A Bobcat 325 is a small compact excavator you'll see trenching, setting lines, or doing detail work where a big Cat or Deere won't fit. People grab the service manual when they're past warranty and need real repair info, not safety stickers. Around my shop that means chasing hydraulic issues, engine work, swing or travel problems, and electrical gremlins that a parts book or operator's manual won't touch.
What this manual helps you do
- Diagnose hydraulic problems, check pressures, and trace leaks in the boom, arm, bucket, and travel circuits on a 325 in the AAC511001-AAC599999 range
- Follow teardown and reassembly steps for cylinders, control valves, drive motors, and swing components on this exact 325 variant
- Trace and troubleshoot wiring using readable diagrams for the 325's starting, charging, lighting, and safety circuits
- Set and verify adjustments on linkages, tracks, controls, and hydraulic settings after repairs so the machine runs straight and digs clean
- Replace major components like pumps, motors, and engine assemblies with the right sequences, test points, and checks for this serial group
Who this is for
This is for a shop mechanic, field tech, small contractor, rental fleet, or owner-operator working on a Bobcat 325 with a serial number between AAC511001 and AAC599999. If you just want basic controls or daily maintenance, you want the operator's handbook instead, not this service manual.
FAQ
Q: Is this a searchable PDF and are the wiring diagrams readable?
A: Yes, these manuals are usually searchable PDFs and the wiring diagrams are laid out so you can zoom in and follow circuits clearly.
Q: How do I know if my machine is covered?
A: Check the serial plate on your 325. If it falls between AAC511001 and AAC599999, this is the right manual.
Q: Is this the right document if I'm doing real repairs, not just greasing and filters?
A: Yes, this is the workshop-level service manual, meant for diagnostics, teardown, and repair work.
Bottom line: If your 325's serial number is in that AAC511001-AAC599999 window and you're doing actual repair work, this is the manual you want. If not, skip it.
📘 Show Index
Table of Contents:
- MAINTENANCE SAFETY
- CONTENTS
- FOREWORD
- FOREWORD
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- Maintenance
- Operation
- Electrical
- Hydraulic System
- Fueling
- Starting
- Spark Arrester Exhaust System
- Welding And Grinding
- Fire Extinguishers
- SERIAL NUMBER LOCATIONS
- Excavator Serial Number
- Engine Serial Number
- DELIVERY REPORT
- BOBCAT EXCAVATOR IDENTIFICATION
- SAFETY & MAINTENANCE
- LIFTING AND BLOCKING THE EXCAVATOR
- UPPERSTRUCTURE SLEW LOCK
- LIFTING THE EXCAVATOR
- OPERATOR CAB (ROPS / TOPS)
- Emergency Exit
- Front Window
- Right Side Windows
- Cab Door
- TRANSPORTING THE EXCAVATOR ON A TRAILER
- Loading And Unloading
- Fastening
- TAILGATE
- Opening And Closing The Tailgate
- Adjusting The Bumper
- Adjusting The Latch
- RIGHT SIDE COVER
- Opening And Closing The Right Side Cover
- Adjusting The Latch
- SERVICE SCHEDULE
- AIR CLEANER SERVICE
- Daily Check
- Replacing The Filters
- CAB FILTERS
- ENGINE COOLING SYSTEM
- Cleaning
- Checking Coolant Level
- Removing And Replacing The Coolant
- FUEL SYSTEM
- Fuel Specifications
- Biodiesel Blend Fuel
- Filling The Fuel Tank
- Removing Water
- Draining The Fuel Tank
- Fuel Filter
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Checking And Adding Engine Oil
- Engine Oil Chart
- Removing And Replacing Oil And Filter
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Hydraulic / Hydrostatic Fluid Chart
- Removing And Replacing The Hydraulic Filters
- Removing And Replacing The Case Drain Filter
- Removing And Replacing The Hydraulic Fluid
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- TRAVEL MOTOR
- Checking And Adding Oil
- Removing And Replacing Oil
- SPARK ARRESTER MUFFLER
- ALTERNATOR BELT
- Belt Adjustment
- Belt Replacement
- SEAT BELT
- Inspection And Maintenance
- MOTION ALARM SYSTEM (IF EQUIPPED)
- Description
- Adjusting Switch Position
- REMOTE START TOOL KIT – MEL1563
- Remote Start Tool – MEL1563
- Service Tool Harness Communicator – MEL1566
- REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
- Description
- Remote Start Tool (Service Tool) – 7003030
- Excavator Service Tool Harness – 6689747
- Computer Service Tool Harness – 6689746
- HYDRAULIC SYSTEM
- HYDRAULIC / HYDROSTATIC SCHEMATICS
- HYDRAULIC SYSTEM INFORMATION
- Glossary Of Hydraulic / Hydrostatic Symbols For Excavators
- Troubleshooting The Hydraulic Circuit
- Troubleshooting The Cylinder Circuit
- Troubleshooting The Swing (Upperstructure Slew) Circuit
- Troubleshooting The Travel Circuit
- CYLINDER (BOOM)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (ARM)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (BOOM SWING)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (BUCKET)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (BLADE)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (CLAMP)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- VALVES (MAIN RELIEF)
- Testing And Adjusting The Main Relief Valves
- VALVES (PORT RELIEF)
- Testing And Adjusting The Port Relief Valves
- VALVES (CROSSPORT RELIEF)
- Testing And Adjusting The Crossport Relief Valves
- VALVE (PRESSURE REDUCING)
- Testing And Adjusting The Pressure Reducing Valve
- HYDRAULIC CONTROL VALVE
- Description
- Removal And Installation
- Control Valve Identification
- Disassembly
- Right Travel Valve Section Disassembly And Assembly
- Boom Swing Valve Section Disassembly And Assembly
- Boom Valve Section Disassembly And Assembly
- Left Travel Valve Section Disassembly And Assembly
- Arm Valve Section Disassembly And Assembly
- Bucket Valve Section Disassembly And Assembly
- Auxiliary Valve Section Disassembly And Assembly
- Boost Valve Section Disassembly And Assembly
- Blade Valve Section Disassembly And Assembly
- Slew Valve Section Disassembly And Assembly
- Assembly
- HYDRAULIC PUMP
- Description
- Torque Adjustment
- Testing The Piston Pump
- Testing The Gear Pump
- Testing Auxiliary Hydraulic Flow
- Removal And Installation
- Coupler Removal And Installation
- Hydraulic Pump Start Up
- Gear Pump Parts Identification
- Piston Pump Parts Identification
- Disassembly
- Gear Pump Disassembly
- Gear Pump Assembly
- Piston Pump Disassembly
- Piston Pump Assembly
- MANIFOLD ASSEMBLY / ACCUMULATOR
- Description
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- MANIFOLD ASSEMBLY
- Parts Identification
- Disassembly
- Assembly
- TRAVEL MOTOR
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- SWIVEL JOINT
- Description
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- SWING MOTOR
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- SWING MOTOR DRIVE CARRIER
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CONTROL PATTERN SELECTOR VALVE
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- RIGHT CONTROL LEVER (JOYSTICK)
- Testing
- Handle Removal And Installation
- Joystick Assembly, Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- LEFT CONTROL LEVER (JOYSTICK)
- Testing
- Handle Removal And Installation
- Joystick Assembly Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC FILTER MOUNT
- HYDRAULIC RESERVOIR
- OIL COOLER
- DIRECT TO TANK VALVE
- Removal And Installation
- Disassembly And Assembly
- BUILD UP VALVE
- Description
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- CASE DRAIN FILTER
- SLEW LOCK VALVE
- Description
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- UNDERCARRIAGE
- BLADE
- TRACKS
- Track Lug Height
- Adjustment
- Rubber Track Removal And Installation
- Steel Track Removal And Installation
- TRACK FRAME
- Disassembly And Assembly
- Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511315 & Below, A9KO11108 & Below And A9K111109 & Below)
- Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above)
- Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 & Above)
- TRACK DAMAGE IDENTIFICATION
- Cutting Of Steel Cords
- Abrasion Of Embedded Metals
- Separation Of Embedded Metals
- Separation Of Embedded Metals Due To Corrosion
- Cuts On The Lug Side Rubber
- Cracks On The Lug Side Rubber Due To Fatigue
- Lug Abrasion
- Cracks And Cuts On The Lug Side Rubber
- Abrasion Of The Track Roller Side
- Cuts On The Edges Of Track Roller Side
- TRACK IDLER
- Parts Identification
- Disassembly
- Assembly
- TRACK ROLLER (AAC513024 & BELOW, A9K013003 & BELOW AND a9K113001 & BELOW)
- Parts Identification
- Disassembly
- Assembly
- SWING CIRCLE GEAR
- Swing Bearing Removal
- Swing Bearing Installation
- UPPERSTRUCTURE AND SWING SECTION
- UPPERSTRUCTURE
- ROPS CANOPY
- CAB
- Removal And Installation
- Door Removal And Installation
- Front Window Removal And Installation
- Right Side Rear Sliding Window Removal And Installation
- Right Side Front Sliding Window Removal And Installation
- Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
- Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
- Glass Removal
- Glass Installation
- SEAT AND SEAT MOUNT (STANDARD)
- SEAT AND SEAT MOUNT (SUSPENSION)
- RIGHT CONSOLE
- Console Cover Removal And Installation
- Console Base Removal And Installation
- LEFT CONSOLE
- Lower Console Cover Removal And Installation
- Upper Console Cover Removal And Installation
- Compression Spring Removal And Installation
- Compression Spring Disassembly And Assembly
- Lock Lever Removal And Installation
- Console Removal And Installation
- Disassembly And Assembly
- Console Switch Removal And Installation
- Console Base Removal And Installation
- ENGINE SPEED CONTROL
- Removal And Installation
- Adjustment
- BLADE CONTROL
- Lever Removal And Installation
- Linkage Removal And Installation
- Linkage Bar Removal And Installation
- Lower Linkage Removal And Installation
- RIGHT PEDAL AND LINKAGE
- Pedal Removal And Installation
- Pedal Disassembly And Assembly
- Linkage Removal And Installation
- TRAVEL CONTROLS
- Removal And Installation
- Disassembly And Assembly
- Adjustment
- FLOOR MAT AND FLOOR PLATE
- Removal And Installation (Canopy Equipped Excavators)
- Removal And Installation (Cab Equipped Excavators)
- FUEL TANK
- HORN
- SWING FRAME
- Boom Swing Bracket Removal And Installation
- Boom Swing Bracket Hose Installation
- Bushing Removal
- Bushing Installation
- BOOM
- ARM
- Removal And Installation
- Arm To Boom Bushing Removal And Installation
- Arm To Bucket And Bucket Link Bushing Removal And Installation
- BUCKET
- Bucket Teeth Removal And Installation
- Bucket Side Cutting Edge Removal And Installation
- CLAMP
- TAILGATE
- Removal And Installation
- Latch Removal And Installation
- X-CHANGE
- Removal And Installation
- Disassembly
- Assembly
- Check Proper Latch Engagement
- UPPERSTRUCTURE SLEW LOCK
- Removal And Installation
- Disassembly And Assembly
- RIGHT SIDE COVER
- QUICK COUPLER (KLAC™ SYSTEM)
- Troubleshooting
- Daily Inspection
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- QUICK COUPLER (LEHNHOFF® SYSTEM)
- Troubleshooting
- Daily Inspection
- Removal (MS03 And MS08)
- Installation (MS03 And MS08)
- Parts Identification (MS03)
- Disassembly And Assembly (MS03)
- Parts Identification (MS08)
- Disassembly (MS08)
- Assembly (MS08)
- ELECTRICAL SYSTEM & ANALYSIS
- ELECTRICAL SCHEMATICS
- ELECTRICAL SYSTEM INFORMATION
- Troubleshooting Chart
- Description
- Fuse And Relay Location
- BATTERY
- Servicing
- Removing And Installing The Battery
- Using A Booster Battery (Jump Starting)
- ALTERNATOR
- Engine Accessory Drive Belt
- Engine Accessory Drive Belt Tensioner Removal And Installation
- Removal And Installation
- Bracket Removal And Installation
- Description
- Tests
- Alternator Output Test
- Full Field Test
- Alternator Regulator Test
- Parts Identification
- Disassembly And Assembly
- Rotor Continuity Test
- Rectifier Continuity (Diode) Test
- STARTER
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection And Repair
- Assembly
- LIGHTS
- Removal And Installation
- Boom Light Removal And Installation
- Boom Light Bulb Replacement
- TWO-SPEED SWITCH
- FUEL LEVEL SENDER
- Removal And Installation
- Testing
- DIAGNOSTICS SERVICE CODE
- DELUXE INSTRUMENT PANEL SETUP
- Passwords
- Password Entry (For Starting And Operating The Machine)
- Changing The Owner or Operator Password
- Password Lockout Feature
- Job Clock
- RPM
- ENGINE SERVICE
- TROUBLESHOOTING
- MUFFLER
- AIR CLEANER
- RADIATOR
- ENGINE COMPONENTS AND TESTING
- Engine Compression Checking
- Glow Plugs Removal And Installation
- Checking The Glow Plug
- Fuel Shut-Off Solenoid Removal And Installation
- Fuel Injection Pump Check
- Fuel Injection Pump Removal And Installation
- Fuel Injection Pump Timing
- Fuel Injector Nozzles Removal And Installation
- Fuel Injector Nozzle Check
- Valve Seat Tightness
- Valve Clearance Adjustment
- ENGINE
- ENGINE FLYWHEEL
- Flywheel Removal And Installation
- Hydraulic Pump Coupler
- Flywheel Ring Gear
- RECONDITIONING THE ENGINE
- Cylinder Head Removal And Installation
- Cylinder Head Disassembly And Assembly
- Cylinder Head Servicing
- Cylinder Head Top Clearance
- Valve Guide Checking
- Reconditioning The Valve And Valve Seat
- Valve Spring
- Rocker Arm And Shaft Checking
- Timing Gearcase Cover Removal And Installation
- Idler Gear And Camshaft Removal And Installation
- Camshaft Servicing
- Idler Gear And Shaft Servicing
- Timing Gears Checking Backlash
- Fuel Camshaft Removal And Installation
- Fuel Camshaft Governor
- Crankshaft Gear Removal And Installation
- Oil Pump Removal And Installation
- Oil Pump Service
- Checking Engine Oil Pressure
- Valve Tappets
- Piston And Connecting Rod Removal And Installation
- Piston And Connecting Rod Servicing
- Connecting Rod Alignment
- Crankshaft And Bearings Removal And Installation
- Crankshaft And Bearings, Servicing
- Cylinder Bore, Checking
- Water Pump Removal And Installation
- Water Pump Disassembly And Assembly
- HEATING, VENTILATION & AIR CONDITIONING
- HEATER SYSTEM
- REGULAR MAINTENANCE
- Filter Element Removal And Installation
- Heater Coil
- TROUBLESHOOTING
- Blower Motor Does Not Operate
- Blower Motor Operates Normally, But Air Flow Is Insufficient
- Electrical System
- HEATER UNIT
- HEATER COIL
- BLOWER FAN
- Removal And Installation
- Disassembly And Assembly
- Resistor Removal And Installation
- HEATER VALVE
- SPECIFICATIONS
- SPECIFICATIONS
- 325, 328 Excavator Machine Dimensions
- 325 Excavator Machine Dimensions
- 325 With Long Arm Option And 328 Excavator Machine Dimensions
- Performance
- Controls
- Engine
- Hydraulic System
- Hydraulic Cylinders
- Hydraulic Cycle Times
- Drive System
- Undercarriage
- Track
- Electrical
- ENGINE SPECIFICATIONS
- Fuel Injection Nozzles
- Fuel Injection Pump
- Cylinder Head
- Valves
- Valve Springs
- Valve Timing
- Rocker Arms
- Camshaft
- Tappet
- Cylinders
- Piston Rings
- Pistons
- Connecting Rods
- Oil Pump
- Crankshaft
- Timing Gear
- Thermostat
- Engine Bolt Torque
- Crankshaft Re-Grind Data
- TORQUE SPECIFICATIONS
- Torque for General SAE Bolts
- Torque For General Metric Bolts
- HYDRAULIC CONNECTION SPECIFICATIONS
- O-ring Face Seal Connection
- Straight Thread O-ring Fitting
- Tubelines And Hoses
- Flare Fitting
- O-ring Flare Fitting
- Port Seal Fitting
- HYDRAULIC FLUID SPECIFICATIONS
- FUEL, COOLANT AND LUBRICANTS
- CONVERSIONS
- Decimal And Millimeter Equivalents
- U.S. To Metric Conversion
- ALPHABETICAL INDEX
- SERVICE MANUAL REVISION
- Revision No: 325 / 328 – 1
- Revision No: 325 / 328 – 2
- Revision No: 325, 328 – 3
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