A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

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