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

Service Repair Manual
Model
428E BACKHOE LOADER

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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428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) E...
2019/9/26
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g01527020
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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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".
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) .
3/14
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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) .
7. Install access panel (62) .
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8. Remove Tooling (B) from the transmission.
9. Position tube assembly (48) and install bolts (60) .
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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) .
14. Install clips (54) and (52) .
15. Connect hoses (53) and (51) .
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16. Install clip (49) and install cable straps (50) to tube assembly (48) .
17. Connect harness assembly (47) .
18. Connect cable assembly (46) and install nut (45) .
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19. Connect hoses (43) and connect clip (44) .
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) .
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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24. Connect cable assembly (35) .
26. Attach cable straps (33) in order to secure harness assembly (29) .
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).
29. Install bolts (30). Repeat this step for the opposite side.
30. Attach cable strap (31) in order to secure harness assembly (29) .
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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) .
35. Connect hoses (24) .
10/14
428E Backhoe Loader DXC00001-UP (MACHINE) POWERED BY C4.4 (MECH) ...
2019/9/26

36. Position air cleaner assembly (23) and install bolts (22) .
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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43. Attach cable strap (14). Connect hoses (11) to tank (12). Connect harness assemblies (13) to
tank (12) .
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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).
45. Install cover (7) and install bolts (8) .
46. Position plate (5) and install bolts (6) .
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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.
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.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 26 23:17:56 UTC+0800 2019
14/14
2019/9/26

Shutdown SIS
Previous Screen
422E, 428E, 432E, 434E, 442E and 444E Backhoe Loaders Machine Systems
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.
Fri Sep 27 09:19:28 UTC+0800 2019
1/1
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Shutdown SIS
Previous Screen
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
A 1P-1863 Retaining Ring Pliers 1
B 189-0410 Shackle As 2
C
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
1/6
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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.
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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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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7. Use Tooling (C) in order to remove bearings (9). Repeat for the other side.
Table 2
Required Tools
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.
4/6
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1. Lower the temperature of bearings (9). Use Tooling (D) in order to install bearings (9) .
2. Attach Tooling (B) and a suitable lifting device to bucket (5). The weight of bucket (5) is
approximately 907 kg (2000 lb).
5/6
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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.
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) .
Fri Sep 27 09:20:16 UTC+0800 2019
6/6
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Shutdown SIS
Previous Screen
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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1. Disconnect hose assemblies (1) .
2. Start the machine. Activate switch (2) in order to disengage the coupler pins. Lower the
loader arms and back away from the bucket.
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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2. Connect hose assemblies (1) .
Fri Sep 27 09:21:04 UTC+0800 2019
3/3
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Shutdown SIS
Previous Screen
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
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".
1/7
2019/9/27

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