Bobcat 442 Compact Excavator Repair Service Manual – 6987204

(S/N: ADBR11001 & Above – S/N: ADBS11001 & Above)
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This workshop repair service manual PDF download for the 442 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Excavator 442
S/N: ADBR11001 & Above
S/N: ADBS11001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
DELIVERY REPORT
SERIAL NUMBER LOCATIONS
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6987204 (5-10)
Total Pages : 951

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB
Description
Entering And Exiting The Excavator
Raising And Lowering The Left Console
Emergency Exit
TRANSPORTING THE EXCAVATOR
REAR COVER
Opening And Closing The Rear Cover
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SERVICE SCHEDULE
AIR CLEANER
Daily Check
Replacing The Filters
FRESH AIR FILTER
Removal And Installation
COOLING SYSTEM
Cleaning The Cooling System
Checking Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Pre-Filter Removal And Installation
Fuel Filter Removal And Installation
Draining The Fuel Tank
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Oil
Replacing The Hydraulic Oil
Hydraulic Filter Removal
Hydraulic Filter Installation
Diagnostic Couplers
LUBRICATION OF THE EXCAVATOR
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
ALTERNATOR BELT
Adjusting Belt Tension
FAN/FUEL PUMP BELT
Adjusting Belt Tension
AIR CONDITIONING COMPRESSOR BELT
Adjusting Belt Tension
CAB TILT PROCEDURE
Installing The Cab Tilt Hinges
Tilting The Cab

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
Description
BOOM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
ARM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BOOM OFFSET CYLINDER
Testing
BOOM OFFSET CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BLADE CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
RELIEF VALVES
Description
Testing The Three Spool Control Valve Main Relief Valve
Adjusting The Three Spool Control Valve Main Relief Valve
PORT RELIEF VALVES
Adjustment Procedure
PRESSURE REDUCING VALVE
Description
Testing
Adjustment
DUMP VALVE
Description
Testing
Adjustment
Removal And Installation
Parts Identification
Disassembly And Assembly
SIX SPOOL HYDRAULIC CONTROL VALVE
Removal And Installation
Control Valve Identification
Disassembly And Assembly
Left Travel And Right Travel Valve Section Disassembly And Assembly
Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly
Inlet Valve Section Disassembly And Assembly
THREE SPOOL HYDRAULIC CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
Boom Offset And Blade Valve Section Disassembly And Assembly
Inlet/Upperstructure Swing Valve Section Disassembly And Assembly
HYDRAULIC PISTON PUMP
Hydraulic Pump Work Sheet
Testing Information
Pump Testing
Load Sense Relief Valve Adjustment
Removal And Installation
Coupler Removal And Installation
Torque Limiter Valve Parts Identification
Torque Limiter Valve Removal and Installation
Torque Limiter Valve Disassembly
Torque Limiter Valve Assembly
Initial Torque Limiter Valve Setting
Pump Control Parts Identification
Pump Control Removal And Installation
Pump Control Disassembly And Assembly
Parts Identification
Disassembly
Assembly
HYDRAULIC GEAR PUMP
Removal And Installation
Parts Identification
Disassembly
Assembly
ACCUMULATOR
Description
Removal And Installation
TRAVEL MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification
Disassembly And Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR DRIVE CARRIER
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING BRAKE VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
SWING BRAKE RELEASE VALVE
Removal And Installation
SWING BRAKE RELEASE VALVE (CONT’D)
Parts Identification
Disassembly And Assembly
JOYSTICK CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
JOYSTICK LOCKOUT/TWO SPEED VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly And Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly and Assembly
TRAVEL LEVER/FOOT PEDAL VALVE
Left Travel Lever/Foot Pedal Valve Removal And Installation
Right Travel Lever/Foot Pedal Valve Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Description
SECONDARY FRONT AUXILIARY VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE
Removal And Installation
AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (CONT’D)
Parts Identification
Disassembly And Assembly
BLADE VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
BLADE FLOAT VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
BOOM OFFSET VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
BOOM LOAD HOLDING VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
OIL TEMPERATURE REGULATOR
Description
Removal And Installation
AUXILIARY HYDRAULICS SELECTOR VALVE
Removal And Installation
HYDRAULIC PISTON PUMP DRIVE COUPLER
Removal And Installation

UNDERCARRIAGE
BLADE
Removal And Installation
TRACKS
Track Lug Height
Rubber Track Clearance
Steel Track Clearance
Track Adjustment
Rubber Track Removal And Installation
TRACK FRAME
Disassembly And Assembly
Drive Sprocket Removal And Installation
TRACK IDLER
Parts Identification
Disassembly
Assembly
UPPER TRACK ROLLER
Parts Identification
Disassembly
Assembly
LOWER TRACK ROLLER
Parts Identification
Disassembly
Assembly
GREASE CYLINDER
Parts Identification
Disassembly
Assembly
TRACK DAMAGE IDENTIFICATION
Cutting Of Steel Cords
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Abrasion Of The Track Roller Side
Cuts On The Edges Of Track Roller Side

UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Removal And Installation
Swing Bearing Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Front Window Gas Strut Removal And Installation
Front Window Pivot Frame Removal And Installation
Lower Front Widow Removal And Installation
Door, Left Side, Right Side And Rear Window Removal
Door, Left Side, Right Side And Rear Window Installation
Cab Visor Removal And Installation
Top Window Removal And Installation
SEAT AND SEAT MOUNT
Removal And Installation
RIGHT CONSOLE
Description
LEFT CONSOLE
Removal And Installation
Disassembly And Assembly
Console Lockout Switch Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
Disassembly And Assembly
CONTROL LEVERS
Description
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Bushing Removal And Installation
FLOOR MAT
Removal And Installation
BOOM
Removal And Installation
Bushing Removal And Installation
ARM
Removal And Installation
Bushing Removal And Installation
BUCKET
Removal And Installation
REAR COVER
Removal And Installation
RIGHT SIDE COVER
Removal And Installation
COUNTERWEIGHT
Removal And Installation

ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location
BATTERY
Servicing
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Parts Identification
Alternator Identification
Charging System Check
Rectifier Continuity (Diode) Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Capacitor Continuity Test
Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
FRONT CAB LIGHT
Removal And Installation
Disassembly And Assembly
TWO SPEED SWITCH
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
WIPER MOTOR
Removal And Installation
BATTERY DISCONNECT SWITCH
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
E-Prom Information
OIL TEMPERATURE COMPONENTS
Sensor Testing
Gauge Testing

ENGINE SERVICE
TROUBLESHOOTING
Chart
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR/OIL COOLER
Removal And Installation
ENGINE COMPONENTS AND TESTING
Engine Compression Checking
Checking The Manifold Heater
Manifold Heater Removal And Installation
Fuel Shutoff Solenoid Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Removal
Fuel Injection Pump Timing
Fuel Injection Pump Installation
Fuel Injector Removal And Installation
Fuel Injector, Checking
Fuel Injector Disassembly
Fuel Injector Assembly
Timing Belt Inspection
Timing Belt Removal
Timing Belt Installation
Valve Clearance Adjustment
Valve Timing, Checking
Aneroid Device
ENGINE
Removal And Installation
FLYWHEEL
Removal And Installation
Flywheel Ring Gear
RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
Disassembly
Assembly
Cylinder, Checking
Camshaft Bearing, Checking
Camshaft Bearing, Removal And Installation
Control Rod Guide Bushing Removal
Control Rod Guide Bushing Installation
Rear Cover Seal Removal And Installation
Crankshaft, Checking
Connecting Rod, Checking
Piston, Checking
Piston Pin, Checking
Piston Rings Installation
Piston Installation On The Connecting Rod
Cylinder Head Disassembly
Valves, Checking
Valve Clearance Adjustment
Cylinder Head Assembly
Rocker Arm And Bracket, Checking
Front Cover Disassembly
Front Cover Assembly
Turbo Charger Removal and Installation
Crankshaft Gear Mounting Bolt Torque Procedure

HEATING, VENTILATION, AIR CONDITIONING
EVAPORATOR UNIT
Removal And Installation
Disassembly And Assembly
Evaporator Removal And Installation
Fan Removal And Installation
Switch Removal And Installation
HEATER UNIT
Removal And Installation
Disassembly And Assembly
HEATER FAN
Removal And Installation
Resistor Removal And Installation
AIR CONDITIONING FAN
Removal And Installation
Switch Removal And Installation
HEATER VALVE
Removal And Installation
AIR CONDITIONING SYSTEM FLOW
Principles
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Heater Air Filter
Air Conditioning Compressor Belt
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Compressor Drive Belt Inspection
Cleaning The Heater Coil
Cleaning The A/C Evaporator Coil
Checking The Electrical System
Engine Coolant Bypassing The Heater Valve
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Blower Motor
Gauge Pressure Related Troubleshooting
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly And Assembly
CONDENSOR
Removal And Installation
RECEIVER/DRYER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
HEATER COIL
Removal And Installation
THERMOSTAT
Removal And Installation

SPECIFICATIONS
HYDRAULIC EXCAVATOR SPECIFICATIONS
Excavator Machine Dimensions
Performance
Controls
Engine
Electrical
Hydraulic System
Hydraulic Cycle Times
Swing System
Hydraulic Cylinders
Drive System
Brake
Undercarriage
Track
Capacities
ENGINE SPECIFICATIONS
General
Fuel System
Valve, Valve Guide And Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head And Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
Governor
ENGINE BOLT TORQUE
Specifications
EXCAVATOR BOLT TORQUE
Specifications
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC FLUID SPECIFICATIONS
Specifications
FUEL, COOLANT AND LUBRICANTS
Chart
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
Revision No: 442 – 1

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