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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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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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