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Bobcat 425 Excavator Service Manual (SN A52011001-A52099999)

Format: PDF (Printable Document)

File Language: English

File Pages: 691

File Size: 18.30 MB (Speed Download Link)

Brand: Bobcat

Model: 425 Excavator

Book No: 6904866

Serial No: SN A52011001-A52099999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat 425 Excavator Service Manual (SN A52011001-A52099999)

This 425 is a small excavator you'd park on a tight job for trenching, service lines, or light demo. The service manual is what you grab when the machine's down and you actually need to fix it, not just run it. Around my shop, I reach for this kind of manual when I'm chasing a hydraulic issue, sorting electrical gremlins, or putting something back together and I don't want to guess.

What this manual helps you do

  • Diagnose hydraulic problems, check pressures, and track down weak boom, arm, or bucket functions
  • Trace and repair wiring issues using readable schematics for starting, charging, and safety circuits
  • Follow step-by-step teardown and reassembly on components like cylinders, drive motors, and swing gearboxes
  • Set and verify adjustments on controls, linkages, and hydraulic settings after repairs
  • Replace major engine and pump components with the right sequences so you don't miss seals, shims, or alignment steps

Who this is for

This is for anyone working on a Bobcat 425 excavator in the A52011001-A52099999 serial range: small contractors, shop mechanics, field techs, or an owner-operator who turns his own wrenches. If you just want to learn how to operate the machine or see what parts to order, you want the operator's handbook or the parts catalog instead.

FAQ

Q: Is this a searchable PDF and are the wiring diagrams readable?

A: Yes, these manuals are usually searchable PDFs and the wiring diagrams are laid out so you can zoom in and read wire labels.

Q: How do I know it fits my exact 425?

A: Check your serial plate. If your 425 starts with A520 and falls between A52011001 and A52099999, this is the right manual.

Q: Is this the right document if I'm doing my own repairs?

A: Yes. This is the workshop service manual, meant for real repair work, not basic operation.

Bottom line: If your 425's serial number falls in that A52011001-A52099999 window and you're doing your own repairs, this is the one you want. If not, skip it.

📘 Show Index

Table of Contents:

  • MAINTENANCE SAFETY
  • ALPHABETICAL INDEX
  • CONTENTS
    • FOREWORD
    • SAFETY INSTRUCTIONS
    • FIRE PREVENTION
      • Maintenance
      • Operation
      • Electrical
      • Hydraulic System
      • Fueling
      • Starting
      • Spark Arrestor Exhaust System
      • Welding And Grinding
      • Fire Extinguishers
    • SERIAL NUMBER LOCATIONS
      • Excavator Serial Number
      • Engine Serial Number
    • DELIVERY REPORT
    • EXCAVATOR IDENTIFICATION
  • SAFETY & MAINTENANCE
    • LIFTING AND BLOCKING THE EXCAVATOR
      • Procedure
    • UPPERSTRUCTURE SLEW LOCK
      • Operation
    • LIFTING THE EXCAVATOR
      • Procedure
    • OPERATOR CAB (ROPS / TOPS)
      • Description
      • Cab Door
      • Front Window
      • Front Wiper
      • Window Washer Reservoir
      • Right Side Window
      • Heating, Ventilation, and Air Conditioning Duct
    • TRANSPORTING THE EXCAVATOR ON A TRAILER
      • Loading And Unloading
      • Fastening
    • TAILGATE
      • Opening And Closing
    • RIGHT SIDE COVER
      • Opening And Closing
    • SERVICE SCHEDULE
      • Chart
    • AIR CLEANER SERVICE
      • Daily Check
      • Replacing Filter Elements
    • ENGINE COOLING SYSTEM
      • Cleaning
      • Checking Level
      • Removing And Replacing Coolant
    • FUEL SYSTEM
      • Fuel Specifications
      • Filling The Fuel Tank
      • Fuel Filters
      • Draining The Fuel Tank
      • Removing Air From The Fuel System
    • ENGINE LUBRICATION SYSTEM
      • Checking And Adding Engine Oil
      • Engine Oil Chart
      • Removing And Replacing Oil Filter
    • HYDRAULIC SYSTEM
      • Checking And Adding Fluid
      • Hydraulic Fluid Chart
      • Removing And Replacing The Hydraulic Filter
      • Removing And Replacing The Case Drain Filter
      • Removing And Replacing The Hydraulic Fluid
    • LUBRICATING THE EXCAVATOR
      • Lubrication Locations
    • TRAVEL MOTOR
      • Checking And Adding Oil
      • Removing And Replacing Oil
    • SPARK ARRESTOR MUFFLER
      • Cleaning Procedure
    • ALTERNATOR BELT
      • Belt Adjustment
      • Belt Replacement
    • SEAT BELT
      • Inspection And Maintenance
    • PIVOT PINS
      • Inspection And Maintenance
    • EXCAVATOR STORAGE AND RETURN TO SERVICE
      • Storage
      • Return to Service
    • STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
      • Procedure
      • Emergency Exits
  • HYDRAULIC SYSTEM
    • HYDRAULIC / HYDROSTATIC SCHEMATICS
    • HYDRAULIC SYSTEM INFORMATION
      • Glossary Of Hydraulic / Hydrostatic Symbols
      • Troubleshooting The Hydraulic Circuit
      • Troubleshooting The Cylinder Circuit
      • Troubleshooting The Swing (Upperstructure Slew) Circuit
      • Troubleshooting The Travel Circuit
    • BOOM CYLINDER
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • ARM CYLINDER
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • BOOM SWING CYLINDER
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • BUCKET CYLINDER
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • BLADE CYLINDER
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CLAMP CYLINDER
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • MAIN RELIEF VALVE
      • Testing And Adjusting The Main Relief Valve
    • PORT RELIEF VALVES
      • Testing And Adjusting Port Relief Valve Pressure
    • CROSSPORT RELIEF VALVES
      • Testing And Adjusting The Crossport Relief Valves
    • PRESSURE REDUCING VALVE
      • Testing And Adjusting The Pressure Reducing Valve
    • HYDRAULIC CONTROL VALVE
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Right Travel Valve Section Disassembly And Assembly
      • Left Travel Valve Section Disassembly And Assembly
      • Blade Valve Section Disassembly And Assembly
      • Slew Valve Section Disassembly And Assembly
      • Auxiliary Valve Section Disassembly And Assembly
      • Bucket Valve Section Disassembly And Assembly
      • Arm Valve Section Disassembly And Assembly
      • Boom Valve Section Disassembly And Assembly
      • Boom Swing Valve Section Disassembly And Assembly
      • Inlet Section Disassembly And Assembly
      • Assembly
    • HYDRAULIC PUMP
      • Description
      • Torque Adjustment
      • Testing The Piston Pump
      • Testing Auxiliary Hydraulic Flow
      • Removal
      • Installation
      • Coupler Removal And Installation
      • Piston Pump Parts Identification
      • Disassembly
      • Piston Pump Disassembly
      • Piston Pump Assembly
      • Assembly
    • MANIFOLD ASSEMBLY / ACCUMULATOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • TRAVEL MOTOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • SWIVEL JOINT
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • SWING MOTOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • SWING MOTOR DRIVE CARRIER
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL PATTERN SELECTOR VALVE
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly and Assembly
    • RIGHT CONTROL LEVER (JOYSTICK)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • LEFT CONTROL LEVER (JOYSTICK)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • TRAVEL CONTROL VALVE
      • Removal and Installation
      • Parts Identification
      • Disassembly And Assembly
    • HYDRAULIC FILTER
      • Description
      • Housing Removal And Installation
    • CASE DRAIN FILTER
      • Description
      • Removal And Installation
    • HYDRAULIC RESERVOIR
      • Description
      • Removal And Installation
    • OIL COOLER
      • Description
      • Removal And Installation
    • DIRECT TO TANK VALVE
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • NON-PRESSURIZED ACCUMULATOR
      • Description
      • Removal And Installation
  • UNDERCARRIAGE
    • BLADE
      • Description
      • Removal And Installation
    • TRACK FRAME COMPONENTS
      • Description
      • Track Lug Height
      • Checking Tension
      • Adjusting Tension
      • Rubber Track Removal And Installation
      • Steel Track Removal And Installation
      • Idler (Front) Removal And Installation
      • Idler (Front) Parts Identification
      • Idler (Front) Disassembly
      • Idler (Front) Assembly
      • Coil Spring Assembly And Cylinder Disassembly And Assembly (W/O Replaceable Shaft)
      • Coil Spring Cylinder Parts Identification (With Replaceable Shaft)
      • Coil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)
      • Roller Removal And Installation
      • Roller Parts Identification
      • Roller Disassembly
      • Roller Assembly
      • Track Guide Removal And Installation
      • Sprocket Removal And Installation
      • Track Damage Identification
      • 1. Coil Spring Assembly 2. O-Ring 3. Spacer (Steel Track Only) 4. Shaft 5. Wiper Seal 6. Wear Ring 7. Back-Up Ring 8. Tube 9. Grease Fitting 10. Bleed Fitting 11. Bolt
    • SWING CIRCLE GEAR
      • Removal And Installation
  • UPPERSTRUCTURE & SWING SECTION
    • UPPERSTRUCTURE
      • Description
      • Removal
      • Installation
    • CANOPY
      • Removal And Installation
    • CAB
      • Removal And Installation
      • Door Removal And Installation
      • Front Window Removal And Installation
      • Right Side Rear Sliding Window Removal And Installation
      • Right Side Front Sliding Window Removal And Installation
      • Glass Removal
      • Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
      • Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
      • Glass Installation
    • SEAT AND SEAT MOUNT
      • Seat Mount Removal And Installation
      • Seat Removal And Installation
    • RIGHT CONSOLE
      • Description
      • Console Cover Removal And Installation
      • Console Base Cover Removal And Installation
    • LEFT CONSOLE
      • Description
      • Joystick Console Cover (Bottom) Removal And Installation
      • Joystick Console Cover (Top) Removal And Installation
      • Compression Spring Removal And Installation
      • Compression Spring Disassembly And Assembly
      • Lever Removal And Installation
      • Joystick Console Frame Removal And Installation
      • Joystick Console Frame Disassembly And Installation
      • Left Rear Console Cover Removal And Installation
      • Left Rear Console Frame Removal And Installation
      • Left Rear Console Frame Disassembly And Assembly
    • BLADE CONTROL
      • Removal And Installation
      • Disassembly And Assembly
      • Linkage Removal And Installation
      • Linkage Disassembly And Assembly
    • UPPERSTRUCTURE SLEW LOCK
      • Removal and Installation
    • FLOOR MAT AND FLOOR PANEL
      • Description
      • Removal And Installation
    • BOOM SWING PEDAL
      • Description
      • Removal And Installation
      • Disassembly And Assembly
      • Linkage Removal And Installation
    • TRAVEL LEVER / PEDALS
      • Description
      • Removal And Installation
      • Disassembly And Assembly
      • Adjustment
      • Linkage Removal And Installation
    • FUEL TANK
      • Removal And Installation
    • HORN
      • Removal And Installation
    • SWING FRAME
      • Description
      • Removal And Installation
      • Hose Routing
      • Bushing Removal And Installation
      • Swing Frame Bushing Removal And Installation
    • BOOM
      • Description
      • Removal And Installation
    • ARM
      • Description
      • Removal And Installation
      • Arm To Boom Bushing Removal And Installation
      • Arm To Bucket And Bucket Link Bushing Removal And Installation
    • BUCKET
      • Removal And Installation (Pin-On Attachment)
      • Bucket Teeth Removal And Installation
      • Bucket Side Cutting Edge Removal And Installation
    • CLAMP
      • Removal And Installation
    • TAILGATE
      • Removal And Installation
      • Latch Removal And Installation
    • RIGHT SIDE COVER
      • Removal And Installation
      • Latch Removal And Installation
    • COUNTERWEIGHT
      • Description
      • Removal And Installation (Long Arm Counterweight)
      • Removal And Installation (Standard Counterweight)
    • LEFT SIDE COVER
      • Removal And Installation
  • ELECTRICAL SYSTEM & ANALYSIS
    • ELECTRICAL SCHEMATICS
    • ELECTRICAL SYSTEM INFORMATION
      • Glossary Of Electrical Symbols
      • Harness Connectors
      • Troubleshooting
      • Description
      • Fuse And Relay Location / Identification
    • BATTERY
      • Removal And Installation
      • Servicing
      • Using A Booster Battery (Jump Starting)
    • ALTERNATOR
      • Belt Adjustment
      • Belt Replacement
      • Charging System Inspection
      • Description
      • Tests
      • Alternator Output Test
      • Full Field Test
      • Alternator Regulator Test
      • Alternator Regulator Test With Voltmeter
      • Removal And Installation
      • Parts Identification
    • STARTER
      • Testing
      • Removal And Installation
      • Parts Identification
    • LIGHTS
      • Upperstructure Light Removal And Installation
      • Upperstructure Light Disassembly And Assembly
      • Boom Light Removal And Installation
      • Boom Light Disassembly And Assembly
    • MAGNETIC LOCKOUT SENSOR
      • Testing Left Console Magnetic Lockout Sensor
      • Left Console Magnetic Lockout Sensor Removal And Installation
    • FUEL LEVEL SENDER
      • Removal And Installation
      • Testing
    • DIAGNOSTIC SERVICE CODES
      • Description
      • Service Codes List
  • ENGINE SERVICE
    • ENGINE INFORMATION
      • Description
      • Specifications
      • Torque Values
      • Troubleshooting
      • Removal And Installation
      • Engine Mount Replacement
      • Compression – Checking
    • ENGINE SPEED CONTROL
      • Removal And Installation
    • SPARK ARRESTOR MUFFLER
      • Removal And Installation
    • AIR CLEANER
      • Removal And Installation
    • ENGINE COOLING SYSTEM
      • Radiator Removal And Installation
      • Radiator Disassembly and Assembly
      • Water Pump Removal And Installation
      • Water Pump Disassembly And Assembly
      • Thermostat Housing Removal And Installation
      • Testing The Thermostat
    • LUBRICATION SYSTEM
      • Oil Pan Removal And Installation
      • Oil Pump Removal And Installation
      • Oil Pump Inspection
      • Engine Oil Pressure – Testing
    • FUEL SYSTEM
      • Fuel Camshaft Removal And Installation
      • Fuel Camshaft Governor Disassembly And Assembly
      • Fuel Shutoff Solenoid – Checking
      • Fuel Shutoff Solenoid Removal And Installation
      • Fuel Injection Pump Removal And Installation
      • Timing The Injection Pump
      • Fuel Injector Removal And Installation
      • Fuel Injector Nozzles Pressure – Checking
      • Nozzle Spray Condition
      • Valve Seat Tightness
    • CYLINDER HEAD
      • Glow Plug – Testing
      • Glow Plug Removal And Installation
      • Valve Clearance Adjustment
      • Valve Timing – Checking
      • Cylinder Head Removal And Installation
      • Cylinder Head Disassembly and Assembly
      • Cylinder Head – Servicing
      • Cylinder Head Top Clearance
      • Valve Guide – Checking
      • Reconditioning The Valve And Valve Seat
      • Valve Spring
      • Valve Tappets
      • Rocker Arm And Shaft – Checking
    • CRANKSHAFT AND PISTONS
      • Piston And Connecting Rod Removal And Installation
      • Piston And Connecting Rod – Servicing
      • Cylinder Bore Checking
      • Connecting Rod Alignment
      • Crankshaft And Bearings Removal And Installation
      • Crankshaft And Bearings – Servicing
    • CAMSHAFT AND TIMING GEARS
      • Timing Gearcase Cover Removal And Installation
      • Timing Gears Backlash – Checking
      • Idler Gear And Shaft Removal And Installation
      • Camshaft – Servicing
      • Idler Gear And Shaft Servicing
    • FLYWHEEL AND HOUSING
      • Flywheel Housing Removal And Installation
      • Hydraulic Pump Coupler Removal And Installation
      • Flywheel Removal And Installation
      • Rear End Plate Removal And Installation
  • HEATER
    • HEATER SYSTEM
      • Description
      • Components
    • REGULAR MAINTENANCE
      • Filter Element Removal And Installation
      • Heater Coil
    • TROUBLESHOOTING
      • Blower Motor Does Not Operate
      • Blower Motor Operates Normally, But Air Flow Is Insufficient
      • Electrical System
    • HEATER UNIT
      • Removal And Installation
    • HEATER COIL
      • Removal And Installation
    • BLOWER FAN
      • Removal And Installation
    • HEATER VALVE
      • Removal And Installation
  • SPECIFICATIONS
    • EXCAVATOR SPECIFICATIONS
      • 425 With Standard Arm
      • 425 With Long Arm Option And 428
      • Performance
      • Controls
      • Engine
      • Hydraulic System
      • Hydraulic Cylinders
      • Hydraulic Cycle Times
      • Electrical
      • Instrumentation
      • Drive System
      • Slew System
      • Undercarriage
      • Crawler Track Design
      • Capacities
      • Fuel Tank
      • Tracks
      • Type
      • Ground Pressure
    • TORQUE SPECIFICATIONS FOR BOLTS
      • Torque For General SAE Bolts
      • Torque For General Metric Bolts
    • HYDRAULIC CONNECTION SPECIFICATIONS
      • O-ring Face Seal Connection
      • Straight Thread O-ring Fitting
      • Tubelines And Hoses
      • Flare Fitting
      • Port Seal Fitting
    • HYDRAULIC FLUID SPECIFICATIONS
      • Specifications
    • CONVERSIONS
      • Decimal And Millimeter Equivalents
      • U.S. To Metric Conversion Chart
  • SERVICE MANUAL REVISION
    • 425 / 428 – 1
    • 425 / 428 – 2
    • 425 / 428 – 3

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