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Bobcat 442 Excavator Service Manual

1,257 pages · Publication 6901801_11_07

$129.55
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Models
442
Serial coverage
SN 522311001 & above, SN 528911001 & above, SN 528611001 & above
Manual type
Service Manual
Pages
1,257
Publication
6901801_11_07
Condition
Brand new
Bobcat 442 Excavator Service Manual, publication 6901801_11_07

What's inside

From the manual's own table of contents: 16 sections, 622 entries. See sample pages (PDF, 427 KB)

MAINTENANCE SAFETY
ALPHABETICAL INDEX
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION9 topics
  • Maintenance
  • Operation
  • Electrical
  • Hydraulic System
  • Fueling
  • Starting
  • Spark Arrestor Exhaust System
  • Welding And Grinding
  • Fire Extinguishers
SERIAL NUMBER LOCATIONS2 topics
  • Excavator Serial Number
  • Engine Serial Number
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE55 topics
  • 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
    • Removal And Installation
  • COOLING SYSTEM
    • Cleaning The Cooling System
    • Checking Coolant Level (S/N 522311001 & Above)
    • Replacing The Coolant (S/N 522311001 & Above)
  • FUEL SYSTEM
    • Fuel Specifications
    • Filling The Fuel Tank
    • Removing Water From The Pre-Filter (S/N 522311001 & Above)
    • Pre-Filter Installation (S/N 522311001 & Above)
    • Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)
    • Fuel Filter Removal And Installation
    • Draining The Fuel Tank
  • ENGINE LUBRICATION SYSTEM
    • Checking Engine Oil
    • Replacing Oil And Filter
    • Checking And Adding Hydraulic Oil
    • Replacing The Hydraulic Oil
    • Hydraulic Filter Removal (S/N 522311001 & Above)
    • Hydraulic Filter Installation (S/N 522311001 & Above)
    • Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above)
    • Diagnostic Couplers (S/N 522311001 & Above)
  • 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 (S/N 522311001 & Above)
  • AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE)
    • Adjusting Belt Tension
  • AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
    • Adjusting Belt Tension
  • CAB TILT PROCEDURE
    • Installing The Cab Tilt Hinges
    • Tilting The Cab
HYDRAULIC SYSTEM216 topics
  • 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
    • 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
    • Description
    • Testing
    • Adjustment
  • PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE)
    • 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 (S/N 522311001 & ABOVE)
    • 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 (S/N 522311001 & ABOVE)
    • Removal And Installation
    • Parts Identification
    • Disassembly
    • Assembly
    • 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
    • Removal And Installation
    • Parts Identification
    • Disassembly
    • Assembly
    • Description
    • Removal And Installation
    • Description
    • 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
    • Parts Identification
    • Disassembly And Assembly
  • JOYSTICK CONTROL PATTERN SELECTOR VALVE
    • Removal And Installation
    • Parts Identification
    • Disassembly And Assembly
  • JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE)
    • Removal And Installation
  • JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) (CONT’D)
    • Parts Identification
    • Disassembly And Assembly
    • 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
  • HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE)
    • Removal And Installation
    • Parts Identification
    • Disassembly And Assembly
  • AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE)
    • Removal And Installation
    • Parts Identification
    • Disassembly And Assembly
  • AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
    • Removal And Installation
  • AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (
    • 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
UNDERCARRIAGE38 topics
  • 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 SECTION45 topics
  • UPPERSTRUCTURE
    • Removal And Installation
    • Swing Bearing Removal And Installation
    • Removal And Installation
    • Door Removal And Installation
    • Front Window Removal And Installation
    • Front Window Disassembly And Assembly (S/N 522311001 & Above)
    • 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
    • Removal And Installation
    • Bushing Removal And Installation
  • BUCKET
    • Removal And Installation
  • COUNTERWEIGHT
    • Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS43 topics
  • ELECTRICAL SCHEMATICS
  • ELECTRICAL SYSTEM INFORMATION
    • Troubleshooting Chart
    • Description
    • Fuse And Relay Location (S/N 522311001 & Above)
  • BATTERY
    • Servicing
    • Removal And Installation
    • Using A Booster Battery (Jump Starting)
  • ALTERNATOR
    • Removal And Installation (S/N 522311001 & Above)
    • 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 (S/N 522311001 & Above)
    • Parts Identification (All Models)
    • Disassembly (All Models)
    • Inspection And Repair (All Models)
    • Assembly (All Models)
    • Removal And Installation
  • 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
ENGINE SERVICE95 topics
  • TROUBLESHOOTING
    • Chart
    • Removal And Installation
  • RADIATOR/OIL COOLER (S/N 522311001 & ABOVE)
    • Removal And Installation
    • Hydraulic Check Valve Removal And Installation
    • Hydraulic Check Valve Disassembly And Assembly
  • ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE)
    • Engine Compression Checking
    • Checking the Glow Plugs
    • Glow Plug 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, Checking
    • Fuel Injector Disassembly
    • Fuel Injector Assembly
    • Valve Clearance Adjustment
    • Thermostat
    • 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 Removal And Installation (Cont’d)
    • Fuel Injector, Checking
    • Fuel Injector Disassembly
    • Fuel Injector Assembly
    • Timing Belt Inspection
    • Timing Belt Removal
    • Timing Belt Installation
    • Valve Clearance Adjustment
    • Valve Timing, Checking
    • Thermostat, Oil Pressure Control Valves & Heater Connections
    • Aneroid Device
    • Removal And Installation
    • Flywheel Ring Gear
    • Removal And Installation
    • Flywheel Ring Gear
  • RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE)
    • Deutz Engine Tools Identification Chart
    • Disassembly
    • Assembly
    • Cylinder, Checking
    • Camshaft Bearing, Checking
    • Camshaft Bearing, Removal And Installation
    • Balancing Shaft Bearing, Checking (If Equipped)
    • Balancing Shaft Bearing, Removal And Installation
    • Control Rod Guide Bushing Installation
    • Rear Cover Seal Removal And Installation
    • Rear Cover Seal Removal And Installation (Cont’d)
    • 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
    • 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 CONDITIONING55 topics
  • EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE)
    • Removal And Installation
    • Disassembly And Assembly
  • HEATER/AC FAN
    • Removal And Installation
    • Resistor Removal And Installation
  • HEATER VALVE
    • Removal And Installation
  • AIR CONDITIONING SYSTEM FLOW
    • Principles
    • Chart
    • 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 A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above)
    • Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above)
    • Checking The Electrical System
    • Engine Coolant By-Passing The Heater Valve
  • GENERAL AIR CONDITIONING SERVICE GUIDELINES
    • Compressor Oil
    • Compressor Oil Check
    • Component Replacement And Refrigeration Leaks
  • SYSTEM TROUBLESHOOTING CHART
    • Blower Motor Does Not Operate
    • Gauge Pressure Related Troubleshooting
  • TEMPERATURE/PRESSURE
    • Chart
  • AIR CONDITIONING SERVICE
    • Chart
  • SYSTEM CHARGING AND RECLAMATION
    • Reclamation Procedure
    • Removal And Installation
    • Parts Identification
    • Compressor Clutch Disassembly And Assembly
    • Removal And Installation
  • HEATER COIL/EVAPORATOR
    • Removal And Installation
  • THERMOSTAT
    • Removal And Installation
  • EXPANSION VALVE
    • Removal And Installation
  • UPGRADED AIR CONDITIONING SYSTEM
    • Evaporator Unit Removal And Installation
    • Disassembly And Assembly
    • Thermostat Removal And Installation
    • Evaporator Removal And Installation
    • Fan Removal And Installation
    • Switch Removal And Installation
SPECIFICATIONS48 topics
  • HYDRAULIC EXCAVATOR SPECIFICATIONS
    • Machine Dimensions
    • Performance
    • Controls
    • Electrical
    • Hydraulic System (S/N 522311001 & Above)
    • Hydraulic Cycle Times
    • Swing System
    • Hydraulic Cylinders
    • Drive System
    • Brakes
    • Undercarriage
    • Track
    • Digging Force
  • ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
    • General
    • Fuel System
    • Valve, Valve Guide and Seat Insert
  • ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) (CONT’D)
    • Piston And Rings
    • Connecting Rod
    • Cylinder Head and Block
    • Crankshaft And Main Bearings
    • Camshaft And Bearings
    • Oil Pump
    • Governor
    • Engine Balancing Shaft And Bearings
    • 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
    • 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
  • CONVERSIONS
    • Decimal And Millimeter Equivalents
    • U.S. To Metric Conversion

Inside this manual

Real pages from this service manual (1,257 pages). Open the sample pages (PDF, 426 KB)

Sample pages from the Bobcat 442 Excavator Service Manual: Diagram, Troubleshooting, Specifications, Foldout diagram
  • Diagram, page 547: 442 Evcavator
  • Troubleshooting, page 851: TROUBLESHOOTING (CONT’D)
  • Specifications, page 1,212: ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
  • Foldout diagram, page 104: 6 SPOOL

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 442 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual 6901801_11_07$129.55
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Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,257 pages

Quantity one is the manual described above.

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Other editions and similar models

Bobcat 442 CompactOperation & Maintenance Manual · 6987203 · $69.75Bobcat 442Service Manual · 6901801_5_10 · $129.55Bobcat 442Service Manual · 6987204_5_10 · $99.79

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