(S/N: 522311001 & Above - S/N: 528911001 & Above - S/N: 528611001 & Above)
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This workshop repair service manual PDF download for the 442 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Excavator 442
S/N: 522311001 & Above
S/N: 528911001 & Above
S/N: 528611001 & Above
TABLE OF CONTENTS :
FOREWORD
SAFETY INSTRUCTIONS
DELIVERY REPORT
SERIAL NUMBER LOCATIONS
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901801 (5-10)
Total Pages : 1259
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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 & 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/N 522311001 & ABOVE)
Removal And Installation
FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
COOLING SYSTEM
Cleaning The Cooling System
Checking Coolant Level (S/N 522311001 & Above)
Replacing The Coolant (S/N 522311001 & Above)
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Removing Water From The Pre-Filter (S/N 522311001 & Above)
Pre-Filter Removal (S/N 522311001 & Above)
Pre-Filter Installation (S/N 522311001 & Above)
Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)
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/N 522311001 & Above)
Hydraulic Filter Installation (S/N 522311001 & Above)
Hydraulic Filter Removal (S/N 528911001 & Above And S/N 528611001 & Above)
Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above)
Diagnostic Couplers (S/N 522311001 & Above)
Diagnostic Couplers (S/N 528911001 & Above And S/N 528611001 & Above)
LUBRICATION OF THE EXCAVATOR
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
ALTERNATOR BELT
Adjusting Belt Tension
FAN/FUEL PUMP BELT
Adjusting Belt Tension (S/N 522311001 & Above)
AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE)
Adjusting Belt Tension
AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Adjusting Belt Tension
CAB TILT PROCEDURE
Installing The Cab Tilt Hinges
Tilting The Cab
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
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
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/N 528911001 & ABOVE AND 528611001 & ABOVE)
Description
Testing
Adjustment
PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE)
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/Upperstructure Swing Valve Section Disassembly And Assembly
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE)
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/N 522311001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
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/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly
Assembly
ACCUMULATOR (S/N 522311001 & ABOVE)
Description
Removal And Installation
ACCUMULATOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
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
SWING BRAKE RELEASE VALVE (CONT’D)
Parts Identification
Disassembly And Assembly
JOYSTICK CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly And Assembly
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
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/FOOT PEDAL VALVE
Left Travel Lever/Foot Pedal Valve Removal And Installation
Right Travel Lever/Foot Pedal Valve Removal And Installation
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/N 522311001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly And Assembly
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly And Assembly
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
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/N 522311001 & Above)
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 & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location (S/N 522311001 & Above)
Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above)
BATTERY
Servicing
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation (S/N 522311001 & Above)
Removal And Installation (S/N 528911001 & Above And 528611001 & Above)
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/N 522311001 & Above)
Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)
Parts Identification (All Models)
Disassembly (All Models)
Inspection And Repair (All Models)
Assembly (All Models)
STARTER (S/N 528911001 & ABOVE & S/N 528611001 & ABOVE)
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/N 522311001 & ABOVE)
Removal And Installation
MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE)
Removal And Installation
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
Hydraulic Check Valve Removal And Installation
Hydraulic Check Valve Disassembly And Assembly
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE)
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/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
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/N 522311001 & ABOVE)
Removal And Installation
ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
FLYWHEEL (S/N 522311001 & ABOVE)
Removal And Installation
Flywheel Ring Gear
FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
Flywheel Ring Gear
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE)
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/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
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/HEATER UNIT (S/N 522311001 & ABOVE)
Removal And Installation
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE)
Removal And Installation
Disassembly And Assembly
HEATER/AC FAN
Removal And Installation
Resistor Removal And Installation
HEATER VALVE
Removal And Installation
AIR CONDITIONING SYSTEM FLOW
Principles
Chart
COMPONENTS (S/N 522311001 & ABOVE)
Identification
COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE)
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Heater Air Filter
Air Conditioning Compressor Belt
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Compressor Drive Belt Inspection
Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above)
Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above)
Checking The Electrical System
Engine Coolant Bypassing 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/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
COMPRESSOR (S/N 522311001 & ABOVE)
Removal And Installation
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
Parts Identification
Compressor Clutch Disassembly And Assembly
CONDENSER (S/N 522311001 & ABOVE)
Removal And Installation
CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Removal And Installation
RECEIVER/DRYER (S/N 522311001 & ABOVE)
Removal And Installation
RECEIVER/DRYER (S/N 528911001 & ABOVE AND 528611001 & ABOVE))
Removal And Installation
PRESSURE SWITCH (S/N 522311001 & ABOVE)
Removal And Installation
PRESSURE SWITCH (S/N 528911001 & ABOVE AND 528611001 & ABOVE)
Removal And Installation
HEATER COIL/EVAPORATOR
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/N 522311001 & Above)
Engine (S/N 528911001 & Above And S/N 528611001 & Above)
Electrical
Hydraulic System (S/N 522311001 & Above)
Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above)
Hydraulic Cycle Times
Swing System
Hydraulic Cylinders
Drive System
Brakes
Undercarriage
Track
Capacities (S/N 522311001 & Above)
Capacities (S/N 528911001 & Above And S/N 528611001 & Above)
Digging Force
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
General
Fuel System
Valve, Valve Guide and Seat Insert
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/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
General
Fuel System
Valve, Valve Guide and Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head and Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE)
Specifications
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
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/N 522311001 & Above)
Chart (S/N 528911001 & Above And S/N 528611001 & Above)
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
SERVICE MANUAL REVISION
SMR-1
SMR-2
SMR-3
SMR-4
SMR-5
SMR-6
SMR-7
SMR-8
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Bobcat 442 Compact Excavator Repair Service Manual - 6901801.pdf
Source : Sitelux.com