Bobcat 425, 428 Compact Excavator Service Manual 6986952 (02-16) – PDF DOWNLOAD
FILE DETAILS:
Bobcat 425, 428 Compact Excavator Service Manual 6986952 (02-16) – PDF DOWNLOAD
Language : English
Pages : 712
Downloadable : Yes
File Type : PDF
Size:20.4 MB
DESCRIPTION:
Bobcat 425, 428 Compact Excavator Service Manual 6986952 (02-16) – PDF DOWNLOAD
425 S/N AACJ11001 & Above
425 S/N A9K311001 & Above
428 S/N A9K411001 & Above
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
TABLE OF CONTENTS:
Bobcat 425, 428 Compact Excavator Service Manual 6986952 (02-16) – PDF DOWNLOAD
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
UPPERSTRUCTURE SLEW LOCK 23
Operation 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS / TOPS) 27
Description 27
Cab Door 27
Front Window 28
Front Wiper 29
Window Washer Reservoir 30
Right Side Window 30
Right Front Window 31
Heating, Ventilation, And Air Conditioning Duct 31
TRANSPORTING THE EXCAVATOR ON A TRAILER 33
Loading And Unloading 33
Fastening 33
TAILGATE 35
Opening And Closing 35
RIGHT SIDE COVER 37
Opening And Closing 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Daily Check 41
Replacing Filter Elements 42
ENGINE COOLING SYSTEM 43
Cleaning 43
Checking Level 44
Removing And Replacing Coolant 45
FUEL SYSTEM 47
Fuel Specifications 47
Biodiesel Blend Fuel 47
Filling The Fuel Tank 48
Fuel Filters 49
Draining The Fuel Tank 51
Removing Air From The Fuel System 51
ENGINE LUBRICATION SYSTEM 53
Checking And Adding Engine Oil 53
Engine Oil Chart 53
Removing And Replacing Oil Filter 54
HYDRAULIC SYSTEM 55
Checking And Adding Fluid 55
Hydraulic Fluid Chart 56
Removing And Replacing The Hydraulic Filter 56
Removing And Replacing The Case Drain Filter 57
Removing And Replacing The Hydraulic Fluid 58
LUBRICATING THE EXCAVATOR 59
Lubrication Locations 59
TRAVEL MOTOR 63
Checking And Adding Oil 63
Removing And Replacing Oil 63
SPARK ARRESTER MUFFLER 65
Cleaning Procedure 65
ALTERNATOR BELT 67
Belt Adjustment 67
Belt Replacement 67
SEAT BELT 69
Inspection And Maintenance 69
MOTION ALARM SYSTEM (IF EQUIPPED) 71
Description 71
Inspecting 71
Adjusting Switch Position 71
EXCAVATOR STORAGE AND RETURN TO SERVICE 73
Storage 73
Return To Service 73
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 75
Procedure 75
Emergency Exits 76
MOTION ALARM SYSTEM (IF EQUIPPED) 77
Description 77
Inspecting 77
Adjusting Switch Position 77
HYDRAULIC SYSTEM 79
HYDRAULIC/HYDROSTATIC SCHEMATICS 83
HYDRAULIC SYSTEM INFORMATION 85
Glossary Of Hydraulic / Hydrostatic Symbols 85
Troubleshooting The Hydraulic Circuit 89
Troubleshooting The Cylinder Circuit 90
Troubleshooting The Swing (Upperstructure Slew) Circuit 91
Troubleshooting The Travel Circuit 92
CYLINDER (BOOM) 93
Testing 93
Removal And Installation 96
Parts Identification 99
Disassembly 100
Assembly 102
CYLINDER (ARM) 105
Testing 105
Removal And Installation 107
Parts Identification 109
Disassembly 110
Assembly 112
CYLINDER (BOOM SWING) 115
Testing 115
Removal And Installation 117
Parts Identification 118
Disassembly 119
Assembly 121
CYLINDER (BUCKET) 125
Testing 125
Removal And Installation 127
Parts Identification 128
Disassembly 129
Assembly 131
CYLINDER (BLADE) 135
Testing 135
Removal And Installation 137
Parts Identification 138
Disassembly 139
Assembly 141
VALVE (MAIN RELIEF) 145
Testing And Adjusting The Main Relief Valve 145
VALVE (PORT RELIEF) 149
Testing And Adjusting Port Relief Valve Pressure 149
VALVE (CROSSPORT RELIEF) 151
Testing And Adjusting The Crossport Relief Valves 151
425 With Standard Arm 153
425, 428 With Long Arm 153
VALVE (PRESSURE REDUCING) 155
Testing And Adjusting The Pressure Reducing Valve 155
HYDRAULIC CONTROL VALVE 157
Description 157
Removal And Installation 158
Parts Identification 161
Disassembly 162
Right Travel Valve Section Disassembly And Assembly 164
Left Travel Valve Section Disassembly And Assembly 168
Blade Valve Section Disassembly And Assembly 172
Slew Valve Section Disassembly And Assembly 181
Auxiliary Valve Section Disassembly And Assembly 186
Bucket Valve Section Disassembly And Assembly 191
Arm Valve Section Disassembly And Assembly 196
Boom Valve Section Disassembly And Assembly 201
Boom Swing Valve Section Disassembly And Assembly 206
Inlet Section Disassembly And Assembly 211
Assembly 216
HYDRAULIC PUMP 223
Description 223
Torque Adjustment 224
Testing The Piston Pump 225
Testing Auxiliary Hydraulic Flow 226
Removal 227
Installation 228
Coupler Removal And Installation 229
Hydraulic Pump Start Up 230
Parts Identification (Piston Pump) 231
Disassembly 232
Piston Pump Disassembly 233
Piston Pump Assembly 239
Assembly 245
MANIFOLD ASSEMBLY / ACCUMULATOR 247
Description 247
Removal And Installation 247
Parts Identification 249
Disassembly And Assembly 250
TRAVEL MOTOR 259
Description 259
Removal And Installation 259
Parts Identification 260
Disassembly 261
Assembly 271
SWIVEL JOINT 283
Description 283
Removal And Installation 283
Parts Identification 285
Disassembly 286
Assembly 287
SWING MOTOR 291
Description 291
Removal And Installation 291
Parts Identification 293
Disassembly 294
Assembly 299
SWING MOTOR (DRIVE CARRIER) 305
Description 305
Removal And Installation 305
Parts Identification 306
Disassembly 307
Assembly 309
CONTROL PATTERN SELECTOR VALVE 313
Description 313
Removal And Installation 313
Parts Identification 314
Disassembly And Assembly 315
RIGHT CONTROL LEVER (JOYSTICK) 317
Description 317
Testing 317
Handle Removal And Installation 319
Removal And Installation 323
Parts Identification 326
Disassembly 327
Assembly 332
LEFT CONTROL LEVER (JOYSTICK) 337
Description 337
Testing 337
Handle Removal And Installation 339
Removal And Installation 342
Parts Identification 344
Disassembly 345
Assembly 350
TRAVEL CONTROL VALVE 355
Removal And Installation 355
Parts Identification 356
Disassembly And Assembly 357
HYDRAULIC FILTER 361
Description 361
Housing Removal And Installation 361
CASE DRAIN FILTER 363
Description 363
Removal And Installation 363
HYDRAULIC RESERVOIR 365
Description 365
Removal And Installation 365
OIL COOLER 367
Description 367
Removal And Installation 367
DIRECT TO TANK VALVE 369
Description 369
Removal And Installation 369
Parts Identification 370
Disassembly And Assembly 371
NON-PRESSURIZED ACCUMULATOR 373
Description 373
Removal And Installation 373
HYDRAULIC X-CHANGE VALVE 375
Removal And Installation 375
Parts Identification 377
Disassembly 378
Assembly 386
CASE DRAIN FILTER MOUNT 395
Removal And Installation 395
UNDERCARRIAGE 397
BLADE 399
Description 399
Removal And Installation 399
TRACK FRAME COMPONENTS 401
Description 401
Track Lug Height 401
Checking Tension 402
Adjusting Tension 403
Rubber Track Removal And Installation 405
Steel Track Removal And Installation 408
Idler (Front) Removal And Installation 411
Idler (Front) Parts Identification 412
Idler (Front) Disassembly 413
Idler (Front) Assembly 415
Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11223 & Below, A9K311309 & Below And A9K411308 & Below) 418
Coil Spring Cylinder Parts Identification (AACS11224 & Above, A9K311310 & Above And A9K411309 & Above) 419
Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11224 & Above, A9K311310 & Above And A9K411309 & Above) 420
Roller Removal And Installation (AACJ13005 & Below, A9K313003 & Below And A9K413005 & Below) 421
Roller Removal And Installation (AACJ13006 & Above, A9K313004 & Above And A9K413006 & Above) 422
Roller Parts Identification (AACJ13005 & Below, A9K313003 & Below And A9K413005 & Below) 423
Roller Disassembly (AACJ13005 & Below, A9K313003 & Below And A9K413005 & Below) 424
Roller Assembly (AACJ13005 & Below, A9K313003 & Below And A9K413005 & Below) 426
Track Guide Removal And Installation 428
Sprocket Removal And Installation 428
Track Damage Identification 429
SWING CIRCLE GEAR 439
Removal And Installation 439
UPPERSTRUCTURE AND SWING SECTION 441
UPPERSTRUCTURE 445
Description 445
Removal 445
Installation 447
CANOPY 449
Removal And Installation 449
CAB 453
Removal And Installation 453
Door Removal And Installation 457
Front Window Removal And Installation 458
Right Side Rear Sliding Window Removal And Installation 461
Right Side Front Sliding Window Removal And Installation 461
Glass Removal 462
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 463
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 463
Glass Installation 464
SEAT AND SEAT MOUNT 471
Seat Mount Removal And Installation 471
Seat Removal And Installation 472
RIGHT CONSOLE 473
Description 473
Console Cover Removal And Installation 473
Console Base Cover Removal And Installation 474
LEFT CONSOLE 477
Description 477
Joystick Console Cover (Bottom) Removal And Installation 477
Joystick Console Cover (Top) Removal And Installation 477
Compression Spring Removal And Installation 478
Compression Spring Disassembly And Assembly 479
Lever Removal And Installation 481
Joystick Console Frame Removal And Installation 483
Joystick Console Frame Disassembly And Installation 484
Left Rear Console Cover Removal And Installation 484
Left Rear Console Frame Removal And Installation 485
Left Rear Console Frame Disassembly And Assembly 487
BLADE CONTROL 489
Removal And Installation 489
Disassembly And Assembly 489
Linkage Removal And Installation 490
Linkage Disassembly And Assembly 492
UPPERSTRUCTURE SLEW LOCK 493
Removal And Installation 493
FLOOR MAT AND FLOOR PANEL 495
Description 495
Removal And Installation 495
BOOM SWING PEDAL 499
Description 499
Removal And Installation 499
Disassembly And Assembly 499
Linkage Removal And Installation 501
TRAVEL LEVER / PEDALS 503
Description 503
Removal And Installation 503
Disassembly And Assembly 504
Adjustment 506
Linkage Removal And Installation 508
FUEL TANK 509
Removal And Installation 509
HORN 513
Removal And Installation 513
SWING FRAME 515
Description 515
Removal And Installation 515
Hose Routing 519
Bushing Removal And Installation 520
Swing Frame Bushing Removal And Installation 520
BOOM 523
Description 523
Removal And Installation 523
ARM 525
Description 525
Removal And Installation 525
Arm To Boom Bushing Removal And Installation 525
Arm To Bucket And Bucket Link Bushing Removal And Installation 526
BUCKET 527
Removal And Installation (Pin-On X-Change) 527
Removal And Installation (Bolt-On X-Change) 532
Removal And Installation (Pin-On Attachment) 538
Bucket Teeth Removal And Installation 539
Bucket Side Cutting Edge Removal And Installation 540
CLAMP 541
Removal And Installation 541
TAILGATE 543
Removal And Installation 543
Latch Removal And Installation 543
X-CHANGE 545
Pin-On Removal And Installation 545
Pin-On Disassembly And Assembly 546
RIGHT SIDE COVER 547
Removal And Installation 547
Latch Removal And Installation 547
COUNTERWEIGHT 549
Description 549
Removal And Installation (Long Arm Counterweight) 549
Removal And Installation (Standard Counterweight) 550
ELECTRICAL SYSTEM & ANALYSIS 551
ELECTRICAL SCHEMATICS 553
ELECTRICAL SYSTEM INFORMATION 555
Glossary Of Electrical Symbols 555
Harness Connectors 558
Troubleshooting 560
Description 561
Fuse And Relay Location / Identification 561
BATTERY 563
Removal And Installation 563
Servicing 564
Using A Booster Battery (Jump Starting) 565
ALTERNATOR 567
Belt Adjustment 567
Belt Replacement 567
Charging System Inspection 568
Description 569
Tests 569
Alternator Output Test 570
Full Field Test 570
Alternator Regulator Test 571
Alternator Regulator Test With Voltmeter 571
Removal And Installation 572
Parts Identification 573
STARTER 575
Testing 575
Removal And Installation 575
Parts Identification 576
LIGHTS 577
Removal And Installation 577
Boom Light Removal And Installation 578
Boom Light Bulb Replacement 578
MAGNETIC LOCKOUT SENSOR 579
Testing Left Console Magnetic Lockout Sensor 579
Left Console Magnetic Lockout Sensor Removal And Installation 580
FUEL LEVEL SENDER 583
Removal And Installation 583
Testing 584
DIAGNOSTIC SERVICE CODES 585
Description 585
Service Codes List 586
ENGINE SERVICE 587
ENGINE INFORMATION 589
Description 589
Specifications 590
Torque Values 594
Troubleshooting 595
Removal And Installation 596
Engine Mount Replacement 600
Compression – Checking 601
ENGINE SPEED CONTROL 603
Removal And Installation 603
SPARK ARRESTER MUFFLER 605
Removal And Installation 605
AIR CLEANER 607
Removal And Installation 607
ENGINE COOLING SYSTEM 609
Radiator Removal And Installation 609
Radiator Disassembly And Assembly 611
Water Pump Removal And Installation 611
Water Pump Disassembly And Assembly 612
Thermostat Housing Removal And Installation 612
Testing The Thermostat 613
LUBRICATION SYSTEM 615
Oil Pan Removal And Installation 615
Oil Pump Removal And Installation 615
Oil Pump Inspection 616
Engine Oil Pressure – Testing 617
FUEL SYSTEM 619
Fuel Camshaft Removal And Installation 619
Fuel Camshaft Governor Disassembly And Assembly 619
Fuel Shutoff Solenoid – Checking 620
Fuel Shutoff Solenoid Removal And Installation 621
Fuel Injection Pump Removal And Installation 622
Timing The Injection Pump 624
Fuel Injector Removal And Installation 626
Fuel Injector Nozzles Pressure – Checking 628
Nozzle Spray Condition 629
Valve Seat Tightness 629
CYLINDER HEAD 631
Glow Plug – Testing 631
Glow Plug Removal And Installation 632
Valve Clearance Adjustment 632
Valve Timing – Checking 633
Cylinder Head Removal And Installation 634
Cylinder Head Disassembly And Assembly 636
Cylinder Head – Servicing 636
Cylinder Head Top Clearance 637
Valve Guide – Checking 637
Reconditioning The Valve And Valve Seat 638
Valve Spring 640
Valve Tappets 641
Rocker Arm And Shaft – Checking 641
CRANKSHAFT AND PISTONS 643
Piston And Connecting Rod Removal And Installation 643
Piston And Connecting Rod – Servicing 645
Cylinder Bore Checking 647
Connecting Rod Alignment 647
Crankshaft And Bearings Removal And Installation 648
Crankshaft And Bearings – Servicing 649
CAMSHAFT AND TIMING GEARS 655
Timing Gearcase Cover Removal And Installation 655
Timing Gears Backlash – Checking 657
Idler Gear And Shaft Removal And Installation 657
Camshaft – Servicing 658
Idler Gear And Shaft Servicing 660
FLYWHEEL AND HOUSING 661
Flywheel Housing Removal And Installation 661
Hydraulic Pump Coupler Removal And Installation 662
Flywheel Removal And Installation 663
Rear End Plate Removal And Installation 663
HEATING, VENTILATION & AIR CONDITIONING 665
HEATER SYSTEM 667
Description 667
Components 667
REGULAR MAINTENANCE 669
Filter Element Removal And Installation 669
Heater Coil 670
TROUBLESHOOTING 671
Blower Motor Does Not Operate 671
Blower Motor Operates Normally, But Air Flow Is Insufficient 671
Electrical System 672
HEATER UNIT 677
Removal And Installation 677
HEATER COIL 679
Removal And Installation 679
BLOWER FAN 681
Removal And Installation 681
HEATER VALVE 683
Removal And Installation 683
SPECIFICATIONS 685
EXCAVATOR SPECIFICATIONS 687
425 With Standard Arm 687
425, 428 With Long Arm Option 689
Performance 691
Controls 691
Engine 691
Hydraulic System 692
Hydraulic Cylinders 692
Hydraulic Cycle Times 692
Electrical 692
Instrumentation 692
Drive System 693
Slew System 693
Undercarriage 693
Crawler Track Design 693
Capacities 693
Fuel Tank 693
Tracks 693
Type 693
Ground Pressure 693
TORQUE SPECIFICATIONS FOR BOLTS 695
Torque For General SAE Bolts 695
Torque For General Metric Bolts 696
HYDRAULIC CONNECTION SPECIFICATIONS 697
O-ring Face Seal Connection 697
Straight Thread O-ring Fitting 697
Tubelines And Hoses 697
Flare Fitting 698
Port Seal Fitting 699
HYDRAULIC FLUID SPECIFICATIONS 701
Specifications 701
CONVERSIONS 703
Decimal And Millimeter Equivalents 703
U S To Metric Conversion Chart 703
SERVICE TOOLS REQUIRED 705
Remote Start Tools 705
Hydraulic Tools 706
Engine Tools 708
HVAC Tools 710
ALPHABETICAL INDEX 711
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
s.m
