6901801 442 sm 11-07.book

6901801 (11-07) © Bobcat Company 2007 Printed in U.S.A. Service Manual S/N 522311001 & Above S/N 528911001 & Above S/N 528611001 & Above 442

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MAINTENANCE SAFETY

MAINTENANCE SAFETY WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. CORRECT CORRECT CORRECT Never service the Bobcat Hydraulic Excavator without instructions.

B-10731a Use the correct procedure to lift and support the excavator. Always lift the blade fully before installing jackstands. B-16637 required daily. WRONG WRONG WRONG B-16672 B-16673 B-16671 Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust Fumes can kill without warning. Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Bobcat Company.

WRONG WRONG WRONG B-16670 B-16669 B-6589 Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding. Keep tailgate closed except for service, Close and latch tailgate before operating the excavator. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training.

Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW23-0805 CORR B- ECT 16638 Cleaning and maintenance are

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ALPHABETICAL INDEX

ALPHABETICAL INDEX ACCUMULATOR..................................................... 20-01 AIR CLEANER ............................................. 10-01, 60-01 AIR CONDITIONING COMPRESSOR BELT.......... 10-01 AIR CONDITIONING SERVICE.............................. 70-01 AIR CONDITIONING SYSTEM FLOW ................... 70-01 ALTERNATOR ........................................................ 50-01 ALTERNATOR BELT............................................... 10-01 ARM ........................................................................ 40-01 ARM CYLINDER..................................................... 20-01 AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE.....

20-01 AUXILIARY HYDRAULIC FLOW CONTROL VALVE............................................... 20-01 AUXILIARY HYDRAULICS SELECTOR VALVE..... 20-01 FAN/FUEL PUMP BELT ..........................................10-01 FLOORMAT.............................................................40-01 FLYWHEEL..............................................................60-01 FRESH AIR FILTER ................................................10-01 FRONT CAB LIGHT ................................................50-01 FUEL COOLANT AND LUBRICANTS...............

SPEC-01 FUEL LEVEL SENDER ...........................................50-01 FUEL SYSTEM........................................................10-01 FUEL TANK .............................................................40-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES..........................................................70-01 GREASE CYLINDER ..............................................30-01 BASIC TROUBLESHOOTING ................................ 70-01 BATTERY................................................................ 50-01 BATTERY DISCONNECT SWITCH........................ 50-01 BLADE ....................................................................

30-01 BLADE CYLINDER ................................................. 20-01 BLADE FLOAT VALVE............................................ 20-01 BLADE VALVE ........................................................ 20-01 BOOM ..................................................................... 40-01 BOOM CYLINDER.................................................. 20-01 BOOM LOAD HOLDING VALVE............................. 20-01 BOOM OFFSET CYLINDER................................... 20-01 BOOM OFFSET VALVE.......................................... 20-01 BUCKET ................................................................. 40-01 BUCKET CYLINDER ..............................................

20-01 HEATER/AC FAN ....................................................70-01 HEATER COIL/EVAPORATOR................................70-01 HEATER VALVE ......................................................70-01 HORN ......................................................................40-01 HYDRAULIC BREAKER APPLICATION VALVE .....20-01 HYDRAULIC EXCAVATOR SPECIFICATIONS. SPEC-01 HYDRAULIC FILTER MOUNT.................................20-01 HYDRAULIC FLUID SPECIFICATIONS............

SPEC-01 HYDRAULIC GEAR PUMP .....................................20-01 HYDRAULIC PISTON PUMP ..................................20-01 HYDRAULIC PISTON PUMP DRIVE COUPLER....20-01 HYDRAULIC RESERVOIR......................................20-01 HYDRAULIC SYSTEM ............................................10-01 HYDRAULIC SYSTEM INFORMATION ..................20-01 CAB......................................................................... 40-01 CAB TILT PROCEDURE......................................... 10-01 COMPONENTS ...................................................... 70-01 COMPRESSOR ......................................................

70-01 CONDENSER ......................................................... 70-01 CONTROL LEVERS ............................................... 40-01 CONVERSIONS ................................................SPEC-01 COOLING SYSTEM................................................ 10-01 COUNTER WEIGHT...............................................

40-01 INSTRUMENT PANEL............................................50-01 JOYSTICK CONTROL PATTERN SELECTOR VALVE.....................................................................20-01 JOYSTICK LOCKOUT/TWO SPEED VALVE..........20-01 LEFT CONSOLE .....................................................40-01 LEFT CONTROL LEVER (JOYSTICK) ...................20-01 LIFTING AND BLOCKING THE EXCAVATOR ........10-01 LIFTING THE EXCAVATOR ....................................10-01 LOWER TRACK ROLLER.......................................30-01 LUBRICATION OF THE EXCAVATOR ....................10-01 DUMP VALVE .........................................................

20-01 ELECTRICAL SYSTEM INFORMATION ................ 50-01 ENGINE .................................................................. 60-01 ENGINE BOLT TORQUE...................................SPEC-01 ENGINE COMPONENENTS AND TESTING ......... 60-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPECIFICATIONS...............................SPEC-01 ENGINE SPEED CONTROL .................................. 40-01 EVAPORATOR/HEATER UNIT............................... 70-01 EXCAVATOR BOLT TORQUE ...........................SPEC-01 EXPANSION VALVE ...............................................

70-01 MUFFLER................................................................60-01 OIL COOLER...........................................................20-01 OIL TEMPERATURE REGULATOR........................20-01 OPERATOR CAB ....................................................10-01 PORT RELIEF VALVES...........................................20-01 PRESSURE REDUCING VALVE.............................20-01 PRESSURE SWITCH..............................................70-01

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ALPHABETICAL INDEX

ALPHABETICAL INDEX (CONT’D) RADIATOR/OIL COOLER.......................................

60-01 REAR COVER..............................................10-01, 40-01 RECEIVER/DRYER.................................................70-01 RECONDITIONING THE ENGINE ..........................60-01 REGULAR MAINTENANCE ....................................70-01 RELIEF VALVES......................................................20-01 RIGHT CONSOLE...................................................40-01 RIGHT CONTROL LEVER (JOYSTICK) .................20-01 RIGHT SIDE COVER ...................................10-01, 40-01 SAFETY...................................................................70-01 SEAT AND SEAT MOUNT.......................................40-01 SECONDARY FRONT AUXILIARY VALVE.............20-01 SERVICE SCHEDULE ............................................10-01 SIX SPOOL HYDRAULIC CONTROL VALVE .........20-01 STARTER ................................................................50-01 SWING BRAKE RELEASE VALVE..........................20-01 SWING BRAKE VALVE ...........................................20-01 SWING FRAME.......................................................40-01 SWING MOTOR ......................................................20-01 SWING MOTOR DRIVE CARRIER .........................20-01 SWIVEL JOINT........................................................20-01 SYSTEM CHARGING AND RECLAMATION ..........70-01 SYSTEM TROUBLESHOOTING CHART ...............70-01 TEMPERATURE/PRESSURE .................................70-01 THERMOSTAT.........................................................70-01 THREE SPOOL HYDRAULIC CONTROL VALVE...20-01 TORQUE SPECIFICATIONS FOR BOLTS........SPEC-01 TRACK DAMAGE IDENTIFICATION.......................30-01 TRACK FRAME.......................................................30-01 TRACK IDLER.........................................................30-01 TRACKS ..................................................................30-01 TRANSPORTING THE EXCAVATOR......................10-01 TRAVEL LEVER/FOOT PEDAL VALVE ..................20-01 TRAVEL MOTOR..........................................10-01, 20-01 TROUBLESHOOTING.............................................60-01 TWO SPEED SWITCH............................................50-01 UPPER TRACK ROLLER........................................30-01 UPPERSTRUCTURE ..............................................40-01 UPGRADED AIR CONDITIONING SYSTEM..........70-01 WIPER MOTOR.......................................................50-01

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