Bobcat 325, 328 Excavator (D Series) Service Manual 6901138 (6-12)

Bobcat 325 / 328 Excavator D-Series Service Manual 6901138 (6-12)

Professional service manual derived strictly from the Table of Contents, delivering diagnostic flows, test procedures, removal and installation steps, overhaul instructions and specification data for Bobcat 325 and 328 D-Series excavators. Coverage spans hydraulic, electrical, engine, undercarriage, upperstructure and HVAC systems to ensure precise repair and reliable performance.

Model Covers:

Bobcat 325 Excavator - S/N 232311001 & Above (D Series)
Bobcat 328 Excavator - S/N 232411001 & Above (D Series)
Ingersoll-Rand - D Series

File Format: PDF

Size: 28.46 MB

No. of pages: 800

Language: English

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

📑 Table of Contents Overview:

Safety, Identification and Scheduled Maintenance

• Foreword, safety instructions and fire prevention for maintenance, operation, electrical and hydraulic work
• Machine and engine serial number locations, excavator identification and delivery report
• Lifting and blocking procedures, swing lock operation and hoisting guidance
• Operator cab and ROPS/TOPS: emergency exits, cab door, front window, glazing care
• Tailgate procedures for early and later models: opening, latch and bumper adjustments
• Service schedule chart with intervals for air cleaner, heater filters, coolant and fuel systems
• Fuel system servicing: spec, water removal, filter service, de-aeration and tank drain
• Engine lubrication: oil level checks, oil and filter replacement
• Hydraulic maintenance: fluid check, diagnostic couplers, hydraulic and case drain filter changes, full fluid replacement
• Travel motor oil service, spark arrester cleaning and comprehensive lubrication procedure

Hydraulic System - Schematics, Testing, Calibration and Overhaul

• Hydraulic/hydrostatic schematics and symbol glossary with troubleshooting charts
• Cylinders: boom, arm, bucket, blade and boom offset - checking, removal and installation, disassembly and assembly
• Relief valves by serial range - main, port and crossport: testing and pressure adjustment with gauge port specs
• Pressure reducing valve procedures for early and later serial ranges
• Hydraulic control valve banks for multiple serial splits - identification, R&I, section teardown and assembly: right/left travel, boom offset, boom, arm, bucket, auxiliary, boost, blade and swing sections
• Hydraulic pump group: torque setting, piston and gear pump testing, auxiliary flow, coupler service, full rebuild
• Manifold assemblies and accumulator variants by serial range - description, R&I, parts identification, disassembly and assembly
• Travel motor, swivel joint (top removal and bottom access methods), swing motor and drive carrier - R&I, parts ID, rebuild
• Control pattern selector valve - R&I, parts identification and assembly
• Direct to tank and build up valves - description, R&I, internal service
• Hydraulic reservoir, filter header, case drain filter and oil cooler service

Undercarriage and Track Systems

• Dozer blade removal and installation
• Tracks: lug height limits, tension adjustment, rubber and steel track removal and installation
• Track frame disassembly/assembly and recoil spring cylinder service across serial splits
• Track damage diagnostics: steel cord cutting, embedded metal abrasion/separation, corrosion driven separation
• Lug side fatigue cracks, edge cuts and roller side abrasion patterns
• Track idler and track roller variants - parts identification, disassembly and assembly by serial range
• Swing circle gear and swing bearing removal/installation with alignment pin guidance

Upperstructure, Cab and Control Linkages

• Upperstructure removal/installation and swing bearing service with alignment procedures
• ROPS canopy and cab - removal/installation; multiple window and panel R&I sequences
• Seats: standard and suspension seat mounts - R&I
• Right and left consoles - covers, bases, compression springs, lock levers, switches - removal, disassembly and assembly
• Engine speed control - R&I and adjustment
• Blade control - lever and linkage system R&I, bar and lower linkage service
• Travel controls - R&I, disassembly and adjustment; right pedal and linkage R&I with calibration
• Floor mats and panels - canopy and cab variants
• Fuel tank and horn R&I
• Swing frame bushings, boom, arm and bucket pin/bushing service; bucket teeth and side cutting edges
• Tailgate latch and release rod service for early and later models
• X-Change quick attachment system - R&I, disassembly, assembly and latch engagement checks
• Klac and Lehnhoff quick coupler systems - troubleshooting, daily inspection, R&I and rebuild

Electrical System and Diagnostics

• Electrical schematics, symbol glossary and troubleshooting charts
• Fuse and relay locations, diagnostic service codes list and instrument panel setup
• Battery servicing, removal/installation and booster starting procedure
• Alternator belt adjustment, output and regulator tests, removal and full rebuild
• Starter removal, inspection, repair and assembly
• Lighting assemblies - removal/installation, disassembly and bulb replacement
• Fuel level sender testing and replacement
• Deluxe instrument panel features: passwords, lockout, job clock and RPM settings

Engine Service, Timing and Reconditioning

• Troubleshooting chart, engine removal/installation and flywheel service
• Muffler, air cleaner and radiator R&I
• Valve clearance adjustment, compression testing, glow plug checks and fuel shutoff solenoid adjustment
• Fuel injection pump checks, R&I and timing; injector nozzle R&I and testing
• Comprehensive reconditioning: cylinder head R&I and rebuild, top clearance, valve guide checks, valve and seat reconditioning, rocker arm service
• Timing gearcase cover R&I, idler gear and camshaft service, backlash checks
• Fuel camshaft and governor, crank gear R&I, oil pump service and oil pressure checks with relief valve inspection
• Piston and connecting rod R&I/servicing, rod alignment, crankshaft and bearings R&I/servicing, cylinder bore inspection
• Water pump removal/installation and rebuild; fan removal/installation

Heater System

• Heater unit R&I, disassembly and assembly
• Heater coil, fan and resistor service with wiring connector procedures
• Heater valve removal and installation

Specifications and Reference Data

• 325 and 328 specifications, plus long arm kit data: dimensions, lift capacities, weights, controls
• Engine, electrical, hydraulic and swing system specifications; cylinders and drive system
• Brakes, undercarriage and track data; capacities and digging force
• Engine specifications, torque values and crankshaft re-grind data
• Torque tables for SAE and metric bolts
• Hydraulic connection standards: O-ring face seal, straight thread O-ring, tubelines and hoses, flare, O-ring flare and port seal fittings
• Hydraulic fluid specifications; fuel, coolant and lubricant charts
• Unit conversions and SMR revision references

This manual provides the full technical depth required for accurate diagnostics, correct repairs and sustained component reliability on Bobcat 325 and 328 D-Series excavators.