Caterpillar Cat 428E BACKHOE LOADER (Prefix DXC) Service Repair Manual (DXC00001 and up)

Service Repair Manual

Model

428E BACKHOE LOADER

428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) E...

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Shutdown SIS Previous Screen Product: BACKHOE LOADER Model: 428E BACKHOE LOADER DXC Configuration: 428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) Engine

Disassembly and Assembly 422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Engine Supplement Media Number -KENR8033-00

Publication Date -01/11/2008

Date Updated -12/11/2008

i03165915

Engine - Install SMCS - 1000-012

Installation Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

185-3630

Strap Wrench As

1

B

1U-7505

Hydraulic Jack

1

C

6V-3145

Load Leveling Beam

1

D

138-7575

Link Bracket

1

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Illustration 1

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Illustration 2

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1. Attach Tooling (A), Tooling (B), and a suitable lifting device to engine (61). The weight of engine (61) is approximately 454 kg (1000 lb). Use Tooling (A), Tooling (B), and the suitable lifting device in order to position engine (61) into the machine.

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Illustration 3

g01527059

2. Install mounting bolts (68) to each side of the engine.

3. Position tube assemblies (70) and connect clips (69) .

4. Use Tooling (A) in order to install engine oil filter (67). Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change".

Illustration 4

g01527055

5. Install bolts (65) into bell housing (66) .

Note: Be sure to connect the ground wires (not shown) and the ground cable (not shown) during the installation of bolts (65) .

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Illustration 5

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g01527040

6. Install bolts (64) into flywheel (63). Tighten bolts (64) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

Note: The engine must be manually rotated in order to access all bolts (64) .

Illustration 6

g01527038

7. Install access panel (62) .

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Illustration 7

g01148798

8. Remove Tooling (B) from the transmission.

Illustration 8

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9. Position tube assembly (48) and install bolts (60) .

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Illustration 9

g01526980

This is viewed from the bottom of the machine.

10. Install clip (59) .

11. Install clip (58) onto tube assembly (48) .

12. Install fuel filter and base (57) .

13. Connect hose (56) and install clip (55) .

Illustration 10

g01526967

14. Install clips (54) and (52) .

15. Connect hoses (53) and (51) .

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Illustration 11

g01526964

16. Install clip (49) and install cable straps (50) to tube assembly (48) .

17. Connect harness assembly (47) .

Illustration 12

g01526956

18. Connect cable assembly (46) and install nut (45) .

Illustration 13

g01526928

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19. Connect hoses (43) and connect clip (44) .

Illustration 14

g01526901

20. Position refrigerant compressor (40) and hose assemblies (41). Install bolts (42) .

21. Position the clamp and install bolt (39) in order to connect hose assemblies (41) .

Illustration 15

g01526884

22. Connect harness assemblies (37) to the starter. Tighten the nuts for harness assemblies (37) to a torque of 3.50 ± 0.25 N·m (31 ± 2 lb in).

23. Connect cable assemblies (38) to the starter. Tighten the nut that secures cable assemblies (38) to a torque of 21 ± 4 N·m (15 ± 3 lb ft).

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Illustration 16

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g01525864

24. Connect cable assembly (35) .

25. Connect harness assembly (29) .

26. Attach cable straps (33) in order to secure harness assembly (29) .

27. Connect harness assembly (36) .

28. Connect harness assemblies (34). Tighten the nuts that secure harness assemblies (34) to a torque of 4.5 ± 0.5 N·m (39.8 ± 4.4 lb in).

Illustration 17

g01525851

29. Install bolts (30). Repeat this step for the opposite side.

30. Attach cable strap (31) in order to secure harness assembly (29) .

31. Connect harness assembly (32) .

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Illustration 18

g01525840

32. Install clip (28) .

33. Install bolt (27) .

34. Use two people in order to position frame assembly (25). The weight of frame assembly (25) is approximately 29 kg (65 lb). Install bolts (26) .

Illustration 19

g01525822

35. Connect hoses (24) .

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Illustration 20

g01525807

36. Position air cleaner assembly (23) and install bolts (22) .

Illustration 21

g01525778

37. Install bolts (19) .

38. Connect clip (20) .

39. Connect hose (21) .

40. Position the tube assembly and install bolt (17) .

41. Connect harness assembly (18) and attach cable straps (16) .

42. Install hose (15) .

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Illustration 22

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g01525761

43. Attach cable strap (14). Connect hoses (11) to tank (12). Connect harness assemblies (13) to tank (12) .

Illustration 23

g01525742

Illustration 24

g01525743

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44. Position exhaust pipe (10) to the correct orientation with the cab. Position the clamp against the mounting bracket. Orient the clamp toward the cab. Install nut (9). Tighten nut (9) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Illustration 25

g01525737

45. Install cover (7) and install bolts (8) .

Illustration 26

g01525732

46. Position plate (5) and install bolts (6) .

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Illustration 27

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g01525773

47. Position floor mat (4). Position plate (3) and install bolts (2). Position plate (3) and install bolts (2) on the opposite side of the cab.

Illustration 28

g01114620

48. Connect ground cable assembly (1) in order to connect the batteries.

49. Fill the transmission with oil. Refer to Operation and Maintenance Manual, "Transmission Oil - Change".

End By: Install the radiator, the refrigerant condenser, the hydraulic oil cooler, and the transmission oil cooler. Refer to Disassembly and Assembly, "Radiator, Refrig Condenser, and Hyd and TMSN Oil Cooler - Install ".

Copyright 1993 - 2019 Caterpillar Inc.

Thu Sep 26 23:17:56 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: BACKHOE LOADER Model: 428E BACKHOE LOADER DXC Configuration: 428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) Engine

Disassembly and Assembly 422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Machine Systems Media Number -KENR8043-00

Publication Date -01/11/2008

Date Updated -12/11/2008

i02989945

System Pressure - Release SMCS - 4250-553-PX; 4300-553-PX; 5050-553-PX

Release Procedure 1. Park on a level surface. If you must park on a grade, chock the machine.

2. Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.

3. Move the speed control lever to the LOW IDLE position.

4. Engage the parking brake.

5. Engage the transmission neutral lock.

6. Lower all attachments to the ground.

7. Stop the engine.

8. Turn the engine start switch key to OFF position for 4 seconds.

9. Turn the engine start switch key back to ON position.

10. Press the hydraulic shutoff switch to the ON position.

11. Operate all hydraulic controls through all positions in order to relieve hydraulic pressure.

Repeat this step until all hydraulic pressure is released.

12. Move the hydraulic control levers to the HOLD position.

13. Turn the engine start switch to OFF position and remove the key.

Copyright 1993 - 2019 Caterpillar Inc.

Fri Sep 27 09:19:28 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: BACKHOE LOADER Model: 428E BACKHOE LOADER DXC Configuration: 428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) Engine

Disassembly and Assembly 422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Machine Systems Media Number -KENR8043-00

Publication Date -01/11/2008

Date Updated -12/11/2008

i03180241

Bucket - Remove and Install SMCS - 6001-010 S/N - DXC1-UP S/N - HXB1-UP S/N - PCR1-UP S/N - RXS1-UP S/N - SXB1-UP

Removal Procedure Table 1 Required Tools Tool

Part Number

A

1P-1863

Retaining Ring Pliers

1

B

189-0410

Shackle As

2

1P-1833

Bearing Puller Adapter

1

FT-1410

Sleeve

1

126-8928

Hard Washer

1

9U-6833

Nut

1

4C-9633

Puller Stud

1

3S-6224

Hydraulic Pump

1

6V-3160

Double Acting Cylinder

1

C

Part Description

Qty

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Start By: A. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Lower the bucket to the ground.

Illustration 1

g01625330

2. Disconnect hose assemblies (1) .

3. Use Tooling (A) in order to remove retaining ring (4). Remove retaining ring (4), washers (2), and pin (3). Repeat for the other lower link assembly.

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428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) E...

Illustration 2

g01625331

Illustration 3

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4. Attach Tooling (B) and a suitable lifting device to bucket (5). The weight of bucket (5) is approximately 907 kg (2000 lb).

5. Use Tooling (A) in order to remove retaining ring (6). Remove retaining ring (6), washers (7), and pin assembly (8). Repeat for the other side.

6. Remove bucket (5) .

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Illustration 4

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g01625333

7. Use Tooling (C) in order to remove bearings (9). Repeat for the other side.

Installation Procedure Table 2 Required Tools Tool

Part Number

Part Description

Qty

A

1P-1863

Retaining Ring Pliers

1

B

189-0410

Shackle As

1

D

1P-0510

Driver Gp

1

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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Illustration 5

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1. Lower the temperature of bearings (9). Use Tooling (D) in order to install bearings (9) .

Illustration 6

g01625331

Illustration 7

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2. Attach Tooling (B) and a suitable lifting device to bucket (5). The weight of bucket (5) is approximately 907 kg (2000 lb).

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3. Position bucket (5). Use Tooling (A) in order to install retaining ring (6). Install pin assembly (8), washers (7), and retaining ring (6). Repeat for the other side.

Illustration 8

g01625330

4. Use Tooling (A) in order to install retaining ring (4). Install pin (3), washers (2), and retaining ring (4). Repeat for the other lower link assembly.

5. Connect hose assemblies (1) .

Copyright 1993 - 2019 Caterpillar Inc.

Fri Sep 27 09:20:16 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: BACKHOE LOADER Model: 428E BACKHOE LOADER DXC Configuration: 428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) Engine

Disassembly and Assembly 422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Machine Systems Media Number -KENR8043-00

Publication Date -01/11/2008

Date Updated -12/11/2008

i03290523

Bucket - Remove and Install - Multipurpose SMCS - 6001-010 S/N - DXC1-UP S/N - HXB1-UP S/N - PCR1-UP S/N - RXS1-UP S/N - SXB1-UP

Removal Procedure Start By: A. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

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Illustration 1

g01620206

1. Disconnect hose assemblies (1) .

Illustration 2

g01620221

2. Start the machine. Activate switch (2) in order to disengage the coupler pins. Lower the loader arms and back away from the bucket.

Installation Procedure

Illustration 3

g01620221

Note: The coupler pins must be engaged in the bucket.

1. Start the machine. Position the machine in order to engage the loader arms into the bucket.

Activate switch (2) in order to engage the coupler pins.

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Illustration 4

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g01620206

2. Connect hose assemblies (1) .

Copyright 1993 - 2019 Caterpillar Inc.

Fri Sep 27 09:21:04 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: BACKHOE LOADER Model: 428E BACKHOE LOADER DXC Configuration: 428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) Engine

Disassembly and Assembly 422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Machine Systems Media Number -KENR8043-00

Publication Date -01/11/2008

Date Updated -12/11/2008

i03259693

Link Assemblies (Lower) - Remove and Install SMCS - 6107-010; 6116-010; 6117-010; 6513-010-LH S/N - DXC1-UP S/N - HXB1-UP S/N - PCR1-UP S/N - RXS1-UP S/N - SXB1-UP

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

1P-1863

Retaining Ring Pliers

1

B

1P-0510

Driver Gp

1

1. Lower the bucket to the ground. Release the hydraulic pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

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