Bobcat 442 Compact Excavator Operation & Maintenance Manual - PDF DOWNLOAD

Operation & Maintenance Manual S/N 522311001 & Above S/N 528611001 & Above S/N 528911001 & Above

Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Bobcat Company or the products of either.

6901800 (5-07) Revised (9-12) (12)

1 of 168

Printed in U.S.A.

©Bobcat Company 2007

Dealer Copy -- Not for Resale

442

2 of 168

Dealer Copy -- Not for Resale

OPERATOR SAFETY WARNINGS WARNING

Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W-2001-1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

WRONG

CORRECT

WRONG

B-10731a

B-16674

B-16609

B-16675

without

Read machine signs, Operation & Maintenance Manual, and Operator’s Handbook.

Do not grasp control handles when entering canopy or cab.

WRONG

MC-1867

MC-1868

Use caution to avoid tipping - do not swing heavy load over side of track.

Keep bystanders out of maximum reach area.

Operate on flat, level ground.

CORRECT

Avoid steep areas or banks that could break away.

Never modify equipment.

Be sure controls are in neutral before starting.

Sound horn and check behind machine before starting.

WRONG

Never operate without approved canopy or cab.

Never use attachments not approved by Bobcat Company.

CORRECT

CORRECT

15° Maximum

15° Maximum

B-16676

Never exceed a slope to the side.

15°

MC-1878C

Never travel up a slope that exceeds 15°.

Do not travel or turn with bucket extended.

Never carry riders.

CORRECT

CORRECT

SAFETY EQUIPMENT 1. Seat Belt 2. Machine Safety Signs 3. Grab Handles 4. Slew Lock 5. Safety Tread

Stop 25° Maximum MC-1878B

MC-1859A

B-21928

Never exceed 25° when going down or backing up a slope.

To leave excavator, lower the attachment.

Fasten seat belt securely.

Stop the engine.

Operate controls only from operator’s seat.

OSW21-0808

3 of 168

Dealer Copy -- Not for Resale

Never operate instructions.

4 of 168

Dealer Copy -- Not for Resale

FOREWORD

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

SAFETY

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . PM-1

OPERATING INSTRUCTIONS

MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . MST-1 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-1

PREVENTIVE MAINTENANCE

REFERENCE INFORMATION

Bobcat Excavator Serial Number

SPECIFICATIONS

Engine Serial Number

NOTES

YOUR BOBCAT® EXCAVATOR DEALER: ADDRESS: PHONE:

Bobcat Company P.O. Box 128 Gwinner, ND 58040-0128

Bobcat Company Europe Drève Richelle 167 B-1410 WATERLOO Belgium

I 5 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

MACHINE SIGN TRANSLATIONS

Write the correct information for YOUR Excavator in the spaces below. Always use these numbers when referring to your Bobcat Excavator.

Dealer Copy -- Not for Resale II 6 of 168

442 Excavator Operation & Maintenance Manual

FOREWORD

FOREWORD

This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of th e Bobcat Excavator. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR Bobcat Excavator. If you have any questions, see your Bobcat Excavator dealer.

BOBCAT APPROVED ATTACHMENTS & ACCESSORIES . . . . . . . . . . . . X BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED . . . . . . . . . . . . . . . . . V BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . IX BUCKETS AND ATTACHMENTS AVAILABLE . . . . . . . . . . . . . . . . . . . . . . X DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

MOTOR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

SYSTEM SETUP & ANALYSIS

TRANSLATIONS

REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII Excavator Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

III 7 of 168

Dealer Copy -- Not for Resale

FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Standard Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale IV 8 of 168

442 Excavator Operation & Maintenance Manual

BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED

ISO 9001:2000 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat chose to assess the Company’s compliance with the ISO 9001:2000 set of s tandards. The BSI registration certifies that the two Bobcat manufacturing plants and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 9001:2000. Only certified assessors, like BSI, can grant registrations.

ISO 9001:2000 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

REGULAR MAINTENANCE ITEMS S/N 522311001 & Above ENGINE OIL FILTER FUEL FILTER FUEL PRE-FILTER PRIMARY AIR FILTER SECONDARY AIR FILTER HYDRAULIC OIL FILTER CAB VENTILATION FILTER FAN/FUEL PUMP BELT ALTERNATOR BELT AIR CONDITIONING BELT HYDRAULIC TANK/ ENGINE OIL DRAIN HOSE TRACK TENSIONER ADAPTER

6675517 5411656567 5445100004 5501660912 5501660914 5380658088 5501661034 5411656409 5411656408 1490953883 5366654556

S/N 528611001 & Above and 528911001 & Above 5411656547 5411656301 5411657863 5501660912 5501660914 5368632568 5501661034 Not Used On This Model 5411657150 1490953974 5366654556

1858000054

1858000054

MOTOR OIL 6903105 SAE 15W40 CE/SG (12 qt.)

6903107 SAE 10W30 CE/SG (12 qt.)

6903109 SAE 30W CE/SG (12 qt.)

6903106 SAE 15W40 CE/SG (1 Gal.) 6903108 SAE 10W30 CE/SG (1 Gal.) 6903110 SAE 30W CS/SG (1 Gal.)

V 9 of 168

6903113 SAE 15W40 CE/SG (2.5 Gal.) 6903112 SAE 10W30 CE/SG (2.5 Gal.) 6903111 SAE 30W CS/SG (2.5 Gal.)

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

CALIFORNIA PROPOSITION 65 WARNING

Dealer Copy -- Not for Resale VI 10 of 168

442 Excavator Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

Engine Serial Number

Always use the s erial number of th e excavator when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

Figure 2

1

Figure 1

1

S/N 522311001 & Above

P-32601

P-56394

1 Excavator Serial Number The excavator serial number plate (Item 1) is located on the frame of the machine in the location shown [Figure 1].

Explanation of loader Serial Number: XXXX XXXXX

S/N 528611001 & Above, S/N 528911001 & Above

Module 2. - Production Sequence (Series) Module 1. Model Engine Combination

P-56395

The engine serial number (Item 1) is located on the engine in the location shown [Figure 2] & [Figure 3].

/

1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

2. The five digit Production Sequence Number identifies the order which the loader is produced.

VII 11 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Figure 3

DELIVERY REPORT Figure 4

B-16315

Dealer Copy -- Not for Resale

The delivery report must be filled out by the dealer and signed by the owne r or operator when the Bob cat Excavator is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 4].

VIII 12 of 168

442 Excavator Operation & Maintenance Manual

BOBCAT EXCAVATOR IDENTIFICATION

ARM CYLINDER BOOM BOOM CYLINDER

OPERATOR HANDBOOK

OPERATOR SEAT WITH SEAT BELT GRAB HANDLE

BUCKET CYLINDER

RETURN TO TANK COUPLER AUXILIARY COUPLERS

BUCKET BLADE CYLINDERS

RIGHT SIDE COVER AUXILARY COUPLERS REAR COVER

UPPERSTRUCTURE

BLADE TIEDOWN

TRACK FRAME

TRACK B-16589 B-16590 IX 13 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

ARM

FEATURES AND ACCESSORIES Standard Items

Options and Accessories

Model 442 Bobcat Excavators are equipped with the following standard items: • • • • • • • • • • •

Below is a list of some equipment available from your Bobcat Excavator dealer as Dealer and/or Factory Installed Accessories and Factory Installed Options. See your Bobcat Dealer for other available options, accessories and attachments.

Enclosed Cab With Heater and Air Conditioning 92 inch (2330 mm) Dozer Blade 17.7 inch (450 mm) Rubber Tracks or Steel Tracks Two-Speed Travel Hydraulic and Travel Control Lockouts Horn Hydraulic Joystick Controls ISO/STD Control Pattern Selection Feature Suspension Seat Blade Float Auxiliary Hydraulics

• • • • • • • •

Subject to change without notice.

Steel Track Flood Lights AM/FM Radio AM/FM/Weather Band Radio Radio Installation Kit Service Kit Travel Motion Alarm Security Ignition

Other • Excavator Operator Training • Excavator Service Safety Training

These and other attachments are approved for use on this model Bobcat Excavator. Do not use unapproved attachments.

Attachments not manufactured by Bobcat may not be approved.

The versatile Bobcat Excavator quickly turns into a multi-job machine with a variety of attachments.

See your Bobcat dealer for more details on these and other attachments and field accessories.

Increase the versatility of your Bobcat Excavator with a variety of bucket sizes.

BUCKETS AND ATTACHMENTS AVAILABLE Many different bucket widths/capacities are available for a variety of applications. See your Bobcat dealer for the correct bucket for your application.

BUCKET SIZE

P/N

WEIGHT

17.7" (450 mm) bucket

6680137

342 lb. (155 kg)

17.7" (450 mm) Ejector Bucket

6680022

441 lb. (200 kg)

23.6" (600 mm) Bucket

6680023

414 lb. (188 kg)

31.5" (800 mm) Bucket

6680024

494 lb (224 kg)

36.0” (914 mm) Trenching Bucket

6680399

617 lb. (280 kg)

59.0" (150 mm) Ditching Bucket

6680025

405 lb. (184 kg)

59.0" (1500 mm) Swing Bucket

6680026

633 lb. (287 kg)

19.7" (500 mm) Clamshell

6680030

772 lb. (350 kg)

Ripper Tooth

6680027

231 lb. (105 kg)

B 1400 Breaker

6814768

960 lb. (435 kg)

39.0” (991 mm) Tilt bucket

725 lb. (329 kg)

Manual Spring Loaded Coupler

200 lb. (91 kg)

X 14 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

BOBCAT APPROVED ATTACHMENTS & ACCESSORIES

SAFETY MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI

SAFETY

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Safe Operation Is The Operator’s Responsibility. . . . . . . . . . . .XIV Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . .XIV

Dealer Copy -- Not for Resale

SYSTEM SETUP & ANALYSIS

TRANSLATIONS

XI 15 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale XII 16 of 168

442 Excavator Operation & Maintenance Manual

•

An Operator’s Handbook is fastened to the operator cab of the E xcavator. It’s brief instructions are convenient to the operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

•

The AEM Safety Manual delivered with the machine gives general safety information.

•

The Compact Excavator Operating Training Course is available through your Bobcat dealer. This course is intended to provide rules and practices of correct operation of the Bo bcat Excavator. The course is available in English and Spanish versions.

•

Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

•

See the PUBLICATIONS AND TRAINING RESOURCES Page in t his manual or y our Bobcat dealer for Service and Parts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web si tes www.training.bobcat.com or www.bobcat.com

Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

The Bobcat Excavator is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat Excavator usage.

The Bobcat Excavator has an internal combustion engine with resultant heat and exhaust. All exhaust gasses can kill or cause illness so use the Excavator with adequate ventilation.

The dealer explains the capabilities and restrictions of the Bobcat Excavator and attachment for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments.

The attachments and buckets are designed for a Rated Lift Capacity. They are designed for secure fastening to the Bobcat Excavator. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the machine attachment combination.

The dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat machine and attachments: •

The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine and attachment is in safe operating condition.

•

The Operation & Maintenance Manual delivered with the machine or attachment gives operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine.

Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

•

Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

Call Before You Dig 1-888-258-0808 When you call, you will be directed to a location in your state/city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)

SI EXC-0206

XIII 17 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS (CONT’D)

A Qualified Operator Must Do The Following:

Safe Operation Is The Operator’s Responsibility

Understand the Written Instructions, Rules and Regulations

Safety Alert Symbol

•

The written instructions from Bobcat Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, Safety Manual and machine signs (decals).

•

Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. Regulations may apply to local driving requirements or use of a Slow Moving Vehicle (SMV) emblem. Regulations may identify a hazard such as a utility line.

This symbol with a warning statement means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

WARNING WARNING Operator must have instructions before running the machine. Untrained operators can cause injury or death.

•

Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered.

•

The new operator must start in an area without bystanders and use all the controls until he or she can operate the machine and attachment safely under all conditions of the work area. Always fasten seat belt before operating.

•

Operator Training Courses are available from your Bobcat dealer in English and Spanish. They provide information for safe and efficient equipment operation. Safety videos are also available.

•

Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

W-2001-1285

IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine.

I-2019-0284

WARNING WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

Know the Work Conditions

W-2044-1285

•

Know the weight of the materials being handled.

Avoid exceeding the Rated Lift Capacity of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of load if handling dense material.

•

The operator must know any prohibited uses or work areas, for example, he or she needs to know about excessive slopes.

Safe Operation Needs A Qualified Operator

•

For an operator to be qualified, he or she must not use drugs or alcoholic drinks which impair alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.

Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the Before Operation Section of this manual.

•

Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing protection or Special Applications Kits are required for some work. See your Bobcat dealer about Bobcat Safety Equipment for your model.

The Bobcat Excavator and attachment must be in good operating condition before use.

Check all of the items on the Bobcat Service Schedule Decal under the 8-10 hour column or as shown in the Operation & Maintenance Manual.

SI EXC-0206

XIV 18 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Have Training with Actual Operation

SAFETY INSTRUCTIONS (CONT’D)

•

Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

•

Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Fire Prevention The machines and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a so urce of arcs or sparks.

Figure 1

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to av oid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

•

Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

•

The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

•

Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight.

Repair or replace any damaged part.

•

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do no t use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

•

Do not use ether or starting fluids on any engine that has glow plugs. These starting aids can cause explosion and injure you or bystanders.

•

Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

•

Stop the engine and let it cool before adding fuel. No smoking!

•

Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].

Sl EXC-0206

XV 19 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the ex haust gases are still hot.

MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the excavator. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Excavator dealer.

Dealer Copy -- Not for Resale

OPERATOR’S HANDBOOK 6901803

6813576

6807776

6589129

6813577 6813581

B-16589

XVI 20 of 168

442 Excavator Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (CONT’D) Follow the instructions on all the Machine Signs (Decals) that are on the excavator. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Excavator dealer.

6811054 under right side cover (S/N 522311001 & Above)

6804233 under right side cover (S/N 522311001 & Above)

6813628 6813575

Dealer Copy -- Not for Resale

6594897

6813578 under rear cover

6595014 (2)

6813581

6595014 (2)

6589129

B-16590

XVII 21 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale XVIII 22 of 168

442 Excavator Operation & Maintenance Manual

OPERATING INSTRUCTIONS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-44 Bucket And Ripper Tooth Installation . . . . . . . . . . . . . . . . . . . . . OI-44 Bucket And Ripper Tooth Removal . . . . . . . . . . . . . . . . . . . . . . OI-45 Clamshell Bucket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-49 Clamshell Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-54 Clamshell Bucket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-53 Fastening The Clamshell Bucket To The Transport Vehicle . . . OI-57 Lifting The Clamshell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-56 Manual Spring Loaded Coupler Attachment Installation . . . . . . OI-60 Manual Spring Loaded Coupler Attachment Removal . . . . . . . . OI-62 Manual Spring Loaded Coupler Installation . . . . . . . . . . . . . . . . . OI-58 Manual Spring Loaded Coupler Removal . . . . . . . . . . . . . . . . . OI-59 Tilt Bucket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-46 Tilt Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-48 Tilt Bucket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-47

OPERATING INSTRUCTIONS

Dealer Copy -- Not for Resale

BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-25 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-25 BOOM SWING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-26 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-27 HYDRAULIC CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Auxiliary Hydraulic Flow Control (S/N 522311001 & Above) . . . OI-23 Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-24 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Relieving Hydraulic Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 Standard Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-17 Upperstructure Slew Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-23 INSTRUMENTS AND CONSOLES. . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Left Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Right Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-43

Continued On Next Page

OI-1 23 of 168

442 Excavator Operation & Maintenance Manual

OPERATING INSTRUCTIONS (CONT’D)

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-8 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-7 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-8 Entering And Exiting The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-7 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-9 Front Window Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-10 Heating, Air Conditioning And Ventilation (Early Models) . . . . . . . . . .OI-12 Heating, Air Conditioning And Ventilation (Later Models) . . . . . . . . . .OI-13 Operation And Maintenance Manual Compartment (Early Models) . . OI-11 Raising And Lowering The Left Console . . . . . . . . . . . . . . . . . . . . . . . .OI-7 Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Wiper/Washer Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 PARKING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-41 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-29 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-32 Cold Temperature Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . .OI-33 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-32 STEERING LEVERS/FOOT PEDALS. . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-14 Forward And Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-14 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-14 TRANSPORTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .OI-42

OI-2 24 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-34 Backfilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-38 Boom Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-37 Driving The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-38 Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-35 Lifting A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-34 Operating In Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-41 Operating On Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-34 Operating On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-39

Figure OI-2

INSTRUMENTS AND CONSOLES Left Console

1

Figure OI-1 3 4

2

5

1

P-58213

Switch - (Item 1) [Figure OI-2] (S/N 528611001 & S/N 528911001 & Above) Future Use

P-56397

Upperstructure Swing Brake - (Item 2) [Figure OI-1] Press the button on the control lever to assist in stopping the upperstructure swing function. (See Upperstructure Slew Brake on Page OI-23.)

2

1

Switch - (Item 3) [Figure OI-1] (S/N 528611001 & Above and S/N 528911001 & Above) Future Use Switch - (Item 4) [Figure OI-1] (S/N 528611001 & Above and S/N 528911001 & Above) 4 Future Use - (Item 4) [Figure OI-1]

3 P-56396

Arm Rest (Adjustable) - (Item 5) [Figure OI-1]

Future Use - (Item 1) [Figure OI-3] Battery Disconnect Switch - (Item 2) [Figure OI-3] Turn the k ey 1/4 turn counterclockwise and remove the key to disconnect the battery from the electrical system.

Install the key and turn 1/4 turn clockwise to connect the battery to the electrical system.

ISO/STD Selector Switch - (Item 3) [Figure OI-3] Push the switch to the r ear for STD operation (the switch is illuminated). Push the switch to the front for ISO operation (the switch is not illuminated).

Fresh Air/ Recirculation Lever (Later Models) - (Item 4) [Figure OI-3] Move the lever towards the rear of the cab for fresh air. Move the lever towards the front of the cab to recirculate the cab air.

25 of 168

OI-3

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-3 Left Control Lever (Joystick) - (Item 1) [Figure OI-1] (See HYDRAULIC CONTROLS on Page OI-16.)

INSTRUMENTS AND CONSOLES (CONT’D)

Figure OI-6

Right Console

5

Figure OI-4

6

1

7 8

3 4

2

9 2

10 1

3 4 11 P-32715

Boom Load Indicator - (Item 1) [Figure OI-6] Shows load on boom cylinder circuit when lifting.

P-32713

Fuel Gauge - (Item 3) [Figure OI-6] Shows the amount of fuel in the tank.

Horn - (Item 2) [Figure OI-4] Press the button on the control lever to sound the horn.

Hourmeter - (I tem 4) [Figure OI-6] Displays the total operating hours on the excavator.

Momentary Hydraulic Switch - (I tem 3) [Figure OI-4] (See HYDRAULIC CONTROLS on Page OI-16.)

Battery Charge Indicator - (Item 5) [Figure OI-6] Light will illuminate when the voltage is out of range.

Momentary Hydraulic Switch - (Item 4) [Figure OI-4] (See HYDRAULIC CONTROLS on Page OI-16.)

Glow Plugs/ Manifold Heater - (Item 6) [Figure OI-6] Light will illuminate when the glow plugs/manifold heater is energized.

Figure OI-5

Engine Oil Pressure Indicator - (Item 7) [Figure OI-6] Light will illuminate when the engine oil pressure is low.

2

Air Filter Indicator - (Item 8) [Figure OI-6] Light will illuminate when the air flow becomes restricted.

1

Hydraulic Oil Filter Indicator - (Item 9) [Figure OI-6] Light will illuminate when the hydraulic oil filter is becoming plugged.

Hydraulic Oil Level Indicator - (I tem 10) [Figure OI-6] Light will illuminate when the hydraulic oil level in the tank is low.

P-32711

Start/Run Switch - (I tem 11) [Figure OI-6] Starts and stops the excavator engine.

Switch - (I tem 1) [Figure OI-5] Future Use (S/N 522311001 & Above) Arm Rest (Adjustable) - (Item 2) [Figure OI-5]

26 of 168

OI-4

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Engine Temperature Gauge - (I tem 2) [Figure OI-6] Shows the engine coolant temperature.

Right Control Lever (Joystick) - (Item 1) [Figure OI-4] (See HYDRAULIC CONTROLS on Page OI-16.)

INSTRUMENTS AND CONSOLES (CONT’D)

Figure OI-8

Right Console (Cont’d) 1

Figure OI-7 1

2

3

2

3

4

5

6

4 7 8

P-56405

Heater/AC Fan Switch - (Item 1) [Figure OI-7] Three speed fan motor control.

Auxiliary Hydraulic Mode Switch - (Item 2) [Figure OI8] Press this switch when using the hydraulic breaker.

(The switch will be illuminated.)

Wiper/Washer Switch - (Item 2) [Figure OI-7] Starts and stops the wiper motor. Press and hold the bottom of the switch to activate the washer.

Float Switch - (Item 3) [Figure OI-8] Press this switch to put the blade in the float position. (The switch will be illuminated.)

Rotating Beacon (If equipped) - (Item 3) [Figure OI-7]

Overload Warning Switch - ( Item 4) [Figure OI-8] Press this switch to engage the overload warning alarm.

(The switch will be illuminated.) The warning alarm will sound when the b oom/arm/bucket functions are being overloaded.

Light Switch - (Item 4) [Figure OI-7] Press the switch to turn on the cab/boom work light.

Motion Alarm (If equipped) - (Item 5) [Figure OI-8] Air Conditioning Switch (Early models) - (I tem 6) [Figure OI-8] Turns on and off the air conditioning.

Engine Speed Control Lever - (Item 7) [Figure OI-8] Controls the RPM of the engine. Push the lever forward for low speed. Pull the lever back to inc rease engine speed.

Temperature Control Lever - (Item 8) [Figure OI-8] Push the lever forward to increase the cab temperatures; backward to decrease temperature.

27 of 168

OI-5

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Two Speed Travel Control Switch - (Item 1) [Figure OI8] Engages and disengages high range travel speed.

(The switch will be illuminated in high range.)

P-56399

INSTRUMENTS AND CONSOLES (CONT’D)

Figure OI-11

Right Console (Cont’d) 1

Figure OI-9

1

3

2

P-32880

Auxiliary Power Outlet - (Item 1) [Figure OI-11] P-32670

Storage Compartment - (Item 1) [Figure OI-9]

Dealer Copy -- Not for Resale

Storage Compartment Lever - (Item 2) [Figure OI-9] Lift up on the lever to open the storage compartment.

Cup Holder - (Item 3) [Figure OI-9] NOTE: Later model excavators with the side mounted air conditioning are not equipped with the storage compartment (Item 1) [Figure OI-8].

Figure OI-10

1

2

P-58140

Air Conditioning/Fan Motor Switch (Later Models) (Item 1) [Figure OI-10] Turns on the air conditioning; three speed fan switch.

Air Conditioning Temperature Control (Later Models) - (Item 2) [Figure OI-10] Turn the switch clockwise to decrease cab temperatures, counterclockwise to increase cab temperatures.

28 of 168

OI-6

442 Excavator Operation and Maintenance Manual

OPERATOR CAB

Raising And Lowering The Left Console

Description

Raise the console before exiting the cab.

The excavator has an oper ator cab as standard equipment.

Figure OI-13

WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

1

W-2069-0200 P-32906

Pull up on the handle (Item 1) [Figure OI-13]. The lift spring will assist in raising the console.

Figure OI-12

Lower the console before operating the excavator.

Push down on the handle (Item 1) [Figure OI-13] until the console is in the down position.

NOTE: When the console is raised, the hydraulic and traction systems are locked and will not operate.

P-32904

Use the grab handles and track to enter and exit the excavator [Figure OI-12].

29 of 168

OI-7

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Entering And Exiting The Excavator

OPERATOR CAB (CONT’D)

Figure OI-16

Emergency Exit The left door, right side window and front window provide exits.

Figure OI-14 S/N 522311001 & Above

P-32908

Exit through the window [Figure OI-16].

1 Cab Door

Push the door all the way open until the latch engages to hold the door in the open position.

Figure OI-15 S/N 528611001 & Above, S/N 528911001 & Above

Figure OI-17

1 1

P-56400

P-32677

Press the window latch (Item 1) [Figure OI-14] & [Figure OI-15] together and slide the window to the rear of th e excavator.

30 of 168

Pull down on the latch (Item 1) [Figure OI-17] to release the door.

OI-8

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

The start key can be used to lock the cab door.

P-32710

OPERATOR CAB (CONT’D)

Figure OI-20

Front Window Figure OI-18 Unlock

Lock 1 1 P-32684

Turn the two latches (Item 1) [Figure OI-20] to the unlocked position.

P-32882

Figure OI-21

1

P-32983 P-32881

Use both window grab handles to pull the top of th e window in [Figure OI-21].

The front window is equipped with a wiper (Item 1) [Figure OI-18] and moveable sunvisor (Item 1) [Figure OI-19].

Continue moving the window in and up over the operator's head.

Opening The Front Window NOTE: The right hand latch is shown. The procedure is the same for both latches.

31 of 168

OI-9

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-19

OPERATOR CAB (CONT’D)

Figure OI-24

Front Window (Cont’d) Figure OI-22

Unlock

Lock

1

Unlock Lock

P-32685

6 Rotate the two latches (Item 1) [Figure OI-24] to the locked position.

P-32683

The front window may be opened approximately 4 inches (181 mm).

Closing The Front Window Figure OI-25 Figure OI-23

Unlock Lock

1 1

P-32976 P-32682

Pull back on the wi ndow until the locks (Item 1) [Figure OI-25] engage the slots in the window hinge.

Rotate the two latches (Item 1) [Figure OI-23] to the unlocked position.

Use both window grab handles to pull the window down [Figure OI-23].

32 of 168

OI-10

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Front Window Ventilation

Turn the two latches (Item 1) [Figure OI-22] to the locked position.

OPERATOR CAB (CONT’D)

Wiper/Washer Fluid Reservoir

Top Window

Figure OI-28

Figure OI-26

1

1 P-32602 P-56401

Excavator S/N 528611001 & Above and S/N 528911001 & Above are equipped with a retractable sun shade (Item 1) [Figure OI-26].

Use an antifreeze temperatures.

Figure OI-27

washer

solution

in

freezing

Operation And Maintenance Manual Compartment (Early Models)

1

Figure OI-29

2 1

P-56402

To extend the shade, pull the handle (Item 1) towards the rear of the ex cavator. Engage the ends of th e shade in the left and right brackets (Item 2) [Figure OI-27] (Right bracket shown)

P-33986

The Operation and Maintenance manual is stored in the compartment (Item 1) [Figure OI-29] behind the operators seat.

To retract the shade, pull the handle (Item 1) towards the rear of th e excavator. Remove the e nds of th e shade from the left and right brackets (Item 2) [Figure OI-27].

Hold the handle and allow the shade to slowly retract to the stored position.

33 of 168

OI-11

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

The reservoir (Item 1) [Figure OI-28] is located behind the operators seat on the left side of the excavator.

OPERATOR CAB (CONT’D)

Figure OI-32

Heating, Air Conditioning And Ventilation (Early Models) The cab fresh air vent is located behind the operators seat.

1

Figure OI-30

Open

Close P-32879

Figure OI-33

P-32676

1 Move the lever (Item 1) [Figure OI-30] to th e right to close the vent.

Move the lever (Item 1) [Figure OI-30] to the left to open the vent.

Figure OI-31 P-33787

There are 4 heat and air conditioning vents (Item 1) [Figure OI-31], [Figure OI-32] & [Figure OI-33].

1

Turn the vents to direct air as desired.

P-32675

34 of 168

OI-12

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

OPERATOR CAB (CONT’D)

Figure OI-36

Heating, Air Conditioning And Ventilation (Later Models) Figure OI-34

1

1

P-56403

1

There are 5 heat vents (Item 1) [Figure OI-34], [Figure OI-35] & [Figure OI-36].

P-56404

Figure OI-35

1 1

1

P-58141 P-32879

There are 2 air conditioning ducts (Item 1) [Figure OI37].

Turn the vents to direct air as desired.

35 of 168

OI-13

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-37

STEERING LEVERS/FOOT PEDALS

Turning

Forward And Reverse Travel

Right Turn

NOTE: The following procedures describe forward, reverse, left & right as seated in the operator's seat.

Figure OI-39

Figure OI-38

1

2

Push the left steering lever forward to turn right [Figure OI-39] while traveling forward.

P-32716

Figure OI-40

Put the blade so that it is at the front of the machine (as you sit in the operator's seat). Slowly move both steering levers* (Item 1) [Figure OI-38] forward for forward travel; backward for reverse travel. * Steering can also be controlled with foot pedals (Item 2) [Figure OI-38].

WARNING •

•

AVOID INJURY OR DEATH Check the blade location before traveling. When the blade is to the rear, operate the steering levers/foot pedals in the opposite direction to when the blade is in the front.

Move the steering levers/foot pedals slowly.

Abrupt lever motion will cause the machine to jerk.

B-19993

Pull the left steering lever backward to turn right [Figure OI-40] while traveling backward.

W-2235-0396

36 of 168

OI-14

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

B-19992

STEERING LEVERS/FOOT PEDALS (CONT’D)

Figure OI-43

Turning (Cont’d) 6 Counter-Rotation Right Turn Figure OI-41

B-19990

Pull the right steering lever backward to tur n left while traveling backward [Figure OI-43].

Counter-Rotation Left Turn

B-19988

Dealer Copy -- Not for Resale

Figure OI-44

Push the left steering lever forward and pull the right steering lever backward [Figure OI-41].

Left Turn Figure OI-42

B-19991

Push the right steering lever forward and pull the left steering lever backward [Figure OI-44] B-19989

Push the right steering lever forward to turn left while traveling forward [Figure OI-42].

37 of 168

OI-15

442 Excavator Operation and Maintenance Manual

HYDRAULIC CONTROLS

Right Control Lever

ISO Control Pattern

Figure OI-47

Left Control Lever Figure OI-45 1

1

P-32713

Figure OI-48

Figure OI-46

B-21924

The right lever is used to operate the boom and bucket [Figure OI-47] & [Figure OI-48].

B-21923

1.

2.

3.

4.

5.

6.

7.

8.

The work equipment (boom, arm, bucket, and upp er structure slew) is operated by using the left and right control levers (joysticks) [Figure OI-45] & [Figure OI-46] and [Figure OI-47] & [Figure OI-48].

The left lever is used to operate the arm and to slew the upperstructure [Figure OI-45] & [Figure OI-46].

1.

2.

3.

4.

5.

6.

7.

8.

Boom lower Boom lower and bucket dump Bucket dump Boom raise and bucket dump Boom raise Boom raise and bucket curl Bucket curl Boom lower and bucket curl

WARNING

Arm out Arm out and slew right Slew right Arm in and slew right Arm in Arm in and slew left Slew left Arm out and slew left

AVOID INJURY OR DEATH Before leaving the machine: • Lower the work equipment to the ground.

• Lower the blade to the ground.

• Stop the engine & remove the key.

W-2196-0595

38 of 168

OI-16

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-16615 P-32673

HYDRAULIC CONTROLS (CONT’D)

Right Control Lever

Standard Control Pattern

Figure OI-51

Left Control Lever Figure OI-49 1

1

P-16615 P-32713

Figure OI-52

Figure OI-50

B-21926

The right lever is used to ope rate the arm and bucket [Figure OI-51] & [Figure OI-52].

B-21925

1.

2.

3.

4.

5.

6.

7.

8.

The work equipment (boom, arm, bucket, and upperstructure slew) is operated by using the right and left control levers (joysticks) [Figure OI-49] & [Figure OI50] and [Figure OI-51] & [Figure OI-52].

The left lever is used to operate the boom and slew the upperstructure [Figure OI-49].

1.

2.

3.

4.

5.

6.

7.

8.

Boom lower Boom lower and slew right Slew right Boom raise and slew right Boom raise Boom raise and slew left Slew left Boom lower and slew left

Arm out Arm out and bucket dump Bucket dump Arm in and bucket dump Arm in Arm in and bucket curl Bucket curl Arm out and bucket curl

WARNING AVOID INJURY OR DEATH Before leaving the machine: • Lower the work equipment to the ground.

• Lower the blade to the ground.

• Stop the engine & remove the key.

W-2196-0595

39 of 168

OI-17

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-16615 P-32673

HYDRAULIC CONTROLS (CONT’D)

Figure OI-54

Quick Couplers The excavator and attachments are equipped with thread together and poppet style couplers.

The excavator has quick couplers installed on both sides of the arm.

Figure OI-53

1 2

P-32834A

The female quick couplers (Item 1) [Figure OI-53] & [Figure OI-54] are used for standard auxiliary hydraulic functions (hydraulic breaker, clamshell, bucket rotation and swing bucket).

The male quick couplers (Item 2) [Figure OI-53] & [Figure OI-54] are used for dual auxiliary hydraulic functions (opening and closing the clamshell bucket).

2

1

P-32836A

The female quick coupler (Item 3) [Figure OI-54] is a direct to tank return line.

WARNING AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments.

Be careful when connecting and disconnecting quick couplers.

W-2220-0396

40 of 168

OI-18

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

3

Thread the couplers (Item 1) from the attachment to the couplers (Item 2) [Figure OI-56] on the excavator.

Tighten the couplers until fully seated.

HYDRAULIC CONTROLS (CONT’D) Quick Couplers (Cont’d) To Connect:

Figure OI-57

Figure OI-55

1

1

2

P-32981

P-32840

Dealer Copy -- Not for Resale

Figure OI-58

Remove any dirt or debris from the surface of both the male and female couplers. Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced. Remove the protective caps (Item 1) [Figure OI-55].

3

Figure OI-56

2

3 1 P-32982

Example: Connect the clamshell bucket rotation to th e female couplers (Item 1) [Figure OI-57] & [Figure OI58].

2

Connect the clamshell bucket open/close cylinder to the male quick couplers (Item 2) [Figure OI-57] & [Figure OI-58].

Thread the protective caps (Item 3) [Figure OI-58] together.

1

P-32980A

41 of 168

OI-19

442 Excavator Operation and Maintenance Manual

HYDRAULIC CONTROLS (CONT’D)

Figure OI-60

Quick Couplers (Cont’d) Figure OI-59

1 1 2

1 P-32841

Install the protective caps (Item 1) [Figure OI-60] on the quick couplers.

P-32835

Dealer Copy -- Not for Resale

Connect the return to tank line from the attachment to the female (poppet style) quick coupler (Item 1) [Figure OI59] (if required).

Turn the diverter valve (Item 2) [Figure OI-59] to d irect hydraulic flow to the auxiliary quick couplers for clamshell open / close functions bucket.

NOTE: The bucket cylinder is inoperable when the diverter valve is turned for dual auxiliary hydraulic operation.

To Disconnect Unthread the couplers on the at tachment from the excavator. Remove the r eturn to t ank line (if installed) from the female coupler (Item 1) [Figure OI-59].

Turn the diverter valve (Item 2) [Figure OI-59] back to restore hydraulic flow to the bucket cylinder.

42 of 168

OI-20

442 Excavator Operation and Maintenance Manual

HYDRAULIC CONTROLS (CONT’D) Relieving Hydraulic Pressure Stop the engine and turn the key to the RUN position.

Figure OI-61

1

P-56405

Dealer Copy -- Not for Resale

Press the hydraulic breaker switch (Item 1) [Figure OI61] OFF. The light is not illuminated.

Figure OI-62

1 1

P-32713

Press the switches (Item 1) [Figure OI-62] on the right control lever several times to relieve the hydraulic pressure.

Turn the key to the OFF position.

43 of 168

OI-21

442 Excavator Operation and Maintenance Manual

HYDRAULIC CONTROLS (CONT’D)

Figure OI-64

Auxiliary Hydraulics Figure OI-63 2

1 1

P-32714

For proper hydraulic breaker operation, press the switch (Item 1) [Figure OI-64]. The switch will be illuminated.

The switch allows full hydraulic flow to the right side coupler for breaker operation.

P-32713

The switches (Item 1 & 2) [Figure OI-63] are used for hydraulic powered attachments (such as a cl amshell bucket).

Push and hold the switch (Item 1) [Figure OI-63] to provide hydraulic flow to the quick couplers. Release the switch to stop hydraulic flow.

Dealer Copy -- Not for Resale

Figure OI-65 1

2

Push and hold the switch (Item 2) [Figure OI-63] to reverse the direction of flow to the quick couplers.

Release the switch to stop hydraulic flow.

P-32713

Press and hold the switch (Item 1) [Figure OI-65] to provide hydraulic flow to the hydraulic breaker. Release the switch to stop hydraulic flow.

NOTE: Left side of the switch (Item 2) [Figure OI-65] is inoperable when the hydraulic breaker operation switch (Item 1) [Figure OI-64] is activated.

44 of 168

OI-22

442 Excavator Operation and Maintenance Manual

HYDRAULIC CONTROLS (CONT’D)

Figure OI-68

Upperstructure Slew Brake Figure OI-66 1

1

P-33152

The auxiliary hydraulic flow control valve (Item 1) [Figure OI-68] is located under the cab floor.

P-32673

Auxiliary Hydraulic Flow Control (S/N 522311001 & Above)

2

The auxiliary hydraulic flow can be increased or decreased.

1

Figure OI-67 P-33151

Loosen the nut (Item 1) and turn the adjustment screw (Item 2) [Figure OI-69] in to increase auxiliary hydraulic flow/ out to decrease hydraulic flow. Tighten the nut after the flow adjustment has been made.

1

Maximum Flow — 26.4 GPM (100 L/min.)

Minimum Flow — 0.0 GPM (0 L/min.)

P-32701

Pull up on and remove the floormat (Item 1) [Figure OI67].

45 of 168

OI-23

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-69

When slewing the upperstructure while working on a slope, push and hold the slew brake button (Item 1) [Figure OI-66] until the slew circuit is engaged. Release the button when the upperstructure starts to slew. This will prevent the upp erstructure from drifting when the slew circuit is first engaged.

HYDRAULIC CONTROLS (CONT’D)

Figure OI-72

Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above) The auxiliary hydraulic flow can be increased or decreased.

1

Figure OI-70

1 P-58215

The auxiliary hydraulic flow control valve (Item 1) [Figure OI-72] is located under the cab floor.

P-32701

Pull up on and remove the floormat (Item 1) [Figure OI70].

Figure OI-71

1

2

1 P-58214

Loosen the nut (Item 1) and turn the adjustment screw (Item 2) [Figure OI-73] in to increase auxiliary hydraulic flow / out to decrease hydraulic flow. Tighten the nut after the flow adjustment has been made.

Maximum Flow — 26.4 GPM (100 L/min.)

P-32702

Minimum Flow — 0.0 GPM (0 L/min.)

Remove the battery compartment cover (Item 1) [Figure OI-71].

46 of 168

OI-24

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-73

BLADE CONTROL LEVER Operation Figure OI-74

1

2 P-32716

Dealer Copy -- Not for Resale

Push the lever (Item 1) [Figure OI-74] forward to lo wer the blade.

Pull the lever (Item 1) [Figure OI-74] backward to raise the blade.

NOTE: Keep the blade lowered when digging to help stabilize the excavator.

Figure OI-75

1

P-32714

Push the switch (Item 1) [Figure OI-75] to put the blade in the float position (the switch will be illuminated).

47 of 168

OI-25

442 Excavator Operation and Maintenance Manual

BOOM SWING PEDAL Operation Push the left side of the pedal (Item 2) [Figure OI-74] to swing the boom to the left.

Push the right side of the pedal (Item 2) [Figure OI-74] to swing the boom to the right.

Dealer Copy -- Not for Resale

Figure OI-76

B-16610A

NOTE: The purpose of the boom swing pedal is to offset the boom with respect to the upperstructure for digging close to a structure [Figure OI-76].

48 of 168

OI-26

442 Excavator Operation and Maintenance Manual

DAILY INSPECTION Check the following items before each day of operation:

IMPORTANT

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule is a guide for correct maintenance of the Bobcat Excavator. It is located inside the rear door of the excavator and also in the MACHINE SIGN TRANSLATION SECTION.

•

Operator Cab and mounting hardware.

Seat belt and mounting hardware.

Damaged decals, replace as needed.

Check control console lockout.

Air cleaner and intake hoses.

Engine oil level and for engine leaks.

Hydraulic fluid level and system for leaks.

Grease all pivot points.

Cylinder and attachment pivot points.

Track tension.

Repair broken and loose parts.

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 12 inches (300 mm) from the decal. Wash from the center of the decal toward the edges.

I-2226-0104

Dealer Copy -- Not for Resale

• • • • • • • • • • •

•

WARNING AVOID INJURY OR DEATH 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-2003-0807

Fluids such as engine oil, hydraulic fluid, coolants, etc. must be disposed of in an environmentally safe manner.

Some regulations require that the certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

49 of 168

OI-27

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

DAILY INSPECTION (CONT’D)

6814224

50 of 168

OI-28

442 Excavator Operation and Maintenance Manual

PRE-STARTING PROCEDURE

Figure OI-79

Figure OI-77 2

3

4

1 5 P-32680 P-33986

Pull up on the lever (Item 1) [Figure OI-79] to adjust the seat forward or backward.

Read and understand the O peration & Maintenance Manual and the Operator's Handbook (Item 1) [Figure OI-77] before operating.

Pull up on the lever (Item 2) [Figure OI-79] to adjust the bottom of the seat forward or backward.

Pull up on the lever (Item 3) [Figure OI-79] to adjust the incline of the seat bottom.

Figure OI-78

Turn the adjustment knob (Item 4) until the operators weight is shown in the window (Item 5) [Figure OI-79].

The seat is adjustable from 110 lb. (50 Kg) to 285 lb. (130 Kg).

Figure OI-80

1 P-32904

Use the grab handles and the tracks to ent er the excavator [Figure OI-78].

P-32679

Pull up on the lever (Item 1) [Figure OI-80] to change the incline of the seat back.

51 of 168

OI-29

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

PRE-STARTING PROCEDURE (CONT’D)

Figure OI-83

Figure OI-81

1

1

P-32672 P-32678

Rotate the adjustment wheel (Item 1) [Figure OI-83] to raise or lower the armrests.

Turn the adjustment knob (Item 1) [Figure OI-81] to adjust the lumbar support in the seat back.

Figure OI-84

1 1

P-32857 P-32671

Adjust the mirror (Item 1) [Figure OI-84] for a clear view to the rear of the excavator from the operator's seat.

Raise the arm rest (Item 1) [Figure OI-82].

NOTE: The right armrest is shown. The procedure is the same for the left arm rest.

52 of 168

OI-30

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-82

PRE-STARTING PROCEDURE (CONT’D) Figure OI-85

1

P-32907

Fasten the seat belt (Item 1) [Figure OI-85].

Dealer Copy -- Not for Resale

Figure OI-86

P-32906

Lower the control console [Figure OI-86].

NOTE: There is a control lock switch in the left console which deactivates the hydraulic control levers (joysticks) and the traction drive system when the control console is in the raised position. The console must be in the down position for the hydraulic control levers (joysticks) and traction system to operate.

NOTE: If the control lock switch does not deactivate the control levers and the traction system when console is raised, see your Bobcat dealer for service.

53 of 168

OI-31

442 Excavator Operation and Maintenance Manual

STARTING THE ENGINE

Figure OI-89

Key Switch Stop

Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page OI-29.)

Run/Preheat

WARNING • •

Start

AVOID INJURY OR DEATH Fasten seat belt, start and operate only from the operator’s seat.

Never wear loose clothing when working near machine.

1

B-16666

W-2135-1108

Turn the key (Item 2) [Figure OI-88] & (Item 1) [Figure OI-89] to the RUN/PREHEAT position.

Figure OI-87

1 1

P-32716

Put the control levers (Item 1) [Figure OI-87] in the neutral position.

P-32715

The glow plug light (Item 1) [Figure OI-90] will be illuminated, showing the gl ow plugs are on. Wait for the light to go off. When the glow plug light goes out, turn the key to the start position and release the key when the engine starts. The key will return to the run position.

Figure OI-88

2

Stop the engine if the warning lights and alarm do not go off. Check for the cause before starting the engine again.

1 Turn the key switch OFF to stop the engine.

Low Speed High Speed P-32714

Move the engine speed control (Item 1) [Figure OI-88] fully forward to the low speed position.

54 of 168

OI-32

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-90

STARTING THE ENGINE (CONT’D)

Figure OI-92

Cold Temperature Starting Procedure 1

IMPORTANT Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again.

I-2034-0700 P-32715

If the temperature is below freezing, perform the following to make starting the engine easier:

When the light goes out, turn the key to the start position and release the key when the engine starts. The key will return to the run position. When the engine speed increases, move the speed control lever to the low speed position until the engine warms up. Turn the key switch off to stop the engine.

Make sure the battery if fully charged.

NOTE: If the battery is discharged (but not frozen) a booster battery can be used to jump start the excavator. (See Using A Booster Battery (Jump Starting) on Page PM-29.)

Install an engine heater.

IMPORTANT

Figure OI-91

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again.

2

I-2034-0700

1

IMPORTANT

Low Speed

Machines warmed up with moderate engine speed and light load have longer life.

High Speed

I-2015-0284

P-32714

Move the speed control lever (Item 1) [Figure OI-91] back to the high speed position.

WARNING

Turn the key (Item 2) [Figure OI-91] to the RUN/ PREHEAT position.

AVOID INJURY OR DEATH Do not use ether with glow plug (preheat) systems.

Explosion can result which can cause injury, death, or severe engine damage.

W-2071-0907

55 of 168

OI-33

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

The glow plug/manifold heat light (Item 1) [Figure OI-92] will be illuminated showing the glow plugs are on. Wait for the light to go off.

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-7.)

OPERATING PROCEDURE Operating On Public Roads

WARNING

When operating on a public road or highway, always follow local regulations. For example: A slow moving vehicle (SMV) sign, or direction signals may be required.

AVOID INJURY OR DEATH Keep objects balanced and as close to the backhoe and ground as possible when lifting with the backhoe. Swing lifted objects slowly. Always lower objects to the ground before leaving the machine.

Check with utility companies for underground electrical, water, gas lines, etc. Work slowly in areas of underground utilities.

W-2115-0189

WARNING AVOID INJURY OR DEATH Do not exceed Rated Operating Capacity (ROC).

Excessive load can cause tipping or loss of control.

W-2053-0903

Dealer Copy -- Not for Resale

Lifting A Load Do not exceed the rated load capacity.

Extend the bucket cylinder completely and lower the boom to the ground. Stop the engine.

Wrap the chain assembly around the bucket mounting plate.

Figure OI-93

B-16613

Make sure the load is evenly weighted and centered on the lifting chain, and is secured to prevent the load from shifting [Figure OI-93].

Lift and position the load. When the lo ad is in pos ition and tension is removed from the lift chain (secondary lift system), remove the secondary lift system.

56 of 168

OI-34

442 Excavator Operation and Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Figure OI-96

Excavating Lower the blade to provide stability.

Figure OI-94

TS-2062

Raise the boom, retract the arm and curl the bucket [Figure OI-96].

NOTE: Do not allow the bucket teeth to contact the ground when swinging the upperstructure.

Extend the arm, lower the boom and open the bucket [Figure OI-94].

Figure OI-97 Figure OI-95

B-16611 TS-2063

Extend the arm and uncurl the bucket to dump the material into a pile or truck [Figure OI-97].

Retract the arm, while lowering boom and c urling the bucket [Figure OI-95].

IMPORTANT Avoid operating hydraulics over relief pressure.

Failure to do so will overheat hydraulic components.

I-2213-0402

57 of 168

OI-35

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Rotate the upperstructure.

TS-2064

OPERATING PROCEDURE (CONT’D) Excavating (Cont’d) Figure OI-98 WRONG

TS-2061

Do not dig under the excavator [Figure OI-98].

Dealer Copy -- Not for Resale

Do not use the bucket as a br eaker or pile driver. It is better to excavate hard or rocky ground after breaking it with other equipment. This will reduce damage to th e excavator.

Do not move the excavator while the bu cket is in th e ground.

Dig only by moving the boom and arm toward the excavator.

Do not back dig (digging by moving the boom and arm away from the excavator). Damage to the attachments may occur.

WARNING Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

W-2119-0788

58 of 168

OI-36

442 Excavator Operation and Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Figure OI-101

Boom Offset Figure OI-99

6

B-16632A

Swing the upperstructure, offset the bo om to the r ight [Figure OI-99], center [Figure OI-100], and left [Figure OI-101] to dig a s quare hole the width of t he machine without repositioning the excavator.

B-16612A

Figure OI-100

Dealer Copy -- Not for Resale

Figure OI-102

6

B-16631A B-16610A

The boom offset allows the operator to dig close to buildings and other structures [Figure OI-102].

59 of 168

OI-37

442 Excavator Operation and Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Driving The Excavator

Backfilling

When operating on uneven ground, operate as slow as possible and avoid sudden changes in direction.

Figure OI-103

Avoid traveling over objects such as rocks, trees, stumps, etc.

When working on wet or soft ground, put planks on th e ground to pr ovide a s olid base to travel on and prevent the excavator from getting stuck.

Figure OI-104

B-16633

B-16634

If one or both tracks have become stuck in soft or wet ground, raise one track at a time by turning the upperstructure and pushing the bucket against the ground [Figure OI-104].

Put planks under the tracks and drive the excavator to dry ground.

Figure OI-105

B-16635

The bucket may also be used to pull the excavator. Raise the blade, extend the arm and lower the boom. Operate the boom and arm in a digging manner [Figure OI-105].

60 of 168

OI-38

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Use the blade to backfill the trench or hole after excavating [Figure OI-103].

OPERATING PROCEDURE (CONT’D)

WARNING

Operating On Slopes

WARNING

• •

• • •

AVOID INJURY OR DEATH Do not travel across or up slopes that are over 15 degrees.

Do not travel down or back up slopes that exceed 25 degrees.

Look in the direction of travel.

•

AVOID INJURY OR DEATH Avoid steep areas or banks that could break away.

Keep boom centered and attachments as low as possible when traveling on slopes or in rough conditions. Look in the direction of travel.

Always fasten seat belt.

W-2498-0304

Figure OI-107

W-2497-0304

Traveling On Side Slopes When going down a slope, control the speed with the steering levers and the speed control lever.

Figure OI-106

12 in.

(304 mm) Maximum 15° Maximum B-16676

Figure OI-108 25° Maximum Traveling Up Slopes TS-2068

When going down grades that exceed 15 degrees, put the machine in the position shown, and run the engine slowly [Figure OI-106].

Operate as slow as possible and avoid sudden changes in lever direction.

Avoid traveling over objects such as rocks, trees, stumps, etc.

15° Maximum

Stop the machine before moving the upper equipment controls. Never allow the blade to strike a solid object.

Damage to the blade or hydraulic cylinder can result.

61 of 168

TS-2067

When traveling up sl opes or on side slopes that ar e 15 degrees or less, position the machine as shown and run the engine slow [Figure OI-107] & [Figure OI-108].

OI-39

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Traveling Down or Backing Up Slopes

OPERATING PROCEDURE (CONT’D)

Figure OI-110

Operating On Slopes (Cont’d)

1

1

Figure OI-109 Recommended Position For Working On A Slope

P-32716

When operating on a slope, level a work area [Figure OI109] before beginning.

When the engine stops on a s lope, move the steering levers to the neutral position. Lower the boom/bucket to the ground.

If this is not possible, the following procedures should be used:

NOTE:

Do not work on slopes which are over 15 degrees.

Use a slow work cycle. Avoid working with the tracks across the slope. This will reduce stability and increase the tendency for the machine to slide.

Position the ex cavator with the blade downhill and lowered.

If the engine stops, the boom/bucket (attachments) can be lowered to the ground using hydraulic pressure which is stored in the accumulator.

The console must be in the down position, and the key switch in the ON position.

Use the control lever to lower the boom.

Avoid swinging or extending the bucket more than necessary in a down hill direction. When you must swing the bucket downhill, keep the arm low and skid the bucket downhill.

Start the engine and resume operation.

When working with the bucket on the uphill side, keep the bucket as close to the ground as possible. Dump the spoil far enough away from the trench or hole to prevent the possibility of a cave in.

62 of 168

OI-40

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

To brake the machine when going down a slope, move the steering levers (Item 1) [Figure OI-110] to the NEUTRAL position. This will engage the hydrostatic braking.

B-16758

OPERATING PROCEDURE (CONT’D)

PARKING THE EXCAVATOR

Operating In Water

Stop the machine on l evel ground. Lower the wo rk equipment and the blade to the ground.

Mud and water should be removed from the machine before parking. In fr eezing temperatures, park the machine on boards or concrete to prevent the track or undercarriage from freezing to the ground and preventing machine movement.

Run the engine at idle speed for about 5 minutes to allow it to cool.

Figure OI-112

Figure OI-111 2

Water Level

P-32714

B-16664

Move the speed control lever (Item 1) [Figure OI-112] fully forward to the low engine speed position.

Do not operate or immerse the excavator in water higher than the bottom of the swing circle [Figure OI-111].

Turn the key switch (Item 2) [Figure OI-112] to STOP.

Grease the excavator when it has been operated or immersed in water for a per iod of time. Greasing forces the water out of the lubrication areas.

Disconnect the seat belt. Remove the key from the switch to prevent operation of machine by unauthorized personnel. Raise the control console and exit the machine.

Water must be removed from the cylinder rods. If wa ter freezes to t he cylinder rod, the cylinder seals can be damaged when the rod is retracted.

63 of 168

OI-41

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

TRANSPORTING THE EXCAVATOR

Figure OI-114

When transporting the machine, observe the rules, motor vehicle laws and vehicle limit ordinances. Use a transport and towing vehicle of adequate length and capacity.

1

Secure the p arking brakes and block the wheels of th e transport vehicle.

Align the ramps with the center of the transport vehicle.

Secure the ramps to the truck bed and be sure ramp angle does not exceed 15 degrees.

Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width, and can support the weight of the machine.

P-32598

The rear of the trailer must be blocked or supported when loading or unloading the excavator to prevent the front of the transport vehicle from raising.

Determine the direction of th e track movement before moving the machine (blade forward).

Figure OI-113

1

P-32603

Fasten chains to the front corners of the blade (Item 1) [Figure OI-114] and to the tie down loop at the rear track frame (Item 1) [Figure OI-115] to prevent it from moving when going up or down slopes, or during sudden stops.

P-32599

Use chain binders to tighten the chains and then safely tie the chain binder levers to prevent loosening.

Move the machine forward onto the transport vehicle [Figure OI-113].

WARNING

Do not change direction of the machine while it is on the ramps.

AVOID SERIOUS INJURY OR DEATH Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

Lower the boom, arm and bucket to the transport vehicle.

Lower the blade to the transport vehicle.

Stop the engine and remove the key (if equipped).

W-2058-0807

Put blocks at the front and rear of the tracks.

64 of 168

OI-42

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-115

LIFTING THE EXCAVATOR

Figure OI-117

Figure OI-116 2 2

1

1

B-16594 P-32909

Fully extend the cylinders of the bucket, arm & boom so that the excavator is in the position shown [Figure OI116].

Fasten a chain to th e boom (Item 2) [Figure OI-116] & [Figure OI-117] and up to a lifting fixture.

Raise the blade all the way.

Put the all control levers in neutral.

Stop the engine and exit the excavator.

65 of 168

OI-43

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Fasten chains to the ends of the blade (Item 1) [Figure OI-116] & [Figure OI-117] and up to a lifting fixture above the cab. The lifting fixture must extend over the sides of the cab to prevent the chains from hitting the cab.

ATTACHMENTS

Figure OI-120

Bucket And Ripper Tooth Installation

WARNING

1

AVOID INJURY OR DEATH Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

1

W-2052-0907

P-32913

Figure OI-118 Install the cotter pins (Item 1) [Figure OI-120].

1

WARNING

2

Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

3 4

W-2119-0788

3 Figure OI-121

P-32833

Lower the arm (Item 1) and bucket link (Item 2) [Figure OI-118] in to the bucket mount.

Install the pins (Item 3) [Figure OI-118].

The pins must seat against the anti-rotation stops (Item 4) [Figure OI-118].

1

Figure OI-119 1

P-36506

The excavator is shown with the r ipper tooth installed [Figure OI-121].

1

1

P-32831

Install the washers (Item 1) [Figure OI-119].

66 of 168

OI-44

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

4

ATTACHMENTS (CONT’D)

Figure OI-124

Bucket And Ripper Tooth Removal 3

Stop the excavator on a flat level surface. Put the bucket on the ground.

Figure OI-122

2 1 1 P-32832

1

Remove the pins (Item 1) [Figure OI-124].

1

Retract the bucket link (Item 2) and raise the arm (Item 3) [Figure OI-124].

Dealer Copy -- Not for Resale

P-32913

Remove the c otter pins (Item 1) [Figure OI-122] from both pins.

Figure OI-123

1 1 P-32831

Remove the washers (Item 1) [Figure OI-123] from both pins.

67 of 168

OI-45

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-126

Tilt Bucket Installation

WARNING AVOID INJURY OR DEATH Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

2 1

W-2052-0907 P-65778

NOTE: There are 2 models of the tilt bucket. Both installation procedures are the same. The photographs in this instruction show the later model.

Install the pins (Item 1) [Figure OI-126].

The pins must seat against the anti-rotation stops (Item 2) [Figure OI-126].

Figure OI-125

Dealer Copy -- Not for Resale

Figure OI-127 1

2

1

P-65777

1

Lower the arm (Item 1) and bucket link (Item 2) [Figure OI-125] in to the bucket mount.

68 of 168

P-65780

Install the pin lock clips (Item 1) [Figure OI-127].

OI-46

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D)

Tilt Bucket Removal

Tilt Bucket Installation (Cont’d)

Relieve hydraulic pressure. (See Relieving Hydraulic Pressure on Page OI-21.)

Figure OI-128 Remove the hydraulic hoses (Item 1) [Figure OI-128] from the excavator quick couplers.

Figure OI-129

1

1 1

2 1 P-65784

Install the hydraulic hoses (Item 1) [Figure OI-128] from the bucket to the excavator quick couplers.

P-65779

Remove the lock clips (Item 1) and pins (Item 2) [Figure OI-129].

Figure OI-130

2

1

P-65777

Retract the bucket link (Item 1) and raise the arm (Item 2) [Figure OI-130].

69 of 168

OI-47

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

2

ATTACHMENTS (CONT’D)

Figure OI-132

Tilt Bucket Operation NOTE: The side to side movement of the tilt bucket can be slowed by adjusting the auxiliary hydraulic flow. (See Auxiliary Hydraulic Flow Control (S/N 522311001 & Above) on Page OI23.) or (See Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above) on Page OI-24.)

Figure OI-131

P-65782

Figure OI-133

2

P-32713

Push and h old the switch (Item 1) [Figure OI-131] to swing the bucket to the left [Figure OI-132]. Release the button when the correct position of the bucket is obtained.

P-65777

Push and hold the switch (Item 2) [Figure OI-131] to swing to the right [Figure OI-133]. Release the button when the correct position of the bucket is obtained.

WARNING

(See Auxiliary Hydraulics on Page OI-22.)

Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

W-2119-0788

70 of 168

OI-48

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

ATTACHMENTS (CONT’D)

Figure OI-135

Clamshell Bucket Installation NOTE: The Auxiliary Hydraulic Flow must be reset prior to Clamshell Bucket operation. Reset the auxiliary flow to the minimum flow. (See Auxiliary Hydraulic Flow Control (S/N 522311001 & Above) on Page OI-23.) or (See Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above) on Page OI-24.)

1

Figure OI-134 P-36425

Install the bucket link retainer (Item 1) [Figure OI-135] through the pivot pin mount.

1

P-36425

Rotate the retainer (Item 1) [Figure OI-136] around the front of the arm.

Figure OI-137 P-36423

Fully retract the bucket cylinder (Item 1)[Figure OI-134].

1

P-36427

Install the retainer pin (Item 1) [Figure OI-137].

71 of 168

OI-49

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-136

1

ATTACHMENTS (CONT’D)

Figure OI-140

Clamshell Bucket Installation (Cont’d) Figure OI-138

2

1

1 P-36510

Position the clamshell with the hose mounts (Item 1) [Figure OI-140] up, and the bottom of the clamshell towards the blade.

P-36433

Dealer Copy -- Not for Resale

Lower the arm (Item 2) [Figure OI-140] into the mount.

Figure OI-139

Figure OI-141

1 1

P-36434 P-36511

Turn the valves (Item 1) [Figure OI-138] & [Figure OI139] (on both sides of the arm) clockwise, to divert hydraulic flow from the bucket cylinder to the se condary front auxiliary quick couplers.

72 of 168

Install the pivot pin (Item 1) [Figure OI-141].

OI-50

442 Excavator Operation and Maintenance Manual

ATTACHMENT (CONT’D)

Figure OI-144

Clamshell Bucket Installation (Cont’d) Figure OI-142

1 1 2

1 P-36514A

Install the hydraulic hoses (Item 1) [Figure OI-144] from the clamshell to the excavator quick couplers.

P-36512

Dealer Copy -- Not for Resale

Install the retaining plate (Item 1) in the groove (Item 2) [Figure OI-142] of the pivot pin.

Figure OI-143

1

P-36513

Install the bolts (Item 1) [Figure OI-143].

Tighten the bolts to 48 - 5 ft.-lb. (65 - 75 N•m) torque.

73 of 168

OI-51

442 Excavator Operation and Maintenance Manual

ATTACHMENT (CONT’D)

Figure OI-147

Clamshell Bucket Removal Figure OI-145

1

P-36510

Raise the arm (Item 1) [Figure OI-147] P-36515

Dealer Copy -- Not for Resale

Lower the clamshell to th e ground. Use the boom and arm functions to position the clamshell as shown [Figure OI-145].

Remove the hydraulic hoses from the excavator quick couplers.

Figure OI-146

1 2

3

1

P-36513

Remove the bo lts (Item 1), retainer plate (Item 2) and pivot pin (Item 3) [Figure OI-146].

74 of 168

OI-52

442 Excavator Operation and Maintenance Manual

ATTACHMENT (CONT’D)

Figure OI-150

Clamshell Bucket Operation NOTE: The Auxiliary Hydraulic Flow must be reset prior to Clamshell Bucket operation. Reset the auxiliary flow to the minimum flow. (See Auxiliary Hydraulic Flow Control (S/N 522311001 & Above) on Page OI-23.) or (See Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above) on Page OI-24.)

WARNING P-36508

Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

Move the right joystick to th e right (Item 2) [Figure OI148] to open the clamshell [Figure OI-150].

W-2119-0788

Dealer Copy -- Not for Resale

Figure OI-148

1 2

P-32713

Figure OI-149

P-36507

Move the right joystick to the left (Item 1) [Figure OI-148] to close the clamshell [Figure OI-149].

75 of 168

OI-53

442 Excavator Operation and Maintenance Manual

Figure OI-153

ATTACHMENTS (CONT’D) Clamshell Bucket Operation (Cont’d) Figure OI-151

2 1

P-36509

Push and hold the switch (Item 2) [Figure OI-151] to rotate the bucket in the clockwise direction [Figure OI153]. (See Auxiliary Hydraulics on Page OI-22.)

P-32713

Dealer Copy -- Not for Resale

Figure OI-152

P-36509

Push and hold the switch (Item 1) [Figure OI-151] to rotate the bucket in the co unterclockwise direction [Figure OI-152].

76 of 168

OI-54

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D) Lifting The Clamshell Bucket NOTE: Use chains that are in good condition and of adequate size to lift the attachment.

Figure OI-154

1

1

Dealer Copy -- Not for Resale

P-36422

Figure OI-155

1

1

P-36421

Install the chains (Item 1) [Figure OI-154] & [Figure OI155] around the pivot of the clamshell bucket.

77 of 168

OI-55

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-158

Fastening The Clamshell Bucket To The Transport Vehicle Figure OI-156

P-36418

Fasten the chains to the clamshell bucket [Figure OI156], [Figure OI-157], & [Figure OI-158].

P-36419

Use chain binders to prevent the attachment from moving during transport.

Secure the hydraulic hoses to the attachment.

P-36420

78 of 168

OI-56

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-157

ATTACHMENTS (CONT’D)

NOTE: Align the pin retainer hole with the hole in the casting.

Manual Spring Loaded Coupler Installation Figure OI-161

Remove the bucket. (See Bucket And Ripper Tooth Removal on Page OI-45.)

WARNING AVOID INJURY OR DEATH Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

1 2 2

1

W-2052-0907 P-65760

Figure OI-159

Install the retainer bolts (Item 1) and nuts (Item 2) [Figure OI-161].

Dealer Copy -- Not for Resale

1

2 P-65758

Lower the arm (Item 1) and bucket link (Item 2) [Figure OI-159] in to the coupler mount.

Figure OI-160

1

P-65759

Install the pins (Item 1) [Figure OI-160].

79 of 168

OI-57

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-164

Manual Spring Loaded Coupler Removal Figure OI-162 2

2

1 1 P-65758

2

1

Retract the bucket link (Item 1) and raise the arm (Item 2) [Figure OI-164].

P-65760

Dealer Copy -- Not for Resale

Remove the nuts (Item 1) and retainer bolts (Item 2) [Figure OI-162].

Figure OI-163

1

P-65759

Remove the pins (Item 1) [Figure OI-163].

80 of 168

OI-58

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-167

Manual Spring Loaded Coupler Attachment Installation 1

WARNING Keep all bystanders 20 feet (6 m) away from equipment when operating. Contact with moving parts, a trench cave-in or flying objects can cause injury or death.

W-2119-0788

2 P-65764

Figure OI-165

Install the lock pin (Item 1) and retainer pin (Item 2) [Figure OI-167] to hold the locking hooks in the open position. Remove the release bar.

Dealer Copy -- Not for Resale

Figure OI-168

3 1 2 P-65773B

1

Insert the release bar (Item 1) into the manual spring loaded coupler. Remove the retainer pin (Item 2). Rotate the release bar (Item 1) upward slightly and remove the lock pin (Item 3) [Figure OI-165].

2 P-65766

Figure OI-166 Enter the machine, fasten the seat belt and start the engine.

Position the front hooks (Item 1) over the front pin (Item 2) [Figure OI-168] of the attachment.

1

2 P-65762

Using the release bar (Item 1), rotate the locking hooks (Item 2) [Figure OI-166] upwards to the unlock position.

81 of 168

OI-59

442 Excavator Operation and Maintenance Manual

ATTACHMENTS (CONT’D)

Figure OI-171

Manual Spring Loaded Coupler Attachment Installation (Cont'd) Figure OI-169

1 2 1 P-65771

Rotate the locking hooks (Item 1) downward, cupping (engaging) the attachment pin (Item 2) [Figure OI-171].

2 P-65767

Extend the bucket cylinder (curl in) the coupler until the rear pin of the attachment (Item 1) is firmly seated in the coupler (Item 2) [Figure OI-169].

Continue to curl the coupler and attachment until the weight of the attachment is supported by the coupler.

1

Stop the engine and exit the machine.

Figure OI-170

2

3

P-65773

Install the locking pin (Item 1) and retainer pin (Item 2) [Figure OI-172] and remove the release bar.

Check for secure attachment. Never operate without retainer pins (Item 2) [Figure OI-172] installed.

1

2 P-65770

Reinsert the release bar (Item 1) and rotate the loc king hooks (Item 2) [Figure OI-170] upwards slightly.

Remove the r etainer pin and the locking pin (Item 3) [Figure OI-170].

82 of 168

OI-60

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-172

ATTACHMENTS (CONT’D)

Figure OI-175

Manual Spring Loaded Coupler Attachment Removal Figure OI-173

3

1 P-65769

2 1

Position the attachment flat on the ground.

Enter the machine, fasten the seat belt and start the engine.

Stop the engine and exit the machine.

Figure OI-176

Remove the retainer pin (Item 1) [Figure OI-173].

Insert the release bar (Item 2) and rotate the release bar upward slightly and remove the locking pin (Item 3) [Figure OI-173].

Figure OI-174 3

1 P-65765

Retract the bucket cylinder and move the arm forward until the manual spring loaded coupler is clear of the attachment [Figure OI-176].

2

P-65770

Using the release bar (Item 1), rotate the locking hooks (Item 2) upwards to the unlock position and install the locking pin (Item 3) [Figure OI-174].

83 of 168

OI-61

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Install the retainer pin (Item 1) [Figure OI-175] to hold the locking hooks in the open position. Remove the release bar.

P-65773A

Dealer Copy -- Not for Resale 84 of 168

OI-62

442 Excavator Operation and Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 AIR CONDITIONING COMPRESSOR BELT (S/N 528611001 & ABOVE AND S/N 528911001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PM-34 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-34 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 PREVENTIVE MAINTENANCE

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-23 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-23 Fuse And Relay Location (S/N 522311001 & Above) . . . . . . . . . . . . . PM-23 Fuse And Relay Location (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-26 Removing And Installing The Battery. . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . PM-29 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 FAN / FUEL PUMP BELT (S/N 522311001 & ABOVE) . . . . . . . . . . . . . . . PM-33 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 FRESH AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-9 Removal And Installation (S/N 522311001 & Above) . . . . . . . . . . . . . . PM-9 Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-9 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-16 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Fuel Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Pre-Filter Installation (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . PM-14 Pre-Filter Removal (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . PM-12 Pre-Filter Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Removing Water From The Pre-Filter (S/N 522311001 & Above) . . . . .PM-11 Continued On Next Page

PM-1 85 of 168

442 Bobcat Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Checking Coolant Level (S/N 522311001 & Above) . . . . . . . . . . . . . . PM-20 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Replacing The Coolant (S/N 522311001 & Above) . . . . . . . . . . . . . . . PM-21

PREVENTIVE MAINTENANCE (CONT’D) HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-35 Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . PM-35 Diagnostic Couplers (S/N 522311001 & Above) . . . . . . . . . PM-42 Diagnostic Couplers (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-42 Hydraulic Filter Installation (S/N 522311001 & Above) . . . . PM-38 Hydraulic Filter Installation (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-40 Hydraulic Filter Removal (S/N 528611001 & Above and S/N 528911001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-39 Hydraulic Filter Removal (S/N 522311001 & Above) . . . . . . PM-37 Replacing The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . PM-36 LUBRICATING THE ATTACHMENTS. . . . . . . . . . . . . . . . . . . . PM-53 Clamshell Bucket Lubrication. . . . . . . . . . . . . . . . . . . . . . . . PM-54 Tilt Bucket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-53

Dealer Copy -- Not for Resale

LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . PM-49 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-3 REAR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Opening And Closing The Rear Cover . . . . . . . . . . . . . . . . . PM-6 RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Opening And Closing The Right Side Cover . . . . . . . . . . . . . PM-6 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-43 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-46 Rubber Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-43 Steel Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-45 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-48 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-48 Draining The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . PM-48

PM-2 86 of 168

442 Bobcat Excavator Operation & Maintenance Manual

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 W-2003-0903 instructions can cause injury or death.

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

B-10731a

B-14148

B-14142

Bobcat without

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

Never service the Hydraulic Excavator instructions.

B-14147

B-14141

B-14145

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-14146

B-14143

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 rear door closed except for service. Close and latch door 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.

MSW20-0805

87 of 168

PM-3

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

CORRECT

Dealer Copy -- Not for Resale 88 of 168

PM-4

442 Excavator Operation and Maintenance Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat Excavator.

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 W-2003-0903 instructions can cause injury or death.

SERVICE SCHEDULE ITEM

SERVICE REQUIRED

HOURS 8-10

Engine Coolant

Check coolant level. Add coolant as needed. (W ater cooled engines only)

Engine Oil

Check engine oil level and add as needed.

50

100

250

500

z 1000

Track Tension

Check and adjust track tension.

Indicators and Lights

Check for correct operation of indicators and lights.

Operator Cab/Canopy

Check cab/canopy condition and hardware.

Seat Belt

Check seat belt condition and mounting hardware

Safety Signs (Decals)

Check for damaged signs (decals). Replace as needed.

Pivot Points

Grease all machinery pivot points.

Fuel Tank & Filter

Drain water and sediment from fuel tank and filter.

Control Console

Check control console lockout for proper operation.

Swing Circle & Pinion

Grease swing circle and swing pinion.

Door Hinges

Grease door hinges.

Battery

Check battery, cables and electrolyte level.

Belts

Check and adjust bolts.

Travel Motors

Check oil level in both travel motors.

Dealer Copy -- Not for Resale

Hydraulic Fluid Hoses Tube lines and Check the hydraulic fluid level and add as needed. Check Reservoir Breather Cap for damage and leaks. Repair or replaced as needed.

Hydraulic Oil Cooler, *Engine Oil Clean radiator/oil cooler fins. Clean A/C c ondenser.

Cooler, *Radiator, A/C Condenser and Clean/replace cab filter.

Cab Ventilation Filter

Hydraulic Filter

Replace hydraulic filter.

Engine Oil & Filter

Replace engine oil and filter.

Air Filter Intake

Check/clean air filter intake

Alternator & Starter

Check alternator and starter connections.

Fuel Filters

Replace diesel fuel pre-filter and filter.

Engine Valves

Check and adjust engine valve clearance.

Travel Motors

Replace oil in both travel motors.

Engine Cooling System

Drain and flush cooling system. Replace coolant. (Water cooled engines only)

Hydraulic System

Replace hydraulic fluid and filter. Clean reservoir.

*

z

If equipped Service at first 50 hours, then as scheduled Service at first 100 hours, then as scheduled 1000 hours or every six months

89 of 168

PM-5

442 Excavator Operation and Maintenance Manual

REAR COVER

RIGHT SIDE COVER

Opening And Closing The Rear Cover

Opening And Closing The Right Side Cover Figure PM-2

WARNING AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W-2012-0497

1

WARNING P-56407

Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

Figure PM-1

Lower the right side cover and push down firmly to close the rear cover.

NOTE: The start key can be used to lock the right side cover.

1

P-56406

Push the latch (Item 1) [Figure PM-1] and raise the rear cover.

Lower the rear cover and p ush down firmly to close the rear cover.

NOTE: The start key can be used to lock the rear cover.

90 of 168

PM-6

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Push the latch (Item 1) [Figure PM-2] and raise the right side cover.

W-2020-1285

AIR CLEANER

Replacing The Filters

Daily Check

Outer Filter

See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

Unlatch the air filter cover latches (Item 2) [Figure PM-4].

Remove the air filter cover (Item 3) [Figure PM-4].

Figure PM-3 Figure PM-5

1

1

P-32689

If the air filter condition indicator (Item 1) [Figure PM-3] is illuminated, the outer filter element needs to b e replaced.

Remove the outer filter (Item 1) [Figure PM-5].

Check the housing for damage.

Replace the inner filter every third time the outer filter is replaced.

Clean the housing and seal surface. Do not use compressed air.

Figure PM-4 Install the outer filter.

Install the cover.

2

2

3

1

P-32688

Open the right side cover to inspect the air intake (Item 1) [Figure PM-4] for damage or restrictions. (See RIGHT SIDE COVER on Page PM-6.)

91 of 168

PM-7

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-32713

AIR CLEANER (CONT’D)

Inner Filter S/N 528611001 & Above and S/N 528911001 & Above

Replacing The Filters (Cont’d) Inner Filter S/N 522311001 & Above

Replace the inner filter every third time the outer filter has been replaced.

Replace the inner filter every third time the outer filter has been replaced.

Replace the inner filter after the outer filter has been replaced and the air filter indicator is still illuminated.

Replace the inner filter after the outer filter has been replaced and the air filter indicator is still illuminated.

Remove the air cleaner cover and outer filter.

Figure PM-8

Remove the air cleaner cover and outer filter.

Figure PM-6

1

2

P-56408

1

Pull the air filter (Item 1) [Figure PM-8] out of the housing.

P-32690

Pry up on the ends of the air filter (Item 1). Pull the air filter (Item 2) [Figure PM-6] out of the housing.

Discard the inner air filter after it has been removed.

Discard the inner air filter after it has been removed.

Do not clean or reuse the filter. Make sure all sealing surfaces are free of dirt and debris.

Do not clean or reuse the filter. Make sure all sealing surfaces are free of dirt and debris.

Figure PM-9

Figure PM-7

1 1 P-56409 P-32691

Install the new inner filter (Item 1) [Figure PM-9]. Install the outer filter and air cleaner cover.

Install the new inner filter (Item 1) [Figure PM-7]. Install the outer filter and air cleaner cover.

92 of 168

PM-8

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

FRESH AIR FILTER

Figure PM-12

Removal And Installation (S/N 522311001 & Above) See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

1

1 Figure PM-10

1

1

2

P-32910

Remove the four bolts (Item 1) [Figure PM-12].

Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above)

P-32912

Position the excavator as shown [Figure PM-10].

See your Bobcat Excavator Dealer to have the fresh air filter serviced.

Figure PM-11

1

1

1

2

1

1

1

P-32911

Remove the eleven bolts (Item 1) [Figure PM-11] and washers.

Installation: Tighten the bolts to 18 - 19 f t.-lb. (24 - 26 N•m) torque.

Remove the cover (Item 2) [Figure PM-11].

93 of 168

PM-9

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Remove the filter (Item 2) [Figure PM-12].

FUEL SYSTEM

Figure PM-14

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

1

The following is a s uggested blending guideline which should prevent fuel gelling problems during freezing temperatures: NO. 2

NO. 1

+15° (9°)

100%

0%

Down to -20° (-29°)

50%

50%

Below -20° (-29°)

0%

100%

P-32698

See your fuel supplier for local recommendations.

Check the condition of th e fill strainer screen (Item 1) [Figure PM-14]. Clean or replace as necessary.

Filling The Fuel Tank

Use a clean, approved safety container to add fuel. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING!

Figure PM-13

Install and tighten the fuel fill cap. Close the rear cover.

See Service Schedule for the service interval when to remove water from the fuel pre-filter or replace the fuel pre-filter and fuel filter. (See SERVICE SCHEDULE on Page PM-5.)

1

WARNING P-32697

AVOID INJURY OR DEATH Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

Open the rear cover and remove the fuel fill cap (Item 1) [Figure PM-13].

W-2063-0807

NOTE: The fuel fill cap can be locked. Use the fuel fill cap key to lock and unlock the cap.

94 of 168

PM-10

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

TEMP. F° (C°)

FUEL SYSTEM (CONT’D) Removing Water From The Pre-Filter (S/N 522311001 & Above) Open the rear cover.

Figure PM-15

1

Dealer Copy -- Not for Resale

P-32699

Loosen the drain (Item 1) [Figure PM-15] at the bottom of the filter housing to drain water from the filter.

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

95 of 168

PM-11

442 Excavator Operation and Maintenance Manual

FUEL SYSTEM (CONT’D)

Figure PM-17

Pre-Filter Removal (S/N 522311001 & Above) See Service Schedule for the service interval when to replace the fuel pre-filter. (See SERVICE SCHEDULE on Page PM-5.)

2

Clean the area around the fuel pre-filter housing.

Figure PM-16

1

P-32858

Support the filter housing (item 1) and remove the bol t (Item 2) [Figure PM-17] and washer.

Remove the filter.

Dealer Copy -- Not for Resale

Figure PM-18 1 P-32699

Loosen the drain (Item 1) [Figure PM-16] at the bottom of the filter housing and drain the fuel out of the housing.

WARNING 1

AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

P-32859

Remove the gasket (Item 1) [Figure PM-18] from the filter head.

W-2072-0807

96 of 168

PM-12

442 Excavator Operation and Maintenance Manual

FUEL SYSTEM (CONT’D) Pre-filter Removal (S/N 522311001& Above) (Cont’d) Figure PM-19

1

P-32860

Dealer Copy -- Not for Resale

Remove the filter (Item 1) [Figure PM-19] from the filter housing.

Figure PM-20

1

P-32861

Remove the spacer (Item 1) [Figure PM-20] from the filter housing.

97 of 168

PM-13

442 Excavator Operation and Maintenance Manual

FUEL SYSTEM (CONT’D)

Figure PM-23

Pre-Filter Installation (S/N 522311001 & Above) Clean the filter housing in clean solvent and dry with compressed air.

2

Install the s pacer (Item 1) [Figure PM-20 on Page PM13] in the filter housing.

1

Figure PM-21

1

P-32858

Install the filter (Item 1) and bolt (Item 2) [Figure PM-23].

Tighten the bolt to 15 - 18 ft.-lb. (20 - 25 N•m) torque.

Dealer Copy -- Not for Resale

Figure PM-24

P-32860

Install the filter (Item 1) [Figure PM-21] in the housing.

Apply clean motor oil on both sides of the filter gasket.

Figure PM-22

1 P-32699

Close the drain (Item 1) [Figure PM-24] on the bottom of the filter housing.

1

P-32859

Install the ga sket (Item 1) [Figure PM-22] on the filter head.

98 of 168

PM-14

442 Excavator Operation and Maintenance Manual

FUEL SYSTEM (CONT’D)

Fuel Filter Removal And Installation

Pre-Filter Installation (S/N 522311001 & Above) (Cont’d)

See Service Schedule for the service interval when to replace the fuel filter. (See SERVICE SCHEDULE on Page PM-5.)

Figure PM-25 Clean the area around the filter.

Figure PM-27 S/N 522311001 & Above 1

2

P-32862

Remove the bolt (Item 1) and loosen the vent screw (Item 2) [Figure PM-25].

P-32694

Fill the filter through the bolt hole with clean fuel until fuel flows from the vent with no air bubbles.

Figure PM-28 S/N 528611001 & Above, S/N 528911001 & Above

Install the bolt (Item 1) [Figure PM-25].

Tighten the vent screw (Item 2) [Figure PM-25].

Pre-Filter Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above) Figure PM-26

1 P-56411

1

Remove the filter (Item 1) [Figure PM-27] & [Figure PM28].

2

Put clean oil on the seal of the new filter.

Install the filter and hand tighten.

P-56410

Loosen the hose clamps (Item 1) and remove the filter (Item 2) [Figure PM-26].

99 of 168

PM-15

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

FUEL SYSTEM (CONT’D)

Figure PM-31

Draining The Fuel Tank Figure PM-29

1

P-32902

Position the excavator as shown [Figure PM-29].

WARNING

Figure PM-30

AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

1

P-32903

Remove the cap (Item 1) [Figure PM-30] from the drain.

100 of 168

PM-16

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Open the drain (Item 1) [Figure PM-31] and drain the fuel into a container.

P-32901

ENGINE LUBRICATION SYSTEM

Oil Chart

Checking Engine Oil

Figure PM-34

Check the engine oil after every 8-10 hours of operation and before starting the engine for the work shift.

Figure PM-32 S/N 522311001 & Above

1

Figure PM-33 Use a good quality motor oil that meets the correct API Service Classification. See oil chart [Figure PM-34].

S/N 528611001 & Above, S/N 528911001 & Above

1

P-56411

Open the right side cover and remove the dipstick (Item 1) [Figure PM-32] & [Figure PM-33].

Keep the oil level between the marks on the dipstick.

101 of 168

PM-17

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-32692

ENGINE LUBRICATION SYSTEM (CONT’D)

Figure PM-37

Replacing Oil And Filter See Service Schedule for the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page PM-5.)

1

Figure PM-35

P-32886

Install the drain hose (Item 1) [Figure PM-37] on the oil pan. Tighten the hose until oil starts to drain from the oil pan.

Recycle or dispose of used oil in an environmentally safe manner.

Rotate the up perstructure so th e right side is positioned between the tracks [Figure PM-35]. Run the engine until it is at operating temperature. Stop the engine.

Open the right side cover.

Figure PM-36

1

P-32885

Remove the cap (Item 1) [Figure PM-36].

102 of 168

PM-18

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Drain the oil in a container.

P-32884

Put oil in the engine. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-7.)

ENGINE LUBRICATION SYSTEM (CONT’D) Replacing Oil And Filter (Cont’d)

Install the fill cap.

Figure PM-38 Start the engine and let it run for several minutes.

S/N 522311001 & Above

Stop the engine. Check for leaks at the oil filter. Check the oil level on the dipstick (Item 3) [Figure PM-38] & [Figure PM-39].

2

Add oil as needed if it is not at the top mark on the dipstick.

3 1

P-32692

Figure PM-39

Dealer Copy -- Not for Resale

S/N 528611001 & Above, S/N 528911001 & Above

2

3 1 P-56411

Remove the oi l filter (Item 1) [Figure PM-38] & [Figure PM-39] and clean the filter housing surface.

Use a genuine Bobcat replacement oil filter.

Put clean engine oil on th e filter gasket. Install the filter and hand tighten.

Remove the drain hose and install the cap on the oil pan after the oil has been completely drained.

Remove the fi ll cap (Item 2) [Figure PM-38] & [Figure PM-39].

103 of 168

PM-19

442 Excavator Operation and Maintenance Manual

COOLING SYSTEM

Figure PM-41

Cleaning The Cooling System Check the cooling system every day to prevent overheating, loss of performance or engine damage.

1

Open the right side cover.

Use air pressure or water pressure to clean the radiator/ oil cooler. Be careful not to damage the fins when cleaning.

Checking Coolant Level (S/N 522311001 & Above)

P-32844

WARNING AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

W-2070-1203

IMPORTANT

Open the right side cover.

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Figure PM-40

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

1

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I-2124-0497 P-32693

WARNING

Check the coolant level in the surge tank (Item 1) [Figure PM-40].

AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W-2019-0907

104 of 168

PM-20

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

The surge tank (Item 1) [Figure PM-41] must be half full when the engine is cold.

COOLING SYSTEM (CONT’D) Replacing The Coolant (S/N 522311001 & Above)

NOTE: The plug is located next to the alternator mount bracket.

See Service Schedule for the correct service interval to replace the coolant. (See SERVICE SCHEDULE on Page PM-5.)

Drain the coolant from the engine.

Figure PM-44

WARNING AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

1

W-2070-1203

Figure PM-42

P-32847

Remove the lower radiator hose (Item 1) [Figure PM-44].

Drain the coolant from the engine.

After the coolant is removed, install the pl ug (Item 1) [Figure PM-43] and lower radiator hose (Item 1) [Figure PM-44].

Recycle or dispose of the used coolant in an environmentally safe manner.

P-32693

Mix the coolant in a separate container.

When the engine is cool, loosen and remove the radiator cap (Item 1) [Figure PM-42].

NOTE: The excavator is factory filled with ethylene glycol coolant.

Figure PM-43

Add premixed coolant, 50% water and 50% et hylene glycol to the reservoir if the coolant level is low.

One gallon (3,8 L) of ethylene glycol mixed with one gallon (3,8 L) of water is the correct mixture of coolant to provide a -34°F (-37°C) freeze protection.

Use a refractometer to check the condition of ethylene glycol in your cooling system.

1

Fill the radiator with the premixed coolant. Install the radiator cap.

Run the engine until it is at operating temperature.

P-32849

Stop the engine.

Remove the plug (Item 1) [Figure PM-43] from the back side of the engine block.

105 of 168

PM-21

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

COOLING SYSTEM (CONT’D) Replacing The Coolant (S/N 522311001 & Above) (Cont’d) Figure PM-45

1

P-32844

Dealer Copy -- Not for Resale

Check the coolant level (COLD) in the surge tank (Item 1) [Figure PM-45] when cool.

Add coolant to the tank as needed.

106 of 168

PM-22

442 Excavator Operation and Maintenance Manual

ELECTRICAL SYSTEM

WARNING

Description Figure PM-46

AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

1

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

1

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

2

W-2065-0807 P-32706

Figure PM-47

To check or replace the fuses in the right console, remove the three screws (Item 1) and remove the cover (Item 2) [Figure PM-46].

P-32701

The excavator has a 12 volt, negative ground electrical system. The electrical system is protected by fuses located in the right console and beside the b attery [Figure PM-46] & [Figure PM-47]. The fuses will protect the electrical system when there is an electrical overload.

The reason for the ov erload must be fou nd before starting the engine again.

The battery cables must be clean and tight. Check the electrolyte level in the battery. Add distilled water as needed. Remove acid or corrosion from the bat tery and cables with a sodium bicarbonate and water solution.

Put Battery Saver P/N 6664458 or grease on the battery terminals and cable ends to prevent corrosion.

107 of 168

PM-23

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Fuse And Relay Location (S/N 522311001 & Above)

ELECTRICAL SYSTEM (CONT’D) Fuse And Relay Location (S/N 522311001 & Above) (Cont’d)

REF. DESCRIPTION

Figure PM-48

P-32707

AMPERAGE

1

Interior light, radio

5

2

Auxiliary power outlet

20

3

Front lights

15

4

Rear work lights

15

5

Horn

10

6

Heater fan motor

15

7

Wiper/Washer

10

8

Control module signal input

5

9

Optional work lights and heating

K1

Front work lights

relay

K2

Rear work lights

relay

K3

Air Conditioner

relay

Always replace fuses with the same type and capacity.

Dealer Copy -- Not for Resale

Figure PM-50

Figure PM-49

1

P-32701

B-16658

To check or replace fuses beside the battery, pull up on and remove the floor mat (Item 1) [Figure PM-50].

The location and sizes are shown below and [Figure PM48] & [Figure PM-49].

108 of 168

PM-24

442 Excavator Operation and Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Figure PM-53

Fuse And Relay Location (S/N 522311001 & Above) (Cont’d) 1

2

Figure PM-51

1

3

B-16659

The location and sizes are shown below [Figure PM-52] & [Figure PM-53].

REF.

DESCRIPTION

AMPERAGE

Remove the battery compartment cover (Item 1) [Figure PM-51].

1 (FA)

Main fuse

30

2 (FB)

Pre-Heat

60

Figure PM-52

3 (K01)

Pre-Heat

relay

Always replace fuses with the same type and capacity.

1 2

3

P-32705

Remove the covers (Item 1) [Figure PM-52] for access to the two fuses.

109 of 168

PM-25

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-32702

ELECTRICAL SYSTEM (CONT’D)

Figure PM-56

Fuse And Relay Location (S/N 528611001 & Above and S/N 528911001 & Above) Figure PM-54

2

2

1

B-23196

The location and sizes are shown below [Figure PM-55] & [Figure PM-56].

P-32706

To check or replace the fuses in the right console, remove the screws (Item 1) and remove the cover (Item 2) [Figure PM-54].

Figure PM-55

P-58260

DESCRIPTION

AMPER AGE

1

Key switch, interior light, security ignition (If equipped)

10A

2

Aux power outlet, radio, heater

15A

3

Rotating beacon (If equipped)

10A

4

Flood light (Front)

15S

5

Flood light (Back)

15A

6

Fuel pump

15A

7

Horn, panel light, security ignition (If equipped)

10A

8

Heater fan

15A

9

Wiper/washer, radio

15A

10

Hyd. oil level, hyd functions, overload warning

5A

11

Travel pressure switch

5A

12

Main hyd. system

5A

13

Left and right joystick

5A

14

Air conditioning box

10A

K1

Flood light (Front)

Relay

K2

Flood light (Rear)

Relay

K3

Open

Relay

K01 Switch power

Relay

Always replace fuses with the same type and capacity.

110 of 168

PM-26

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

REF.

ELECTRICAL SYSTEM (CONT’D)

Figure PM-59

Fuse And Relay Location (S/N 528611001 & Above and S/N 528911001 & Above) (Cont’d) 1

Figure PM-57

2

3

1 P-32705

Remove the covers (Item 1) [Figure PM-59] for access to the two fuses.

P-32701

To check or replace fuses beside the battery, pull up on and remove the floor mat (Item 1) [Figure PM-57].

2

1

Figure PM-58

3 B-23197

1

The location and sizes are shown below (Item 1) [Figure PM-59] & [Figure PM-60].

P-32702

Remove the battery compartment cover (Item 1) [Figure PM-58].

REF.

DESCRIPTION

AMPERAGE

1 (FA)

Main fuse

40

2 (FB)

Pre-Heat

50

3 (K03)

Intake air heat

relay

Always replace fuses with the same type and capacity.

111 of 168

PM-27

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure PM-60

ELECTRICAL SYSTEM (CONT’D) Fuse And Relay Location (S/N 528611001 & Above and S/N 528911001 & Above) (Cont’d) Open the right side cover.

Figure PM-61

1

Dealer Copy -- Not for Resale

P-56417

Figure PM-62

1

P-56416

The location is shown below [Figure PM-61] & [Figure PM-62].

REF.

DESCRIPTION

AMPERAGE

1 (K02)

Starter, additional fueling

Relay

Always replace relays with the same type and capacity.

112 of 168

PM-28

442 Excavator Operation and Maintenance Manual

ELECTRICAL SYSTEM (CONT’D) Using A Booster Battery (Jump Starting) If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator's seat and one person to co nnect and disconnect the battery cables.

Be sure the key switch is OFF. The booster battery must be 12 volt.

Figure PM-63

Dealer Copy -- Not for Resale

1

P-32701

Pull up on and remove the floor mat (Item 1) [Figure PM63].

Figure PM-64

1

P-32702

Remove the battery compartment cover (Item 1) [Figure PM-64].

113 of 168

PM-29

442 Excavator Operation and Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Figure PM-65

Using a Booster Battery (Jump Starting) (Cont’d) 2

WARNING AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

1

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

P-32708

Connect one end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal (Item 1) [Figure PM-65] of the excavator battery.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

Connect the end of the second cable to the negative (-) terminal of the booster battery. Connect the other end of the same cable to the ex cavator frame (Item 2) [Figure PM-65] (away from the battery).

WARNING

NOTE: (See Cold Temperature Starting Procedure on Page OI-33.)

AVOID INJURY OR DEATH Keep arcs, sparks flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame.

Start the engine. After the engine has started, remove the ground (-) cable first (Item 2) [Figure PM-65].

Disconnect the cable from the excavator battery (Item 1) [Figure PM-65].

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury.

W-2066-0705

114 of 168

PM-30

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

W-2065-0807

ELECTRICAL SYSTEM (CONT’D)

Figure PM-66

Removing And Installing The Battery

IMPORTANT 1 If jump starting the excavator from a second machine: When jump starting the excavator from a battery installed in a second machine, make sure the engine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

P-32701

I-2060-0906

Pull up on and remove the floormat (Item 1) [Figure PM66].

IMPORTANT Damage to the alternator can occur if: • Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.)

• Extra battery cables (booster cables) are connected wrong.

1

I-2023-1285

P-32702

WARNING

Remove the battery compartment cover (Item 1) [Figure PM-67].

AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W-2065-0807

115 of 168

PM-31

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure PM-67

ELECTRICAL SYSTEM (CONT’D)

WARNING

Removing And Installing The Battery (Cont’d) Figure PM-68

AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

2

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

1

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W-2065-0807 P-32703

Dealer Copy -- Not for Resale

Disconnect the negative (-) cable (Item 1) [Figure PM68] first.

Disconnect the positive (+) cable (Item 2) [Figure PM68].

Figure PM-69

1

2

1

P-32704

Remove the nuts (Item 1) and remove the hold down clamp (Item 2) [Figure PM-69].

Remove the battery.

Always clean the terminals and the cable ends, even when installing a new battery.

Install the battery. Install the hold down clamp and tighten the bolts.

Connect the battery cables. Connect the negative (-) cable (Item 1) [Figure PM-68] last to prevent sparks.

116 of 168

PM-32

442 Excavator Operation and Maintenance Manual

ALTERNATOR BELT

FAN / FUEL PUMP BELT (S/N 522311001 & ABOVE)

Adjusting Belt Tension

Adjusting Belt Tension

Check the alternator belt deflection at the mid span of the belt between the crankshaft pulley and alternator pulley.

Figure PM-72

Apply approximately 33 lb. (45 mm) force to the belt. The belt should deflect 0.40 inches (10 mm).

Figure PM-70 1

1 1

Check the fan / fuel pump belt deflection mid span of the belt between the crankshaft pulley and the fuel pump pulley (Item 1) [Figure PM-72].

P-32846

Apply approximately 33 lb. (45 N) of force to the belt. The belt should deflect 0.40 inches (10 mm).

Figure PM-71 Figure PM-73

1 1

1 1

B-16596A B-16596A

Loosen the three alternator bolts (Item 1) [Figure PM-70] & [Figure PM-71] and rotate the alternator until the belt is correctly tensioned.

Loosen the two bolts (Item 1) [Figure PM-73] on the fuel pump mount. Rotate the fuel pump until the belt is correctly tensioned.

Tighten the bolts.

Tighten the bolts.

117 of 168

PM-33

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-32845

AIR CONDITIONING COMPRESSOR BELT (S/N 528611001 & Above and S/N 528911001 & Above) Adjusting Belt Tension Figure PM-74

1

P-56413

Dealer Copy -- Not for Resale

Check the air conditioning compressor belt deflection mid span of the b elt between the c rankshaft pulley and the compressor pulley (Item 1) [Figure PM-74].

Apply approximately 33 lb. (45 mm) force to the belt. The belt should deflect 0,40 inches (10 mm).

Figure PM-75

1

1

1

1 P-58069

Loosen the bolts (Item 1) [Figure PM-75] and rotate the compressor until the belt is correctly tensioned.

Tighten the bolts.

118 of 168

PM-34

442 Excavator Operation and Maintenance Manual

HYDRAULIC SYSTEM

Figure PM-77

Checking And Adding Hydraulic Oil Put the machine on a flat level surface.

Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine.

Open the rear cover.

1

Figure PM-76

P-32851

Add the correct oil to the reservoir until it is visible in the sight gauge. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-7.)

1

Check the breather cap and clean as necessary. Replace the cap if damaged.

P-32695

Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [Figure PM-76].

119 of 168

Install the reservoir cap.

Close the rear cover.

PM-35

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Clean the surface around the reservoir (breather) cap and remove the cap from the reservoir (Item 1) [Figure PM-77].

Remove the drain hose and install the cap on the hydraulic reservoir.

HYDRAULIC SYSTEM (CONT’D) Replacing The Hydraulic Oil

Add fluid to the reservoir. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-7.)

See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed.

Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine.

Open the rear cover.

WARNING

Figure PM-78

AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

1

WARNING AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

P-32899

Remove the c ap (Item 1) [Figure PM-78] from the hydraulic reservoir drain.

Figure PM-79

W-2072-0807

1 P-32900

Install the drain hose (Item 1) [Figure PM-79] on th e hydraulic reservoir. Tighten the hose until oil starts to drain from the reservoir.

Drain the fluid into a container.

Recycle or dispose of the fluid in an environmentally safe manner.

120 of 168

PM-36

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

W-2103-0508

HYDRAULIC SYSTEM (CONT’D)

Figure PM-82

Hydraulic Filter Removal (S/N 522311001 & Above) See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

1

Open the rear cover.

Figure PM-80

1 P-32855

Dealer Copy -- Not for Resale

Remove the filter (Item 1) [Figure PM-82] from the filter bowl.

P-32696

Remove the filter cover (Item 1) [Figure PM-80] and spring.

Figure PM-81

1

P-32853

Remove the filter and filter bowl (Item 1) [Figure PM-81].

121 of 168

PM-37

442 Excavator Operation and Maintenance Manual

HYDRAULIC SYSTEM (CONT’D)

Figure PM-85

Hydraulic Filter Installation (S/N 522311001 & Above) 1

Clean the filter bowl in clean solvent and dry with compressed air.

Figure PM-83

1 P-32853

Install the filter and filter bowl (Item 1) [Figure PM-85].

Figure PM-86

Inspect the O-rings (Item 1) [Figure PM-83] on th e outside and inside bottom of the filter bowl. Replace the O-rings if damaged.

Figure PM-84 1

1

P-32852

Inspect the O-ring (Item 1) [Figure PM-86]. Replace if damaged.

Figure PM-87

1

P-32855

Install a new filter (Item 1) [Figure PM-84] in the filter bowl.

P-32696

Install the spring and cover (Item 1) [Figure PM-87].

122 of 168

PM-38

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-32977

HYDRAULIC SYSTEM (CONT’D)

Figure PM-90

Hydraulic Filter Removal (S/N 528611001 & Above and S/N 528911001 & Above) See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

1

Open the rear cover.

Figure PM-88

1 P-58143

Dealer Copy -- Not for Resale

Remove the filter (Item 1) [Figure PM-90] from the filter bowl.

P-58219

Remove the filter cover (Item 1) [Figure PM-88] and spring.

Figure PM-89

1

P-58216

Remove the filter and filter bowl (Item 1) [Figure PM-89].

123 of 168

PM-39

442 Excavator Operation and Maintenance Manual

HYDRAULIC SYSTEM (CONT’D)

Figure PM-93

Hydraulic Filter Installation (S/N 528611001 & Above and S/N 528911001 & Above) Clean the filter bowl in clean solvent and dry with compressed air.

1

Figure PM-91

1

P-58143

Install the filter (Item 1) [Figure PM-93] in the filter bowl.

P-58142

1

Inspect the O-ring (Item 1) [Figure PM-91] on the outside of the filter bowl. Replace the O-rings if damaged.

Figure PM-92

P-58216

Install the filter and filter bowl (Item 1) [Figure PM-94].

1

P-58217

Install the O-ring (Item 1) [Figure PM-92] in the bottom of the new filter.

124 of 168

PM-40

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure PM-94

HYDRAULIC SYSTEM (CONT’D) Hydraulic Filter Installation (S/N 528611001 & Above and S/N 528911001 & Above) (Cont’d) Figure PM-95

1 P-58218

Dealer Copy -- Not for Resale

Inspect the O-ring (Item 1) [Figure PM-95]. Replace if damaged.

Figure PM-96

1

P-58219

Install the spring and cover (Item 1) [Figure PM-96].

125 of 168

PM-41

442 Excavator Operation and Maintenance Manual

HYDRAULIC SYSTEM (CONT’D)

Diagnostic Couplers (S/N 528611001 & Above and S/N 528911001 & Above)

Diagnostic Couplers (S/N 522311001 & Above) Open the rear cover and right side cover.

Open the rear cover and right side cover.

Figure PM-97

Figure PM-100

1 1

P-32843

Figure PM-98

P-58221

Dealer Copy -- Not for Resale

Figure PM-101

1

1

1

P-32842

Figure PM-99 P-58220

The two diagnostic couplers (Item 1) [Figure PM-100] & [Figure PM-101] are located on the hydraulic circuitry.

1 The couplers can be used to ch eck circuit pressures.

(Refer to the Service Manual)

P-33048

The four diagnostic couplers (Item 1) [Figure PM-97], [Figure PM-98] & [Figure PM-99] are located on the hydraulic circuitry.

The couplers can be used to ch eck circuit pressures.

(Refer to the Service Manual)

126 of 168

PM-42

442 Excavator Operation and Maintenance Manual

TRACK TENSION

Figure PM-103

Rubber Track Clearance NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. For the correct service interval (See SERVICE SCHEDULE on Page PM-5.)

1

NOTE: On new excavators or on excavators with new rubber tracks installed, check and adjust as needed the rubber track clearance two to three times on the first day of operation.

P-32888

Raise the blade fully and install jackstands (Item 1) [Figure PM-102] & [Figure PM-103] under the blade and track frame. Lower the boom until all machine weight is on the jackstands.

WARNING AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

Dealer Copy -- Not for Resale

Stop the engine.

W-2142-0189

Raise one side of the machine (approximately four inches) using the boom and arm.

Figure PM-102

1

P-32889

127 of 168

PM-43

442 Excavator Operation and Maintenance Manual

TRACK TENSION (CONT’D) Rubber Track Clearance (Cont'd) Figure PM-104

1

P-32891

Dealer Copy -- Not for Resale

Figure PM-105

Track Frame

0.787” (20 mm) Track Roller

Track B-14067

Measure the track sag at the third roller (Item 1) [Figure PM-104] from the front of the track frame. Do not get fingers in pinch points between the track and track roller.

Use a bolt or dowel of the appropriate size to check the gap between the contact edge of the r oller and the to p edge of the track guide lug [Figure PM-105].

Rubber track clearance 0.787 inches (20 mm).

128 of 168

PM-44

442 Excavator Operation and Maintenance Manual

TRACK TENSION (CONT’D)

Figure PM-106

Steel Track Clearance NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. For the correct service interval (See SERVICE SCHEDULE on Page PM-5.)

WARNING

1

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

NOTE: On new excavators or on excavators with new steel tracks installed, check and adjust as needed the steel track clearance two to three times on the first day of operation.

Park the excavator on a flat and level surface.

Put a s traight edge (Item 1) on the top o f the t rack surface between the rear sprocket and the to p idler wheel. Measure between the top of th e track and the bottom of the straight edge [Figure PM-107].

Steel track clearance 0.79 inches (20 mm).

129 of 168

PM-45

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

W-2142-0903

TRACK TENSION (CONT’D)

Figure PM-109

Adjustment Figure PM-107 1 1 2

P-32893

Install the track tensioning adapter (Item 1) [Figure PM109] on the end of a grease gun.

P-32891

See your Bobcat dealer for replacement track tensioning adapter (P/N 1858000054).

Remove the bottom bolt and washer (Item 2) [Figure PM-107].

Figure PM-110

Dealer Copy -- Not for Resale

Loosen the top bolt (Item 1) [Figure PM-107].

Pivot the cover out of the way.

Figure PM-108

1

P-32894

1 Install the adapter (Item 1) [Figure PM-110] on the track tensioner.

P-32892

Remove the grease fitting adapter (Item 1) [Figure PM108] from the end of a grease gun.

130 of 168

PM-46

442 Excavator Operation and Maintenance Manual

TRACK TENSION (CONT’D)

Figure PM-113

Adjustment (Cont’d) Figure PM-111

1

2

1

P-32974

To release track tension, loosen the ten sioner (Item 1) [Figure PM-113]. Do not remove the tensioner.

P-32896

After track tension has been released, remove all grease from the tensioner area.

Repeat the procedure for the other track.

1

2

P-32895

Add grease to the track tensioner until the track tension indicator (Item 1) is flush with the cylinder edge (Item 2) [Figure PM-111] & [Figure PM-112].

131 of 168

PM-47

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

NOTE: Do not remove the tensioner (Item 1) [Figure PM-113] unless pressure is released.

Figure PM-112

TRAVEL MOTOR

Draining The Travel Motor

Checking Oil Level

See Service Schedule for the correct service interval.

(See SERVICE SCHEDULE on Page PM-5.)

Figure PM-114 Figure PM-115 2

1 1 1

P-32898

Put the machine on a level surface with the plugs positioned as shown (Item 1 & 2) [Figure PM-114].

Put the machine on a level surface with the plugs positioned as shown (Item 1 & 2) [Figure PM-115].

Remove the plug (Item 1) [Figure PM-114]. the oil level should be at the bottom edge of the plug hole.

Remove both plugs (Items 1 & 2) [Figure PM-115] and drain into a container. Recycle or dispose of the fluid in an environmentally safe manner.

Remove the plug (Item 2) and add gear lube through the hole if the oil level is below the hole (Item 1) [Figure PM114]. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-7.)

After all the gear lube is removed, rotate the track motor to the position shown [Figure PM-114].

Install both plugs.

Add gear lube to the plug hole (Item 2) until the gear lube level is at the bo ttom edge of th e plug hole (Item 1) [Figure PM-114] Install and tighten the plugs.

Repeat the procedure for the other side.

Repeat the procedure for the other side.

132 of 168

PM-48

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

P-32897

LUBRICATING THE EXCAVATOR

Figure PM-118

See Service Schedule for the best performance of th e machine.(See SERVICE SCHEDULE on Page PM-5.)

Always use a good quality lithium based multipurpose grease when lubricating the machine. Apply the lubricant until extra grease shows.

7

Lubricate the following locations on th e excavator EVERY 8-10 HOURS: Figure PM-116

P-32869

1

7. Boom pivot (1) [Figure PM-118] Figure PM-119

3

P-32866 P-32898

8 Ref. Description (# of Fittings) 1. Right blade cylinder rod end (1) [Figure PM-116] 2. Right blade cylinder base end (1) [Figure PM-116] P-32868 P-32868

3. Right side blade pivot (1) [Figure PM-116] Figure PM-117 8. Boom swing pivot (2) [Figure PM-119] 4

5 6

P-32867 P-32898

4. Left blade cylinder rod end (1) [Figure PM-117] 5. Left blade cylinder base end (1) [Figure PM-117] 6. Left side blade pivot (1) [Figure PM-117]

133 of 168

PM-49

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

2

LUBRICATING THE EXCAVATOR (CONT’D)

Figure PM-122

Figure PM-120

13 12 9

10

P-32877 P-32876 P-32878

12. Boom cylinder base end (1) [Figure PM-122] 13. Arm cylinder base end (1) [Figure PM-122]

10. Boom swing cylinder rod end (1) [Figure PM-120]

Figure PM-123

Dealer Copy -- Not for Resale

9. Boom swing cylinder base end (1) [Figure PM-120]

Figure PM-121 14

11

P-32875 P-32877 P-32877

14. Arm cylinder rod end (1) [Figure PM-123] 11. Boom cylinder rod end (1) [Figure PM-121]

134 of 168

PM-50

442 Excavator Operation and Maintenance Manual

LUBRICATING THE EXCAVATOR (CONT’D)

Figure PM-126

Figure PM-124

17

15

P-32872 P-32874

17. Bucket cylinder rod end (1) [Figure PM-126] 15. Arm pivot (1) [Figure PM-124]

Figure PM-127

18 16 20

19

P-32871 P-32873

18. Bucket link pivot (1) [Figure PM-127] 16. Bucket cylinder base end (1) [Figure PM-125]

19. Bucket pivot (1) [Figure PM-127] 20. Bucket link (2) [Figure PM-127] Lubricate the following locations on th e excavator EVERY 50 HOURS:

135 of 168

PM-51

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Figure PM-125

LUBRICATING THE EXCAVATOR (CONT’D) Figure PM-128

21

22

P-32870

21. Swing circle bearing (1) [Figure PM-128]

Dealer Copy -- Not for Resale

22. Swing circle pinion (1) [Figure PM-128] Figure PM-129

23

23

P-32875

23. Door hinges (2) [Figure PM-129]

136 of 168

PM-52

442 Excavator Operation and Maintenance Manual

LUBRICATING THE ATTACHMENTS Tilt Bucket Lubrication Always use a good quality Lithium based multipurpose grease when lubricating the attachment. Apply the lubricant until extra grease shows.

Lubricate the following locations EVERY 8-10 HOURS: Figure PM-130

1

Dealer Copy -- Not for Resale

2

P-36530

1. Bucket pivot (1) [Figure PM-130] 2. Cylinder base end (1) [Figure PM-130] Figure PM-131

3

P-36531

3. Cylinder rod end (1) [Figure PM-131]

137 of 168

PM-53

442 Excavator Operation and Maintenance Manual

LUBRICATING THE ATTACHMENTS (CONT’D)

Figure PM-133

Clamshell Bucket Lubrication Always use a good quality Lithium based multipurpose grease when lubricating the attachment. Apply the lubricant until extra grease shows.

Lubricate the following locations EVERY 8-10 HOURS: Figure PM-132 2

P-36519

Figure PM-134 1

P-36518

1. Bucket pivot points (4) [Figure PM-132] 2 2 P-36520

2. Cylinder link pivots (5) [Figure PM-133] & [Figure PM-134]

138 of 168

PM-54

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

1

MACHINE SIGN TRANSLATIONS COOLANT (6811054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-14 LIFT CHART (6813628) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-4 MECHANICAL SPRING LOADED COUPLER (7130241) . . . . . . . . . MST-15 SERVICE SCHEDULE (6814224). . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 UNDERCARRIAGE COMPONENTS (6589129). . . . . . . . . . . . . . . . . MST-14 WARNING (6813577) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-3 WARNING (6807776) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-10

MACHINE SIGN TRANSLATIONS

MST-1 139 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

WARNING (6813581, 6813576, 6804233) . . . . . . . . . . . . . . . . . . . . . MST-13

Dealer Copy -- Not for Resale MST-2 140 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

WARNING (6813577)

MST-3 141 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

LIFT CHART (6813628)

MST-4 142 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

LIFT CHART (6813628) (CONT’D)

MST-5 143 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

LIFT CHART (6813628) (CONT’D)

MST-6 144 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

SERVICE SCHEDULE (6814224)

MST-7 145 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

SERVICE SCHEDULE (6813578) (CONT’D)

MST-8 146 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

SERVICE SCHEDULE (6813578) (CONT’D)

MST-9 147 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

WARNING (6807776)

MST-10 148 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

WARNING (6807776) (CONT’D)

MST-11 149 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

WARNING (6807776) (CONT’D)

MST-12 150 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

WARNING (6813581, 6813576, 6804233)

MST-13 151 of 168

442 Excavator Operation & Maintenance Manual

COOLANT (6811054)

Dealer Copy -- Not for Resale

UNDERCARRIAGE COMPONENTS (6589129)

MST-14 152 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

MECHANICAL SPRING LOADED COUPLER (7130241)

MST-15 153 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

MECHANICAL SPRING LOADED COUPLER (7130241) (CONT’D)

MST-16 154 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

MECHANICAL SPRING LOADED COUPLER (7130241) (CONT’D)

MST-17 155 of 168

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale MST-18 156 of 168

442 Excavator Operation & Maintenance Manual

SPECIFICATIONS ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS . . . . . SPEC-9

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Engine (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Engine (S/N 528611001 & Above and S/N 528911001 & Above) SPEC-4 Excavator Machine Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Hydraulic System (S/N 522311001 & Above) . . . . . . . . . . . . . . . SPEC-5 Hydraulic System (S/N 528611001 & Above and S/N 528911001& Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6

SPEC-1 157 of 168

SPECIFICATIONS

442 Excavator Operation & Maintenance Manual

Dealer Copy -- Not for Resale

FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . SPEC-7 Chart (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-7 Chart (S/N 528611001 & Above and S/N 528911001 & Above) . SPEC-8

Dealer Copy -- Not for Resale SPEC-2 158 of 168

442 Excavator Operation & Maintenance Manual

SPECIFICATIONS Excavator Machine Dimensions All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

1710” (9340)

243” (6170) 205” (5195) 107” (272)

104” (2639)

167” (4250)

286” (7260)

B-16592

159 of 168

SPEC-3

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

• •

SPECIFICATIONS (CONT’D) Performance Specifications Operating Weight w/cab (w/ 24 inch Bucket)

16534 lb. (7500 kg)

Travel Speed

Low 1.7 mph (2,7 km/hr.)

High 3.2 mph (5,2 km/hr.)

Controls Steering

Two hand levers or foot pedals

Hydraulics

Two hand operated levers (joysticks) control boom, bucket, arm and cab swing

Auxiliary Hydraulics

Electric switches in joysticks

Brakes Travel Service & Parking

Hydrostatic swing drive acts as swing brake

Service

Spring loaded multi disc brake acting as parking brake when the control lever is in neutral

Engine (S/N 522311001 & Above) Make/Model

Deutz BF4 M 1012 E

Fuel/Cooling

Diesel/Liquid (Antifreeze mixture)

Horsepower (SAE Net)

71 HP (53 kW) @ 2000 RPM

Number of Cylinders

Four

Lubrication

Pressure System W/Filter

Air Cleaner

Dry replaceable cartridge, dual element

Engine (S/N 528611001 & Above and S/N 528911001 & Above) Make/Model

Deutz BF4 M 2011

Fuel/Cooling

Diesel/Liquid (Oil cooled)

Horsepower (SAE Net)

73 HP (54 kW) @ 2200 RPM

Number of Cylinders

Four

Lubrication

Pressure System W/Filter

Air Cleaner

Dry replaceable cartridge, dual element

160 of 168

SPEC-4

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Swing

Hydraulically released, spring loaded

SPECIFICATIONS (CONT’D) Hydraulic System (S/N 522311001 & Above) Hydraulic Circuit 1 (Piston Pump)

Boom, arm, bucket, & travel functions 37.5 GPM (142 L/min.)

4060 PSI (280 bar)

Hydraulic Circuit 2 (gear pump)

Swing, blade & boom swing function 17.4 GPM (66 L/min.) (combined) 3335 PSI (230 bar)

Auxiliary Flow

26.4 GPM (100 L/min.)

Hydraulic Circuit 1 (Piston Pump)

Boom, arm, bucket, & travel functions 41.2 GPM (156 L/min.)

4060 PSI (280 bar)

Hydraulic Circuit 2 (gear pump)

Swing, blade & boom swing function 17.9 GPM (68 LPM) (combined) 3335 PSI (230 bar)

Auxiliary Flow

26.4 GPM (100 L/min.)

Hydraulic Cylinders Cylinder

Bore

Rod

Stroke

Boom

4.7” (120 mm)

2.4” (60 mm)

33.5” (850 mm)

Arm

4.5” (115 mm)

2.8” (70 mm)

26.4” (670 mm)

Bucket

3.5” (90 mm)

2.4” (60 mm)

28.3” (720 mm)

Boom Swing

4.1” (105 mm)

2.4” (60 mm)

24.6” (625 mm)

Blade

3.9” (100 mm)

2.0” (50 mm)

7.9” (200 mm)

Hydraulic Cycle Times Bucket Curl

2.2 Seconds

Bucket Dump

2.7 Seconds

Arm Retract

3.5 Seconds

Arm Extend

4.2 Seconds

Boom Raise

6.5 Seconds

Boom Lower

5.9 Seconds

Boom Swing Left

9.7 Seconds

Boom Swing Right

9.7 Seconds

Blade Raise

2.2 Seconds

Blade Lower

2.2 Seconds

Slew

10 RPM

161 of 168

SPEC-5

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Hydraulic System (S/N 528611001 & Above and S/N 528911001& Above)

SPECIFICATIONS (CONT’D) Drive System Final Drive

Each track is driven by an axial piston motor

Type of Reduction

Two stage planetary gear reduction

Max. Drawbar Pull

13613 lb. (60.5 KN)

Gradability

60%

Undercarriage Crawler

Tractor design

Rollers

Sealed rollers with box section track roller frame

Track Adjusters

Grease type track adjusters with shock absorbing recoil spring

Width

18 inch (450 mm)

No. of Shoes (Steel Track)

42

No. of Track Rollers

7

Ground Pressure Rubber Track Steel Track

4.1 PSI (0.28 bar) 4.23 PSI (0.29 bar)

Electrical System Alternator

14-volts, 55 amp, open, negative ground

Battery

12 volts - 450 CCA @ 05F (-185C)

162 of 168

SPEC-6

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

Track

FUEL, COOLANT AND LUBRICANTS Chart (S/N 522311001 & Above) Use this chart for correct selection of Fuel, Coolant and Lubricants.

Engine oil

Fuel

KIND OF FLUID

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

*Use SAE Viscosity Number as Listed With API Classification CD or Better

*Diesel Fuel

CAPACITY REFILL 10.5 qt. (10 L)

Temp. F° +15° (9°) Down to -20° (-29°) Below -20° (-29°)

No. 2 100% 50% 0%

No.1 0% 50% 100%

34 Gal. (130 L)

Cooling System

**Coolant Mixture

3 Gal. (12,0 L)

Hydraulic Tank

***Bobcat Fluid (P/N 6563328)

Tank Cap. 29 Gal. (110 L)

Drive Motors (each side)

Gear Lube

SAE - 80 W-90 LS

1.9 qt. (1,8 L)

* Engine Oil Change Interval Relating to Diesel Fuel Sulfur Content *** If Bobcat fluid (P/N 6563328) is not available, use Engine Oil SAE 10W-30/10W-40, Class SE, or better.

When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule Contents Page PM-5.

Change engine oil and filter according to the fol lowing chart if fuel sulphur content is above 0.5%.

FUEL SULPHUR CONTENT

CHANGE INTERVAL OF ENGINE & OIL FILTER

0.5 to 1.0%

1/2 of Regular Interval

Above 1.0%

1/4 of Regular Interval

163 of 168

** COOLANT MIXTURE Ethylene Glycol (Factory Installed) Add premixed coolant; 50% water and 50% et hylene glycol to the surge tank if the coolant level is low.

Use a refractometer to check the condition of ethylene glycol in the cooling system.

SPEC-7

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

RESERVOIR

FUEL, COOLANT AND LUBRICANTS (CONT’D) Chart (S/N 528611001 & Above and S/N 528911001 & Above) Use this chart for correct selection of Fuel, Coolant and Lubricants.

KIND OF FLUID

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

Engine oil/ Engine *Use SAE coolant Viscosity Number as Listed With API Classification CD or Better

Fuel

*Diesel Fuel

Hydraulic Tank

Bobcat Fluid (P/N 66903117)

Drive Motors (each side)

Gear Lube

CAPACITY REFILL 14.8 qt. (14 L) System Capacity 10 qt. (9.4 L) w/ filter oil change

Temp. F° +15° (9°) Down to -20° (-29°) Below -20° (-29°)

No. 2 100% 50% 0%

No.1 0% 50% 100%

34 Gal. (130 L)

Tank Cap. 29 Gal. (110 L) SAE - 80 W-90 LS

1.9 qt. (1,8 L)

* Engine Oil Change Interval Relating to Diesel Fuel Sulfur Content When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule Contents Page PM-5.

Change engine oil and filter according to the fol lowing chart if fuel sulphur content is above 0.5%.

FUEL SULPHUR CONTENT

CHANGE INTERVAL OF ENGINE & OIL FILTER

0.5 to 1.0%

1/2 of Regular Interval

Above 1.0%

1/4 of Regular Interval

164 of 168

SPEC-8

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

RESERVOIR

ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS The following publications are also available for your Bobcat Excavator. You can order them from your Bobcat dealer.

For the latest information on Bobcat products and the Bobcat Company, visit our web site at www.bobcat.com; you can also order Operator and Service Training materials online through www.bobcatstore.com OPERATION & MAINTENANCE MANUAL 6901800

OPERATOR’S HANDBOOK 6901803

- Gives basic operation instructions and safety warnings.

COMPACT EXCAVATOR OPERATOR TRAINING COURSE 6903186

- Complete instructions on the correct operation and the routine maintenance of the Bobcat Excavator.

SERVICE MANUAL

EXCAVATOR SERVICE SAFETY COURSE 6900916

6901801

- Intro duces Service Technicians to step-by-step basics of proper and safe excavator maintenance and servicing procedures.

- Complete maintenance instructions for your Bobcat Excavator.

OPERATOR SAFETY VIDEO 6903181

SAFETY MANUAL 6570354 - Provides basic safety instructions.

- Provide basic safety procedures and warnings for your Bobcat Excavator

OPERATOR SAFETY DVD 6904762

Provides basic safety instructions contained in a ll Bobcat Safety Videos in both English and Spanish.

165 of 168

SPEC-9

442 Excavator Operation and Maintenance Manual

Dealer Copy -- Not for Resale

- Introduces operator to step-by-step basics of Compact Excavator operation.

Dealer Copy -- Not for Resale 166 of 168

SPEC-10

442 Excavator Operation and Maintenance Manual

WARRANTY Bobcat Excavators

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company’s option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement. Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to diesel engine fuel injection pumps and injectors. The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. This warranty does not cover replacement of scheduled service items such as oil, filters, tune-up parts, and other high-wear items.

This warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any accessory or attachment not approved by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

6570375 (3-04)

167 of 168

Printed in U.S.A.

Dealer Copy -- Not for Resale

Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Excavator will be free from proven defects in material and workmanship with respect to (i) all components of the product except as otherwise specified herein for twelve (12) months, (ii) tracks for twelve (12) months on a prorated basis based on the remaining depth of the track at the time any defect is discovered, and (iii) Bobcat brand batteries, for an additional twelve (12) months after the initial twelve month warranty period, provided that Bobcat Company shall only reimburse a fixed portion of the cost of replacing the battery during such additional twelve months. The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

168 of 168

Dealer Copy -- Not for Resale