Complete repair service manual with Electrical Wiring Diagrams for Bobcat 418, 425, 428 Compact Excavators, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Compact Excavators 418, 425, 428 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6904865 (10-07) - 425 Compact Excavator Operation & Maintenance Manual.pdf
6904866 (7-07) - 425 Compact Excavator Service Manual.pdf
6904866 (07-07) - 425 Compact Excavator Service Manual.pdf
6904866 (09-09) - 425, 428 Compact Excavator Service Manual.pdf
6904866 (11-06) - 425 Compact Excavator Service Manual.pdf
6986852 (8-08) - 418 Compact Excavator Operation & Maintenance Manual.pdf
6986853 (07-14) - 418 Compact Excavator Service Manual.pdf
6986853 (10-10) - 418 Compact Excavator Service Manual.pdf
6986951 (10-09) - 425, 428 Compact Excavator Operation & Maintenance Manual.pdf
6986952 (5-09) - 425, 428 Compact Excavator Service Manual.pdf

Total Pages: 2,221 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6904865 (10-07) - 425 Compact Excavator Operation & Maintenance Manual...1
  CONTENTS...5
  FOREWORD...7
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...9
    REGULAR MAINTENANCE ITEMS...9
    SERIAL NUMBER LOCATIONS...11
      Excavator Serial Number...11
      Engine Serial Number...11
    DELIVERY REPORT...11
    EXCAVATOR IDENTIFICATION...12
    FEATURES, ACCESSORIES AND ATTACHMENTS...13
      Standard Items...13
      Options and Accessories...13
      Attachments...13
      Buckets Available...13
      Falling Object Guards (FOGS)...14
      Special Applications Kit...14
      Special Applications Kit Inspection And Maintenance...14
  SAFETY & TRAINING RESOURCES...15
    SAFETY INSTRUCTIONS...17
      Before Operation...17
      Safe Operation Is The Operator’s Responsibility...18
      Safe Operation Needs A Qualified Operator...18
      Avoid Silica Dust...19
    FIRE PREVENTION...19
      Maintenance...19
      Operation...19
      Electrical...19
      Hydraulic System...20
      Fueling...20
      Starting...20
      Spark Arrestor Exhaust System...20
      Welding And Grinding...20
      Fire Extinguishers...20
    MACHINE SIGNS (DECALS)...21
    PUBLICATIONS AND TRAINING RESOURCES...23
  OPERATING INSTRUCTIONS...25
    INSTRUMENTS AND CONSOLES...27
      Cab Interior Light (If Equipped)...27
      Left Console...27
      Right Console...28
      Function Icons...29
      STD / ISO Selector Valve...30
      Upperstructure Slew Lock...30
      Raising And Lowering The Console...30
      Two-Speed Travel...31
      Fresh Air Recirculation (If Equipped)...31
    OPERATOR CANOPY (ROPS / TOPS)...32
      Description...32
    OPERATOR CAB (ROPS / TOPS)...32
      Description...32
      Cab Door...33
      Front Window...34
      Front Wiper...35
      Window Washer Reservoir...35
      Right Side Window...36
      Heating, Ventilation, and Air Conditioning Duct...37
    TRAVEL CONTROLS...38
      Description...38
      Forward And Reverse Travel...38
      Turning...38
    HYDRAULIC CONTROLS...40
      Description...40
      STANDARD Control Pattern...40
      ISO Control Pattern...41
      Quick Couplers...42
      Auxiliary Hydraulics...43
      Relieving Hydraulic Pressure (Excavator And Attachment)...43
      Return To Tank Valve (If Equipped)...43
    BLADE CONTROL LEVER...44
      Operation...44
    BOOM SWING PEDAL...44
      Operation...44
    DAILY INSPECTION...45
      Daily Inspection And Maintenance...46
    PRE-STARTING PROCEDURE...47
      Operation & Maintenance Manual And Operator’s Handbook Locations...47
      Entering The Excavator...47
      Seat Adjustment...48
      Seat Belt Adjustment...48
      Control Console...48
    STARTING THE ENGINE...49
      Key Switch...49
      Keyless...50
      Cold Temperature Starting...51
      Warming The Hydraulic System...52
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...53
      Procedure...53
      Emergency Exits...54
    ATTACHMENTS...55
      Installing And Removing The Attachment (Hydraulic X-Change)...55
      Installing And Removing The Attachment (Pin-On X- Change)...59
      Installing And Removing The Attachment (Bolt-On X- Change)...65
      Installing And Removing The Attachment (Pin-On Attachment)...71
    OPERATING PROCEDURE...72
      Inspect The Work Area...72
      Lowering The Work Equipment (Engine STOPPED)...72
      Operating On Public Roads...72
      Lifting A Load...73
      Excavating...74
      Boom Swing...76
      Backfilling...77
      Driving The Excavator...77
      Operating On Slopes...78
      Operating In Water...80
      Avoiding Track Damage...80
    TOWING THE EXCAVATOR...80
      Procedure...80
    LIFTING THE EXCAVATOR...81
      Procedure...81
    TRANSPORTING THE EXCAVATOR ON A TRAILER...82
      Loading And Unloading...82
      Fastening...82
  PREVENTIVE MAINTENANCE...83
    MAINTENANCE SAFETY...85
    SERVICE SCHEDULE...87
      Chart...87
    CONTROL CONSOLE LOCKOUTS...88
      Inspection And Maintenance...88
    SEAT BELT...89
      Inspection And Maintenance...89
    MOTION ALARM SYSTEM (IF EQUIPPED)...90
      Description...90
      Inspecting...90
      Adjusting Switch Position...90
    TAILGATE...91
      Opening And Closing...91
    RIGHT SIDE COVER...92
      Opening And Closing...92
    CAB FILTERS...93
      Cleaning And Maintenance (Early Models)...93
      Cleaning And Maintenance (Later Models)...94
    AIR CLEANER SERVICE...95
      Daily Check...95
      Replacing Filter Elements...95
    FUEL SYSTEM...97
      Fuel Specifications...97
      Filling The Fuel Tank...97
      Fuel Filters...98
      Draining The Fuel Tank...100
      Removing Air From The Fuel System...100
    ENGINE LUBRICATION SYSTEM...101
      Checking And Adding Engine Oil...101
      Engine Oil Chart...101
      Removing And Replacing Oil Filter...102
    ENGINE COOLING SYSTEM...103
      Cleaning...103
      Checking Level...104
      Removing And Replacing Coolant...105
    ELECTRICAL SYSTEM...106
      Description...106
      Fuse And Relay Location / Identification...106
      Battery Maintenance...107
      Using A Booster Battery (Jump Starting)...108
      Removing And Installing Battery...109
    HYDRAULIC SYSTEM...110
      Checking And Adding Fluid...110
      Hydraulic Fluid Chart...110
      Removing And Replacing The Hydraulic Filter...111
      Removing And Replacing The Case Drain Filter...111
      Removing And Replacing The Hydraulic Fluid...112
    SPARK ARRESTOR MUFFLER...113
      Cleaning Procedure...113
    TRACK TENSION...114
      Adjusting...114
    TRAVEL MOTOR...116
      Checking And Adding Oil...116
      Removing And Replacing Oil...116
    ALTERNATOR BELT...117
      Belt Adjustment...117
      Belt Replacement...117
    X-CHANGE...118
      Inspection And Maintenance...118
    TRACK ROLLER AND IDLER LUBRICATION...118
      Procedure...118
    BUCKET...119
      Bucket Teeth Removal And Installation...119
    LUBRICATING THE EXCAVATOR...120
      Lubrication Locations...120
    PIVOT PINS...122
      Inspection And Maintenance...122
    EXCAVATOR STORAGE AND RETURN TO SERVICE...123
      Storage...123
      Return to Service...123
  SYSTEM SETUP AND ANALYSIS...125
    DIAGNOSTIC SERVICE CODE...127
      Service Codes List...127
    DISPLAY CONTROLLER PANEL SETUP...128
      Passwords...128
      Password Entry (For Starting and Operating the Machine)...128
      Changing The Operator Password...128
      Password Lockout Feature...129
      Job Clock...129
      RPM...129
      Viewing Service Codes (Key Switch)...130
      Viewing Service Codes (Keyless)...130
  MACHINE SIGN TRANSLATIONS...131
    WARNING (6808185)...133
    LIFT CHART...134
      425 STANDARD ARM (7132125)...134
      425 With LONG ARM OPTION (7135359)...137
    SERVICE SCHEDULE (7151799)...140
    WARNING (6807776)...143
    WARNING (6804114, 6817225, 6804233)...145
    WARNING (6817815)...146
    WARNING (6808474)...146
    WARNING (6576048)...147
    WARNING (6815915)...148
    USING THE X-CHANGE SYSTEM (7102651)...149
    USING THE X-CHANGE SYSTEM (7134587)...152
    WARNING (6809829)...155
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...156
  SPECIFICATIONS...157
    EXCAVATOR SPECIFICATIONS...159
      425 With Standard Arm And Long Arm Option...159
      425 With Standard Arm...160
      425 With Long Arm Option...161
      Performance...162
      Controls...162
      Engine...162
      Hydraulic System...163
      Hydraulic Cylinders...163
      Hydraulic Cycle Times...163
      Electrical...163
      Instrumentation...163
      Drive System...164
      Slew System...164
      Undercarriage...164
      Crawler Track Design...164
      Capacities...164
      Fuel Tank...164
      Tracks...164
      Type...164
      Ground Pressure...164
  WARRANTY...165
  ALPHABETICAL INDEX...169
6904866 (07-07) - 425 Compact Excavator Service Manual...171
  MAINTENANCE SAFETY...173
  ALPHABETICAL INDEX...175
  CONTENTS...177
    FOREWORD...179
    SAFETY INSTRUCTIONS...181
      Fire Prevention...183
    SERIAL NUMBER LOCATIONS...185
      Excavator Serial Number...185
      Engine Serial Number...185
    DELIVERY REPORT...186
    EXCAVATOR IDENTIFICATION...187
  SAFETY AND MAINTENANCE...189
    LIFTING AND BLOCKING THE EXCAVATOR...191
      Procedure...191
    UPPERSTRUCTURE SLEW LOCK...193
      Operation...193
    LIFTING THE EXCAVATOR...195
      Procedure...195
    OPERATOR CAB (ROPS / TOPS)...197
      Description...197
      Cab Door...197
      Front Window...198
      Front Wiper...199
      Window Washer Reservoir...199
      Right Side Window...200
      Heating, Ventilation, and Air Conditioning Duct...201
    TRANSPORTING THE EXCAVATOR ON A TRAILER...203
      Loading And Unloading...203
      Fastening...203
    TAILGATE...205
      Opening And Closing...205
    RIGHT SIDE COVER...207
      Opening And Closing...207
    SERVICE SCHEDULE...209
      Chart...209
    AIR CLEANER SERVICE...211
      Daily Check...211
      Replacing Filter Elements...211
    ENGINE COOLING SYSTEM...213
      Cleaning...213
      Checking Level...214
      Removing And Replacing Coolant...215
    FUEL SYSTEM...217
      Fuel Specifications...217
      Filling The Fuel Tank...217
      Fuel Filters...218
      Draining The Fuel Tank...220
      Removing Air From The Fuel System...220
    ENGINE LUBRICATION SYSTEM...221
      Checking And Adding Engine Oil...221
      Engine Oil Chart...221
      Removing And Replacing Oil Filter...222
    HYDRAULIC SYSTEM...223
      Checking And Adding Fluid...223
      Hydraulic Fluid Chart...223
      Removing And Replacing The Hydraulic Filter...224
      Removing And Replacing The Case Drain Filter...224
      Removing And Replacing The Hydraulic Fluid...225
    LUBRICATING THE EXCAVATOR...227
      Lubrication Locations...227
    TRAVEL MOTOR...231
      Checking And Adding Oil...231
      Removing And Replacing Oil...231
    SPARK ARRESTOR MUFFLER...233
      Cleaning Procedure...233
    ALTERNATOR BELT...235
      Belt Adjustment...235
      Belt Replacement...235
    SEAT BELT...237
      Inspection And Maintenance...237
    PIVOT PINS...239
      Inspection And Maintenance...239
    EXCAVATOR STORAGE AND RETURN TO SERVICE...241
      Storage...241
      Return to Service...241
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...243
      Procedure...243
      Emergency Exits...244
  HYDRAULIC SYSTEM...245
    HYDRAULIC/HYDROSTATIC SCHEMATIC...251
    HYDRAULIC SYSTEM INFORMATION...253
      Glossary Of Hydraulic / Hydrostatic Symbols...253
      Troubleshooting The Hydraulic Circuit...257
      Troubleshooting The Cylinder Circuit...258
      Troubleshooting The Swing (Upperstructure Slew) Circuit...259
      Troubleshooting The Travel Circuit...260
    BOOM CYLINDER...261
      Testing...261
      Removal And Installation...264
      Parts Identification...267
      Disassembly...268
      Assembly...270
    ARM CYLINDER...273
      Testing...273
      Removal And Installation...275
      Parts Identification...277
      Disassembly...278
      Assembly...280
    BOOM SWING CYLINDER...283
      Testing...283
      Removal And Installation...285
      Parts Identification...286
      Disassembly...287
      Assembly...289
    BUCKET CYLINDER...293
      Testing...293
      Removal And Installation...295
      Parts Identification...296
      Disassembly...297
      Assembly...299
    BLADE CYLINDER...303
      Testing...303
      Removal And Installation...305
      Parts Identification...306
      Disassembly...307
      Assembly...309
    MAIN RELIEF VALVE...313
      Testing And Adjusting The Main Relief Valve...313
    PORT RELIEF VALVES...317
      Testing And Adjusting Port Relief Valve Pressure...317
    CROSSPORT RELIEF VALVES...319
      Testing And Adjusting The Crossport Relief Valves...319
    PRESSURE REDUCING VALVE...323
      Testing And Adjusting The Pressure Reducing Valve...323
    HYDRAULIC CONTROL VALVE...325
      Description...325
      Removal And Installation...326
      Parts Identification...329
      Disassembly...330
      Right Travel Valve Section Disassembly And Assembly...332
      Left Travel Valve Section Disassembly And Assembly...336
      Blade Valve Section Disassembly And Assembly...340
      Slew Valve Section Disassembly And Assembly...349
      Auxiliary Valve Section Disassembly And Assembly...354
      Bucket Valve Section Disassembly And Assembly...359
      Arm Valve Section Disassembly And Assembly...364
      Boom Valve Section Disassembly And Assembly...369
      Boom Swing Valve Section Disassembly And Assembly...374
      Inlet Section Disassembly And Assembly...379
      Assembly...384
    HYDRAULIC PUMP...391
      Description...391
      Torque Adjustment...392
      Testing The Piston Pump...393
      Testing Auxiliary Hydraulic Flow...394
      Removal...395
      Installation...396
      Coupler Removal And Installation...397
      Parts Identification (Piston Pump)...398
      Disassembly...399
      Piston Pump Disassembly...400
      Piston Pump Assembly...406
      Assembly...412
    MANIFOLD ASSEMBLY / ACCUMULATOR...413
      Description...413
      Removal And Installation...413
      Parts Identification...415
      Disassembly And Assembly...416
    TRAVEL MOTOR...425
      Description...425
      Removal And Installation...425
      Parts Identification...426
      Disassembly...427
      Assembly...437
    SWIVEL JOINT...449
      Description...449
      Removal And Installation...449
      Parts Identification...451
      Disassembly...452
      Assembly...453
    SWING MOTOR...457
      Description...457
      Removal And Installation...457
      Parts Identification...459
      Disassembly...460
      Assembly...465
    SWING MOTOR DRIVE CARRIER...471
      Description...471
      Removal And Installation...471
      Parts Identification...472
      Disassembly...473
      Assembly...475
    CONTROL PATTERN SELECTOR VALVE...479
      Description...479
      Removal And Installation...479
      Parts Identification...480
      Disassembly and Assembly...481
    RIGHT CONTROL LEVER (JOYSTICK)...483
      Description...483
      Testing...483
      Handle Removal And Installation...484
      Removal And Installation...488
      Parts Identification...491
      Disassembly...492
      Assembly...497
    LEFT CONTROL LEVER (JOYSTICK)...503
      Description...503
      Testing...503
      Handle Removal And Installation...504
      Removal And Installation...507
      Parts Identification...509
      Disassembly...510
      Assembly...515
    TRAVEL CONTROL VALVE...521
      Removal and Installation...521
      Parts Identification...522
      Disassembly And Assembly...523
    HYDRAULIC FILTER...527
      Description...527
      Housing Removal And Installation...527
    CASE DRAIN FILTER...529
      Description...529
      Removal And Installation...529
    HYDRAULIC RESERVOIR...531
      Description...531
      Removal And Installation...531
    OIL COOLER...533
      Description...533
      Removal And Installation...533
    DIRECT TO TANK VALVE...535
      Desciption...535
      Removal And Installation...535
      Parts Identification...536
      Disassembly And Assembly...537
    NON-PRESSURIZED ACCUMULATOR...539
      Desciption...539
      Removal And Installation...539
    HYDRAULIC X-CHANGE VALVE...541
      Removal And Installation...541
      Parts Identification...543
      Disassembly...544
      Assembly...552
  UNDERCARRIAGE...561
    BLADE...563
      Description...563
      Removal And Installation...563
    TRACK FRAME COMPONENTS...565
      Description...565
      Track Lug Height...565
      Checking Tension...566
      Adjusting Tension...567
      Rubber Track Removal And Installation...569
      Steel Track Removal And Installation...572
      Idler (Front) Removal And Installation...575
      Idler (Front) Parts Identification...576
      Idler (Front) Disassembly...577
      Idler (Front) Assembly...579
      Coil Spring Assembly And Cylinder Disassembly And Assembly...582
      Roller Removal and Installation...583
      Roller Parts Identification...584
      Roller Disassembly...585
      Roller Assembly...587
      Track Guide Removal And Installation...589
      Track Damage Identification...590
    SWING CIRCLE GEAR...601
      Removal And Installation...601
  UPPERSTRUCTURE & SWING SECTION...603
    UPPERSTRUCTURE...607
      Description...607
      Removal...607
      Installation...610
    CANOPY...613
      Removal And Installation...613
    CAB...617
      Removal And Installation...617
      Door Removal And Installation...622
      Front Window Removal And Installation...623
      Right Side Rear Sliding Window Removal And Installation...626
      Right Side Front Sliding Window Removal And Installation...626
      Glass Removal...627
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...628
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...628
      Glass Installation...629
    SEAT AND SEAT MOUNT...635
      Seat Mount Removal And Installation...635
      Seat Removal And Installation...636
    RIGHT CONSOLE...637
      Description...637
      Console Cover Removal And Installation...637
      Console Base Cover Removal And Installation...638
    LEFT CONSOLE...641
      Description...641
      Joystick Console Cover (Bottom) Removal And Installation...641
      Joystick Console Cover (Top) Removal And Installation...642
      Compression Spring Removal And Installation...643
      Compression Spring Disassembly And Assembly...643
      Lever Removal And Installation...645
      Joystick Console Frame Removal And Installation...647
      Joystick Console Frame Disassembly And Installation...648
      Left Rear Console Cover Removal And Installation...649
      Left Rear Console Frame Removal And Installation...650
      Left Rear Console Frame Disassembly And Assembly...652
    BLADE CONTROL...653
      Removal And Installation...653
      Disassembly And Assembly...653
      Linkage Removal And Installation...654
      Linkage Disassembly And Assembly...656
    UPPERSTRUCTURE SLEW LOCK...657
      Removal and Installation...657
    FLOOR MAT AND FLOOR PANEL...659
      Description...659
      Removal And Installation...659
    BOOM SWING PEDAL...663
      Description...663
      Removal And Installation...663
      Disassembly And Assembly...664
      Linkage Removal And Installation...666
    TRAVEL LEVER / PEDALS...667
      Description...667
      Removal And Installation...667
      Disassembly And Assembly...668
      Adjustment...670
      Linkage Removal And Installation...672
    FUEL TANK...673
      Removal And Installation...673
    HORN...677
      Removal And Installation...677
    SWING FRAME...679
      Description...679
      Removal And Installation...679
      Hose Routing...683
      Bushing Removal And Installation...684
      Swing Frame Bushing Removal And Installation...684
    BOOM...687
      Description...687
      Removal And Installation...687
    ARM...691
      Description...691
      Removal And Installation...691
      Arm To Boom Bushing Removal And Installation...692
      Arm To Bucket And Bucket Link Bushing Removal And Installation...692
    BUCKET...695
      Removal And Installation (Pin-On X-Change)...695
      Removal And Installation (Bolt-On X-Change)...701
      Removal And Installation (Pin-On Attachment)...707
      Bucket Teeth Removal And Installation...708
      Bucket Side Cutting Edge Removal And Installation...709
    TAILGATE...711
      Removal And Installation...711
      Latch Removal And Installation...711
    X-CHANGE...713
      Pin-On Removal And Installation...713
      Pin-On Disassembly and Assembly...714
    X-CHANGE (HYDRAULIC)...715
      Removal And Installation...715
      Parts Identification...718
      Disassembly...719
      Assembly...724
    RIGHT SIDE COVER...733
      Removal And Installation...733
      Latch Removal And Installation...733
    COUNTERWEIGHT...735
      Description...735
      Removal And Installation (Long Arm Counterweight)...735
      Removal And Installation (Standard Counterweight)...736
    LEFT SIDE COVER...737
      Removal And Installation...737
  ELECTRICAL SYSTEM AND ANALYSIS...739
    ELECTRICAL SCHEMATICS...741
    ELECTRICAL SYSTEM INFORMATION...743
      Glossary Of Electrical Symbols...743
      Harness Connectors...746
      Troubleshooting...748
      Description...749
      Fuse And Relay Location / Identification...749
    BATTERY...751
      Removal And Installation...751
      Servicing...752
      Using A Booster Battery (Jump Starting)...753
    ALTERNATOR...755
      Belt Adjustment...755
      Belt Replacement...755
      Charging System Inspection...756
      Description...757
      Tests...757
      Alternator Output Test...758
      Full Field Test...758
      Alternator Regulator Test...759
      Alternator Regulator Test With Voltmeter...759
      Removal And Installation...760
      Parts Identification...761
    STARTER...763
      Testing...763
      Removal And Installation...764
      Parts Identification...765
    LIGHTS...767
      Upperstructure Light Removal And Installation...767
      Upperstructure Light Disassembly And Assembly...767
      Boom Light Removal And Installation...768
      Boom Light Disassembly And Assembly...768
    MAGNETIC LOCKOUT SENSOR...769
      Testing Left Console Magnetic Lockout Sensor...769
      Left Console Magnetic Lockout Sensor Removal And Installation...770
    FUEL LEVEL SENDER...773
      Removal And Installation...773
      Testing...774
    DIAGNOSTIC SERVICE CODES...775
      Description...775
      Service Codes List...776
  ENGINE SERVICE...777
    ENGINE INFORMATION...779
      Description...779
      Specifications...780
      Torque Values...784
      Troubleshooting...785
      Removal And Installation...786
      Engine Mount Replacement...790
      Compression - Checking...791
    ENGINE SPEED CONTROL...793
      Removal And Installation...793
    SPARK ARRESTOR MUFFLER...795
      Removal And Installation...795
    AIR CLEANER...797
      Removal And Installation...797
    ENGINE COOLING SYSTEM...799
      Radiator Removal And Installation...799
      Radiator Disassembly and Assembly...801
      Water Pump Removal And Installation...801
      Water Pump Disassembly And Assembly...802
      Thermostat Housing Removal And Installation...802
      Testing The Thermostat...803
    LUBRICATION SYSTEM...805
      Oil Pan Removal And Installation...805
      Oil Pump Removal And Installation...805
      Oil Pump Inspection...806
      Engine Oil Pressure - Testing...807
    FUEL SYSTEM...809
      Fuel Camshaft Removal And Installation...809
      Fuel Camshaft Governor Disassembly And Assembly...809
      Fuel Shutoff Solenoid - Checking...810
      Fuel Shutoff Solenoid Removal And Installation...811
      Fuel Injection Pump Removal And Installation...812
      Timing The Injection Pump...814
      Fuel Injector Removal And Installation...816
      Fuel Injector Nozzles Pressure - Checking...818
      Nozzle Spray Condition...819
      Valve Seat Tightness...819
    CYLINDER HEAD...821
      Glow Plug - Testing...821
      Glow Plug Removal And Installation...822
      Valve Clearance Adjustment...822
      Valve Timing - Checking...823
      Cylinder Head Removal And Installation...824
      Cylinder Head Disassembly and Assembly...826
      Cylinder Head - Servicing...826
      Cylinder Head Top Clearance...827
      Valve Guide - Checking...827
      Reconditioning The Valve And Valve Seat...828
      Valve Spring...830
      Valve Tappets...831
      Rocker Arm And Shaft - Checking...831
    CRANKSHAFT AND PISTONS...833
      Piston And Connecting Rod Removal And Installation...833
      Piston And Connecting Rod - Servicing...835
      Cylinder Bore Checking...837
      Connecting Rod Alignment...838
      Crankshaft And Bearings Removal And Installation...838
      Crankshaft And Bearings - Servicing...840
    CAMSHAFT AND TIMING GEARS...845
      Timing Gearcase Cover Removal And Installation...845
      Timing Gears Backlash - Checking...847
      Idler Gear And Shaft Removal And Installation...847
      Camshaft - Servicing...848
      Idler Gear And Shaft Servicing...850
    FLYWHEEL AND HOUSING...851
      Flywheel Housing Removal And Installation...851
      Hydraulic Pump Coupler Removal And Installation...852
      Flywheel Removal And Installation...853
      Rear End Plate Removal And Installation...853
  HEATER...855
    HEATER SYSTEM...857
      Description...857
      Components...857
    REGULAR MAINTENANCE...859
      Filter Element Removal And Installation...859
      Heater Coil...860
    TROUBLESHOOTING...861
      Blower Motor Does Not Operate...861
      Blower Motor Operates Normally, But Air Flow Is Insufficient...861
      Electrical System...862
    HEATER UNIT...867
      Removal And Installation...867
    HEATER COIL...869
      Removal And Installation...869
    BLOWER FAN...871
      Removal And Installation...871
    HEATER VALVE...873
      Removal And Installation...873
  SPECIFICATIONS...875
    EXCAVATOR SPECIFICATIONS...877
      425 With Standard Arm...877
      425 With Long Arm Option...879
      Performance...881
      Controls...881
      Engine...881
      Hydraulic System...882
      Hydraulic Cylinders...882
      Hydraulic Cycle Times...882
      Electrical...882
      Instrumentation...882
      Drive System...883
      Slew System...883
      Undercarriage...883
      Crawler Track Design...883
      Capacities...883
      Fuel Tank...883
      Tracks...883
      Type...883
      Ground Pressure...883
    TORQUE SPECIFICATIONS FOR BOLTS...885
      Torque For General SAE Bolts...885
      Torque For General Metric Bolts...886
    HYDRAULIC CONNECTION SPECIFICATIONS...887
      O-ring Face Seal Connection...887
      Straight Thread O-ring Fitting...888
      Tubelines And Hoses...888
      Flare Fitting...889
      Port Seal Fitting...890
    HYDRAULIC FLUID SPECIFICATIONS...891
      Specifications...891
    CONVERSIONS...893
      Decimal And Millimeter Equivalents...893
      U.S. To Metric Conversion Chart...893
  SMR...895
    425-1...895
6904866 (09-09) - 425, 428 Compact Excavator Service Manual...897
  MAINTENANCE SAFETY...899
  ALPHABETICAL INDEX...901
  CONTENTS...903
    FOREWORD...905
    SAFETY INSTRUCTIONS...907
    FIRE PREVENTION...908
      Maintenance...908
      Operation...908
      Electrical...908
      Hydraulic System...909
      Fueling...909
      Starting...909
      Spark Arrestor Exhaust System...909
      Welding And Grinding...909
      Fire Extinguishers...909
    SERIAL NUMBER LOCATIONS...910
      Excavator Serial Number...910
      Engine Serial Number...910
    DELIVERY REPORT...911
    EXCAVATOR IDENTIFICATION...912
  SAFETY & MAINTENANCE...913
    LIFTING AND BLOCKING THE EXCAVATOR...915
      Procedure...915
    UPPERSTRUCTURE SLEW LOCK...917
      Operation...917
    LIFTING THE EXCAVATOR...919
      Procedure...919
    OPERATOR CAB (ROPS / TOPS)...921
      Description...921
      Cab Door...921
      Front Window...922
      Front Wiper...923
      Window Washer Reservoir...923
      Right Side Window...924
      Heating, Ventilation, and Air Conditioning Duct...925
    TRANSPORTING THE EXCAVATOR ON A TRAILER...927
      Loading And Unloading...927
      Fastening...927
    TAILGATE...929
      Opening And Closing...929
    RIGHT SIDE COVER...931
      Opening And Closing...931
    SERVICE SCHEDULE...933
      Chart...933
    AIR CLEANER SERVICE...935
      Daily Check...935
      Replacing Filter Elements...935
    ENGINE COOLING SYSTEM...937
      Cleaning...937
      Checking Level...938
      Removing And Replacing Coolant...939
    FUEL SYSTEM...941
      Fuel Specifications...941
      Filling The Fuel Tank...941
      Fuel Filters...942
      Draining The Fuel Tank...944
      Removing Air From The Fuel System...944
    ENGINE LUBRICATION SYSTEM...945
      Checking And Adding Engine Oil...945
      Engine Oil Chart...945
      Removing And Replacing Oil Filter...946
    HYDRAULIC SYSTEM...947
      Checking And Adding Fluid...947
      Hydraulic Fluid Chart...947
      Removing And Replacing The Hydraulic Filter...948
      Removing And Replacing The Case Drain Filter...948
      Removing And Replacing The Hydraulic Fluid...949
    LUBRICATING THE EXCAVATOR...951
      Lubrication Locations...951
    TRAVEL MOTOR...955
      Checking And Adding Oil...955
      Removing And Replacing Oil...955
    SPARK ARRESTOR MUFFLER...957
      Cleaning Procedure...957
    ALTERNATOR BELT...959
      Belt Adjustment...959
      Belt Replacement...959
    SEAT BELT...961
      Inspection And Maintenance...961
    PIVOT PINS...963
      Inspection And Maintenance...963
    EXCAVATOR STORAGE AND RETURN TO SERVICE...965
      Storage...965
      Return to Service...965
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...967
      Procedure...967
      Emergency Exits...968
  HYDRAULIC SYSTEM...969
    HYDRAULIC / HYDROSTATIC SCHEMATICS...975
    HYDRAULIC SYSTEM INFORMATION...977
      Glossary Of Hydraulic / Hydrostatic Symbols...977
      Troubleshooting The Hydraulic Circuit...981
      Troubleshooting The Cylinder Circuit...982
      Troubleshooting The Swing (Upperstructure Slew) Circuit...983
      Troubleshooting The Travel Circuit...984
    BOOM CYLINDER...985
      Testing...985
      Removal And Installation...988
      Parts Identification...991
      Disassembly...992
      Assembly...994
    ARM CYLINDER...997
      Testing...997
      Removal And Installation...999
      Parts Identification...1001
      Disassembly...1002
      Assembly...1004
    BOOM SWING CYLINDER...1007
      Testing...1007
      Removal And Installation...1009
      Parts Identification...1010
      Disassembly...1011
      Assembly...1013
    BUCKET CYLINDER...1017
      Testing...1017
      Removal And Installation...1019
      Parts Identification...1020
      Disassembly...1021
      Assembly...1023
    BLADE CYLINDER...1027
      Testing...1027
      Removal And Installation...1029
      Parts Identification...1030
      Disassembly...1031
      Assembly...1033
    CLAMP CYLINDER...1037
      Testing...1037
      Removal And Installation...1038
      Parts Identification...1039
      Disassembly...1040
      Assembly...1043
    MAIN RELIEF VALVE...1049
      Testing And Adjusting The Main Relief Valve...1049
    PORT RELIEF VALVES...1053
      Testing And Adjusting Port Relief Valve Pressure...1053
    CROSSPORT RELIEF VALVES...1055
      Testing And Adjusting The Crossport Relief Valves...1055
    PRESSURE REDUCING VALVE...1059
      Testing And Adjusting The Pressure Reducing Valve...1059
    HYDRAULIC CONTROL VALVE...1061
      Description...1061
      Removal And Installation...1062
      Parts Identification...1065
      Disassembly...1066
      Right Travel Valve Section Disassembly And Assembly...1068
      Left Travel Valve Section Disassembly And Assembly...1072
      Blade Valve Section Disassembly And Assembly...1076
      Slew Valve Section Disassembly And Assembly...1085
      Auxiliary Valve Section Disassembly And Assembly...1090
      Bucket Valve Section Disassembly And Assembly...1095
      Arm Valve Section Disassembly And Assembly...1100
      Boom Valve Section Disassembly And Assembly...1105
      Boom Swing Valve Section Disassembly And Assembly...1110
      Inlet Section Disassembly And Assembly...1115
      Assembly...1120
    HYDRAULIC PUMP...1127
      Description...1127
      Torque Adjustment...1128
      Testing The Piston Pump...1129
      Testing Auxiliary Hydraulic Flow...1130
      Removal...1131
      Installation...1132
      Coupler Removal And Installation...1133
      Piston Pump Parts Identification...1134
      Disassembly...1135
      Piston Pump Disassembly...1136
      Piston Pump Assembly...1142
      Assembly...1148
    MANIFOLD ASSEMBLY / ACCUMULATOR...1149
      Description...1149
      Removal And Installation...1149
      Parts Identification...1151
      Disassembly And Assembly...1152
    TRAVEL MOTOR...1161
      Description...1161
      Removal And Installation...1161
      Parts Identification...1162
      Disassembly...1163
      Assembly...1173
    SWIVEL JOINT...1185
      Description...1185
      Removal And Installation...1185
      Parts Identification...1187
      Disassembly...1188
      Assembly...1189
    SWING MOTOR...1193
      Description...1193
      Removal And Installation...1193
      Parts Identification...1195
      Disassembly...1196
      Assembly...1201
    SWING MOTOR DRIVE CARRIER...1207
      Description...1207
      Removal And Installation...1207
      Parts Identification...1208
      Disassembly...1209
      Assembly...1211
    CONTROL PATTERN SELECTOR VALVE...1215
      Description...1215
      Removal And Installation...1215
      Parts Identification...1216
      Disassembly and Assembly...1217
    RIGHT CONTROL LEVER (JOYSTICK)...1219
      Description...1219
      Testing...1219
      Handle Removal And Installation...1220
      Removal And Installation...1224
      Parts Identification...1227
      Disassembly...1228
      Assembly...1233
    LEFT CONTROL LEVER (JOYSTICK)...1239
      Description...1239
      Testing...1239
      Handle Removal And Installation...1240
      Removal And Installation...1243
      Parts Identification...1245
      Disassembly...1246
      Assembly...1251
    TRAVEL CONTROL VALVE...1257
      Removal and Installation...1257
      Parts Identification...1258
      Disassembly And Assembly...1259
    HYDRAULIC FILTER...1263
      Description...1263
      Housing Removal And Installation...1263
    CASE DRAIN FILTER...1265
      Description...1265
      Removal And Installation...1265
    HYDRAULIC RESERVOIR...1267
      Description...1267
      Removal And Installation...1267
    OIL COOLER...1269
      Description...1269
      Removal And Installation...1269
    DIRECT TO TANK VALVE...1271
      Description...1271
      Removal And Installation...1271
      Parts Identification...1272
      Disassembly And Assembly...1273
    NON-PRESSURIZED ACCUMULATOR...1275
      Description...1275
      Removal And Installation...1275
  UNDERCARRIAGE...1277
    BLADE...1279
      Description...1279
      Removal And Installation...1279
    TRACK FRAME COMPONENTS...1281
      Description...1281
      Track Lug Height...1281
      Checking Tension...1282
      Adjusting Tension...1283
      Rubber Track Removal And Installation...1285
      Steel Track Removal And Installation...1288
      Idler (Front) Removal And Installation...1291
      Idler (Front) Parts Identification...1292
      Idler (Front) Disassembly...1293
      Idler (Front) Assembly...1295
      Coil Spring Assembly And Cylinder Disassembly And Assembly (W/O Replaceable Shaft)...1298
      Coil Spring Cylinder Parts Identification (With Replaceable Shaft)...1299
      Coil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)...1300
      Roller Removal And Installation...1301
      Roller Parts Identification...1302
      Roller Disassembly...1303
      Roller Assembly...1305
      Track Guide Removal And Installation...1307
      Sprocket Removal And Installation...1307
      Track Damage Identification...1308
      1. Coil Spring Assembly 2. O-Ring 3. Spacer (Steel Track Only) 4. Shaft 5. Wiper Seal 6. Wear Ring 7. Back-Up Ring 8. Tube 9. Grease Fitting 10. Bleed Fitting 11. Bolt...1299
    SWING CIRCLE GEAR...1319
      Removal And Installation...1319
  UPPERSTRUCTURE & SWING SECTION...1321
    UPPERSTRUCTURE...1325
      Description...1325
      Removal...1325
      Installation...1328
    CANOPY...1331
      Removal And Installation...1331
    CAB...1335
      Removal And Installation...1335
      Door Removal And Installation...1340
      Front Window Removal And Installation...1341
      Right Side Rear Sliding Window Removal And Installation...1344
      Right Side Front Sliding Window Removal And Installation...1344
      Glass Removal...1345
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...1346
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...1346
      Glass Installation...1347
    SEAT AND SEAT MOUNT...1353
      Seat Mount Removal And Installation...1353
      Seat Removal And Installation...1353
    RIGHT CONSOLE...1355
      Description...1355
      Console Cover Removal And Installation...1355
      Console Base Cover Removal And Installation...1356
    LEFT CONSOLE...1359
      Description...1359
      Joystick Console Cover (Bottom) Removal And Installation...1359
      Joystick Console Cover (Top) Removal And Installation...1360
      Compression Spring Removal And Installation...1361
      Compression Spring Disassembly And Assembly...1361
      Lever Removal And Installation...1363
      Joystick Console Frame Removal And Installation...1365
      Joystick Console Frame Disassembly And Installation...1366
      Left Rear Console Cover Removal And Installation...1367
      Left Rear Console Frame Removal And Installation...1368
      Left Rear Console Frame Disassembly And Assembly...1370
    BLADE CONTROL...1371
      Removal And Installation...1371
      Disassembly And Assembly...1371
      Linkage Removal And Installation...1372
      Linkage Disassembly And Assembly...1374
    UPPERSTRUCTURE SLEW LOCK...1375
      Removal and Installation...1375
    FLOOR MAT AND FLOOR PANEL...1377
      Description...1377
      Removal And Installation...1377
    BOOM SWING PEDAL...1381
      Description...1381
      Removal And Installation...1381
      Disassembly And Assembly...1382
      Linkage Removal And Installation...1384
    TRAVEL LEVER / PEDALS...1385
      Description...1385
      Removal And Installation...1385
      Disassembly And Assembly...1386
      Adjustment...1388
      Linkage Removal And Installation...1390
    FUEL TANK...1391
      Removal And Installation...1391
    HORN...1395
      Removal And Installation...1395
    SWING FRAME...1397
      Description...1397
      Removal And Installation...1397
      Hose Routing...1401
      Bushing Removal And Installation...1402
      Swing Frame Bushing Removal And Installation...1402
    BOOM...1405
      Description...1405
      Removal And Installation...1405
    ARM...1409
      Description...1409
      Removal And Installation...1409
      Arm To Boom Bushing Removal And Installation...1410
      Arm To Bucket And Bucket Link Bushing Removal And Installation...1410
    BUCKET...1413
      Removal And Installation (Pin-On Attachment)...1413
      Bucket Teeth Removal And Installation...1414
      Bucket Side Cutting Edge Removal And Installation...1415
    CLAMP...1417
      Removal And Installation...1417
    TAILGATE...1419
      Removal And Installation...1419
      Latch Removal And Installation...1419
    RIGHT SIDE COVER...1421
      Removal And Installation...1421
      Latch Removal And Installation...1421
    COUNTERWEIGHT...1423
      Description...1423
      Removal And Installation (Long Arm Counterweight)...1423
      Removal And Installation (Standard Counterweight)...1424
    LEFT SIDE COVER...1425
      Removal And Installation...1425
  ELECTRICAL SYSTEM & ANALYSIS...1427
    ELECTRICAL SCHEMATICS...1429
    ELECTRICAL SYSTEM INFORMATION...1430
      Glossary Of Electrical Symbols...1430
      Harness Connectors...1433
      Troubleshooting...1435
      Description...1436
      Fuse And Relay Location / Identification...1436
    BATTERY...1438
      Removal And Installation...1438
      Servicing...1439
      Using A Booster Battery (Jump Starting)...1440
    ALTERNATOR...1442
      Belt Adjustment...1442
      Belt Replacement...1442
      Charging System Inspection...1443
      Description...1444
      Tests...1444
      Alternator Output Test...1445
      Full Field Test...1445
      Alternator Regulator Test...1446
      Alternator Regulator Test With Voltmeter...1446
      Removal And Installation...1447
      Parts Identification...1448
    STARTER...1450
      Testing...1450
      Removal And Installation...1451
      Parts Identification...1452
    LIGHTS...1454
      Upperstructure Light Removal And Installation...1454
      Upperstructure Light Disassembly And Assembly...1454
      Boom Light Removal And Installation...1455
      Boom Light Disassembly And Assembly...1455
    MAGNETIC LOCKOUT SENSOR...1456
      Testing Left Console Magnetic Lockout Sensor...1456
      Left Console Magnetic Lockout Sensor Removal And Installation...1457
    FUEL LEVEL SENDER...1460
      Removal And Installation...1460
      Testing...1461
    DIAGNOSTIC SERVICE CODES...1462
      Description...1462
      Service Codes List...1463
  ENGINE SERVICE...1464
    ENGINE INFORMATION...1466
      Description...1466
      Specifications...1467
      Torque Values...1471
      Troubleshooting...1472
      Removal And Installation...1473
      Engine Mount Replacement...1477
      Compression - Checking...1478
    ENGINE SPEED CONTROL...1480
      Removal And Installation...1480
    SPARK ARRESTOR MUFFLER...1482
      Removal And Installation...1482
    AIR CLEANER...1484
      Removal And Installation...1484
    ENGINE COOLING SYSTEM...1486
      Radiator Removal And Installation...1486
      Radiator Disassembly and Assembly...1488
      Water Pump Removal And Installation...1488
      Water Pump Disassembly And Assembly...1489
      Thermostat Housing Removal And Installation...1489
      Testing The Thermostat...1490
    LUBRICATION SYSTEM...1492
      Oil Pan Removal And Installation...1492
      Oil Pump Removal And Installation...1492
      Oil Pump Inspection...1493
      Engine Oil Pressure - Testing...1494
    FUEL SYSTEM...1496
      Fuel Camshaft Removal And Installation...1496
      Fuel Camshaft Governor Disassembly And Assembly...1496
      Fuel Shutoff Solenoid - Checking...1497
      Fuel Shutoff Solenoid Removal And Installation...1498
      Fuel Injection Pump Removal And Installation...1499
      Timing The Injection Pump...1501
      Fuel Injector Removal And Installation...1503
      Fuel Injector Nozzles Pressure - Checking...1505
      Nozzle Spray Condition...1506
      Valve Seat Tightness...1506
    CYLINDER HEAD...1508
      Glow Plug - Testing...1508
      Glow Plug Removal And Installation...1509
      Valve Clearance Adjustment...1509
      Valve Timing - Checking...1510
      Cylinder Head Removal And Installation...1511
      Cylinder Head Disassembly and Assembly...1513
      Cylinder Head - Servicing...1513
      Cylinder Head Top Clearance...1514
      Valve Guide - Checking...1514
      Reconditioning The Valve And Valve Seat...1515
      Valve Spring...1517
      Valve Tappets...1518
      Rocker Arm And Shaft - Checking...1518
    CRANKSHAFT AND PISTONS...1520
      Piston And Connecting Rod Removal And Installation...1520
      Piston And Connecting Rod - Servicing...1522
      Cylinder Bore Checking...1524
      Connecting Rod Alignment...1525
      Crankshaft And Bearings Removal And Installation...1525
      Crankshaft And Bearings - Servicing...1527
    CAMSHAFT AND TIMING GEARS...1532
      Timing Gearcase Cover Removal And Installation...1532
      Timing Gears Backlash - Checking...1534
      Idler Gear And Shaft Removal And Installation...1534
      Camshaft - Servicing...1535
      Idler Gear And Shaft Servicing...1537
    FLYWHEEL AND HOUSING...1538
      Flywheel Housing Removal And Installation...1538
      Hydraulic Pump Coupler Removal And Installation...1539
      Flywheel Removal And Installation...1540
      Rear End Plate Removal And Installation...1540
  HEATER...1542
    HEATER SYSTEM...1544
      Description...1544
      Components...1544
    REGULAR MAINTENANCE...1546
      Filter Element Removal And Installation...1546
      Heater Coil...1547
    TROUBLESHOOTING...1548
      Blower Motor Does Not Operate...1548
      Blower Motor Operates Normally, But Air Flow Is Insufficient...1548
      Electrical System...1549
    HEATER UNIT...1554
      Removal And Installation...1554
    HEATER COIL...1556
      Removal And Installation...1556
    BLOWER FAN...1558
      Removal And Installation...1558
    HEATER VALVE...1560
      Removal And Installation...1560
  SPECIFICATIONS...1562
    EXCAVATOR SPECIFICATIONS...1564
      425 With Standard Arm...1564
      425 With Long Arm Option And 428...1566
      Performance...1568
      Controls...1568
      Engine...1568
      Hydraulic System...1569
      Hydraulic Cylinders...1569
      Hydraulic Cycle Times...1569
      Electrical...1569
      Instrumentation...1569
      Drive System...1570
      Slew System...1570
      Undercarriage...1570
      Crawler Track Design...1570
      Capacities...1570
      Fuel Tank...1570
      Tracks...1570
      Type...1570
      Ground Pressure...1570
    TORQUE SPECIFICATIONS FOR BOLTS...1572
      Torque For General SAE Bolts...1572
      Torque For General Metric Bolts...1573
    HYDRAULIC CONNECTION SPECIFICATIONS...1574
      O-ring Face Seal Connection...1574
      Straight Thread O-ring Fitting...1575
      Tubelines And Hoses...1575
      Flare Fitting...1576
      Port Seal Fitting...1577
    HYDRAULIC FLUID SPECIFICATIONS...1578
      Specifications...1578
    CONVERSIONS...1580
      Decimal And Millimeter Equivalents...1580
      U.S. To Metric Conversion Chart...1580
  SERVICE MANUAL REVISION...1582
    425 / 428 - 1...1582
    425 / 428 - 2...1584
    425 / 428 - 3...1586
6904866 (11-06) - 425 Compact Excavator Service Manual...1588
  MAINTENANCE SAFETY...1590
  ALPHABETICAL INDEX...1592
  CONTENTS...1594
    FOREWORD...1596
    SAFETY INSTRUCTIONS...1598
      Fire Prevention...1600
    SERIAL NUMBER LOCATIONS...1602
      Excavator Serial Number...1602
      Engine Serial Number...1602
    DELIVERY REPORT...1603
    EXCAVATOR IDENTIFICATION...1604
  SAFETY AND MAINTENANCE...1606
    LIFTING AND BLOCKING THE EXCAVATOR...1608
      Procedure...1608
    UPPERSTRUCTURE SLEW LOCK...1610
      Operation...1610
    LIFTING THE EXCAVATOR...1612
      Procedure...1612
    OPERATOR CAB (ROPS / TOPS)...1614
      Description...1614
      Cab Door...1614
      Front Window...1615
      Front Wiper...1616
      Window Washer Reservoir...1616
      Right Side Window...1617
      Heating, Ventilation, and Air Conditioning Duct...1618
    TRANSPORTING THE EXCAVATOR ON A TRAILER...1620
      Loading And Unloading...1620
      Fastening...1620
    TAILGATE...1622
      Opening And Closing...1622
    RIGHT SIDE COVER...1624
      Opening And Closing...1624
    SERVICE SCHEDULE...1626
      Chart...1626
    AIR CLEANER SERVICE...1628
      Daily Check...1628
      Replacing Filter Elements...1628
    ENGINE COOLING SYSTEM...1630
      Cleaning...1630
      Checking Level...1631
      Removing And Replacing Coolant...1632
    FUEL SYSTEM...1634
      Fuel Specifications...1634
      Filling The Fuel Tank...1634
      Fuel Filters...1635
      Draining The Fuel Tank...1637
      Removing Air From The Fuel System...1637
    ENGINE LUBRICATION SYSTEM...1638
      Checking And Adding Engine Oil...1638
      Engine Oil Chart...1638
      Removing And Replacing Oil Filter...1639
    HYDRAULIC SYSTEM...1640
      Checking And Adding Fluid...1640
      Hydraulic Fluid Chart...1640
      Removing And Replacing The Hydraulic Filter...1641
      Removing And Replacing The Case Drain Filter...1641
      Removing And Replacing The Hydraulic Fluid...1642
    LUBRICATING THE EXCAVATOR...1644
      Lubrication Locations...1644
    TRAVEL MOTOR...1648
      Checking And Adding Oil...1648
      Removing And Replacing Oil...1648
    SPARK ARRESTOR MUFFLER...1650
      Cleaning Procedure...1650
    ALTERNATOR BELT...1652
      Belt Adjustment...1652
      Belt Replacement...1652
    SEAT BELT...1654
      Inspection And Maintenance...1654
    PIVOT PINS...1656
      Inspection And Maintenance...1656
    EXCAVATOR STORAGE AND RETURN TO SERVICE...1658
      Storage...1658
      Return to Service...1658
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...1660
      Procedure...1660
      Emergency Exits...1661
  HYDRAULIC SYSTEM...1662
    HYDRAULIC/HYDROSTATIC SCHEMATICS...1668
    HYDRAULIC SYSTEM INFORMATION...1670
      Glossary Of Hydraulic / Hydrostatic Symbols...1670
      Troubleshooting The Hydraulic Circuit...1674
      Troubleshooting The Cylinder Circuit...1675
      Troubleshooting The Swing (Upperstructure Slew) Circuit...1676
      Troubleshooting The Travel Circuit...1677
    BOOM CYLINDER...1678
      Testing...1678
      Removal And Installation...1681
      Parts Identification...1684
      Disassembly...1685
      Assembly...1687
    ARM CYLINDER...1690
      Testing...1690
      Removal And Installation...1692
      Parts Identification...1694
      Disassembly...1695
      Assembly...1697
    BOOM SWING CYLINDER...1700
      Testing...1700
      Removal And Installation...1702
      Parts Identification...1703
      Disassembly...1704
      Assembly...1706
    BUCKET CYLINDER...1710
      Testing...1710
      Removal And Installation...1712
      Parts Identification...1713
      Disassembly...1714
      Assembly...1716
    BLADE CYLINDER...1720
      Testing...1720
      Removal And Installation...1722
      Parts Identification...1723
      Disassembly...1724
      Assembly...1726
    MAIN RELIEF VALVE...1730
      Testing And Adjusting The Main Relief Valve...1730
    PORT RELIEF VALVES...1734
      Testing And Adjusting Port Relief Valve Pressure...1734
    CROSSPORT RELIEF VALVES...1736
      Testing And Adjusting The Crossport Relief Valves...1736
    PRESSURE REDUCING VALVE...1740
      Testing And Adjusting The Pressure Reducing Valve...1740
    HYDRAULIC CONTROL VALVE...1742
      Description...1742
      Removal And Installation...1743
      Parts Identification...1746
      Disassembly...1747
      Right Travel Valve Section Disassembly And Assembly...1749
      Left Travel Valve Section Disassembly And Assembly...1753
      Blade Valve Section Disassembly And Assembly...1757
      Slew Valve Section Disassembly And Assembly...1766
      Auxiliary Valve Section Disassembly And Assembly...1771
      Bucket Valve Section Disassembly And Assembly...1776
      Arm Valve Section Disassembly And Assembly...1781
      Boom Valve Section Disassembly And Assembly...1786
      Boom Swing Valve Section Disassembly And Assembly...1791
      Inlet Section Disassembly And Assembly...1796
      Assembly...1801
    HYDRAULIC PUMP...1808
      Description...1808
      Torque Adjustment...1809
      Testing The Piston Pump...1810
      Testing Auxiliary Hydraulic Flow...1811
      Removal...1812
      Installation...1813
      Coupler Removal And Installation...1814
      Parts Identification (Piston Pump)...1815
      Disassembly...1816
      Piston Pump Disassembly...1817
      Piston Pump Assembly...1823
      Assembly...1829
    MANIFOLD ASSEMBLY / ACCUMULATOR...1830
      Description...1830
      Removal And Installation...1830
      Parts Identification...1832
      Disassembly And Assembly...1833
    TRAVEL MOTOR...1842
      Description...1842
      Removal And Installation...1842
      Parts Identification...1843
      Disassembly...1844
      Assembly...1854
    SWIVEL JOINT...1866
      Description...1866
      Removal And Installation...1866
      Parts Identification...1868
      Disassembly...1869
      Assembly...1870
    SWING MOTOR...1874
      Description...1874
      Removal And Installation...1874
      Parts Identification...1876
      Disassembly...1877
      Assembly...1882
    SWING MOTOR DRIVE CARRIER...1888
      Description...1888
      Removal And Installation...1888
      Parts Identification...1889
      Disassembly...1890
      Assembly...1892
    CONTROL PATTERN SELECTOR VALVE...1896
      Description...1896
      Removal And Installation...1896
      Parts Identification...1897
      Disassembly and Assembly...1898
    RIGHT CONTROL LEVER (JOYSTICK)...1900
      Description...1900
      Testing...1900
      Handle Removal And Installation...1901
      Removal And Installation...1905
      Parts Identification...1908
      Disassembly...1909
      Assembly...1914
    LEFT CONTROL LEVER (JOYSTICK)...1920
      Description...1920
      Testing...1920
      Handle Removal And Installation...1921
      Removal And Installation...1924
      Parts Identification...1926
      Disassembly...1927
      Assembly...1932
    TRAVEL CONTROL VALVE...1938
      Removal and Installation...1938
      Parts Identification...1939
      Disassembly And Assembly...1940
    HYDRAULIC FILTER...1944
      Description...1944
      Housing Removal And Installation...1944
    CASE DRAIN FILTER...1946
      Description...1946
      Removal And Installation...1946
    HYDRAULIC RESERVOIR...1948
      Description...1948
      Removal And Installation...1948
    OIL COOLER...1950
      Description...1950
      Removal And Installation...1950
    DIRECT TO TANK VALVE...1952
      Desciption...1952
      Removal And Installation...1952
      Parts Identification...1953
      Disassembly And Assembly...1954
    NON-PRESSURIZED ACCUMULATOR...1956
      Desciption...1956
      Removal And Installation...1956
  UNDERCARRIAGE...1958
    BLADE...1960
      Description...1960
      Removal And Installation...1960
    TRACK FRAME COMPONENTS...1962
      Description...1962
      Track Lug Height...1962
      Checking Tension...1963
      Adjusting Tension...1964
      Rubber Track Removal And Installation...1966
      Steel Track Removal And Installation...1969
      Idler (Front) Removal And Installation...1972
      Idler (Front) Parts Identification...1973
      Idler (Front) Disassembly...1974
      Idler (Front) Assembly...1976
      Coil Spring Assembly And Cylinder Disassembly And Assembly...1979
      Roller Removal and Installation...1980
      Roller Parts Identification...1981
      Roller Disassembly...1982
      Roller Assembly...1984
      Track Guide Removal And Installation...1986
      Track Damage Identification...1987
    SWING CIRCLE GEAR...1998
      Removal And Installation...1998
  UPPERSTRUCTURE & SWING SECTION...2000
    UPPERSTRUCTURE...2004
      Description...2004
      Removal...2004
      Installation...2007
    CANOPY...2010
      Removal And Installation...2010
    CAB...2014
      Removal And Installation...2014
      Door Removal And Installation...2019
      Front Window Removal And Installation...2020
      Right Side Rear Sliding Window Removal And Installation...2023
      Right Side Front Sliding Window Removal And Installation...2023
      Glass Removal...2024
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...2025
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...2025
      Glass Installation...2026
    SEAT AND SEAT MOUNT...2032
      Seat Mount Removal And Installation...2032
      Seat Removal And Installation...2033
    RIGHT CONSOLE...2034
      Description...2034
      Console Cover Removal And Installation...2034
      Console Base Cover Removal And Installation...2035
    LEFT CONSOLE...2038
      Description...2038
      Joystick Console Cover (Bottom) Removal And Installation...2038
      Joystick Console Cover (Top) Removal And Installation...2039
      Compression Spring Removal And Installation...2040
      Compression Spring Disassembly And Assembly...2040
      Lever Removal And Installation...2042
      Joystick Console Frame Removal And Installation...2044
      Joystick Console Frame Disassembly And Installation...2045
      Left Rear Console Cover Removal And Installation...2046
      Left Rear Console Frame Removal And Installation...2047
      Left Rear Console Frame Disassembly And Assembly...2049
    BLADE CONTROL...2050
      Removal And Installation...2050
      Disassembly And Assembly...2050
      Linkage Removal And Installation...2051
      Linkage Disassembly And Assembly...2053
    UPPERSTRUCTURE SLEW LOCK...2054
      Removal and Installation...2054
    FLOOR MAT AND FLOOR PANEL...2056
      Description...2056
      Removal And Installation...2056
    BOOM SWING PEDAL...2060
      Description...2060
      Removal And Installation...2060
      Disassembly And Assembly...2061
      Linkage Removal And Installation...2063
    TRAVEL LEVER / PEDALS...2064
      Description...2064
      Removal And Installation...2064
      Disassembly And Assembly...2065
      Adjustment...2067
      Linkage Removal And Installation...2069
    FUEL TANK...2070
      Removal And Installation...2070
    HORN...2074
      Removal And Installation...2074
    SWING FRAME...2076
      Description...2076
      Removal And Installation...2076
      Hose Routing...2080
      Bushing Removal And Installation...2081
      Swing Frame Bushing Removal And Installation...2081
    BOOM...2084
      Description...2084
      Removal And Installation...2084
    ARM...2088
      Description...2088
      Removal And Installation...2088
      Arm To Boom Bushing Removal And Installation...2089
      Arm To Bucket And Bucket Link Bushing Removal And Installation...2089
    BUCKET...2092
      Removal And Installation (Pin-On X-Change)...2092
      Removal And Installation (Bolt-On X-Change)...2098
      Removal And Installation (Pin-On Attachment)...2104
      Bucket Teeth Removal And Installation...2105
      Bucket Side Cutting Edge Removal And Installation...2106
    TAILGATE...2108
      Removal And Installation...2108
      Latch Removal And Installation...2108
    X-CHANGE...2110
      Pin-On Removal And Installation...2110
      Pin-On Disassembly and Assembly...2111
    RIGHT SIDE COVER...2112
      Removal And Installation...2112
      Latch Removal And Installation...2112
    COUNTERWEIGHT...2114
      Description...2114
      Removal And Installation (Long Arm Counterweight)...2114
      Removal And Installation (Standard Counterweight)...2115
    LEFT SIDE COVER...2116
      Removal And Installation...2116
  ELECTRICAL SYSTEM AND ANALYSIS...2118
    ELECTRICAL SCHEMATICS...2120
    ELECTRICAL SYSTEM INFORMATION...2122
      Glossary Of Electrical Symbols...2122
      Harness Connectors...2125
      Troubleshooting...2127
      Description...2128
      Fuse And Relay Location / Identification...2128
    BATTERY...2130
      Removal And Installation...2130
      Servicing...2131
      Using A Booster Battery (Jump Starting)...2132
    ALTERNATOR...2134
      Belt Adjustment...2134
      Belt Replacement...2134
      Charging System Inspection...2135
      Description...2136
      Tests...2136
      Alternator Output Test...2137
      Full Field Test...2137
      Alternator Regulator Test...2138
      Alternator Regulator Test With Voltmeter...2138
      Removal And Installation...2139
      Parts Identification...2140
    STARTER...2142
      Testing...2142
      Removal And Installation...2143
      Parts Identification...2144
    LIGHTS...2146
      Upperstructure Light Removal And Installation...2146
      Upperstructure Light Disassembly And Assembly...2146
      Boom Light Removal And Installation...2147
      Boom Light Disassembly And Assembly...2147
    MAGNETIC LOCKOUT SENSOR...2148
      Testing Left Console Magnetic Lockout Sensor...2148
      Left Console Magnetic Lockout Sensor Removal And Installation...2149
    FUEL LEVEL SENDER...2152
      Removal And Installation...2152
      Testing...2153
    DIAGNOSTIC SERVICE CODES...2154
      Description...2154
      Service Codes List...2155
  ENGINE SERVICE...2156
    ENGINE INFORMATION...2158
      Description...2158
      Specifications...2159
      Torque Values...2163
      Troubleshooting...2164
      Removal And Installation...2165
      Engine Mount Replacement...2169
      Compression - Checking...2170
    ENGINE SPEED CONTROL...2172
      Removal And Installation...2172
    SPARK ARRESTOR MUFFLER...2174
      Removal And Installation...2174
    AIR CLEANER...2176
      Removal And Installation...2176
    ENGINE COOLING SYSTEM...2178
      Radiator Removal And Installation...2178
      Radiator Disassembly and Assembly...2180
      Water Pump Removal And Installation...2180
      Water Pump Disassembly And Assembly...2181
      Thermostat Housing Removal And Installation...2181
      Testing The Thermostat...2182
    LUBRICATION SYSTEM...2184
      Oil Pan Removal And Installation...2184
      Oil Pump Removal And Installation...2184
      Oil Pump Inspection...2185
      Engine Oil Pressure - Testing...2186
    FUEL SYSTEM...2188
      Fuel Camshaft Removal And Installation...2188
      Fuel Camshaft Governor Disassembly And Assembly...2188
      Fuel Shutoff Solenoid - Checking...2189
      Fuel Shutoff Solenoid Removal And Installation...2190
      Fuel Injection Pump Removal And Installation...2191
      Timing The Injection Pump...2193
      Fuel Injector Removal And Installation...2195
      Fuel Injector Nozzles Pressure - Checking...2197
      Nozzle Spray Condition...2198
      Valve Seat Tightness...2198
    CYLINDER HEAD...2200
      Glow Plug - Testing...2200
      Glow Plug Removal And Installation...2201
      Valve Clearance Adjustment...2201
      Valve Timing - Checking...2202
      Cylinder Head Removal And Installation...2203
      Cylinder Head Disassembly and Assembly...2205
      Cylinder Head - Servicing...2205
      Cylinder Head Top Clearance...2206
      Valve Guide - Checking...2206
      Reconditioning The Valve And Valve Seat...2207
      Valve Spring...2209
      Valve Tappets...2210
      Rocker Arm And Shaft - Checking...2210
    CRANKSHAFT AND PISTONS...2212
      Piston And Connecting Rod Removal And Installation...2212
      Piston And Connecting Rod - Servicing...2214
      Cylinder Bore Checking...2216
      Connecting Rod Alignment...2217
      Crankshaft And Bearings Removal And Installation...2217
      Crankshaft And Bearings - Servicing...2219
    CAMSHAFT AND TIMING GEARS...2224
      Timing Gearcase Cover Removal And Installation...2224
      Timing Gears Backlash - Checking...2226
      Idler Gear And Shaft Removal And Installation...2226
      Camshaft - Servicing...2227
      Idler Gear And Shaft Servicing...2229
    FLYWHEEL AND HOUSING...2230
      Flywheel Housing Removal And Installation...2230
      Hydraulic Pump Coupler Removal And Installation...2231
      Flywheel Removal And Installation...2232
      Rear End Plate Removal And Installation...2232
  HEATER...2234
    HEATER SYSTEM...2236
      Description...2236
      Components...2236
    REGULAR MAINTENANCE...2238
      Filter Element Removal And Installation...2238
      Heater Coil...2239
    TROUBLESHOOTING...2240
      Blower Motor Does Not Operate...2240
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2240
      Electrical System...2241
    HEATER UNIT...2246
      Removal And Installation...2246
    HEATER COIL...2248
      Removal And Installation...2248
    BLOWER FAN...2250
      Removal And Installation...2250
    HEATER VALVE...2252
      Removal And Installation...2252
  SPECIFICATIONS...2254
    EXCAVATOR SPECIFICATIONS...2256
      425 With Standard Arm...2256
      425 With Long Arm Option...2258
      Performance...2260
      Controls...2260
      Engine...2260
      Hydraulic System...2261
      Hydraulic Cylinders...2261
      Hydraulic Cycle Times...2261
      Electrical...2261
      Instrumentation...2261
      Drive System...2262
      Slew System...2262
      Undercarriage...2262
      Crawler Track Design...2262
      Capacities...2262
      Fuel Tank...2262
      Tracks...2262
      Type...2262
      Ground Pressure...2262
    TORQUE SPECIFICATIONS FOR BOLTS...2264
      Torque For General SAE Bolts...2264
      Torque For General Metric Bolts...2265
    HYDRAULIC CONNECTION SPECIFICATIONS...2266
      O-ring Face Seal Connection...2266
      Straight Thread O-ring Fitting...2267
      Tubelines And Hoses...2267
      Flare Fitting...2268
      Port Seal Fitting...2269
    HYDRAULIC FLUID SPECIFICATIONS...2270
      Specifications...2270
    CONVERSIONS...2272
      Decimal And Millimeter Equivalents...2272
      U.S. To Metric Conversion Chart...2272
6904866 (7-07) - 425 Compact Excavator Service Manual...2274
  MAINTENANCE SAFETY...2276
  ALPHABETICAL INDEX...2278
  CONTENTS...2280
    FOREWORD...2282
    SAFETY INSTRUCTIONS...2284
      Fire Prevention...2286
    SERIAL NUMBER LOCATIONS...2288
      Excavator Serial Number...2288
      Engine Serial Number...2288
    DELIVERY REPORT...2289
    EXCAVATOR IDENTIFICATION...2290
  SAFETY AND MAINTENANCE...2292
    LIFTING AND BLOCKING THE EXCAVATOR...2294
      Procedure...2294
    UPPERSTRUCTURE SLEW LOCK...2296
      Operation...2296
    LIFTING THE EXCAVATOR...2298
      Procedure...2298
    OPERATOR CAB (ROPS / TOPS)...2300
      Description...2300
      Cab Door...2300
      Front Window...2301
      Front Wiper...2302
      Window Washer Reservoir...2302
      Right Side Window...2303
      Heating, Ventilation, and Air Conditioning Duct...2304
    TRANSPORTING THE EXCAVATOR ON A TRAILER...2306
      Loading And Unloading...2306
      Fastening...2306
    TAILGATE...2308
      Opening And Closing...2308
    RIGHT SIDE COVER...2310
      Opening And Closing...2310
    SERVICE SCHEDULE...2312
      Chart...2312
    AIR CLEANER SERVICE...2314
      Daily Check...2314
      Replacing Filter Elements...2314
    ENGINE COOLING SYSTEM...2316
      Cleaning...2316
      Checking Level...2317
      Removing And Replacing Coolant...2318
    FUEL SYSTEM...2320
      Fuel Specifications...2320
      Filling The Fuel Tank...2320
      Fuel Filters...2321
      Draining The Fuel Tank...2323
      Removing Air From The Fuel System...2323
    ENGINE LUBRICATION SYSTEM...2324
      Checking And Adding Engine Oil...2324
      Engine Oil Chart...2324
      Removing And Replacing Oil Filter...2325
    HYDRAULIC SYSTEM...2326
      Checking And Adding Fluid...2326
      Hydraulic Fluid Chart...2326
      Removing And Replacing The Hydraulic Filter...2327
      Removing And Replacing The Case Drain Filter...2327
      Removing And Replacing The Hydraulic Fluid...2328
    LUBRICATING THE EXCAVATOR...2330
      Lubrication Locations...2330
    TRAVEL MOTOR...2334
      Checking And Adding Oil...2334
      Removing And Replacing Oil...2334
    SPARK ARRESTOR MUFFLER...2336
      Cleaning Procedure...2336
    ALTERNATOR BELT...2338
      Belt Adjustment...2338
      Belt Replacement...2338
    SEAT BELT...2340
      Inspection And Maintenance...2340
    PIVOT PINS...2342
      Inspection And Maintenance...2342
    EXCAVATOR STORAGE AND RETURN TO SERVICE...2344
      Storage...2344
      Return to Service...2344
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...2346
      Procedure...2346
      Emergency Exits...2347
  HYDRAULIC SYSTEM...2348
    HYDRAULIC/HYDROSTATIC SCHEMATIC...2354
    HYDRAULIC SYSTEM INFORMATION...2356
      Glossary Of Hydraulic / Hydrostatic Symbols...2356
      Troubleshooting The Hydraulic Circuit...2360
      Troubleshooting The Cylinder Circuit...2361
      Troubleshooting The Swing (Upperstructure Slew) Circuit...2362
      Troubleshooting The Travel Circuit...2363
    BOOM CYLINDER...2364
      Testing...2364
      Removal And Installation...2367
      Parts Identification...2370
      Disassembly...2371
      Assembly...2373
    ARM CYLINDER...2376
      Testing...2376
      Removal And Installation...2378
      Parts Identification...2380
      Disassembly...2381
      Assembly...2383
    BOOM SWING CYLINDER...2386
      Testing...2386
      Removal And Installation...2388
      Parts Identification...2389
      Disassembly...2390
      Assembly...2392
    BUCKET CYLINDER...2396
      Testing...2396
      Removal And Installation...2398
      Parts Identification...2399
      Disassembly...2400
      Assembly...2402
    BLADE CYLINDER...2406
      Testing...2406
      Removal And Installation...2408
      Parts Identification...2409
      Disassembly...2410
      Assembly...2412
    MAIN RELIEF VALVE...2416
      Testing And Adjusting The Main Relief Valve...2416
    PORT RELIEF VALVES...2420
      Testing And Adjusting Port Relief Valve Pressure...2420
    CROSSPORT RELIEF VALVES...2422
      Testing And Adjusting The Crossport Relief Valves...2422
    PRESSURE REDUCING VALVE...2426
      Testing And Adjusting The Pressure Reducing Valve...2426
    HYDRAULIC CONTROL VALVE...2428
      Description...2428
      Removal And Installation...2429
      Parts Identification...2432
      Disassembly...2433
      Right Travel Valve Section Disassembly And Assembly...2435
      Left Travel Valve Section Disassembly And Assembly...2439
      Blade Valve Section Disassembly And Assembly...2443
      Slew Valve Section Disassembly And Assembly...2452
      Auxiliary Valve Section Disassembly And Assembly...2457
      Bucket Valve Section Disassembly And Assembly...2462
      Arm Valve Section Disassembly And Assembly...2467
      Boom Valve Section Disassembly And Assembly...2472
      Boom Swing Valve Section Disassembly And Assembly...2477
      Inlet Section Disassembly And Assembly...2482
      Assembly...2487
    HYDRAULIC PUMP...2494
      Description...2494
      Torque Adjustment...2495
      Testing The Piston Pump...2496
      Testing Auxiliary Hydraulic Flow...2497
      Removal...2498
      Installation...2499
      Coupler Removal And Installation...2500
      Parts Identification (Piston Pump)...2501
      Disassembly...2502
      Piston Pump Disassembly...2503
      Piston Pump Assembly...2509
      Assembly...2515
    MANIFOLD ASSEMBLY / ACCUMULATOR...2516
      Description...2516
      Removal And Installation...2516
      Parts Identification...2518
      Disassembly And Assembly...2519
    TRAVEL MOTOR...2528
      Description...2528
      Removal And Installation...2528
      Parts Identification...2529
      Disassembly...2530
      Assembly...2540
    SWIVEL JOINT...2552
      Description...2552
      Removal And Installation...2552
      Parts Identification...2554
      Disassembly...2555
      Assembly...2556
    SWING MOTOR...2560
      Description...2560
      Removal And Installation...2560
      Parts Identification...2562
      Disassembly...2563
      Assembly...2568
    SWING MOTOR DRIVE CARRIER...2574
      Description...2574
      Removal And Installation...2574
      Parts Identification...2575
      Disassembly...2576
      Assembly...2578
    CONTROL PATTERN SELECTOR VALVE...2582
      Description...2582
      Removal And Installation...2582
      Parts Identification...2583
      Disassembly and Assembly...2584
    RIGHT CONTROL LEVER (JOYSTICK)...2586
      Description...2586
      Testing...2586
      Handle Removal And Installation...2587
      Removal And Installation...2591
      Parts Identification...2594
      Disassembly...2595
      Assembly...2600
    LEFT CONTROL LEVER (JOYSTICK)...2606
      Description...2606
      Testing...2606
      Handle Removal And Installation...2607
      Removal And Installation...2610
      Parts Identification...2612
      Disassembly...2613
      Assembly...2618
    TRAVEL CONTROL VALVE...2624
      Removal and Installation...2624
      Parts Identification...2625
      Disassembly And Assembly...2626
    HYDRAULIC FILTER...2630
      Description...2630
      Housing Removal And Installation...2630
    CASE DRAIN FILTER...2632
      Description...2632
      Removal And Installation...2632
    HYDRAULIC RESERVOIR...2634
      Description...2634
      Removal And Installation...2634
    OIL COOLER...2636
      Description...2636
      Removal And Installation...2636
    DIRECT TO TANK VALVE...2638
      Desciption...2638
      Removal And Installation...2638
      Parts Identification...2639
      Disassembly And Assembly...2640
    NON-PRESSURIZED ACCUMULATOR...2642
      Desciption...2642
      Removal And Installation...2642
    HYDRAULIC X-CHANGE VALVE...2644
      Removal And Installation...2644
      Parts Identification...2646
      Disassembly...2647
      Assembly...2655
  UNDERCARRIAGE...2664
    BLADE...2666
      Description...2666
      Removal And Installation...2666
    TRACK FRAME COMPONENTS...2668
      Description...2668
      Track Lug Height...2668
      Checking Tension...2669
      Adjusting Tension...2670
      Rubber Track Removal And Installation...2672
      Steel Track Removal And Installation...2675
      Idler (Front) Removal And Installation...2678
      Idler (Front) Parts Identification...2679
      Idler (Front) Disassembly...2680
      Idler (Front) Assembly...2682
      Coil Spring Assembly And Cylinder Disassembly And Assembly...2685
      Roller Removal and Installation...2686
      Roller Parts Identification...2687
      Roller Disassembly...2688
      Roller Assembly...2690
      Track Guide Removal And Installation...2692
      Track Damage Identification...2693
    SWING CIRCLE GEAR...2704
      Removal And Installation...2704
  UPPERSTRUCTURE & SWING SECTION...2706
    UPPERSTRUCTURE...2710
      Description...2710
      Removal...2710
      Installation...2713
    CANOPY...2716
      Removal And Installation...2716
    CAB...2720
      Removal And Installation...2720
      Door Removal And Installation...2725
      Front Window Removal And Installation...2726
      Right Side Rear Sliding Window Removal And Installation...2729
      Right Side Front Sliding Window Removal And Installation...2729
      Glass Removal...2730
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...2731
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...2731
      Glass Installation...2732
    SEAT AND SEAT MOUNT...2738
      Seat Mount Removal And Installation...2738
      Seat Removal And Installation...2739
    RIGHT CONSOLE...2740
      Description...2740
      Console Cover Removal And Installation...2740
      Console Base Cover Removal And Installation...2741
    LEFT CONSOLE...2744
      Description...2744
      Joystick Console Cover (Bottom) Removal And Installation...2744
      Joystick Console Cover (Top) Removal And Installation...2745
      Compression Spring Removal And Installation...2746
      Compression Spring Disassembly And Assembly...2746
      Lever Removal And Installation...2748
      Joystick Console Frame Removal And Installation...2750
      Joystick Console Frame Disassembly And Installation...2751
      Left Rear Console Cover Removal And Installation...2752
      Left Rear Console Frame Removal And Installation...2753
      Left Rear Console Frame Disassembly And Assembly...2755
    BLADE CONTROL...2756
      Removal And Installation...2756
      Disassembly And Assembly...2756
      Linkage Removal And Installation...2757
      Linkage Disassembly And Assembly...2759
    UPPERSTRUCTURE SLEW LOCK...2760
      Removal and Installation...2760
    FLOOR MAT AND FLOOR PANEL...2762
      Description...2762
      Removal And Installation...2762
    BOOM SWING PEDAL...2766
      Description...2766
      Removal And Installation...2766
      Disassembly And Assembly...2767
      Linkage Removal And Installation...2769
    TRAVEL LEVER / PEDALS...2770
      Description...2770
      Removal And Installation...2770
      Disassembly And Assembly...2771
      Adjustment...2773
      Linkage Removal And Installation...2775
    FUEL TANK...2776
      Removal And Installation...2776
    HORN...2780
      Removal And Installation...2780
    SWING FRAME...2782
      Description...2782
      Removal And Installation...2782
      Hose Routing...2786
      Bushing Removal And Installation...2787
      Swing Frame Bushing Removal And Installation...2787
    BOOM...2790
      Description...2790
      Removal And Installation...2790
    ARM...2794
      Description...2794
      Removal And Installation...2794
      Arm To Boom Bushing Removal And Installation...2795
      Arm To Bucket And Bucket Link Bushing Removal And Installation...2795
    BUCKET...2798
      Removal And Installation (Pin-On X-Change)...2798
      Removal And Installation (Bolt-On X-Change)...2804
      Removal And Installation (Pin-On Attachment)...2810
      Bucket Teeth Removal And Installation...2811
      Bucket Side Cutting Edge Removal And Installation...2812
    TAILGATE...2814
      Removal And Installation...2814
      Latch Removal And Installation...2814
    X-CHANGE...2816
      Pin-On Removal And Installation...2816
      Pin-On Disassembly and Assembly...2817
    X-CHANGE (HYDRAULIC)...2818
      Removal And Installation...2818
      Parts Identification...2821
      Disassembly...2822
      Assembly...2827
    RIGHT SIDE COVER...2836
      Removal And Installation...2836
      Latch Removal And Installation...2836
    COUNTERWEIGHT...2838
      Description...2838
      Removal And Installation (Long Arm Counterweight)...2838
      Removal And Installation (Standard Counterweight)...2839
    LEFT SIDE COVER...2840
      Removal And Installation...2840
  ELECTRICAL SYSTEM AND ANALYSIS...2842
    ELECTRICAL SCHEMATICS...2844
    ELECTRICAL SYSTEM INFORMATION...2846
      Glossary Of Electrical Symbols...2846
      Harness Connectors...2849
      Troubleshooting...2851
      Description...2852
      Fuse And Relay Location / Identification...2852
    BATTERY...2854
      Removal And Installation...2854
      Servicing...2855
      Using A Booster Battery (Jump Starting)...2856
    ALTERNATOR...2858
      Belt Adjustment...2858
      Belt Replacement...2858
      Charging System Inspection...2859
      Description...2860
      Tests...2860
      Alternator Output Test...2861
      Full Field Test...2861
      Alternator Regulator Test...2862
      Alternator Regulator Test With Voltmeter...2862
      Removal And Installation...2863
      Parts Identification...2864
    STARTER...2866
      Testing...2866
      Removal And Installation...2867
      Parts Identification...2868
    LIGHTS...2870
      Upperstructure Light Removal And Installation...2870
      Upperstructure Light Disassembly And Assembly...2870
      Boom Light Removal And Installation...2871
      Boom Light Disassembly And Assembly...2871
    MAGNETIC LOCKOUT SENSOR...2872
      Testing Left Console Magnetic Lockout Sensor...2872
      Left Console Magnetic Lockout Sensor Removal And Installation...2873
    FUEL LEVEL SENDER...2876
      Removal And Installation...2876
      Testing...2877
    DIAGNOSTIC SERVICE CODES...2878
      Description...2878
      Service Codes List...2879
  ENGINE SERVICE...2880
    ENGINE INFORMATION...2882
      Description...2882
      Specifications...2883
      Torque Values...2887
      Troubleshooting...2888
      Removal And Installation...2889
      Engine Mount Replacement...2893
      Compression - Checking...2894
    ENGINE SPEED CONTROL...2896
      Removal And Installation...2896
    SPARK ARRESTOR MUFFLER...2898
      Removal And Installation...2898
    AIR CLEANER...2900
      Removal And Installation...2900
    ENGINE COOLING SYSTEM...2902
      Radiator Removal And Installation...2902
      Radiator Disassembly and Assembly...2904
      Water Pump Removal And Installation...2904
      Water Pump Disassembly And Assembly...2905
      Thermostat Housing Removal And Installation...2905
      Testing The Thermostat...2906
    LUBRICATION SYSTEM...2908
      Oil Pan Removal And Installation...2908
      Oil Pump Removal And Installation...2908
      Oil Pump Inspection...2909
      Engine Oil Pressure - Testing...2910
    FUEL SYSTEM...2912
      Fuel Camshaft Removal And Installation...2912
      Fuel Camshaft Governor Disassembly And Assembly...2912
      Fuel Shutoff Solenoid - Checking...2913
      Fuel Shutoff Solenoid Removal And Installation...2914
      Fuel Injection Pump Removal And Installation...2915
      Timing The Injection Pump...2917
      Fuel Injector Removal And Installation...2919
      Fuel Injector Nozzles Pressure - Checking...2921
      Nozzle Spray Condition...2922
      Valve Seat Tightness...2922
    CYLINDER HEAD...2924
      Glow Plug - Testing...2924
      Glow Plug Removal And Installation...2925
      Valve Clearance Adjustment...2925
      Valve Timing - Checking...2926
      Cylinder Head Removal And Installation...2927
      Cylinder Head Disassembly and Assembly...2929
      Cylinder Head - Servicing...2929
      Cylinder Head Top Clearance...2930
      Valve Guide - Checking...2930
      Reconditioning The Valve And Valve Seat...2931
      Valve Spring...2933
      Valve Tappets...2934
      Rocker Arm And Shaft - Checking...2934
    CRANKSHAFT AND PISTONS...2936
      Piston And Connecting Rod Removal And Installation...2936
      Piston And Connecting Rod - Servicing...2938
      Cylinder Bore Checking...2940
      Connecting Rod Alignment...2941
      Crankshaft And Bearings Removal And Installation...2941
      Crankshaft And Bearings - Servicing...2943
    CAMSHAFT AND TIMING GEARS...2948
      Timing Gearcase Cover Removal And Installation...2948
      Timing Gears Backlash - Checking...2950
      Idler Gear And Shaft Removal And Installation...2950
      Camshaft - Servicing...2951
      Idler Gear And Shaft Servicing...2953
    FLYWHEEL AND HOUSING...2954
      Flywheel Housing Removal And Installation...2954
      Hydraulic Pump Coupler Removal And Installation...2955
      Flywheel Removal And Installation...2956
      Rear End Plate Removal And Installation...2956
  HEATER...2958
    HEATER SYSTEM...2960
      Description...2960
      Components...2960
    REGULAR MAINTENANCE...2962
      Filter Element Removal And Installation...2962
      Heater Coil...2963
    TROUBLESHOOTING...2964
      Blower Motor Does Not Operate...2964
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2964
      Electrical System...2965
    HEATER UNIT...2970
      Removal And Installation...2970
    HEATER COIL...2972
      Removal And Installation...2972
    BLOWER FAN...2974
      Removal And Installation...2974
    HEATER VALVE...2976
      Removal And Installation...2976
  SPECIFICATIONS...2978
    EXCAVATOR SPECIFICATIONS...2980
      425 With Standard Arm...2980
      425 With Long Arm Option...2982
      Performance...2984
      Controls...2984
      Engine...2984
      Hydraulic System...2985
      Hydraulic Cylinders...2985
      Hydraulic Cycle Times...2985
      Electrical...2985
      Instrumentation...2985
      Drive System...2986
      Slew System...2986
      Undercarriage...2986
      Crawler Track Design...2986
      Capacities...2986
      Fuel Tank...2986
      Tracks...2986
      Type...2986
      Ground Pressure...2986
    TORQUE SPECIFICATIONS FOR BOLTS...2988
      Torque For General SAE Bolts...2988
      Torque For General Metric Bolts...2989
    HYDRAULIC CONNECTION SPECIFICATIONS...2990
      O-ring Face Seal Connection...2990
      Straight Thread O-ring Fitting...2991
      Tubelines And Hoses...2991
      Flare Fitting...2992
      Port Seal Fitting...2993
    HYDRAULIC FLUID SPECIFICATIONS...2994
      Specifications...2994
    CONVERSIONS...2996
      Decimal And Millimeter Equivalents...2996
      U.S. To Metric Conversion Chart...2996
  SMR...2998
    425-1...2998
6986852 (8-08) - 418 Compact Excavator Operation & Maintenance Manual...3000
  OPERATOR SAFETY WARNING...3002
  CONTENTS...3004
  FOREWORD...3006
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...3008
    REGULAR MAINTENANCE ITEMS...3008
    SERIAL NUMBER LOCATIONS...3009
      Excavator Serial Number...3009
      Engine Serial Number...3009
    DELIVERY REPORT...3010
    BOBCAT EXCAVATOR IDENTIFICATION...3011
    FEATURES, ACCESSORIES, AND ATTACHMENTS...3012
      Standard Features...3012
      Options and Accessories...3012
      Attachments...3012
  SAFETY & TRAINING RESOURCES...3014
    SAFETY INSTRUCTIONS...3016
      Before Operation...3016
      Safe Operation Is The Operator’s Responsibility...3017
      Safe Operation Needs A Qualified Operator...3017
      Avoid Silica Dust...3018
    FIRE PREVENTION...3018
      Maintenance...3018
      Operation...3018
      Electrical...3018
      Hydraulic System...3019
      Fueling...3019
      Starting...3019
      Spark Arrestor Exhaust System...3019
      Welding And Grinding...3019
      Fire Extinguishers...3019
    MACHINE SIGNS (DECALS)...3020
    PUBLICATIONS AND TRAINING RESOURCES...3022
  OPERATING INSTRUCTIONS...3024
    INSTRUMENTS AND CONTROLS...3026
      Instrumentation...3026
      Operator Controls...3027
      Raising and Lowering the Console(s)...3028
      Adjusting Console Position...3028
      Engine Speed Control Lever...3029
      Two-Speed Travel...3029
      STD / ISO Selector Valve...3029
      Upperstructure Slew Lock...3029
    TIP-OVER PROTECTIVE STRUCTURE (TOPS)...3030
      TOPS Position...3030
      Raising And Lowering The TOPS...3030
    MOTION ALARM SYSTEM (IF EQUIPPED)...3032
      Operation...3032
    TRAVEL CONTROLS...3033
      Description...3033
      Forward and Reverse Travels...3033
      Turning...3033
    HYDRAULIC CONTROLS...3035
      Description...3035
      STANDARD Control Pattern...3035
      ISO Control Pattern...3036
      Quick Couplers (If Equipped)...3037
      Auxiliary Hydraulic Pedal...3038
      Relieve Hydraulic Pressure (Excavator and Attachment)...3038
    BOOM SWING PEDAL...3039
      Operation...3039
    BLADE CONTROL...3039
      Blade / Track Expansion Lever...3039
      Raising and Lowering the Blade...3039
    TRACK FRAME EXPANSION...3040
      Expanding and Retracting the Tracks...3040
    DAILY INSPECTION...3042
      Daily Inspection and Maintenance...3043
    PRE-STARTING PROCEDURE...3044
      Operation & Maintenance Manual and Operator's Handbook Locations...3044
      Entering the Excavator...3045
    STARTING THE ENGINE...3046
      Key Switch...3046
      Cold Temperature Starting Procedure...3047
      Warming the Hydraulic System...3048
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...3049
    ATTACHMENTS...3050
      Installing and Removing Attachments...3050
    OPERATING PROCEDURE...3051
      Inspecting the Work Area...3051
      Lowering the Work Equipment (Engine STOPPED)...3051
      Operating on Public Roads...3051
      Lifting a Load...3052
      Excavating...3052
      Boom Swing...3054
      Backfilling...3055
      Driving the Excavator...3055
      Operating on Slopes...3056
      Operating in Water...3058
    TOWING THE EXCAVATOR...3058
    LIFTING THE EXCAVATOR...3059
    TRANSPORTING THE EXCAVATOR...3060
      Loading onto Transport Vehicle...3060
      Fastening to Transport Vehicle...3061
  PREVENTIVE MAINTENANCE...3062
    MAINTENANCE SAFETY...3064
    SERVICE SCHEDULE...3066
      Chart...3066
    CONTROL CONSOLE LOCKOUT...3067
      Inspection and Maintenance...3067
    SEAT BELT...3068
      Inspection and Maintenance...3068
    MOTION ALARM SYSTEM (IF EQUIPPED)...3069
      Description...3069
      Inspecting...3069
      Adjusting Switch Position...3069
    TAILGATE...3070
      Opening and Closing the Tailgate...3070
    AIR CLEANER...3071
      Daily Check...3071
      Replacing the Filter Elements...3071
    FUEL SYSTEM...3073
      Fuel Specifications...3073
      Biodiesel Blend Fuel...3073
      Filling the Fuel Tank...3074
      Fuel Filters...3074
      Draining the Fuel Tank...3074
      Removing Air From the Fuel System...3075
    ENGINE LUBRICATION SYSTEM...3076
      Checking And Adding Engine Oil...3076
      Engine Oil Chart...3076
      Removing and Replacing Oil and Filter...3077
    ENGINE COOLING SYSTEM...3078
      Cleaning...3078
      Checking Level...3078
      Removing and Replacing the Coolant...3079
    ELECTRICAL SYSTEM...3080
      Description...3080
      Fuses...3080
      Fuel Timer, Relays and Diode Location / Identification...3080
      Battery Maintenance...3081
      Using a Booster Battery (Jump Starting)...3082
      Removing and Installing the Battery...3083
    HYDRAULIC SYSTEM...3084
      Checking and Adding Hydraulic Oil...3084
      Hydraulic Fluid Chart...3084
      Replacing the Hydraulic Filter...3085
      Draining Hydraulic Oil...3086
    SPARK ARRESTOR MUFFLER...3087
      Cleaning Procedure...3087
    TRACK TENSION...3088
      Adjusting...3088
    TRAVEL MOTOR...3089
      Checking and Adding Oil...3089
      Draining the Travel Motor...3089
    ALTERNATOR BELT...3090
      Adjusting the Alternator Belt...3090
    BLADE EXTENSION...3092
      Description...3092
      Extending and Retracting...3092
    TRACK ROLLER AND IDLER LUBRICATION...3093
      Procedure...3093
    LUBRICATING THE EXCAVATOR...3094
      Lubrication Locations...3094
    EXCAVATOR STORAGE AND RETURN TO SERVICE...3098
      Storage...3098
      Return to Service...3098
  MACHINE SIGN TRANSLATIONS...3100
    WARNING (7153147)...3102
    LIFT CHART (7153145)...3103
    SERVICE SCHEDULE (7153144)...3106
    WARNING (7135260)...3109
    WARNING (6589058)...3110
    WARNING (6804114)...3110
    WARNING (6804233)...3110
    WARNING (7161612)...3111
    WARNING (7151554)...3111
    WARNING (6808345)...3112
    WARNING (6808346)...3112
    DO NOT ADD ETHYLENE GLYCOL COOLANT (6708929)...3113
    WARNING (6576048)...3113
  SPECIFICATIONS...3114
    SPECIFICATIONS...3116
      418 Excavator Machine Dimensions...3116
      Performance...3118
      Controls...3118
      Engine...3118
      Hydraulic System...3119
      Hydraulic Cylinders...3119
      Hydraulic Cycle Times...3120
      Electrical...3120
      Drive System...3120
      Swing System...3120
      Undercarriage...3120
      Crawler Track Design...3120
      Capacities...3121
      Fuel Tank...3121
      Tracks...3121
      Type...3121
      Ground Pressure...3121
  WARRANTY...3122
  ALPHABETICAL INDEX...3126
6986853 (07-14) - 418 Compact Excavator Service Manual...3128
  MAINTENANCE SAFETY...3130
  CONTENTS...3132
  FOREWORD...3134
    FOREWORD...3136
    SAFETY INSTRUCTIONS...3138
    FIRE PREVENTION...3140
      Maintenance...3140
      Operation...3140
      Electrical...3140
      Hydraulic System...3140
      Fueling...3140
      Starting...3140
      Spark Arrester Exhaust System...3140
      Welding And Grinding...3141
      Fire Extinguishers...3141
    SERIAL NUMBER LOCATIONS...3142
      Excavator Serial Number...3142
      Engine Serial Number...3142
    DELIVERY REPORT...3143
    BOBCAT EXCAVATOR IDENTIFICATION...3144
  SAFETY AND MAINTENANCE...3146
    LIFTING AND BLOCKING THE EXCAVATOR...3148
      Procedure...3148
    UPPERSTRUCTURE SLEW LOCK...3150
      Operation...3150
    LIFTING THE EXCAVATOR...3152
      Procedure...3152
    TRANSPORTING THE EXCAVATOR ON A TRAILER...3154
      Loading And Unloading...3154
      Fastening...3155
    FOLD-DOWN TOPS...3156
      TOPS Position...3156
      Lowering The Fold-Down TOPS...3156
      Raising The Fold-Down TOPS...3157
    TAILGATE...3158
      Opening And Closing...3158
    SERVICE SCHEDULE...3160
      Chart...3160
    AIR CLEANER SERVICE...3162
      Daily Check...3162
      Replacing The Filter Elements...3162
    ENGINE COOLING SYSTEM...3164
      Cleaning...3164
      Checking Level...3164
      Removing And Replacing The Coolant...3165
    FUEL SYSTEM...3166
      Fuel Specifications...3166
      Biodiesel Blend Fuel...3166
      Filling The Fuel Tank...3167
      Fuel Filters...3167
      Draining The Fuel Tank...3167
      Removing Air From The Fuel System...3168
    ENGINE LUBRICATION SYSTEM...3170
      Checking And Adding Engine Oil...3170
      Engine Oil Chart...3170
      Removing And Replacing Oil And Filter...3171
    HYDRAULIC SYSTEM...3172
      Checking And Adding Hydraulic Oil...3172
      Hydraulic / Hydrostatic Fluid Chart...3172
      Removing And Replacing Hydraulic Filter...3173
      Removing And Replacing Hydraulic Fluid...3174
    LUBRICATING THE EXCAVATOR...3176
      Lubrication Locations...3176
    TRAVEL MOTOR...3180
      Checking And Adding Oil...3180
      Removing And Replacing Oil...3180
    SPARK ARRESTER MUFFLER...3182
      Cleaning Procedure...3182
    ALTERNATOR BELT...3184
      Belt Adjustment...3184
      Belt Replacement...3185
    SEAT BELT...3186
      Inspection And Maintenance...3186
    CONTROL CONSOLE LOCKOUT...3188
      Inspection And Maintenance...3188
    EXCAVATOR STORAGE AND RETURN TO SERVICE...3190
      Storage...3190
      Return To Service...3190
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...3192
      Procedure...3192
    MOTION ALARM...3194
      Description...3194
      Inspecting...3194
      Adjusting Switch Position...3195
    REMOTE START TOOL KIT - MEL1563...3196
      Remote Start Tool - MEL1563...3196
      Service Tool Harness Communicator - MEL1566...3198
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...3200
      Description...3200
      Remote Start Tool (Service Tool) - 7003030...3201
      Excavator Service Tool Harness - 6689747...3202
      Computer Service Tool Harness - 6689746...3203
  HYDRAULIC SYSTEM...3204
    HYDRAULIC/HYDROSTATIC SCHEMATICS...3208
    HYDRAULIC SYSTEM INFORMATION...3210
      Glossary Of Hydraulic / Hydrostatic Symbols...3210
      Troubleshooting The Hydraulic Circuit...3214
      Troubleshooting The Cylinder Circuit...3215
      Troubleshooting The Swing (Upperstructure Slew) Circuit...3216
      Troubleshooting The Travel Circuit...3217
    CYLINDER (BOOM)...3218
      Testing...3218
      Removal And Installation...3219
      Parts Identification...3221
      Disassembly...3222
      Assembly...3224
    CYLINDER (ARM)...3228
      Testing...3228
      Removal And Installation...3230
      Parts Identification...3231
      Disassembly...3232
      Assembly...3234
    CYLINDER (BOOM SWING)...3238
      Testing...3238
      Removal And Installation...3239
      Parts Identification...3241
      Disassembly...3242
      Assembly...3244
    CYLINDER (BUCKET)...3248
      Testing...3248
      Removal And Installation...3249
      Parts Identification...3251
      Disassembly...3252
      Assembly...3254
    CYLINDER (BLADE)...3258
      Testing...3258
      Removal And Installation...3259
      Parts Identification...3260
      Disassembly...3261
      Assembly...3263
    CYLINDER (TRACK FRAME EXPANSION)...3266
      Testing...3266
      Removal And Installation...3267
      Parts Identification...3271
      Disassembly...3272
      Assembly...3274
    VALVE (MAIN RELIEF)...3278
      Testing And Adjusting...3278
    VALVES (PORT RELIEF)...3280
      Testing And Adjusting...3280
    VALVE (PRESSURE REDUCING)...3282
      Testing And Adjusting...3282
    HYDRAULIC CONTROL VALVE...3284
      Description...3284
      Removal And Installation...3284
      Parts Identification...3292
      Disassembly...3293
      Left Travel Valve Section Disassembly And Assembly...3294
      Slew Valve Section Disassembly And Assembly...3297
      Arm Valve Section Disassembly And Assembly...3301
      Boom Swing Valve Section Disassembly And Assembly...3305
      Auxiliary Valve Section Disassembly And Assembly...3310
      Blade Valve Section Disassembly And Assembly...3314
      Bucket Valve Section Disassembly And Assembly...3317
      Boom Valve Section Disassembly And Assembly...3321
      Right Travel Valve Section Disassembly And Assembly...3326
      Assembly...3329
    HYDRAULIC PUMP...3334
      Description...3334
      Testing The Hydraulic Pump...3334
      Removal And Installation...3336
      Parts Identification...3338
      Disassembly...3339
      Assembly...3342
    MANIFOLD ASSEMBLY / ACCUMULATOR...3346
      Description...3346
      Removal And Installation...3346
      Parts Identification...3349
      Disassembly...3350
      Assembly...3356
    TRAVEL MOTOR...3362
      Description...3362
      Removal And Installation...3362
      Parts Identification...3363
      Disassembly...3364
      Assembly...3371
    SWIVEL JOINT...3380
      Description...3380
      Removal And Installation...3380
      Parts Identification (AB4711001 to AB4711897)...3384
      Parts Identification (AB4711898 & Above, B39211001 & Above)...3385
      Disassembly...3386
      Assembly...3388
    SWING MOTOR...3392
      Description...3392
      Removal And Installation...3392
      Parts Identification...3397
      Disassembly...3398
      Assembly...3404
    CONTROL PATTERN SELECTOR VALVE...3412
      Description...3412
      Removal And Installation...3412
      Disassembly And Assembly...3413
    CONTROL LEVER (JOYSTICK) (RIGHT)...3416
      Description...3416
      Testing...3416
      Handle Removal And Installation...3418
      Removal And Installation...3419
      Parts Identification...3420
      Disassembly...3421
      Assembly...3425
    CONTROL LEVER (JOYSTICK) (LEFT)...3430
      Description...3430
      Testing...3430
      Handle Removal And Installation...3432
      Removal And Installation...3434
      Parts Identification...3435
      Disassembly...3436
      Assembly...3440
    HYDRAULIC RESERVOIR...3444
      Description...3444
      Removal And Installation...3444
    OIL COOLER...3450
      Description...3450
      Removal And Installation...3450
    BLADE / TRACK EXPAND VALVE...3452
      Description...3452
      Block Removal And Installation...3452
      Control Handle Removal And Installation...3453
      Block Disassembly And Assembly...3454
    BUILD-UP VALVE...3456
      Description...3456
      Removal And Installation...3456
      Disassembly And Assembly...3458
    TWO-SPEED CONTROL VALVE...3460
      Description...3460
      Block Removal And Installation...3460
      Solenoid Removal And Installation...3462
      Block Disassembly And Assembly...3463
  UNDERCARRIAGE...3466
    BLADE...3468
      Description...3468
      Extension Removal And Installation...3468
      Blade Removal And Installation...3469
    TRACK UNDERCARRIAGE COMPONENTS...3470
      Description...3470
      Track Lug Height...3470
      Checking Tension...3471
      Adjusting Tension...3472
      Track Removal And Installation...3473
      Idler Removal And Installation...3474
      Idler Parts Identification...3475
      Idler Disassembly...3476
      Idler Assembly...3477
      Track Tensioner Removal And Installation...3478
      Track Tensioner Disassembly And Assembly...3479
      Roller Removal And Installation...3479
      Removal And Installation Of Expandable Track Frame...3480
    TRACK MAINTENANCE...3482
      Track Damage Identification...3482
    SWING CIRCLE GEAR...3494
      Removal And Installation...3494
  UPPERSTRUCTURE AND SWING SECTION...3496
    UPPERSTRUCTURE...3500
      Description...3500
      Removal...3500
      Installation...3504
    TOPS...3510
      Removal And Installation...3510
    SEAT...3512
      Removal And Installation...3512
    RIGHT CONSOLE...3514
      Joystick Console Cover Removal And Installation...3514
      Gas Spring Removal And Installation...3515
      Compression Spring Removal And Installation...3515
      Lever Removal And Installation...3516
      Joystick Console Frame Removal And Installation...3517
      Joystick Console Frame Disassembly And Assembly...3518
    LEFT CONSOLE...3520
      Joystick Console Cover Removal And Installation...3520
      Gas Spring Removal And Installation...3521
      Compression Spring Removal And Installation...3521
      Lever Removal And Installation...3522
      Joystick Console Frame Removal And Installation...3523
      Joystick Console Frame Disassembly And Assembly...3524
    ENGINE SPEED CONTROL...3526
      Removal And Installation...3526
      Cable Removal...3528
      Cable Installation...3530
    BLADE CONTROL...3534
      Removal And Installation...3534
      Disassembly And Assembly...3536
      Two-Speed Switch Removal And Installation...3537
    SWING LOCK...3540
      Removal And Installation...3540
      Disassembly And Assembly...3540
    RIGHT PEDAL AND LINKAGE...3542
      Right Pedal Removal And Installation...3542
      Linkage Removal And Installation...3542
      Linkage Disassembly And Assembly...3544
    TRAVEL CONTROLS...3546
      Right Hand Travel Control Removal And Installation...3546
      Right Hand Travel Control Disassembly And Assembly...3546
      Left Hand Travel Control Removal And Installation...3547
      Left Hand Travel Control Disassembly And Assembly...3548
    LEFT PEDAL AND LINKAGE...3550
      Pedal Removal And Installation...3550
      Linkage Removal And Installation...3550
      Linkage Disassembly And Assembly...3552
    FLOOR PANELS...3554
      Description...3554
      Left Floor Panel Removal And Installation...3554
      Right Floor Panel Removal And Installation...3554
    FUEL TANK...3556
      Removal And Installation...3556
    HORN...3558
      Removal And Installation...3558
    SWING FRAME...3560
      Description...3560
      Removal And Installation...3561
      Bushing Removal...3562
      Bushing Installation...3563
      Boom Pivot Bushing Removal...3563
      Boom Pivot Bushing Installation...3563
    BOOM...3564
      Description...3564
      Removal And Installation...3564
    ARM...3566
      Description...3566
      Removal And Installation...3566
      Arm To Boom Bushing Removal And Installation...3567
      Arm To Bucket And Bucket Link Bushing Removal And Installation...3567
    BUCKET...3568
      Removal And Installation...3568
    TAILGATE...3570
      Removal And Installation...3570
      Latch Removal And Installation...3571
    COUNTER WEIGHTS...3572
      Rear Counter Weight Removal And Installation...3572
      Left Side Counter Weight Removal And Installation...3572
      Right Side Counter Weight Removal And Installation...3573
    SIDE COVERS...3574
      Upper Left Side Cover Removal And Installation...3574
      Upper Right Side Cover Removal And Installation...3574
      Lower Left Side Cover Removal And Installation...3575
      Lower Right Side Cover Removal And Installation...3576
    INSTRUMENT PANEL...3578
      Removal And Installation...3578
      Disassembly And Assembly...3579
    QUICK COUPLER (KLAC™ SYSTEM)...3582
      Troubleshooting...3582
      Daily Inspection...3582
      Removal And Installation...3583
      Parts Identification...3585
      Disassembly...3586
      Assembly...3588
    QUICK COUPLER (LEHNHOFF® SYSTEM)...3590
      Troubleshooting...3590
      Daily Inspection...3590
      Removal (MS03 And MS08)...3591
      Installation (MS03 And MS08)...3592
      Parts Identification (MS03)...3593
      Disassembly And Assembly (MS03)...3594
      Parts Identification (MS08)...3595
      Disassembly (MS08)...3596
      Assembly (MS08)...3599
  ELECTRICAL SYSTEM & ANALYSIS...3604
    ELECTRICAL SCHEMATICS...3606
    ELECTRICAL SYSTEM INFORMATION...3607
      Glossary Of Electrical Symbols...3607
      Troubleshooting...3610
      Description...3611
      Fuses...3611
      Fuel Timer, Relays And Diode Location / Identification...3611
      Fuel Timer And Diode Location / Identification...3612
    BATTERY...3613
      Servicing...3613
      Removal And Installation...3614
      Using A Booster Battery (Jump Starting)...3615
    ALTERNATOR...3617
      Description...3617
      Tests...3617
      Alternator Output Test...3618
      Full Field Test...3618
      Alternator Regulator Test...3619
      Alternator Regulator Test With Voltmeter...3619
      Removal And Installation...3620
      Charging System Inspection...3622
      Parts Identification...3623
    STARTER...3625
      Removal And Installation...3625
      Parts Identification...3626
      Cleaning And Inspection...3626
    LIGHTS...3627
      Boom Light Removal And Installation...3627
      Light Bulb Removal And Installation...3627
      Light Switch Removal And Installation...3628
    MICROSWITCH...3631
      Testing Left Console Microswitch...3631
      Left Console Microswitch Removal And Installation...3631
      Testing Right Console Microswitch...3632
      Right Console Microswitch Removal And Installation...3632
    FUEL LEVEL SENDER...3633
      Removal And Installation...3633
      Testing...3633
  ENGINE SERVICE...3635
    ENGINE INFORMATION...3637
      Description...3637
      Specifications...3638
      Torque Values...3642
      Troubleshooting...3644
      Engine Removal And Installation...3645
      Engine Mount Replacement...3655
      Engine Compression - Checking...3656
    MUFFLER...3657
      Removal And Installation...3657
    AIR CLEANER...3661
      Removal And Installation...3661
    ENGINE COOLING SYSTEM...3663
      Radiator Removal And Installation...3663
      Water Pump Removal And Installation...3665
      Water Pump Disassembly And Assembly...3665
      Thermostat Removal And Installation...3666
      Thermostat - Checking...3666
    LUBRICATION SYSTEM...3667
      Oil Pan Removal And Installation...3667
      Oil Pump Removal And Installation...3668
      Oil Pump - Service...3668
      Engine Oil Pressure - Testing...3669
      Relief Valve...3670
    FUEL SYSTEM...3671
      Fuel Shutoff Solenoid Removal And Installation...3671
      Fuel Shutoff Timer Removal And Installation...3671
      Fuel Injection Pump - Checking...3672
      Fuel Injection Pump Removal And Installation...3673
      Fuel Injection Pump - Timing...3675
      Fuel Camshaft Removal And Installation...3677
      Fuel Camshaft Governor...3677
      Fuel Injector Removal And Installation...3678
      Fuel Injector Nozzle Pressure - Checking...3679
      Valve Seat Tightness...3681
    CYLINDER HEAD...3683
      Glow Plug Removal And Installation...3683
      Valve Clearance Adjustment...3684
      Cylinder Head Removal And Installation...3685
      Cylinder Head Disassembly And Assembly...3687
      Cylinder Head - Servicing...3688
      Cylinder Head Top Clearance...3689
      Valve Guide - Checking...3689
      Valve And Valve Seat Reconditioning...3691
      Valve Spring...3692
      Valve Tappets...3693
      Rocker Arm And Shaft - Checking...3693
    CRANKSHAFT AND PISTONS...3695
      Piston And Connecting Rod Removal And Installation...3695
      Piston And Connecting Rod - Servicing...3696
      Cylinder Bore - Checking...3699
      Connecting Rod Alignment...3699
      Crankshaft And Bearings Removal And Installation...3700
      Crankshaft And Bearings - Servicing...3702
    CAMSHAFT AND TIMING GEARS...3705
      Timing Gearcase Cover Removal And Installation...3705
      Timing Gears Checking Backlash...3707
      Idler Gear And Camshaft Removal And Installation...3707
      Idler Gear And Shaft - Servicing...3710
    FLYWHEEL AND HOUSING...3711
      Removal And Installation...3711
      Hydraulic Pump Coupler Removal And Installation...3712
      Flywheel Removal And Installation...3712
      Rear End Plate Removal And Installation...3713
  SPECIFICATIONS...3715
    418 EXCAVATOR SPECIFICATIONS...3717
      Machine Dimensions...3717
      Performance...3719
      Controls...3719
      Engine (418 S/N AB4711001 & Above)...3720
      Engine (418 S/N B39211001 & Above)...3720
      Hydraulic System...3721
      Hydraulic Cylinders...3721
      Hydraulic Cycle Times...3722
      Electrical...3722
      Drive System...3722
      Swing System...3722
      Undercarriage...3722
      Capacities...3723
      Tracks...3723
      Ground Pressure...3723
    TECHNICAL SERVICE GUIDE SPECIFICATIONS...3725
      Engine...3725
      Engine Torques...3725
      Cooling System...3725
      Excavator Torques...3726
      Lubrication...3726
      Torque For General SAE Bolts...3727
      Torque For General Metric Bolts...3728
    HYDRAULIC CONNECTION SPECIFICATIONS...3729
      O-ring Face Seal Connection...3729
      Straight Thread O-ring Fitting...3730
      Tubelines And Hoses...3730
      Flare Fitting...3731
      Port Seal Fitting...3732
    HYDRAULIC FLUID SPECIFICATIONS...3733
      Specifications...3733
    CONVERSIONS...3735
      Decimal And Millimeter Equivalents...3735
      U.S. To Metric Conversion Chart...3735
    SERVICE TOOLS REQUIRED...3737
      Remote Start Tools...3737
      Hydraulic Tools...3738
      Engine Tools...3740
      HVAC Tools...3742
  ALPHABETICAL INDEX...3743
6986853 (10-10) - 418 Compact Excavator Service Manual...3745
  MAINTENANCE SAFETY...3747
  ALPHABETICAL INDEX...3749
  CONTENTS...3751
    FOREWORD...3753
    SAFETY INSTRUCTIONS...3755
    FIRE PREVENTION...3757
      Maintenance...3757
      Operation...3757
      Electrical...3757
      Hydraulic System...3757
      Fueling...3757
      Starting...3757
      Spark Arrestor Exhaust System...3757
      Welding And Grinding...3758
      Fire Extinguishers...3758
    SERIAL NUMBER LOCATIONS...3759
      Excavator Serial Number...3759
      Engine Serial Number...3759
    DELIVERY REPORT...3760
    BOBCAT EXCAVATOR IDENTIFICATION...3761
  SAFETY AND MAINTENANCE...3763
    LIFTING AND BLOCKING THE EXCAVATOR...3765
      Procedure...3765
    UPPERSTRUCTURE SLEW LOCK...3767
    LIFTING THE EXCAVATOR...3769
    TRANSPORTING THE EXCAVATOR ON A TRAILER...3771
      Loading And Unloading...3771
      Fastening To Transport Vehicle...3772
    FOLD-DOWN TOPS...3773
      TOPS Position...3773
      Lowering The Fold-Down TOPS...3773
      Raising The Fold-Down TOPS...3774
    TAILGATE...3775
      Opening And Closing The Tailgate...3775
    SERVICE SCHEDULE...3777
      Chart...3777
    AIR CLEANER...3779
      Daily Check...3779
      Replacing The Filters...3779
    COOLING SYSTEM...3781
      Cleaning The Cooling System...3781
      Checking The Coolant Level...3781
      Replacing The Coolant...3782
    FUEL SYSTEM...3785
      Fuel Specifications...3785
      Biodiesel Blend Fuel...3785
      Filling The Fuel Tank...3786
      Removing Water From The Fuel Filter...3786
      Replacing The Fuel Filter...3786
      Draining The Fuel Tank...3787
      Removing Air From The Fuel System...3787
    ENGINE LUBRICATION SYSTEM...3789
      Checking Engine Oil...3789
      Replacing Oil And Filter...3789
    HYDRAULIC SYSTEM...3791
      Checking And Adding Hydraulic Oil...3791
      Diagnostic Connectors...3791
      Replacing The Hydraulic Filter...3792
      Replacing Hydraulic Oil...3793
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...3795
    TRAVEL MOTOR...3799
      Checking Oil Level...3799
      Draining The Travel Motor...3799
    SPARK ARRESTER MUFFLER...3801
      Cleaning Procedure...3801
    ALTERNATOR BELT...3803
      Adjusting The Alternator Belt...3803
    SEAT BELT...3805
      Inspection And Maintenance...3805
    CONTROL CONSOLE LOCKOUTS...3807
      Inspection And Maintenance...3807
    EXCAVATOR STORAGE AND RETURN TO SERVICE...3809
      Storage...3809
      Return To Service...3809
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...3811
    MOTION ALARM (IF EQUIPPED)...3813
      Description...3813
      Inspecting...3813
      Adjusting Switch Position...3814
  HYDRAULIC SYSTEM...3815
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3819
    HYDRAULIC SYSTEM INFORMATION...3821
      Glossary Of Hydraulic / Hydrostatic Symbols...3821
      Troubleshooting The Hydraulic Circuit...3825
      Troubleshooting The Cylinder Circuit...3826
      Troubleshooting The Swing (Upperstructure Slew) Circuit...3827
      Troubleshooting The Travel Circuit...3828
    BOOM CYLINDER...3829
      Testing...3829
      Removal And Installation...3830
      Parts Identification...3832
      Disassembly...3833
      Assembly...3835
    ARM CYLINDER...3839
      Testing...3839
      Removal And Installation...3841
      Parts Identification...3842
      Disassembly...3843
      Assembly...3845
    BOOM SWING CYLINDER...3849
      Testing...3849
      Removal And Installation...3850
      Parts Identification...3852
      Disassembly...3853
      Assembly...3855
    BUCKET CYLINDER...3859
      Testing...3859
      Removal And Installation...3860
      Parts Identification...3862
      Disassembly...3863
      Assembly...3865
    BLADE CYLINDER...3869
      Testing...3869
      Removal And Installation...3870
      Parts Identification...3871
      Disassembly...3872
      Assembly...3874
    TRACK FRAME EXPANSION CYLINDER...3877
      Testing...3877
      Removal And Installation...3878
      Parts Identification...3882
      Disassembly...3883
      Assembly...3885
    MAIN RELIEF VALVE...3889
      Testing And Adjusting The Main Relief Valve...3889
    PORT RELIEF VALVES...3891
      Testing And Adjusting The Port Relief Valve Pressure...3891
    PRESSURE REDUCING VALVE...3893
      Testing And Adjusting The Pressure Reducing Valve...3893
    HYDRAULIC CONTROL VALVE...3895
      Description...3895
      Removal And Installation...3895
      Parts Identification...3904
      Disassembly...3905
      Left Travel Valve Section Disassembly And Assembly...3906
      Slew Valve Section Disassembly And Assembly...3909
      Arm Valve Section Disassembly And Assembly...3913
      Boom Swing Valve Section Disassembly And Assembly...3918
      Auxiliary Valve Section Disassembly And Assembly...3923
      Blade Valve Section Disassembly And Assembly...3927
      Bucket Valve Section Disassembly And Assembly...3931
      Boom Valve Section Disassembly And Assembly...3935
      Right Travel Valve Section Disassembly And Assembly...3940
      Assembly...3943
    HYDRAULIC PUMP...3949
      Description...3949
      Testing The Hydraulic Pump...3949
      Removal And Installation...3951
      Parts Identification...3953
      Disassembly...3954
      Assembly...3956
    MANIFOLD ASSEMBLY / ACCUMULATOR...3961
      Description...3961
      Removal And Installation...3961
      Parts Identification...3964
      Disassembly...3965
      Assembly...3971
    TRAVEL MOTOR...3977
      Description...3977
      Removal And Installation...3977
      Parts Identification...3978
      Disassembly...3979
      Assembly...3986
    SWIVEL JOINT...3995
      Description...3995
      Removal And Installation...3995
      Parts Identification...3998
      Disassembly...3999
      Assembly...4001
    SLEW MOTOR...4005
      Description...4005
      Removal And Installation...4005
      Parts Identification...4011
      Disassembly...4012
      Assembly...4018
    CONTROL PATTERN SELECTOR VALVE...4027
      Description...4027
      Removal And Installation...4027
      Disassembly And Assembly...4028
    RIGHT CONTROL LEVER (JOYSTICK)...4031
      Description...4031
      Testing...4031
      Handle Removal And Installation...4033
      Removal And Installation...4034
      Parts Identification...4035
      Disassembly...4036
      Assembly...4041
    LEFT CONTROL LEVER (JOYSTICK)...4045
      Description...4045
      Testing...4045
      Handle Removal And Installation...4047
      Removal And Installation...4049
      Parts Identification...4050
      Disassembly...4051
      Assembly...4056
    HYDRAULIC RESERVOIR...4061
      Description...4061
      Removal And Installation...4061
    OIL COOLER (IF EQUIPPED)...4067
      Description...4067
      Removal And Installation...4067
    BLADE / TRACK EXPAND VALVE...4069
      Description...4069
      Block Removal And Installation...4069
      Control Handle Removal And Installation...4070
      Block Disassembly And Assembly...4071
    BUILD-UP VALVE...4073
      Description...4073
      Removal And Installation...4073
      Disassembly And Assembly...4075
    TWO SPEED CONTROL VALVE...4077
      Description...4077
      Block Removal And Installation...4077
      Solenoid Removal And Installation...4079
      Block Disassembly And Assembly...4080
  UNDERCARRIAGE...4083
    BLADE...4085
      Description...4085
      Extension Removal And Installation...4085
      Blade Removal And Installation...4086
    TRACKS...4087
      Track Lug Height...4087
      Track Tension Adjustment...4087
      Removal And Installation...4089
    TRACK FRAME...4091
      Disassembly And Assembly...4091
      Removal And Installation Of Expandable Track Frame...4092
    TRACK DAMAGE IDENTIFICATION...4095
      Cutting Of The Steel Cords...4095
      Causes Of The Damage...4095
      Abrasion Of Embedded Metals...4096
      Separation Of Embedded Metals...4097
      Separation Of Embedded Metals Due To Corrosion...4098
      Cuts On The Lug Side Rubber...4099
      Cracks On The Lug Side Rubber Due To Fatigue...4100
      Lug Abrasion...4101
      Cracks And Cuts On The Lug Side Rubber...4102
      Abrasion Of The Track Roller Side...4103
      Cuts On The Edges Of The Track Roller Side...4104
    TRACK IDLER...4107
      Parts Identification...4107
      Disassembly...4108
      Assembly...4109
    TRACK ROLLER...4113
      Parts Identification...4113
      Disassembly...4114
      Assembly...4115
    SWING CIRCLE GEAR...4119
      Removal And Installation...4119
  UPPERSTRUCTURE AND SWING SECTION...4121
    UPPERSTRUCTURE...4125
      Description...4125
      Removal...4125
      Installation...4129
    TOPS...4135
      Removal And Installation...4135
    SEAT...4137
      Removal And Installation...4137
    RIGHT CONSOLE...4139
      Joystick Console Cover Removal And Installation...4139
      Gas Spring Removal And Installation...4140
      Compression Spring Removal And Installation...4140
      Lever Removal And Installation...4141
      Joystick Console Frame Removal And Installation...4142
      Joystick Console Frame Disassembly And Assembly...4142
    LEFT CONSOLE...4145
      Joystick Console Cover Removal And Installation...4145
      Gas Spring Removal And Installation...4146
      Compression Spring Removal And Installation...4146
      Lever Removal And Installation...4147
      Joystick Console Frame Removal And Installation...4148
      Joystick Console Frame Disassembly And Assembly...4148
    ENGINE SPEED CONTROL...4151
      Removal And Installation...4151
      Cable Removal...4153
      Cable Installation...4155
    BLADE CONTROL...4159
      Removal And Installation...4159
      Disassembly And Assembly...4161
      Two Speed Switch Removal And Installation...4162
    UPPERSTRUCTURE SLEW LOCK...4165
      Removal And Installation...4165
      Disassembly And Assembly...4165
    RIGHT PEDAL...4167
      Pedal Removal And Installation...4167
      Control Linkage Removal And Installation...4167
      Control Linkage Disassembly And Assembly...4169
    TRAVEL CONTROLS...4173
      Right Hand Travel Control Removal And Installation...4173
      Right Hand Travel Control Disassembly And Assembly...4173
      Left Hand Travel Control Removal And Installation...4173
      Left Hand Travel Control Disassembly And Assembly...4175
    LEFT PEDAL...4177
      Pedal Removal And Installation...4177
      Control Linkage Removal And Installation...4177
      Control Linkage Disassembly And Assembly...4179
    FLOOR PANELS...4181
      Description...4181
      Left Floor Panel Removal And Installation...4181
      Right Floor Panel Removal And Installation...4181
    FUEL TANK...4183
      Removal And Installation...4183
    HORN...4185
      Removal And Installation...4185
    SWING FRAME...4187
      Description...4187
      Removal And Installation...4187
      Bushing Removal...4188
      Bushing Installation...4189
      Boom Pivot Bushing Removal...4190
      Boom Pivot Bushing Installation...4190
    BOOM...4191
      Description...4191
      Removal And Installation...4191
    ARM...4193
      Description...4193
      Removal And Installation...4193
      Arm To Boom Bushing Removal And Installation...4194
      Arm To Bucket And Bucket Link Bushing Removal And Installation...4194
    BUCKET...4195
      Removal And Installation...4195
    TAILGATE...4197
      Removal And Installation...4197
      Latch Removal And Installation...4198
    COUNTER WEIGHTS...4199
      Rear Counter Weight Removal And Installation...4199
      Left Hand Side Counter Weight Removal And Installation...4199
      Right Hand Side Counter Weight Removal And Installation...4200
    SIDE COVERS...4203
      Upper Left Hand Side Cover Removal And Installation...4203
      Upper Right Hand Side Cover Removal And Installation...4203
      Lower Left Hand Side Cover Removal And Installation...4204
      Lower Right Hand Side Cover Removal And Installation...4205
    INSTRUMENT PANEL...4207
      Removal And Installation...4207
      Disassembly And Assembly...4208
  ELECTRICAL SYSTEM AND ANALYSIS...4211
    ELECTRICAL SCHEMATIC...4213
    ELECTRICAL SYSTEM INFORMATION...4214
      Glossary Of Electrical Symbols...4214
      Troubleshooting...4217
      Description...4218
      Fuse And Relay Location / Identification...4218
      Fuel Timer Location / Identification...4219
    BATTERY...4220
      Servicing...4220
      Removal And Installation...4221
      Using A Booster Battery (Jump Starting)...4222
    ALTERNATOR...4224
      Description...4224
      Tests...4224
      Alternator Output Test...4225
      Full Field Test...4225
      Alternator Regulator Test...4226
      Alternator Regulator Test With Voltmeter...4226
      Removal And Installation...4227
      Charging System Inspection...4229
      Parts Identification...4230
    STARTER...4232
      Removal And Installation...4232
      Parts Identification...4233
      Cleaning And Inspection...4233
    LIGHTS...4234
      Boom Light Removal And Installation...4234
      Light Bulb Removal And Installation...4234
      Light Switch Removal And Installation...4235
    MICROSWITCH...4238
      Testing Left Console Microswitch...4238
      Left Console Microswitch Removal And Installation...4238
      Testing Right Console Microswitch...4239
      Right Console Microswitch Removal And Installation...4239
    FUEL LEVEL SENDER...4240
      Removal And Installation...4240
      Testing...4240
  ENGINE SERVICE...4242
    TROUBLESHOOTING...4244
      Chart...4244
    SPARK ARRESTOR MUFFLER...4246
      Removal And Installation...4246
    AIR CLEANER...4250
      Removal And Installation...4250
    RADIATOR...4252
      Removal And Installation...4252
    ENGINE COMPONENTS AND TESTING...4254
      Valve Clearance Adjustment...4254
      Engine Compression Checking...4255
      Fuel Shutoff Solenoid - Checking...4255
      Fuel Shutoff Solenoid Removal And Installation...4256
      Fuel Shutoff Timer Removal And Installation...4256
      Fuel Injection Pump Check...4257
      Fuel Injection Pump Removal And Installation...4258
      Fuel Injection Pump Timing...4260
      Fuel Injector Removal And Installation...4262
      Fuel Injector Checking...4263
      Valve Seat Tightness...4265
      Glow Plug Removal And Installation...4265
    ENGINE...4268
      Description...4268
      Removal And Installation...4269
      Engine Mount Replacement...4279
    FLYWHEEL AND HOUSING...4280
      Flywheel Housing Removal And Installation...4280
      Hydraulic Pump Coupler Removal And Installation...4281
      Flywheel Removal And Installation...4281
      Rear End Plate Removal And Installation...4282
    RECONDITIONING THE ENGINE...4284
      Cylinder Head Removal And Installation...4284
      Cylinder Head Disassembly And Assembly...4285
      Cylinder Head, Servicing...4286
      Cylinder Head Top Clearance...4287
      Valve Guide, Checking...4287
      Valve Timing, Checking...4289
      Valve And Valve Seat Reconditioning...4289
      Valve Spring...4290
      Valve Tappets...4291
      Rocker Arm And Shaft, Checking...4292
      Timing Gearcase Cover Removal And Installation...4292
      Idler Gear And Camshaft Removal And Installation...4294
      Idler Gear And Shaft, Servicing...4297
      Timing Gears Checking Backlash...4298
      Fuel Camshaft Removal And Installation...4298
      Fuel Camshaft Governor...4299
      Crankshaft Gear Removal And Installation...4299
      Oil Pan Removal And Installation...4300
      Oil Pump Removal And Installation...4301
      Oil Pump, Service...4301
      Engine Oil Pressure, Checking...4302
      Relief Valve...4303
      Piston And Connecting Rod Removal And Installation...4303
      Piston And Connecting Rod, Servicing...4305
      Connecting Rod Alignment...4307
      Crankshaft And Bearings Removal And Installation...4307
      Crankshaft And Bearings, Servicing...4309
      Cylinder Bore, Checking...4311
      Water Pump Removal And Installation...4312
      Water Pump Disassembly And Assembly...4312
      Thermostat Removal And Installation...4313
      Testing The Thermostat...4313
  SPECIFICATIONS...4314
    SPECIFICATIONS 418 EXCAVATOR...4316
      Machine Dimensions...4316
      Performance...4318
      Controls...4318
      Engine...4318
      Hydraulic system...4319
      Hydraulic cylinders...4319
      Hydraulic Cycle Times...4320
      Electrical...4320
      Drive system...4320
      Swing System...4320
      Undercarriage...4320
      Capacities...4321
      Tracks...4321
      Ground Pressure...4321
    ENGINE SPECIFICATIONS...4322
      Engine...4322
      Fuel Injector Nozzles...4322
      Fuel Injection Pump...4322
      Cylinder Head...4322
      Valves...4322
      Valve Springs...4322
      Rocker Arms...4323
      Camshaft...4323
      Cylinders...4323
      Piston Rings...4323
      Pistons...4324
      Connecting Rods...4324
      Crankshaft...4324
      Oil Pump...4324
      Thermostat...4325
      Torque Values...4326
    TORQUE SPECIFICATIONS FOR BOLTS...4328
      Torque For General SAE Bolts...4328
      Torque For General Metric Bolts...4329
    HYDRAULIC CONNECTION SPECIFICATIONS...4330
      O-ring Face Seal Connection...4330
      Straight Thread O-ring Fitting...4331
      Tubelines And Hoses...4331
      Flare Fitting...4332
      Port Seal Fitting...4333
    HYDRAULIC FLUID SPECIFICATIONS...4334
      Specifications...4334
    CONVERSIONS...4336
      Decimal And Millimeter Equivalents...4336
      U.S. To Metric Conversion Chart...4336
  SERVICE MANUAL REVISION...4338
    Revision No: 418 - 1...4338
6986951 (10-09) - 425, 428 Compact Excavator Operation & Maintenance Manual...4340
  OPERATOR SAFETY WARNING...4342
  CONTENTS...4344
  FOREWORD...4346
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...4348
    REGULAR MAINTENANCE ITEMS...4348
    SERIAL NUMBER LOCATIONS...4350
      Excavator Serial Number...4350
      Engine Serial Number...4350
    DELIVERY REPORT...4350
    EXCAVATOR IDENTIFICATION...4351
    FEATURES, ACCESSORIES AND ATTACHMENTS...4352
      Standard Items...4352
      Options and Accessories...4352
      Attachments...4352
      Buckets Available...4352
      Falling Object Guards (FOGS)...4353
      Special Applications Kit...4353
      Special Applications Kit Inspection And Maintenance...4353
  SAFETY & TRAINING RESOURCES...4354
    SAFETY INSTRUCTIONS...4356
      Before Operation...4356
      Safe Operation Is The Operator’s Responsibility...4357
      Safe Operation Needs A Qualified Operator...4357
      Avoid Silica Dust...4358
    FIRE PREVENTION...4358
      Maintenance...4358
      Operation...4358
      Electrical...4358
      Hydraulic System...4359
      Fueling...4359
      Starting...4359
      Spark Arrestor Exhaust System...4359
      Welding And Grinding...4359
      Fire Extinguishers...4359
    MACHINE SIGNS (DECALS)...4360
    PUBLICATIONS AND TRAINING RESOURCES...4362
  OPERATING INSTRUCTIONS...4364
    INSTRUMENTS AND CONSOLES...4368
      Cab Interior Light (If Equipped)...4368
      Left Console...4368
      Right Console...4369
      Function Icons...4370
      STD / ISO Selector Valve...4371
      Upperstructure Slew Lock...4371
      Raising And Lowering The Console...4371
      Two-Speed Travel...4372
      Fresh Air Recirculation (If Equipped)...4372
    OPERATOR CANOPY (ROPS / TOPS)...4373
      Description...4373
    OPERATOR CAB (ROPS / TOPS)...4373
      Description...4373
      Cab Door...4374
      Front Window...4375
      Front Wiper...4376
      Window Washer Reservoir...4376
      Right Side Window...4377
      Heating, Ventilation, and Air Conditioning Duct...4378
    TRAVEL CONTROLS...4379
      Description...4379
      Forward And Reverse Travel...4379
      Turning...4379
    MOTION ALARM SYSTEM (IF EQUIPPED)...4381
      Operation...4381
    HYDRAULIC CONTROLS...4382
      Description...4382
      STANDARD Control Pattern...4382
      ISO Control Pattern...4383
      Quick Couplers...4384
      Auxiliary Hydraulics...4385
      Relieving Hydraulic Pressure (Excavator And Attachment)...4385
      Return To Tank Valve (If Equipped)...4385
    BLADE CONTROL LEVER...4386
      Operation...4386
    BOOM SWING PEDAL...4386
      Operation...4386
    DAILY INSPECTION...4387
      Daily Inspection And Maintenance...4388
    PRE-STARTING PROCEDURE...4389
      Operation & Maintenance Manual And Operator’s Handbook Locations...4389
      Entering The Excavator...4389
      Seat Adjustment...4390
      Seat Belt Adjustment...4390
      Control Console...4390
    STARTING THE ENGINE...4391
      Key Switch...4391
      Keyless...4392
      Cold Temperature Starting...4393
      Warming The Hydraulic System...4394
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...4395
      Procedure...4395
      Emergency Exits...4396
    ATTACHMENTS...4397
      Installing And Removing The Attachment (Hydraulic X-Change)...4397
      Installing And Removing The Attachment (Pin-On X- Change)...4401
      Installing And Removing The Attachment (Bolt-On X- Change)...4407
      Installing And Removing The Attachment (Pin-On Attachment)...4413
    OPERATING PROCEDURE...4414
      Inspect The Work Area...4414
      Basic Operating Instructions...4414
      Lowering The Work Equipment (Engine STOPPED)...4414
      Lifting A Load...4415
      Excavating...4416
      Boom Swing...4418
      Backfilling...4419
      Driving The Excavator...4419
      Operating On Slopes...4420
      Operating In Water...4422
      Avoiding Track Damage...4423
    TOWING THE EXCAVATOR...4424
      Procedure...4424
    LIFTING THE EXCAVATOR...4425
      Procedure...4425
    TRANSPORTING THE EXCAVATOR ON A TRAILER...4426
      Loading And Unloading...4426
      Fastening...4426
  PREVENTIVE MAINTENANCE...4428
    MAINTENANCE SAFETY...4430
    SERVICE SCHEDULE...4432
      Chart...4432
    CONTROL CONSOLE LOCKOUTS...4433
      Inspection And Maintenance...4433
    SEAT BELT...4434
      Inspection And Maintenance...4434
    MOTION ALARM SYSTEM (IF EQUIPPED)...4435
      Description...4435
      Inspecting...4435
      Adjusting Switch Position...4435
    TAILGATE...4436
      Opening And Closing...4436
    RIGHT SIDE COVER...4437
      Opening And Closing...4437
    CAB FILTERS...4438
      Cleaning And Maintenance...4438
    AIR CLEANER SERVICE...4439
      Daily Check...4439
      Replacing Filter Elements...4439
    FUEL SYSTEM...4441
      Fuel Specifications...4441
      Biodiesel Blend Fuel...4441
      Filling The Fuel Tank...4442
      Fuel Filters...4443
      Draining The Fuel Tank...4445
      Removing Air From The Fuel System...4445
    ENGINE LUBRICATION SYSTEM...4446
      Checking And Adding Engine Oil...4446
      Engine Oil Chart...4446
      Removing And Replacing Oil Filter...4447
    ENGINE COOLING SYSTEM...4448
      Cleaning...4448
      Checking Level...4449
      Removing And Replacing Coolant...4450
    ELECTRICAL SYSTEM...4451
      Description...4451
      Fuse And Relay Location / Identification...4451
      Battery Maintenance...4452
      Using A Booster Battery (Jump Starting)...4453
      Removing And Installing Battery...4454
    HYDRAULIC SYSTEM...4455
      Checking And Adding Fluid...4455
      Hydraulic Fluid Chart...4455
      Removing And Replacing The Hydraulic Filter...4456
      Removing And Replacing The Case Drain Filter...4456
      Removing And Replacing The Hydraulic Fluid...4457
    SPARK ARRESTOR MUFFLER...4458
      Cleaning Procedure...4458
    TRACK TENSION...4459
      Adjusting...4459
    TRAVEL MOTOR...4461
      Checking And Adding Oil...4461
      Removing And Replacing Oil...4461
    ALTERNATOR BELT...4462
      Belt Adjustment...4462
      Belt Replacement...4462
    X-CHANGE...4463
      Inspection And Maintenance...4463
    TRACK ROLLER AND IDLER LUBRICATION...4463
      Procedure...4463
    BUCKET...4464
      Bucket Teeth Removal And Installation...4464
    LUBRICATING THE EXCAVATOR...4465
      Lubrication Locations...4465
    PIVOT PINS...4467
      Inspection And Maintenance...4467
    EXCAVATOR STORAGE AND RETURN TO SERVICE...4468
      Storage...4468
      Return to Service...4468
  SYSTEM SETUP AND ANALYSIS...4470
    DIAGNOSTIC SERVICE CODE...4472
      Service Codes List...4472
    DISPLAY CONTROLLER PANEL SETUP...4473
      Passwords...4473
      Password Entry (For Starting and Operating the Machine)...4473
      Changing The Operator Password...4473
      Password Lockout Feature...4474
      Job Clock...4474
      RPM...4474
      Viewing Service Codes (Key Switch)...4475
      Viewing Service Codes (Keyless)...4475
    MAINTENANCE CLOCK...4476
      Description...4476
      Setup...4476
      Reset...4476
  MACHINE SIGN TRANSLATIONS...4478
    WARNING (6808185)...4480
    LIFT CHART...4481
      425 STANDARD ARM (7132125)...4481
      425 With LONG ARM OPTION & 428 (7135359)...4484
    SERVICE SCHEDULE (7158257)...4487
    WARNING (6807776)...4490
    WARNING (6804114, 6817225, 6804233)...4492
    WARNING (6817815)...4493
    WARNING (6808474)...4493
    WARNING (6576048)...4494
    WARNING (6815915)...4495
    USING THE X-CHANGE SYSTEM (7102651)...4496
    USING THE X-CHANGE SYSTEM (7134587)...4499
    WARNING (6809829)...4502
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...4503
  SPECIFICATIONS...4504
    EXCAVATOR SPECIFICATIONS...4506
      425 With Standard Arm, Long Arm Option & 428...4506
      425 With Standard Arm...4507
      425 With Long Arm Option & 428...4508
      Performance...4509
      Controls...4509
      Engine...4509
      Hydraulic System...4510
      Hydraulic Cylinders...4510
      Hydraulic Cycle Times...4510
      Electrical...4510
      Instrumentation...4510
      Drive System...4511
      Slew System...4511
      Undercarriage...4511
      Crawler Track Design...4511
      Capacities...4511
      Fuel Tank...4511
      Tracks...4511
      Type...4511
      Ground Pressure...4511
  WARRANTY...4512
    WARRANTY...4514
  ALPHABETICAL INDEX...4516
6986952 (5-09) - 425, 428 Compact Excavator Service Manual...4518
  ALPHABETICAL INDEX...4522
  CONTENTS...4524
    FOREWORD...4525
    SAFETY INSTRUCTIONS...4527
    FIRE PREVENTION...4529
      Maintenance...4529
      Operation...4529
      Electrical...4529
      Hydraulic System...4529
      Fueling...4529
      Starting...4529
      Spark Arrestor Exhaust System...4529
      Welding And Grinding...4530
      Fire Extinguishers...4530
    SERIAL NUMBER LOCATIONS...4531
      Excavator Serial Number...4531
      Engine Serial Number...4531
    DELIVERY REPORT...4532
    EXCAVATOR IDENTIFICATION...4533
  SAFETY AND MAINTENANCE...4534
    LIFTING AND BLOCKING THE EXCAVATOR...4536
      Procedure...4536
    UPPERSTRUCTURE SLEW LOCK...4540
      Operation...4540
    LIFTING THE EXCAVATOR...4542
      Procedure...4542
    OPERATOR CAB (ROPS / TOPS)...4544
      Description...4544
      Cab Door...4544
      Front Window...4545
      Front Wiper...4546
      Window Washer Reservoir...4546
      Right Side Window...4547
      Heating, Ventilation, and Air Conditioning Duct...4548
    TRANSPORTING THE EXCAVATOR ON A TRAILER...4550
      Loading And Unloading...4550
      Fastening...4550
    TAILGATE...4552
      Opening And Closing...4552
    RIGHT SIDE COVER...4554
      Opening And Closing...4554
    SERVICE SCHEDULE...4556
      Chart...4556
    AIR CLEANER SERVICE...4558
      Daily Check...4558
      Replacing Filter Elements...4559
    ENGINE COOLING SYSTEM...4560
      Cleaning...4560
      Checking Level...4561
      Removing And Replacing Coolant...4562
    FUEL SYSTEM...4566
      Fuel Specifications...4566
      Biodiesel Blend Fuel...4566
      Filling The Fuel Tank...4567
      Fuel Filters...4568
      Draining The Fuel Tank...4570
      Removing Air From The Fuel System...4570
    ENGINE LUBRICATION SYSTEM...4572
      Checking And Adding Engine Oil...4572
      Engine Oil Chart...4572
      Removing And Replacing Oil Filter...4573
    HYDRAULIC SYSTEM...4574
      Checking And Adding Fluid...4574
      Hydraulic Fluid Chart...4574
      Removing And Replacing The Hydraulic Filter...4575
      Removing And Replacing The Case Drain Filter...4575
      Removing And Replacing The Hydraulic Fluid...4576
    LUBRICATING THE EXCAVATOR...4578
      Lubrication Locations...4578
    TRAVEL MOTOR...4582
      Checking And Adding Oil...4582
      Removing And Replacing Oil...4582
    SPARK ARRESTOR MUFFLER...4584
      Cleaning Procedure...4584
    ALTERNATOR BELT...4586
      Belt Adjustment...4586
      Belt Replacement...4586
    SEAT BELT...4588
      Inspection And Maintenance...4588
    PIVOT PINS...4590
      Inspection And Maintenance...4590
    EXCAVATOR STORAGE AND RETURN TO SERVICE...4592
      Storage...4592
      Return To Service...4592
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...4594
      Procedure...4594
      Emergency Exits...4595
    MOTION ALARM SYSTEM (IF EQUIPPED)...4596
      Description...4596
      Adjusting Switch Position...4596
  HYDRAULIC SYSTEM...4598
    HYDRAULIC SCHEMATICS...4604
    HYDRAULIC SYSTEM INFORMATION...4606
      Glossary Of Hydraulic / Hydrostatic Symbols...4606
      Troubleshooting The Hydraulic Circuit...4610
      Troubleshooting The Cylinder Circuit...4611
      Troubleshooting The Swing (Upperstructure Slew) Circuit...4612
      Troubleshooting The Travel Circuit...4613
    BOOM CYLINDER...4614
      Testing...4614
      Removal And Installation...4617
      Parts Identification...4620
      Disassembly...4621
      Assembly...4623
    ARM CYLINDER...4626
      Testing...4626
      Removal And Installation...4628
      Parts Identification...4630
      Disassembly...4631
      Assembly...4633
    BOOM SWING CYLINDER...4636
      Testing...4636
      Removal And Installation...4638
      Parts Identification...4639
      Disassembly...4640
      Assembly...4642
    BUCKET CYLINDER...4646
      Testing...4646
      Removal And Installation...4648
      Parts Identification...4649
      Disassembly...4650
      Assembly...4652
    BLADE CYLINDER...4656
      Testing...4656
      Removal And Installation...4658
      Parts Identification...4659
      Disassembly...4660
      Assembly...4662
    CLAMP CYLINDER...4666
      Testing...4666
      Removal And Installation...4667
      Parts Identification...4668
      Disassembly...4669
      Assembly...4672
    MAIN RELIEF VALVE...4678
      Testing And Adjusting The Main Relief Valve...4678
    PORT RELIEF VALVES...4682
      Testing And Adjusting Port Relief Valve Pressure...4682
    CROSSPORT RELIEF VALVES...4684
      Testing And Adjusting The Crossport Relief Valves...4684
    PRESSURE REDUCING VALVE...4688
      Testing And Adjusting The Pressure Reducing Valve...4688
    HYDRAULIC CONTROL VALVE...4690
      Description...4690
      Removal And Installation...4691
      Parts Identification...4694
      Disassembly...4695
      Right Travel Valve Section Disassembly And Assembly...4697
      Left Travel Valve Section Disassembly And Assembly...4701
      Blade Valve Section Disassembly And Assembly...4705
      Slew Valve Section Disassembly And Assembly...4714
      Auxiliary Valve Section Disassembly And Assembly...4719
      Bucket Valve Section Disassembly And Assembly...4724
      Arm Valve Section Disassembly And Assembly...4729
      Boom Valve Section Disassembly And Assembly...4734
      Boom Swing Valve Section Disassembly And Assembly...4739
      Inlet Section Disassembly And Assembly...4744
      Assembly...4749
    HYDRAULIC PUMP...4756
      Description...4756
      Torque Adjustment...4757
      Testing The Piston Pump...4758
      Testing Auxiliary Hydraulic Flow...4759
      Removal...4760
      Installation...4761
      Coupler Removal And Installation...4762
      Hydraulic Pump Start Up...4763
      Parts Identification (Piston Pump)...4764
      Disassembly...4765
      Piston Pump Disassembly...4766
      Piston Pump Assembly...4772
      Assembly...4778
    MANIFOLD ASSEMBLY / ACCUMULATOR...4780
      Description...4780
      Removal And Installation...4780
      Parts Identification...4782
      Disassembly And Assembly...4783
    TRAVEL MOTOR...4792
      Description...4792
      Removal And Installation...4792
      Parts Identification...4793
      Disassembly...4794
      Assembly...4804
    SWIVEL JOINT...4816
      Description...4816
      Removal And Installation...4816
      Parts Identification...4818
      Disassembly...4819
      Assembly...4820
    SWING MOTOR...4824
      Description...4824
      Removal And Installation...4824
      Parts Identification...4826
      Disassembly...4827
      Assembly...4832
    SWING MOTOR DRIVE CARRIER...4838
      Description...4838
      Removal And Installation...4838
      Parts Identification...4839
      Disassembly...4840
      Assembly...4842
    CONTROL PATTERN SELECTOR VALVE...4846
      Description...4846
      Removal And Installation...4846
      Parts Identification...4847
      Disassembly and Assembly...4848
    RIGHT CONTROL LEVER (JOYSTICK)...4850
      Description...4850
      Testing...4850
      Handle Removal And Installation...4851
      Removal And Installation...4855
      Parts Identification...4858
      Disassembly...4859
      Assembly...4864
    LEFT CONTROL LEVER (JOYSTICK)...4870
      Description...4870
      Testing...4870
      Handle Removal And Installation...4871
      Removal And Installation...4874
      Parts Identification...4876
      Disassembly...4877
      Assembly...4882
    TRAVEL CONTROL VALVE...4888
      Removal and Installation...4888
      Parts Identification...4889
      Disassembly And Assembly...4890
    HYDRAULIC FILTER...4894
      Description...4894
      Housing Removal And Installation...4894
    CASE DRAIN FILTER...4896
      Description...4896
      Removal And Installation...4896
    HYDRAULIC RESERVOIR...4898
      Description...4898
      Removal And Installation...4898
    OIL COOLER...4900
      Description...4900
      Removal And Installation...4900
    DIRECT TO TANK VALVE...4902
      Description...4902
      Removal And Installation...4902
      Parts Identification...4903
      Disassembly And Assembly...4904
    NON-PRESSURIZED ACCUMULATOR...4906
      Description...4906
      Removal And Installation...4906
    HYDRAULIC X-CHANGE VALVE...4908
      Removal And Installation...4908
      Parts Identification...4910
      Disassembly...4911
      Assembly...4919
    SLEW LOCK VALVE...4928
      Description...4928
      Removal And Installation...4928
      Parts Identification...4929
      Disassembly And Assembly...4930
  UNDERCARRIAGE...4934
    BLADE...4936
      Description...4936
      Removal And Installation...4936
    TRACK FRAME COMPONENTS...4938
      Description...4938
      Track Lug Height...4938
      Checking Tension...4939
      Adjusting Tension...4940
      Rubber Track Removal And Installation...4942
      Steel Track Removal And Installation...4945
      Idler (Front) Removal And Installation...4948
      Idler (Front) Parts Identification...4949
      Idler (Front) Disassembly...4950
      Idler (Front) Assembly...4952
      Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11223 & Below, A9K311309 & Below And A9K411308 & Below)...4955
      Coil Spring Cylinder Parts Identification (AACS11224 & Above, A9K311310 & Above And A9K411309 & Above)...4956
      Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11224 & Above, A9K311310 & Above And A9K411309 & Above)...4957
      Coil Spring Assembly And Cylinder Disassembly And Assembly (AACJ11224 & Above, A9K311310 & Above And A9K411309 & Above)...4958
      Roller Removal And Installation...4958
      Roller Parts Identification...4959
      Roller Disassembly...4960
      Roller Assembly...4962
      Track Guide Removal And Installation...4964
      Sprocket Removal And Installation...4964
      Track Damage Identification...4965
      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...4956
    SWING CIRCLE GEAR...4976
      Removal And Installation...4976
  UPPERSTRUCTURE & SWING SECTION...4978
    UPPERSTRUCTURE...4982
      Description...4982
      Removal...4982
      Installation...4984
    CANOPY...4986
      Removal And Installation...4986
    CAB...4990
      Removal And Installation...4990
      Door Removal And Installation...4994
      Front Window Removal And Installation...4995
      Right Side Rear Sliding Window Removal And Installation...4998
      Right Side Front Sliding Window Removal And Installation...4998
      Glass Removal...4999
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...5000
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...5000
      Glass Installation...5001
    SEAT AND SEAT MOUNT...5006
      Seat Mount Removal And Installation...5006
      Seat Removal And Installation...5007
    RIGHT CONSOLE...5008
      Description...5008
      Console Cover Removal And Installation...5008
      Console Base Cover Removal And Installation...5009
    LEFT CONSOLE...5012
      Description...5012
      Joystick Console Cover (Bottom) Removal And Installation...5012
      Joystick Console Cover (Top) Removal And Installation...5012
      Compression Spring Removal And Installation...5013
      Compression Spring Disassembly And Assembly...5014
      Lever Removal And Installation...5016
      Joystick Console Frame Removal And Installation...5018
      Joystick Console Frame Disassembly And Installation...5019
      Left Rear Console Cover Removal And Installation...5019
      Left Rear Console Frame Removal And Installation...5020
      Left Rear Console Frame Disassembly And Assembly...5022
    BLADE CONTROL...5024
      Removal And Installation...5024
      Disassembly And Assembly...5024
      Linkage Removal And Installation...5025
      Linkage Disassembly And Assembly...5027
    UPPERSTRUCTURE SLEW LOCK...5028
      Removal and Installation...5028
    FLOOR MAT AND FLOOR PANEL...5030
      Description...5030
      Removal And Installation...5030
    BOOM SWING PEDAL...5034
      Description...5034
      Removal And Installation...5034
      Disassembly And Assembly...5034
      Linkage Removal And Installation...5036
    TRAVEL LEVER / PEDALS...5038
      Description...5038
      Removal And Installation...5038
      Disassembly And Assembly...5039
      Adjustment...5041
      Linkage Removal And Installation...5043
    FUEL TANK...5044
      Removal And Installation...5044
    HORN...5048
      Removal And Installation...5048
    SWING FRAME...5050
      Description...5050
      Removal And Installation...5050
      Hose Routing...5054
      Bushing Removal And Installation...5055
      Swing Frame Bushing Removal And Installation...5055
    BOOM...5058
      Description...5058
      Removal And Installation...5058
    ARM...5060
      Description...5060
      Removal And Installation...5060
      Arm To Boom Bushing Removal And Installation...5060
      Arm To Bucket And Bucket Link Bushing Removal And Installation...5061
    BUCKET...5062
      Removal And Installation (Pin-On X-Change)...5062
      Removal And Installation (Bolt-On X-Change)...5067
      Removal And Installation (Pin-On Attachment)...5073
      Bucket Teeth Removal And Installation...5074
      Bucket Side Cutting Edge Removal And Installation...5075
    CLAMP...5076
      Removal And Installation...5076
    TAILGATE...5078
      Removal And Installation...5078
      Latch Removal And Installation...5078
    X-CHANGE...5080
      Pin-On Removal And Installation...5080
      Pin-On Disassembly and Assembly...5081
    X-CHANGE (HYDRAULIC)...5082
      Removal And Installation...5082
      Parts Identification...5085
      Disassembly...5086
      Assembly...5091
    RIGHT SIDE COVER...5100
      Removal And Installation...5100
      Latch Removal And Installation...5100
    COUNTERWEIGHT...5102
      Description...5102
      Removal And Installation (Long Arm Counterweight)...5102
      Removal And Installation (Standard Counterweight)...5103
    LEFT SIDE COVER...5104
      Removal And Installation...5104
  ELECTRICAL SYSTEM AND ANALYSIS...5106
    ELECTRICAL SCHEMATICS...5108
    ELECTRICAL SYSTEM INFORMATION...5110
      Glossary Of Electrical Symbols...5110
      Harness Connectors...5113
      Troubleshooting...5115
      Description...5116
      Fuse And Relay Location / Identification...5116
    BATTERY...5118
      Removal And Installation...5118
      Servicing...5119
      Using A Booster Battery (Jump Starting)...5120
    ALTERNATOR...5122
      Belt Adjustment...5122
      Belt Replacement...5122
      Charging System Inspection...5123
      Description...5124
      Tests...5124
      Alternator Output Test...5125
      Full Field Test...5125
      Alternator Regulator Test...5126
      Alternator Regulator Test With Voltmeter...5126
      Removal And Installation...5127
      Parts Identification...5128
    STARTER...5130
      Testing...5130
      Removal And Installation...5130
      Parts Identification...5131
    LIGHTS...5132
      Upperstructure Light Removal And Installation...5132
      Upperstructure Light Disassembly And Assembly...5132
      Boom Light Removal And Installation...5133
      Boom Light Disassembly And Assembly...5133
    MAGNETIC LOCKOUT SENSOR...5134
      Testing Left Console Magnetic Lockout Sensor...5134
      Left Console Magnetic Lockout Sensor Removal And Installation...5135
    FUEL LEVEL SENDER...5138
      Removal And Installation...5138
      Testing...5139
    DIAGNOSTIC SERVICE CODES...5140
      Description...5140
      Service Codes List...5141
  ENGINE SERVICE...5142
    ENGINE INFORMATION...5144
      Description...5144
      Specifications...5145
      Torque Values...5149
      Troubleshooting...5150
      Removal And Installation...5151
      Engine Mount Replacement...5155
      Compression - Checking...5156
    ENGINE SPEED CONTROL...5158
      Removal And Installation...5158
    SPARK ARRESTOR MUFFLER...5160
      Removal And Installation...5160
    AIR CLEANER...5162
      Removal And Installation...5162
    ENGINE COOLING SYSTEM...5164
      Radiator Removal And Installation...5164
      Radiator Disassembly and Assembly...5166
      Water Pump Removal And Installation...5166
      Water Pump Disassembly And Assembly...5167
      Thermostat Housing Removal And Installation...5167
      Testing The Thermostat...5168
    LUBRICATION SYSTEM...5170
      Oil Pan Removal And Installation...5170
      Oil Pump Removal And Installation...5170
      Oil Pump Inspection...5171
      Engine Oil Pressure - Testing...5172
    FUEL SYSTEM...5174
      Fuel Camshaft Removal And Installation...5174
      Fuel Camshaft Governor Disassembly And Assembly...5174
      Fuel Shutoff Solenoid - Checking...5175
      Fuel Shutoff Solenoid Removal And Installation...5176
      Fuel Injection Pump Removal And Installation...5177
      Timing The Injection Pump...5179
      Fuel Injector Removal And Installation...5181
      Fuel Injector Nozzles Pressure - Checking...5183
      Nozzle Spray Condition...5184
      Valve Seat Tightness...5184
    CYLINDER HEAD...5186
      Glow Plug - Testing...5186
      Glow Plug Removal And Installation...5187
      Valve Clearance Adjustment...5187
      Valve Timing - Checking...5188
      Cylinder Head Removal And Installation...5189
      Cylinder Head Disassembly And Assembly...5191
      Cylinder Head - Servicing...5191
      Cylinder Head Top Clearance...5192
      Valve Guide - Checking...5192
      Reconditioning The Valve And Valve Seat...5193
      Valve Spring...5195
      Valve Tappets...5196
      Rocker Arm And Shaft - Checking...5196
    CRANKSHAFT AND PISTONS...5198
      Piston And Connecting Rod Removal And Installation...5198
      Piston And Connecting Rod - Servicing...5200
      Cylinder Bore Checking...5202
      Connecting Rod Alignment...5202
      Crankshaft And Bearings Removal And Installation...5203
      Crankshaft And Bearings - Servicing...5204
    CAMSHAFT AND TIMING GEARS...5210
      Timing Gearcase Cover Removal And Installation...5210
      Timing Gears Backlash - Checking...5212
      Idler Gear And Shaft Removal And Installation...5212
      Camshaft - Servicing...5213
      Idler Gear And Shaft Servicing...5215
    FLYWHEEL AND HOUSING...5216
      Flywheel Housing Removal And Installation...5216
      Hydraulic Pump Coupler Removal And Installation...5217
      Flywheel Removal And Installation...5218
      Rear End Plate Removal And Installation...5218
  HEATER...5220
    HEATER SYSTEM...5222
      Description...5222
      Components...5222
    REGULAR MAINTENANCE...5224
      Filter Element Removal And Installation...5224
      Heater Coil...5225
    TROUBLESHOOTING...5226
      Blower Motor Does Not Operate...5226
      Blower Motor Operates Normally, But Air Flow Is Insufficient...5226
      Electrical System...5227
    HEATER UNIT...5232
      Removal And Installation...5232
    HEATER COIL...5234
      Removal And Installation...5234
    BLOWER FAN...5236
      Removal And Installation...5236
    HEATER VALVE...5238
      Removal And Installation...5238
  SPECIFICATIONS...5240
    EXCAVATOR SPECIFICATIONS...5242
      425 With Standard Arm...5242
      425 With Long Arm Option & 428...5244
      Performance...5246
      Controls...5246
      Engine...5246
      Hydraulic System...5247
      Hydraulic Cylinders...5247
      Hydraulic Cycle Times...5247
      Electrical...5247
      Instrumentation...5247
      Drive System...5248
      Slew System...5248
      Undercarriage...5248
      Crawler Track Design...5248
      Capacities...5248
      Fuel Tank...5248
      Tracks...5248
      Type...5248
      Ground Pressure...5248
    TORQUE SPECIFICATIONS FOR BOLTS...5250
      Torque For General SAE Bolts...5250
      Torque For General Metric Bolts...5251
    HYDRAULIC CONNECTION SPECIFICATIONS...5252
      O-Ring Face Seal Connection...5252
      Straight Thread O-Ring Fitting...5252
      Tubelines And Hoses...5252
      Flare Fitting...5253
      Port Seal Fitting...5254
    HYDRAULIC FLUID SPECIFICATIONS...5256
      Specifications...5256
    CONVERSIONS...5258
      Decimal And Millimeter Equivalents...5258
      U.S. To Metric Conversion Chart...5258
  SERVICE MANUAL REVISION...5260
    Revision No: 425 / 428 - 1...5260
    
Bobcat Compact Excavators 418, 425, 428 Repair Service Manuals