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Bobcat 428 Excavator Service Manual (SN A1HW11001-A1HW99999)

Format: PDF (Printable Document)

File Language: English

File Pages: 691

File Size: 18.30 MB (Speed Download Link)

Brand: Bobcat

Model: 428 Excavator

Book No: 6904866

Serial No: SN A1HW11001-A1HW99999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat 428 Excavator Service Manual (SN A1HW11001-A1HW99999)

The Bobcat 428 is a compact excavator you'll see trenching, digging service lines, and doing tight access work where a skid steer just can't reach. The people who grab this service manual are the ones actually turning wrenches: small contractors, owner-operators, and shop or field techs who are past warranty and need real repair info. They're chasing hydraulic issues, engine problems, or wiring faults and want factory-style procedures, not sales fluff.

What this manual helps you do

  • Diagnose hydraulic problems by following step-by-step pressure and flow checks on the 428's working and travel circuits
  • Trace and troubleshoot electrical faults using factory wiring diagrams for this exact serial range
  • Follow teardown and reassembly procedures for components like cylinders, swing motor, and travel motors
  • Check and set adjustments on controls, linkages, and pilot controls so the machine digs straight and smooth
  • Verify specs and sequences when doing engine work, cooling system repairs, or pump replacement on the 428

Who this is for

This is for anyone working on a Bobcat 428 excavator in the A1HW11001 to A1HW99999 serial range: small contractors, rental fleets, shop mechanics, and owner-operators. If you only need basic controls, daily checks, and safety, you want the operator's handbook instead, not this manual.

FAQ

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

A: Yes, these manuals are normally supplied as searchable PDFs and the wiring diagrams are laid out so you can zoom in and follow circuits.

Q: How do I know if it covers my exact machine?

A: Check your serial plate. If your 428 starts with A1HW and falls between A1HW11001 and A1HW99999, this is the right manual.

Q: Is this the right document if I'm doing real repairs, not just maintenance?

A: Yes, this is the workshop-level service manual, meant for diagnostics and repair work, not just basic upkeep.

Bottom line: If your machine is a Bobcat 428 in that A1HW11001-A1HW99999 range and you're doing actual repair work, this is the manual you want.

📘 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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