Complete workshop repair & service manual with electrical wiring diagrams for Bobcat 442 Compact Excavator. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Bobcat 442 Compact Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

6901800 (5-07) - 442 Operation & Maintenance Manual.pdf
6901801 (5-10) - 442 Service Manual.pdf
6987203 (5-09) - 442 Compact Excavator Operation & Maintenance Manual.pdf
6987204 (5-10) - 442 Compact Excavator Service Manual.pdf

EXCERPT:
"AIR CONDITIONING SYSTEM FLOW"
"Principles"
"In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit. At these five points in the system the refrigerant goes through pressure and temperature changes."
"The compressor (Item 1) takes in heated, low pressure refrigerant gas through the suction valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge valve (high pressure side) on the condenser (Item 2) [Figure 70-40-1 on Page 70-40- 3]."
"Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the refrigerant from a gas to a liquid."
"The liquid refrigerant moves on to the receiver/dryer (Item 3) where impurities such as moisture and dirt are filtered out. The receiver/dryer also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still under high pressure) flows to the expansion valve (Item 4) [Figure 70-40-1 on Page 70-40- 3]."
"The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5). As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low- pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the evaporator. The hot humid air of the machine’s cab is drawn through or blown into the evaporator by the evaporator fan (Item 6) [Figure 70-40-1 on Page 70-40-3]. Since the refrigerant is colder than the air, it absorbs the heat from the air and produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and drips into the drain pan, which directs the water out of the cab."
"The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor…”

6901800 (5-07) - 442 Operation & Maintenance Manual....2
  OPERATOR SAFETY WARNINGS....4
  CONTENTS....6
  FOREWORD....8
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....10
    REGULAR MAINTENANCE ITEMS....10
    MOTOR OIL....10
    SERIAL NUMBER LOCATIONS....12
      Excavator Serial Number....12
      Engine Serial Number....12
    DELIVERY REPORT....13
    BOBCAT EXCAVATOR IDENTIFICATION....14
    FEATURES AND ACCESSORIES....15
      Standard Items....15
      Options and Accessories....15
      Other....15
    BOBCAT APPROVED ATTACHMENTS & ACCESSORIES....15
    BUCKETS AND ATTACHMENTS AVAILABLE....15
  SAFETY....16
    SAFETY INSTRUCTIONS....18
      Before Operation....18
      Safe Operation Is The Operator’s Responsibility....19
      Safe Operation Needs A Qualified Operator....19
      Fire Prevention....20
    MACHINE SIGNS (DECALS)....21
  OPERATING INSTRUCTIONS....24
    INSTRUMENTS AND CONSOLES....26
      Left Console....26
      Right Console....27
    OPERATOR CAB....30
      Description....30
      Entering And Exiting The Excavator....30
      Raising And Lowering The Left Console....30
      Emergency Exit....31
      Cab Door....31
      Front Window....32
      Front Window Ventilation....33
      Top Window....34
      Wiper/Washer Fluid Reservoir....34
      Operation And Maintenance Manual Compartment (Early Models)....34
      Heating, Air Conditioning And Ventilation (Early Models)....35
      Heating, Air Conditioning And Ventilation (Later Models)....36
    STEERING LEVERS/FOOT PEDALS....37
      Forward And Reverse Travel....37
      Turning....37
    HYDRAULIC CONTROLS....39
      ISO Control Pattern....39
      Standard Control Pattern....40
      Quick Couplers....41
      Relieving Hydraulic Pressure....44
      Auxiliary Hydraulics....45
      Upperstructure Slew Brake....46
      Auxiliary Hydraulic Flow Control (S/N 522311001 & Above)....46
      Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above)....47
    BLADE CONTROL LEVER....48
      Operation....48
    BOOM SWING PEDAL....49
      Operation....49
    DAILY INSPECTION....50
    PRE-STARTING PROCEDURE....52
    STARTING THE ENGINE....55
      Key Switch....55
      Cold Temperature Starting Procedure....56
    OPERATING PROCEDURE....57
      Operating On Public Roads....57
      Lifting A Load....57
      Excavating....58
      Boom Offset....60
      Backfilling....61
      Driving The Excavator....61
      Operating On Slopes....62
      Operating In Water....64
    PARKING THE EXCAVATOR....64
    TRANSPORTING THE EXCAVATOR....65
    LIFTING THE EXCAVATOR....66
    ATTACHMENTS....67
      Bucket And Ripper Tooth Installation....67
      Bucket And Ripper Tooth Removal....68
      Tilt Bucket Installation....69
      Tilt Bucket Removal....70
      Tilt Bucket Operation....71
      Clamshell Bucket Installation....72
      Clamshell Bucket Removal....75
      Clamshell Bucket Operation....76
      Lifting The Clamshell Bucket....78
      Fastening The Clamshell Bucket To The Transport Vehicle....79
      Manual Spring Loaded Coupler Installation....80
      Manual Spring Loaded Coupler Removal....81
      Manual Spring Loaded Coupler Attachment Installation....82
      Manual Spring Loaded Coupler Attachment Removal....84
  PREVENTIVE MAINTENANCE....86
    MAINTENANCE SAFETY....88
    SERVICE SCHEDULE....90
    REAR COVER....91
      Opening And Closing The Rear Cover....91
    RIGHT SIDE COVER....91
      Opening And Closing The Right Side Cover....91
    AIR CLEANER....92
      Daily Check....92
      Replacing The Filters....92
    FRESH AIR FILTER....94
      Removal And Installation (S/N 522311001 & Above)....94
      Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above)....94
    FUEL SYSTEM....95
      Fuel Specifications....95
      Filling The Fuel Tank....95
      Removing Water From The Pre-Filter (S/N 522311001 & Above)....96
      Pre-Filter Removal (S/N 522311001 & Above)....97
      Pre-Filter Installation (S/N 522311001 & Above)....99
      Pre-Filter Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above)....100
      Fuel Filter Removal And Installation....100
      Draining The Fuel Tank....101
    ENGINE LUBRICATION SYSTEM....102
      Checking Engine Oil....102
      Oil Chart....102
      Replacing Oil And Filter....103
    COOLING SYSTEM....105
      Cleaning The Cooling System....105
      Checking Coolant Level (S/N 522311001 & Above)....105
      Replacing The Coolant (S/N 522311001 & Above)....106
    ELECTRICAL SYSTEM....108
      Description....108
      Fuse And Relay Location (S/N 522311001 & Above)....108
      Fuse And Relay Location (S/N 528611001 & Above and S/N 528911001 & Above)....111
      Using A Booster Battery (Jump Starting)....114
      Removing And Installing The Battery....116
    ALTERNATOR BELT....118
      Adjusting Belt Tension....118
    FAN / FUEL PUMP BELT (S/N 522311001 & Above)....118
      Adjusting Belt Tension....118
    AIR CONDITIONING COMPRESSOR BELT (S/N 528611001 & Above and S/N 528911001 & Above)....119
      Adjusting Belt Tension....119
    HYDRAULIC SYSTEM....120
      Checking And Adding Hydraulic Oil....120
      Replacing The Hydraulic Oil....121
      Hydraulic Filter Removal (S/N 522311001 & Above)....122
      Hydraulic Filter Installation (S/N 522311001 & Above)....123
      Hydraulic Filter Removal (S/N 528611001 & Above and S/N 528911001 & Above)....124
      Hydraulic Filter Installation (S/N 528611001 & Above and S/N 528911001 & Above)....125
      Diagnostic Couplers (S/N 522311001 & Above)....127
      Diagnostic Couplers (S/N 528611001 & Above and S/N 528911001 & Above)....127
    TRACK TENSION....128
      Rubber Track Clearance....128
      Steel Track Clearance....130
      Adjustment....131
    TRAVEL MOTOR....133
      Checking Oil Level....133
      Draining The Travel Motor....133
    LUBRICATING THE EXCAVATOR....134
    LUBRICATING THE ATTACHMENTS....138
      Tilt Bucket Lubrication....138
      Clamshell Bucket Lubrication....139
  MACHINE SIGN TRANSLATIONS....140
    WARNING (6813577)....142
    LIFT CHART (6813628)....143
    SERVICE SCHEDULE (6814224)....146
    WARNING (6807776)....149
    WARNING (6813581, 6813576, 6804233)....152
    UNDERCARRIAGE COMPONENTS (6589129)....153
    COOLANT (6811054)....153
    MECHANICAL SPRING LOADED COUPLER (7130241)....154
  SPECIFICATIONS....158
    SPECIFICATIONS....160
      Excavator Machine Dimensions....160
      Performance Specifications....161
      Controls....161
      Engine (S/N 522311001 & Above)....161
      Engine (S/N 528611001 & Above and S/N 528911001 & Above)....161
      Hydraulic System (S/N 522311001 & Above)....162
      Hydraulic System (S/N 528611001 & Above and S/N 528911001& Above)....162
      Hydraulic Cylinders....162
      Hydraulic Cycle Times....162
      Drive System....163
      Undercarriage....163
      Track....163
      Electrical System....163
    FUEL, COOLANT AND LUBRICANTS....164
      Chart (S/N 522311001 & Above)....164
      Chart (S/N 528611001 & Above and S/N 528911001 & Above)....165
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....166
6901801 (5-10) - 442 Service Manual....170
  MAINTENANCE SAFETY....172
  ALPHABETICAL INDEX....174
  CONTENTS....176
    FOREWORD....178
    SAFETY INSTRUCTIONS....180
    FIRE PREVENTION....182
      Maintenance....182
      Operation....182
      Electrical....182
      Hydraulic System....182
      Fueling....182
      Starting....182
      Spark Arrestor Exhaust System....182
      Welding And Grinding....183
      Fire Extinguishers....183
    SERIAL NUMBER LOCATIONS....184
      Excavator Serial Number....184
      Engine Serial Number....184
    DELIVERY REPORT....185
    BOBCAT EXCAVATOR IDENTIFICATION....186
  SAFETY & MAINTENANCE....188
    LIFTING AND BLOCKING THE EXCAVATOR....192
      Procedure....192
    LIFTING THE EXCAVATOR....194
      Procedure....194
    OPERATOR CAB....196
      Description....196
      Entering And Exiting The Excavator....196
      Raising And Lowering The Left Console....196
      Emergency Exit....197
    TRANSPORTING THE EXCAVATOR....198
    REAR COVER....200
      Opening And Closing The Rear Cover....200
    RIGHT SIDE COVER....202
      Opening And Closing The Right Side Cover....202
    SERVICE SCHEDULE....204
    AIR CLEANER....206
      Daily Check....206
      Replacing The Filters....206
    FRESH AIR FILTER (S/N 522311001 & ABOVE)....210
      Removal And Installation....210
    FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....212
      Removal And Installation....212
    COOLING SYSTEM....214
      Cleaning The Cooling System....214
      Checking Coolant Level (S/N 522311001 & Above)....214
      Replacing The Coolant (S/N 522311001 & Above)....215
    FUEL SYSTEM....218
      Fuel Specifications....218
      Filling The Fuel Tank....218
      Removing Water From The Pre-Filter (S/N 522311001 & Above)....219
      Pre-Filter Removal (S/N 522311001 & Above)....220
      Pre-Filter Installation (S/N 522311001 & Above)....221
      Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)....223
      Fuel Filter Removal And Installation....224
      Draining The Fuel Tank....225
    ENGINE LUBRICATION SYSTEM....226
      Checking Engine Oil....226
      Replacing Oil And Filter....227
    HYDRAULIC SYSTEM....230
      Checking And Adding Hydraulic Oil....230
      Replacing The Hydraulic Oil....231
      Hydraulic Filter Removal (S/N 522311001 & Above)....232
      Hydraulic Filter Installation (S/N 522311001 & Above)....233
      Hydraulic Filter Removal (S/N 528911001 & Above And S/N 528611001 & Above)....235
      Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above)....236
      Diagnostic Couplers (S/N 522311001 & Above)....238
      Diagnostic Couplers (S/N 528911001 & Above And S/N 528611001 & Above)....239
    LUBRICATION OF THE EXCAVATOR....240
    TRAVEL MOTOR....244
      Checking Oil Level....244
      Draining The Travel Motor....244
    ALTERNATOR BELT....246
      Adjusting Belt Tension....246
    FAN/FUEL PUMP BELT....248
      Adjusting Belt Tension (S/N 522311001 & Above)....248
    AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE)....250
      Adjusting Belt Tension....250
    AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....252
      Adjusting Belt Tension....252
    CAB TILT PROCEDURE....254
      Installing The Cab Tilt Hinges....254
      Tilting The Cab....255
  HYDRAULIC SYSTEM....262
    HYDRAULIC / HYDROSTATIC SCHEMATICS....270
    HYDRAULIC SYSTEM INFORMATION....274
      Troubleshooting Chart....274
      Description....279
    BOOM CYLINDER....282
      Testing....282
      Removal And Installation....284
      Parts Identification....288
      Disassembly....289
      Assembly....294
    ARM CYLINDER....300
      Testing....300
      Removal And Installation....300
      Parts Identification....304
      Disassembly....305
      Assembly....310
    BOOM OFFSET CYLINDER....316
      Testing....316
      Removal And Installation....319
      Parts Identification....323
      Disassembly....324
      Assembly....328
    BUCKET CYLINDER....336
      Testing....336
      Removal And Installation....336
      Parts Identification....340
      Disassembly....341
      Assembly....345
    BLADE CYLINDER....352
      Testing....352
      Removal And Installation....353
      Parts Identification....355
      Disassembly....356
      Assembly....361
    RELIEF VALVES....368
      Description....368
      Testing The Three Spool Control Valve Main Relief Valve....369
      Adjusting The Three Spool Control Valve Main Relief Valve....369
    PORT RELIEF VALVES....370
      Adjustment Procedure....370
    PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE)....372
      Description....372
      Testing....372
      Adjustment....373
    PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE)....374
      Description....374
      Testing....374
      Adjustment....375
    DUMP VALVE....376
      Description....376
      Testing....376
      Adjustment....376
      Removal And Installation....377
      Parts Identification....378
      Disassembly And Assembly....379
    SIX SPOOL HYDRAULIC CONTROL VALVE....384
      Removal And Installation....384
      Control Valve Identification....388
      Disassembly And Assembly....389
      Left Travel And Right Travel Valve Section Disassembly And Assembly....392
      Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly....395
      Inlet Valve Section Disassembly And Assembly....400
    THREE SPOOL HYDRAULIC CONTROL VALVE....402
      Removal And Installation....402
      Parts Identification....404
      Disassembly And Assembly....405
      Boom Offset And Blade Valve Section Disassembly And Assembly....407
      Inlet/Upperstructure Swing Valve Section Disassembly And Assembly....411
    HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE)....416
      Hydraulic Pump Work Sheet....416
      Testing Information....419
      Pump Testing....421
      Load Sense Relief Valve Adjustment....424
      Removal And Installation....430
      Coupler Removal And Installation....433
      Torque Limiter Valve Parts Identification....434
      Torque Limiter Valve Removal and Installation....435
      Torque Limiter Valve Disassembly....436
      Torque Limiter Valve Assembly....440
      Initial Torque Limiter Valve Setting....444
      Pump Control Parts Identification....446
      Pump Control Removal And Installation....447
      Pump Control Disassembly And Assembly....448
      Parts Identification....453
      Disassembly....454
      Assembly....463
    HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE)....474
      Removal And Installation....474
      Parts Identification....475
      Disassembly....476
      Assembly....485
    HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....494
      Hydraulic Pump Work Sheet....494
      Testing Information....497
      Pump Testing....498
      Load Sense Relief Valve Adjustment....501
      Removal And Installation....506
      Coupler Removal And Installation....508
      Torque Limiter Valve Parts Identification....509
      Torque Limiter Valve Removal and Installation....510
      Torque Limiter Valve Disassembly....511
      Torque Limiter Valve Assembly....515
      Initial Torque Limiter Valve Setting....519
      Pump Control Parts Identification....521
      Pump Control Removal And Installation....522
      Pump Control Disassembly And Assembly....523
      Parts Identification....528
      Disassembly....529
      Assembly....538
    HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....548
      Removal And Installation....548
      Parts Identification....550
      Disassembly....551
      Assembly....554
    ACCUMULATOR (S/N 522311001 & ABOVE)....558
      Description....558
      Removal And Installation....558
    ACCUMULATOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....560
      Description....560
      Removal And Installation....560
    TRAVEL MOTOR....562
      Removal And Installation....562
      Parts Identification....563
      Disassembly....564
      Assembly....581
    SWIVEL JOINT....600
      Removal And Installation....600
      Parts Identification....602
      Disassembly And Assembly....603
    SWING MOTOR....606
      Removal And Installation....606
      Parts Identification....608
      Disassembly....609
      Assembly....615
    SWING MOTOR DRIVE CARRIER....622
      Removal And Installation....622
      Parts Identification....624
      Disassembly....625
      Assembly....634
    SWING BRAKE VALVE....648
      Removal And Installation....648
      Parts Identification....649
      Disassembly And Assembly....650
    SWING BRAKE RELEASE VALVE....652
      Removal And Installation....652
    SWING BRAKE RELEASE VALVE (CONT’D)....653
      Parts Identification....653
      Disassembly And Assembly....654
    JOYSTICK CONTROL PATTERN SELECTOR VALVE....656
      Removal And Installation....656
      Parts Identification....657
      Disassembly And Assembly....658
    JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE)....660
      Removal And Installation....660
      Parts Identification....661
      Disassembly And Assembly....662
    JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....664
      Removal And Installation....664
      Parts Identification....666
      Disassembly And Assembly....667
    RIGHT CONTROL LEVER (JOYSTICK)....672
      Testing....672
      Handle Removal And Installation....673
      Removal And Installation....674
      Parts Identification....676
      Disassembly And Assembly....677
    LEFT CONTROL LEVER (JOYSTICK)....682
      Testing....682
      Handle Removal And Installation....683
      Removal And Installation....684
      Parts Identification....686
      Disassembly and Assembly....687
    TRAVEL LEVER/FOOT PEDAL VALVE....692
      Left Travel Lever/Foot Pedal Valve Removal And Installation....692
      Right Travel Lever/Foot Pedal Valve Removal And Installation....693
      Parts Identification....695
      Disassembly And Assembly....696
    HYDRAULIC FILTER MOUNT....700
      Removal And Installation....700
    HYDRAULIC RESERVOIR....702
      Removal And Installation....702
    OIL COOLER....708
      Description....708
    SECONDARY FRONT AUXILIARY VALVE....710
      Removal And Installation....710
      Parts Identification....711
      Disassembly And Assembly....712
    HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE)....716
      Removal And Installation....716
      Parts Identification....717
      Disassembly And Assembly....718
    AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE)....720
      Removal And Installation....720
      Parts Identification....721
      Disassembly And Assembly....722
    AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....724
      Removal And Installation....724
      Parts Identification....725
      Disassembly And Assembly....726
    BLADE VALVE....730
      Removal And Installation....730
      Parts Identification....731
      Disassembly And Assembly....732
    BLADE FLOAT VALVE....736
      Removal And Installation....736
      Parts Identification....737
      Disassembly And Assembly....738
    BOOM OFFSET VALVE....742
      Removal And Installation....742
      Parts Identification....743
      Disassembly And Assembly....744
    BOOM LOAD HOLDING VALVE....750
      Removal And Installation....750
      Parts Identification....751
      Disassembly....752
      Assembly....759
    OIL TEMPERATURE REGULATOR....766
      Description....766
      Removal And Installation....766
    AUXILIARY HYDRAULICS SELECTOR VALVE....768
      Removal And Installation....768
    HYDRAULIC PISTON PUMP DRIVE COUPLER....770
      Removal And Installation....770
  UNDERCARRIAGE....772
    BLADE....774
      Removal And Installation....774
    TRACKS....776
      Track Lug Height....776
      Rubber Track Clearance....777
      Steel Track Clearance....778
      Track Adjustment....779
      Rubber Track Removal And Installation....781
    TRACK FRAME....784
      Disassembly And Assembly....784
      Drive Sprocket Removal And Installation....788
    TRACK IDLER....790
      Parts Identification....790
      Disassembly....791
      Assembly....794
    UPPER TRACK ROLLER....800
      Parts Identification....800
      Disassembly....801
      Assembly....803
    LOWER TRACK ROLLER....808
      Parts Identification....808
      Disassembly....809
      Assembly....812
    GREASE CYLINDER....818
      Parts Identification....818
      Disassembly....819
      Assembly....820
    TRACK DAMAGE IDENTIFICATION....822
      Cutting Of Steel Cords....822
      Abrasion Of Embedded Metals....823
      Separation Of Embedded Metals....824
      Separation Of Embedded Metals Due To Corrosion....825
      Cuts On The Lug Side Rubber....826
      Cracks On The Lug Side Rubber Due To Fatigue....827
      Lug Abrasion....828
      Cracks And Cuts On The Lug Side Rubber....829
      Abrasion Of The Track Roller Side....830
      Cuts On The Edges Of Track Roller Side....831
  UPPERSTRUCTURE & SWING SECTION....834
    UPPERSTRUCTURE....836
      Removal And Installation....836
      Swing Bearing Removal And Installation....841
    CAB....844
      Removal And Installation....844
      Door Removal And Installation....851
      Front Window Removal And Installation....852
      Front Window Disassembly And Assembly (S/N 522311001 & Above)....857
      Front Window Gas Strut Removal And Installation....860
      Front Window Pivot Frame Removal And Installation....861
      Lower Front Widow Removal And Installation....862
      Door, Left Side, Right Side And Rear Window Removal....863
      Door, Left Side, Right Side And Rear Window Installation....864
      Cab Visor Removal And Installation....866
      Top Window Removal And Installation....867
    SEAT AND SEAT MOUNT....868
      Removal And Installation....868
    RIGHT CONSOLE....870
      Description....870
    LEFT CONSOLE....872
      Removal And Installation....872
      Disassembly And Assembly....877
      Console Lockout Switch Removal And Installation....879
    ENGINE SPEED CONTROL....880
      Removal And Installation....880
      Disassembly And Assembly....882
    CONTROL LEVERS....884
      Description....884
    FUEL TANK....886
      Removal And Installation....886
    HORN....890
      Removal And Installation....890
    SWING FRAME....892
      Removal And Installation....892
      Bushing Removal And Installation....896
    FLOOR MAT....898
      Removal And Installation....898
    BOOM....900
      Removal And Installation....900
      Bushing Removal And Installation....907
    ARM....908
      Removal And Installation....908
      Bushing Removal And Installation....911
    BUCKET....912
      Removal And Installation....912
    REAR COVER....914
      Removal And Installation....914
    RIGHT SIDE COVER....916
      Removal And Installation....916
    COUNTERWEIGHT....920
      Removal And Installation....920
  ELECTRICAL SYSTEM & ANALYSIS....924
    ELECTRICAL SCHEMATICS....926
    ELECTRICAL SYSTEM INFORMATION....935
      Troubleshooting Chart....935
      Description....936
      Fuse And Relay Location (S/N 522311001 & Above)....937
      Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above)....939
    BATTERY....943
      Servicing....943
      Removal And Installation....944
      Using A Booster Battery (Jump Starting)....946
    ALTERNATOR....949
      Removal And Installation (S/N 522311001 & Above)....949
      Removal And Installation (S/N 528911001 & Above And 528611001 & Above)....951
      Parts Identification....953
      Alternator Identification....954
      Charging System Check....955
      Rectifier Continuity (Diode) Test....957
      Disassembly....959
      Stator Continuity Test....965
      Stator Ground Test....965
      Rotor Continuity Test....965
      Rotor Ground Test....966
      Capacitor Continuity Test....966
      Assembly....967
    STARTER....975
      Removal And Installation (S/N 522311001 & Above)....975
      Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)....976
      Parts Identification (All Models)....977
      Disassembly (All Models)....978
      Inspection And Repair (All Models)....986
      Assembly (All Models)....988
    STARTER (S/N 528911001 & ABOVE & S/N 528611001 & ABOVE)....999
      Removal And Installation....999
    FRONT CAB LIGHT....1001
      Removal And Installation....1001
      Disassembly And Assembly....1002
    TWO SPEED SWITCH....1005
      Removal And Installation....1005
    FUEL LEVEL SENDER....1007
      Removal And Installation....1007
    WIPER MOTOR....1009
      Removal And Installation....1009
    BATTERY DISCONNECT SWITCH....1011
      Removal And Installation....1011
    INSTRUMENT PANEL....1013
      Removal And Installation....1013
      E-Prom Information....1014
  ENGINE SERVICE....1015
    TROUBLESHOOTING....1019
      Chart....1019
    MUFFLER (S/N 522311001 & ABOVE)....1021
      Removal And Installation....1021
    MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1025
      Removal And Installation....1025
    AIR CLEANER....1027
      Removal And Installation....1027
    RADIATOR/OIL COOLER (S/N 522311001 & ABOVE)....1029
      Removal And Installation....1029
    RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1037
      Removal And Installation....1037
      Hydraulic Check Valve Removal And Installation....1041
      Hydraulic Check Valve Disassembly And Assembly....1042
    ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE)....1043
      Engine Compression Checking....1043
      Checking the Glow Plugs....1045
      Glow Plug Removal And Installation....1046
      Fuel Shutoff Solenoid Checking....1047
      Fuel Shutoff Solenoid Removal And Installation....1048
      Fuel Injection Pump Removal....1049
      Fuel Injection Pump Timing....1051
      Fuel Injection Pump Installation....1057
      Fuel Injector, Checking....1060
      Fuel Injector Disassembly....1061
      Fuel Injector Assembly....1063
      Valve Clearance Adjustment....1065
      Thermostat....1066
    ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1067
      Engine Compression Checking....1067
      Checking the Manifold Heater....1069
      Manifold Heater Removal And Installation....1070
      Fuel Shutoff Solenoid Checking....1071
      Fuel Shutoff Solenoid Removal And Installation....1072
      Fuel Injection Pump Removal....1073
      Fuel Injection Pump Timing....1075
      Fuel Injection Pump Installation....1076
      Fuel Injector Removal And Installation....1079
      Fuel Injector Removal And Installation (Cont’d)....1080
      Fuel Injector, Checking....1080
      Fuel Injector Disassembly....1081
      Fuel Injector Assembly....1083
      Timing Belt Inspection....1085
      Timing Belt Removal....1086
      Timing Belt Installation....1088
      Valve Clearance Adjustment....1094
      Valve Timing, Checking....1095
      Thermostat, Oil Pressure Control Valves & Heater Connections....1097
      Aneroid Device....1100
    ENGINE (S/N 522311001 & ABOVE)....1103
      Removal And Installation....1103
    ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1113
      Removal And Installation....1113
    FLYWHEEL (S/N 522311001 & ABOVE)....1119
      Removal And Installation....1119
      Flywheel Ring Gear....1120
    FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1121
      Removal And Installation....1121
      Flywheel Ring Gear....1122
    RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE)....1123
      Deutz Engine Tools Identification Chart....1123
      Disassembly....1124
      Assembly....1131
      Cylinder, Checking....1169
      Camshaft Bearing, Checking....1170
      Camshaft Bearing, Removal And Installation....1171
      Balancing Shaft Bearing, Checking (If Equipped)....1172
      Balancing Shaft Bearing, Removal And Installation....1173
      Control Rod Guide Bushing Installation....1174
      Rear Cover Seal Removal And Installation....1176
      Rear Cover Seal Removal And Installation (Cont’d)....1177
      Crankshaft, Checking....1178
      Connecting Rod, Checking....1180
      Piston, Checking....1183
      Piston Pin, Checking....1184
      Piston Rings Installation....1185
      Piston Installation On The Connecting Rod....1186
      Cylinder Head Disassembly....1187
      Valves, Checking....1188
      Valve Clearance Adjustment....1189
      Cylinder Head Assembly....1190
      Rocker Arm And Bracket, Checking....1191
      Front Cover Disassembly....1192
      Front Cover Assembly....1193
      Turbo Charger Removal and Installation....1194
    RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1197
      Deutz Engine Tools Identification Chart....1197
      Disassembly....1198
      Assembly....1205
      Cylinder, Checking....1224
      Camshaft Bearing, Checking....1225
      Camshaft Bearing, Removal And Installation....1226
      Control Rod Guide Bushing Removal....1227
      Control Rod Guide Bushing Installation....1229
      Rear Cover Seal Removal And Installation....1234
      Crankshaft, Checking....1235
      Connecting Rod, Checking....1237
      Piston, Checking....1240
      Piston Pin, Checking....1241
      Piston Rings Installation....1242
      Piston Installation On The Connecting Rod....1243
      Cylinder Head Disassembly....1244
      Valves, Checking....1245
      Valve Clearance Adjustment....1246
      Cylinder Head Assembly....1247
      Rocker Arm And Bracket, Checking....1249
      Front Cover Disassembly....1250
      Front Cover Assembly....1256
      Turbo Charger Removal and Installation....1266
      Crankshaft Gear Mounting Bolt Torque Procedure....1268
  HEATING, VENTILATION, AIR CONDITIONING....1271
    EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE)....1275
      Removal And Installation....1275
    EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE)....1277
      Removal And Installation....1277
      Disassembly And Assembly....1281
    HEATER/AC FAN....1287
      Removal And Installation....1287
      Resistor Removal And Installation....1289
    HEATER VALVE....1291
      Removal And Installation....1291
    AIR CONDITIONING SYSTEM FLOW....1294
      Principles....1294
      Chart....1295
    COMPONENTS (S/N 522311001 & ABOVE)....1297
      Identification....1297
    COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE)....1299
      Identification....1299
    SAFETY....1303
      Safety Equipment....1303
    REGULAR MAINTENANCE....1305
      Heater Air Filter....1305
      Air Conditioning Compressor Belt....1305
      Cleaning The Condenser....1306
    BASIC TROUBLESHOOTING....1307
      Poor A/C Performance....1307
      Compressor Drive Belt Inspection....1308
      Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above)....1308
      Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above)....1309
      Checking The Electrical System....1311
      Engine Coolant Bypassing The Heater Valve....1320
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....1323
      Compressor Oil....1323
      Compressor Oil Check....1323
      Component Replacement And Refrigeration Leaks....1325
    SYSTEM TROUBLESHOOTING CHART....1327
      Blower Motor Does Not Operate....1327
      Gauge Pressure Related Troubleshooting....1328
    TEMPERATURE/PRESSURE....1331
      Chart....1331
    AIR CONDITIONING SERVICE....1333
      Chart....1333
    SYSTEM CHARGING AND RECLAMATION....1335
      Reclamation Procedure....1335
    COMPRESSOR (S/N 522311001 & ABOVE)....1339
      Removal And Installation....1339
    COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1341
      Removal And Installation....1341
      Parts Identification....1342
      Compressor Clutch Disassembly And Assembly....1343
    CONDENSER (S/N 522311001 & ABOVE)....1347
      Removal And Installation....1347
    CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1349
      Removal And Installation....1349
    RECEIVER/DRYER (S/N 522311001 & ABOVE)....1351
      Removal And Installation....1351
    RECEIVER/DRYER (S/N 528911001 & ABOVE AND 528611001 & ABOVE))....1353
      Removal And Installation....1353
    PRESSURE SWITCH (S/N 522311001 & ABOVE)....1355
      Removal And Installation....1355
    PRESSURE SWITCH (S/N 528911001 & ABOVE AND 528611001 & ABOVE)....1357
      Removal And Installation....1357
    HEATER COIL/EVAPORATOR....1359
      Removal And Installation....1359
    THERMOSTAT....1361
      Removal And Installation....1361
    EXPANSION VALVE....1363
      Removal And Installation....1363
    UPGRADED AIR CONDITIONING SYSTEM....1365
      Evaporator Unit Removal And Installation....1365
      Disassembly And Assembly....1368
      Thermostat Removal And Installation....1371
      Evaporator Removal And Installation....1371
      Fan Removal And Installation....1372
      Switch Removal And Installation....1372
  SPECIFICATIONS....1373
    HYDRAULIC EXCAVATOR SPECIFICATIONS....1375
      Machine Dimensions....1375
      Performance....1376
      Controls....1376
      Engine (S/N 522311001 & Above)....1376
      Engine (S/N 528911001 & Above And S/N 528611001 & Above)....1377
      Electrical....1377
      Hydraulic System (S/N 522311001 & Above)....1377
      Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above)....1378
      Hydraulic Cycle Times....1378
      Swing System....1378
      Hydraulic Cylinders....1378
      Drive System....1379
      Brakes....1379
      Undercarriage....1379
      Track....1379
      Capacities (S/N 522311001 & Above)....1380
      Capacities (S/N 528911001 & Above And S/N 528611001 & Above)....1380
      Digging Force....1380
    ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)....1381
      General....1381
      Fuel System....1381
      Valve, Valve Guide and Seat Insert....1382
      Piston And Rings....1383
      Connecting Rod....1384
      Cylinder Head and Block....1384
      Crankshaft And Main Bearings....1385
      Camshaft And Bearings....1386
      Oil Pump....1386
      Governor....1386
      Engine Balancing Shaft And Bearings....1386
    ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1387
      General....1387
      Fuel System....1387
      Valve, Valve Guide and Seat Insert....1388
      Piston And Rings....1389
      Connecting Rod....1390
      Cylinder Head and Block....1390
      Crankshaft And Main Bearings....1391
      Camshaft And Bearings....1392
      Oil Pump....1392
    ENGINE BOLT TORQUE (S/N 522311001 & ABOVE)....1393
      Specifications....1393
    ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....1397
      Specifications....1397
    EXCAVATOR BOLT TORQUE....1401
      Specifications....1401
    TORQUE SPECIFICATIONS FOR BOLTS....1403
      Torque For General SAE Bolts....1403
      Torque For General Metric Bolts....1403
    HYDRAULIC FLUID SPECIFICATIONS....1405
      Specifications....1405
    FUEL, COOLANT AND LUBRICANTS....1407
      Chart (S/N 522311001 & Above)....1407
      Chart (S/N 528911001 & Above And S/N 528611001 & Above)....1409
    CONVERSIONS....1411
      Decimal And Millimeter Equivalents....1411
      U.S. To Metric Conversion....1412
  SERVICE MANUAL REVISIONS....1413
    SMR-1....1413
    SMR-2....1415
    SMR-3....1417
    SMR-4....1419
    SMR-5....1421
    SMR-6....1423
    SMR-7....1425
    SMR-8....1427
6987203 (5-09) - 442 Compact Excavator Operation & Maintenance Manual....1429
  CONTENTS....1433
  FOREWORD....1435
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....1437
    REGULAR MAINTENANCE ITEMS....1437
    ENGINE OIL....1437
    SERIAL NUMBER LOCATIONS....1439
      Excavator Serial Number....1439
      Engine Serial Number....1439
    DELIVERY REPORT....1439
    EXCAVATOR IDENTIFICATION....1440
    FEATURES, ACCESSORIES AND ATTACHMENTS....1441
      Standard Items....1441
      Options and Accessories....1441
      Attachments....1441
      Buckets Available....1441
      Falling Object Guards (FOGS)....1442
      Special Applications Kit....1442
      Special Applications Kit Inspection And Maintenance....1442
  SAFETY & TRAINING RESOURCES....1443
    SAFETY INSTRUCTIONS....1445
      Before Operation....1445
      Safe Operation Is The Operator’s Responsibility....1446
      Safe Operation Needs A Qualified Operator....1446
      Avoid Silica Dust....1447
    FIRE PREVENTION....1447
      Maintenance....1447
      Operation....1447
      Electrical....1447
      Hydraulic System....1448
      Fueling....1448
      Starting....1448
      Spark Arrestor Exhaust System....1448
      Welding And Grinding....1448
      Fire Extinguishers....1448
    MACHINE SIGNS (DECALS)....1449
    PUBLICATIONS AND TRAINING MATERIALS....1451
  OPERATING INSTRUCTIONS....1453
    INSTRUMENTS AND CONSOLES....1455
      Left Console....1455
      Right Console....1456
      Raising And Lowering The Left Console....1458
    OPERATOR CAB....1459
      Description....1459
      Cab Door....1459
      Front Window....1460
      Front Window Ventilation....1461
      Right Side Windows....1462
      Wiper/Washer Fluid Reservoir....1462
      Heating, Ventilation And Air Conditioning Duct....1463
    TRAVEL CONTROLS....1464
      Description....1464
      Forward And Reverse Travel....1464
      Turning....1464
    EMERGENCY EXIT....1466
      Right Side Window....1466
      Front Window....1466
    MOTION ALARM SYSTEM (IF EQUIPPED)....1467
      Operation....1467
    HYDRAULIC CONTROLS....1468
      Description....1468
      Standard Control Pattern....1468
      ISO Control Pattern....1469
      Quick Couplers....1470
      Auxiliary Hydraulics....1473
      Relieving Hydraulic Pressure....1474
      Upperstructure Slew Brake....1475
    BLADE CONTROL LEVER....1476
      Operation....1476
    BOOM SWING PEDAL....1476
      Operation....1476
    DAILY INSPECTION....1477
      Daily Inspection And Maintenance....1478
    PRE-STARTING PROCEDURE....1479
      Operation And Maintenance Manual And Operator’s Handbook Locations....1479
      Entering And Exiting The Excavator....1479
      Seat Adjustment....1480
      Seat Belt Adjustment....1481
      Control Console....1482
    STARTING THE ENGINE....1483
      Key Switch....1483
      Cold Temperature Starting Procedure....1484
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR....1485
      Procedure....1485
    ATTACHMENTS....1486
      Bucket And Ripper Tooth Installation....1486
      Bucket And Ripper Tooth Removal....1487
      Tilt Bucket Installation....1488
      Tilt Bucket Removal....1489
      Tilt Bucket Operation....1490
      Clamshell Bucket Installation....1491
      Clamshell Bucket Removal....1494
      Clamshell Bucket Operation....1495
      Lifting The Clamshell Bucket....1497
      Fastening The Clamshell Bucket To The Transport Vehicle....1498
      Manual Spring Loaded Coupler Installation....1499
      Manual Spring Loaded Coupler Removal....1500
      Manual Spring Loaded Coupler Attachment Installation....1501
      Manual Spring Loaded Coupler Attachment Removal....1503
    OPERATING PROCEDURE....1504
      Inspect The Work Area....1504
      Lowering The Work Equipment (Engine STOPPED)....1504
      Operating On Public Roads....1504
      Lifting A Load....1505
      Excavating....1506
      Boom Swing....1508
      Backfilling....1509
      Driving The Excavator....1509
      Operating On Slopes....1510
      Operating In Water....1512
    TOWING THE EXCAVATOR....1512
      Procedure....1512
    LIFTING THE EXCAVATOR....1513
      Procedure....1513
    TRANSPORTING THE EXCAVATOR ON A TRAILER....1514
      Loading And Unloading....1514
      Fastening....1514
  PREVENTIVE MAINTENANCE....1515
    SERVICE SCHEDULE....1519
      Chart....1519
    CONTROL CONSOLE LOCKOUTS....1520
      Inspection And Maintenance....1520
    SEAT BELT....1521
      Inspection And Maintenance....1521
    MOTION ALARM SYSTEM (IF EQUIPPED)....1522
      Description....1522
      Inspecting....1522
      Adjustment....1522
    REAR COVER....1524
      Opening And Closing....1524
    RIGHT SIDE COVER....1524
      Opening And Closing....1524
    AIR CLEANER SERVICE....1525
      Daily Check....1525
      Replacing Filter Elements....1525
    FRESH AIR FILTER....1527
      Removal And Installation....1527
    FUEL SYSTEM....1528
      Fuel Specifications....1528
      Biodiesel Blend Fuel....1528
      Filling The Fuel Tank....1529
      Pre-Filter Removal And Installation (If Equipped)....1529
      Fuel Filter Removal And Installation....1530
      Draining The Fuel Tank....1531
    ENGINE LUBRICATION SYSTEM....1532
      Checking Engine Oil....1532
      Oil Chart....1532
      Removing And Replacing Oil And Filter....1533
    ENGINE COOLING SYSTEM....1535
      Cleaning....1535
      Checking Level....1535
      Removing And Replacing Coolant....1536
    ELECTRICAL SYSTEM....1538
      Description....1538
      Fuse And Relay Location....1539
      Using A Booster Battery (Jump Starting)....1541
      Removing And Installing Battery....1543
    ALTERNATOR BELT....1545
      Adjusting Belt Tension....1545
    FAN BELT....1545
      Adjusting Belt Tension....1545
    AIR CONDITIONING COMPRESSOR BELT....1546
      Adjusting Belt Tension....1546
    HYDRAULIC SYSTEM....1547
      Checking And Adding Hydraulic Oil....1547
      Replacing The Hydraulic Oil....1548
      Hydraulic Filter Removal....1549
      Hydraulic Filter Installation....1550
      Diagnostic Couplers....1551
    TRACK TENSION....1552
      Rubber Track Clearance....1552
      Steel Track Clearance....1554
      Adjustment....1555
    TRAVEL MOTOR....1557
      Checking Oil Level....1557
      Draining The Travel Motor....1557
    LUBRICATING THE EXCAVATOR....1558
      Lubrication Locations....1558
    LUBRICATING THE ATTACHMENTS....1562
      Tilt Bucket Lubrication....1562
      Clamshell Bucket Lubrication....1563
    EXCAVATOR STORAGE AND RETURN TO SERVICE....1564
      Storage....1564
      Return to Service....1564
  MACHINE SIGN TRANSLATIONS....1565
    WARNING (6813577)....1567
    LIFT CHART (6813628)....1568
    SERVICE SCHEDULE (6814224)....1571
    WARNING (6807776)....1574
    WARNING (6813581, 6813576, 6804233)....1577
    UNDERCARRIAGE COMPONENTS (6589129)....1578
    COOLANT (6811054)....1578
    MECHANICAL SPRING LOADED COUPLER (7130241)....1579
  SPECIFICATIONS....1581
    SPECIFICATIONS....1583
      Excavator Machine Dimensions....1583
      Performance Specifications....1584
      Controls....1584
      Engine....1584
      Hydraulic System....1585
      Hydraulic Cylinders....1585
      Hydraulic Cycle Times....1586
      Electrical System....1586
      Drive System....1586
      Undercarriage....1586
      Capacities....1586
      Tracks....1587
  WARRANTY....1589
    WARRANTY....1591
  ALPHABETICAL INDEX....1593
6987204 (5-10) - 442 Compact Excavator Service Manual....1595
  MAINTENANCE SAFETY....1597
  ALPHABETICAL INDEX....1599
  CONTENTS....1601
    FOREWORD....1602
    SAFETY INSTRUCTIONS....1604
    FIRE PREVENTION....1606
      Maintenance....1606
      Operation....1606
      Electrical....1606
      Hydraulic System....1606
      Fueling....1606
      Starting....1606
      Spark Arrestor Exhaust System....1606
      Welding And Grinding....1607
      Fire Extinguishers....1607
    SERIAL NUMBER LOCATIONS....1608
      Excavator Serial Number....1608
      Engine Serial Number....1608
    DELIVERY REPORT....1609
  SAFETY AND MAINTENANCE....1611
    LIFTING AND BLOCKING THE EXCAVATOR....1613
      Procedure....1613
    LIFTING THE EXCAVATOR....1615
      Procedure....1615
    OPERATOR CAB....1617
      Description....1617
      Entering And Exiting The Excavator....1617
      Raising And Lowering The Left Console....1617
      Emergency Exit....1618
    TRANSPORTING THE EXCAVATOR....1619
    REAR COVER....1621
      Opening And Closing The Rear Cover....1621
    RIGHT SIDE COVER....1623
      Opening And Closing The Right Side Cover....1623
    SERVICE SCHEDULE....1625
    AIR CLEANER....1627
      Daily Check....1627
      Replacing The Filters....1627
    FRESH AIR FILTER....1629
      Removal And Installation....1629
    COOLING SYSTEM....1631
      Cleaning The Cooling System....1631
      Checking Coolant Level....1631
      Replacing The Coolant....1632
    FUEL SYSTEM....1635
      Fuel Specifications....1635
      Filling The Fuel Tank....1635
      Pre-Filter Removal And Installation....1636
      Fuel Filter Removal And Installation....1636
      Draining The Fuel Tank....1636
    ENGINE LUBRICATION SYSTEM....1639
      Checking Engine Oil....1639
      Oil Chart....1639
      Replacing Oil And Filter....1639
    HYDRAULIC SYSTEM....1641
      Checking And Adding Hydraulic Oil....1641
      Replacing The Hydraulic Oil....1642
      Hydraulic Filter Removal....1643
      Hydraulic Filter Installation....1644
      Diagnostic Couplers....1646
    LUBRICATION OF THE EXCAVATOR....1647
    TRAVEL MOTOR....1651
      Checking Oil Level....1651
      Draining The Travel Motor....1651
    ALTERNATOR BELT....1653
      Adjusting Belt Tension....1653
    FAN/FUEL PUMP BELT....1655
      Adjusting Belt Tension....1655
    AIR CONDITIONING COMPRESSOR BELT....1657
      Adjusting Belt Tension....1657
    CAB TILT PROCEDURE....1659
      Installing The Cab Tilt Hinges....1659
      Tilting The Cab....1660
  HYDRAULIC SYSTEM....1667
    HYDRAULIC / HYDROSTATIC SCHEMATICS....1673
    HYDRAULIC SYSTEM INFORMATION....1675
      Troubleshooting Chart....1675
      Description....1680
    BOOM CYLINDER....1683
      Testing....1683
      Removal And Installation....1685
      Parts Identification....1689
      Disassembly....1690
      Assembly....1695
    ARM CYLINDER....1701
      Testing....1701
      Removal And Installation....1701
      Parts Identification....1705
      Disassembly....1706
      Assembly....1711
    BOOM OFFSET CYLINDER....1717
      Testing....1717
    BOOM OFFSET CYLINDER....1720
      Removal And Installation....1720
      Parts Identification....1724
      Disassembly....1725
      Assembly....1729
    BUCKET CYLINDER....1737
      Testing....1737
      Removal And Installation....1737
      Parts Identification....1741
      Disassembly....1742
      Assembly....1746
    BLADE CYLINDER....1753
      Testing....1753
      Removal And Installation....1754
      Parts Identification....1756
      Disassembly....1757
      Assembly....1762
    RELIEF VALVES....1769
      Description....1769
      Testing The Three Spool Control Valve Main Relief Valve....1770
      Adjusting The Three Spool Control Valve Main Relief Valve....1770
    PORT RELIEF VALVES....1771
      Adjustment Procedure....1771
    PRESSURE REDUCING VALVE....1773
      Description....1773
      Testing....1773
      Adjustment....1774
    DUMP VALVE....1775
      Description....1775
      Testing....1775
      Adjustment....1775
      Removal And Installation....1776
      Parts Identification....1777
      Disassembly And Assembly....1778
    SIX SPOOL HYDRAULIC CONTROL VALVE....1783
      Removal And Installation....1783
      Control Valve Identification....1787
      Disassembly And Assembly....1788
      Left Travel And Right Travel Valve Section Disassembly And Assembly....1791
      Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly....1794
      Inlet Valve Section Disassembly And Assembly....1799
    THREE SPOOL HYDRAULIC CONTROL VALVE....1801
      Removal And Installation....1801
      Parts Identification....1803
      Disassembly And Assembly....1804
      Boom Offset And Blade Valve Section Disassembly And Assembly....1806
      Inlet/Upperstructure Swing Valve Section Disassembly And Assembly....1810
    HYDRAULIC PISTON PUMP....1815
      Hydraulic Pump Work Sheet....1815
      Testing Information....1818
      Pump Testing....1819
      Load Sense Relief Valve Adjustment....1822
      Removal And Installation....1827
      Coupler Removal And Installation....1829
      Torque Limiter Valve Parts Identification....1830
      Torque Limiter Valve Removal and Installation....1831
      Torque Limiter Valve Disassembly....1832
      Torque Limiter Valve Assembly....1836
      Initial Torque Limiter Valve Setting....1840
      Pump Control Parts Identification....1842
      Pump Control Removal And Installation....1843
      Pump Control Disassembly And Assembly....1844
      Parts Identification....1849
      Disassembly....1850
      Assembly....1859
    HYDRAULIC GEAR PUMP....1869
      Removal And Installation....1869
      Parts Identification....1871
      Disassembly....1872
      Assembly....1875
    ACCUMULATOR....1879
      Description....1879
      Removal And Installation....1879
    TRAVEL MOTOR....1881
      Removal And Installation....1881
      Parts Identification....1882
      Disassembly....1883
      Assembly....1900
    SWIVEL JOINT....1919
      Removal And Installation....1919
      Parts Identification....1921
      Disassembly And Assembly....1922
    SWING MOTOR....1925
      Removal And Installation....1925
      Parts Identification....1927
      Disassembly....1928
      Assembly....1934
    SWING MOTOR DRIVE CARRIER....1941
      Removal And Installation....1941
      Parts Identification....1943
      Disassembly....1944
      Assembly....1953
    SWING BRAKE VALVE....1967
      Removal And Installation....1967
      Parts Identification....1968
      Disassembly And Assembly....1969
    SWING BRAKE RELEASE VALVE....1971
      Removal And Installation....1971
    SWING BRAKE RELEASE VALVE (CONT’D)....1972
      Parts Identification....1972
      Disassembly And Assembly....1973
    JOYSTICK CONTROL PATTERN SELECTOR VALVE....1975
      Removal And Installation....1975
      Parts Identification....1976
      Disassembly And Assembly....1977
    JOYSTICK LOCKOUT/TWO SPEED VALVE....1979
      Removal And Installation....1979
      Parts Identification....1981
      Disassembly And Assembly....1982
    RIGHT CONTROL LEVER (JOYSTICK)....1987
      Testing....1987
      Handle Removal And Installation....1988
      Removal And Installation....1989
      Parts Identification....1991
      Disassembly And Assembly....1992
    LEFT CONTROL LEVER (JOYSTICK)....1997
      Testing....1997
      Handle Removal And Installation....1998
      Removal And Installation....1999
      Parts Identification....2001
      Disassembly and Assembly....2002
    TRAVEL LEVER/FOOT PEDAL VALVE....2007
      Left Travel Lever/Foot Pedal Valve Removal And Installation....2007
      Right Travel Lever/Foot Pedal Valve Removal And Installation....2008
      Parts Identification....2010
      Disassembly And Assembly....2011
    HYDRAULIC FILTER MOUNT....2015
      Removal And Installation....2015
    HYDRAULIC RESERVOIR....2017
      Removal And Installation....2017
    OIL COOLER....2023
      Description....2023
    SECONDARY FRONT AUXILIARY VALVE....2025
      Removal And Installation....2025
      Parts Identification....2026
      Disassembly And Assembly....2027
    AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE....2031
      Removal And Installation....2031
    AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (CONT’D)....2032
      Parts Identification....2032
      Disassembly And Assembly....2033
    BLADE VALVE....2037
      Removal And Installation....2037
      Parts Identification....2038
      Disassembly And Assembly....2039
    BLADE FLOAT VALVE....2043
      Removal And Installation....2043
      Parts Identification....2044
      Disassembly And Assembly....2045
    BOOM OFFSET VALVE....2049
      Removal And Installation....2049
      Parts Identification....2050
      Disassembly And Assembly....2051
    BOOM LOAD HOLDING VALVE....2057
      Removal And Installation....2057
      Parts Identification....2058
      Disassembly....2059
      Assembly....2066
    OIL TEMPERATURE REGULATOR....2073
      Description....2073
      Removal And Installation....2073
    AUXILIARY HYDRAULICS SELECTOR VALVE....2075
      Removal And Installation....2075
    HYDRAULIC PISTON PUMP DRIVE COUPLER....2077
      Removal And Installation....2077
  UNDERCARRIAGE....2079
    BLADE....2081
      Removal And Installation....2081
    TRACKS....2083
      Track Lug Height....2083
      Rubber Track Clearance....2084
      Steel Track Clearance....2085
      Track Adjustment....2086
      Rubber Track Removal And Installation....2088
    TRACK FRAME....2091
      Disassembly And Assembly....2091
      Drive Sprocket Removal And Installation....2094
    TRACK IDLER....2095
      Parts Identification....2095
      Disassembly....2096
      Assembly....2100
    UPPER TRACK ROLLER....2107
      Parts Identification....2107
      Disassembly....2108
      Assembly....2110
    LOWER TRACK ROLLER....2115
      Parts Identification....2115
      Disassembly....2116
      Assembly....2119
    GREASE CYLINDER....2125
      Parts Identification....2125
      Disassembly....2126
      Assembly....2127
    TRACK DAMAGE IDENTIFICATION....2129
      Cutting Of Steel Cords....2129
      Abrasion Of Embedded Metals....2130
      Separation Of Embedded Metals....2131
      Separation Of Embedded Metals Due To Corrosion....2132
      Cuts On The Lug Side Rubber....2133
      Cracks On The Lug Side Rubber Due To Fatigue....2134
      Lug Abrasion....2135
      Cracks And Cuts On The Lug Side Rubber....2136
      Abrasion Of The Track Roller Side....2137
      Cuts On The Edges Of Track Roller Side....2138
  UPPERSTRUCTURE & SWING SECTION....2141
    UPPERSTRUCTURE....2143
      Removal And Installation....2143
      Swing Bearing Removal And Installation....2148
    CAB....2151
      Removal And Installation....2151
      Door Removal And Installation....2157
      Front Window Removal And Installation....2158
      Front Window Gas Strut Removal And Installation....2163
      Front Window Pivot Frame Removal And Installation....2164
      Lower Front Widow Removal And Installation....2165
      Door, Left Side, Right Side And Rear Window Removal....2166
      Door, Left Side, Right Side And Rear Window Installation....2167
      Cab Visor Removal And Installation....2169
      Top Window Removal And Installation....2170
    SEAT AND SEAT MOUNT....2171
      Removal And Installation....2171
    RIGHT CONSOLE....2173
      Description....2173
    LEFT CONSOLE....2175
      Removal And Installation....2175
      Disassembly And Assembly....2180
      Console Lockout Switch Removal And Installation....2182
    ENGINE SPEED CONTROL....2183
      Removal And Installation....2183
      Disassembly And Assembly....2185
    CONTROL LEVERS....2187
      Description....2187
    FUEL TANK....2189
      Removal And Installation....2189
    HORN....2193
      Removal And Installation....2193
    SWING FRAME....2195
      Removal And Installation....2195
      Bushing Removal And Installation....2199
    FLOOR MAT....2201
      Removal And Installation....2201
    BOOM....2203
      Removal And Installation....2203
      Bushing Removal And Installation....2210
    ARM....2211
      Removal And Installation....2211
      Bushing Removal And Installation....2214
    BUCKET....2215
      Removal And Installation....2215
    REAR COVER....2217
      Removal And Installation....2217
    RIGHT SIDE COVER....2219
      Removal And Installation....2219
    COUNTERWEIGHT....2223
      Removal And Installation....2223
  ELECTRICAL SYSTEM AND ANALYSIS....2227
    ELECTRICAL SCHEMATICS....2229
    ELECTRICAL SYSTEM INFORMATION....2234
      Troubleshooting Chart....2234
      Description....2235
      Fuse And Relay Location....2236
    BATTERY....2240
      Servicing....2240
      Removal And Installation....2241
      Using A Booster Battery (Jump Starting)....2243
    ALTERNATOR....2246
      Removal And Installation....2246
      Parts Identification....2248
      Alternator Identification....2249
      Charging System Check....2249
      Rectifier Continuity (Diode) Test....2251
      Disassembly....2253
      Stator Continuity Test....2259
      Stator Ground Test....2259
      Rotor Continuity Test....2259
      Rotor Ground Test....2260
      Capacitor Continuity Test....2260
      Assembly....2261
    STARTER....2268
      Removal And Installation....2268
      Parts Identification....2269
      Disassembly....2270
      Inspection And Repair....2278
      Assembly....2280
    FRONT CAB LIGHT....2290
      Removal And Installation....2290
      Disassembly And Assembly....2291
    TWO SPEED SWITCH....2294
      Removal And Installation....2294
    FUEL LEVEL SENDER....2296
      Removal And Installation....2296
    WIPER MOTOR....2298
      Removal And Installation....2298
    BATTERY DISCONNECT SWITCH....2300
      Removal And Installation....2300
    INSTRUMENT PANEL....2302
      Removal And Installation....2302
      E-Prom Information....2303
    OIL TEMPERATURE COMPONENTS....2304
      Sensor Testing....2304
      Gauge Testing....2304
  ENGINE SERVICE....2306
    TROUBLESHOOTING....2308
      Chart....2308
    MUFFLER....2310
      Removal And Installation....2310
    AIR CLEANER....2312
      Removal And Installation....2312
    RADIATOR/OIL COOLER....2314
      Removal And Installation....2314
    ENGINE COMPONENTS AND TESTING....2322
      Engine Compression Checking....2322
      Checking The Manifold Heater....2324
      Manifold Heater Removal And Installation....2325
      Fuel Shutoff Solenoid Checking....2326
      Fuel Shutoff Solenoid Removal And Installation....2327
      Fuel Injection Pump Removal....2328
      Fuel Injection Pump Timing....2330
      Fuel Injection Pump Installation....2331
      Fuel Injector Removal And Installation....2334
      Fuel Injector, Checking....2335
      Fuel Injector Disassembly....2336
      Fuel Injector Assembly....2337
      Timing Belt Inspection....2339
      Timing Belt Removal....2340
      Timing Belt Installation....2342
      Valve Clearance Adjustment....2348
      Valve Timing, Checking....2349
      Aneroid Device....2351
    ENGINE....2356
      Removal And Installation....2356
    FLYWHEEL....2362
      Removal And Installation....2362
      Flywheel Ring Gear....2363
    RECONDITIONING THE ENGINE....2364
      Deutz Engine Tools Identification Chart....2364
      Disassembly....2365
      Assembly....2372
      Cylinder, Checking....2390
      Camshaft Bearing, Checking....2391
      Camshaft Bearing, Removal And Installation....2392
      Control Rod Guide Bushing Removal....2393
      Control Rod Guide Bushing Installation....2395
      Rear Cover Seal Removal And Installation....2400
      Crankshaft, Checking....2402
      Connecting Rod, Checking....2404
      Piston, Checking....2407
      Piston Pin, Checking....2408
      Piston Rings Installation....2409
      Piston Installation On The Connecting Rod....2410
      Cylinder Head Disassembly....2411
      Valves, Checking....2412
      Valve Clearance Adjustment....2413
      Cylinder Head Assembly....2414
      Rocker Arm And Bracket, Checking....2416
      Front Cover Disassembly....2417
      Front Cover Assembly....2423
      Turbo Charger Removal and Installation....2433
      Crankshaft Gear Mounting Bolt Torque Procedure....2436
  HEATING, VENTILATION, AIR CONDITIONING....2438
    EVAPORATOR UNIT....2440
      Removal And Installation....2440
      Disassembly And Assembly....2443
      Evaporator Removal And Installation....2445
      Fan Removal And Installation....2446
      Switch Removal And Installation....2446
    HEATER UNIT....2448
      Removal And Installation....2448
      Disassembly And Assembly....2452
    HEATER FAN....2458
      Removal And Installation....2458
      Resistor Removal And Installation....2460
    AIR CONDITIONING FAN....2462
      Removal And Installation....2462
      Switch Removal And Installation....2462
    HEATER VALVE....2464
      Removal And Installation....2464
    AIR CONDITIONING SYSTEM FLOW....2467
      Principles....2467
      Chart....2468
    COMPONENTS....2470
      Identification....2470
    SAFETY....2474
      Safety Equipment....2474
    REGULAR MAINTENANCE....2476
      Heater Air Filter....2476
      Air Conditioning Compressor Belt....2476
      Cleaning The Condenser....2477
    BASIC TROUBLESHOOTING....2478
      Poor A/C Performance....2478
      Compressor Drive Belt Inspection....2479
      Cleaning The Heater Coil....2480
      Cleaning The A/C Evaporator Coil....2480
      Checking The Electrical System....2481
      Engine Coolant Bypassing The Heater Valve....2490
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....2492
      Compressor Oil....2492
      Compressor Oil Check....2492
      Component Replacement And Refrigeration Leaks....2494
    SYSTEM TROUBLESHOOTING CHART....2496
      Blower Motor....2496
      Gauge Pressure Related Troubleshooting....2497
    TEMPERATURE/PRESSURE....2500
      Chart....2500
    AIR CONDITIONING SERVICE....2502
      Chart....2502
    SYSTEM CHARGING AND RECLAMATION....2504
      Reclamation Procedure....2504
    COMPRESSOR....2508
      Removal And Installation....2508
      Compressor Clutch Disassembly And Assembly....2509
    CONDENSOR....2512
      Removal And Installation....2512
    RECEIVER/DRYER....2514
      Removal And Installation....2514
    PRESSURE SWITCH....2516
      Removal And Installation....2516
    HEATER COIL....2518
      Removal And Installation....2518
    THERMOSTAT....2520
      Removal And Installation....2520
  SPECIFICATIONS....2522
    HYDRAULIC EXCAVATOR SPECIFICATIONS....2524
      Excavator Machine Dimensions....2524
      Performance....2525
      Controls....2525
      Engine....2525
      Electrical....2526
      Hydraulic System....2526
      Hydraulic Cycle Times....2526
      Swing System....2526
      Hydraulic Cylinders....2527
      Drive System....2527
      Brake....2527
      Undercarriage....2527
      Track....2527
      Capacities....2527
    ENGINE SPECIFICATIONS....2528
      General....2528
      Fuel System....2528
      Valve, Valve Guide And Seat Insert....2528
      Piston And Rings....2529
      Connecting Rod....2529
      Cylinder Head And Block....2529
      Crankshaft And Main Bearings....2530
      Camshaft And Bearings....2530
      Oil Pump....2530
      Governor....2530
    ENGINE BOLT TORQUE....2532
      Specifications....2532
    EXCAVATOR BOLT TORQUE....2534
      Specifications....2534
    TORQUE SPECIFICATIONS FOR BOLTS....2536
      Torque For General SAE Bolts....2536
      Torque For General Metric Bolts....2536
    HYDRAULIC FLUID SPECIFICATIONS....2538
      Specifications....2538
    FUEL, COOLANT AND LUBRICANTS....2540
      Chart....2540
    CONVERSIONS....2542
      Decimal And Millimeter Equivalents....2542
      U.S. To Metric Conversion....2543
  SERVICE MANUAL REVISION....2544
    Revision No: 442 - 1....2544