BOBCAT 425 COMPACT EXCAVATOR Service Repair Manual SN A9K311001 & Above

Service Manual 425, 428 Compact Excavator 425 S/N AACJ11001 & Above 425 S/N A9K311001 & Above 428 S/N A9K411001 & Above

6986952 (2-08)

Printed in U.S.A.

© Bobcat Company 2008

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

B-10731A

CORRECT

CORRECT

B-19964

B-19959

Never service the Bobcat Compact Excavator without instructions.

Use the correct procedure to lift and support the excavator.

WRONG

WRONG

WRONG

B-19965

B-19960

B-19966

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Vent exhaust to outside when engine must be run for service.

Exhaust system must be tightly sealed. Exhaust fumes can kill without warning.

WRONG

WRONG

B-19962

B-19958

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust machine with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking, or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protections approved for type of welding.

Keep tailgate closed except for service. Close and latch tailgate before operating the excavator.

Cleaning and maintenance are required daily.

Always lower the bucket and blade to the ground before doing any maintenance.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

B-19798

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW28-0805

ALPHABETICAL INDEX AIR CLEANER ........................................................ 60-01 AIR CLEANER SERVICE ....................................... 10-01 ALTERNATOR ....................................................... 50-01 ALTERNATOR BELT............................................... 10-01 ARM ........................................................................ 40-01 ARM CYLINDER .................................................... 20-01 BATTERY................................................................ 50-01 BLADE ................................................................... 30-01 BLADE CONTROL.................................................. 40-01 BLADE CYLINDER ................................................. 20-01 BLOWER FAN ........................................................ 70-01 BOOM ..................................................................... 40-01 BOOM CYLINDER .................................................. 20-01 BOOM SWING CYLINDER..................................... 20-01 BOOM SWING PEDAL ........................................... 40-01 BUCKET ................................................................. 40-01 BUCKET CYLINDER .............................................. 20-01 CAB......................................................................... 40-01 CAMSHAFT AND TIMING GEARS......................... 60-01 CANOPY ................................................................. 40-01 CASE DRAIN FILTER ............................................ 20-01 CLAMP CYLINDER ................................................ 20-01 CONVERSIONS ...............................................SPEC-01 CONTROL PATTERN SELECTOR VALVE ............20-01 COUNTERWEIGHT ............................................... 40-01 CRANKSHAFT AND PISTONS .............................. 60-01 CROSSPORT RELIEF VALVES ............................ 20-01 CYLINDER HEAD ................................................... 60-01

HEATER COIL .........................................................70-01 HEATER SYSTEM...................................................70-01 HEATER UNIT .........................................................70-01 HEATER VALVE ......................................................70-01 HORN .....................................................................40-01 HYDRAULIC CONTROL VALVE .............................20-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01 HYDRAULIC FILTER...............................................20-01 HYDRAULIC PUMP ................................................20-01 HYDRAULIC RESERVOIR......................................20-01 HYDRAULIC SYSTEM ............................................10-01 HYDRAULIC SYSTEM INFORMATION .................20-01 HYDRAULIC X-CHANGE VALVE............................20-01 LEFT CONTROL LEVER (JOYSTICK) ...................20-01 LEFT CONSOLE .....................................................40-01 LEFT SIDE COVER.................................................40-01 LIFTING AND BLOCKING THE EXCAVATOR ........10-01 LIFTING THE EXCAVATOR ....................................10-01 LIGHTS....................................................................50-01 LUBRICATION SYSTEM .........................................60-01 LUBRICATING THE EXCAVATOR ..........................10-01 MAGNETIC LOCKOUT SENSOR ...........................50-01 MAIN RELIEF VALVE ..............................................20-01 MANIFOLD ASSEMBLY / ACCUMULATOR ...........20-01 MOTION ALARM SYSTEM (IF EQUIPPED) ...........20-01 NON-PRESSURIZED ACCUMULATOR .................20-01

DIAGNOSTICS SERVICE CODES......................... 50-01 DIRECT TO TANK VALVE ...................................... 20-01

OIL COOLER...........................................................20-01 OPERATOR CAB (ROPS/TOPS) ............................10-01

ELECTRICAL SYSTEM INFORMATION ................ 50-01 ENGINE COOLING SYSTEM ...................... 10-01, 60-01 ENGINE INFORMATION ........................................ 60-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPEED CONTROL .................................. 60-01 EXCAVATOR SPECIFICATIONS .......................SPEC-01 EXCAVATOR STORAGE AND RETURN TO SERVICE ............................................................. 10-01

PIVOT PINS ............................................................10-01 PORT RELIEF VALVES...........................................20-01 PRESSURE REDUCING VALVE.............................20-01 REGULAR MAINTENANCE ...................................70-01 RIGHT CONTROL LEVER (JOYSTICK) .................20-01 RIGHT CONSOLE ...................................................40-01 RIGHT SIDE COVER ..................................10-01, 40-01

FLOOR MAT AND FLOOR PANELS ...................... 40-01 FLYWHEEL AND HOUSING................................... 60-01 FUEL LEVEL SENDER........................................... 50-01 FUEL SYSTEM ............................................ 10-01, 60-01 FUEL TANK............................................................. 40-01

Continued On Next Page 425, 428 Service Manual

ALPHABETICAL INDEX (CONT’D) SEAT AND SEAT MOUNT...................................40-01 SEAT BELT .............................................................10-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTOR MUFFLER ...................10-01, 60-01 STARTER ............................................................... 50-01 STOPPING THE ENGINE AND LEAVING THE EXCAVATOR ................................................10-01 SWING CIRCLE GEAR ...........................................30-01 SWING FRAME .......................................................40-01 SWING MOTOR .....................................................20-01 SWING MOTOR DRIVE CARRIER..........................20-01 SWIVEL JOINT .......................................................20-01 TAILGATE .....................................................10-01, 40-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01 TRACK FRAME COMPONENTS ............................30-01 TRANSPORTING THE EXCAVATOR ON A TRAILER.....................................................10-01 TRAVEL LEVER / PEDALS .....................................40-01 TRAVEL MOTOR......................................... 10-01, 20-01 TROUBLESHOOTING.............................................70-01 UPPERSTRUCTURE ..............................................40-01 UPPERSTRUCTURE SLEW LOCK .............10-01, 40-01 X-CHANGE..............................................................40-01 X-CHANGE (HYDRAULIC)......................................40-01

425, 428 Service Manual

SAFETY AND MAINTENANCE

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

HYDRAULIC SYSTEM

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

UNDERCARRIAGE

EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 UNDERCARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01

UPPERSTRUCTURE & SWING SECTION ELECTRICAL SYSTEM AND ANALYSIS

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

HEATER

SPECIFICATIONS

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425, 428 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/ FOPS 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 Bobcat 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, 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 foot pedals lock and control lever locks are in working order.

14. Check the condition of the battery and cables.

7. Inspect the air cleaner for damage or leaks. Check the condition of the element.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

oil

or

8. Check the electrical charging system.

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SAFETY INSTRUCTIONS

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

•

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 machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine.

Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

•

Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

•

An 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 AEM Safety Manual delivered with the machine gives general safety information.

•

The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

•

The Compact Excavator Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com.

This course is intended to provide rules and practices of correct operation of the Bobcat excavator. The course is available in English and Spanish versions.

•

Service Safety Training Courses are available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com. They provide information for safe and correct service procedures.

•

The Bobcat compact excavator Safety Video is available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com.

WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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.

Untrained operators and failure to follow instructions can cause injury or death.

W-2003-0903

WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

W-2044-1285

IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine.

I-2019-0284

SI EXC-1007 SM

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425, 428 Service Manual

SAFETY INSTRUCTIONS (CONT’D) The dealer and owner / operator review the recommended uses of the product when delivered. If the owner / operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.

Cutting or drilling concrete containing sand or rock containing quartz may result in exposure to silica dust.

Do not exceed Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other job site Rules and Regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer.

Call Before You Dig Dial 811 (USA Only) 1-888-258-0808 (USA & Canada) When you call, you will be directed to a location in your state / province, or city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.).

SI EXC-1007 SM

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425, 428 Service Manual

Hydraulic System

FIRE PREVENTION

Check hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Hydraulic tubes and hoses must be properly routed and have adequate support and secure clamps.

Tighten or replace any parts that show leakage.

Maintenance

Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Fueling

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a machine near open flames or sparks. Fill the fuel tank outdoors.

The operator’s area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

Starting Do not use ether or starting fluids on any engine that has glow plugs. These starting aids can cause explosion and injure you or bystanders.

All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.

Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

Operation Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

Spark Arrestor Exhaust System The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

Electrical

Check the spark arrestor exhaust system regularly to make sure it is maintained and working properly. Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed.

Battery gas can explode and cause serious injury. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump staring. Do not jump start or charge a frozen or damaged battery. Keep any open flames or sparks away from batteries. Do not smoke in battery charging area.

SI EXC-1007 SM

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425, 428 Service Manual

FIRE PREVENTION (CONT’D) Welding And Grinding Always clean the machine and attachment, disconnect the battery, and disconnect the wiring from the Bobcat controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding.

Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts.

Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as hoods, fenders or covers can be flammable or explosive.

Repair such components in a well ventilated area away from open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits are located and how to use them. Inspect the fire extinguisher and service the fire extinguisher regularly.

Obey the recommendations on the instructions plate.

SI EXC-1007 SM VIII

425, 428 Service Manual

SERIAL NUMBER LOCATIONS

Engine Serial Number

Always use the serial number of the excavator 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.

Figure 2

1 Excavator Serial Number Figure 1

1

P-70501A

The engine serial number (Item 1) is located on the engine in the location shown [Figure 2].

1

P-69863

The excavator serial number plate (Item 1) is located on the frame of the machine in the location shown [Figure 1].

Explanation of Excavator Serial Number: XXXX XXXXX Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination 1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

2. The five digit Production Sequence Number identifies the order which the excavator is produced.

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425, 428 Service Manual

DELIVERY REPORT Figure 3

B-16315

The delivery report must be filled out by the dealer and signed by the owner or operator when the Bobcat Excavator is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 3].

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425, 428 Service Manual

EXCAVATOR IDENTIFICATION

OPERATOR HANDBOOK

ARM CYLINDER

AUXILIARY QUICK COUPLERS

OPERATOR SEAT With SEAT BELT

LIFT POINT

CONTROL LEVERS (JOYSTICKS)

BUCKET CYLINDER BOOM ARM

BUCKET LINK

BOOM CYLINDER X-CHANGE® TIE DOWN / LIFT POINTS

BLADE CYLINDER

†BUCKET ●CANOPY/CAB (ROPS/TOPS)

RIGHT SIDE COVER REAR DOOR BLADE

COUNTERWEIGHTS

TRACK FRAME TIE DOWN

UPPERSTRUCTURE B-23467 B-23469

TRACK † ●

BUCKET - Several different buckets and other attachments are available from the Bobcat Excavator.

ROPS, TOPS - (Roll Over Protective Structure / Tip Over Protective Structure) as standard equipment. The ROPS/ TOPS meets SAE J1040, ISO 3471 and ISO 12117.

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SAFETY AND MAINTENANCE

SAFETY AND MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . .

10-70-1 10-70-2 10-70-1 10-70-3

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . .

Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . .

Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing And Replacing Oil Filter . . . . . . . . . . . . . . . . . .

10-90-1 10-90-1 10-90-1 10-90-2

EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . 10-170-1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open the right side cover. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..............................................

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing And Replacing The Case Drain Filter . . . . . . .

Removing And Replacing The Hydraulic Filter . . . . . . . .

Removing And Replacing The Hydraulic Fluid . . . . . . . .

10-80-1 10-80-5 10-80-2 10-80-3 10-80-1 10-80-5

10-100-1 10-100-1 10-100-1 10-100-2 10-100-2 10-100-3

LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1 LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . 10-110-1 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 Continued On Next Page

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SAFETY AND MAINTENANCE (CONT’D) OPERATOR CAB (ROPS / TOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2 Front Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3 Heating, Ventilation, and Air Conditioning Duct . . . . . . . . . . . . . . . 10-20-5 Right Side Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4 Window Washer Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 STOPPING THE ENGINE AND LEAVING THE EXCAVATOR . . . . . 10-180-1 Emergency Exits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 TRANSPORTING THE EXCAVATOR ON A TRAILER . . . . . . . . . . . . 10-30-1 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1 Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1

10-02

425, 428 Service Manual

LIFTING AND BLOCKING THE EXCAVATOR Procedure Always park the machine on a level surface.

Figure 10-10-1

P-69958A

Raise one side of the machine (approximately 4 in.) using the boom and arm as shown in [Figure 10-10-1].

Raise the blade fully and install jackstands under the blade and the track frame. Lower the boom until all machine weight is on the jackstands.

Stop the engine.

WARNING Put jackstands under the blade and rear corners of the undercarriage before working under the machine.

Failure to block up the machine may allow it to move or fall and result in injury or death.

W-2218-1195

WARNING AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

W-2142-0903

10-10-1

425, 428 Service Manual

UPPERSTRUCTURE SLEW LOCK Operation Figure 10-11-1

1 2

P-69867

Push down on the front (Item 1) [Figure 10-11-1] of the foot pedal to engage the upperstructure swing lock.

Push down on the rear (Item 2) [Figure 10-11-1] to disengage the upperstructure slew lock.

NOTE: Upperstructure must be in the straight forward or straight rearward position for upperstructure to lock.

10-11-1

425, 428 Service Manual

LIFTING THE EXCAVATOR

Figure 10-12-2

Procedure Figure 10-12-1 2 1

2

1

P-69913A

P-69906

Fully extend the cylinders of the bucket, arm, and boom so that the excavator is in the position as shown [Figure 10-12-1].

Raise the blade all the way.

Fasten chains to the ends of the blade (Item 1) [Figure 10-12-1] and [Figure 10-12-2] and up to a lifting fixture above the canopy/cab. The lifting fixture must extend over the sides of the canopy/cab to prevent the chains from hitting the ROPS/TOPS. Install a 1 in. (25 mm) bolt and nut (Grade 5 or 8) through the holes at the boom (Item 2) [Figure 10-12-1] and [Figure 10-12-2]. Fasten a chain from the bolt to the lift fixture.

Put all the control levers in neutral.

WARNING •

• • •

AVOID INJURY OR DEATH Use a lifting fixture with sufficient capacity for the weight of the excavator plus any added attachments.

Maintain center of gravity and balance when lifting.

Do not swing boom or upperstructure. Engage the upperstructure slew lock.

Never lift with operator on machine.

W-2202-0607

10-12-1

425, 428 Service Manual

OPERATOR CAB (ROPS / TOPS)

Cab Door

Description

Figure 10-20-1

The excavator has an optional operator cab (ROPS/ TOPS) (Roll Over Protective Structure/Tip Over Protective Structure). The ROPS/TOPS meets SAE J1040, ISO 3471 and ISO 12117.

2

An enclosed cab (ROPS/TOPS) is an Option or can be installed as a Field Accessory.

Both the cab and canopy provide operator protection if the excavator is tipped over. The seat belt must be worn for ROPS /TOPS protection.

1

P-68192

WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

W-2069-0200

The cab door can be locked (Item 1) [Figure 10-20-1] with the same key as the starter switch.

Push the door all the way open (Item 2) [Figure 10-20-1] until the latch engages to hold the door in the open position.

Figure 10-20-2

2 1

P-68193

When the door is in the open position, push down on the latch (Item 1) [Figure 10-20-2] and close the door.

From inside the cab, open the door using handle (Item 2) [Figure 10-20-2].

10-20-1

425, 428 Service Manual

Figure 10-20-5

OPERATOR CAB (ROPS / TOPS) (CONT’D) Front Window Opening The Front Window Figure 10-20-3

1

P-69886

Use both window grab handles to pull the top of the window in [Figure 10-20-5].

Continue moving the window in and up over the operator’s head until the window is fully raised.

P-49097

Retract the two top window latch pins (Item 1) [Figure 10-20-3].

Figure 10-20-6

Figure 10-20-4

2

1

P-66518A

1 When the window is fully raised, the latch (Item 1) will close on the bracket. Turn the two top latches (Item 2) [Figure 10-20-6] to the locked position.

P-49098

Turn the two top latches (Item 1) [Figure 10-20-4] to the unlocked position.

Closing The Front Window Support the window while releasing both window latch pins and placing the pins in the unlocked position [Figure 10-20-6].

Support the window using the left grab handle and pull down on the latch (Item 1) [Figure 10-20-5] to release the window.

Use both window grab handles to pull the window down [Figure 10-20-5].

Rotate the top latches (Item 1) [Figure 10-20-4] to the locked position (Item 1) [Figure 10-20-3].

10-20-2

425, 428 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D)

Window Washer Reservoir

Front Wiper

Figure 10-20-8

Figure 10-20-7

1

1

P-69870 P-49095

The window washer reservoir (Item 1) [Figure 10-20-8] is located under the right side cover.

The front window is equipped with a wiper (Item 1) [Figure 10-20-7] and washer.

10-20-3

425, 428 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D)

Opening The Right Front Window

Right Side Window

Figure 10-20-11

Opening The Right Rear Window Figure 10-20-9

1 1

P-49119

Pull back on the latch / handle (Item 1) [Figure 10-2011].

P-49176

Figure 10-20-12 Pull forward on the latch / handle (Item 1) [Figure 10-209].

Figure 10-20-10

1

1

P-49120

Pull the latch / handle (Item 1) [Figure 10-20-12] back to open the window.

P-49177

Closing The Right Front Window Pull the latch / handle (Item 1) [Figure 10-20-10] forward to open the window.

Push the handle forward to close the window.

Closing The Right Rear Window Push the handle back to close the window.

10-20-4

425, 428 Service Manual

Figure 10-20-14

OPERATOR CAB (ROPS / TOPS) (CONT’D) Heating, Ventilation, and Air Conditioning Duct

1 NOTE: The air conditioner duct can be ordered and used on heater models.

There are two HVAC ducts that the operator can choose to install.

2 3

Figure 10-20-13 1

P-42588

Place the air conditioning duct (Item 1) on the housing and over the locking stud (Item 2) [Figure 10-20-14].

Reinstall the screw (Item 3) [Figure 10-20-14].

Figure 10-20-15 P-69871

The small duct (Item 1) [Figure 10-20-13] is standard for heater use.

The large duct (Item 1) [Figure 10-20-14] is standard for models that have air conditioner available.

NOTE: This duct (Item 1) [Figure 10-20-14] can be removed for improved operator visibility.

1 Installation P-42590

Remove the screw and pull straight up to remove the duct (Item 1) [Figure 10-20-13].

Fully seat the duct and rotate the lock (Item 1) [Figure 10-20-15].

10-20-5

425, 428 Service Manual

Fastening

TRANSPORTING THE EXCAVATOR ON A TRAILER Loading And Unloading

Figure 10-30-2

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.

Secure the parking brakes and block the wheels of the transport vehicle.

1

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.

1

Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width and can support the weight of the machine.

The rear of the trailer must be blocked or supported when loading or unloading the excavator to prevent the front of the transport vehicle from raising.

P-69899A

Figure 10-30-3

Determine the direction of the track movement before moving the machine (blade forward).

Engage the slew lock.

Figure 10-30-1

1

P-69894

Fasten chains to the front corners of the blade (Item 1) [Figure 10-30-2] and to the tie down loop at the rear of the track frame (Item 1) [Figure 10-30-3] to prevent it from moving when going up or down slopes or during sudden stops.

P-69892

Use chain binders to tighten the chains and then safely tie the chain binder levers to prevent loosening.

Move the machine forward onto the transport vehicle [Figure 10-30-1].

WARNING

Do not change direction of the machine while it is on the ramps.

Lower the boom, arm, bucket, and blade to the transport vehicle.

Stop the engine and remove the key (if equipped).

AVOID SERIOUS INJURY OR DEATH 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-2058-0807

Put blocks at the front and rear of the tracks.

10-30-1

425, 428 Service Manual

Figure 10-40-2

TAILGATE Opening And Closing

WARNING 1

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W-2012-0497

P-73464

WARNING Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

W-2020-1285

Hold the tailgate up and pull outward on the latch (Item 1) [Figure 10-40-2]. Slowly lower the tailgate until the latch is locked and holds the tailgate open.

Closing Lift up slightly on the tailgate and push inward on the latch (Item 1) [Figure 10-40-2]. Slowly lower the tailgate until the tailgate is fully closed.

Opening Figure 10-40-1

1 1

P-69922A

Pull outward on the latch (Item 1) [Figure 10-40-1] and lift the tailgate up.

NOTE: The tailgate can be locked using the start key.

10-40-1

425, 428 Service Manual

Figure 10-41-2

RIGHT SIDE COVER Opening And Closing

WARNING

1

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W-2012-0497

Opening P-73479

Figure 10-41-1

Hold the side cover up and pull outward on the latch (Item 1) [Figure 10-41-2]. Slowly lower the side cover until the latch is locked and holds the side cover open.

Closing 1

1

Lift up slightly on the side cover and push inward on the latch (Item 1) [Figure 10-41-2]. Slowly lower the side cover until the side cover is fully closed.

P-69925A

Pull outward on the latch (Item 1) [Figure 10-41-1] and lift the side cover up.

NOTE: The side cover can be locked using the start key.

10-41-1

425, 428 Service Manual

SERVICE SCHEDULE Chart 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 Bobcat Excavator.

WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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. Untrained operators and failure to follow instructions can cause injury or death.

W-2003-0903

SERVICE SCHEDULE ITEM Engine Coolant Engine Oil Hydraulic Fluid, Hoses and Tubelines, Reservoir Breather Cap Engine Air Filter and Air System Tracks Indicators and Lights Operator Canopy/Cab Seat Belt Safety Signs and Safety Treads Pivot Points * Cab Heater Air Filter Console Lockout X-Change Swing Circle and Pinion Fuel Tank & Filter Battery Spark Arrestor Muffler Fuel Filters Travel Motor Inline Fuel Filter Engine Oil and Filter Alternator Belt Radiator, Oil Cooler Primary Hydraulic Filter and reservoir breather Case Drain Filter Alternator & Starter Engine Valves Hydraulic System Travel Motor Coolant

* ● ▼ ^ ■

SERVICE REQUIRED Check coolant level. Add premixed coolant as needed.

Check the engine oil level and add as needed.

Check the hydraulic fluid level and add as needed. Check for damage and leaks. Repair or replace as needed.

Check condition indicator and empty dust cup as needed. Check air system for leaks.

Check and adjust track tension as needed.

Check for correct operation of all indicators and lights.

Check condition. Check mounting hardware.

Check condition. Check mounting hardware.

Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn.

Grease all machinery pivot points.

Clean the filter as needed.

Check console lockout for proper operation.

Lubricate and inspect for damage or loose parts.

Grease two fittings.

Drain water and sediment from fuel tank and fuel filter.

Check battery, cables, connections and electrolyte level. Add distilled water as needed.

Clean the spark chamber.

Replace fuel filter.

Check the oil level in both travel motors.

Replace inline fuel filter.

Replace oil and filter. Use CD or better grade oil and Bobcat filter.

Check condition of belt and adjust as needed.

Clean debris from the radiator fins.

Replace the primary hydraulic filter and reservoir breather.

Replace the case drain filter.

Check the alternator and starter connections.

Check and adjust the engine valve clearance.

Replace the hydraulic fluid and filters. Clean the reservoir.

Replace the lubricant in both travel motors.

Drain and flush the cooling system. Replace the coolant.

HOURS ■

8-10

50

100

■

250 500

■ 1000

●

▼

^ ^ ^ ^

^ Every 2 years

If Equipped Change after the first 50 hours, then as scheduled.

First oil and filter change must occur at 50 hours; then as scheduled.

Check after the first 100 hours, then as scheduled.

Or every 12 months.

10-50-1

425, 428 Service Manual

AIR CLEANER SERVICE See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

Daily Check The air cleaner is located in the engine compartment.

Open the tailgate to access the air cleaner for service.

(See Opening And Closing on Page 10-40-1.)

Figure 10-60-1 1 2

3 2 P-73186

Check the condition indicator (Item 1) [Figure 10-60-1]. If the red ring shows in the condition indicator, the filter needs to be replaced.

Replace the inner filter every third time the outer filter is replaced or as indicated.

10-60-1

425, 428 Service Manual

Check the air intake hose and the air cleaner housing for damage. Make sure all connections are tight.

AIR CLEANER SERVICE (CONT’D) Replacing Filter Elements

After the outer filter has been replaced, press the button (Item 3) [Figure 10-60-3] on the end of the condition indicator and start the engine. Run at full RPM, then reduce engine speed and stop the engine. If the red ring shows in the condition indicator, replace the inner filter.

Outer Filter Release the two fasteners (Item 2) [Figure 10-60-1].

Remove and clean the dust cup (Item 3) [Figure 10-601].

Figure 10-60-2

Inner Filter Only replace the inner filter under the following conditions:

1

•

Replace the inner filter every third time the outer filter is replaced.

•

After the outer filter has been replaced, press the button (Item 3) [Figure 10-60-3] on the top of the condition indicator and start the engine. Run at full RPM, then reduce engine speed and stop the engine.

If the red ring shows in the condition indicator, replace the inner filter.

Figure 10-60-4 P73187

Pull the outer filter (Item 1) [Figure 10-60-2] from the air cleaner housing.

Check the housing for damage.

Clean the housing and the seal surface. DO NOT use compressed air.

1

Install a new filter.

Figure 10-60-3

P-73188

Remove the dust cup, outer filter and inner filter (Item 1) [Figure 10-60-4].

3

NOTE: Make sure all sealing surfaces are free of dirt and debris.

2

Install the new inner filter.

Install the outer filter and the dust cup.

2 1

Press the button on the condition indicator to remove the red ring.

P-73186A

Install the dust cup (Item 1) and engage the fasteners (Item 2) [Figure 10-60-3].

10-60-2

425, 428 Service Manual

ENGINE COOLING SYSTEM Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Use air pressure or water pressure to clean the radiator and oil cooler. Be careful not to damage fins when cleaning.

Reinstall the cover (Item 2) with the four bolts (Item 1) [Figure 10-70-1].

Cleaning NOTE: Allow the cooling system and engine to cool before servicing or cleaning the cooling system.

Open the tailgate.

Figure 10-70-1 2 1 1

1

1 P-69941

Remove the four bolts (Item 1) and remove the cover (Item 2) [Figure 10-70-1].

Figure 10-70-2

2

1

P-69942

Clean both sides of the oil cooler (Item 1) and the radiator (Item 2) [Figure 10-70-2]

10-70-1

425, 428 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Checking Level

IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

WARNING AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

W-2070-1203

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I-2124-0497

W-2019-0907

Open the tailgate.

Figure 10-70-3

1

P-73193

Check the coolant level in the coolant recovery tank (Item 1) [Figure 10-70-3].

The coolant level must be between the MIN and MAX marks on the coolant recovery tank when the engine is cold.

NOTE: The cooling system is factory filled with propylene glycol (purple color). DO NOT mix propylene glycol with ethylene glycol.

10-70-2

425, 428 Service Manual

Figure 10-70-5

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant See the Service Schedule for correct service intervals.

(See Chart on Page 10-50-1.)

Stop the engine. Open the tailgate

WARNING 1

AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

P-69944

W-2070-1203

Put a hose on the drain valve at the bottom of the radiator. Open the drain valve (Item 1) [Figure 10-70-5] and drain the coolant into a container.

Figure 10-70-4 1

After all the coolant is removed, close the drain valve.

Recycle or dispose of the used coolant in an environmentally safe manner.

2

Mix the coolant in a separate container for correct capacity. (See Capacities on Page SPEC-10-7.)

NOTE: The cooling system is factory filled with propylene glycol (purple color). DO NOT mix propylene glycol with ethylene glycol.

P-73193

Add premixed coolant; 47% water and 53% propylene glycol to the radiator and recovery tank.

When the engine is cool, remove the coolant from the recovery tank (Item 1) [Figure 10-70-4].

When the engine is cool, loosen and remove the radiator cap (Item 2) [Figure 10-70-4].

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a -34°F (-37°C) freeze protection.

Use a refractometer to check the condition of propylene glycol in your cooling system. Install the radiator cap. Be sure the radiator cap is tight.

Run the engine until it is at operating temperature. Stop the engine.

Add coolant to the recovery tank as needed.

Close the tailgate.

10-70-3

425, 428 Service Manual

FUEL SYSTEM

Biodiesel Blend Fuel

Fuel Specifications

Biodiesel blend fuel has unique qualities that should be considered before using in this machine:

Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

The following is a suggested blending guideline which should prevent fuel gelling problems during freezing temperature Temp. F° (C°) Above +15° (-9°) Down to -20° (-29°) Below -20° (-29°)

No. 2

No. 1

100% 50% 0%

0% 50% 100%

•

Cold weather conditions can lead to plugged fuel system components and hard starting.

•

Biodiesel blend fuel is an excellent medium for microbial growth and contamination which can cause corrosion and plugging of fuel system components.

•

Use of biodiesel blend fuel may result in premature failure of fuel system components, such as plugged fuel filters and deteriorated fuel lines.

•

Shorter maintenance intervals may be required, such as cleaning the fuel system and replacing fuel filters and fuel lines.

•

Using biodiesel blended fuels containing more than five percent biodiesel can affect engine life and cause deterioration of hoses, tubelines, injectors, injector pump and seals.

At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel must be used in this machine.

Apply the following guidelines if biodiesel blend fuel is used: •

Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in the fuel tank.

The following fuels may also be used in this machine: •

Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.

•

Ensure that the fuel tank cap is securely tightened.

•

Biodiesel Blend Fuel - Must contain no more than five percent biodiesel mixed with low sulfur or ultra low sulfur petroleum based diesel. This is commonly marketed as B5 blended diesel fuel.

•

Biodiesel blend fuel can damage painted surfaces, remove all spilled fuel from painted surfaces immediately.

•

Drain all water from the fuel filter daily before operating the machine.

•

Do not exceed engine oil change interval. Extended oil change intervals can cause engine damage.

•

Before vehicle storage; drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

WARNING Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W-2063-0887

NOTE: Biodiesel blend fuel does not have long term stability and should not be stored for more than three months.

WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W-2103-1285

10-80-1

425, 428 Service Manual

FUEL SYSTEM (CONT’D)

Open the right side cover.

Filling The Fuel Tank

Figure 10-80-1

WARNING

1

AVOID INJURY OR DEATH Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W-2063-0807

P-73004

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W-2103-0807

Remove the fuel fill cap (Item 1) [Figure 10-80-1].

Use a clean, approved safety container to add fuel. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING! Install and tighten the fuel fill cap.

Clean up any spilled fuel.

See the Service Schedule for the service interval when to remove water from or replace the fuel filter. (See Chart on Page 10-50-1.)

NOTE: The fuel cap can be locked using the start key.

10-80-2

425, 428 Service Manual

FUEL SYSTEM (CONT’D)

Replacing Elements

Fuel Filters

The floor mat and floor panel will need to be removed for access to both fuel filters.

Removing Water See the Service Schedule for the service interval when to replace elements. (See Chart on Page 10-50-1.)

Figure 10-80-2

Figure 10-80-4

1 1 2 1 P-69932

P-73050

Turn the upperstructure so the boom is centered between the rear tracks for easier access to the fuel filter (Item 1) [Figure 10-80-2] that is located in the upperstructure behind the boom.

Remove the two bolts (Item 1) and plate (Item 2) [Figure 10-80-4].

Figure 10-80-3

Figure 10-80-5

1

1

P-69933

Loosen the drain (Item 1) [Figure 10-80-3] at the bottom of the filter to drain water from the filter.

P-73051

Remove the floor mat (Item 1) [Figure 10-80-5] and insulation.

See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

10-80-3

425, 428 Service Manual

Figure 10-80-8

FUEL SYSTEM (CONT’D) Fuel Filters (Cont’d) Replacing Elements (Cont’d)

1 Figure 10-80-6

1 1 1

1

1

P-69933

Remove the filter (Item 1) [Figure 10-80-8].

2 1

Clean the area around the filter housing. Put clean oil on the seal of the new filter. Install the fuel filter and hand tighten. Clean up any spilled fuel.

1 P-73053

Remove the seven bolts (Item 1) and the floor panel (Item 2) [Figure 10-80-6].

Remove the air from the fuel system. (See Removing Air From The Fuel System on Page 10-80-5.)

Figure 10-80-7

1

2

P-73021

NOTE: Fuel will flow from the fuel inlet hose when it is removed from the inline filter. Clamp off the inlet hose before removing it from the filter or plug the hose when it is removed.

Remove the filter (Item 1) [Figure 10-80-7] from the retaining clamp.

Remove the two hose clamps (Item 2). Remove and replace the filter (Item 1) [Figure 10-80-7].

10-80-4

425, 428 Service Manual

Reuse, recycle or dispose of fuel in an environmentally safe manner.

FUEL SYSTEM (CONT’D) Draining The Fuel Tank See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

WARNING

Figure 10-80-9

AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

1

W-2072-0807

Removing Air From The Fuel System P-69933

NOTE: For correct procedure for accessing fuel filter and fuel hose shown below (See Fuel Filters on Page 10-80-3.)

The excavator fuel system is a self bleed system and is purged of air every time the start key is turned to the run position or keyless switch is pressed.

Loosen the drain (Item 1) [Figure 10-80-9] at the bottom of the filter to drain water from the filter. (See Fuel Filters on Page 10-80-3.)

Figure 10-80-10

1

P-73021

Remove the inlet hose (Item 1) [Figure 10-80-10] from the fuel filter.

Turn the start key to the ON position.

Drain the fuel into a container.

Turn the start key to the OFF position.

10-80-5

425, 428 Service Manual

ENGINE LUBRICATION SYSTEM

Engine Oil Chart

Checking And Adding Engine Oil

Figure 10-90-2

Check the engine oil after every 8 - 10 hours of operation and before starting the engine.

Figure 10-90-1

1

P-73189

Open the tailgate and remove the dipstick (Item 1) [Figure 10-90-1].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets the correct API Service Classification.

B-16320

Use a good quality motor oil that meets the correct API Service Classification [Figure 10-90-2].

Install the dipstick and close the tailgate.

10-90-1

425, 428 Service Manual

Figure 10-90-5

ENGINE LUBRICATION SYSTEM (CONT’D) Removing And Replacing Oil Filter See the Service Schedule for the service interval for replacing the engine oil and filter. (See Chart on Page 1050-1.)

Run the engine until it is at operating temperature. Stop the engine.

Figure 10-90-3

1

P-73191

Remove the oil filter (Item 1) [Figure 10-90-5] and clean the filter housing surface.

Recycle or dispose of used oil in an environmentally safe manner.

1

Use a genuine Bobcat replacement filter.

Put clean oil on the filter gasket. Install the filter and hand tighten.

P-73190

Install and tighten the oil plug.

Position the upperstructure (Item 1) [Figure 10-90-3] so the tailgate is centered between the rear tracks.

Figure 10-90-6

1

Open the tailgate.

Figure 10-90-4

P-73192

1 Remove the fill cap (Item 1) [Figure 10-90-6].

Put oil in the engine. (See Engine Oil Chart on Page 1090-1.) (See Capacities on Page SPEC-10-7.)

P-69937

Install the fill cap.

Remove the plug (Item 1) [Figure 10-90-4] from the bottom of the engine oil pan. Drain the oil into a container.

Recycle or dispose of used oil in an environmentally safe manner.

Start the engine and let it run for several minutes.

Stop the engine. Check for leaks at the oil filter. Check the oil level.

Add oil as needed if it is not at the top mark on the dipstick.

10-90-2

425, 428 Service Manual

HYDRAULIC SYSTEM

Figure 10-100-2

Checking And Adding Fluid Put the machine on a flat level surface.

Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade fully. Stop the engine.

Open the right side cover.

1

Figure 10-100-1 2 P-73003

Check the condition of the fill strainer screen (Item 1) [Figure 10-100-2]. Clean or replace as necessary.

1

Be sure the screen is installed before adding fluid.

Add the correct fluid to the reservoir until it is visible in the sight gauge.

Check the cap and clean as necessary. Replace the cap if damaged.

P-73002

Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [Figure 10-100-1].

Install the cap. Close the tailgate.

Hydraulic Fluid Chart

Clean the surface around the reservoir (breather) cap and remove the cap (Item 2) [Figure 10-100-1] from the reservoir.

Figure 10-100-3

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W-2103-0807

P-64023A

Use the correct hydraulic fluid shown in chart [Figure 10100-3].

Add hydraulic fluid as needed to bring the level to the center of sight gauge (Item 1) [Figure 10-100-3].

Install the oil fill cap.

10-100-1

425, 428 Service Manual

HYDRAULIC SYSTEM (CONT’D)

Removing And Replacing The Case Drain Filter

Removing And Replacing The Hydraulic Filter

NOTE: The hydraulic tank must be drained before removing the case drain filter. (See Removing And Replacing The Hydraulic Fluid on Page 10-100-3.)

WARNING

Open the right side cover.

AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

Drain the hydraulic tank. (See Removing And Replacing The Hydraulic Fluid on Page 10-100-3.)

Figure 10-100-5

W-2103-0807

See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

Open the tailgate.

Figure 10-100-4

2

1 P-73001

1 Remove the hose (Item 1). Remove the filter (Item 2) [Figure 10-100-5] from the bottom of the hydraulic tank.

Remove the elbow from the old filter and install it on the new filter but do not tighten the jam nut. The elbow will need to be orientated correctly after the filter is installed.

P-73195

Remove the straight adapter from the old filter and install it on the new filter. Tighten the adapter.

Remove the hydraulic filter (Item 1) [Figure 10-100-4].

Clean the housing where the filter gasket makes contact.

NOTE: The straight adapter may remain installed in the hydraulic tank when the filter is removed.

Put clean hydraulic fluid on the gasket. Install the new filter and hand tighten only.

Install a new filter and tighten. Orientate the elbow and tighten the jam nut. Reinstall the hose and tighten.

10-100-2

425, 428 Service Manual

Figure 10-100-7

HYDRAULIC SYSTEM (CONT’D) Removing And Replacing The Hydraulic Fluid See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

2

WARNING AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

1 P-69998

Remove the drain hose (Item 1) [Figure 10-100-7] from the clamp and route it out the side of the upperstructure.

W-2072-0807

Remove the drain hose cap (Item 2) [Figure 10-100-7].

Retract the arm and bucket cylinders, lower the bucket to the ground. Lower the blade to the ground. Stop the engine.

Open the right side cover.

Drain the fluid into a container.

Recycle or dispose of the fluid in an environmentally safe manner.

Install the drain hose cap (Item 2) [Figure 10-100-7].

Figure 10-100-6

Reposition the hose back into the upperstructure and secure it to the clamp.

Always replace the filters when changing the hydraulic oil.

Install new Bobcat hydraulic fluid. (See Capacities on Page SPEC-10-7.) (See Hydraulic Fluid Chart on Page 10-100-1.)

1

NOTE: If the pump has been removed from the excavator for repair, see the Service Manual for the correct procedure for removing air from the hydraulic pump and from the hydraulic system.

P-69997

A hydraulic reservoir drain hose (Item 1) [Figure 10-1006] is located below the reservoir and secured to the upperstructure with a clamp.

10-100-3

425, 428 Service Manual

Figure 10-110-2

LUBRICATING THE EXCAVATOR Lubrication Locations Lubricate the excavator as specified in the Service Schedule for the best performance of the machine. (See Chart on Page 10-50-1.)

5 4

Record the operating hours each time you lubricate the excavator.

Always use a good quality lithium based multipurpose grease when lubricating the machine. Apply the lubricant until extra grease shows.

Lubricate the following locations on the excavator EVERY 8 - 10 HOURS:

6

P-69970

4. Boom Swing Cylinder Rod End (1) [Figure 10-110-2]

Figure 10-110-1

5. Boom Cylinder Base End (1) [Figure 10-110-2] 1 6. Boom Swing Bottom Pin (1) [Figure 10-110-2] Figure 10-110-3

3 3

9 7

2 8

P-69969

Ref Description (# of Fittings) 1. Blade Cylinder Rod End (1) [Figure 10-110-1]

8 P-69994

2. Blade Cylinder Base End (1) [Figure 10-110-1] 3. Blade Pivots (2) [Figure 10-110-1]

7. Boom Swing Top Pin (1) [Figure 10-110-3] 8. Boom Swing Pivot (3) [Figure 10-110-3] 9. Boom Pivot (1) [Figure 10-110-3]

10-110-1

425, 428 Service Manual

Figure 10-110-6

LUBRICATING THE EXCAVATOR (CONT’D) Lubrication Locations (Cont’d)

16

Figure 10-110-4 11 15

16

P-73038

10

15. Bucket / Arm Pin (1) [Figure 10-110-6] P-69971

16. Bucket Link Pin (2) [Figure 10-110-6] 10. Boom Cylinder Rod End (1) [Figure 10-110-4]

Figure 10-110-7

11. Arm Cylinder Base End (1) [Figure 10-110-4] Figure 10-110-5 12

18

13

14

18

17 P-73039

17. Bucket Cylinder Rod End (1) [Figure 10-110-7] P-69990

18. Bucket Link (2) [Figure 10-110-7] 12. Arm Cylinder Rod End (1) [Figure 10-110-5] 13. Arm Pivot (1) [Figure 10-110-5] 14. Bucket Cylinder Base End (1) [Figure 10-110-5]

10-110-2

425, 428 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D) Lubrication Locations (Cont’d) Figure 10-110-8

21

20 19

P-69993

19. Boom Swing Cylinder Base End (1) [Figure 10-110-8] Lubricate the following locations on the hydraulic excavator EVERY 50 HOURS: 20. Slew Circle (1) [Figure 10-110-8] 21. Slew Pinion (1) [Figure 10-110-8]. (Install 3 - 4 pumps of grease then rotate the upperstructure 90°. Install 3 - 4 pumps of grease and again rotate the upperstructure 90°. Repeat this until the slew pinion has been greased at four positions.)

10-110-3

425, 428 Service Manual

TRAVEL MOTOR

Removing And Replacing Oil

Checking And Adding Oil

See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

Figure 10-120-1 Park the excavator on a level surface with plugs (Items 1 & 2) [Figure 10-120-1] in the position shown. Remove both plugs and drain the lubricant into a container.

WARNING

1

AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

2

W-2103-0807

P-69996

Park the excavator on a level surface with the plugs (Items 1 & 2) [Figure 10-120-1] in the position as shown.

Remove the plug (Item 1) [Figure 10-120-1]. The lube level must be at the bottom edge of the hole.

Install the bottom plug (Item 2) [Figure 10-120-1]. Add lubricant (SAE 80W90) through the top plug hole until the lube level is at the bottom edge of the hole. (See Capacities on Page SPEC-10-7.)

Install the plug (Item 1) [Figure 10-120-1].

Add lubricant (SAE 80W90) through the hole if the lube level is low. (See Capacities on Page SPEC-10-7.)

10-120-1

425, 428 Service Manuall

Figure 10-130-1

SPARK ARRESTOR MUFFLER Cleaning Procedure See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)

WARNING 1 AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

W-2050-0807

P-69996

Remove the plug (Item 1) [Figure 10-130-1] from the bottom of the muffler.

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. The carbon deposits will be forced out of the muffler plug hole (Item 1) [Figure 10-130-1].

WARNING Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles.

Failure to obey can cause serious injury.

W-2011-1285

Stop the engine. Install and tighten the plug.

Close the tailgate.

WARNING Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

W-2068-1285

WARNING When the engine is running during service, the steering levers must be in neutral.

Failure to do so can cause injury or death.

W-2203-0595

Do not operate the excavator with a defective exhaust system.

Stop the engine. Open the tailgate.

10-130-1

425, 428 Service Manual

ALTERNATOR BELT

Belt Replacement

Belt Adjustment

Figure 10-140-2

Open the tailgate.

1

Figure 10-140-1

2 1

P-73197

Remove the two bolts (Item 1) and remove the shield assembly (Item 2) [Figure 10-140-2].

P-73196

Figure 10-140-3 Using a belt tension gauge, measure the belt tension midway between the crankshaft pulley and alternator pulley [Figure 10-140-1].

1

Belt tension is as follows: New belt 70 - 80 ft. lb. (311 - 356 N) Used belt 56 - 66 ft. lb. (249 - 294 N)

WARNING • • •

2

AVOID INJURY OR DEATH Do Not Operate with damaged or missing screens, shields or rubber deflectors.

Stop engine before cleaning or servicing.

Contact with moving parts or flying objects can cause injury or death.

W-2528-0406

P-73199

Loosen the bolts (Items 1 & 2) [Figure 10-140-3] until the alternator can be moved toward the engine. Remove the old belt and install a new belt.

Adjust the alternator outward until the belt tension is correct. Tighten the two bolts (Items 1 & 2) [Figure 10140-3].

Replace the alternator belt shield assembly.

10-140-1

425, 428 Service Manual

Figure 10-150-1

SEAT BELT Inspection And Maintenance

WARNING Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death.

W-2466-0703

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly yearly or more often if the machine is exposed to severe environmental conditions or applications.

The seat belt system should be repaired or replaced if it shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet (UV) rays from the sun, dusty/dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), or hardware.

B-22283

The items below are referenced in [Figure 10-150-1].

1. Check the seat belt webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. look for cuts, wear, fraying, dirt and stiffness.

2. Check the buckle and latch for proper function. Make sure latch plate is not excessively worn, deformed or buckle is not damaged.

3. Check the retractor web storage device (if equipped) by extending the seat belt webbing to determine if it extends and retracts the webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have weakened.

See your Bobcat dealer for approved seat belt system replacement parts for your machine.

10-150-1

425, 428 Service Manual

PIVOT PINS Inspection And Maintenance Figure 10-160-1

1

2

1

1 P-69995

The boom, arm and cylinders pivots (Item 1) have a large pin held in position with a snap ring (Item 2) [Figure 10160-1].

Check that the snap rings are securely inserted into the grooves on the pins and that the snap rings are not damaged. See your Bobcat dealer for replacement parts.

10-160-1

425, 428 Service Manual

EXCAVATOR STORAGE AND RETURN TO SERVICE

Return To Service

Storage

After the Bobcat Excavator has been in storage, it is necessary to follow a list of items to return the excavator to service.

Sometimes it may be necessary to store your Bobcat Excavator for an extend period of time. Below is a list of items to perform before storage.

•

Thoroughly clean the excavator including the engine compartment.

•

Lubricate the excavator.

•

Replace worn or damaged parts.

•

Drive the excavator onto planks in a dry protected shelter.

•

Lower the boom fully with the bucket flat on the ground.

•

Check the engine and hydraulic oil levels; check coolant level.

•

Install a fully charged battery.

•

Remove grease from exposed cylinder rods.

•

Check all belt tensions.

•

Be sure all shields and guards are in place.

•

Lubricate the excavator.

•

Remove cover from exhaust pipe opening.

•

Start the engine and let run for a few minutes while observing the instrument panels and systems for correct operation.

•

Put grease on any exposed cylinder rods.

•

Put fuel stabilizer in the fuel tank and run the engine a few minutes to circulate the stabilizer to the pump and fuel injectors.

•

Drive the excavator off of the planks.

•

Operate machine, check for correct function.

•

Drain and flush the cooling system. Refill with premixed coolant.

•

Stop the engine and check for leaks. Repair as needed.

•

Replace all fluids and filters (engine, hydraulic).

•

Replace all filters (i.e.: air cleaner, heater, etc.).

•

Put all controls in neutral position.

•

Remove the battery. Be sure the electrolyte level is correct then charge the battery. Store it in a cool dry place above freezing temperatures and charge it periodically during storage.

•

Cover the exhaust pipe opening.

•

Tag the machine to indicate that it is in storage condition.

10-170-1

425, 428 Service Manual

Figure 10-180-3

STOPPING THE ENGINE AND LEAVING THE EXCAVATOR Procedure Figure 10-180-1

STOP

ON

START

6808261

Figure 10-180-4 P-69888A

Stop the machine on level ground. Lower the work equipment and the blade to the ground [Figure 10-1801].

Figure 10-180-2 1

P16616

1 Turn the key switch to STOP [Figure 10-180-3] or press the STOP Button (Item 1) [Figure 10-180-4].

Disconnect the seat belt. Remove the key from the switch to prevent operation of machine by unauthorized personnel. Raise the control console and exit the machine.

P-69884

Move the engine speed control (Item 1) [Figure 10-1802] to low idle.

Let the engine run at idle speed for five minutes before stopping the engine.

10-180-1

425, 428 Service Manual

Front Window

STOPPING THE ENGINE AND LEAVING THE EXCAVATOR (CONT’D)

Figure 10-180-6

Emergency Exits The right side rear window and the front window provide exits.

Right Side Rear Window Figure 10-180-5

P-69886

Raise the front window and exit through the window [Figure 10-180-6].

P-69885

NOTE: If the excavator has a Special Applications Kit installed, the front window is NOT an emergency exit.

Exit through the window [Figure 10-180-5].

10-180-2

425, 428 Service Manual

MOTION ALARM SYSTEM (IF EQUIPPED)

Figure 10-190-3

Description This excavator may be equipped with a motion alarm system. The motion alarm will sound when the operator moves the travel control levers in the either the forward or reverse direction

2

Figure 10-190-1

1

1

P-73827

Inspect the motion alarm electrical connections (Item 1) [Figure 10-190-3], wire harness (Item 2) [Figure 10-1903] and motion alarm switches (Item 1) [Figure 10-190-4] for tightness and damage. Repair or replace any damaged components.

If the motion alarm switch requires adjustment, see information below.

P-49757

Adjusting Switch Position

Figure 10-190-2

Stop the engine. Remove the floormat and floor plate.

(See Service Manual for procedure for floormat and floor plate removal.)

1

Figure 10-190-4 Switch Roller Contacting Bearing

P-49758

2

Inspect for damaged or missing motion alarm decal (Item 1) [Figure 10-190-1] (cab machine) or (Item 1) [Figure 10-190-2] (canopy machine). Replace if required.

3 1 P-61516

Sit in the operator’s seat. Turn excavator key to ON position but do not start the engine.

Move the travel control levers (one lever at a time) in the forward direction. The motion alarm must sound. Move the travel control levers (one lever at a time) in the reverse direction. The motion alarm must sound.

Turn excavator key to OFF position.

The motion alarm is mounted to the bottom rear of the excavator at the louver opening. (The louver must be removed to access the back-up alarm. See the Service Manual for the correct procedure.)

Loosen the screws (Item 2) [Figure 10-190-4] securing the motion alarm switch.

Position the motion alarm switch roller (Item 1) so that it makes contact with bearing (Item 3) until it opens the switch circuit. (Listen for the click of the switch.) Torque the screws (Item 2) [Figure 10-190-4] securing the switch to the bracket to 14 - 19 in.-lb. (1,6 - 2,1 N•m).

10-190-1

425, 428 Service Manual

HYDRAULIC SYSTEM ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-21-1 20-21-8 20-21-6 20-21-5 20-21-3 20-21-1

BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-24-1 20-24-7 20-24-5 20-24-4 20-24-3 20-24-1

HYDRAULIC SYSTEM

BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-22-1 20-22-7 20-22-5 20-22-4 20-22-3 20-22-1

BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-23-1 20-23-7 20-23-5 20-23-4 20-23-3 20-23-1

CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-121-1 CLAMP CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-25-1 20-25-7 20-25-4 20-25-3 20-25-2 20-25-1

Continued On Next Page 20-01

425, 428 Service Manual

HYDRAULIC SYSTEM (CONT’D) CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .

20-100-1 20-100-1 20-100-3 20-100-2 20-100-1

CROSSPORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . 20-32-1 Testing And Adjusting The Crossport Relief Valves . . . . . . 20-32-1 DIRECT TO TANK VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .

20-150-1 20-150-1 20-150-3 20-150-2 20-150-1

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Arm Valve Section Disassembly And Assembly . . . . . . . 20-40-40 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-60 Auxiliary Valve Section Disassembly And Assembly . . . . 20-40-30 Blade Valve Section Disassembly And Assembly . . . . . . 20-40-16 Boom Swing Valve Section Disassembly And Assembly. 20-40-50 Boom Valve Section Disassembly And Assembly . . . . . . 20-40-45 Bucket Valve Section Disassembly And Assembly . . . . . 20-40-35 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6 Inlet Section Disassembly And Assembly . . . . . . . . . . . . 20-40-55 Left Travel Valve Section Disassembly And Assembly . . 20-40-12 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 Right Travel Valve Section Disassembly And Assembly . . 20-40-8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-2 Blade Valve Section Disassembly And Assembly . . . . . . 20-40-16 HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 Housing Removal And Installation . . . . . . . . . . . . . . . . . . 20-120-1 Continued On Next Page

20-02

425, 428 Service Manual

HYDRAULIC SYSTEM (CONT’D) HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-23 Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . 20-50-7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6 Parts Identification (Piston Pump) . . . . . . . . . . . . . . . . . . . 20-50-9 Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17 Piston Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5 Testing Auxiliary Hydraulic Flow . . . . . . . . . . . . . . . . . . . . 20-50-4 Testing The Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3 Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2 HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . .

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . .

Troubleshooting The Cylinder Circuit. . . . . . . . . . . . . . . . .

Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . .

Troubleshooting The Swing (Upperstructure Slew) Circuit Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . .

20-10-1 20-10-1 20-10-6 20-10-5 20-10-7 20-10-8

HYDRAULIC X-CHANGE VALVE . . . . . . . . . . . . . . . . . . . . . 20-170-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-12 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1 LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . .20-111-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-13 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-8 Handle Removal And Installation. . . . . . . . . . . . . . . . . . . .20-111-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-5 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-7 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111-1 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1 Testing And Adjusting The Main Relief Valve . . . . . . . . . . 20-30-1 Continued On Next Page

20-03

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HYDRAULIC SYSTEM (CONT’D) MANIFOLD ASSEMBLY / ACCUMULATOR . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-60-1 20-60-1 20-60-4 20-60-3 20-60-1

NON-PRESSURIZED ACCUMULATOR . . . . . . . . . . . . . . . . 20-160-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1 PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1 Testing And Adjusting Port Relief Valve Pressure . . . . . . . 20-31-1 PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . 20-33-1 Testing And Adjusting The Pressure Reducing Valve . . . . 20-33-1 RIGHT CONTROL LEVER (JOYSTICK). . . . . . . . . . . . . . . . 20-110-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-15 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-10 Handle Removal And Installation . . . . . . . . . . . . . . . . . . . 20-110-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1 SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-90-1 20-90-9 20-90-1 20-90-4 20-90-3 20-90-1

SWING MOTOR DRIVE CARRIER. . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-91-1 20-91-5 20-91-1 20-91-3 20-91-2 20-91-1

Continued On Next Page

20-04

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HYDRAULIC SYSTEM (CONT’D) SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

20-80-1 20-80-5 20-80-1 20-80-4 20-80-3 20-80-1

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-13 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

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