Bobcat Excavators 425 428 6986952 Service Manual 2 08-21416B320092.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS FIRE PREVENTION Maintenance Operation Electrical Hydraulic System Fueling Starting Spark Arrestor Exhaust System Welding And Grinding Fire Extinguishers SERIAL NUMBER LOCATIONS Excavator Serial Number Engine Serial Number DELIVERY REPORT EXCAVATOR IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE EXCAVATOR Procedure UPPERSTRUCTURE SLEW LOCK Operation LIFTING THE EXCAVATOR Procedure OPERATOR CAB (ROPS Description Cab Door Front Window Front Wiper Window Washer Reservoir Right Side Window Heating, Ventilation, and Air Conditioning Duct TRANSPORTING THE EXCAVATOR ON A TRAILER Loading And Unloading Fastening TAILGATE Opening And Closing RIGHT SIDE COVER Opening And Closing SERVICE SCHEDULE Chart AIR CLEANER SERVICE Daily Check Replacing Filter Elements ENGINE COOLING SYSTEM Cleaning Checking Level Removing And Replacing Coolant FUEL SYSTEM Fuel Specifications Biodiesel Blend Fuel Filling The Fuel Tank Fuel Filters Draining The Fuel Tank Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking And Adding Engine Oil Engine Oil Chart Removing And Replacing Oil Filter HYDRAULIC SYSTEM Checking And Adding Fluid Hydraulic Fluid Chart Removing And Replacing The Hydraulic Filter Removing And Replacing The Case Drain Filter Removing And Replacing The Hydraulic Fluid LUBRICATING THE EXCAVATOR Lubrication Locations TRAVEL MOTOR Checking And Adding Oil Removing And Replacing Oil SPARK ARRESTOR MUFFLER Cleaning Procedure ALTERNATOR BELT Belt Adjustment Belt Replacement SEAT BELT Inspection And Maintenance PIVOT PINS Inspection And Maintenance EXCAVATOR STORAGE AND RETURN TO SERVICE Storage Return To Service STOPPING THE ENGINE AND LEAVING THE EXCAVATOR Procedure Emergency Exits MOTION ALARM SYSTEM (IF EQUIPPED) Description Adjusting Switch Position HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic Troubleshooting The Hydraulic Circuit Troubleshooting The Cylinder Circuit Troubleshooting The Swing (Upperstructure Slew) Circuit Troubleshooting The Travel Circuit BOOM CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly ARM CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly BOOM SWING CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly BUCKET CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly BLADE CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly CLAMP CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly MAIN RELIEF VALVE Testing And Adjusting The Main Relief Valve PORT RELIEF VALVES Testing And Adjusting Port Relief Valve Pressure CROSSPORT RELIEF VALVES Testing And Adjusting The Crossport Relief Valves PRESSURE REDUCING VALVE Testing And Adjusting The Pressure Reducing Valve HYDRAULIC CONTROL VALVE Description Removal And Installation Parts Identification Disassembly Right Travel Valve Section Disassembly And Assembly Left Travel Valve Section Disassembly And Assembly Blade Valve Section Disassembly And Assembly Slew Valve Section Disassembly And Assembly Auxiliary Valve Section Disassembly And Assembly Bucket Valve Section Disassembly And Assembly Arm Valve Section Disassembly And Assembly Boom Valve Section Disassembly And Assembly Boom Swing Valve Section Disassembly And Assembly Inlet Section Disassembly And Assembly Assembly HYDRAULIC PUMP Description Torque Adjustment Testing The Piston Pump Testing Auxiliary Hydraulic Flow Removal Installation Coupler Removal And Installation Hydraulic Pump Start Up Parts Identification (Piston Pump) Disassembly Piston Pump Disassembly Piston Pump Assembly Assembly MANIFOLD ASSEMBLY Description Removal And Installation Parts Identification Disassembly And Assembly TRAVEL MOTOR Description Removal And Installation Parts Identification Disassembly Assembly SWIVEL JOINT Description Removal And Installation Parts Identification Disassembly Assembly SWING MOTOR Description Removal And Installation Parts Identification Disassembly Assembly SWING MOTOR DRIVE CARRIER Description Removal And Installation Parts Identification Disassembly Assembly CONTROL PATTERN SELECTOR VALVE Description Removal And Installation Parts Identification Disassembly and Assembly RIGHT CONTROL LEVER (JOYSTICK) Description Testing Handle Removal And Installation Removal And Installation Parts Identification Disassembly Assembly LEFT CONTROL LEVER (JOYSTICK) Description Testing Handle Removal And Installation Removal And Installation Parts Identification Disassembly Assembly TRAVEL CONTROL VALVE Removal and Installation Parts Identification Disassembly And Assembly HYDRAULIC FILTER Description Housing Removal And Installation CASE DRAIN FILTER Description Removal And Installation HYDRAULIC RESERVOIR Description Removal And Installation OIL COOLER Description Removal And Installation DIRECT TO TANK VALVE Description Removal And Installation Parts Identification Disassembly And Assembly NON-PRESSURIZED ACCUMULATOR Description Removal And Installation HYDRAULIC X-CHANGE VALVE Removal And Installation Parts Identification Disassembly Assembly UNDERCARRIAGE BLADE Description Removal And Installation TRACK FRAME COMPONENTS Description Track Lug Height Checking Tension Adjusting Tension Rubber Track Removal And Installation Steel Track Removal And Installation Idler (Front) Removal And Installation Idler (Front) Parts Identification Idler (Front) Disassembly Idler (Front) Assembly Coil Spring Assembly And Cylinder Disassembly And Assembly Roller Removal And Installation Roller Parts Identification Roller Disassembly Roller Assembly Track Guide Removal And Installation Sprocket Removal And Installation Track Damage Identification SWING CIRCLE GEAR Removal And Installation UPPERSTRUCTURE & SWING SECTION UPPERSTRUCTURE Description Removal Installation CANOPY Removal And Installation 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 Glass Removal 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 Installation SEAT AND SEAT MOUNT Seat Mount Removal And Installation Seat Removal And Installation RIGHT CONSOLE Description Console Cover Removal And Installation Console Base Cover Removal And Installation LEFT CONSOLE Description Joystick Console Cover (Bottom) Removal And Installation Joystick Console Cover (Top) Removal And Installation Compression Spring Removal And Installation Compression Spring Disassembly And Assembly Lever Removal And Installation Joystick Console Frame Removal And Installation Joystick Console Frame Disassembly And Installation Left Rear Console Cover Removal And Installation Left Rear Console Frame Removal And Installation Left Rear Console Frame Disassembly And Assembly BLADE CONTROL Removal And Installation Disassembly And Assembly Linkage Removal And Installation Linkage Disassembly And Assembly UPPERSTRUCTURE SLEW LOCK Removal and Installation FLOOR MAT AND FLOOR PANEL Description Removal And Installation BOOM SWING PEDAL Description Removal And Installation Disassembly And Assembly Linkage Removal And Installation TRAVEL LEVER Description Removal And Installation Disassembly And Assembly Adjustment Linkage Removal And Installation FUEL TANK Removal And Installation HORN Removal And Installation SWING FRAME Description Removal And Installation Hose Routing Bushing Removal And Installation Swing Frame Bushing Removal And Installation BOOM Description Removal And Installation ARM Description Removal And Installation Arm To Boom Bushing Removal And Installation Arm To Bucket And Bucket Link Bushing Removal And Installation BUCKET Removal And Installation (Pin-On X-Change) Removal And Installation (Bolt-On X-Change) Removal And Installation (Pin-On Attachment) Bucket Teeth Removal And Installation Bucket Side Cutting Edge Removal And Installation TAILGATE Removal And Installation Latch Removal And Installation X-CHANGE Pin-On Removal And Installation Pin-On Disassembly and Assembly X-CHANGE (HYDRAULIC) Removal And Installation Parts Identification Disassembly Assembly RIGHT SIDE COVER Removal And Installation Latch Removal And Installation COUNTERWEIGHT Description Removal And Installation (Long Arm Counterweight) Removal And Installation (Standard Counterweight) LEFT SIDE COVER Removal And Installation ELECTRICAL SYSTEM AND ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Glossary Of Electrical Symbols Harness Connectors Troubleshooting Description Fuse And Relay Location BATTERY Removal And Installation Servicing Using A Booster Battery (Jump Starting) ALTERNATOR Belt Adjustment Belt Replacement Charging System Inspection Description Tests Alternator Output Test Full Field Test Alternator Regulator Test Alternator Regulator Test With Voltmeter Removal And Installation Parts Identification STARTER Testing Removal And Installation Parts Identification LIGHTS Upperstructure Light Removal And Installation Upperstructure Light Disassembly And Assembly Boom Light Removal And Installation Boom Light Disassembly And Assembly MAGNETIC LOCKOUT SENSOR Testing Left Console Magnetic Lockout Sensor Left Console Magnetic Lockout Sensor Removal And Installation FUEL LEVEL SENDER Removal And Installation Testing DIAGNOSTIC SERVICE CODES Description Service Codes List ENGINE SERVICE ENGINE INFORMATION Description Specifications Torque Values Troubleshooting Removal And Installation Engine Mount Replacement Compression - Checking ENGINE SPEED CONTROL Removal And Installation SPARK ARRESTOR MUFFLER Removal And Installation AIR CLEANER Removal And Installation ENGINE COOLING SYSTEM Radiator Removal And Installation Radiator Disassembly and Assembly Water Pump Removal And Installation Water Pump Disassembly And Assembly Thermostat Housing Removal And Installation Testing The Thermostat LUBRICATION SYSTEM Oil Pan Removal And Installation Oil Pump Removal And Installation Oil Pump Inspection Engine Oil Pressure - Testing FUEL SYSTEM Fuel Camshaft Removal And Installation Fuel Camshaft Governor Disassembly And Assembly Fuel Shutoff Solenoid - Checking Fuel Shutoff Solenoid Removal And Installation Fuel Injection Pump Removal And Installation Timing The Injection Pump Fuel Injector Removal And Installation Fuel Injector Nozzles Pressure - Checking Nozzle Spray Condition Valve Seat Tightness CYLINDER HEAD Glow Plug - Testing Glow Plug Removal And Installation Valve Clearance Adjustment Valve Timing - Checking 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 Valve Tappets Rocker Arm And Shaft - Checking CRANKSHAFT AND PISTONS Piston And Connecting Rod Removal And Installation Piston And Connecting Rod - Servicing Cylinder Bore Checking Connecting Rod Alignment Crankshaft And Bearings Removal And Installation Crankshaft And Bearings - Servicing CAMSHAFT AND TIMING GEARS Timing Gearcase Cover Removal And Installation Timing Gears Backlash - Checking Idler Gear And Shaft Removal And Installation Camshaft - Servicing Idler Gear And Shaft Servicing FLYWHEEL AND HOUSING Flywheel Housing Removal And Installation Hydraulic Pump Coupler Removal And Installation Flywheel Removal And Installation Rear End Plate Removal And Installation HEATER HEATER SYSTEM Description Components 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 Removal And Installation HEATER COIL Removal And Installation BLOWER FAN Removal And Installation HEATER VALVE Removal And Installation SPECIFICATIONS EXCAVATOR SPECIFICATIONS 425 With Standard Arm 425 With Long Arm Option & 428 Performance Controls Engine Hydraulic System Hydraulic Cylinders Hydraulic Cycle Times Electrical Instrumentation Drive System Slew System Undercarriage Crawler Track Design Capacities Fuel Tank Tracks Type Ground Pressure TORQUE SPECIFICATIONS FOR BOLTS 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 Port Seal Fitting HYDRAULIC FLUID SPECIFICATIONS Specifications CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion Chart . 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