Bobcat 425, 428 Compact Excavator Repair Service Manual – 6986952

425 (S/N: AACJ11001 & Above) – 425 (S/N: A9K311001 & Above) – 428 (S/N: A9K411001 & Above)
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This workshop repair service manual PDF download for the 425 & 428 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Excavator 425 & 428
425 (S/N: AACJ11001 & Above)
425 (S/N: A9K311001 & Above)
428 (S/N: A9K411001 & Above)

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM AND ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6986952 (5-09)
Total Pages : 744

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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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 / TOPS)
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 SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
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 / ACCUMULATOR
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
SLEW LOCK VALVE
Description
Removal And Installation
Parts Identification
Disassembly And 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 (AACJ11223 & Below, A9K311309 & Below And A9K411308 & Below)
Coil Spring Cylinder Parts Identification (AACS11224 & Above, A9K311310 & Above And A9K411309 & Above)
Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11224 & Above, A9K311310 & Above And A9K411309 & Above)
Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11224 & Above, A9K311310 & Above And A9K411309 & Above)
Roller Removal And Installation
Roller Parts Identification
Roller Disassembly
Roller Assembly
Track Guide Removal And Installation
Sprocket Removal And Installation
Track Damage Identification
1. Coil Spring Assembly 2. O-Ring 3. Spacer (Steel Track Only) 4. Shaft 5. Wiper Seal 6. Back-Up Ring 7. Wear Ring 8. Tube 9. Bolt 10. Grease Fitting 11. Bleed Fitting
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 / PEDALS
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
CLAMP
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 / Identification
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

SERVICE MANUAL REVISION
Revision No: 425 / 428 – 1

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