pressure setup: main relief, port relief, crossport relief and pressure reducing valve calibration
• Main control valve sections: travel, swing, boom swing, arm, bucket, auxiliary, boom and blade - removal, sectional rebuild and installation
• Hydraulic pump group: torque specs, piston and gear pump testing, auxiliary flow checks, pump disassembly and assembly
• Accumulator and manifold block - R&I and component rebuild
• Travel motor, swivel joint and swing motor teardown and installation
• Control pattern selector valve R&I and internal inspection
• Joystick control assemblies - lever test, disassembly and reassembly
• Hydraulic filter header, oil cooler, reservoir, solenoid block and relief valves service

Undercarriage and Track System

• Dozer blade extension, removal and installation
• Track inspection, tension adjustment, rubber track removal and installation
• Track frame disassembly and assembly, including expandable track system
• Track carcass damage diagnosis: cord breakage, rubber delamination, abrasion and fatigue patterns
• Idler and roller rebuild: parts identification, teardown and lubrication
• Slew gear removal, inspection and reinstallation

Upperstructure, Cab and Control Linkage Service

• Upperstructure removal and installation, ROPS canopy and cab teardown
• Door, glazing, window latches, heater ducting and wiper system repairs
• Seat mount, floor plates, right and left console disassembly and rebuild
• Engine speed control and blade control cable service
• Travel pedals, linkage shafts and bracket installation and adjustment
• Fuel tank R&I, swing frame service and pivot bushing replacement
• Boom, arm and bucket pin/bushing service and tailgate latch replacement
• Quick couplers (Klac and Lehnhoff) - troubleshooting, teardown and rebuild

Electrical System and Troubleshooting

• Complete electrical schematics and component location overview
• Fuse and relay layout, fuel timer diagnostics and diode testing
• Battery servicing, booster start, alternator output/regulator testing and removal
• Starter teardown, cleaning and rebuild
• Lighting systems, bulb replacement and switch controls
• Microswitch and two-speed button testing and replacement
• Fuel level sender testing and wiring service

Engine System - Timing, Diagnostics and Overhaul

• Engine troubleshooting, torque data, regrind limits and compression testing
• Spark arrester, air cleaner, cooling system radiator and thermostat service
• Lubrication system: oil pump service, pressure testing and relief valve inspection
• Fuel injection pump timing and delivery valve testing, injector and nozzle service, glow plug inspection
• Cylinder head teardown, valve seat conditioning, guide checks, rocker arm service and pressure testing
• Pistons, rods and crankshaft: clearance checks, bearing inspection, reassembly and torque steps
• Camshaft and timing gear backlash checks and housing reassembly
• Flywheel, hydraulic pump drive and rear plate installation

Heater System

• Heater core, fan, louvers, resistor, filter and valve servicing

Specifications and Technical Reference

• Excavator dimensions, performance charts, lift capacity and cycle time data
• Hydraulic, electrical and engine specification charts
• Torque tables for SAE and metric fasteners
• Hydraulic fitting types, port standards and fluid requirements
• Conversion tables and service tool listings

This manual delivers the full technical depth required for accurate repairs, dependable diagnostics and long-term operating reliability of Bobcat 325 and 328 compact excavators.