Bobcat 442 Mini Excavator Service Manual-16B16941-21416B320012.pdf -Bookmark created by https://wimanual.com 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 BOBCAT EXCAVATOR IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE EXCAVATOR Procedure LIFTING THE EXCAVATOR Procedure OPERATOR CAB Description Entering And Exiting The Excavator Raising And Lowering The Left Console Emergency Exit TRANSPORTING THE EXCAVATOR REAR COVER Opening And Closing The Rear Cover RIGHT SIDE COVER Opening And Closing The Right Side Cover SERVICE SCHEDULE AIR CLEANER Daily Check Replacing The Filters FRESH AIR FILTER (S Removal And Installation FRESH AIR FILTER (S Removal And Installation COOLING SYSTEM Cleaning The Cooling System Checking Coolant Level (S Replacing The Coolant (S FUEL SYSTEM Fuel Specifications Filling The Fuel Tank Removing Water From The Pre-Filter (S Pre-Filter Removal (S Pre-Filter Installation (S Pre-Filter Removal And Installation (S Fuel Filter Removal And Installation Draining The Fuel Tank ENGINE LUBRICATION SYSTEM Checking Engine Oil Replacing Oil And Filter HYDRAULIC SYSTEM Checking And Adding Hydraulic Oil Replacing The Hydraulic Oil Hydraulic Filter Removal (S Hydraulic Filter Installation (S Hydraulic Filter Removal (S Hydraulic Filter Installation (S Diagnostic Couplers (S Diagnostic Couplers (S LUBRICATION OF THE EXCAVATOR TRAVEL MOTOR Checking Oil Level Draining The Travel Motor ALTERNATOR BELT Adjusting Belt Tension FAN Adjusting Belt Tension (S AIR CONDITIONING COMPRESSOR BELT (S Adjusting Belt Tension AIR CONDITIONING COMPRESSOR BELT (S Adjusting Belt Tension CAB TILT PROCEDURE Installing The Cab Tilt Hinges Tilting The Cab HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Troubleshooting Chart Description BOOM CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly ARM CYLINDER Testing Removal And Installation Parts Identification Disassembly Assembly BOOM OFFSET CYLINDER Testing BOOM OFFSET CYLINDER 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 RELIEF VALVES Description Testing The Three Spool Control Valve Main Relief Valve Adjusting The Three Spool Control Valve Main Relief Valve PORT RELIEF VALVES Adjustment Procedure PRESSURE REDUCING VALVE (S Description Testing Adjustment PRESSURE REDUCING VALVE (S Description Testing Adjustment DUMP VALVE Description Testing Adjustment Removal And Installation Parts Identification Disassembly And Assembly SIX SPOOL HYDRAULIC CONTROL VALVE Removal And Installation Control Valve Identification Disassembly And Assembly Left Travel And Right Travel Valve Section Disassembly And Assembly Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly Inlet Valve Section Disassembly And Assembly THREE SPOOL HYDRAULIC CONTROL VALVE Removal And Installation Parts Identification Disassembly And Assembly Boom Offset And Blade Valve Section Disassembly And Assembly Inlet HYDRAULIC PISTON PUMP (S Hydraulic Pump Work Sheet Testing Information Pump Testing Load Sense Relief Valve Adjustment Removal And Installation Coupler Removal And Installation Torque Limiter Valve Parts Identification Torque Limiter Valve Removal and Installation Torque Limiter Valve Disassembly Torque Limiter Valve Assembly Initial Torque Limiter Valve Setting Pump Control Parts Identification Pump Control Removal And Installation Pump Control Disassembly And Assembly Parts Identification Disassembly Assembly HYDRAULIC GEAR PUMP (S Removal And Installation Parts Identification Disassembly Assembly HYDRAULIC PISTON PUMP (S Hydraulic Pump Work Sheet Testing Information Pump Testing Load Sense Relief Valve Adjustment Removal And Installation Coupler Removal And Installation Torque Limiter Valve Parts Identification Torque Limiter Valve Removal and Installation Torque Limiter Valve Disassembly Torque Limiter Valve Assembly Initial Torque Limiter Valve Setting Pump Control Parts Identification Pump Control Removal And Installation Pump Control Disassembly And Assembly Parts Identification Disassembly Assembly HYDRAULIC GEAR PUMP (S Removal And Installation Parts Identification Disassembly Assembly ACCUMULATOR (S Description Removal And Installation ACCUMULATOR (S Description Removal And Installation TRAVEL MOTOR Removal And Installation Parts Identification Disassembly Assembly SWIVEL JOINT Removal And Installation Parts Identification Disassembly And Assembly SWING MOTOR Removal And Installation Parts Identification Disassembly Assembly SWING MOTOR DRIVE CARRIER Removal And Installation Parts Identification Disassembly Assembly SWING BRAKE VALVE Removal And Installation Parts Identification Disassembly And Assembly SWING BRAKE RELEASE VALVE Removal And Installation Parts Identification Disassembly And Assembly JOYSTICK CONTROL PATTERN SELECTOR VALVE Removal And Installation Parts Identification Disassembly And Assembly JOYSTICK LOCKOUT Removal And Installation JOYSTICK LOCKOUT Parts Identification Disassembly And Assembly JOYSTICK LOCKOUT Removal And Installation Parts Identification Disassembly And Assembly RIGHT CONTROL LEVER (JOYSTICK) Testing Handle Removal And Installation Removal And Installation Parts Identification Disassembly And Assembly LEFT CONTROL LEVER (JOYSTICK) Testing Handle Removal And Installation Removal And Installation Parts Identification Disassembly and Assembly TRAVEL LEVER Left Travel Lever Right Travel Lever Parts Identification Disassembly And Assembly HYDRAULIC FILTER MOUNT Removal And Installation HYDRAULIC RESERVOIR Removal And Installation OIL COOLER Description SECONDARY FRONT AUXILIARY VALVE Removal And Installation Parts Identification Disassembly And Assembly HYDRAULIC BREAKER APPLICATION VALVE (S Removal And Installation Parts Identification Disassembly And Assembly AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S Removal And Installation Parts Identification Disassembly And Assembly AUXILIARY HYDRAULIC FLOW CONTROL Removal And Installation AUXILIARY HYDRAULIC FLOW CONTROL Parts Identification Disassembly And Assembly BLADE VALVE Removal And Installation Parts Identification Disassembly And Assembly BLADE FLOAT VALVE Removal And Installation Parts Identification Disassembly And Assembly BOOM OFFSET VALVE Removal And Installation Parts Identification Disassembly And Assembly BOOM LOAD HOLDING VALVE Removal And Installation Parts Identification Disassembly Assembly OIL TEMPERATURE REGULATOR Description Removal And Installation AUXILIARY HYDRAULICS SELECTOR VALVE Removal And Installation HYDRAULIC PISTON PUMP DRIVE COUPLER Removal And Installation UNDERCARRIAGE BLADE Removal And Installation TRACKS Track Lug Height Rubber Track Clearance Steel Track Clearance Track Adjustment Rubber Track Removal And Installation TRACK FRAME Disassembly And Assembly Drive Sprocket Removal And Installation TRACK IDLER Parts Identification Disassembly Assembly UPPER TRACK ROLLER Parts Identification Disassembly Assembly LOWER TRACK ROLLER Parts Identification Disassembly Assembly GREASE CYLINDER Parts Identification Disassembly Assembly TRACK DAMAGE IDENTIFICATION Cutting Of Steel Cords Abrasion Of Embedded Metals Separation Of Embedded Metals Separation Of Embedded Metals Due To Corrosion Cuts On The Lug Side Rubber Cracks On The Lug Side Rubber Due To Fatigue Lug Abrasion Cracks And Cuts On The Lug Side Rubber Abrasion Of The Track Roller Side Cuts On The Edges Of Track Roller Side UPPERSTRUCTURE & SWING SECTION UPPERSTRUCTURE Removal And Installation Swing Bearing Removal And Installation CAB Removal And Installation Door Removal And Installation Front Window Removal And Installation Front Window Disassembly And Assembly (S Front Window Gas Strut Removal And Installation Front Window Pivot Frame Removal And Installation Lower Front Widow Removal And Installation Door, Left Side, Right Side And Rear Window Removal Door, Left Side, Right Side And Rear Window Installation Cab Visor Removal And Installation Top Window Removal And Installation SEAT AND SEAT MOUNT Removal And Installation RIGHT CONSOLE Description LEFT CONSOLE Removal And Installation Disassembly And Assembly Console Lockout Switch Removal And Installation ENGINE SPEED CONTROL Removal And Installation Disassembly And Assembly CONTROL LEVERS Description FUEL TANK Removal And Installation HORN Removal And Installation SWING FRAME Removal And Installation Bushing Removal And Installation FLOOR MAT Removal And Installation BOOM Removal And Installation Bushing Removal And Installation ARM Removal And Installation Bushing Removal And Installation BUCKET Removal And Installation REAR COVER Removal And Installation RIGHT SIDE COVER Removal And Installation COUNTERWEIGHT Removal And Installation ELECTRICAL SYSTEM AND ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Troubleshooting Chart Description Fuse And Relay Location (S Fuse And Relay Location (S BATTERY Servicing Removal And Installation Using A Booster Battery (Jump Starting) ALTERNATOR Removal And Installation (S Removal And Installation (S Parts Identification Alternator Identification Charging System Check Rectifier Continuity (Diode) Test Disassembly Stator Continuity Test Stator Ground Test Rotor Continuity Test Rotor Ground Test Capacitor Continuity Test Assembly STARTER Removal And Installation (S Removal And Installation (S Parts Identification (All Models) Disassembly (All Models) Inspection And Repair (All Models) Assembly (All Models) STARTER (S Removal And Installation FRONT CAB LIGHT Removal And Installation Disassembly And Assembly TWO SPEED SWITCH Removal And Installation FUEL LEVEL SENDER Removal And Installation WIPER MOTOR Removal And Installation BATTERY DISCONNECT SWITCH Removal And Installation INSTRUMENT PANEL Removal And Installation E-Prom Information ENGINE SERVICE TROUBLESHOOTING Chart MUFFLER (S Removal And Installation MUFFLER (S Removal And Installation AIR CLEANER Removal And Installation RADIATOR Removal And Installation RADIATOR Removal And Installation Hydraulic Check Valve Removal And Installation Hydraulic Check Valve Disassembly And Assembly ENGINE COMPONENTS AND TESTING (S Engine Compression Checking Checking the Glow Plugs Glow Plug Removal And Installation Fuel Shutoff Solenoid Checking Fuel Shutoff Solenoid Removal And Installation Fuel Injection Pump Removal Fuel Injection Pump Timing Fuel Injection Pump Installation Fuel Injector, Checking Fuel Injector Disassembly Fuel Injector Assembly Valve Clearance Adjustment Thermostat ENGINE COMPONENTS AND TESTING (S Engine Compression Checking Checking the Manifold Heater Manifold Heater Removal And Installation Fuel Shutoff Solenoid Checking Fuel Shutoff Solenoid Removal And Installation Fuel Injection Pump Removal Fuel Injection Pump Timing Fuel Injection Pump Installation Fuel Injector Removal And Installation Fuel Injector Removal And Installation (Cont�d) Fuel Injector, Checking Fuel Injector Disassembly Fuel Injector Assembly Timing Belt Inspection Timing Belt Removal Timing Belt Installation Valve Clearance Adjustment Valve Timing, Checking Thermostat, Oil Pressure Control Valves & Heater Connections Aneroid Device ENGINE (S Removal And Installation ENGINE (S Removal And Installation FLYWHEEL (S Removal And Installation Flywheel Ring Gear FLYWHEEL (S Removal And Installation Flywheel Ring Gear RECONDITIONING THE ENGINE (S Deutz Engine Tools Identification Chart Disassembly Assembly Cylinder, Checking Camshaft Bearing, Checking Camshaft Bearing, Removal And Installation Balancing Shaft Bearing, Checking (If Equipped) Balancing Shaft Bearing, Removal And Installation Control Rod Guide Bushing Installation Rear Cover Seal Removal And Installation Rear Cover Seal Removal And Installation (Cont�d) Crankshaft, Checking Connecting Rod, Checking Piston, Checking Piston Pin, Checking Piston Rings Installation Piston Installation On The Connecting Rod Cylinder Head Disassembly Valves, Checking Valve Clearance Adjustment Cylinder Head Assembly Rocker Arm And Bracket, Checking Front Cover Disassembly Front Cover Assembly Turbo Charger Removal and Installation RECONDITIONING THE ENGINE (S Deutz Engine Tools Identification Chart Disassembly Assembly Cylinder, Checking Camshaft Bearing, Checking Camshaft Bearing, Removal And Installation Control Rod Guide Bushing Removal Control Rod Guide Bushing Installation Rear Cover Seal Removal And Installation Crankshaft, Checking Connecting Rod, Checking Piston, Checking Piston Pin, Checking Piston Rings Installation Piston Installation On The Connecting Rod Cylinder Head Disassembly Valves, Checking Valve Clearance Adjustment Cylinder Head Assembly Rocker Arm And Bracket, Checking Front Cover Disassembly Front Cover Assembly Turbo Charger Removal and Installation Crankshaft Gear Mounting Bolt Torque Procedure HEATING, VENTILATION, AIR CONDITIONING EVAPORATOR Removal And Installation EVAPORATOR Removal And Installation Disassembly And Assembly HEATER Removal And Installation Resistor Removal And Installation HEATER VALVE Removal And Installation AIR CONDITIONING SYSTEM FLOW Principles Chart COMPONENTS (S Identification COMPONENTS (S Identification SAFETY Safety Equipment REGULAR MAINTENANCE Heater Air Filter Air Conditioning Compressor Belt Cleaning The Condenser BASIC TROUBLESHOOTING Poor A Compressor Drive Belt Inspection Cleaning The A Cleaning The A Checking The Electrical System Engine Coolant By-Passing The Heater Valve GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Compressor Oil Check Component Replacement And Refrigeration Leaks SYSTEM TROUBLESHOOTING CHART Blower Motor Does Not Operate Gauge Pressure Related Troubleshooting TEMPERATURE Chart AIR CONDITIONING SERVICE Chart SYSTEM CHARGING AND RECLAMATION Reclamation Procedure COMPRESSOR (S Removal And Installation COMPRESSOR (S Removal And Installation Parts Identification Compressor Clutch Disassembly And Assembly CONDENSER (S Removal And Installation CONDENSOR (S Removal And Installation RECEIVER Removal And Installation RECEIVER Removal And Installation PRESSURE SWITCH (S Removal And Installation PRESSURE SWITCH (S Removal And Installation HEATER COIL Removal And Installation THERMOSTAT Removal And Installation EXPANSION VALVE Removal And Installation UPGRADED AIR CONDITIONING SYSTEM Evaporator Unit Removal And Installation Disassembly And Assembly Thermostat Removal And Installation Evaporator Removal And Installation Fan Removal And Installation Switch Removal And Installation SPECIFICATIONS HYDRAULIC EXCAVATOR SPECIFICATIONS Machine Dimensions Performance Controls Engine (S Engine (S Electrical Hydraulic System (S Hydraulic System (S Hydraulic Cycle Times Swing System Hydraulic Cylinders Drive System Brakes Undercarriage Track Capacities (S Capacities (S Digging Force ENGINE SPECIFICATIONS (S General Fuel System Valve, Valve Guide and Seat Insert ENGINE SPECIFICATIONS (S Piston And Rings Connecting Rod Cylinder Head and Block Crankshaft And Main Bearings Camshaft And Bearings Oil Pump Governor Engine Balancing Shaft And Bearings ENGINE SPECIFICATIONS (S General Fuel System Valve, Valve Guide and Seat Insert ENGINE SPECIFICATIONS (S Piston And Rings ENGINE SPECIFICATIONS (S Connecting Rod Cylinder Head and Block Crankshaft And Main Bearings ENGINE SPECIFICATIONS (S Camshaft And Bearings Oil Pump ENGINE BOLT TORQUE (S Specifications ENGINE BOLT TORQUE (S Specifications EXCAVATOR BOLT TORQUE Specifications TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts Torque For General Metric Bolts HYDRAULIC FLUID SPECIFICATIONS Specifications FUEL, COOLANT AND LUBRICANTS Chart (S Chart (S CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion SMR 442-1 442-2 442-3 442-4 442-5 442-6 442-7 . 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