Bobcat 442 Excavator Service Manual 6901801 (5-10) – PDF DOWNLOAD

Description

Bobcat 442 Excavator Service Manual 6901801 (5-10) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 442 Excavator Service Manual 6901801 (5-10) – PDF DOWNLOAD

Language : English
Pages :1259
Downloadable : Yes
File Type : PDF
Size: 35.5 MB

DESCRIPTION:

Bobcat 442 Excavator Service Manual 6901801 (5-10) – PDF DOWNLOAD

S/N 522311001 & Above
S/N 528911001 & Above
S/N 528611001 & Above

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.

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

TABLE OF CONTENTS:

Bobcat 442 Excavator Service Manual 6901801 (5-10) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB 27
Description 27
Entering And Exiting The Excavator 27
Raising And Lowering The Left Console 27
Emergency Exit 28
TRANSPORTING THE EXCAVATOR 29
REAR COVER 31
Opening And Closing The Rear Cover 31
RIGHT SIDE COVER 33
Opening And Closing The Right Side Cover 33
SERVICE SCHEDULE 35
AIR CLEANER 37
Daily Check 37
Replacing The Filters 37
FRESH AIR FILTER (S/N 522311001 & ABOVE) 41
Removal And Installation 41
FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 43
Removal And Installation 43
COOLING SYSTEM 45
Cleaning The Cooling System 45
Checking Coolant Level (S/N 522311001 & Above) 45
Replacing The Coolant (S/N 522311001 & Above) 46
FUEL SYSTEM 49
Fuel Specifications 49
Filling The Fuel Tank 49
Removing Water From The Pre-Filter (S/N 522311001 & Above) 50
Pre-Filter Removal (S/N 522311001 & Above) 51
Pre-Filter Installation (S/N 522311001 & Above) 52
Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) 54
Fuel Filter Removal And Installation 55
Draining The Fuel Tank 56
ENGINE LUBRICATION SYSTEM 57
Checking Engine Oil 57
Replacing Oil And Filter 58
HYDRAULIC SYSTEM 61
Checking And Adding Hydraulic Oil 61
Replacing The Hydraulic Oil 62
Hydraulic Filter Removal (S/N 522311001 & Above) 63
Hydraulic Filter Installation (S/N 522311001 & Above) 64
Hydraulic Filter Removal (S/N 528911001 & Above And S/N 528611001 & Above) 66
Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above) 67
Diagnostic Couplers (S/N 522311001 & Above) 69
Diagnostic Couplers (S/N 528911001 & Above And S/N 528611001 & Above) 70
LUBRICATION OF THE EXCAVATOR 71
TRAVEL MOTOR 75
Checking Oil Level 75
Draining The Travel Motor 75
ALTERNATOR BELT 77
Adjusting Belt Tension 77
FAN/FUEL PUMP BELT 79
Adjusting Belt Tension (S/N 522311001 & Above) 79
AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE) 81
Adjusting Belt Tension 81
AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 83
Adjusting Belt Tension 83
CAB TILT PROCEDURE 85
Installing The Cab Tilt Hinges 85
Tilting The Cab 86
HYDRAULIC SYSTEM 93
HYDRAULIC / HYDROSTATIC SCHEMATICS 101
HYDRAULIC SYSTEM INFORMATION 105
Troubleshooting Chart 105
Description 110
BOOM CYLINDER 113
Testing 113
Removal And Installation 115
Parts Identification 119
Disassembly 120
Assembly 125
ARM CYLINDER 131
Testing 131
Removal And Installation 131
Parts Identification 135
Disassembly 136
Assembly 141
BOOM OFFSET CYLINDER 147
Testing 147
Removal And Installation 150
Parts Identification 154
Disassembly 155
Assembly 159
BUCKET CYLINDER 167
Testing 167
Removal And Installation 167
Parts Identification 171
Disassembly 172
Assembly 176
BLADE CYLINDER 183
Testing 183
Removal And Installation 184
Parts Identification 186
Disassembly 187
Assembly 192
RELIEF VALVES 199
Description 199
Testing The Three Spool Control Valve Main Relief Valve 200
Adjusting The Three Spool Control Valve Main Relief Valve 200
PORT RELIEF VALVES 201
Adjustment Procedure 201
PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE) 203
Description 203
Testing 203
Adjustment 204
PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE) 205
Description 205
Testing 205
Adjustment 206
DUMP VALVE 207
Description 207
Testing 207
Adjustment 207
Removal And Installation 208
Parts Identification 209
Disassembly And Assembly 210
SIX SPOOL HYDRAULIC CONTROL VALVE 215
Removal And Installation 215
Control Valve Identification 219
Disassembly And Assembly 220
Left Travel And Right Travel Valve Section Disassembly And Assembly 223
Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly 226
Inlet Valve Section Disassembly And Assembly 231
THREE SPOOL HYDRAULIC CONTROL VALVE 233
Removal And Installation 233
Parts Identification 235
Disassembly And Assembly 236
Boom Offset And Blade Valve Section Disassembly And Assembly 238
Inlet/Upperstructure Swing Valve Section Disassembly And Assembly 242
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) 247
Hydraulic Pump Work Sheet 247
Testing Information 250
Pump Testing 252
Load Sense Relief Valve Adjustment 255
Removal And Installation 261
Coupler Removal And Installation 264
Torque Limiter Valve Parts Identification 265
Torque Limiter Valve Removal and Installation 266
Torque Limiter Valve Disassembly 267
Torque Limiter Valve Assembly 271
Initial Torque Limiter Valve Setting 275
Pump Control Parts Identification 277
Pump Control Removal And Installation 278
Pump Control Disassembly And Assembly 279
Parts Identification 284
Disassembly 285
Assembly 294
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) 305
Removal And Installation 305
Parts Identification 306
Disassembly 307
Assembly 316
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 325
Hydraulic Pump Work Sheet 325
Testing Information 328
Pump Testing 329
Load Sense Relief Valve Adjustment 332
Removal And Installation 337
Coupler Removal And Installation 339
Torque Limiter Valve Parts Identification 340
Torque Limiter Valve Removal and Installation 341
Torque Limiter Valve Disassembly 342
Torque Limiter Valve Assembly 346
Initial Torque Limiter Valve Setting 350
Pump Control Parts Identification 352
Pump Control Removal And Installation 353
Pump Control Disassembly And Assembly 354
Parts Identification 359
Disassembly 360
Assembly 369
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 379
Removal And Installation 379
Parts Identification 381
Disassembly 382
Assembly 385
ACCUMULATOR (S/N 522311001 & ABOVE) 389
Description 389
Removal And Installation 389
ACCUMULATOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 391
Description 391
Removal And Installation 391
TRAVEL MOTOR 393
Removal And Installation 393
Parts Identification 394
Disassembly 395
Assembly 412
SWIVEL JOINT 431
Removal And Installation 431
Parts Identification 433
Disassembly And Assembly 434
SWING MOTOR 437
Removal And Installation 437
Parts Identification 439
Disassembly 440
Assembly 446
SWING MOTOR DRIVE CARRIER 453
Removal And Installation 453
Parts Identification 455
Disassembly 456
Assembly 465
SWING BRAKE VALVE 479
Removal And Installation 479
Parts Identification 480
Disassembly And Assembly 481
SWING BRAKE RELEASE VALVE 483
Removal And Installation 483
SWING BRAKE RELEASE VALVE (CONT’D) 484
Parts Identification 484
Disassembly And Assembly 485
JOYSTICK CONTROL PATTERN SELECTOR VALVE 487
Removal And Installation 487
Parts Identification 488
Disassembly And Assembly 489
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) 491
Removal And Installation 491
Parts Identification 492
Disassembly And Assembly 493
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 495
Removal And Installation 495
Parts Identification 497
Disassembly And Assembly 498
RIGHT CONTROL LEVER (JOYSTICK) 503
Testing 503
Handle Removal And Installation 504
Removal And Installation 505
Parts Identification 507
Disassembly And Assembly 508
LEFT CONTROL LEVER (JOYSTICK) 513
Testing 513
Handle Removal And Installation 514
Removal And Installation 515
Parts Identification 517
Disassembly and Assembly 518
TRAVEL LEVER/FOOT PEDAL VALVE 523
Left Travel Lever/Foot Pedal Valve Removal And Installation 523
Right Travel Lever/Foot Pedal Valve Removal And Installation 524
Parts Identification 526
Disassembly And Assembly 527
HYDRAULIC FILTER MOUNT 531
Removal And Installation 531
HYDRAULIC RESERVOIR 533
Removal And Installation 533
OIL COOLER 539
Description 539
SECONDARY FRONT AUXILIARY VALVE 541
Removal And Installation 541
Parts Identification 542
Disassembly And Assembly 543
HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE) 547
Removal And Installation 547
Parts Identification 548
Disassembly And Assembly 549
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE) 551
Removal And Installation 551
Parts Identification 552
Disassembly And Assembly 553
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 555
Removal And Installation 555
Parts Identification 556
Disassembly And Assembly 557
BLADE VALVE 561
Removal And Installation 561
Parts Identification 562
Disassembly And Assembly 563
BLADE FLOAT VALVE 567
Removal And Installation 567
Parts Identification 568
Disassembly And Assembly 569
BOOM OFFSET VALVE 573
Removal And Installation 573
Parts Identification 574
Disassembly And Assembly 575
BOOM LOAD HOLDING VALVE 581
Removal And Installation 581
Parts Identification 582
Disassembly 583
Assembly 590
OIL TEMPERATURE REGULATOR 597
Description 597
Removal And Installation 597
AUXILIARY HYDRAULICS SELECTOR VALVE 599
Removal And Installation 599
HYDRAULIC PISTON PUMP DRIVE COUPLER 601
Removal And Installation 601
UNDERCARRIAGE 603
BLADE 605
Removal And Installation 605
TRACKS 607
Track Lug Height 607
Rubber Track Clearance 608
Steel Track Clearance 609
Track Adjustment 610
Rubber Track Removal And Installation 612
TRACK FRAME 615
Disassembly And Assembly 615
Drive Sprocket Removal And Installation 619
TRACK IDLER 621
Parts Identification 621
Disassembly 622
Assembly 625
UPPER TRACK ROLLER 631
Parts Identification 631
Disassembly 632
Assembly 634
LOWER TRACK ROLLER 639
Parts Identification 639
Disassembly 640
Assembly 643
GREASE CYLINDER 649
Parts Identification 649
Disassembly 650
Assembly 651
TRACK DAMAGE IDENTIFICATION 653
Cutting Of Steel Cords 653
Abrasion Of Embedded Metals 654
Separation Of Embedded Metals 655
Separation Of Embedded Metals Due To Corrosion 656
Cuts On The Lug Side Rubber 657
Cracks On The Lug Side Rubber Due To Fatigue 658
Lug Abrasion 659
Cracks And Cuts On The Lug Side Rubber 660
Abrasion Of The Track Roller Side 661
Cuts On The Edges Of Track Roller Side 662
UPPERSTRUCTURE & SWING SECTION 665
UPPERSTRUCTURE 667
Removal And Installation 667
Swing Bearing Removal And Installation 672
CAB 675
Removal And Installation 675
Door Removal And Installation 682
Front Window Removal And Installation 683
Front Window Disassembly And Assembly (S/N 522311001 & Above) 688
Front Window Gas Strut Removal And Installation 691
Front Window Pivot Frame Removal And Installation 692
Lower Front Widow Removal And Installation 693
Door, Left Side, Right Side And Rear Window Removal 694
Door, Left Side, Right Side And Rear Window Installation 695
Cab Visor Removal And Installation 697
Top Window Removal And Installation 698
SEAT AND SEAT MOUNT 699
Removal And Installation 699
RIGHT CONSOLE 701
Description 701
LEFT CONSOLE 703
Removal And Installation 703
Disassembly And Assembly 708
Console Lockout Switch Removal And Installation 710
ENGINE SPEED CONTROL 711
Removal And Installation 711
Disassembly And Assembly 713
CONTROL LEVERS 715
Description 715
FUEL TANK 717
Removal And Installation 717
HORN 721
Removal And Installation 721
SWING FRAME 723
Removal And Installation 723
Bushing Removal And Installation 727
FLOOR MAT 729
Removal And Installation 729
BOOM 731
Removal And Installation 731
Bushing Removal And Installation 738
ARM 739
Removal And Installation 739
Bushing Removal And Installation 742
BUCKET 743
Removal And Installation 743
REAR COVER 745
Removal And Installation 745
RIGHT SIDE COVER 747
Removal And Installation 747
COUNTERWEIGHT 751
Removal And Installation 751
ELECTRICAL SYSTEM & ANALYSIS 755
ELECTRICAL SCHEMATICS 757
ELECTRICAL SYSTEM INFORMATION 766
Troubleshooting Chart 766
Description 767
Fuse And Relay Location (S/N 522311001 & Above) 768
Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above) 770
BATTERY 774
Servicing 774
Removal And Installation 775
Using A Booster Battery (Jump Starting) 777
ALTERNATOR 780
Removal And Installation (S/N 522311001 & Above) 780
Removal And Installation (S/N 528911001 & Above And 528611001 & Above) 782
Parts Identification 784
Alternator Identification 785
Charging System Check 786
Rectifier Continuity (Diode) Test 788
Disassembly 790
Stator Continuity Test 796
Stator Ground Test 796
Rotor Continuity Test 796
Rotor Ground Test 797
Capacitor Continuity Test 797
Assembly 798
STARTER 806
Removal And Installation (S/N 522311001 & Above) 806
Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) 807
Parts Identification (All Models) 808
Disassembly (All Models) 809
Inspection And Repair (All Models) 817
Assembly (All Models) 819
STARTER (S/N 528911001 & ABOVE & S/N 528611001 & ABOVE) 830
Removal And Installation 830
FRONT CAB LIGHT 832
Removal And Installation 832
Disassembly And Assembly 833
TWO SPEED SWITCH 836
Removal And Installation 836
FUEL LEVEL SENDER 838
Removal And Installation 838
WIPER MOTOR 840
Removal And Installation 840
BATTERY DISCONNECT SWITCH 842
Removal And Installation 842
INSTRUMENT PANEL 844
Removal And Installation 844
E-Prom Information 845
ENGINE SERVICE 846
TROUBLESHOOTING 850
Chart 850
MUFFLER (S/N 522311001 & ABOVE) 852
Removal And Installation 852
MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 856
Removal And Installation 856
AIR CLEANER 858
Removal And Installation 858
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) 860
Removal And Installation 860
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 868
Removal And Installation 868
Hydraulic Check Valve Removal And Installation 872
Hydraulic Check Valve Disassembly And Assembly 873
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) 874
Engine Compression Checking 874
Checking the Glow Plugs 876
Glow Plug Removal And Installation 877
Fuel Shutoff Solenoid Checking 878
Fuel Shutoff Solenoid Removal And Installation 879
Fuel Injection Pump Removal 880
Fuel Injection Pump Timing 882
Fuel Injection Pump Installation 888
Fuel Injector, Checking 891
Fuel Injector Disassembly 892
Fuel Injector Assembly 894
Valve Clearance Adjustment 896
Thermostat 897
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 898
Engine Compression Checking 898
Checking the Manifold Heater 900
Manifold Heater Removal And Installation 901
Fuel Shutoff Solenoid Checking 902
Fuel Shutoff Solenoid Removal And Installation 903
Fuel Injection Pump Removal 904
Fuel Injection Pump Timing 906
Fuel Injection Pump Installation 907
Fuel Injector Removal And Installation 910
Fuel Injector Removal And Installation (Cont’d) 911
Fuel Injector, Checking 911
Fuel Injector Disassembly 912
Fuel Injector Assembly 914
Timing Belt Inspection 916
Timing Belt Removal 917
Timing Belt Installation 919
Valve Clearance Adjustment 925
Valve Timing, Checking 926
Thermostat, Oil Pressure Control Valves & Heater Connections 928
Aneroid Device 931
ENGINE (S/N 522311001 & ABOVE) 934
Removal And Installation 934
ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 944
Removal And Installation 944
FLYWHEEL (S/N 522311001 & ABOVE) 950
Removal And Installation 950
Flywheel Ring Gear 951
FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 952
Removal And Installation 952
Flywheel Ring Gear 953
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) 954
Deutz Engine Tools Identification Chart 954
Disassembly 955
Assembly 962
Cylinder, Checking 1000
Camshaft Bearing, Checking 1001
Camshaft Bearing, Removal And Installation 1002
Balancing Shaft Bearing, Checking (If Equipped) 1003
Balancing Shaft Bearing, Removal And Installation 1004
Control Rod Guide Bushing Installation 1005
Rear Cover Seal Removal And Installation 1007
Rear Cover Seal Removal And Installation (Cont’d) 1008
Crankshaft, Checking 1009
Connecting Rod, Checking 1011
Piston, Checking 1014
Piston Pin, Checking 1015
Piston Rings Installation 1016
Piston Installation On The Connecting Rod 1017
Cylinder Head Disassembly 1018
Valves, Checking 1019
Valve Clearance Adjustment 1020
Cylinder Head Assembly 1021
Rocker Arm And Bracket, Checking 1022
Front Cover Disassembly 1023
Front Cover Assembly 1024
Turbo Charger Removal and Installation 1025
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 1028
Deutz Engine Tools Identification Chart 1028
Disassembly 1029
Assembly 1036
Cylinder, Checking 1055
Camshaft Bearing, Checking 1056
Camshaft Bearing, Removal And Installation 1057
Control Rod Guide Bushing Removal 1058
Control Rod Guide Bushing Installation 1060
Rear Cover Seal Removal And Installation 1065
Crankshaft, Checking 1066
Connecting Rod, Checking 1068
Piston, Checking 1071
Piston Pin, Checking 1072
Piston Rings Installation 1073
Piston Installation On The Connecting Rod 1074
Cylinder Head Disassembly 1075
Valves, Checking 1076
Valve Clearance Adjustment 1077
Cylinder Head Assembly 1078
Rocker Arm And Bracket, Checking 1080
Front Cover Disassembly 1081
Front Cover Assembly 1087
Turbo Charger Removal and Installation 1097
Crankshaft Gear Mounting Bolt Torque Procedure 1099
HEATING, VENTILATION, AIR CONDITIONING 1102
EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE) 1106
Removal And Installation 1106
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) 1108
Removal And Installation 1108
Disassembly And Assembly 1112
HEATER/AC FAN 1118
Removal And Installation 1118
Resistor Removal And Installation 1120
HEATER VALVE 1122
Removal And Installation 1122
AIR CONDITIONING SYSTEM FLOW 1125
Principles 1125
Chart 1126
COMPONENTS (S/N 522311001 & ABOVE) 1128
Identification 1128
COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE) 1130
Identification 1130
SAFETY 1134
Safety Equipment 1134
REGULAR MAINTENANCE 1136
Heater Air Filter 1136
Air Conditioning Compressor Belt 1136
Cleaning The Condenser 1137
BASIC TROUBLESHOOTING 1138
Poor A/C Performance 1138
Compressor Drive Belt Inspection 1139
Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above) 1139
Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above) 1140
Checking The Electrical System 1142
Engine Coolant Bypassing The Heater Valve 1151
GENERAL AIR CONDITIONING SERVICE GUIDELINES 1154
Compressor Oil 1154
Compressor Oil Check 1154
Component Replacement And Refrigeration Leaks 1156
SYSTEM TROUBLESHOOTING CHART 1158
Blower Motor Does Not Operate 1158
Gauge Pressure Related Troubleshooting 1159
TEMPERATURE/PRESSURE 1162
Chart 1162
AIR CONDITIONING SERVICE 1164
Chart 1164
SYSTEM CHARGING AND RECLAMATION 1166
Reclamation Procedure 1166
COMPRESSOR (S/N 522311001 & ABOVE) 1170
Removal And Installation 1170
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 1172
Removal And Installation 1172
Parts Identification 1173
Compressor Clutch Disassembly And Assembly 1174
CONDENSER (S/N 522311001 & ABOVE) 1178
Removal And Installation 1178
CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 1180
Removal And Installation 1180
RECEIVER/DRYER (S/N 522311001 & ABOVE) 1182
Removal And Installation 1182
RECEIVER/DRYER (S/N 528911001 & ABOVE AND 528611001 & ABOVE)) 1184
Removal And Installation 1184
PRESSURE SWITCH (S/N 522311001 & ABOVE) 1186
Removal And Installation 1186
PRESSURE SWITCH (S/N 528911001 & ABOVE AND 528611001 & ABOVE) 1188
Removal And Installation 1188
HEATER COIL/EVAPORATOR 1190
Removal And Installation 1190
THERMOSTAT 1192
Removal And Installation 1192
EXPANSION VALVE 1194
Removal And Installation 1194
UPGRADED AIR CONDITIONING SYSTEM 1196
Evaporator Unit Removal And Installation 1196
Disassembly And Assembly 1199
Thermostat Removal And Installation 1202
Evaporator Removal And Installation 1202
Fan Removal And Installation 1203
Switch Removal And Installation 1203
SPECIFICATIONS 1204
HYDRAULIC EXCAVATOR SPECIFICATIONS 1206
Machine Dimensions 1206
Performance 1207
Controls 1207
Engine (S/N 522311001 & Above) 1207
Engine (S/N 528911001 & Above And S/N 528611001 & Above) 1208
Electrical 1208
Hydraulic System (S/N 522311001 & Above) 1208
Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above) 1209
Hydraulic Cycle Times 1209
Swing System 1209
Hydraulic Cylinders 1209
Drive System 1210
Brakes 1210
Undercarriage 1210
Track 1210
Capacities (S/N 522311001 & Above) 1211
Capacities (S/N 528911001 & Above And S/N 528611001 & Above) 1211
Digging Force 1211
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) 1212
General 1212
Fuel System 1212
Valve, Valve Guide and Seat Insert 1213
Piston And Rings 1214
Connecting Rod 1215
Cylinder Head and Block 1215
Crankshaft And Main Bearings 1216
Camshaft And Bearings 1217
Oil Pump 1217
Governor 1217
Engine Balancing Shaft And Bearings 1217
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 1218
General 1218
Fuel System 1218
Valve, Valve Guide and Seat Insert 1219
Piston And Rings 1220
Connecting Rod 1221
Cylinder Head and Block 1221
Crankshaft And Main Bearings 1222
Camshaft And Bearings 1223
Oil Pump 1223
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE) 1224
Specifications 1224
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) 1228
Specifications 1228
EXCAVATOR BOLT TORQUE 1232
Specifications 1232
TORQUE SPECIFICATIONS FOR BOLTS 1234
Torque For General SAE Bolts 1234
Torque For General Metric Bolts 1234
HYDRAULIC FLUID SPECIFICATIONS 1236
Specifications 1236
FUEL, COOLANT AND LUBRICANTS 1238
Chart (S/N 522311001 & Above) 1238
Chart (S/N 528911001 & Above And S/N 528611001 & Above) 1240
CONVERSIONS 1242
Decimal And Millimeter Equivalents 1242
U S To Metric Conversion 1243
SERVICE MANUAL REVISIONS 1244
SMR-1 1244
SMR-2 1246
SMR-3 1248
SMR-4 1250
SMR-5 1252
SMR-6 1254
SMR-7 1256
SMR-8 1258

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