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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