EXHAUST. Crossover Manifold Replacement TX420 & & up. Crossover Manifold Removal

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Lorena Grant
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Crossover Manifold Replacement TX420 & 425 250000401 & up 4. Using an 8mm socket, remove the top bolt from the heat shield (Fig. 0245).

0243). Fig 0245 PICT-1639 5. Using a 5/8 socket, remove the 2 lower bolts securing the heat shield to the pump mount (Fig. 0246).

1 Crossover Manifold Replacement TX420 & & up 4. Using an 8mm socket, remove the top bolt from the heat shield (Fig. 0245). Crossover Manifold Removal 1. Open and support the hood with the hood support rod. 2. Remove the right and left side engine guards (Fig. 0243). Fig 0245 PICT Using a 5/8 socket, remove the 2 lower bolts securing the heat shield to the pump mount (Fig. 0246). Fig 0243 PICT-1506a 3. Remove the air cleaner cover (Fig. 0244). Fig 0246 PICT-1640 Fig 0244 PICT-1638 TX420, TX425 Series Service Manual Rev

6. Position the heat shield so that it is out of the way of the manifold

Separate the muffler pipe from the manifold crossover (Fig. 0249).

Using a 1/2 socket, loosen the two nuts securing the muffler clamp to the

Using a 13mm socket, remove all 4 nuts securing the manifold crossover to the

2 6. Position the heat shield so that it is out of the way of the manifold crossover (Fig. 0247). 8. Separate the muffler pipe from the manifold crossover (Fig. 0249). Fig 0247 PICT-1641 Fig 0249 PICT Using a 1/2 socket, loosen the two nuts securing the muffler clamp to the muffler and slide the clamp down the muffler pipe (Fig. 0248). 9. Using a 13mm socket, remove all 4 nuts securing the manifold crossover to the engine (Fig. 0250). Note: The 2 inside nuts will require the use of a universal attachment on the 13mm socket. Fig 0248 PICT-1643 Fig 0250 PICT Rev. 001 TX420, TX425 Series Service Manual

10. Remove the manifold crossover from the engine (Fig. 0251). 3.

Fig 0251 PICT-1647 Fig 0253 PICT-1649 Crossover Manifold Installation 1.

Install the 2 exhaust gaskets so that the flat side of the gasket is facing the engine

Install the 4 nuts onto the manifold studs securing the manifold crossover to the engine.

3 10. Remove the manifold crossover from the engine (Fig. 0251). 3. Position the manifold pipe onto the 4 manifold studs on the engine (Fig. 0253). Fig 0251 PICT-1647 Fig 0253 PICT-1649 Crossover Manifold Installation 1. The two exhaust gaskets must be replaced before installing the manifold crossover. 2. Install the 2 exhaust gaskets so that the flat side of the gasket is facing the engine (Fig. 0252). 4. Install the 4 nuts onto the manifold studs securing the manifold crossover to the engine. Tighten the 4 nuts using a 13mm socket (Fig. 0254). Note: The 2 inside nuts will require the use of a universal attachment on the 13mm socket. Fig 0254 PICT-1646 Fig 0252 PICT-1648 TX420, TX425 Series Service Manual Rev

5. Slide the muffler pipe up onto the manifold crossover pipe (Fig. 0255). 7.

Tighten using a 5/8 socket and torque to 50 ft-lbs. (Fig. 0257).

Position the muffler clamp in the overlapped area of the two pipes.

4 5. Slide the muffler pipe up onto the manifold crossover pipe (Fig. 0255). 7. Install the two lower bolts that secure the heat shield to the pump mount. Tighten using a 5/8 socket and torque to 50 ft-lbs. (Fig. 0257). Fig 0255 PICT-1650 Fig 0257 PICT Position the muffler clamp in the overlapped area of the two pipes. Using a 1/2 socket, tighten the two nuts to secure the muffler clamp and pipes in place (Fig. 0256). 8. Install the top bolt securing the heat shield to the throttle plate. Tighten using an 8mm socket (Fig. 0258). Fig 0256 PICT-1643 Fig 0258 PICT Rev. 001 TX420, TX425 Series Service Manual

5 9. Install the air cleaner cover (Fig. 0259). Muffler Replacement TX420 & & up Muffler Removal 1. Lift the loader arms to the full up position and install the cylinder lock. 2. Using a 3/4 socket and wrench, loosen 2 of the 4 bolts/nuts on one side of the counterweight. Support the weight and remove the other 2 bolts, washers and nuts using the same socket and wrench. Remove the front counterweight (Fig. 0261). Fig 0259 PICT Install the left and right side engine guards (Fig. 0260). Fig 0261 PICT-1653 Fig 0260 PICT Start the engine and check for exhaust leaks. 12. Lower the hood. TX420, TX425 Series Service Manual Rev

3. Using a 1/2 socket, remove the two sets of carriage bolts,

washers securing the muffler/heat shield assembly to the frame

Remove the muffler heat shield (Fig. 0263). 6.

6 3. Using a 1/2 socket, remove the two sets of carriage bolts, washers and nuts holding the muffler heat shield onto the front grill (Fig. 0262). 5. Using a 7/16 socket and wrench, remove the 4 sets of bolts and washers securing the muffler/heat shield assembly to the frame (Fig. 0264). Fig 0262 PICT-1655 Fig 0264 PICT Remove the muffler heat shield (Fig. 0263). 6. Remove the right and left side engine guards (Fig. 0265). Fig 0263 PICT-1657 Fig 0265 PICT-1506a 5-6 Rev. 001 TX420, TX425 Series Service Manual

7. Using a 1/2 socket, loosen the 2 nuts on the muffler clamp (Fig. 0266).

Position the muffler heat shield so that the rounded notch lines up with the muffler

Slide the muffler clamp up onto the manifold crossover. Fig 0268 PICT-1662a 9.

7 7. Using a 1/2 socket, loosen the 2 nuts on the muffler clamp (Fig. 0266). Muffler Installation 1. Position the muffler heat shield so that the rounded notch lines up with the muffler opening on the front grill (Fig. 0268). Fig 0266 PICT Slide the muffler clamp up onto the manifold crossover. Fig 0268 PICT-1662a 9. Remove the muffler assembly (Fig. 0267). 2. Insert the muffler pipe into the front grill opening (Fig. 0269). Fig 0267 PICT-1661 Fig 0269 PICT-1664 TX420, TX425 Series Service Manual Rev

3. Slide the muffler pipe onto the manifold crossover (Fig. 0270). 5.

and washers. Tighten using a 7/16 socket and wrench (Fig. 0271). Fig 0272 PICT-1667 6.

8 3. Slide the muffler pipe onto the manifold crossover (Fig. 0270). 5. Slide one side of the front counterweight onto the two bolts/washer/nut assemblies on the front of the frame (Fig. 0272). Note: The weight should be installed between the washers and the frame. Fig 0270 PICT Align the muffler with the 4 holes in the heat shield and install the 4 sets of bolts and washers. Tighten using a 7/16 socket and wrench (Fig. 0271). Fig 0272 PICT Install the second set of bolts, washers, and nuts to secure the other side of the front counterweight. Do not tighten the nuts and bolts (Fig. 0273). Fig 0271 PICT-1666 Fig 0273 PICT-7640a 5-8 Rev. 001 TX420, TX425 Series Service Manual

Fig 0276 PICT-1653 Fig 0274 PICT-1668 8. Install the 2 carriage bolts, washers and nuts to secure the front heat shield (Fig. 0275). 10.

9 7. Slide the front muffler heat shield down in between the weight and the front counter weight so that the heat shield is resting on the top two bolts (Fig. 0274). 9. Using a 3/4 socket and wrench, tighten the 4 bolts and nuts securing the counterweight (Fig. 0276). Fig 0276 PICT-1653 Fig 0274 PICT Install the 2 carriage bolts, washers and nuts to secure the front heat shield (Fig. 0275). 10. Slide the exhaust clamp into place. Using a 1/2 socket, tighten the 2 nuts on the clamp (Fig. 0277). Fig 0275 PICT-1655 Fig 0277 PICT-1660 TX420, TX425 Series Service Manual Rev

10 11. Install the right side engine guard (Fig. 0278). Fig 0278 PICT-1506a 12. Start the engine and check for exhaust leaks. 13. Lower the loader arms. 14. Lower the hood Rev. 001 TX420, TX425 Series Service Manual

HYDRAULICS. TX420 & & lower. Hydraulic Tandem Pump Removal. 4. Remove the LH side panel (Fig. 0388).

HYDRAULICS. TX420 & & lower. Hydraulic Tandem Pump Removal. 4. Remove the LH side panel (Fig. 0388). TX420 & 425 240000299 & lower 4. Remove the LH side panel (Fig. 0388). Hydraulic Tandem Pump Removal Note: Cleanliness is a key factor in a successful repair of any hydraulic system. Thoroughly clean all