X 325 X 328
Excavator Service Manual
325 (S/N 514013001 & Above) 328 (S/N 516611001 & Above)
6900462 (3–98)
© Melroe Company 1998 Printed in U.S.A.
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
DRIVE SECTION
UPPER WORKS & SWING SECTION CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
MAIN FRAME & TRACKS
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
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325 (S/N 514013001 & Above), 328 Excavator Service Manual
FOREWORD This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing and adjustment procedures for the hydraulic excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc. A general inspection of the following items must be made after the hydraulic excavator has had service or repair: 1. Check that the ROPS/TOPS/ FOGS is in good condition and is not modified.
9. Safety treads must be in good condition.
2. Check that ROPS/TOPS mounting hardware is tightened and is Melroe approved.
10. Check for correct function of indicator lamps (Optional on some models).
3. The seat belt must be correctly installed, functional and in good condition.
11. Check hydraulic fluid level, engine oil level and fuel supply.
4. Inspect for loose or broken parts or connections.
12. Inspect for fuel, oil or hydraulic fluid leaks.
5. Machine signs must be legible and in the correct location.
13. Lubricate the excavator.
6. Steering levers, control levers and foot pedals must return to neutral. Check that control lever locks are in working condition.
14. Check the condition of the battery and cables.
7. Inspect the air cleaner for damage or leaks. Check the condition of the element.
15. Check for any field modifications not completed.
8. Check the electrical charging system.
Recommend to the owner that all necessary corrections be made before the machine is returned to service.
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SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.
W–2003–0797
The following publications provide information on the safe use and maintenance of the excavator and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the excavator gives operating information as well as routine maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat Excavator dealer.
• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator dealer.
• The Bobcat Hydraulic Excavator has a plastic Operator’s Handbook fastened to the operator cab. It’s brief instructions
are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals. • The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.
• The Bobcat Compact Excavator Operator Training Course is available through your local dealer. This course is intended to provide rules and practices of correct operation of the Hydraulic Excavator.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.
Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.
This notice identifies procedures which must be followed to avoid damage to the machine. I–2019–0284
W–2044–1285
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
SI20–0498
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SERIAL NUMBER LOCATIONS
A
Always use the complete serial number (including the first four digits) of the machine when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. Example: 514013001
325 S/N 514013001–514014899
HYDRAULIC EXCAVATOR SERIAL NUMBER The excavator serial number is on the right front side of the machine frame [A] & [B]. N–00386
B
325 S/N 514014900 & Above 328 S/N 516611001 & Above
N–16370
ENGINE SERIAL NUMBER
C
The engine serial number is located on the engine block, near the fuel injection pump [C].
N–16357
DELIVERY REPORT
D
The Delivery Report items must be explained to the owner/operator by the dealer. The dealer is to fill out the form and the owner/operator signs the form to indicate his understanding [D].
Revised April 99
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HYDRAULIC EXCAVATOR IDENTIFICATION 325ExcavatorServiceManual#6900462S/N514013001&Above–ContentsSection
AUXILIARY COUPLERS
OPERATOR SEAT
CONTROL LEVERS (JOYSTICK) BOOM
SEAT BELT AUXILIARY SELECTOR VALVE
BUCKET CYLINDER
TWO SPEED SWITCH BOOM CYLINDER
BUCKET LINK
BLADE CYLINDER
BUCKET GRAB HANDLES *CANOPY/CAB (ROPS/TOPS) ARM CYLINDER
ENGINE COVER
ARM
UPPERSTRUCTURE BLADE TRACK TRACK FRAME * FOGS (Falling Object Guards) is available from your Bobcat Excavator dealer. viii
B–14274 B–14275
325 (S/N 514013001 & Above), 328 Excavator Service Manual
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PREVENTIVE MAINTENANCE
Page Number
AIR CLEANER SERVICE Replacing The Filter Element (325 S/N 514013001–514014899) . . . . 1–7 Replacing The Filter Element (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 ALTERNATOR BELT Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 ELECTRICAL SYSTEM Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 ENGINE COVER Opening The Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 Engine Oil And Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 FUEL SYSTEM Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter (325 S/N 514013001– 514014899) . . . . . . . . . . . . . . . . . . . . Fuel Filter (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System (325 S/N 514013001– 514014899) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–10 1–11 1–11 1–10 1–11 1–12 1–12
HEATER AIR FILTER SERVICE (325 S/N 514013001–514014899) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25 (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above) . . . . 1–25 HYDRAULIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing The Drain Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing The Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–17 1–18 1–18 1–18
LIFTING AND BLOCKING THE EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 LUBRICATION OF THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SPARK ARRESTOR MUFFLER Cleaning The Spark Arrestor Muffler (325 S/N 514013001–514014899) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 Cleaning The Spark Arrestor Muffler (325 S/N 514014900 & Above) & (328 S/N 516611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 TRANSPORTING THE HYDRAULIC EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 TRAVEL MOTOR Checking The Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 Draining And Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 Revised April 99 –1–1–
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SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Hydraulic Excavator. Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.
W–2003–0797
ITEM Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Cab Seat Belt Safety Signs (Decals) Tracks All Machinery Pivot Points Hyd. Fluid, Hoses and Tubelines Fuel Tank/Fuel Filter Swing Circle Swing Pinion Spark Arrestor Muffler Alternator/Fan Belt Engine Oil and Filter Travel Motor Fuel Filter Battery Cooling System Alternator and Starter Hydraulic Filter Case Drain Filter Engine Valve Clearance Cooling System Hydraulic Tank Travel Motor Cab Heater Air Filter
SERVICE REQUIRED
8–10
50
100
250
500 1000
Replace the filter element only when the red ring shows in the indicator window. Check for leaks and damaged components. Check the oil level and add oil as needed. Check coolant level in recovery tank. Check for correct operation. Check the fastening bolts, nuts, and condition of cab/canopy. Check the condition and that fasteners are tight. Check for damaged signs (decals) replace as needed. Check and adjust tension. Lubricate 23 grease fittings. Check fluid level and add as needed. Check for damage and leaks. Repair and replace as needed. Drain water and sediment from fuel tank/fuel filter. Lubricate two grease fittings. Lubricate one grease fitting. Clean spark chamber. Check and adjust tension. Replace oil and filter element. Check fluid level and add oil as needed. Replace filter element. Check cables, connections and electrolyte level. Add distilled water as needed. Clean the radiator fins. Check the condition. Replace filter element. Clean filter with solvent, dry with air pressure. Check and adjust as needed Drain, flush and add new coolant to the cooling system. Change the fluid, clean fill neck strainer. Change the oil. Clean the filter.
* *
** **
**
*After the first 50 hours of machine operation do the following: Replace the engine oil and filter. Check the condition of the alternator/fan belt. **After the first 100 hours of machine operation do the following procedures: Change oil in final drive case. Clean case drain filter. Replace hydraulic filter. Or Every 12 Months.
–1–3–
325 (S/N 514013001 & Above), 328 Excavator Service Manual
LIFTING AND BLOCKING THE EXCAVATOR
A
Procedure
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death [A].
P–06204
B
W–2003–0797
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
W–2017–0286
P–08369
Always park the machine on a level surface. Raise the machine using the boom and arm [A]. Fully raise the blade and install jackstands under the blade [A] and track frame [B]. Lower the boom until all the machine weight is on the jackstands. Repeat the procedure for the other side. Stop the engine.
–1–4–
325 (S/N 514013001 & Above), 328 Excavator Service Manual
TRANSPORTING THE HYDRAULIC EXCAVATOR
A
• Make sure the parking brakes on the transport vehicle are engaged and wheels are blocked. • Align the ramps with the center of the transport vehicle. Secure the ramps to the truck bed and be sure ramp angle does not exceed 15 degrees. • Use metal loading ramps and slip resistant surface. • Make sure the ramps are the correct length and width, and can support the weight of the machine. • Determine the direction of the track movement before moving the machine (blade forward). Engage the swing lock pin to lock the upperstructure.
P–08421
• Move the machine forward onto the transport vehicle [A].
B
• Do not change direction of the machine while it is on the ramps. • After loading the machine, position the arm and bucket as shown [B]. • Lower the boom. • Stop the engine and remove the key. Use the following procedure to fasten the Excavator to the transport vehicle: P–08422
• Put blocks under the front and rear of the track shoes. • Fasten hold down chains to the front corners of the blade and to the tie down loop at the track frame to prevent it from moving when going up or down slopes, or during sudden stops [C] & [D].
C
• Use chain binders to tighten the chains and then safety tie the chain binder levers to prevent loosening. When transporting the machine, observe the rules, motor vehicle laws and vehicle limit ordinances. Use a transport and towing vehicle of adequate length and capacity.
P–02278
D
Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.
W–2058–0494
P–12016
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