Professional Documents
Culture Documents
Service
Manual
S/N 522311001 & Above
S/N 528911001 & Above
S/N 528611001 & Above
Printed in U.S.A.
6901801 (11-07) ©Bobcat Company 2007
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
SAFETY...................................................................70-01
SEAT AND SEAT MOUNT.......................................40-01
SECONDARY FRONT AUXILIARY VALVE .............20-01
SERVICE SCHEDULE ............................................10-01
SIX SPOOL HYDRAULIC CONTROL VALVE .........20-01
STARTER ................................................................50-01
SWING BRAKE RELEASE VALVE..........................20-01
SWING BRAKE VALVE ...........................................20-01
SWING FRAME .......................................................40-01
SWING MOTOR ......................................................20-01
SWING MOTOR DRIVE CARRIER .........................20-01
SWIVEL JOINT........................................................20-01
SYSTEM CHARGING AND RECLAMATION ..........70-01
SYSTEM TROUBLESHOOTING CHART ...............70-01
TEMPERATURE/PRESSURE .................................70-01
THERMOSTAT.........................................................70-01
THREE SPOOL HYDRAULIC CONTROL VALVE...20-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TRACK DAMAGE IDENTIFICATION.......................30-01
TRACK FRAME .......................................................30-01
TRACK IDLER .........................................................30-01
TRACKS ..................................................................30-01
TRANSPORTING THE EXCAVATOR......................10-01
TRAVEL LEVER/FOOT PEDAL VALVE ..................20-01
TRAVEL MOTOR..........................................10-01, 20-01
TROUBLESHOOTING.............................................60-01
TWO SPEED SWITCH ............................................50-01
WIPER MOTOR.......................................................50-01
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
SPECIFICATIONS
442 Excavator
I Service Manual
442 Excavator
II Service Manual
FOREWORD
This manual is for the Bobcat Hydraulic Excavator mechanic. It provides necessary servicing and adjustment procedures
for the hydraulic excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for
operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the hydraulic excavator has had service or repair:
1. Check that the ROPS/TOPS/ 9. Safety treads must be in good
FOPS is in good condition condition.
and is NOT modified.
442 Excavator
III Service Manual
442 Excavator
IV Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
SI EXC-1007 SM
442 Excavator
V Service Manual
SAFETY INSTRUCTIONS (CONT’D)
SI EXC-1007 SM
442 Excavator
VI Service Manual
FIRE PREVENTION Hydraulic System
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
SI EXC-1007 SM
442 Excavator
VII Service Manual
FIRE PREVENTION (CONT’D)
Fire Extinguishers
SI EXC-1007 SM
442 Excavator
VIII Service Manual
SERIAL NUMBER LOCATIONS Engine Serial Number
Figure 1
Figure 3
P-56394 1
442 Excavator
IX Service Manual
DELIVERY REPORT
Figure 4
B-16315
442 Excavator
X Service Manual
BOBCAT EXCAVATOR IDENTIFICATION
ARM CYLINDER
OPERATOR
HANDBOOK
BOOM
ARM
OPERATOR
BOOM SEAT With
CYLINDER SEAT BELT
RETURN
TO TANK
COUPLER GRAB
HANDLE
AUXILIARY
COUPLERS
BUCKET
CYLINDER
RIGHT
SIDE
AUXILARY
COVER
REAR COVER COUPLERS
UPPERSTRUCTURE
BLADE
B-16590
442 Excavator
XI Service Manual
442 Excavator
XII Service Manual
SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001
& ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62-1
442 Excavator
10-01 Service Manual
SAFETY AND MAINTENANCE (CONT’D)
442 Excavator
10-02 Service Manual
SAFETY AND MAINTENANCE (CONT’D)
442 Excavator
10-03 Service Manual
442 Excavator
10-04 Service Manual
LIFTING AND BLOCKING THE EXCAVATOR Figure 10-10-1
Procedure
WARNING 1
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
or fall and result in injury or death.
W-2218-1195
P-32889
Figure 10-10-2
WARNING
AVOID INJURY OR DEATH
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0189
1
Raise one side of the machine (approximately 4 inches)
using the boom and arm.
P-32888
442 Excavator
10-10-1 Service Manual
442 Excavator
10-10-2 Service Manual
LIFTING THE EXCAVATOR Figure 10-11-2
Procedure
WARNING
AVOID INJURY OR DEATH
• Use a lifting fixture with sufficient capacity for
the weight of the excavator plus any added
attachments. 2 1
• Maintain center of gravity and balance when
lifting.
• Do not swing boom or upperstructure.
B-16594
• Never lift with operator on machine.
W-2434-0502
P-32909
Fully retract the boom cylinder and fully extend the arm
and bucket cylinders so the excavator is in the position as
shown [Figure 10-11-1].
442 Excavator
10-11-1 Service Manual
442 Excavator
10-11-2 Service Manual
OPERATOR CAB Raising And Lowering The Left Console
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat.
W-2069-1299
1
Entering And Exiting The Excavator
P-32904
Use the grab handles and track to enter and exit the
excavator [Figure 10-20-1].
442 Excavator
10-20-1 Service Manual
OPERATOR CAB (CONT’D) Figure 10-20-5
Emergency Exit
Figure 10-20-3
P-32908
1
Exit through the window [Figure 10-20-5].
P-32710
Figure 10-20-4
S/N 528911001 & Above
S/N 528611001 & Above
P-56400
442 Excavator
10-20-2 Service Manual
TRANSPORTING THE EXCAVATOR Figure 10-30-2
Use ramps that are the correct length and width, and can P-32598
support the weight of the machine.
The rear of the trailer must be blocked or supported when Figure 10-30-3
loading or unloading the excavator to prevent the front of
the transport vehicle from raising.
P-32603
442 Excavator
10-30-1 Service Manual
442 Excavator
10-30-2 Service Manual
REAR COVER
WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
WARNING
Keep the rear door closed when operating the
machine. Failure to do so could seriously injure a
bystander.
W-2020-1285
Figure 10-40-1
P-56406
Lower the rear cover and push down firmly to close the
cover.
442 Excavator
10-40-1 Service Manual
442 Excavator
10-40-2 Service Manual
RIGHT SIDE COVER
Figure 10-41-2
P-56407
Lower the right side cover and push down firmly to close
the cover.
NOTE: The start key can be used to lock the right side
cover.
442 Excavator
10-41-1 Service Manual
442 Excavator
10-41-2 Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Excavator.
* If equipped
Service at first 50 hours, then as scheduled
Service at first 100 hours, then as scheduled
z 1000 hours or every six months
442 Excavator
10-50-1 Service Manual
442 Excavator
10-50-2 Service Manual
AIR CLEANER Replacing The Filters
See the Service Schedule for the correct service interval. Unlatch the air filter cover latches (Item 2) [Figure 10-60-
(See SERVICE SCHEDULE on Page 10-50-1.) 2].
Figure 10-60-1 Remove the air filter cover (Item 3) [Figure 10-60-2].
Figure 10-60-3
P-32713
P-32689
If the air filter condition indicator (Item 1) [Figure 10-60-
1] is illuminated, the filter element needs to be replaced.
Remove the outer filter (Item 1) [Figure 10-60-3].
Open the right side cover. (See RIGHT SIDE COVER on
Page 10-41-1.) Check the housing for damage.
Figure 10-60-2 Clean the housing and seal surface. Do not use
compressed air.
2
3
P-32688
442 Excavator
10-60-1 Service Manual
AIR CLEANER (CONT’D) Figure 10-60-5
Replace the inner filter every third time the outer filter has
been replaced.
Replace the inner filter after the outer filter has been
replaced and the air filter indicator is still illuminated.
1 P-32690
Pry up on the ends of the air filter (Item 1). Pull the air
filter (Item 2) [Figure 10-60-4] out of the housing.
442 Excavator
10-60-2 Service Manual
AIR CLEANER (CONT’D) Figure 10-60-7
Replace the inner filter every third time the outer filter has
been replaced.
Replace the inner filter after the outer filter has been
replaced and the air filter indicator is still illuminated.
1
Remove the air cleaner cover and outer filter.
1
P-56408
442 Excavator
10-60-3 Service Manual
442 Excavator
10-60-4 Service Manual
FRESH AIR FILTER (S/N 522311001 & ABOVE) Figure 10-61-3
1
2
P-32910
P-32912
Figure 10-61-2
2
1 1
1 1
1 1
P-32911
442 Excavator
10-61-1 Service Manual
442 Excavator
10-61-2 Service Manual
FRESH AIR FILTER (S/N 528911001 & ABOVE AND
S/N 528611001 & ABOVE)
Figure 10-62-1
1
1
P-58101
Figure 10-62-2
P-58100
442 Excavator
10-62-1 Service Manual
442 Excavator
10-62-2 Service Manual
COOLING SYSTEM Figure 10-70-2
WARNING
1
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
Cleaning The Cooling System The surge tank (Item 1) [Figure 10-70-2] must be half full
when the engine is cold.
Open the right side cover.
Do not remove radiator cap when the engine is hot. Too little antifreeze reduces the additives which
You can be seriously burned. protect the internal engine components; reduces the
W-2070-1285 boiling point and freeze protection of the system.
Open the right side cover. Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
Figure 10-70-1 engine damage.
I-2124-0497
P-32693
442 Excavator
10-70-1 Service Manual
COOLING SYSTEM (CONT’D) Figure 10-70-4
WARNING 1
Figure 10-70-3
Remove the plug (Item 1) [Figure 10-70-4] from the back
side of the engine block.
1
NOTE: The plug is located next to the alternator
mount bracket.
P-32693
442 Excavator
10-70-2 Service Manual
COOLING SYSTEM (CON’T) Figure 10-70-6
Figure 10-70-5
1
P-32844
442 Excavator
10-70-3 Service Manual
442 Excavator
10-70-4 Service Manual
FUEL SYSTEM Figure 10-80-2
Fuel Specifications
See your fuel supplier for local recommendations. Check the condition of the fill strainer screen (Item 1)
[Figure 10-80-2]. Clean or replace as necessary.
Filling The Fuel Tank
Use a clean, approved safety container to add fuel. Add
NOTE: The fuel fill cap can be locked. Use the fuel fill fuel only in an area that has a free movement of air and
cap key to lock and unlock the cap. no flames or sparks. NO SMOKING!
Figure 10-80-1 Install and tighten the fuel fill cap. Close the tailgate.
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
1
explosion or fire.
W-2063-0887
P-32697
Open the rear cover and remove the fuel fill cap (Item 1)
[Figure 10-80-1].
442 Excavator
10-80-1 Service Manual
FUEL SYSTEM (CONT’D)
Figure 10-80-3
1
P-32699
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
442 Excavator
10-80-2 Service Manual
FUEL SYSTEM (CONT’D) Figure 10-80-6
Figure 10-80-4
1
P-32859
Figure 10-80-7
1
P-32699
1
Loosen the drain (Item 1) [Figure 10-80-4] at the bottom
of the filter housing and drain the fuel out of the housing.
Figure 10-80-5
P-32860
2
Remove the filter (Item 1) [Figure 10-80-7] from the filter
1 housing.
P-32858
442 Excavator
10-80-3 Service Manual
FUEL SYSTEM (CONT’D) Figure 10-80-10
Figure 10-80-8
1
P-32860
Remove the spacer (Item 1) [Figure 10-80-8] from the Figure 10-80-11
filter housing.
Figure 10-80-9
1
P-32859
P-32861
442 Excavator
10-80-4 Service Manual
FUEL SYSTEM (CONT’D) Figure 10-80-14
Figure 10-80-12
1
2
1
P-32862
Remove the bolt (Item 1) and loosen the vent screw (Item
2) [Figure 10-80-14].
P-32858
Fill the filter through the bolt hole with clean fuel until fuel
flows from the vent with no air bubbles.
Install the filter housing (Item 1) and bolt (Item 2) [Figure
10-80-12]. Install the bolt (Item 1) [Figure 10-80-14].
Tighten the bolt to 15-18 ft.-lbs. (20-25 Nm) torque. Tighten the vent screw (Item 2) [Figure 10-80-14].
Figure 10-80-13
1
P-32699
442 Excavator
10-80-5 Service Manual
FUEL SYSTEM (CONT’D)
Figure 10-80-15
P-56410
442 Excavator
10-80-6 Service Manual
FUEL SYSTEM (CONT’D)
Figure 10-80-16
P-32694
Figure 10-80-17
P-56411
442 Excavator
10-80-7 Service Manual
FUEL SYSTEM (CONT’D) Figure 10-80-20
P-32902
P-32901 WARNING
Position the excavator as shown [Figure 10-80-18]. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Figure 10-80-19 Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
P-32903
442 Excavator
10-80-8 Service Manual
ENGINE LUBRICATION SYSTEM Figure 10-90-3
Check the engine oil every day before starting the engine
for the work shift.
Figure 10-90-1
P-32692
Use a good quality motor oil that meets the correct API
Figure 10-90-2 Service Classification [Figure 10-90-3].
S/N 528911001 & Above
P-56411
Open the right side cover and remove the dipstick (Item
1) [Figure 10-90-1] & [Figure 10-90-2].
442 Excavator
10-90-1 Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-6
Figure 10-90-4
P-32886
Figure 10-90-5
P-32885
442 Excavator
10-90-2 Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D) Put oil in the engine. (See FUEL, COOLANT AND
LUBRICANTS on Page SPEC-70-1.)
Replacing Oil And Filter (Cont’d)
Install the fill cap.
Figure 10-90-7
Start the engine and let it run for several minutes.
S/N 522311001 & Above
Stop the engine. Check for leaks at the oil filter. Check
the oil level.
P-32692
Figure 10-90-8
P-56411
Put clean engine oil on the filter gasket. Install the filter
and hand tighten.
Remove the drain hose and install the cap on the oil pan
after the oil has been completely drained.
442 Excavator
10-90-3 Service Manual
442 Excavator
10-90-4 Service Manual
HYDRAULIC SYSTEM Figure 10-100-2
Figure 10-100-1
P-32851
Check the hydraulic oil level, it must be visible in the sight Install the reservoir cap.
gauge (Item 1) [Figure 10-100-1].
Close the rear cover.
442 Excavator
10-100-1 Service Manual
HYDRAULIC SYSTEM (CONT’D) Remove the drain hose and install the cap on the
hydraulic reservoir.
Replacing The Hydraulic Oil
Add fluid to the reservoir. (See FUEL, COOLANT AND
See the Service Schedule for the correct service interval. LUBRICANTS on Page SPEC-70-1).
(See SERVICE SCHEDULE on Page 10-50-1).
Run the machine through the hydraulic functions. Stop
Retract the arm and bucket cylinders, lower the bucket to the engine. Check the fluid level and add as needed.
the ground. Stop the engine.
Figure 10-100-3
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
1
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
P-32899
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
Remove the cap (Item 1) [Figure 10-100-3] from the enters skin or eyes, get immediate medical attention
hydraulic reservoir drain. from a physician familiar with this injury.
W-2072-0496
Figure 10-100-4
P-32900
442 Excavator
10-100-2 Service Manual
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-7
Figure 10-100-5
P-32855
P-32696
Figure 10-100-6
P-32853
442 Excavator
10-100-3 Service Manual
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-10
Figure 10-100-8
1
P-32853
Figure 10-100-11
P-32977
Figure 10-100-9
P-32852
P-32855
442 Excavator
10-100-4 Service Manual
HYDRAULIC SYSTEM (CONT’D)
Figure 10-100-12
P-32696
442 Excavator
10-100-5 Service Manual
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-15
Figure 10-100-13
1
P-58143
P-58219
Figure 10-100-14
P-58216
442 Excavator
10-100-6 Service Manual
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-18
Figure 10-100-16
1
P-58143
Figure 10-100-19
P-58142
Figure 10-100-17
P-58216
P-58217
442 Excavator
10-100-7 Service Manual
HYDRAULIC SYSTEM (CONT’D)
Figure 10-100-20
1
P-58218
Figure 10-100-21
P-58219
442 Excavator
10-100-8 Service Manual
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-24
P-33048
P-32842
442 Excavator
10-100-9 Service Manual
HYDRAULIC SYSTEM (CONT’D) Figure 10-100-27
Figure 10-100-25
P-63745
Figure 10-100-26
P-58220
442 Excavator
10-100-10 Service Manual
LUBRICATION OF THE EXCAVATOR Figure 10-110-3
Figure 10-110-1
P-32869
3 Figure 10-110-4
P-32866 8
P-32867
442 Excavator
10-110-1 Service Manual
LUBRICATION OF THE EXCAVATOR (CONT’D) Figure 10-110-7
Figure 10-110-5
13
12
10
P-32876
P-32878
12. Boom cylinder base end (1) [Figure 10-110-7]
13. Arm cylinder base end (1) [Figure 10-110-7]
9. Boom swing cylinder base end (1) [Figure 10-110-5]
10. Boom swing cylinder rod end (1) [Figure 10-110-5] Figure 10-110-8
Figure 10-110-6
14
11
P-32875
P-32877
14. Arm cylinder rod end (1) [Figure 10-110-8]
442 Excavator
10-110-2 Service Manual
LUBRICATION OF THE EXCAVATOR (CONT’D) Figure 10-110-11
Figure 10-110-9
17
15
P-32872
P-32874
17. Bucket cylinder rod end (1) [Figure 10-110-11]
Figure 10-110-10
18
16 20
19
P-32871
P-32873
18. Bucket link pivot (1) [Figure 10-110-12]
19. Bucket pivot (1) [Figure 10-110-12]
16. Bucket cylinder base end (1) [Figure 10-110-10] 20. Bucket link (2) [Figure 10-110-12]
442 Excavator
10-110-3 Service Manual
LUBRICATION OF THE EXCAVATOR (CONT’D) Figure 10-110-14
Figure 10-110-13
1
2
P-32870
3
P-32975
442 Excavator
10-110-4 Service Manual
TRAVEL MOTOR Draining The Travel Motor
Checking Oil Level See the Service Schedule for the correct service interval.
(See SERVICE SCHEDULE on Page 10-50-1).
Figure 10-120-1
Figure 10-120-2
1
2
P-32898
P-32897
Install both plugs. Add gear lube to the plug hole (Item 2) until the oil level is
at the bottom edge of the plug hole (Item 1) [Figure 10-
Repeat the procedure for the other side. 120-1]. Install and tighten the plugs.
442 Excavator
10-120-1 Service Manual
442 Excavator
10-120-2 Service Manual
ALTERNATOR BELT Figure 10-130-2
Figure 10-130-1
1
1
1
B-16596
442 Excavator
10-130-1 Service Manual
442 Excavator
10-130-2 Service Manual
FAN/FUEL PUMP BELT Figure 10-140-2
Figure 10-140-1
1
1
1
P-32845
B-16596
Check the fan/fuel pump belt deflection mid span of the
belt between the crankshaft pulley and the fuel pump
pulley (Item 1) [Figure 10-140-1]. Loosen the two bolts (Item 1) [Figure 10-140-2] on the
fuel pump mount. Rotate the fuel pump until the belt is
Apply approximately 33 lb. (15 Kg) force to the belt. The correctly tensioned.
belt should deflect 0.40 inches (10 mm).
Tighten the bolts.
442 Excavator
10-140-1 Service Manual
442 Excavator
10-140-2 Service Manual
AIR CONDITIONING COMPRESSOR BELT (S/N Figure 10-150-2
522311001 & ABOVE)
Figure 10-150-1 2
P-40475
442 Excavator
10-150-1 Service Manual
442 Excavator
10-150-2 Service Manual
AIR CONDITIONING COMPRESSOR BELT (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
Figure 10-151-3
P-56413
Figure 10-151-4
1
1
1
1
P-58069
442 Excavator
10-151-1 Service Manual
442 Excavator
10-151-2 Service Manual
CAB TILT PROCEDURE Figure 10-160-3
Figure 10-160-1
2
1 1
P-33034
Figure 10-160-4
Remove the four bolts (Item 1) [Figure 10-160-1] from
the front of the excavator.
Figure 10-160-2
2
2
2
1
1
P-33035
442 Excavator
10-160-1 Service Manual
CAB TILT PROCEDURE (CONT’D) Figure 10-160-7
Figure 10-160-5
P-33030
2 Figure 10-160-8
P-33036
P-33031
P-33029
442 Excavator
10-160-2 Service Manual
CAB TILT PROCEDURE (CONT’D) Figure 10-160-11
1 1
1
1 P-33042
P-33038
442 Excavator
10-160-3 Service Manual
CAB TILT PROCEDURE (CONT’D) Later Models
Early Models
Figure 10-160-12
1
P-63545
Figure 10-160-15
P-33043
Figure 10-160-13
P-63544
442 Excavator
10-160-4 Service Manual
CAB TILT PROCEDURE (CONT’D) All Models
Figure 10-160-16
2 1
1 P-33794
Figure 10-160-19
P-63542
Figure 10-160-17
P-33793
1
Turn the bolts (Item 1) down flush with the plate (Item 2)
[Figure 10-160-16] & [Figure 10-160-17].
442 Excavator
10-160-5 Service Manual
CAB TILT PROCEDURE (CONT’D) Figure 10-160-22
Figure 10-160-20
1
1
P-33040
I-2215-0502
Figure 10-160-23
1
P-33041 1
P-33036
Winch the cab forward until the front of the cab (Item 1)
contacts the bumpers (Item 2) [Figure 10-160-23].
442 Excavator
10-160-6 Service Manual
CAB TILT PROCEDURE (CONT’D) Figure 10-160-25
Figure 10-160-24
1 P-33046
Reverse the direction of the winch and lower the cab until
the approved cab support device (Item 1) [Figure 10-
160-25] fully engages the cab mount hole and the weight
of the cab is resting on the support device.
Figure 10-160-26
3 1
P-33045
WARNING
Avoid injury or death. Never work under the
excavator cab without installing an approved cab
support device.
W-2435-0502
442 Excavator
10-160-7 Service Manual
442 Excavator
10-160-8 Service Manual
HYDRAULIC SYSTEM
442 Excavator
20-01 Service Manual
HYDRAULIC SYSTEM (CONT’D)
442 Excavator
20-02 Service Manual
HYDRAULIC SYSTEM (CONT’D)
442 Excavator
20-04 Service Manual
HYDRAULIC SYSTEM (CONT’D)
442 Excavator
20-05 Service Manual
HYDRAULIC SYSTEM (CONT’D)
442 Excavator
20-06 Service Manual
HYDRAULIC SYSTEM (CONT’D)
442 Excavator
20-07 Service Manual
442 Excavator
20-08 Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
442 EXCAVATOR
(S/N 522311001 AND ABOVE)
(PRINTED APRIL 2005)
MS1422legend
LEGEND
1 BACK-UP RELIEF VALVE
4350 PSI (300 Bar) 17 CROSS PORT RELIEF VALVE - 2 STAGE 32 RETURN BLOCK With Check Valve
1450 PSI (100 Bar) / 3625 PSI (250 Bar) 72.5 PSI (5 Bar)
2 LOAD SENSE RELIEF VALVE
4060 PSI (280 Bar) 33 MAIN FILTER
18 ANTI-CAVITATION VALVE
3 PORT RELIEF VALVE - Boom Cyl.
(Rod End) 4350 PSI (300 Bar) 19 ORIFICE 0.06 inch (1,5 mm)
34 PRESSURIZED BREATHER / FILL CAP
4 PORT RELIEF VALVE - Boom Cyl. 5 PSI (0,34 Bar)
20 ORIFICE - One Way Restrictor
(Base End) 2610 PSI (180 Bar) 0.0023 inch (0,6 mm)
5 PORT RELIEF VALVE - Arm Cyl. 35 HYDRAULIC RESERVOIR - PRESSURIZED
21 PRESSURE REDUCING VALVE Reservoir Volume 29 gal (110 L)
(Rod End) 4350 PSI (300 Bar) 508 PSI (35 Bar) System Volume 37 gal (140 L)
6 PORT RELIEF VALVE - Arm Cyl. 22 ACCUMULATOR 145 PSI (10 Bar)
(Base End) 4350 PSI (300 Bar) 36 COMPENSATOR - Standard
23 DUMP VALVE - PUMP 2 ( Boom, Arm, Bucket, Auxiliary, Left Travel
7 PORT RELIEF VALVE - Bucket Cyl. and Right Travel)
(Rod End) 4350 PSI (300 Bar) 1595 PSI (110 Bar)
PORT RELIEF VALVE - Bucket Cyl. 24 HYDRAULIC PISTON PUMP 37 CROSS PORT RELIEF VALVE -
8
(Base End) 4350 PSI (300 Bar) Minimum Displacement Travel Motor 4060 PSI (280 Bar)
0.0 GPM (0.0 L/min) @ 2000 RPM
9 PORT RELIEF VALVE - Auxiliary Maximum Displacement 38 COUNTERBALANCE SPOOL (Travel
4350 PSI (300 Bar) 37.5 GPM (142 L/min) @ 2000 RPM Motor)
NOTE: With clamp installed - Reset 25 Torque Limitor 39 TWO SPEED SHIFT SPOOL
port relief valve to 3625 PSI (250 Bar)
40 SHUTTLE VALVE - DRIVE PRESSURE
26 PUMP MARGIN SPOOL
10 PORT RELIEF VALVE - Auxiliary 365 PSI (25 Bar)
4350 PSI (300 Bar) 41 BRAKE CONTROL SPOOL
27 TORQUE LIMITER SUPPLY SPOOL
11 LOAD SENSE BLEED CARTRIDGE 42 SELECTOR VALVE - MANUAL
290 PSI (20 Bar) (Bucket Cylinder or Secondary Auxiliaries)
28 OIL TEMPERATURE REGULATOR
12 43 CHECK VALVE - Accumulator
MAIN RELIEF VALVE (Gear Pump) 131 degrees F. (55 degrees C.)
3335 PSI (230 Bar)
29 OIL COOLER 44 LOAD CHECK VALVE - Boom Swing
13 PILOTED OPERATED TWO POSITION 334 PSI (23 Bar)
VALVE
30 HYDRAULIC PUMP # 1 Gear Type 45 ISO/STANDARD VALVE
14 CHECK VALVE 8.7 GPM (33 L/min.) at 2000 Engine RPM
46 CHECK VALVE
15 ORIFICE 31 HYDRAULIC PUMP # 2 Gear Type
8.7 GPM (33 L/min.) at 2000 Engine RPM
16 PORT RELIEF VALVE
NOTE: Unless otherwise specified
5075 PSI (350 Bar)
springs have NO significant
pressure value.
Under carriage
36 36 36 36 36 36
LS M b B1 A b B2 A2 b B3 A3 b B4 A4 b B5 A5 b B6 A6
P a A1 B1 a A2 B2 a A3 B3 T
P
M
11 2 39
44
X1
1
MA 37 MB
12
T T3
6 SPOOL VALVE T T T T T T T T
T1
B A B A B A B A 37
SWING RELIEF PRESSURE
BOOM CONTROL VALVE
BOOM ARM BUCKET AUXILIARY LEFT TRAVEL RIGHT TRAVEL BLADE SWING 46
SWING
T1 a a a a a a
b b b 38
3 4 5 6 7 8 9 10 3 SPOOL VALVE
46
3 1
2 40
45 Y12
a p
b t 41
Y TRAVEL
MOTOR
45 A B
a p
b t
X 4 5 6 7
3
2 8
1
27 SWIVEL
JOINT BLADE CYLINDER
2 4 1 3 2 4 3 1
B X
TRAVEL
P P A MOTOR B
25 T T 41
S1 S2 A
MAIN FILTER 17 SWING BRAKE
34 RELEASE VALVE
T P R P
Y3 1 2 Y5
22
33
21
P
S
T
LEGEND
1 BACK-UP RELIEF VALVE
4350 PSI (300 bar) 17 CROSS PORT RELIEF VALVE - 2 STAGE 33 MAIN FILTER
1450 PSI (100 bar) / 3625 PSI (250 bar) With 43.5 PSI (3 bar) Filter By-Pass Valve
2 LOAD SENSE RELIEF VALVE
4060 PSI (280 bar) 18 ANTI-CAVITATION VALVE 34 PRESSURIZED BREATHER / FILL CAP
3 PORT RELIEF VALVE - Boom Cyl. 5 PSI (0,34 bar)
(Rod End) 4350 PSI (300 bar) 19 ORIFICE 0.003 inch (0,8 mm)
7 PORT RELIEF VALVE - Bucket Cyl. 23 CHECK VALVE 37 CROSS PORT RELIEF VALVE -
(Rod End) 4350 PSI (300 bar) Travel Motor 4060 PSI (280 bar)
39
LS M b B1 A1 b B2 A2 b B3 A3 b B4 A4 b B5 A5 b B6 A6
36 36 36 36 36 P a A1 B1 a A2 B2 a A3 B3 T
P X1
M
T
11
MA 37
37
2 B
1 12
43 44
T3
T 38
T T T T T T T T
B A B A B A B A T1 BOOM
6 SPOOL SWING BLADE 44
OFFSET M
VALVE
BOOM ARM BUCKET AUX. LEFT RIGHT
a a a 7 8 a 10 a a 40
T1 3 4 5 6 9 TRAVEL TRAVEL
45 41
a p
A B
b t
Y
Y25
a p P P 4 5 6 7
3
2 8
b t T T 1 BLADE CYLINDERS
X DDF
45 Y26
AUXILIARY SWIVEL JOINT
CONTROL VALVE (BOTTOM PORTS)
A B
LEFT RIGHT
Y18 Y19 JOYSTICK JOYSTICK
A B
P T
17 T
41
MA
A
19
47 S 40
Pst
44
SWING
18 S1 MOTOR
38
B
P T 43 44
Pst
FR1
27 B 37
17 MB 20
MA 37 MB
FR2 26
29
28 25
X T
P2 S1
A X1
LR
46 SWING BRAKE
31 32
24 30 R P RELEASE VALVE 39
S2
P M 1 2 3
Y3 Y5 Y12
34
21 22
23
TRAVEL
MAIN
SBO MOTOR
FILTER S L1 L
VARIABLE
DISPLACEMENT
33
PUMP 35
T V-0621 (10-15-07)
ACCUMULATOR
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
442 Excavator
20-10-1 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
442 Excavator
20-10-2 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
442 Excavator
20-10-3 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
442 Excavator
20-10-4 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
442 Excavator
20-10-5 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D) Figure 20-10-2
Description
2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888
P-32843
The hydraulic system has two separate hydraulic circuits.
The piston pump circuit supplies fluid to the six spool The coupler (Item 2) [Figure 20-10-2] is used to check
hydraulic control valve. the load sense relief valve, safety relief valve and piston
pump torque limiter supply adjustment.
The six spool control valve contains the boom, arm,
bucket auxiliary, left and right travel valve sections. The gear pump circuit supplies fluid to the three spool
hydraulic control valve.
Figure 20-10-1
The three spool control valve contains the upperstructure
swing, blade and boom swing valve sections.
Figure 20-10-3
P-33367
1
442 Excavator
20-10-6 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D) Figure 20-10-6
Description (Cont’d)
Figure 20-10-4
1
P-33048
Figure 20-10-5
P-32842
442 Excavator
20-10-7 Service Manual
442 Excavator
20-10-8 Service Manual
BOOM CYLINDER Figure 20-20-3
Testing
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
1
Figure 20-20-1
P-33401
Figure 20-20-4
1
P-33396
Figure 20-20-2
P-33403
P-33399
442 Excavator
20-20-1 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-7
Testing (Cont’d)
Figure 20-20-5
1
1 P-33395
Figure 20-20-8
Install a block (Item 1) [Figure 20-20-5] under the
cylinder housing.
Figure 20-20-6 2
P-36026
Start the engine and retract the boom cylinder (Item 1) If there is any oil leakage from the base end fitting (Item
[Figure 20-20-6]. 2) [Figure 20-20-8] on the boom cylinder, remove the
cylinder for repair or replacement.
Stop the engine.
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
442 Excavator
20-20-2 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-10
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
1
IMPORTANT
P-33394
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Disconnect the hose (Item 1) [Figure 20-20-10] from the
tubelines and ports to keep dirt out. Dirt can quickly rod end.
damage the system.
I-2003-0888 Figure 20-20-11
Figure 20-20-9
1
P-33395
P-33391
Disconnect the hose (Item 1) [Figure 20-20-11] from the
base end.
Remove the load sense line (Item 1) and two pilot hoses
(Item 2) [Figure 20-20-9].
442 Excavator
20-20-3 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-14
Figure 20-20-12
P-33400
Figure 20-20-13
P-33402
442 Excavator
20-20-4 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-18
Figure 20-20-16
1
P-33401
Figure 20-20-17
P-33399
442 Excavator
20-20-5 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-21
Figure 20-20-19
P-33405
Figure 20-20-20
P-33404
442 Excavator
20-20-6 Service Manual
BOOM CYLINDER (CONT’D)
Parts Identification
1
2
3
5 14
6
7
8 15
9
10 16
11
17
16
12
13 3
18
1
2
B-16949
442 Excavator
20-20-7 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-24
Disassembly
Figure 20-20-22
2 2
P-36056
Figure 20-20-25
P-36053
1
Install a block (Item 1) [Figure 20-20-22] under the end
of the cylinder housing.
Figure 20-20-23
1
P-36057
P-36054
442 Excavator
20-20-8 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-28
Disassembly (Cont’d)
Figure 20-20-26
P-36068
Figure 20-20-29
Remove the 12 bolts (Item 1) [Figure 20-20-26] from the
head.
Figure 20-20-27
1
2
1 P-36067
442 Excavator
20-20-9 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-32
Disassembly (Cont’d)
Figure 20-20-30
2 1
P-36076
1
Figure 20-20-33
Clamp the rod end in a vise, support the end of the rod
with a wood block (Item 1) [Figure 20-20-30].
1
Use care not to damage the rod.
Figure 20-20-31
P-36074
P-36070
442 Excavator
20-20-10 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-36
Disassembly (Cont’d) 1
Figure 20-20-34
P-36071
P-36078
442 Excavator
20-20-11 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-40
Disassembly (Cont’d)
Figure 20-20-38
1
P-36085
Remove the rod from the vise. Remove the snap ring
P-36079 (Item 1) [Figure 20-20-40].
Figure 20-20-41
Remove the two wear rings (Item 1) [Figure 20-20-38].
Figure 20-20-39
2 1
3
4 P-36086
442 Excavator
20-20-12 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-43
Assembly
1
Use the following tools to assemble the cylinder.
Lubricate all O-rings and seals with hydraulic oil during Figure 20-20-44
installation.
Figure 20-20-42
P-36086
P-36084
Make sure the bearing is fully seated in the housing (Item
1) [Figure 20-20-43] and install the snap ring (Item 1)
[Figure 20-20-44].
Install the bearing (Item 1) [Figure 20-20-42] in the rod
end.
442 Excavator
20-20-13 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-47
Assembly (Cont’d)
Figure 20-20-45 2
1
P-36080
Install the wiper (Item 1), wear ring (Item 2) and backup
P7427 ring (Item 3) [Figure 20-20-47].
Figure 20-20-48
Install the rod seal on the rod seal tool [Figure 20-20-45].
Figure 20-20-46
P-36079
P-36081
442 Excavator
20-20-14 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-51
Assembly (Cont’d)
Figure 20-20-49
2 1
1
P-36071
Figure 20-20-50
1
P-36072
P-35979
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-50].
442 Excavator
20-20-15 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-55
Assembly (Cont’d)
Figure 20-20-53
P-36082
Clamp the rod end in a vise. Support the end of the rod
1 P-36073 with a wood block (Item 1) [Figure 20-20-55]. Use care
not to damage the rod.
Figure 20-20-54
1
1 2
P-36076
P-36074
Install the head (Item 1) and piston (Item 2) [Figure 20-
20-56].
Install the steel rings (Item 1) [Figure 20-20-54].
442 Excavator
20-20-16 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-59
Assembly (Cont’d)
Figure 20-20-57
P-36066
Figure 20-20-58
1 1
P-36068
P-36083 Fully seat the bearing and install the snap ring (Item 1)
[Figure 20-20-60].
442 Excavator
20-20-17 Service Manual
BOOM CYLINDER (CONT’D) Figure 20-20-63
Assembly (Cont’d) 1
Figure 20-20-61
P-36064
2
1
Install the twelve bolts (Item 1) [Figure 20-20-63].
P-36155 Tighten the bolts to 107 ft.-lb. (145 N•m) torque.
Figure 20-20-64
Clamp the base end of the cylinder in a vise and support
the end of the housing with a block (Item 1) [Figure 20-
20-61]. Use care not to damage the cylinder housing.
442 Excavator
20-20-18 Service Manual
ARM CYLINDER Removal And Installation
Fully retract the bucket and arm cylinders. Lower the boom to the ground.
Lower the boom to the ground. With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Figure 20-21-1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
1 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-21-3
P-33406
1
P-33406
P-36023
If there is any oil leakage from the base end fitting (Item
2) [Figure 20-21-2] on the arm cylinder, remove the
cylinder for repair or replacement.
442 Excavator
20-21-1 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-6
Figure 20-21-4
1
P-33408
Figure 20-21-7
Install a sling (Item 1) [Figure 20-21-4] on the cylinder.
Figure 20-21-5
P-33409
P-33415 Remove the bolt (Item 1) [Figure 20-21-7] from the rod
end retaining pin.
442 Excavator
20-21-2 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-10
Figure 20-21-8
1 P-33413
Figure 20-21-11
Remove the spacer (Item 1) [Figure 20-21-8].
Figure 20-21-9
P-33414
442 Excavator
20-21-3 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-14
Figure 20-21-12 1
1
P-33416
Figure 20-21-13
1
P-33418
P-33417
Remove the cylinder [Figure 20-21-15].
442 Excavator
20-21-4 Service Manual
ARM CYLINDER (CONT’D)
Parts Identification
2
3
5
14
6
7
8 15
9
10 16
11 17
13 16
12
3
18
1
2
B-16948
442 Excavator
20-21-5 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-18
Disassembly
Figure 20-21-19
P-36061
P-36062
442 Excavator
20-21-6 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-22
Disassembly (Cont’d)
Figure 20-21-20
1 1
P-36067
Figure 20-21-21
1 P-36069
P-36068 Clamp the rod end in a vise. Support the end of the rod
with a wood block (Item 1) [Figure 20-21-23].
Remove the snap ring (Item 1) [Figure 20-21-21] from Use care not to damage the rod.
the base end of the cylinder.
442 Excavator
20-21-7 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-26
Disassembly (Cont’d)
1
Figure 20-21-24
P-36074
Figure 20-21-27
Apply moderate heat to the nut (Item 1) [Figure 20-21-
24]. Remove the nut. 1
Figure 20-21-25
2 1
P-36073
442 Excavator
20-21-8 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-30
Disassembly (Cont’d)
2
1
Figure 20-21-28
P-36078
Figure 20-21-31
Remove the back-up rings (Item 1) [Figure 20-21-28].
Figure 20-21-29
1 1
P-36079
442 Excavator
20-21-9 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-34
Disassembly (Cont’d)
Figure 20-21-32
2 1
4
3 P-36086
Figure 20-21-33
P-36085
Remove the rod from the vise. Remove the snap ring
(Item 1) [Figure 20-21-33].
442 Excavator
20-21-10 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-36
Assembly
Lubricate all O-rings and seals with hydraulic oil during Figure 20-21-37
installation.
Figure 20-21-35
1
1
P-36086
P-36084
Make sure the bearing is fully seated in the housing
[Figure 20-21-36] and install the snap ring (Item 1)
[Figure 20-21-37].
Install the bearing (Item 1) [Figure 20-21-35] in the rod
end.
442 Excavator
20-21-11 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-40
Assembly (Cont’d)
Figure 20-21-38
1
P-36080
Install the wiper (Item 1), wear ring (Item 2) and back-up
P7427 ring (Item 3) [Figure 20-21-40].
Figure 20-21-41
Install the rod seal on the rod seal tool [Figure 20-21-38].
Figure 20-21-39
P-36079
P-36081
442 Excavator
20-21-12 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-44
Assembly (Cont’d)
Figure 20-21-42
1
2
1
P-36071
Figure 20-21-43
1
P-36072
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-43].
1
P-36073
442 Excavator
20-21-13 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-49
Assembly (Cont’d)
Figure 20-21-47
1 1 2
P-36076
Figure 20-21-50
Install the steel rings (Item 1) [Figure 20-21-47].
Figure 20-21-48
P-36070
1
Clamp the rod end in a vise. Support the end of the rod Tighten the nut to 1364 ft.-lb. (1850 N•m) torque.
with a wood block (Item 1) [Figure 20-21-48]. Use care
not to damage the rod.
442 Excavator
20-21-14 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-53
Assembly (Cont’d)
Figure 20-21-51
P-36068
Fully seat the bearing and install the snap ring (Item 1)
P-36083 [Figure 20-21-53].
Figure 20-21-54
Install a ring compressor on the piston (Item 1) [Figure
20-21-51] and compress the seal to the correct size.
Figure 20-21-52
1
2
P-36155
442 Excavator
20-21-15 Service Manual
ARM CYLINDER (CONT’D) Figure 20-21-57
Assembly (Cont’d)
Figure 20-21-55
1
2
1
P-36063
Figure 20-21-58
Install the head (Item 1) [Figure 20-21-55] in the
housing.
Figure 20-21-56
1 1
P-36062
442 Excavator
20-21-16 Service Manual
BOOM OFFSET CYLINDER Figure 20-22-3
Testing
Figure 20-22-1
P-33701
P-33699
P-33700
Testing (Cont’d)
IMPORTANT
Figure 20-22-5
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-22-7
1
P-33703
Figure 20-22-6
P-33706
1
Figure 20-22-8
P-33704
1
To test the cylinder, the cab must be tilted. Use the blade
(Item 1) [Figure 20-22-6] as an attaching point for the
hand winch and tilt the cab. (See Tilting The Cab on
Page 10-160-2).
442 Excavator
20-22-2 Service Manual
BOOM OFFSET CYLINDER (CONT’D)
Testing (Cont’d)
Figure 20-22-9
P-33708
If there is any oil leakage from the base end fitting (Item
2) [Figure 20-22-9] on the boom offset cylinder, remove
the cylinder for repair or replacement.
Figure 20-22-10
P-33701
P-33699
P-33700
442 Excavator
20-22-4 Service Manual
BOOM OFFSET CYLINDER (CONT’D)
Figure 20-22-16
1
1
P-33703
Figure 20-22-15
P-33705
1
Figure 20-22-17
P-33704
2
To remove the cylinder, the cab must be tilted. Use the
blade (Item 1) [Figure 20-22-15] as an attaching point for
the hand winch and tilt the cab. (SSee Tilting The Cab on
Page 10-160-2).
P-33706
NOTE: Make sure the blade is not in the float position
(if equipped) before tilting the cab.
Loosen the clamp (Item 1) [Figure 20-22-17].
Figure 20-22-18
P-33709
Figure 20-22-19
1
1
2
P-33710
P-33708
Remove the spacer (Item 1) [Figure 20-22-21].
442 Excavator
20-22-6 Service Manual
BOOM OFFSET CYLINDER (CONT’D)
Figure 20-22-22
P-33711
Figure 20-22-23
P-33712
Parts Identification
1. Snap Ring
2. Bearing
3. Housing
4. O-Ring
5. Backup Ring
6. Ring
7. Seal
8. Seal
9. Head 2
10. Bolt 1
11. Wiper Seal 3
12. Nut
13. Steel Ring
14. Piston Seals
15. Piston
16. Cylinder Rod
17. Grease Fitting 4
5
6
7
8
9 7
10
11
12
13
14
15
13
17
16
2
1
B-16942
442 Excavator
20-22-8 Service Manual
BOOM OFFSET CYLINDER (CONT’D) Figure 20-22-26
Disassembly
Figure 20-22-24
P-36065
Figure 20-22-27
P-36182
1
Support the cylinder with a block (Item 1) [Figure 20-22-
24]. Use care not to damage the cylinder housing.
Figure 20-22-25
1 P-36068
P-36064
Disassembly (Cont’d)
Figure 20-22-28
P-36070
Figure 20-22-31
Remove the bearing (Item 1) [Figure 20-22-28].
Figure 20-22-29
2 1
P-36076
P-36069
Clamp the rod end in a vise. Support the end of the rod
with a wood block (Item 1) [Figure 20-22-29]. Use care
not to damage the rod.
442 Excavator
20-22-10 Service Manual
BOOM OFFSET CYLINDER (CONT’D) Figure 20-22-34
Disassembly (Cont’d)
Figure 20-22-32
1
P-36072
Figure 20-22-33
1
P-36071
1 P-36073
Disassembly (Cont’d)
1
Figure 20-22-36
2
3 4
P-36080
Remove the wiper (Item 1) wear ring (Item 2), seal (Item
P-36078 3) and back-up ring (Item 4) [Figure 20-22-38].
Figure 20-22-39
Remove the O-ring (Item 1) and back-up ring (Item 2)
[Figure 20-22-36] from the head.
Figure 20-22-37
1
P-36085
Remove the rod from the vise. Remove the snap ring
P-36079 (Item 1) [Figure 20-22-39].
442 Excavator
20-22-12 Service Manual
BOOM OFFSET CYLINDER (CONT’D) Assembly
P-36084
Assembly (Cont’d)
Figure 20-22-42
P7427
Install the rod seal on the rod seal tool [Figure 20-22-44].
P-36085
NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-22-43
Rotate the handles to collapse the rod seal [Figure 20-
22-44].
Figure 20-22-45
P-36086
442 Excavator
20-22-14 Service Manual
BOOM OFFSET CYLINDER (CONT’D) Figure 20-22-48
Assembly (Cont’d)
2
Figure 20-22-46 1
2 1
3 P-36078
Figure 20-22-49
Install the wiper (Item 1), wear ring (Item 2) and back-up
ring (Item 3) [Figure 20-22-46].
Figure 20-22-47
P-35979
Install the new seal on the tool and slowly stretch it until it
P-36079 fits the piston [Figure 20-22-49].
Assembly (Cont’d)
Figure 20-22-50
1 P-36073
1
Install the wear rings (Item 1) [Figure 20-22-52].
P-36071
Figure 20-22-53
P-36074
442 Excavator
20-22-16 Service Manual
BOOM OFFSET CYLINDER (CONT’D) Figure 20-22-56
Assembly (Cont’d)
Figure 20-22-54
P-36070
1
Apply thread lock adhesive (Loctite™ 270) to the threads
P-36082 and install the nut (Item 1) [Figure 20-22-56].
Figure 20-22-55
1 2
P-36083
Install the head (Item 1) and piston (Item 2) [Figure 20- Leave the piston in the compressor for three minutes.
22-55].
Remove the rod and head assembly from the vise.
Assembly (Cont’d)
Figure 20-22-58
3
2
1
P-36155
1
Clamp the base end of the cylinder in a vise and support
P-36066 the end of the housing with a block (Item 1) [Figure 20-
22-60]. Use care not to damage the cylinder housing.
Install the bearing (Item 1) [Figure 20-22-58] in to the Support the rod assembly with wood blocks (item 2)
base end of the cylinder housing. [Figure 20-22-60].
NOTE: The bearing can only be installed through the Install a ring compressor (Item 3) [Figure 20-22-60] on
snap ring side of the housing. the piston to compress the steel rings to the correct size.
Figure 20-22-61
1 1
P-36068
Fully seat the bearing and install the snap ring (Item 1)
[Figure 20-22-59].
P-36065
442 Excavator
20-22-18 Service Manual
BOOM OFFSET CYLINDER (CONT’D)
Assembly (Cont’d)
Figure 20-22-62
P-36064
Fully retract the bucket and arm cylinders. Fully retract the arm cylinder and lower the boom until the
bucket is on the ground.
Lower the boom to the ground.
Figure 20-23-65
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Figure 20-23-63 1
P-33713
With the engine off and the key in the run position, move
Remove the hydraulic hose (Item 1) [Figure 20-23-63] the joysticks to relieve hydraulic pressure.
from the base end of the bucket cylinder.
Figure 20-23-64
IMPORTANT
When repairing hydrostatic and hydraulic systems,
2 clean the work area before disassembly and keep all
1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-36030
If there is any oil leakage from the base end fitting (Item
2) [Figure 20-23-64] on the bucket cylinder, remove the
cylinder for repair or replacement.
442 Excavator
20-23-1 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-68
Figure 20-23-66
2
P-33716
Figure 20-23-69
Remove the hose (Item 1) [Figure 20-23-66] from the
base end.
Figure 20-23-67
P-33717
P-33715
442 Excavator
20-23-2 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-72
Figure 20-23-70
P-33720
Figure 20-23-71
P-33721
442 Excavator
20-23-3 Service Manual
BUCKET CYLINDER (CONT’D)
Figure 20-23-74
P-33722
Figure 20-23-75
P-33723
442 Excavator
20-23-4 Service Manual
BUCKET CYLINDER (CONT’D)
Parts Identification
5
6
8 7
14
10 9
15
11
16
13
17
12 3
18
1
2
B-16947
442 Excavator
20-23-5 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-78
Disassembly
1
Use the following tools to disassemble the cylinder.
Figure 20-23-79
1
1
P-36182
Figure 20-23-77
Remove the rod assembly (Item 1) [Figure 20-23-79].
1
3
P-36183
442 Excavator
20-23-6 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-82
Disassembly (Cont’d)
Figure 20-23-80
1
1
P-36190
Clamp the rod end in a vise. Support the end of the rod
P-36067 with a wood block (Item 1) [Figure 20-23-82].
Figure 20-23-81
1 P-36191
P-36068
Apply moderate heat to the nut (Item 1) [Figure 20-23-
83].
Remove the bearing (Item 1) [Figure 20-23-81].
442 Excavator
20-23-7 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-86
Disassembly (Cont’d)
1
Figure 20-23-84
2 1
3
P-36194
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-23-84].
1
Figure 20-23-85
P-36193
P-36192
442 Excavator
20-23-8 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-91
Disassembly (Cont’d)
2 1
Figure 20-23-89
4 3
P-36080
Remove the wiper (Item 1), wear ring (Item 2), seal (Item
P-36078 3) and back-up ring (Item 4) [Figure 20-23-91].
Figure 20-23-92
Remove the O-ring (Item 1) and back-up ring (Item 2)
[Figure 20-23-89] from the head.
Figure 20-23-90
P-36085
Remove the rod from the vise. Remove the snap ring
P-36079 (Item 1) [Figure 20-23-92].
442 Excavator
20-23-9 Service Manual
BUCKET CYLINDER (CONT’D) Assembly
P-36084
442 Excavator
20-23-10 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-97
Assembly (Cont’d)
Figure 20-23-95
P7427
Install the rod seal on the rod seal tool [Figure 20-23-97].
P-36085
NOTE:‘ During installation the spring side of the seal
must be toward the inside of the cylinder.
Figure 20-23-96
Rotate the handles to collapse the rod seal [Figure 20-
23-97].
Figure 20-23-98
P-36086
442 Excavator
20-23-11 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-101
Assembly (Cont’d)
1
Figure 20-23-99
2
P-36078
3
Figure 20-23-102
Install the wiper (Item 1), wear ring (Item 2) and back-up
ring (Item 3) [Figure 20-23-99].
Figure 20-23-100
P-35979
Install the new seal on the tool and slowly stretch it until it
P-36079 fits the piston [Figure 20-23-102].
442 Excavator
20-23-12 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-105
Assembly (Cont’d)
Figure 20-23-103
P-36194
Figure 20-23-104
P-36195
P-36193
442 Excavator
20-23-13 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-109
Assembly (Cont’d)
Figure 20-23-107
1
1 P-36191
Figure 20-23-110
Clamp the rod end in a vise. Support the end of the rod
with a wood block (Item 1) [Figure 20-23-107]. Use care
not to damage the rod.
1
Figure 20-23-108
2 3
1
P-36197
Install the head (Item 1) and piston (Item 2) [Figure 20- Remove the rod assembly from the vise.
23-108].
442 Excavator
20-23-14 Service Manual
BUCKET CYLINDER (CONT’D) Figure 20-23-113
Assembly (Cont’d)
Figure 20-23-111
1 2
1
P-36155
Install the bearing (Item 1) [Figure 20-23-111] into the Support the rod assembly with wood blocks (Item 2)
base end of the cylinder housing. [Figure 20-23-113].
NOTE: The bearing can only be installed through the Install a ring compressor (Item 3) [Figure 20-23-113] on
snap ring side of the housing. the piston to compress the steel rings to the correct size.
Figure 20-23-114
1
P-36068
P-36065
Fully seat the bearing and install the snap ring (Item 1)
[Figure 20-23-112].
Install the head (Item 1) [Figure 20-23-114] in the
housing.
442 Excavator
20-23-15 Service Manual
BUCKET CYLINDER (CONT’D)
Assembly (Cont’d)
Figure 20-23-115
P-36064
Figure 20-23-116
3
1
P-36183
442 Excavator
20-23-16 Service Manual
BLADE CYLINDER Figure 20-24-3
Testing
Figure 20-24-1
1
P-36029
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.
Figure 20-24-2
P-36028
442 Excavator
20-24-1 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-5
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.
IMPORTANT P-33449
When repairing hydrostatic and hydraulic systems, Remove the bolt (Item 1) [Figure 20-24-5] and nut from
clean the work area before disassembly and keep all the base end retaining pin.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Installation: Tighten the bolt to 48-55 ft.-lb. (65-75 N•m)
damage the system. torque.
I-2003-0888
Figure 20-24-6
Figure 20-24-4
1
2
1 P-33450
P-35918
442 Excavator
20-24-2 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-9
Figure 20-24-7
1
P-33447
Figure 20-24-10
P-33448
Figure 20-24-8
1
1
P-33445
Install a sling (Item 1) [Figure 20-24-7] & [Figure 20-24- Figure 20-24-11
8] on the rod end and base end of the cylinder.
P-33443
442 Excavator
20-24-3 Service Manual
BLADE CYLINDER (CONT’D)
Parts Identification
6 3
7
8
9
10
11 8
12
14
13 15
3 16
17
2 1
B-16946
442 Excavator
20-24-4 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-13
Disassembly
IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts 1
clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2056-0793
P-35994
Use the following tools to disassemble the cylinder.
MEL1074-O-Ring Seal Hook Remove the bolt (Item 1) and seal carrier (Item 2)
[Figure 20-24-13] from the fittings.
Hold the cylinder over a drain pan and slowly move the
rod in and out to remove the oil from the cylinder. Figure 20-24-14
Figure 20-24-12
P-35996
2
P-35993
442 Excavator
20-24-5 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-17
Disassembly (Cont’d)
1
Figure 20-24-15
2
1
P-35991
Figure 20-24-18
Remove the seal (Item 1) [Figure 20-24-15] from the
seal carrier.
2
Figure 20-24-16 2
1
P-35990
442 Excavator
20-24-6 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-21
Disassembly (Cont’d)
Figure 20-24-19
P-35986
Figure 20-24-20
2
1
P-35985
P-35988
Remove the snap ring (Item 1) and bearing (Item 2)
[Figure 20-24-22].
Remove the rod assembly (Item 1) [Figure 20-24-20]
from the housing.
442 Excavator
20-24-7 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-25
Disassembly (Cont’d)
Figure 20-24-23
1
2
3
1
P-35974
Figure 20-24-26
Clamp the rod end in a vise and install a wood block to
support the end of the rod [Figure 20-24-23]. Use care
not to damage the rod.
Remove the nut (Item 1), piston (Item 2) and head (Item 3
3) [Figure 20-24-23] 2
Figure 20-24-24
3
P-35977
1
Remove the wiper (Item 1), seal (Item 2) and wear ring
1 (Item 3) [Figure 20-24-26].
2
P-35982
442 Excavator
20-24-8 Service Manual
BLADE CYLINDER (CONT’D)
Disassembly (Cont’d)
Figure 20-24-27
2
1
P-35973
Figure 20-24-28
P-35972
442 Excavator
20-24-9 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-30
Assembly
Lubricate all O-rings and seals with hydraulic oil during Install the rod seal on the rod seal tool [Figure 20-24-30].
assembly.
NOTE: During installation, the spring side of the seal
Figure 20-24-29 must be toward the inside of the cylinder.
P-35972
442 Excavator
20-24-10 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-34
Assembly (Cont’d)
1
Figure 20-24-32
2
P-35973
Figure 20-24-35
Install the wear ring (Item 1) and wiper (Item 2) [Figure
20-24-32].
Figure 20-24-33
P-35979
Install the new seal on the tool and slowly stretch it until it
P-35974 fits the piston [Figure 20-24-35].
442 Excavator
20-24-11 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-38
Assembly (Cont’d)
Figure 20-24-36
P-35982
1
Figure 20-24-37
P-35978
1
Clamp the rod end in a vise [Figure 20-24-39]. Use care
P-35981 not to damage the rod.
442 Excavator
20-24-12 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-42
Assembly (Cont’d)
Figure 20-24-40 1
2
1
P-35985
3
Figure 20-24-43
Install the head (Item 1) and piston (Item 2) [Figure 20-
24-40].
Support the rod with a wood block and tighten the nut to
1143 ft.-lb. (1550 N•m) torque.
Figure 20-24-41
P-35986
P-35983
442 Excavator
20-24-13 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-46
Assembly (Cont’d)
Figure 20-24-44 1
P-35989
Figure 20-24-47
Clamp the base end of the cylinder housing in a vise
[Figure 20-24-44].
Figure 20-24-45
3 2
P-35990
P-35988
442 Excavator
20-24-14 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-50
Assembly (Cont’d) 3
1
Figure 20-24-48
1
2
2
2
4
3 P-35997
Install the cover (Item 1) on the cylinder housing with the Figure 20-24-51
hole (Item 3) over the base end port (Item 2) [Figure 20-
24-48].
Figure 20-24-49 1
P-35996
1
442 Excavator
20-24-15 Service Manual
BLADE CYLINDER (CONT’D) Figure 20-24-54
Assembly (Cont’d)
Figure 20-24-52
1 1
1
P-35993
3 2
Install the bolt (Item 1) and seal carrier (Item 2) into the
fitting (Item 3) [Figure 20-24-52].
Figure 20-24-53
1
P-35998
442 Excavator
20-24-16 Service Manual
RELIEF VALVES Figure 20-30-3
Description
Figure 20-30-1
1
P-32843
The gear pump circuit has one main relief valve (Item 1) The backup relief valve and load sense relief valve are
[Figure 20-30-1] located on the three spool valve. tested and adjusted during the piston pump testing and
adjusting. (See Pump Testing on Page 20-50-6 or See
The relief valve is factory set at 3335 PSI (230 bar). Pump Testing on Page 20-52-5.)
Figure 20-30-2
P-33367
The piston pump circuit has one load sense relief valve
(Item 1) [Figure 20-30-2] and one backup relief valve
(Item 1) [Figure 20-30-3] located on the six spool valve.
The load sense relief valve (Item 1) [Figure 20-30-2] is
factory set at 4060 PSI (280 bar).
442 Excavator
20-30-1 Service Manual
RELIEF VALVES (CONT’D) Adjusting The Three Spool Control Valve Main Relief
Valve
Testing The Three Spool Control Valve Main Relief
Valve Stop the engine.
1
1
P-33371 P-33373
Install a 5000 PSI (345 bar) pressure gauge on the front Figure 20-30- 6
test coupler (Item 1) [Figure 20-30-4] of the gear pump.
Tighten the lock nut and retest the main relief valve.
442 Excavator
20-30-2 Service Manual
PORT RELIEF VALVES Figure 20-31-2
Adjustment Procedure
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888
P-35504
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat Remove the protective end cap (Item 1) [Figure 20-31-
hydraulic fluid. 2].
Figure 20-31-1
P-35503
442 Excavator
20-31-1 Service Manual
442 Excavator
20-31-2 Service Manual
PRESSURE REDUCING VALVE (S/N 528911001 & Figure 20-32-2
ABOVE AND 528611001 & ABOVE)
Description
P-63747
442 Excavator
20-32-1 Service Manual
PRESSURE REDUCING VALVE (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D)
Adjustment
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Figure 20-32-3
P-63748
Figure 20-32-4
2
1
P-63750
442 Excavator
20-32-2 Service Manual
PRESSURE REDUCING VALVE (S/N 522311001 & Figure 20-33-2
ABOVE)
Description
Testing
Figure 20-33-1
P-33376
1
The pressure at the gauge (Item 1) [Figure 20-33-2]
should be 508 PSI (35 bar).
P-33048
442 Excavator
20-33-1 Service Manual
PRESSURE REDUCING VALVE (S/N 522311001 &
ABOVE) (CONT’D)
Adjustment
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Figure 20-33-3
P-33378
Figure 20-33-4
1
3
P-33377
442 Excavator
20-33-2 Service Manual
DUMP VALVE Adjustment
Hydraulic oil from the gear pumps supply the three spool Figure 20-34-2
valve. When pressure rises in the valve the dump valve
opens and allows oil from one of the gear pumps to flow
directly to tank.
Testing
Figure 20-34-1
2 1
P-33375
Install a 5000 PSI (345 bar) gauge on the test port (Item Tighten the lock nut and retest the dump valve.
1) [Figure 20-34-1] of the rear gear pump.
442 Excavator
20-34-1 Service Manual
DUMP VALVE (CONT’D) Figure 20-34-4
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-33383
Figure 20-34-3
1
1
P-33382
442 Excavator
20-34-2 Service Manual
DUMP VALVE (CONT’D)
Parts Identification
1 Valve
2 O-Ring
3 Spring
4 Spool
5 Fitting
6 Plug
7 Spring
8 Spring Seat
9 Valve Body
5
3
2
9 4
2
2
5
5
2 8
6
7
2
6
MS1533
442 Excavator
20-34-3 Service Manual
DUMP VALVE (CONT’D) Figure 20-34-7
Figure 20-34-5
P-36126
1
Figure 20-34-6
P-36127
1
442 Excavator
20-34-4 Service Manual
DUMP VALVE (CONT’D) Figure 20-34-11
Figure 20-34-9
P-36130
1
Remove the fitting (Item 1) [Figure 20-34-11].
P-36128
Figure 20-34-12
Figure 20-34-10
1
P-36129
442 Excavator
20-34-5 Service Manual
DUMP VALVE (CONT’D) Figure 20-34-15
Figure 20-34-13
1
P-36133
Figure 20-34-14
1
1
P-36134
P-36132
Remove the plug (Item 1) [Figure 20-34-16].
442 Excavator
20-34-6 Service Manual
DUMP VALVE (CONT’D) Figure 20-34-19
Figure 20-34-17
1
P-36129
Figure 20-34-18
P-36136
442 Excavator
20-34-7 Service Manual
442 Excavator
20-34-8 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE Figure 20-40-3
Figure 20-40-1
1 1
P-35162
Figure 20-40-4
1
P-35160
Figure 20-40-2 2
1 1
P-35163
P-35161
442 Excavator
20-40-1 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-7
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-35166
Figure 20-40-5
1 1
1
1
2
P-35164 1
Figure 20-40-6
Remove the 2 hoses (Item 1) [Figure 20-40-8].
1
1 P-35165
442 Excavator
20-40-2 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-11
Figure 20-40-9 1
1 P-35171
Figure 20-40-12
Remove the 7 hoses (Item 1) [Figure 20-40-9] from the
A ports of the valve.
Figure 20-40-10
1 1
P-35172
1
1 1 Remove the 4 bolts (Item 1) [Figure 20-40-12] and
P-35170 washers.
442 Excavator
20-40-3 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D)
Figure 20-40-13
P-35173
442 Excavator
20-40-4 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D)
ITEM DESCRIPTION
1 Inlet Section
2 Boom Section
3 Arm Section
4 Bucket Section
5 Auxiliary Section
6 Left Travel
7 Right Travel
8 Outlet
9 Port Relief 4350 psi (300 bar)
10 Port Relief 2610 psi (180 bar)
9 9 9 9
1 8
2 3 4 5 6 7
10 9 9 9
B-16827
442 Excavator
20-40-5 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-16
Figure 20-40-14
1
1 2
1
P-35238
1
Figure 20-40-17
Remove the 3 bolts (Item 1) [Figure 20-40-14].
Figure 20-40-15
P-35239
1
P-35237
442 Excavator
20-40-6 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-20
Figure 20-40-18
1
1 1
1 2
P-35242
1
Remove the O-rings (Item 1) [Figure 20-40-20] from the
2 P-35240 auxiliary valve section.
Figure 20-40-19
1
1
1
1
2
1 P-35243
442 Excavator
20-40-7 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-24
Figure 20-40-22
1
1
1
1
P-35246
Figure 20-40-25
Remove the O-rings (Item 1) [Figure 20-40-22] from the
arm valve section.
Figure 20-40-23
1
1 1 1
1
P-35247
1
Remove the rods (Item 1) [Figure 20-40-25] from the
inlet section.
2
P-35245 Installation: Tighten the rods to 18 ft.-lb. (25 N•m)
torque.
442 Excavator
20-40-8 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-28
Figure 20-40-26
P-35251
1
Figure 20-40-29
P-35249
Figure 20-40-27
P-35252
1
2
1
P-35250
442 Excavator
20-40-9 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-32
Figure 20-40-30
1
1
2
P-35254
Figure 20-40-33
1
P-35258
P-35255
Remove the pressure compensator (Item 1) [Figure 20-
40-31].
Remove the O-ring (Item 1) [Figure 20-40-33].
442 Excavator
20-40-10 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-36
Figure 20-40-34
P-35259
1
Remove the plugs (Item 1) [Figure 20-40-36].
Figure 20-40-35
P-35253
P-35257
442 Excavator
20-40-11 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-40
P-35262
1
Remove the plastic plug (Item 1) [Figure 20-40-40].
Figure 20-40-41
P-35261
Figure 20-40-39
P-35263
1
1 Remove the plug (Item 1) [Figure 20-40-41].
P-35260
442 Excavator
20-40-12 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-44
Figure 20-40-42
1
1
1
P-35264
Figure 20-40-43 2
1
P-35281
442 Excavator
20-40-13 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-48
Figure 20-40-46
1
2
2
1
P-35282
Figure 20-40-49
P-35280
P-35279
Record the distance of spool stroke limitation adjustment
screw (Item 1) [Figure 20-40-47] for correct installation.
(Auxiliary Valve Section only) Remove the O-ring (Item 1) [Figure 20-40-49].
442 Excavator
20-40-14 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-52
Figure 20-40-50
1
P-35268
2
Figure 20-40-51
1 2
1 P-35269
P-35267
442 Excavator
20-40-15 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D)
Figure 20-40-54
P-35270
442 Excavator
20-40-16 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-57
Figure 20-40-55
2
1
2
P-35273
Figure 20-40-58
Remove the load sense relief valve (Item 1) [Figure 20-
40-55].
Figure 20-40-56
P-35274
P-35272
442 Excavator
20-40-17 Service Manual
SIX SPOOL HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-61
P-35277
1
Remove the O-ring (Item 1) [Figure 20-40-61].
P-35278
P-35276
442 Excavator
20-40-18 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-3
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 2
tubelines and ports to keep dirt out. Dirt can quickly 1 1
damage the system. 1
I-2003-0888
P-33800
Figure 20-41- 1
Figure 20-41-4
1
1
1
1 1
P-33802
P-33801
442 Excavator
20-41-1 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE
(CONT’D)
Figure 20-41-5
P-33798
Figure 20-41-6
P-33797
442 Excavator
20-41-2 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE
(CONT’D)
Parts Identification
1. Swing/Inlet Section
2. Blade Section
3. Boom Offset Section
4. Outlet Section
5. Load Check Valve
6. Main Relief Valve
1 2 3 4
6
5
B-16941
442 Excavator
20-41-3 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-9
(CONT’D)
Figure 20-41-7
1
2
P-35764
1
Remove the 4 tie rod nuts (Item 1) [Figure 20-41-7]. Figure 20-41-10
Figure 20-41-8
1 2
P-35765
442 Excavator
20-41-4 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE
(CONT’D)
P-35766
Figure 20-41-12
Cut
2.0”
0.5625” dia.
1.500”
0.750”
B-14674
442 Excavator
20-41-5 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-15
(CONT’D)
Figure 20-41-13
1
P-35769
Figure 20-41-16
P-35767
Figure 20-41-14
1 2 3
3 P-35771
1 2
P-35768
442 Excavator
20-41-6 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-19
(CONT’D)
Figure 20-41-17
2
1
P-35774
Remove the O-ring (Item 1) and seal ring (Item 2) Remove the valve end cover (Item 2) [Figure 20-41-19]
[Figure 20-41-17]. from both ends.
1
1
P-35773
P-35775
Remove the O-rings (Item 1) and back-up ring (Item 2) Remove the O-ring (Item 1) [Figure 20-41-20].
[Figure 20-41-18].
442 Excavator
20-41-7 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-23
(CONT’D)
Figure 20-41-21 1
P-35778
2
1
P-35779
P-35777
442 Excavator
20-41-8 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE
(CONT’D)
Figure 20-41-25
1 1
P-35780
442 Excavator
20-41-9 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-28
(CONT’D)
Figure 20-41-26
2
1
1
1
P-35782
Remove the plug (Item 1) [Figure 20-41-26]. Remove the valve end cover (Item 2) [Figure 20-41-28]
from both ends.
Installation: Tighten the plug to 46-57 ft.-lb. (63-77 N•m)
torque. Figure 20-41-29
Figure 20-41-27
1 2
P-35775
P-35768
Remove the O-ring (Item 1) [Figure 20-41-29].
442 Excavator
20-41-10 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-32
(CONT’D)
Figure 20-41-30
1
1
P-35785
1
1
1
P-35779
P-35784
442 Excavator
20-41-11 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE Figure 20-41-36
(CONT’D)
2
1
1
P-35787
Figure 20-41-35
1
1
P-35788
P-35786
442 Excavator
20-41-12 Service Manual
THREE SPOOL HYDRAULIC CONTROL VALVE
(CONT’D)
Figure 20-41-38
P-35789
442 Excavator
20-41-13 Service Manual
442 Excavator
20-41-14 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE)
If any of the following adjustments are not obtainable, pump repair is required.
The outline listed below, gives the four adjustments for setting the hydraulic pump. The adjustments are listed in the order
in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page
location within the Service Manual for the complete adjustment procedure.
5. Remove the plug and install fitting and hose from the Torque Limit Supply Spool to a drain pan.
6. Install a 725 PSI (50 bar) pressure gauge on the test port on the six spool control valve.
11. Remove the Hose and Fitting from the Torque Limiter Supply Spool and Plug the Port
__________ PM PRESSURE
17. Install 5000 PSI (345 bar) gauge ont he test port on the six spool valve.
19. Run engine at high idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens.
20. Adjust back-up relief valve as necessary to get 4350 ± 50 PSI (300 ± 3,45 bar).
442 Excavator
20-50-1 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONT’D)
__________ PM PRESSURE
22. Install 5000 PSI (345 bar) Gauge on the test port on the six spool control valve.
23. Run Engine at High Idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens.
24. Adjust Load Sense Relief Valve as Necessary to get 4060 ± 50 PSI (280 ±3,45 bar).
__________ PRESSURE
26. Remove the 5000 PSI Gauge, from the Pump Diagnostic Coupler at the Control Valve.
27. Remove the inlet hose from the six spool hydraulic control valve, install a cap on the valve and install the inlet hose
on the inlet side of the hydraulic tester.
28. Route the outlet hose of the hydraulic tester to the hydraulic reservoir.
29. Bottom out the pump margin spool (approximately six turns in)
__________ FLOW
__________ FLOW
442 Excavator
20-50-2 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONT’D)
39. Install the pump outlet hose on the six spool hydraulic control valve.
40. Reset pump margin spool to 363 ± 20 PSI (25 ± 1,38 bar).
442 Excavator
20-50-3 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 1
ABOVE) (CONT’D)
Testing Information 2
3
The testing of the piston pump must be done in the
following order:
1
Torque limiter supply pressure
Pump margin pressure
Load sense relief valve
Torque Limiter
Item 4 [Figure 1]: 37° JIC flare union, Bobcat P/N 45KN-
8.
442 Excavator
20-50-4 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-4
ABOVE) (CONT’D)
Figure 20-50-2
P-40571
Turn the cover over and install the nut (Item 1) [Figure
20-50-4].
P-40569
Drill a 1.0625 inch (26 mm) hole in the center of the cover
(Item 1) [Figure 20-50-2].
Figure 20-50-3
P-40570
442 Excavator
20-50-5 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-7
ABOVE) (CONT’D)
4
Pump Testing
5
Torque Limiter Supply Pressure Adjustment
Figure 20-50-5
3
1
2
P-40566
1
Install a fitting and drain hose (Item 1) [Figure 20-50-7].
Place the other end of the hose in a drain pan.
Install a 725 PSI (500 bar) pressure gauge on the test Loosen the nut (Item 2) [Figure 20-50-7].
coupler (Item 1) [Figure 20-50-5].
Turn the pump margin spool (bottom spool) (Item 3)
Figure 20-50-6 [Figure 20-50-7] all the way in (approximately 6 turns).
Remove the plug (Item 2) [Figure 20-50-6]. Turn the pump margin spool (bottom spool) (Item 3)
[Figure 20-50-7] back to its original position
(approximately 6 turns).
442 Excavator
20-50-6 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-9
ABOVE) (CONT’D)
Figure 20-50-8 1
2
P-40560
442 Excavator
20-50-7 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Curl the bucket until the bucket cylinder is fully extended
ABOVE) (CONT’D) and the relief valve opens.
Back-up Relief Valve Adjustment The pressure at the gauge (Item 2) [Figure 20-50-11]
should be 4350 PSI (300 bar).
Figure 20-50-10
Stop the engine.
Figure 20-50-12
P-33368
1
2 2
P-33370
P-33366
442 Excavator
20-50-8 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-15
ABOVE) (CONT’D)
Figure 20-50-14
P-33367
2
1
Remove the plastic cap (Item 1) [Figure 20-50-15].
Figure 20-50-16
P-33366
Stop the engine. Loosen the lock nut (Item 1) [Figure 20-50-16].
Tighten the lock nut and retest the load sense relief valve.
442 Excavator
20-50-9 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-19
ABOVE) (CONT’D)
Figure 20-50-17
1 1
P-40577
Figure 20-50-20
P-40567
Figure 20-50-18
2 1
P-40578
P-40576
442 Excavator
20-50-10 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-23
ABOVE) (CONT’D)
P-40574
Figure 20-50-22
1
P-40575
442 Excavator
20-50-11 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-27
ABOVE) (CONT’D)
Figure 20-50-25
P-40560
Figure 20-50-26
1
1
P-40562
442 Excavator
20-50-12 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-31
ABOVE) (CONT’D)
Figure 20-50-29
1
2
3
P-40583
Figure 20-50-30 Turn the hydraulic tester flow control (Item 2) clockwise
until the gauge (Item 3) [Figure 20-50-29] reads 3480
PSI (240 bar).
442 Excavator
20-50-13 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Figure 20-50-32
P-40562
442 Excavator
20-50-14 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-34
ABOVE) (CONT’D)
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-33806
Figure 20-50-33
1 P-35228
P-33805
Reposition the hoses (Item 1) [Figure 20-50-35] to gain
access to the piston pump.
442 Excavator
20-50-15 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-38
ABOVE) (CONT’D)
Figure 20-50-36
1 1
P-35231
Figure 20-50-37
1
1
2
1
P-35232
1
Remove the 4 bolts (Item 1) [Figure 20-50-39].
P-35230
442 Excavator
20-50-16 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-42
ABOVE) (CONT’D)
P-35235
P-35233 Separate the pump from the engine and remove the
pump.
Figure 20-50-41
P-35234
442 Excavator
20-50-17 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-45
ABOVE) (CONT’D)
P-35316
Figure 20-50-44
P-35318
442 Excavator
20-50-18 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
1. Plug
2. O-Ring
3. Spring
4. Spring Seat
5. Spool Assembly
7
6. Spool
7. Bolt
8. O-Ring
9. Spring Seat
10. Spring
11. Spring
12. O-Ring 19
13. Body
14. Locknut
15. Washer
16. Screw
17. Nut 6
18. Cap
19. Housing
5
4
3
2
1
8
18
17
16
14 15
13
12
11
10
9
B-15929
442 Excavator
20-50-19 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Clean the outside of the pump with clean solvent and dry
with compressed air before removing any components
from the pump.
Figure 20-50-46
P-35319
Figure 20-50-47
P-35330
442 Excavator
20-50-20 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-50
ABOVE) (CONT’D)
Figure 20-50-48
1
1
N-23329
P-35320
N-23328
442 Excavator
20-50-21 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-54
ABOVE) (CONT’D)
Figure 20-50-52 2
N-23333
1
2 Remove the two springs (Items 1 & 2) [Figure 20-50-54].
Figure 20-50-53
1
1
P-35322
N-23332
442 Excavator
20-50-22 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-58
ABOVE) (CONT’D)
Figure 20-50-56
1
2
P-35325
Figure 20-50-57
2
P-35326
P-35324
442 Excavator
20-50-23 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Figure 20-50-60
1
4
P-35327
Figure 20-50-61
P-35328
442 Excavator
20-50-24 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-63
ABOVE) (CONT’D)
Figure 20-50-62
P-35327
Figure 20-50-64
P-35328
P-35325
442 Excavator
20-50-25 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-67
ABOVE) (CONT’D)
Figure 20-50-65
N-23332
Figure 20-50-68
Install the dust cap (Item 1) [Figure 20-50-65].
Figure 20-50-66
1
2 2
1 P-35321
N-23333
NOTE: Install the big spring first and the small spring
second.
442 Excavator
20-50-26 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-71
ABOVE) (CONT’D)
Figure 20-50-69
N-23328
1
Install the O-ring (Item 1) on the plug. Install the plug
(Item 2) [Figure 20-50-71].
P-35320
Figure 20-50-72
Figure 20-50-70
N-23327
2
Install the O-ring (Item 1) [Figure 20-50-72].
1
N-23329
442 Excavator
20-50-27 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Figure 20-50-73
1
P-35323
Figure 20-50-74
P-35322
442 Excavator
20-50-28 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-77
ABOVE) (CONT’D)
Figure 20-50-75
4.21”
(107 mm)
P-40592
Figure 20-50-78
N-23336
Figure 20-50-76
2 1
P-35330
3.78”
(96 mm) Align the linkage pin (Item 1) on the hydraulic piston
pump into the hole (Item 1) [Figure 20-50-78] in the
torque limiter valve.
P-40592
Turn the valve slightly to align the dowel pin (Item 2) on
the hydraulic piston pump into the hole (Item 2) [Figure
Measure from the cap to the top of the large adjustment 20-50-78] in the torque limiter valve.
screw. Set the large adjustment screw to 3.78 inches (96
mm) [Figure 20-50-76]. NOTE: Care should be taken not to scratch or
damage the valve spool.
442 Excavator
20-50-29 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Figure 20-50-79
P-35319
442 Excavator
20-50-30 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
1. Cap
2. O-Ring
3. Nut 1
4. Adjusting Screw
5. Adjustment Screw Body 1
6. Spring Seat 2
7. Spring
8. Spring 2
3
9. Spring Seat
10. Spool 3
11. Plug 2
12. Valve Body
2
13. Bolt
14. Fitting 4
15. Elbow
4
5
2
6
2
7 6
8
7
9 8
10 9
10
2 11
11
2
2 2
2
12
2
14
13
15 2
14 2
2
11 11
MS1540
442 Excavator
20-50-31 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Clean the outside of the pump with clean solvent and dry
with compressed air before removing any components
from the pump.
Figure 20-50-80
P-35319
Figure 20-50-81
1 1
P-35331
442 Excavator
20-50-32 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-84
ABOVE) (CONT’D)
Figure 20-50-82 4
3
2
1
1
P-35335
Remove the adjustment screw (Item 1), nut (Item 2), and
O-ring washer (Item 3) from the adjustment assembly
P-35332 (Item 4) [Figure 20-50-84].
Figure 20-50-83
3 2 3 1 4
1 P-35344
P-35333 Remove the adjustment seat (Item 1), large spring (Item
2), and the small spring (Item 3) [Figure 20-50-85] from
the adjustment assembly.
Before disassembling the pump margin control, remove
the cap (Item 1) and O-ring washer (Item 2) [Figure 20- Remove the O-ring (Item 4) [Figure 20-50-85].
50-83] from the adjustment assembly.
442 Excavator
20-50-33 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-88
ABOVE) (CONT’D)
Figure 20-50-86
N-23380
1
Check the spool for scratches and be sure the orifice
(Item 1) [Figure 20-50-88] is not plugged.
P-35336
Figure 20-50-89
Figure 20-50-87
1
1
P-35338
442 Excavator
20-50-34 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-92
ABOVE) (CONT’D)
Figure 20-50-90
1 2
1
P-35341
Figure 20-50-91
P-35342
P-35340
Loosen the nut (Item 1) [Figure 20-50-93].
442 Excavator
20-50-35 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-96
ABOVE) (CONT’D)
3
1
P-35345
P-35343
Figure 20-50-95
P-35346
4
3
Remove the spool (Item 1) [Figure 20-50-97].
1
2
P-35344
442 Excavator
20-50-36 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-100
ABOVE) (CONT’D)
Figure 20-50-98
1
1
P-35348
N-23379
Figure 20-50-99
P-35347
442 Excavator
20-50-37 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Parts Identification
1. Seal
2. Shaft
3. Bolt
4. Bearing
5. Plug
6. Piston
6
3
4
5
4
B-19529
442 Excavator
20-50-38 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-102
ABOVE) (CONT’D)
Disassembly
IMPORTANT 3
Remove the torque limiter valve.(See “Torque Limiter NOTE: The position of the dowel pin (Item 2) on the
Valve Removal and Installation” on page 20. pin assembly, with the locating hole on the
swash plate cradle (Item 3) [Figure 20-50-102].
Remove the pump control assembly. See “Pump Control
Removal And Installation” on page 32. Figure 20-50-103
Figure 20-50-101
P-35350
442 Excavator
20-50-39 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-106
ABOVE) (CONT’D)
1
Disassembly (Cont’d)
Figure 20-50-104 3
2
N-23386
Remove the O-ring (Item 1) [Figure 20-50-104] from the Remove the stroking piston/spring assembly (Item 3)
plug. [Figure 20-50-106].
Figure 20-50-105
1 1
2 1
1 1 N-23387
P-35351
Inspect the destroking piston (Item 1) [Figure 20-50-107]
for scratches and replace as needed.
Loosen and remove the four bolts (Item 1) [Figure 20-50-
105].
442 Excavator
20-50-40 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-110
ABOVE) (CONT’D)
Disassembly (Cont‘d)
Figure 20-50-108
1
2
1
N-23390
N-23391
Lay the pump assembly on its side and remove the rotary
group, swash plate, and shaft (Item 1) [Figure 20-50-
111] from the housing.
N-23389
442 Excavator
20-50-41 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-114
ABOVE) (CONT’D)
Disassembly (Cont’d) 1
Figure 20-50-112
2
1
P-35354
3
Figure 20-50-113
P-35355
1
P-35361
442 Excavator
20-50-42 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-118
ABOVE) (CONT’D)
Disassembly (Cont’d)
1
Figure 20-50-116
2
4 4
3
3 2 2
1 3
4
N-15289
Figure 20-50-117
4
1 2
N-15290
3
N-15288
Tighten the nut (Item 1) until the spring is compressed
enough to remove the snap ring (Item 2) [Figure 20-50-
Install the threaded rod and nut (Item 1) through the 119].
trimmed washer (Item 2) and through the block assembly
(Item 3) [Figure 20-50-117]. Loosen the nut to release the tension on the spring and
remove the bolts and washers.
NOTE: The modified washer (Item 2) must fit over the
spring but must also fit inside the snap ring
(Item 4) [Figure 20-50-117].
442 Excavator
20-50-43 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-122
ABOVE) (CONT’D)
Disassembly (Cont’d)
Figure 20-50-120
1
2 3 3
3 1 2
N-23395
Figure 20-50-121
1 2 1
N-15284
442 Excavator
20-50-44 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-126
ABOVE) (CONT’D)
Disassembly (Cont’d)
Figure 20-50-124
1
N-15277
Figure 20-50-125
1
1
N-15280
442 Excavator
20-50-45 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-130
ABOVE) (CONT’D)
Disassembly (Cont’d)
Figure 20-50-128
1
1
N-23415
Figure 20-50-129
1
N-23418
442 Excavator
20-50-46 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-134
ABOVE) (CONT’D)
Disassembly (Cont’d)
Figure 20-50-132
1
1
P-35353
Figure 20-50-133
P-35352
442 Excavator
20-50-47 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-136
ABOVE) (CONT’D)
Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-23418
N-23419
N-23417
442 Excavator
20-50-48 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-140
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-138
P-35356
Figure 20-50-139
2
1
1
N-15285
442 Excavator
20-50-49 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-144
ABOVE) (CONT’D)
Assembly (Cont’d)
2
Figure 20-50-142 1
P-35358
Figure 20-50-145
To find the correct shim washer thickness for bearing end
play, the shaft/bearing assembly (Item 1) [Figure 20-50-
142] must be installed in the housing.
Figure 20-50-143
P-35360
N-23425
442 Excavator
20-50-50 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-147
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-146
N-15277
0.001 Nominal Pre-load Apply Loctite™ 241 and install the torque limiter plate
(Item 1) and bolt (Item 2) on the swash plate (Item 3)
= 0.151 ± thickness of the spacer needed. (See [Figure 20-50-148].
Assembly (Cont’d) on Page 20-50-50.)
442 Excavator
20-50-51 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-151
ABOVE) (CONT’D)
Assembly (Cont’d) 1
Figure 20-50-149
2
1
P-35354
3
2 1
2
P-35361
442 Excavator
20-50-52 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-155
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-153 3 2
1 2 3
N-15299
Figure 20-50-156
Install the shaft/swash plate assembly (Item 1) [Figure
20-50-153] in the cylinder block.
Figure 20-50-154 2
1
N-15289
Lay the pump housing on its side and install the rotary
group assembly, swash plate, and shaft in the housing
[Figure 20-50-154].
442 Excavator
20-50-53 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-159
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-157
2
1
3
N-23390
Figure 20-50-160
NOTE: The modified washer (Item 1) must fit over the
spring, but must also fit inside the snap ring
(Item 2) [Figure 20-50-157].
Figure 20-50-158
1 2
1
N-23386
442 Excavator
20-50-54 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-163
ABOVE) (CONT’D)
Assembly (Cont’d)
1
Figure 20-50-161
2
N-23431
1
Figure 20-50-162
1
P-35363
442 Excavator
20-50-55 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-167
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-165
1
P-35366
Align the marks and install the port block assembly (Item
1) [Figure 20-50-167] on the pump housing.
P-35364
Figure 20-50-168
1
P-35367
442 Excavator
20-50-56 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 & Figure 20-50-171
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-169
1 3
1
2
N-23355
P-35349 Make sure the dowel pin (Item 2) is fully seated in the
hole (Item 3) [Figure 20-50-171] on the swash plate.
Install the O-ring (Item 1) [Figure 20-50-169] on the plug. Figure 20-50-172
Figure 20-50-170
1
1
1
N-23354
P-35368
Apply Loctite™ 241 on the bolt (Item 1) [Figure 20-50-
172]. Tighten the bolt to 10 ft.-lbs. (13 Nm) torque.
Install the plugs (Item 1) [Figure 20-50-170].
Install the torque limiter valve. See “Torque Limiter Valve
Removal and Installation” on page 20.
442 Excavator
20-50-57 Service Manual
HYDRAULIC PISTON PUMP (S/N 522311001 &
ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-50-173
P-35349
Place the pump on its side and fill approximately half full
with clean hydraulic fluid.
Figure 20-50-174
P-35350
442 Excavator
20-50-58 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2 P-33806
Open the rear cover. (See Opening And Closing The
Rear Cover on Page 10-40-1.)
Remove the supply hose (Item 1) [Figure 20-51- 2].
Open the right side cover. (See Opening And Closing
The Right Side Cover on Page 10-41-1.) Remove the hose (Item 2) [Figure 20-51- 2].
1 2
1
P-33805 P-33807
Remove the hose (Item 1) [Figure 20-51-1]. Remove the tee fitting (Item 1) [Figure 20-51- 3].
442 Excavator
20-51-1 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONT’D)
Parts Identification
1 Nut
2 Gear
3 Key
4 Plate Mount
5 Gasket 1 2
6 Snap Ring 3
4
7 Seal
8 Plate 5 6
7 8
9 Dowel Pin
10 Bolt
9
11 Fitting 13
12 O-Ring 15 17
13 Housing 16 14
14 O-Ring 18 9
15 Load Seal 19 10
16 Load Seal 17 12
Backup Ring 18 18 9
11
17 Plug 10
16
18 Bearing 17
19 15 9
19 Gear 18 8
20 End Cap
21 Washer 15
17 16
22 Bolt 7
10
23 Tee Fitting 14 18 19
24 Diagnostic 9 13 9
Coupler 10
18
25 Cap 11
12 17
11 17
19
10 18
16
12
9 15 9
14 20
18
10 23 21
24 17
22
25
MS1544
442 Excavator
20-51-2 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 5
(CONT’D)
Disassembly
Figure 20-51- 4
1 1
2
P-33811
1
1 1
Figure 20-51- 6
2
P-33808
P-33812
442 Excavator
20-51-3 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 9
(CONT’D)
Disassembly (Cont’d)
Figure 20-51- 7
1
1
P-33813
1
Remove the O-ring (Item 1) [Figure 20-51- 9] from the
pump.
P-33809
Figure 20-51- 10
Figure 20-51- 8
P-33987
1
Place the pump coupler (Item 1) [Figure 20-51- 10] in a
vise that is equipped with soft jaws.
P-33810 Remove the pump from the vise and remove the nut.
442 Excavator
20-51-4 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 13
(CONT’D)
Disassembly (Cont’d)
Figure 20-51- 11
1 1
P-33991
1
Mark and remove the bolts (Item 1) [Figure 20-51- 13]
and washers.
P-33988
NOTE: Different length bolts are used. Mark the bolts
before removal for correct installation.
Use a puller to remove the pump coupler (Item 1) [Figure
20-51- 11]. Figure 20-51- 14
Figure 20-51- 12
1
P-33992
P-33989
Remove the end cap (Item 1) [Figure 20-51- 14].
442 Excavator
20-51-5 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 17
(CONT’D)
Disassembly (Cont’d)
1
Figure 20-51- 15
P-33996
2
Remove the O-ring (Item 1) [Figure 20-51- 17].
Figure 20-51- 16
1
1
P-33997
P-33995
442 Excavator
20-51-6 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 21
(CONT’D)
Disassembly (Cont’d)
1
Figure 20-51- 19
P-33999
Figure 20-51- 20
P-35000
1
P-33998
442 Excavator
20-51-7 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 25
(CONT’D)
Disassembly (Cont’d)
Figure 20-51- 23
1
1
2
P-35003
Figure 20-51- 26
Remove the load seal and load seal back-up ring (Item 1)
[Figure 20-51- 23].
Figure 20-51- 24
1
P-35004
442 Excavator
20-51-8 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 29
(CONT’D)
Disassembly (Cont’d)
Figure 20-51- 27 1
P-35001
Remove the load seal and load seal back-up ring (Item 1)
[Figure 20-51- 29].
P-35005
Figure 20-51- 30
Figure 20-51- 28
P-35002
442 Excavator
20-51-9 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 33
(CONT’D)
Disassembly (Cont’d)
Figure 20-51- 31 1
P-35001
Remove the load seal and load seal back-up ring (Item 1)
[Figure 20-51- 33].
P-35007
Figure 20-51- 34
Figure 20-51- 32
P-35002
442 Excavator
20-51-10 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 37
(CONT’D)
Disassembly (Cont’d)
Figure 20-51- 35 1
P-35011
P-35012
P-35010
442 Excavator
20-51-11 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 41
(CONT’D)
Assembly
Figure 20-51- 39
1
P-35010
Figure 20-51- 42
P-35012
Figure 20-51- 40
1
P-35009
P-35011
442 Excavator
20-51-12 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 45
(CONT’D)
Assembly (Cont’d)
Figure 20-51- 43 1
P-35001
P-35008
442 Excavator
20-51-13 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 49
(CONT’D)
Assembly (Cont’d)
Figure 20-51- 47
P-35006
Figure 20-51- 50
P-35007
1
Install the gears (Item 1) [Figure 20-51- 47].
Figure 20-51- 48
P-35005
P-35002
442 Excavator
20-51-14 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 53
(CONT’D)
Assembly (Cont’d)
Figure 20-51- 51 1
2
P-35003
Figure 20-51- 54
Install the load seal back-up ring (Item 1) in the groove of
the load seal (Item 2) [Figure 20-51- 51].
Figure 20-51- 52
1
2
P-35002
Install the load seal and load seal back-up ring (Item 1)
[Figure 20-51- 52].
442 Excavator
20-51-15 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 57
(CONT’D)
Assembly (Cont’d)
Figure 20-51- 55 1
P-35000
Figure 20-51- 56 1
P-33999
P-35001
442 Excavator
20-51-16 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 61
(CONT’D)
Assembly (Cont’d)
Figure 20-51- 59
P-33997
Figure 20-51- 60
1
P-33995
442 Excavator
20-51-17 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 65
(CONT’D)
Assembly (Cont’d)
1
Figure 20-51- 63
1
P-33992
Figure 20-51- 64
1
1
2
P-33991
P-33993
Install the load seal and load seal back-up ring (Item 1)
[Figure 20-51- 64].
442 Excavator
20-51-18 Service Manual
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 69
(CONT’D)
Assembly (Cont’d)
Figure 20-51- 67
P-33811
1
Figure 20-51- 70
P-33989
1
Install the key (Item 1) [Figure 20-51- 67] on the shaft.
Figure 20-51- 68
2
P-33812
P-33987
442 Excavator
20-51-19 Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Figure 20-51- 73
(CONT’D)
Assembly (Cont’d)
2
Figure 20-51- 71
2
2 2
2
P-33809
2
1
Install the fitting (Item 1) [Figure 20-51- 73] on the pump.
1
P-33808 Install the bolts (Item 2) [Figure 20-51- 73].
Figure 20-51- 72
P-33810
442 Excavator
20-51-20 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
If any of the following adjustments are not obtainable, pump repair is required.
The outline listed below, gives the four adjustments for setting the hydraulic pump. The adjustments are listed in the order
in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page
location within the Service Manual for the complete adjustment procedure.
42. Remove the plug and install fitting and hose from the Torque Limit Supply Spool to a drain pan.
43. Install a 725 psi (50 bar) pressure gauge on the test port on the six spool control valve.
48. Remove the Hose and Fitting from the Torque Limiter Supply Spool and Plug the Port
__________ PM PRESSURE
54. Install 5000 PSI (345 bar) gauge on the test port on the six spool valve.
56. Run engine at high idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens.
57. Adjust backup relief valve as necessary to get 4350 ± 50 PSI (300 ± 3,4 bar).
442 Excavator
20-52-1 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
__________ PM PRESSURE
59. Install 5000 PSI (345 bar) Gauge on the test port on the six spool control valve.
60. Run Engine at High Idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens.
61. Adjust Load Sense Relief Valve as Necessary to get 4060 ± 50 PSI (280 ± 3,4 bar).
__________ PRESSURE
63. Remove the 5000 PSI (345 bar) Gauge, from the Pump Diagnostic Coupler at the Control Valve.
64. Remove the inlet hose from the six spool hydraulic control valve, install a cap on the valve and install the inlet hose
on the inlet side of the hydraulic tester.
65. Route the outlet hose of the hydraulic tester to the hydraulic reservoir.
66. Bottom out the pump margin spool (approximately six turns in)
__________ FLOW
__________ FLOW
442 Excavator
20-52-2 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
76. Install the pump outlet hose on the six spool hydraulic control valve.
77. Reset pump margin spool to 363 ± 20 PSI (25 ± 1,4 bar).
442 Excavator
20-52-3 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-1
AND S/N 528611001 & ABOVE) (CONT’D)
Testing Information
5
The testing of the piston pump must be done in the
following order:
442 Excavator
20-52-4 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-4
AND S/N 528611001 & ABOVE) (CONT’D)
Pump Testing
5
4
Torque Limiter Supply Pressure Adjustment
Figure 20-52-2
1
2
P-58096
1
Install a fitting and drain hose (Item 1) [Figure 20-52-4].
Place the other end of the hose in a drain pan.
Install a 725 PSI (500 bar) pressure gauge on the test Loosen the nut (Item 2) [Figure 20-52-4].
coupler (Item 1) [Figure 20-52-2].
Turn the pump margin spool (bottom spool) (Item 3)
Figure 20-52-3 [Figure 20-52-4] all the way in. (Approximately 6 turns)
Remove the plug (Item 2) [Figure 20-52-3]. Turn the pump margin spool (bottom spool) (Item 3)
[Figure 20-52-4] back to its original position.
(Approximately 6 turns)
442 Excavator
20-52-5 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-6
AND S/N 528611001 & ABOVE) (CONT’D)
2
P-58094
442 Excavator
20-52-6 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-9
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-8
1
P-58098
2
P-58095
442 Excavator
20-52-7 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Curl the bucket until the bucket cylinder is fully extended
AND S/N 528611001 & ABOVE) (CONT’D) and the relief valve opens.
Back-up Relief Valve Adjustment (Cont’d) The pressure at the gauge (Item 2) [Figure 20-52-11]
should be 4060 PSI (280 bar).
Figure 20-52-10
Stop the engine.
1 Figure 20-52-12
P-58099
Figure 20-52-11
1
2
1
P-33368
2
Loosen the lock nut (Item 1) [Figure 20-52-13].
442 Excavator
20-52-8 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-16
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-14
1
1
P-40577
Figure 20-52-17
P-40567
Figure 20-52-15
2 1
P-40578
P-40576
442 Excavator
20-52-9 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-20
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-18
1
P-58655
Figure 20-52-19
1
P-40580
442 Excavator
20-52-10 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-24
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-22 3
1
1
2
P-40580
Figure 20-52-25
1 1
P-58097
P-58650
Loosen the nut (Item 1) and turn the adjustment screw
(Item 2) [Figure 20-52-23] all the way in (approximately 6
turns). Remove the dust cover (Item 1) [Figure 20-52-25].
442 Excavator
20-52-11 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Install the protective cap on the hydraulic pump torque
AND S/N 528611001 & ABOVE) (CONT’D) limiter.
Figure 20-52-27
1
2 1
P-58651
When the proper flow is obtained, 41 GPM (155 L/min) at Retest and adjust the pump margin spool as needed.
1450 PSI (100 bar), lock the 27 mm nut (Item 2) [Figure (See Pump Margin Pressure Adjustment on Page 20-52-
20-52-26]. 6.)
NOTE: Changing the flow at low pressure (27 mm ALL PUMP ADJUSTMENTS ARE NOW COMPLETED.
nut) will affect flow at high pressure (13 mm
nut).
442 Excavator
20-52-12 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-29
AND S/N 528611001 & ABOVE) (CONT’D)
P-58531
IMPORTANT Remove the bolts (Item 1) and hose (Item 2) [Figure 20-
52-29].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Figure 20-52-30
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-52-28
1 P-58532
P-58530
442 Excavator
20-52-13 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-33
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-31
1
1
P-58535
Figure 20-52-32
1
P-58536
P-58534
Install a sling (Item 1) [Figure 20-52-34] on the pump.
442 Excavator
20-52-14 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-37
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-35
P-58539
Figure 20-52-36 1
P-58540
442 Excavator
20-52-15 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
1. O-Ring
2. Plug
3. Spring
4. Spool
5. Spring Seat 4 5
3 3
6. Cap 4 6
7
7. Nut 10 7
8. Adjustment Screw
9. Washer 8
10. Adjustment Body
1
1
9
1
B-26227
442 Excavator
20-52-16 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Clean the outside of the pump with clean solvent and dry
with compressed air before removing any components
from the pump.
Figure 20-52-39
P-58599
Figure 20-52-40
P-58601
442 Excavator
20-52-17 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-43
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-41 1
P-58604
Figure 20-52-42
3 2 1
P11468
P-58603
442 Excavator
20-52-18 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-47
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-45
3 2 1
P-58607
Figure 20-52-46
1 1
P-58608
Remove the plugs (Items) [Figure 20-52-46]. NOTE: If the adjustment assembly is removed and/or
disassembled, the torque limiter must be
tested and adjusted after the pump assembly
is installed in the machine. See “Initial Torque
Limiter Valve Setting” on page 26.)
442 Excavator
20-52-19 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-51
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-49
1
1 P-35326
Figure 20-52-50
3
1
4
2
P-35327
442 Excavator
20-52-20 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-53
P11475
442 Excavator
20-52-21 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-55
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-54
P-35327
Figure 20-52-56
P11475
P11473
442 Excavator
20-52-22 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-59
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-57
1
P-58607
Figure 20-52-58
1 1
1
P-58606
1 1
P-58608
442 Excavator
20-52-23 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-63
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-61 1
1 2
3
P-58604
2
1
P-58603
Install the springs (Items 1 & 2). Install the O-ring (Item 3)
on the plug (Item 4) [Figure 20-52-64].
442 Excavator
20-52-24 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-65
P-58602
442 Excavator
20-52-25 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-68
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-66
4.44”
(113 mm)
P11473
1
Measure from the cap to the top of the small adjusting
screw [Figure 20-52-68]. Set the small adjustment screw
to 4.44 inches (113 mm).
Figure 20-52-69
P11472
3 1
Remove the dust cap (Item 1) [Figure 20-52-66].
Figure 20-52-67
2
4
P-58601
3.98”
(101 mm) Align the linkage pin (Item 1) on the hydraulic piston
pump into the hole (Item 2) [Figure 20-52-69] in the
torque limiter valve.
P11473
Turn the valve slightly to align the dowel pin (Item 3) on
the hydraulic piston pump into the hole (Item 4) [Figure
Measure from the cap to the top of the large adjustment 20-52-69] in the torque limiter valve.
screw. Set the large adjustment screw to 3.98 inches
(101 mm) [Figure 20-52-67]. NOTE: Care should be taken not to scratch or
damage the valve spool.
442 Excavator
20-52-26 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-70
P-58600
Figure 20-52-71
P-58599
442 Excavator
20-52-27 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
1. Cap
2. O-Ring
3. Jam Nut
4. Adjusting Screw
5. O-Ring 1
6. Adjustment Assembly
7. Adjustment Assembly 2
8. Disc 3
9. Spring 2
10. Spring
11. Spring 4 1
12. Spring
2
13. Spring Retainer
14. Spring Retainer 6 3
15. O-Ring 2
16. Plug
5 4
17. Bolt
18.O-Ring
8 7
19. O-Ring
20. Housing
21. Orifice 5
22. Spool
9 8
10
11 12
13
14
18
19
21 16
15
18
17
20
17
17
22
22 17
2 2
16 16
TS-01531
442 Excavator
20-52-28 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-72
P-58599
Figure 20-52-73
1 1
P-58609
442 Excavator
20-52-29 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-76
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-74 4
2
3
1
N-23359
Figure 20-52-75
2
4
1
3
3
N-23360
2
N-23358 Remove the adjustment seat (Item 1) [Figure 20-52-77]
from the adjustment assembly.
Before disassembling the pump margin control, remove Remove the large spring (Item 2) and the small spring
the cap (Item 1) and O-ring washer (Item 2) [Figure 20- (Item 3) [Figure 20-52-77] from the adjustment
52-75] from the adjustment assembly. assembly.
Measure the adjustment screw (Item 3) [Figure 20-52- Replace the O-ring (Item 4) [Figure 20-52-77] before
75], thread length for the correct initial adjustment. installation.
442 Excavator
20-52-30 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-80
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-78
1 1
N-23380
Figure 20-52-81
N-23361
Figure 20-52-79
1
1
N-23362
N-23364
442 Excavator
20-52-31 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-84
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-82
2
1
1 N-23366
Check the O-ring washer (Item 1) [Figure 20-52-82] and Figure 20-52-85
replace as needed.
Figure 20-52-83
N-23367
N-23365
442 Excavator
20-52-32 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-88
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-86
2
N-23377
4
Remove the spring guide (Item 1) [Figure 20-52-88].
3
1 Figure 20-52-89
N-23368
Remove the adjustment screw (Item 1), jam nut (Item 2),
and O-ring washer (Item 3) from the adjustment
assembly (Item 4) [Figure 20-52-86].
Figure 20-52-87
3 1
2 N-23378
1
N-23369
442 Excavator
20-52-33 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-92
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-52-90
1
1
N-23382
N-23379
Figure 20-52-91
1
N-23381
442 Excavator
20-52-34 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Parts Identification
1. Seal
2. Shaft
3. Bolt
4. Bearing
5. Plug
6. Piston
6
3
4
5
4
B-19529
442 Excavator
20-52-35 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-94
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly
IMPORTANT 1
Figure 20-52-93
1
1
P-58611
442 Excavator
20-52-36 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-98
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-96 2
1 1
P-58614
1
Remove the 4 bolts (Item 1) [Figure 20-52-98].
2
P-58612 Remove the block port assembly (Item 2) [Figure 20-52-
98] from the pump.
1 N-23386
442 Excavator
20-52-37 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-102
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-100
1
1
N-23389
Figure 20-52-101
1
2
1
N-23390
N-23388
442 Excavator
20-52-38 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-106
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
2
1
Figure 20-52-104
N-15287
1
3 2 2
1 3
N-23392
N-15299
Slide the rotary group (Item 1) from the shaft assembly To remove the spring from inside the cylinder block, use
(Item 2) [Figure 20-52-105]. a threaded rod (or bolt) (Item 1) two trimmed washers
(Item 2) and two nuts (Item 3) [Figure 20-52-107].
NOTE: It is NOT important that the pistons are
installed in their original positions.
442 Excavator
20-52-39 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-110
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-108
4 1
2 N-15290
3
Tighten the nut (Item 1) until the spring is compressed
enough to remove the snap ring (Item 2) [Figure 20-52-
N-15288 110].
Figure 20-52-109
1 2 3
1
2
4
3
N-15291
N-15289
442 Excavator
20-52-40 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-114
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-112
1
1 2
N-15284
Figure 20-52-113
1
N-23394
3
3
1 2 Remove the snap ring (Item 1) [Figure 20-52-115] from
the housing.
N-23395
442 Excavator
20-52-41 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-118
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-116
N-15280
1 1
1
N-23397
N-15277
442 Excavator
20-52-42 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-122
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-120 1
N-23416
Figure 20-52-121
1
1
N-23418
442 Excavator
20-52-43 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 20-52-124
N-23419
442 Excavator
20-52-44 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-127
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly
Figure 20-52-125
2
N-23416
Figure 20-52-128
N-23419
Figure 20-52-126 1
N-23417
1
N-23418
442 Excavator
20-52-45 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-131
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 20-52-129 1
N-23394
Figure 20-52-130
2
N-15285
442 Excavator
20-52-46 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-135
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
1
Figure 20-52-133
2
2
P-58614
Figure 20-52-134
N-23429
N-23425
442 Excavator
20-52-47 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Example: (In Inches):
AND S/N 528611001 & ABOVE) (CONT’D)
0.150 Measure movement of shaft
Assembly (Cont'd)
0.001 Nominal Pre-load
Figure 20-52-137
= 0.151 ± thickness of the spacer needed.
Remove the two end plate mounting bolts from the pump.
Figure 20-52-138
N-23430
1
Install a dial indicator on the housing as shown [Figure
20-52-137] and set it to zero. 1
442 Excavator
20-52-48 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-141
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 20-52-139
3
2 1
N-15291
1 2
3 2 3
1 2
N-23393
N-15299
442 Excavator
20-52-49 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-145
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 20-52-143
2
1
4
2
4
1
N-15290
4 3
NOTE: The modified washer (Item 1) [Figure 20-52-
144] must fit over the spring, but must also fit
N-15289 inside the snap ring (Item 2) [Figure 20-52-
145].
Install the threaded rod and nut (Item 1) through the Tighten the nut (Item 1) until the spring is compressed
modified washer (Item 2) and the block assembly (Item 3) enough to install the snap ring (Item 2) [Figure 20-52-
[Figure 20-52-143]. 145].
NOTE: The modified washer (Item 2) must fit between Remove the threaded rod/washer assembly.
the three pins (Item 4) [Figure 20-52-143].
Figure 20-52-146
Figure 20-52-144
2
1
P-58616
N-15288
442 Excavator
20-52-50 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-149
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 20-52-147
2 N-15276
Lay the pump housing on its side and install the rotary
group assembly, swash plate, and shaft in the housing
P-58615 [Figure 20-52-149].
Figure 20-52-150
Install the piston assembly (Item 1) in the cylinder block
(Item 2) [Figure 20-52-147].
1
2
N-23390
442 Excavator
20-52-51 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-153
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd) 1
Figure 20-52-151 1
1
1
2
N-23397
N-23431
442 Excavator
20-52-52 Service Manual
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE Figure 20-52-157
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 20-52-155
1
2
1
P-58611
Figure 20-52-158
2
2
P-58614
1
Align the marks and install the back port assembly (Item
1) [Figure 20-52-156] on the pump housing.
442 Excavator
20-52-53 Service Manual
442 Excavator
20-52-54 Service Manual
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE Figure 20-53-2
AND S/N 528611001 & ABOVE)
IMPORTANT
P-58490
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Remove the 4 bolts (Item 1) [Figure 20-53-2] and the
tubelines and ports to keep dirt out. Dirt can quickly hose.
damage the system.
I-2003-0888
Figure 20-53-3
Figure 20-53-1
1 1
1 1
P-58491
P-58489
Remove the 2 bolts (Item 1) [Figure 20-53-3].
Remove the 4 bolts (Item 1) [Figure 20-53-1] and Installation: Apply thread adhesive (Loctite™ 242) to the
remove the hose. bolt threads. Tighten the bolts to 48-55 ft.-lb. (65-75 N•m)
torque.
442 Excavator
20-53-1 Service Manuall
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 20-53-4
P-58492
442 Excavator
20-53-2 Service Manual
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Parts Identification
1. Snap Ring 3
2. Seal
3. Pump Flange 2
4. Set Screw 1 2
5. Bushing 4
6. Backup Ring 5
7. Bearing
8. Gear
9. Housing
10. Washer
11. Bolt
7 2 6
8
7
2
6
5
11
10
5
442 Excavator
20-53-3 Service Manuall
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE Figure 20-53-7
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly
Figure 20-53-5
P-58495
Figure 20-53-8
1 1
1
P-58493
Figure 20-53-6
P-58496
P-58494
442 Excavator
20-53-4 Service Manual
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE Figure 20-53-11
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont’d)
Figure 20-53-9 1
P-58502
Figure 20-53-10
P-58501
442 Excavator
20-53-5 Service Manuall
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont’d)
Figure 20-53-13
P-58497
Figure 20-53-14
P-58498
442 Excavator
20-53-6 Service Manual
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE Figure 20-53-17
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly
2
Clean all parts in solvent and dry with compressed air.
Figure 20-53-15
1 P-58501
Figure 20-53-18
P-58498 2
1
Install the seal (Item 1) [Figure 20-53-15].
Figure 20-53-16
P-58503
442 Excavator
20-53-7 Service Manuall
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE Figure 20-53-21
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-53-19 1
P-58506
Figure 20-53-20
P-58505
442 Excavator
20-53-8 Service Manual
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont’d)
Figure 20-53-22
P-58493
Figure 20-53-23
P-58494
Turn the pump over and install the washers and bolts
(Item 1) [Figure 20-53-22] & [Figure 20-53-23].
442 Excavator
20-53-9 Service Manuall
442 Excavator
20-53-10 Service Manual
ACCUMULATOR (S/N 522311001 & ABOVE) Figure 20-60-2
Description
With the engine off and the key in the run position, move 1
the control levers to relieve hydraulic pressure.
P-33160
Figure 20-60-1
P-33161
1
Remove the accumulator (Item 1) [Figure 20-60-3].
P-33159
442 Excavator
20-60-1 Service Manual
442 Excavator
20-60-2 Service Manual
ACCUMULATOR (S/N 528911001 & ABOVE AND S/N
528611001 & ABOVE)
Description
With the engine off and the key in the run position, move
the control levers to relieve hydraulic pressure.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-61-4
P-58102
442 Excavator
20-61-1 Service Manual
442 Excavator
20-61-2 Service Manual
TRAVEL MOTOR Figure 20-70-3
Figure 20-70-1
1 1
P-40958
1
Remove the bolts (Item 1) from the flange (Item 2)
[Figure 20-70-3].
Figure 20-70-2
1
1
P-40957
442 Excavator
20-70-1 Service Manual
TRAVEL MOTOR (CONT’D)
Parts Identification
1. Plug
2. Snap Ring
3. End Cover
4. Gear
5. Bearing
6. Nut
7. Housing
8. Seal 7
9. Piston
10. Discs
11. Spring
12. Swash Plate 9
10 2
13. O-Ring 5 5
9 4
14. Piston Assy. 8 4
15. Poppet
16. Shaft
2
5
5
4
1
2 13
13 16
13 11
11 14 12
11
15
B-24939
442 Excavator
20-70-2 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-6
Disassembly 1
2
Drain the travel motor oil. (See Draining The Travel Motor
on Page 10-120-1.)
Figure 20-70-4
1
1
2
P-61589
3
Remove the O-ring (Item 1) and planetary carrier (Item 2)
[Figure 20-70-6].
Remove the drain plugs (Item 1), snap ring (Item 2) and
cover (Item 3) [Figure 20-70-4].
1
Figure 20-70-5
1
P-61591
P-61588
442 Excavator
20-70-3 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-10
Disassembly (Cont’d)
Figure 20-70-8 1
P-46412
Figure 20-70-11
Pry the planetary gears (Item 1) [Figure 20-70-8] off of
the carrier.
1
1
1
2 P-61596
Remove the snap ring (Item 1). Remove the sun gear
(Item 2) [Figure 20-70-11].
1
P-61593
442 Excavator
20-70-4 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-14
Disassembly (Cont’d)
Figure 20-70-12
1 1
P-61599
1
Center punch and drill the nut where shown (Item 1)
P-61597 [Figure 20-70-14].
Figure 20-70-15
1
1
2
P-61598
P-61600
Pry the planetary gears (Item 1) [Figure 20-70-13] off of
the carrier.
Install a puller (Item 1) on the ring gear (Item 2) [Figure
Record the orientation of the gear/bearing assembly. The 20-70-15].
gear/bearing assembly can only be installed in one
direction. Remove the ring gear.
442 Excavator
20-70-5 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-18
Disassembly (Cont’d)
Figure 20-70-16
2
1
P-61604
2
1
P-61606
P-61603
442 Excavator
20-70-6 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-22
Disassembly (Cont’d)
1
Figure 20-70-20
P-61609
1 1
P-58848
P-61838
442 Excavator
20-70-7 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-26
Disassembly (Cont’d)
1
Figure 20-70-24
P-58851
1
2
Loosen the retainer (Item 1) [Figure 20-70-26].
P-58849
Figure 20-70-27
Figure 20-70-25
P-58852
442 Excavator
20-70-8 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-30
Disassembly (Cont’d)
Figure 20-70-28
2 1
P-58855
Figure 20-70-31
Remove the poppet (Item 1) [Figure 20-70-28].
Figure 20-70-29
1
1
P-58856
442 Excavator
20-70-9 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-34
Disassembly (Cont’d)
Figure 20-70-32
1
P-61791
Figure 20-70-33 2
1
3
2 1
P-61792
442 Excavator
20-70-10 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-38
Disassembly (Cont’d)
Figure 20-70-36
1
P-58862
1 P-61790
442 Excavator
20-70-11 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-42
Disassembly (Cont’d)
1
Figure 20-70-40
P-61793
Figure 20-70-41
1
2
2
1
P-61794
3
Remove the poppet (Item 1), back-up rings (Item 2), and
O-ring (Item 3) [Figure 20-70-41].
442 Excavator
20-70-12 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-46
Disassembly (Cont’d)
Figure 20-70-44
1
1
P-61799
3
2 1
P-58849
442 Excavator
20-70-13 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-50
Disassembly (Cont’d)
Figure 20-70-48
P-58873
Figure 20-70-51
Remove the spring seat (Item 1) [Figure 20-70-48].
Figure 20-70-49
1
1
P-58874
442 Excavator
20-70-14 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-54
Disassembly (Cont’d)
5
Figure 20-70-52
2
5
4
2
1 1
1
3
P-61805
Remove the spring seat (Item 1), spring (Item 2), spring
P-58875 seat (Item 3), spool (Item 4) and alignment pins (Item 5)
[Figure 20-70-54].
Remove the 8 bolts (Item 1), and lock valve (Item 2) Figure 20-70-55
[Figure 20-70-52].
Figure 20-70-53
1
P-61806
Turn the lock valve over. Remove the snap ring (Item 1)
[Figure 20-70-53].
442 Excavator
20-70-15 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-58
Disassembly (Cont’d)
Figure 20-70-56 2
1
2 1
1
P-61782
Figure 20-70-59
Remove the 26 springs (Item 1) and spring retainer (Item
2) [Figure 20-70-56].
1
Figure 20-70-57
P-58887
442 Excavator
20-70-16 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-62
Disassembly (Cont’d)
1
Figure 20-70-60
1 P-58836
Figure 20-70-61
P-58837
P-58889
442 Excavator
20-70-17 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-66
Disassembly (Cont’d)
Figure 20-70-64
1
1
P-58840
Figure 20-70-67
Remove the brake disc stop (Item 1) [Figure 20-70-64].
Figure 20-70-65
1 2
1
1
2
P-58841
P-58839 Remove the piston plate pivot (Item 1) and shaft (Item 2)
[Figure 20-70-67].
442 Excavator
20-70-18 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-70
Disassembly (Cont’d)
Figure 20-70-68
1
1
P-58847
Figure 20-70-69 1
2
1
P-61807A
442 Excavator
20-70-19 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-73
Assembly
1
1
P-61807A
P-61807
Install the seal (Item 1). Install the bearing race (Item 2)
[Figure 20-70-72]. Install the piston assembly (Item 1) [Figure 20-70-74].
442 Excavator
20-70-20 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-77
Assembly (Cont’d)
1
Figure 20-70-75
P-61779
Figure 20-70-76 1
P-58842
442 Excavator
20-70-21 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-81
Assembly (Cont’d)
1
Figure 20-70-79
P-61673
Figure 20-70-82
Install the shaft (Item 1) [Figure 20-70-79].
Figure 20-70-80
1 1
2 3
P-61674
1
5
4
P-61672 Apply assembly lube to the sleeves and springs (Item 1)
[Figure 20-70-82] and install.
442 Excavator
20-70-22 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-85
Assembly (Cont’d)
Figure 20-70-83
1
1 P-61677
Figure 20-70-84
P-58888
442 Excavator
20-70-23 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-89
Assembly (Cont’d)
Figure 20-70-87 1
P-61783
Figure 20-70-90
Install the brake piston (Item 1) [Figure 20-70-87].
2
Figure 20-70-88 1
3
3
1
2
2
P-61781
2
P-61782 Install the spring retainer (Item 1) and springs (Item 2)
[Figure 20-70-90] as shown.
Install the snap ring (Item 1) and three O-rings (Item 2) The lock valve alignment pins must engage the open
[Figure 20-70-88]. spring slots (Item 3) [Figure 20-70-90] leaving one open
spring slot on each side of the alignment pins.
442 Excavator
20-70-24 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-93
Assembly (Cont’d)
Figure 20-70-91
1
P-61784
1
3
1
4 P-58877
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3), spring seat (Item 4), and alignment pins (Item 5)
[Figure 20-70-92].
442 Excavator
20-70-25 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-97
Assembly (Cont’d)
Figure 20-70-95
1
2
2
P-58873
Figure 20-70-98
Install the lock valve (Item 1) on the hub. Install the eight
bolts (Item 2) [Figure 20-70-95] and tighten to 55-60 ft.-
lb. (75-85 N•m) torque.
Figure 20-70-96
1
1
P-61800
P-58874
442 Excavator
20-70-26 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-101
Assembly (Cont’d) 1
Figure 20-70-99 2
P-58855
Figure 20-70-102
Install the O-ring (Item 1) and spring (Item 2) [Figure 20-
70-99].
Figure 20-70-100 1
P-61798
442 Excavator
20-70-27 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-105
Assembly (Cont’d)
Figure 20-70-103 2
2
1
3 1
2
P-61792
Figure 20-70-106
Install the O-ring (Item 1) and back-up rings (Item 2)
[Figure 20-70-103].
Figure 20-70-104 1
P-61797
442 Excavator
20-70-28 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-109
Assembly (Cont’d)
Figure 20-70-107
2
1
1
2 3
P-61794
Figure 20-70-110
Install the O-ring (Item 1), shims (Item 2), and spring
(Item 3) [Figure 20-70-107].
Figure 20-70-108 1
P-61793
442 Excavator
20-70-29 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-113
Assembly (Cont’d)
1
Figure 20-70-111 2 3
2
3
1 P-61790
Install the O-ring (Item 1), shims (Item 2) and spring (Item
P-61792 3) [Figure 20-70-113].
Figure 20-70-114
Install the O-ring (Item 1), back-up rings (Item 2), and
poppet (Item 3) [Figure 20-70-111]. 1
Figure 20-70-112
P-58857
442 Excavator
20-70-30 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-117
Assembly (Cont’d)
Figure 20-70-115
1
2
P-58853
Figure 20-70-116
1 1
P-58852
442 Excavator
20-70-31 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-121
Assembly (Cont’d)
Figure 20-70-119 1
P-58848
Figure 20-70-120 1
P-61606
442 Excavator
20-70-32 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-125
Assembly (Cont’d) 1
Figure 20-70-123
P-61810
2 2
P-46426
442 Excavator
20-70-33 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-129
Assembly (Cont’d) 1
Figure 20-70-127
P-61811
Shake off the excess alcohol and install the seal ring
P-61785 assembly (Item 1) [Figure 20-70-129].
Apply a light film of oil to the metal seal ring. Figure 20-70-130
Figure 20-70-128
P-61812
Check the seal stand off height. The stand off height
P-61786 must be uniform with no twists in the O-ring [Figure 20-
70-130].
Check the seal stand off height. The stand off height
must be uniform with no twists in the O-ring [Figure 20-
70-128].
442 Excavator
20-70-34 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-133
Assembly (Cont’d)
Figure 20-70-131
1
P-61598
Figure 20-70-134
Install the ring gear (Item 1) [Figure 20-70-131].
1
Figure 20-70-132
P-61597
442 Excavator
20-70-35 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-137
Assembly (Cont’d)
Figure 20-70-135 2
2
1
1
P-61593
2
Install the driveshaft (Item 1) and washers (Item 2)
P-61596 [Figure 20-70-137].
Figure 20-70-138
Install the sungear (Item 1) and snap ring (Item 2)
[Figure 20-70-135].
Figure 20-70-136
1
P-61592
442 Excavator
20-70-36 Service Manual
TRAVEL MOTOR (CONT’D) Figure 20-70-141
Assembly (Cont’d)
Figure 20-70-139
1
1 1
P-61588
P-61585
Install the cover (Item 1), snap ring (Item 2) and drain
P-61589 plugs (Item 3) [Figure 20-70-142].
442 Excavator
20-70-37 Service Manual
442 Excavator
20-70-38 Service Manual
SWIVEL JOINT Figure 20-80-3
1
1 1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-38631
Tilt the cab. (See Tilting The Cab on Page 10-160-2.)
Figure 20-80-4
1
1
2 1
1
P-38636
P-38630
Mark and remove the 4 hoses (Item 1) [Figure 20-80-1]
from the top of the swivel joint.
Remove the 3 left bolts (Item 1) [Figure 20-80-4] and
Figure 20-80-2 washers.
1 1
P-38638
442 Excavator
20-80-1 Service Manual
SWIVEL JOINT (CONT’D) Figure 20-80-7
Figure 20-80-5
1
1 P-38634
Figure 20-80-6
1 1
1
P-38635
P-38633 Rotate and lower the swivel joint from the excavator.
442 Excavator
20-80-2 Service Manual
SWIVEL JOINT (CONT’D)
Parts Identification
B-24943A
442 Excavator
20-80-3 Service Manual
SWIVEL JOINT (CONT’D) Figure 20-80-11
1
P-40048
Figure 20-80-10
2 P-40049
1
1
Remove the snap ring (Item 1) [Figure 20-80-12].
P-40047
442 Excavator
20-80-4 Service Manual
SWIVEL JOINT (CONT’D) Figure 20-80-15
P-40052
1 2
1
2
P-40051
P-40044
442 Excavator
20-80-5 Service Manual
442 Excavator
20-80-6 Service Manual
SWING MOTOR Figure 20-90-3
2
1 P-38627
P-38628
IMPORTANT
Figure 20-90-2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 20-90-4
P-38629
1 1
2
P-38641
442 Excavator
20-90-1 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-7
Figure 20-90-5
2 1
1 2
1
1
P-38644
Mark and remove the 4 bolts (Item 1). Remove the split Remove the motor.
flange hoses (Item 2) [Figure 20-90-5].
Figure 20-90-8
Figure 20-90-6
P-38645
P-38643
442 Excavator
20-90-2 Service Manual
SWING MOTOR (CONT’D)
Parts Identification
1 Valve
2 Plug
3 End Cap
4 Bolt
5 O-ring
6 Pin
7 Bearing
8 Snap Ring
9 Locking Ring
10 Seal
11 Drive Shaft
7 7
8
6
2
11
1
5
2
10
3
4
8
9
5
6 2
4
B-19528
442 Excavator
20-90-3 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-11
Disassembly 1
Figure 20-90-9
P-38676
1
Figure 20-90-10
P-38677
442 Excavator
20-90-4 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-15
Disassembly (Cont’d)
Figure 20-90-13
1
1
P-38683
Figure 20-90-14
1
2 1
P-38685
P-38682
442 Excavator
20-90-5 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-19
Disassembly (Cont’d)
Figure 20-90-17
1
1
P-38687
Figure 20-90-18
1
P-38688
1
Remove the seal (Item 1) [Figure 20-90-20] from the
P-38686 retainer.
442 Excavator
20-90-6 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-23
Disassembly (Cont’d)
Figure 20-90-21 2
1
1
P-38691
Figure 20-90-24
P-38689
Figure 20-90-22 1
P-38692
442 Excavator
20-90-7 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-27
Disassembly (Cont’d)
Figure 20-90-25
1
P-38697
2
Figure 20-90-26 1
3
2
1
P-38698
442 Excavator
20-90-8 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-31
Disassembly (Cont’d)
Figure 20-90-29
1 1
P-38706
1 2
P-38703
P-38700
442 Excavator
20-90-9 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-34
Assembly
Check all parts for rough surfaces and wear, replace any
worn or damaged parts. 1
Figure 20-90-35
P-38702
1
2
P-38707
442 Excavator
20-90-10 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-38
Assembly (Cont’d)
Figure 20-90-36 1
P-38697
Figure 20-90-37 3
1
2
1
P-38695
442 Excavator
20-90-11 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-42
Assembly (Cont’d)
Figure 20-90-40
P-38689
Figure 20-90-41
1
P-38690
442 Excavator
20-90-12 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-46
Assembly (Cont’d)
Figure 20-90-44
P-38686
Figure 20-90-45
P-38679
1
P-38685
442 Excavator
20-90-13 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-51
Assembly (Cont’d)
Figure 20-90-49
2
3
1
1
P-38681
1
Figure 20-90-50
1 1
1
1
P-38677
P-38682
Install the crossport relief valves (Item 1) [Figure 20-90-
52] and tighten to __ ft.-lb. (__ N•m) torque.
Install the 2 long bolts (Item 1) and 3 short bolts (Item 2)
[Figure 20-90-50].
442 Excavator
20-90-14 Service Manual
SWING MOTOR (CONT’D) Figure 20-90-55
Assembly (Cont’d)
Figure 20-90-53
P-38674
Figure 20-90-54
P-38675
442 Excavator
20-90-15 Service Manual
442 Excavator
20-90-16 Service Manual
SWING MOTOR DRIVE CARRIER Figure 20-91-3
Figure 20-91-1
1
1
P-38649
Figure 20-91-4
P-38646
1
P-38647
P-38648
442 Excavator
20-91-1 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D)
Figure 20-91-5
P-38650
Figure 20-91-6
P-38651
442 Excavator
20-91-2 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D)
Parts Identification
1 Snap Ring
2 Plunger Disc 1
3 O-Ring 1
4 Bolt 16
5 Brake Housing 2 20
1 17
6 Seal 3
7 Seal 15
8 Brake Disc
9 Piston
10 Belleville Spring 4 5 22
11 Spring Support
12 Driveshaft 23
3
13 Shim 24
14 Thrust Washer
6 23
15 Shim
16 Bearing 7
25
17 Gear
18 Pin 26
19 Bearing
8
20 Sun Gear
21 Pinion Cage
22 Planetary Gear 9 27
23 Nut
10
24 Locking Plate
25 Bearing 11
26 Seal 1
27 Drive Housing
28 Bearing
12 28
29 Seal
30 Washer 1
29
31 Pinion 1 14
13 15
16 30
17
19
15
21 14
13
18 31
1
19
20
442 Excavator
20-91-3 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-9
Disassembly
Figure 20-91-7
2 2
1
P-38908
Figure 20-91-8
2 P-38909
Turn the brake housing over and remove the O-ring (Item
1) [Figure 20-91-10].
1 P-38907
442 Excavator
20-91-4 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-13
Disassembly (Cont’d)
Figure 20-91-11
P-38912
1
Note the orientation of the belleville spring (Item 1)
P-38910 [Figure 20-91-13].
P-38913
P-38911
Turn the brake housing over and tap the piston out
Remove the support disc (Item 1) [Figure 20-91-12]. [Figure 20-91-14].
442 Excavator
20-91-5 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-17
Disassembly (Cont’d)
Figure 20-91-15
1
P-38916
Turn the brake housing over and remove the two seals
(Item 1) [Figure 20-91-15].
1
Figure 20-91-16
P-38917
P-38915
442 Excavator
20-91-6 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-21
Disassembly (Cont’d)
Figure 20-91-19
1
P-38920
P-38922
P-38919
442 Excavator
20-91-7 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-25
Disassembly (Cont’d)
Figure 20-91-23
P-38925
Figure 20-91-26
Remove the snap ring (Item 1) [Figure 20-91-23] and
washer.
Figure 20-91-24
1
1
P-38926
442 Excavator
20-91-8 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-29
Disassembly (Cont’d)
Figure 20-91-27 2
P-38930
Figure 20-91-28
P-38997
442 Excavator
20-91-9 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-33
Disassembly (Cont’d)
Figure 20-91-31
P-40000
1
Remove the nut (Item 1) [Figure 20-91-33].
P-38998
Figure 20-91-34
Figure 20-91-32
P-40001
Press the pinion out the bottom of the carrier [Figure 20-
1 91-34].
P-38999
442 Excavator
20-91-10 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-37
Disassembly (Cont’d)
Figure 20-91-35 1
P-40004
1
Turn the carrier over and remove the scraper seal (Item
P-40002 1) [Figure 20-91-37].
Figure 20-91-38
Remove the pinion (item 1) and top bearing (Item 2)
[Figure 20-91-35].
2
Figure 20-91-36
P-40005
442 Excavator
20-91-11 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D)
Disassembly (Cont’d)
Figure 20-91-39
P-40007
Figure 20-91-40
P-40008
442 Excavator
20-91-12 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-43
Assembly
Figure 20-91-41
P-40014
1
Pack the lower bearing (Item 1) [Figure 20-91-43] with a
good quality high temperature NLGI grease.
Figure 20-91-44
P-40008
P-40015
P-40009
442 Excavator
20-91-13 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-47
Assembly (Cont’d)
Figure 20-91-45 1
P-40005
Turn the carrier over and install the bearing race (Item 1)
P-40006 [Figure 20-91-47].
Figure 20-91-48
Apply a light coat of grease to the bearing side of the
washer (Item 1) [Figure 20-91-45].
Figure 20-91-46
1
P-40004
442 Excavator
20-91-14 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-51
Assembly (Cont’d)
Figure 20-91-49
P-40017
Figure 20-91-50
P-40000
1
Apply clean hydraulic fluid or assembly lube to the top Loosen the nut 15 to 30 degrees after the inner nut has
bearing (Item 1) [Figure 20-91-50]. been installed. The shaft should turn when 1.5-3.7 ft.-lb.
(2-5 N•m) of force is applied to the shaft.
442 Excavator
20-91-15 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-55
Assembly (Cont’d)
Figure 20-91-53
1
P-38998
Figure 20-91-54 3
2
P-40020
P-38997
Place the washer (Item 1) and snap ring (Item 2) [Figure
20-91-56] on the planetary carrier.
Support the carrier in a press. Clamp the carrier shaft
with approximately 800 lb. (1085 N•m) of force [Figure Apply assembly lube to the bottom of the planetary gear
20-91-54]. stud (Item 3) [Figure 20-91-56].
442 Excavator
20-91-16 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-59
Assembly (Cont’d)
Figure 20-91-57 1
P-40023
Figure 20-91-58 1
P-40024
442 Excavator
20-91-17 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-63
Assembly (Cont’d)
Figure 20-91-61
P-40028
Figure 20-91-62
P-40029
P-40027
442 Excavator
20-91-18 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-67
Assembly (Cont’d)
Figure 20-91-65
1
1
P-38925
Figure 20-91-68
Install the washer (Item 1) [Figure 20-91-65].
Figure 20-91-66
2 P-38924
442 Excavator
20-91-19 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-71
Assembly (Cont’d)
Figure 20-91-69
1
P-40031
Figure 20-91-72
Install the snap ring (Item 1) [Figure 20-91-69].
Figure 20-91-70
P-40032
442 Excavator
20-91-20 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-75
Assembly (Cont’d)
1
Figure 20-91-73
P-40035
Figure 20-91-76
Apply assembly lube to the thrust washers and install the
top and bottom washers (Item 1) [Figure 20-91-73].
1
Figure 20-91-74
1
2
1
P-40037
Turn the pinion cage over and install the snap rings (Item
P-40034 1) [Figure 20-91-76].
442 Excavator
20-91-21 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-79
Assembly (Cont’d)
Figure 20-91-77
1
2
P-38912
Figure 20-91-78
1
P-38911
P-38914
Install the spring support (Item 1) [Figure 20-91-80].
442 Excavator
20-91-22 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-83
Assembly (Cont’d)
Figure 20-91-81
P-38906
P-38909 P-40038
Install the O-ring (Item 1) [Figure 20-91-82]. Install the driveshaft (Item 1) [Figure 20-91-84].
442 Excavator
20-91-23 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-87
Assembly (Cont’d)
Figure 20-91-85
P-40041
Figure 20-91-88
Install the internal and external brake discs (Item 1)
[Figure 20-91-85].
Figure 20-91-86
P-40040
P-40042
442 Excavator
20-91-24 Service Manual
SWING MOTOR DRIVE CARRIER (CONT’D)
Assembly (Cont’d)
Figure 20-91-89
1
2
P-40043
Install the snap ring (Item 1). Remove the tube (Item 2)
[Figure 20-91-89] and press assembly from the carrier.
442 Excavator
20-91-25 Service Manual
442 Excavator
20-91-26 Service Manual
SWING BRAKE VALVE Figure 20-92-3
Figure 20-92-1
P-33381
1
Remove the 2 bolts (Item 1) [Figure 20-92-3] and
washers.
Remove the wire harness (Item 1) [Figure 20-92-1]. Remove the valve.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-92-2
P-33380
442 Excavator
20-92-1 Service Manual
SWING BRAKE VALVE (CONT’D)
Parts Identification
1. Housing
2. Back-up Ring
3. O-Ring
4. Solenoid Valve
5. Coil
6. Nut
3
2
2
2
2
5
6
MS1536
442 Excavator
20-92-2 Service Manual
SWING BRAKE VALVE (CONT’D) Figure 20-92-6
Figure 20-92-4
P-35916
Figure 20-92-5 1
1 1
2 2
2
P-35917
1
442 Excavator
20-92-3 Service Manual
442 Excavator
20-92-4 Service Manual
SWING BRAKE RELEASE VALVE Figure 20-93-2
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P-33386
I-2003-0888
1
1
2
1
P-33385
442 Excavator
20-93-1 Service Manual
SWING BRAKE RELEASE VALVE (CONT’D)
Parts Identification
1 Fitting
2 O-ring
3 Check Ball
1
4 Valve Body
5 Spool
6 Spring
5
2
6
1
MS1535
442 Excavator
20-93-2 Service Manual
SWING BRAKE RELEASE VALVE (CONT’D) Figure 20-93-5
Figure 20-93-3
P-36119
1
Remove the spring (Item 1) [Figure 20-93-5].
Figure 20-93-6
P-36117
Figure 20-93-4
P-36120
P-36118
442 Excavator
20-93-3 Service Manual
SWING BRAKE RELEASE VALVE (CON’TD) Figure 20-93-9
Figure 20-93-7
P-36122
Figure 20-93-8 Clean all parts in solvent and dry with compressed air
before assembly.
P-36121
442 Excavator
20-93-4 Service Manual
JOYSTICK CONTROL PATTERN SELECTOR VALVE Figure 20-100-3
Figure 20-100-1
3
1
4 4
1
P-33158
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-100-2
1 1
1
P-33157
442 Excavator
20-100-1 Service Manual
JOYSTICK CONTROL PATTERN SELECTOR VALVE
(CONT’D)
Parts Identification
1 Valve Body
2 Back up Ring
3 O-ring
4 Fitting
5 Spool
6 Coil
7 Nut
2
2
2
2
3
3
3 5
4 3
6
MS1534
442 Excavator
20-100-2 Service Manual
JOYSTICK CONTROL PATTERN SELECTOR VALVE Figure 20-100-6
(CONT’D)
Figure 20-100-4 1
1
1
2
2
1
P-36288
Figure 20-100-5
1
P-36289
442 Excavator
20-100-3 Service Manual
442 Excavator
20-100-4 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-101-2
522311001 & ABOVE)
Figure 20-101-1
1
1
P-33163
1
2
Mark and remove the 4 hoses (Item 1) [Figure 20-101-
2].
Figure 20-101-3
P-33162
1
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
P-33164
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Remove the 2 bolts (Item 1) [Figure 20-101-3] and
damage the system. washers.
I-2003-0888
442 Excavator
20-101-1 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) (CONT’D)
Parts Identification
1 Nut
2 Coil
1
3 Spool
4 O-Ring
5 Back-up Ring
1
6 Valve Body
4 5
4
MS1538
442 Excavator
20-101-2 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-101-6
522311001 & ABOVE) (CONT’D)
Figure 20-101-4
1
1
P-36219
Figure 20-101-5
1
1
P-36220
P-36218
442 Excavator
20-101-3 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-101-10
522311001 & ABOVE) (CONT’D)
1 P-36223
Remove the spool (Item 1) [Figure 20-101-8] Installation: Clean all components with solvent and dry
with compressed air.
Figure 20-101-9
Inspect all parts and replace any that are damaged.
2
2
P-36222
442 Excavator
20-101-4 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-102-2
528911001 & ABOVE AND S/N 528611001 & ABOVE)
Figure 20-102-1 1
1
1
P-58103
1
1
Mark and remove the hoses (Item 1) [Figure 20-102-2].
Figure 20-102-3
P-58102
IMPORTANT 1
442 Excavator
20-102-1 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-102-6
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-102-4
P-58107
P-58105
Figure 20-102-5
1
P-58106
442 Excavator
20-102-2 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Parts Identification
1. Nut
2. O-Ring
3. Coil
4. Spool
5. Plug
6. Spring
1 1
7. Ball
8. Valve Body
2 2
9. Back-up Ring
10. Accumulator
11. Valve Block
3 3
12. Test Fitting W/Cap 1
13. Pressure
Reducing Valve 2 2
2
5
9
4 3
2
4
6
2
7
2 2
8
2 4
9 9 2
2
9 2 9 2 2 2
9
9 2
9 2
10
2
9
2
2
9
2
2 11 13
12
MS2024S
442 Excavator
20-102-3 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-102-9
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-102-7
P-58110
P-58109
P-58078
442 Excavator
20-102-4 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-102-13
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
P-58113
1
Remove the spools (Item 1) [Figure 20-102-13].
Figure 20-102-14
P-58111
2 1 1
1
P-58114
P-58112
442 Excavator
20-102-5 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N Figure 20-102-17
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-102-15
1
P-58117
1
Remove the valve body (Item 1) [Figure 20-102-17].
Figure 20-102-18
P-58115
Figure 20-102-16 2
2
1
4 1
P-58118
3
Remove the back-up ring (Item 1) and O-rings (Item 2)
[Figure 20-102-18].
P-58116
442 Excavator
20-102-6 Service Manual
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-102-19
P-58119
Figure 20-102-20
2 1
1 2
P-58120
442 Excavator
20-102-7 Service Manual
442 Excavator
20-102-8 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-2
Testing
Figure 20-110-1 1
P-33804
Remove the hose from the control valve. The operating pressure should be approximately 507 PSI
(35 bar).
442 Excavator
20-110-1 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-5
Figure 20-110-3
1 1
P-35945
1
P-35946
Remove the 4 bolts (Item 1) [Figure 20-110-4] and Installation: Use a small flat blade screwdriver to rebend
washers. the wire terminal tabs on each wire before installing the
individual wires in the connector bodies.
Remove the cover (Item 2) [Figure 20-110-4].
442 Excavator
20-110-2 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Removal And Installation
Figure 20-110-7
2 1
P-33029
1 1
P-35947
Remove the 2 bolts (Item 1) [Figure 20-110-9] and
washers.
Pull up on the joystick boot, and loosen the four mount
bolts (Item 1) [Figure 20-110-7]. Remove the arm rest.
Remove the grommet and wire harness (Item 2) [Figure Figure 20-110-10
20-110-7] from the joystick body.
Figure 20-110-8 1
1
2
1
2
P-35944
442 Excavator
20-110-3 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)
1
P-35945
1
1
1 P-35947
P-35949
442 Excavator
20-110-4 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)
Parts Identification
1. Handle
2. Dust Boot
3. Nut
4. Swivel Joint/Bolt
5. Washers 1
6. Plate
7. Plunger Assembly
8. Seal
9. Spool Assembly
10. Spring
11. Valve Body (Top)
12. O-Ring 2
13. Alignment Pin
14. Valve Body (Bottom)
15. Bolt
3
10
11
12 12
13 13
14
12
15
B-16943
442 Excavator
20-110-5 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-16
P-35926
Figure 20-110-17
Remove the grommet and wire harness (Item 1) [Figure
20-110-14]. 1
Figure 20-110-15
3
1
2
P-21715
442 Excavator
20-110-6 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-20
Figure 20-110-18 2
P-35929
1
1
P-35930
P-35928
442 Excavator
20-110-7 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-24
Figure 20-110-22 1
P-35934
2
Figure 20-110-23 2
P-35935
P-35933
442 Excavator
20-110-8 Service Manual
RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-28
Figure 20-110-26
1
1
P-35938
Figure 20-110-27
P-35937
442 Excavator
20-110-9 Service Manual
442 Excavator
20-110-10 Service Manual
LEFT CONTROL LEVER (JOYSTICK) Figure 20-111-2
Testing
Figure 20-111-1
1
1
2
P-33804
Remove the hose from the control valve. The operating pressure should be approximately 507 PSI
(35 bar).
442 Excavator
20-111-1 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-5
Figure 20-111-3
1
1
1
P-35939
1
Figure 20-111-4
1
2
1
P-35940
1
Mark the wires to the connector body (Item 1) [Figure
20-111-6].
442 Excavator
20-111-2 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Removal And Installation
Figure 20-111-7
1 1
1
1
1 1
P-35919
1
P-35942
Remove the 4 screws (Item 1) [Figure 20-111-9].
Pull up on the joystick boot and loosen the 4 mount bolts Raise the console.
(Item 1) [Figure 20-111-7].
Figure 20-111-10
Remove the grommet and wire harness (Item 2) [Figure
20-111-7] from the joystick body.
2
Pull up on the joystick boot.
Figure 20-111-8
1
2 1
1
P-35920
442 Excavator
20-111-3 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-13
Figure 20-111-11
1
1
1
1
1
P-35923
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-111-12
P-35922
442 Excavator
20-111-4 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D)
Parts Identification
1. Handle
2. Dust Boot
3. Nut
4. Swivel Joint/Bolt
5. Washers
6. Plate
1
7. Plunger Assembly
8. Seal
9. Spool Assembly
10. Spring
11. Valve Body (Top)
12. O-Ring 2
13. Alignment Pin
14. Valve Body (Bottom)
15. Bolt 3
7
8
10
11
12 12
13 13
14
12
15
B-16944
442 Excavator
20-111-5 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-16
Figure 20-111-14
1
P-35926
Figure 20-111-17
Remove the grommet and wire harness (Item 1) [Figure
20-111-14].
1
Figure 20-111-15
1
3
P-21715
442 Excavator
20-111-6 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-20
Figure 20-111-18 2
P-35929
1
1
P-35930
P-35928
442 Excavator
20-111-7 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-24
Figure 20-111-22 1
P-35934
2
Remove the spring (Item 1) [Figure 20-111-24].
P-35932
Figure 20-111-25
Figure 20-111-23
P-35935
P-35933
442 Excavator
20-111-8 Service Manual
LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-28
Figure 20-111-26
1 1
P-35938
Figure 20-111-27
P-35937
442 Excavator
20-111-9 Service Manual
442 Excavator
20-111-10 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE Figure 20-112-2
Figure 20-112-1
1
1
1
P-33233
Figure 20-112-3
Mark and remove the four tee fittings (Item 1) [Figure 20-
112-1].
IMPORTANT 1
P-33232
442 Excavator
20-112-1 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D) Figure 20-112-6
Figure 20-112-4
1
P-33236
Figure 20-112-7
P-33234
1
Figure 20-112-5
P-33237
P-33235
442 Excavator
20-112-2 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D) Figure 20-112-10
Figure 20-112-8
P-33240
1
P-33239
Figure 20-112-9
P-33238
442 Excavator
20-112-3 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D)
Parts Identification
1 Dust Boot
2 Plunger Body
1
3 O-Ring
4 Push Rod 1
5 Retainer 2
6 Piston
2
7 Spring 3
8 Shim
3
9 Spool
10 Spring 4
11 Valve Body 4
3
3 5
5 6
6
7
7
8
9
9
10
10
11
MS1546
442 Excavator
20-112-4 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D) Figure 20-112-13
Figure 20-112-11
P-33243
Figure 20-112-12
1
P-33244
P-33242
442 Excavator
20-112-5 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D) Figure 20-112-17
Figure 20-112-15
2
2
P-33246
1
Remove the bolt (Item 1) [Figure 20-112-17].
P-33248
NOTE: Use care when removing the bolt, the plunger
assemblies (Item 2) [Figure 20-112-17] are
Installation: Align the hole (Item 1) in the pin with the set spring loaded.
screw (Item 2) [Figure 20-112-15].
Figure 20-112-18
Figure 20-112-16
P-33247
P-33245
442 Excavator
20-112-6 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D) Figure 20-112-21
Figure 20-112-19
1 1
P-36227
Figure 20-112-22
Remove the push rod (Item 1) [Figure 20-112-19] from
the plunger body.
Figure 20-112-20
1 2
P-36229
442 Excavator
20-112-7 Service Manual
TRAVEL LEVER/FOOT PEDAL VALVE (CONT’D) Figure 20-112-25
Figure 20-112-23
1 1
1
1
P-36232
Compress the spring (Item 1) until the retainer (Item 2) Installation: Clean all components with solvent and dry
[Figure 20-112-23] can be removed. with compressed air.
Figure 20-112-24 Inspect all parts and replace any that are damaged.
P-36231
442 Excavator
20-112-8 Service Manual
HYDRAULIC FILTER MOUNT Figure 20-120-3
Figure 20-120-1
1
1
2 1
P-40559
1
Remove the 4 bolts (Item 1) [Figure 20-120-3] and
P-40557 washers.
Figure 20-120-4
Remove the screw (Item 1) from the electrical connector
(Item 2) [Figure 20-120-1]. Remove the electrical
connector.
Figure 20-120-2
P-40533
P-40558
442 Excavator
20-120-1 Service Manual
442 Excavator
20-120-2 Service Manual
HYDRAULIC RESERVOIR Figure 20-130-3
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P-38628
I-2003-0888
Figure 20-130-4
Figure 20-130-2
1
1
P-40535
P-38629
442 Excavator
20-130-1 Service Manual
HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-7
Figure 20-130-5
2
1
1
P-40539
Figure 20-130-6
1
2
P-40540
442 Excavator
20-130-2 Service Manual
HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-11
Figure 20-130-9
1
2
P-40546
Remove the 2 bolts (Item 1) and nuts from the fuel filter
P-40541 (Item 2) [Figure 20-130-11]. Remove the fuel filter.
Figure 20-130-12
Remove the screw (Item 1) and disconnect the electrical
connector (Item 2) [Figure 20-130-9].
Figure 20-130-10
1
1
1 2
P-40545
442 Excavator
20-130-3 Service Manual
HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-15
Figure 20-130-13
1
1 P-40548
Figure 20-130-16
Mark and remove the 2 wires (Item 1) [Figure 20-130-13]
from the fuel sending unit.
Figure 20-130-14
2
P-35231
442 Excavator
20-130-4 Service Manual
HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-19
Figure 20-130-17
1
2 1
P-40550
1
Remove the plug and fitting (Item 1) [Figure 20-130-19]
P-35232 from the bottom of the hydraulic reservoir.
1
1
P-40549 P-40551
Mark and remove the hose (Item 1) [Figure 20-130-18]. Remove the 2 mount bolts (Item 1) [Figure 20-130-20]
and washers from the right hand side of the hydraulic
reservoir.
442 Excavator
20-130-5 Service Manual
HYDRAULIC RESERVOIR (CONT’D) Figure 20-130-23
Figure 20-130-21
1 1
P-40554
Figure 20-130-24
Remove the 2 mount bolts (Item 1) and bracket (Item 2)
[Figure 20-130-21].
Figure 20-130-22
P-40555
Raise the hoist and slide the hydraulic reservoir out the
P-40553 rear of the excavator [Figure 20-130-24].
442 Excavator
20-130-6 Service Manual
OIL COOLER
Description
442 Excavator
20-140-1 Service Manual
442 Excavator
20-140-2 Service Manual
SECONDARY FRONT AUXILIARY VALVE Figure 20-150-3
Figure 20-150-1
1 1
P-33155
P-33153
WARNING
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-150-2
P-33154
442 Excavator
20-150-1 Service Manual
SECONDARY FRONT AUXILIARY VALVE (CONT’D)
Parts Identification
1 Nut
2 O-Ring
3 Coil
4 Actuators 1
5 Spring 2
6 Spring Retainer 3
7 Plate 7 2
8 Valve Body
9 Bolt
4
10 Spool
2
2 5
6
10
6
5
2
3
2
1
MS1545
442 Excavator
20-150-2 Service Manual
SECONDARY FRONT AUXILIARY VALVE (CONT’D) Figure 20-150-6
Figure 20-150-4
1 1
1 1
P-36234
1
P-36236
P-36235
1 1
P-36237
442 Excavator
20-150-3 Service Manual
SECONDARY FRONT AUXILIARY VALVE (CONT’D) Figure 20-150-11
Figure 20-150-9
1
2
3 P-36239
3
2 Remove the spool (Item 1) [Figure 20-150-11].
1
P-36238
Figure 20-150-12
Figure 20-150-10
P-36240
P-36244
442 Excavator
20-150-4 Service Manual
SECONDARY FRONT AUXILIARY VALVE (CONT’D) Figure 20-150-15
P-36243
1
Remove the 4 bolts (Item 1) and plate (Item 2) [Figure Installation: Clean all components with solvent and dry
20-150-13] from the valve body. with compressed air.
Figure 20-150-14 Inspect all parts and replace any that are damaged.
P-36242
442 Excavator
20-150-5 Service Manual
442 Excavator
20-150-6 Service Manual
HYDRAULIC BREAKER APPLICATION VALVE (S/N Figure 20-160-2
522311001 & ABOVE)
Figure 20-160-1 1
P-33166
1
IMPORTANT 1
P-33167
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Remove the bolts (Item 1) [Figure 20-160-3] and
tubelines and ports to keep dirt out. Dirt can quickly washers.
damage the system.
I-2003-0888
Installation: Install 2 washers (Item 2) between the cab
and valve. Install 1 washer (Item 3) [Figure 20-160-3] on
the bolts. Tighten the bolts to 6-7 ft.-lb. (8-10 N•m)
torque.
442 Evcavator
20-160-1 Service Manual
HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE) (CONT’D)
Parts Identification
1. Valve Body
2. Back-up Ring
3. O-Ring
4. Spool
5. Coil
6. Nut
4
3
3
5
MS1536
442 Excavator
20-160-2 Service Manual
HYDRAULIC BREAKER APPLICATION VALVE Figure 20-160-6
(CONT’D)
Figure 20-160-4
1
1 2
2
2
P-36282
Figure 20-160-5
1 P-36283
1
NOTE: Do not remove the 4 fittings (Item 1) [Figure
20-160-7] The fittings are welded to the valve
block. Removing the fittings will damage the
block and fittings.
Remove the spool (Item 1) [Figure 20-160-5]. Use new O-rings and back-up rings.
442 Evcavator
20-160-3 Service Manual
442 Excavator
20-160-4 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ Figure 20-170-2
N 522311001 & ABOVE)
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
P-33250
damage the system.
I-2003-0888
1 1
P-33249
442 Excavator
20-170-1 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/N 522311001 & ABOVE) (CONT’D)
Parts Identification
1 Plug
2 Seal
3 Valve Body
4 Spool
5 Spring
6 Spring Seat
7 O-Ring
8 Adjustor 1
1 2
3
2
MS1537
442 Excavator
20-170-2 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ Figure 20-170-5
N 522311001 & ABOVE) (CONT’D)
Figure 20-170-3
P-36247
1
1
Loosen the adjustor (Item 1) [Figure 20-170-5].
Figure 20-170-4 4
3
2 1
P-36248
Remove the adjustor (Item 1), spring seat (Item 2), spring
(Item 3) and spool (Item 4) [Figure 20-170-6].
P-36246
442 Excavator
20-170-3 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ Figure 20-170-9
N 522311001 & ABOVE) (CONT’D)
1
P-36251
Remove the O-ring (Item 1) [Figure 20-170-7] from the Installation: Clean all components with solvent and dry
adjustor. with compressed air.
Figure 20-170-8 Inspect all parts and replace any that are damaged.
P-36250
442 Excavator
20-170-4 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL/ Figure 20-171-2
HYDRAULIC BREAKER APPLICATION VALVE (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly P-58074
1
1 2
1 1
P-58073
P-58076
442 Excavator
20-171-1 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Parts Identification
1. Valve Block
2. O-Ring
3. Back-up Ring
4. Spool
5. Plug
6. Flow Regulator
7. Spool
8. Coil
9. Nut
5
2
4
23
1
3
2
2
3
2 2
2
3 6
3
8
2
9
MS2023S
442 Excavator
20-171-2 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL/ Figure 20-171-6
HYDRAULIC BREAKER APPLICATION VALVE (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-171-4
P-58079
P-58077
Figure 20-171-5
P-58080
P-58078
442 Excavator
20-171-3 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL/ Figure 20-171-10
HYDRAULIC BREAKER APPLICATION VALVE (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-171-8 1
P-58083
1
Remove the flow regulator (Item 1) [Figure 20-171-10].
Figure 20-171-11
P-58081
Figure 20-171-9
2
1 1
1
P-58120
P-58082
442 Excavator
20-171-4 Service Manual
AUXILIARY HYDRAULIC FLOW CONTROL/ Figure 20-171-14
HYDRAULIC BREAKER APPLICATION VALVE (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 20-171-12
1
P-58086
P-58084
Figure 20-171-13
1
1
P-58087
1
442 Excavator
20-171-5 Service Manual
442 Excavator
20-171-6 Service Manual
BLADE VALVE Figure 20-180-2
2
P-33252
P-33251 Mark and remove the 2 tee fittings (Item 2) [Figure 20-
180-2].
Remove the linkage (Item 1) [Figure 20-180-1] from the Figure 20-180-3
valve.
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
P-33253
442 Excavator
20-180-1 Service Manual
BLADE VALVE (CONT’D)
Parts Identification
1 Plunger Body 1
2 O-Ring
1
3 Push Rod
2
4 Shim
5 Retainer 2
6 Piston 3
7 Spring
33
8 Spool 2
9 Spring
2
10 Valve Body
4
11 Plug
4 5
5 6
6
7
7
4
9
9
2
11
10
MS1548
442 Excavator
20-180-2 Service Manual
BLADE VALVE (CONT’D) Figure 20-180-6
Figure 20-180-4
2
1
1
P-36267
Figure 20-180-7
Remove the 2 bolts (Item 1) from the plate (Item 2)
[Figure 20-180-4]. Remove the plate.
2
Figure 20-180-5
P-36256
442 Excavator
20-180-3 Service Manual
BLADE VALVE (CONT’D) Figure 20-180-10
Figure 20-180-8
1
1
3
P-36259
1
Remove the plunger assemblies (Item 1) [Figure 20-180-
P-36257 10].
Figure 20-180-11
Remove the 4 outside bolts (Item 1) and center bolt (Item
2) [Figure 20-180-8].
Figure 20-180-9
2
P-36260
2
Remove the push rod (Item 1) [Figure 20-180-11] from
1 the plunger body.
P-36258
442 Excavator
20-180-4 Service Manual
BLADE VALVE (CONT’D) Figure 20-180-14
Figure 20-180-12 3
2 1
3
2
1
P-36264
Figure 20-180-15
Remove the O-ring (Item 1) [Figure 20-180-12] from the
plunger body.
Figure 20-180-13 1
1 2
P-36230
442 Excavator
20-180-5 Service Manual
BLADE VALVE (CONT’D) Figure 20-180-18
Figure 20-180-16
1
5
4
3
2
P-36115
Figure 20-180-19
Remove the retainer (Item 1), piston (Item 2), spring
(Item 3), and shims (Item 4) from the spool (Item 5)
[Figure 20-180-16].
Figure 20-180-17
1
1
1 P-36266
Remove the 2 plugs (Item 1) [Figure 20-180-17]. Installation: Clean all components with solvent and dry
with compressed air.
442 Excavator
20-180-6 Service Manual
BLADE FLOAT VALVE Figure 20-181-3
Figure 20-181-1 1
P-33389
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-33390
Figure 20-181-2
P-33388
442 Excavator
20-181-1 Service Manual
BLADE FLOAT VALVE (CONT’D)
Parts Identification
1 Plate
2 O-Ring
3 Valve Body
4 Spring Retainer
5 Spring
6 O-Ring
7 Solenoid Valve 1
8 Coil
9 Nut 9
10 Bolt 6
11 Spool
8
12 Plug
2
3 7
6
5
4
10
11
4
5
6
12
MS1558
442 Excavator
20-181-2 Service Manual
BLADE FLOAT VALVE (CONT’D) Figure 20-181-7
Figure 20-181-5
P-36044
Figure 20-181-6
1
P-36045
2 1
P-36043
442 Excavator
20-181-3 Service Manual
BLADE FLOAT VALVE (CONT’D) Figure 20-181-11
Figure 20-181-9
2
1
1
P-36048
Figure 20-181-10
2
1
1
P-36049
442 Excavator
20-181-4 Service Manual
BLADE FLOAT VALVE (CONT’D) Figure 20-181-15
Figure 20-181-13
1
1
P-36052
Figure 20-181-14
3
2
P-36051
442 Excavator
20-181-5 Service Manual
442 Excavator
20-181-6 Service Manual
BOOM OFFSET VALVE Figure 20-190-17
IMPORTANT 1
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P-33229
I-2003-0888
Figure 20-190-18
1
1 P-33228
442 Excavator
20-190-1 Service Manual
BOOM OFFSET VALVE (CONT’D)
Parts Identification
1 Dust Boot
1
2 Plunger Body
3 O-Ring
4 Push Rod 1 2
5 Retainer
6 Piston
7 Spring 2 3
8 Shim
9 Spool 3
10 Spring 4
11 Valve body 4
12 Seal Carrier 3
13 Seal 3 5
14 Fitting
5 6
15 Bolt
6
7
12
7
13
8 12
8
13 14
9
14
3
9
3
15
10 15
10
11
MS1547
442 Excavator
20-190-2 Service Manual
BOOM OFFSET VALVE (CONT’D) Figure 20-190-21
Figure 20-190-19
P-36272
Figure 20-190-20
3 1
P-36273
2
Remove the dust boots (Item 1) [Figure 20-190-22].
P-36270
442 Excavator
20-190-3 Service Manual
BOOM OFFSET VALVE (CONT’D) Figure 20-190-25
Figure 20-190-23 1
P-36276
Figure 20-190-26
Remove the bolt (Item 1) [Figure 20-190-23].
P-36260
1
P-36275
442 Excavator
20-190-4 Service Manual
BOOM OFFSET VALVE (CONT’D) Figure 20-190-29
Figure 20-190-27
2
1
2
1
P-36277
Figure 20-190-30
Remove the O-ring (Item 1) [Figure 20-190-27] from the
plunger body.
Figure 20-190-28
1
P-36230
442 Excavator
20-190-5 Service Manual
BOOM OFFSET VALVE (CONT’D) Figure 20-190-33
Figure 20-190-31
5
4 1
3 2
2
1
P-35994
Figure 20-190-34
Remove the retainer (Item 1), piston (Item 2) spring (Item
3) and shims (Item 4) from the spool (Item 5) [Figure 20-
190-31].
Figure 20-190-32
2
1
P-35998
1
Installation: The lip (Item 1) on the seal carrier must fit in
the groove (Item 2) [Figure 20-190-34] in the housing.
P-36278
442 Excavator
20-190-6 Service Manual
BOOM OFFSET VALVE (CONT’D) Figure 20-190-37
Figure 20-190-35 1
P-35996
1
2
P-35997
442 Excavator
20-190-7 Service Manual
442 Excavator
20-190-8 Service Manual
BOOM LOAD HOLDING VALVE Figure 20-200-39
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
IMPORTANT
P-33392
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Remove the 4 bolts (Item 1) [Figure 20-200-39].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 N•m)
I-2003-0888 torque.
Figure 20-200-40
2 2 3
2
1
P-33391
P-33393
Remove the load sense line (Item 1) Mark and remove
the pilot pressure lines (Item 2) [Figure 20-200-38].
Remove the O-ring (Item 1) and back-up ring (Item 2)
Remove the tubeline (Item 3) [Figure 20-200-38]. [Figure 20-200-40] from the valve.
442 Excavator
20-200-1 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D)
Parts Identification
1 Relief Valve
1
2 Seal
3 Piston
4 Spring
5 Spring Seat
2
6 O-Ring
2
7 Plug 3
8 Back-up Ring
4
9 Relief Valve
10 Cap 5 10
6
11 Valve Body
7
12 Seal Carrier 7
9 7
13 Seal 7
14 Fitting 6
15 Bolt 8 6
16 Poppet
17 Seal 6 6
18 Coupler 6
19 Cap
6
20 Fitting 11
21 Plug
12
7
13
14
6 16
17
15
6
12
7
6 6 6 13
18
14
21
20 6
20
19
15
MS1539
442 Excavator
20-200-2 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-43
Disassembly
Figure 20-200-41
1
2
P-36115
Figure 20-200-42 1
P-36095
P-36094
442 Excavator
20-200-3 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-47
Disassembly (Cont’d)
Figure 20-200-45
2 P-36114
4
1
3 Remove the O-ring (Item 1) [Figure 20-200-47] from the
P-36096 4 plugs. (Ported plug shown.)
Figure 20-200-48
Remove the bolt (Item 1), washer (Item 2), spring (Item
3) and poppet (Item 4) [Figure 20-200-45].
Figure 20-200-46
P-36100
1
2 1
Remove the cap (Item 1) [Figure 20-200-48] from the
P-36097 relief valve.
442 Excavator
20-200-4 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-51
Disassembly (Cont’d)
Figure 20-200-49
1
1
P-36103
Figure 20-200-50
2
1
P-36104
442 Excavator
20-200-5 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-55
Disassembly (Cont’d)
Figure 20-200-53
1
1
P-35995
Figure 20-200-56
Remove the bolt (Item 1) and seal carrier (Item 2)
[Figure 20-200-53] from the two fittings.
Figure 20-200-54
P-36105
442 Excavator
20-200-6 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-59
Disassembly (Cont’d)
Figure 20-200-57
2
1
1
P-36108
Figure 20-200-60
Remove the O-ring (Item 1) [Figure 20-200-57] from the
fittings.
Figure 20-200-58 1
P-36115
442 Excavator
20-200-7 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-63
Disassembly (Cont’d)
Figure 20-200-61
P-36114
Figure 20-200-64
Remove the seal (Item 1) [Figure 20-200-61] from the
poppet.
Figure 20-200-62
P-36111
1
Loosen the relief valve (Item 1) [Figure 20-200-64].
P-36110
442 Excavator
20-200-8 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D)
Disassembly (Cont’d)
Figure 20-200-65
2
1
P-36112
Figure 20-200-66
2
2
P-36113
442 Excavator
20-200-9 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-68
Assembly
P-36112
1
1
P-36111
P-36113
442 Excavator
20-200-10 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-72
Assembly (Cont’d)
Figure 20-200-70
P-36109
Figure 20-200-73
Install the O-ring (Item 1) [Figure 20-200-70] in the
ported plug.
Figure 20-200-71 1
P-36115
1
Install the O-ring (Item 1) [Figure 20-200-73] on the plug.
P-36110
442 Excavator
20-200-11 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-76
Assembly (Cont’d)
Figure 20-200-74
1
2
P-36105
1
Install the 2 fittings (Item 1) [Figure 20-200-76].
P-36108
Figure 20-200-77
Figure 20-200-75
1
3
P-35997
442 Excavator
20-200-12 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-80
Assembly (Cont’d)
Figure 20-200-78
1 2
P-35998
Figure 20-200-79
1
1
2
P-36104
442 Excavator
20-200-13 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-84
Assembly (Cont’d)
Figure 20-200-82
1 P-36101
Figure 20-200-85
Install the fittings (Item 1) [Figure 20-200-82].
Figure 20-200-83
2
1 1
P-36100
442 Excavator
20-200-14 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-88
Assembly (Cont’d)
Figure 20-200-86
4
1
2
1
3
P-36096
Figure 20-200-87
1
P-36095
2 1
442 Excavator
20-200-15 Service Manual
BOOM LOAD HOLDING VALVE (CONT’D) Figure 20-200-92
Assembly (Cont’d)
Figure 20-200-90
1
1
P-36093
Figure 20-200-91
1
1
P-36092
442 Excavator
20-200-16 Service Manual
OIL TEMPERATURE REGULATOR Figure 20-210-1
Description
1
The oil temperature regulator, when closed, diverts
hydraulic oil from the oil cooler to the hydraulic tank. The
regulator opens at 131° F (55° C) allowing oil to flow
3
through the cooler then to tank.
When repairing hydrostatic and hydraulic systems, Remove the 2 bolts (Item 3) [Figure 20-210-1].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Installation: Tighten the bolts to 6-7 ft.-lb. (8-10 N•m)
tubelines and ports to keep dirt out. Dirt can quickly torque.
damage the system.
I-2003-0888 Remove the valve.
442 Excavator
20-210-1 Service Manual
442 Excavator
20-210-2 Service Manual
AUXILIARY HYDRAULICS SELECTOR VALVE Remove the tubelines (Item 1) and hoses (Item 2)
[Figure 20-220-2].
Removal And Installation
Figure 20-220-3
The procedure is the same for both right and left auxiliary
hydraulic selector valves. The left side is shown.
1
WARNING
Hydraulic fluid escaping under pressure can have 2
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
P-36383
immediately.
W-2145-0290
IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2056-0793
Figure 20-220-2
2
1
2 1
P-36381
442 Excavator
20-220-1 Service Manual
442 Excavator
20-220-2 Service Manual
HYDRAULIC PISTON PUMP DRIVE COUPLER Figure 20-230-6
Figure 20-230-4
P-38128
Figure 20-230-7
P-35231
1
Loosen the clamp (Item 1) [Figure 20-230-4]. Rotate the
clamp to provide clearance to the suction fitting bolts.
P-35232
442 Excavator
20-230-1 Service Manual
HYDRAULIC PISTON PUMP DRIVE COUPLER Figure 20-230-10
(CONT’D)
Figure 20-230-8
1
1 1
1
P-38133
Figure 20-230-9
1
2 1
P-38130
442 Excavator
20-230-2 Service Manual
UNDERCARRIAGE
BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Rubber Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Rubber Track Removal And Installation. . . . . . . . . . . . . . . 30-20-6
Steel Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
442 Excavator
30-01 Service Manual
442 Excavator
30-02 Service Manual
BLADE Figure 30-10-3
Figure 30-10-1
1
P-33439
Figure 30-10-4
P-33437 2
Figure 30-10-2
1
P-33440
Remove the right and left pivot pin retaining nut and bolt
(Item 1) [Figure 30-10-1] & [Figure 30-10-2].
WARNING
Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 N•m) Wear safety glasses to prevent eye injury when any
torque. of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
442 Excavator
30-10-1 Service Manual
BLADE (CONT’D)
Figure 30-10-5
P-33441
Figure 30-10-6
P-33442
442 Excavator
30-10-2 Service Manual
TRACKS
Rubber Track
Figure 30-20-1
Straight Edge
B-14489
442 Excavator
30-20-1 Service Manual
TRACKS (CONT’D) Figure 30-20-2
P-32888
WARNING
AVOID INJURY OR DEATH
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0189
442 Excavator
30-20-2 Service Manual
TRACKS (CONT’D) Steel Track Clearance
Rubber Track Clearance (Cont’d) NOTE: The wear of the pins and bushings on the
undercarriage vary with the working
Figure 30-20-4 conditions and the different types of soil
conditions. It is necessary to inspect track
tension and maintain the correct tension. (See
SERVICE SCHEDULE on Page 10-50-1 for the
correct service interval.).
Figure 30-20-6
1
P-32891
0.79
(20 mm)
Figure 30-20-5
Track Frame
Track Sag
0.787”
(20 mm)
1
Track
Roller
Track
B-14067
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0189
442 Excavator
30-20-3 Service Manual
TRACKS (CONT’D) Figure 30-20-9
Track Adjustment
Figure 30-20-7
1
P-32893
Figure 30-20-10
Loosen the top bolt (Item 1) [Figure 30-20-7].
Figure 30-20-8 1
P-32894
P-32892 WARNING
Remove the grease fitting adapter (Item 1) [Figure 30- Wear safety glasses to prevent eye injury when any
20-8] from the end of a grease gun. of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
442 Excavator
30-20-4 Service Manual
TRACKS (CONT’D) Figure 30-20-13
Figure 30-20-11
1
P-32974
2
P-32895
442 Excavator
30-20-5 Service Manual
TRACKS (CONT’D)
Figure 30-20-16
1
1
1 2
P-40663
Use the boom and arm to lift the blade end of the
machine and install jack stands (Item 1) [Figure 30-20-
14] under the blade.
Figure 30-20-15
P-32891
1
P-40662
442 Excavator
30-20-6 Service Manual
TRACKS (CONT’D) Figure 30-20-19
Figure 30-20-17
1
P-40670
After track tension has been released, remove all grease Figure 30-20-20
from the tensioner area.
Figure 30-20-18
1
P-40671
1
442 Excavator
30-20-7 Service Manual
TRACKS (CONT’D)
Figure 30-20-21
P-40888
Put the front of the track onto the front idler wheel.
442 Excavator
30-20-8 Service Manual
TRACK FRAME
Figure 30-30-1
P-62574
Figure 30-30-3
P-40855
Figure 30-30-2
2 1
P-40857
442 Excavator
30-30-1 Service Manual
TRACK FRAME (CONT’D) Figure 30-30-6
Figure 30-30-4
1
1
2
P-40708
Remove the track tension fitting (Item 1) [Figure 30-30- Figure 30-30-7
4].
1
P-40709
Remove the grease cylinder (Item 1) and plate (Item 2) See Upper Roller Disassembly And Assembly. (See
[Figure 30-30-5]. UPPER TRACK ROLLER on Page 30-50-1.)
442 Excavator
30-30-2 Service Manual
TRACK FRAME (CONT’D)
Figure 30-30-8
1 1
P-40692
Figure 30-30-9
P-40693
442 Excavator
30-30-3 Service Manual
TRACK FRAME (CONT’D) Figure 30-30-11
WARNING
3
2
P-15318
Figure 30-30-10
2
1
P-15317
442 Excavator
30-30-4 Service Manual
TRACK FRAME (CONT’D)
Figure 30-30-12
P-40959
Figure 30-30-13
1
P-40956
442 Excavator
30-30-5 Service Manual
442 Excavator
30-30-6 Service Manual
TRACK IDLER
Parts Identification
1. Bolt
2. Washer
3. Track Tension Guide
4. Recoil Spring Assembly
5. Block
6. Mount
7. Roll Pin
8. O-Ring
9. Shaft
10. O-Ring
11. Seal
12. Bushing
13. Idler Wheel
5
4 1
3 7
2 6
1
10
11
11
10
5 12
6 7
12
10 13
11
11
10
9
8
MS1755
442 Excavator
30-40-1 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-2
Disassembly
Figure 30-40-1
P-40861
P-40860
2 1 3
P-62574
442 Excavator
30-40-2 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-6
Disassembly (Cont’d)
1
Figure 30-40-4
P-40865
2 1
2
1
P-40868
P-40864
442 Excavator
30-40-3 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-10
Disassembly (Cont’d)
Figure 30-40-8
P-40867
Figure 30-40-9
1
P-40705
442 Excavator
30-40-4 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-13
Assembly
1
Clean all parts in solvent and dry with compressed air.
Figure 30-40-11
1 P-40754
Figure 30-40-12
1
P-40870
P-40705
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-40-14] in the mount.
Install the O-ring (Item 1) [Figure 30-40-12] on the seal
ring. Repeat this procedure all four seal assemblies. Use firm even pressure on the installation tool to pop the
O-ring into the housing.
The O-ring and seal ring must be clean and free of any
dust, oil film or foreign matter. Remove the installation tool.
442 Excavator
30-40-5 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-17
Assembly (Cont’d)
Figure 30-40-15
P-40872
Figure 30-40-16
P-40873
P-40869
442 Excavator
30-40-6 Service Manual
TRACK IDLER (CONT’D) Apply a light film of oil to both metal seal rings.
Assembly (Cont’d) NOTE: Do not get any oil on the rubber O-rings.
P-40754 P-40875
Place the seal assembly (Item 1) [Figure 30-40-19] in Install the shaft/mount assembly (Item 1) [Figure 30-40-
the installation tool. 21] in the idler.
The O-ring and seal ring assembly has to be lubricated Figure 30-40-22
with alcohol, so the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
P-40754
442 Excavator
30-40-7 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-25
Assembly (Cont’d)
Figure 30-40-23
1
P-40878
Shake off the excess alcohol and install the seal ring NOTE: Do not get any oil on the rubber O-rings.
assembly (Item 1) [Figure 30-40-23] in the idler.
Figure 30-40-26
Use firm even pressure on the installation tool to pop the
O-ring into the housing.
1
Remove the installation tool.
Figure 30-40-24
P-40879
P-40877
442 Excavator
30-40-8 Service Manual
TRACK IDLER (CONT’D) Figure 30-40-29
Assembly (Cont’d)
Figure 30-40-27
2
P-40863
Press down on the mount (Item 1) and install the roll pin 1 2 3
(Item 2) [Figure 30-40-27].
Figure 30-40-28
2
3
1 P-40862
442 Excavator
30-40-9 Service Manual
TRACK IDLER (CONT’D)
Assembly (Cont’d)
Figure 30-40-31
P-40860
442 Excavator
30-40-10 Service Manual
UPPER TRACK ROLLER
Parts Identification
1. NUT
2. WASHER
3. SNAP RING
4. SEAL COVER
5. SEAL (TWO PIECE)
6. SNAP RING
7. BEARING
8. ROLLER
9. SHAFT
1
2
3
4
5
4
3
2
1
MS1757
442 Excavator
30-50-1 Service Manual
UPPER TRACK ROLLER (CONT’D) Figure 30-50-3
Disassembly
Figure 30-50-1
P-40713
Figure 30-50-2
P-40714
Clean any rust and corrosion from the end of the shaft
P-40712 (Item 1) [Figure 30-50-4] to ease removal of the inner
seal.
442 Excavator
30-50-2 Service Manual
UPPER TRACK ROLLER (CONT’D) Figure 30-50-7
Disassembly (Cont’d)
Figure 30-50-5
2
1
P-40739
Figure 30-50-6 1
P-40740
1
Press the shaft (Item 1) [Figure 30-50-8] off the shaft.
P-40738
Remove the roller from the vise and drain the oil.
Turn the roller over and remove the external snap ring
seal cover, inner and outer seal and internal snap ring.
442 Excavator
30-50-3 Service Manual
UPPER TRACK ROLLER (CONT’D) Assembly
Disassembly (Cont’d) Clean all parts in solvent and dry with compressed air.
2 1
1
P-40741 P-29463
Remove the bearing (Item 1) [Figure 30-50-9] from Inspect the bearings (Item 1) and shaft (Item 2) [Figure
inside the roller. 30-50-10] for wear or damage.
Figure 30-50-11
P-40743
442 Excavator
30-50-4 Service Manual
UPPER TRACK ROLLER (CONT’D) Figure 30-50-14
Assembly (Cont’d)
Figure 30-50-12
P-40744
Figure 30-50-15
Apply assembly lube to both bearings (Item 1) [Figure
30-50-12].
Figure 30-50-13
P-40746
Turn the roller over and press the bearing over the shaft
P-40742 and in to the roller [Figure 30-50-15].
442 Excavator
30-50-5 Service Manual
UPPER TRACK ROLLER (CONT’D) Figure 30-50-18
Assembly (Cont’d)
Figure 30-50-16
1
1 P-40749
Install the snap ring (Item 1) [Figure 30-50-16] on both Figure 30-50-19
sides of the roller.
Figure 30-50-17
1 P-40750
442 Excavator
30-50-6 Service Manual
UPPER TRACK ROLLER (CONT’D) Figure 30-50-22
Assembly (Cont’d)
Figure 30-50-20
P-40713
1
Figure 30-50-21
P-40712
P-40752 Turn the roller over and add 4 oz. (0.12 L) of 10W-30 oil
to the assembly.
Install the inner seal (Item 1) [Figure 30-50-21]. Install the outer seal, inner seal, seal cover and external
snap ring.
NOTE: The inner seal must be fully seated in the
outer seal to prevent any leaks.
442 Excavator
30-50-7 Service Manual
442 Excavator
30-50-8 Service Manual
LOWER TRACK ROLLER
Parts Identification
1. ROLL PIN
2. MOUNT
3. O- RING
4. SEAL
5. BUSHING
6. ROLLER
7. PLUG
8. O-RING
9. SHAFT
2
4
7 4
5 3
6
3
4
4
1 5
2
8
MS1756
442 Excavator
30-60-1 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-3
Disassembly
Figure 30-60-1
P-40696
Figure 30-60-4
Figure 30-60-2
2
1
1
P-40697
P-40694
442 Excavator
30-60-2 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-7
Disassembly (Cont’d)
Figure 30-60-5
P-40705
1
Remove the O-ring (Item 1) [Figure 30-60-7] from all four
P-40706 seal assemblies.
Figure 30-60-8
Remove the seal/O-ring assembly (Item 1) [Figure 30-
60-5] from both mounts.
Figure 30-60-6
P-40701
1
442 Excavator
30-60-3 Service Manual
LOWER TRACK ROLLER (CONT’D)
Disassembly (Cont’d)
Figure 30-60-9
P-40700
Figure 30-60-10
P-40703
442 Excavator
30-60-4 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-12
Assembly
1
Clean all parts in solvent and dry with compressed air.
Figure 30-60-11
1
P-40754
The O-ring and seal ring must be clean and free of any
dust, oil film or foreign matter.
P-40755
442 Excavator
30-60-5 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-16
Assembly (Cont’d)
Figure 30-60-14
P-40759
Figure 30-60-15
P-40760
P-40758
442 Excavator
30-60-6 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-20
Assembly (Cont’d)
Figure 30-60-18 1
P-40757
Figure 30-60-19
P-40756
442 Excavator
30-60-7 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-23
Assembly (Cont’d)
Figure 30-60-21
P-40763
Figure 30-60-22
1
P-40754
P-40762
Place the seal assembly in the installation tool (Item 1)
[Figure 30-60-24].
Apply a light film of oil to both metal seal rings (Item 1)
[Figure 30-60-21] & [Figure 30-60-22]. The O-ring and seal ring assembly has to be lubricated
with alcohol, so the O-ring will slip past the housing
NOTE: Do not get any oil on the rubber O-rings. retaining ring and seal uniformly in the housing radius.
442 Excavator
30-60-8 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-27
Assembly (Cont’d)
Figure 30-60-25
2
1
1
P-40766
Use firm even pressure on the installation tool to pop the Figure 30-60-28
O-ring into the roller.
P-40767
P-40765
442 Excavator
30-60-9 Service Manual
LOWER TRACK ROLLER (CONT’D) Figure 30-60-31
Assembly (Cont’d)
Figure 30-60-29
1
P-40694
Press down on the mount (Item 1) and install the roll pin
(Item 2) [Figure 30-60-29].
Figure 30-60-30
P-40769
Add the oil through the fill hole (Item 1) [Figure 30-60-
30].
442 Excavator
30-60-10 Service Manual
GREASE CYLINDER
Parts Identification
1. ADJUSTER
2. WASHER
3. PLATE
4. HOUSING
5. SEAL
6. SEAL
7. BACK-UP RING
8. CYLINDER
1
2 3
5
6
7
MS1759
442 Excavator
30-70-1 Service Manual
GREASE CYLINDER (CONT’D) Figure 30-70-3
Disassembly
Figure 30-70-1 2
1
1 3
P-40885
Figure 30-70-2
P-40883
442 Excavator
30-70-2 Service Manual
GREASE CYLINDER (CONT’D) Figure 30-70-6
Assembly
1
Clean all parts in solvent and dry with compressed air.
Figure 30-70-4
2
2
P-40887
1
Figure 30-70-5
P-40886
442 Excavator
30-70-3 Service Manual
442 Excavator
30-70-4 Service Manual
TRACK DAMAGE IDENTIFICATION Causes Of The Damage:
Cutting Of Steel Cords When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and the probable cause of the damage. It cut:
is intended to be used for identifying the reason for track
Figure 30-80-3
damage and how to avoid future track damage.
Damage:
Figure 30-80-1
PI-13035
Prevention:
442 Excavator
30-80-1 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Abrasion Of Embedded Metals When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Damage: inevitable. The following cases sometimes accelerate
their abrasion:
Figure 30-80-4
Rubber tracks are driven with an extraordinary heavy
load on them.
Prevention:
P-3865
Replacement:
Figure 30-80-5
Abrasion
D D1=0.67D
PI-13037
442 Excavator
30-80-2 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Figure 30-80-8
Damage:
Guide
Figure 30-80-6
PI-13040
Replacement:
Prevention:
Idler
Similar to the prevention against the cutting of the steel
cords:
442 Excavator
30-80-3 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Figure 30-80-10
Good
Separation of
Bonded
Rubber Cover
PI-13043
Prevention:
442 Excavator
30-80-4 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Damage:
Cuts
Figure 30-80-12
PI-13045
Construction sites
Demolition sites
Concrete ridges
Stumpy fields
442 Excavator
30-80-5 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Replacement:
Cracks On The Lug Side Rubber Due To Fatigue When the cracks reach so deep that they expose the
steel cords, track replacement is required.
Damage:
Causes Of The Damage:
Figure 30-80-14
Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
P-4380
442 Excavator
30-80-6 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Replacement:
Prevention:
Lug Abrasion
PI-13049
442 Excavator
30-80-7 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Damage:
Figure 30-80-18
Crack at the edge of Cut on lug side
embedded metal rubber
PI-13051
442 Excavator
30-80-8 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Damage:
Figure 30-80-20
Track Roller
Abrasion
PI-13053
Prevention:
442 Excavator
30-80-9 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Cuts On The Edges Of Track Roller Side This damage is caused by objects on the field or by
interference with the machine frame.
Damage:
In case of damage by objects on the operating ground:
Figure 30-80-22
Figure 30-80-24
P-4384
PI-13056
Figure 30-80-23
The edges of rubber track are often deformed largely due
to a bumpy ground surface, stones and other objects,
which cause extensive stress on the edges resulting in
the damage. Especially, when a machine drives over
concrete ridges, this type of damage easily occurs
Edge Edge [Figure 30-80-24].
PI-13055
Replacement:
442 Excavator
30-80-10 Service Manual
TRACK DAMAGE IDENTIFICATION (CONT’D)
Figure 30-80-25
Cut
Tear
PI-13057
Prevention:
442 Excavator
30-80-11 Service Manual
442 Excavator
30-80-12 Service Manual
UPPERSTRUCTURE & SWING SECTION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 40-130-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1 SAFETY &
MAINTENANCE
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 40-120-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
UPPER-
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 STRUCTURE &
Cab Visor Removal And Installation . . . . . . . . . . . . . . . . 40-20-23 SWING SECTION
Door, Left Side, Right Side And Rear Window Installation 40-20-21
Door, Left Side, Right Side And Rear Window Removal . 40-20-20
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-20-8
Front Window Disassembly And Assembly (S/N 522311001 &
Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-14
Front Window Gas Strut Removal And Installation . . . . . 40-20-17 ELECTRICAL
Front Window Pivot Frame Removal And Installation . . . 40-20-18 SYSTEM &
Front Window Removal And Installation . . . . . . . . . . . . . . 40-20-9 ANALYSIS
Lower Front Widow Removal And Installation . . . . . . . . . 40-20-19
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Top Window Removal And Installation. . . . . . . . . . . . . . . 40-20-24 ENGINE
SERVICE
CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Continued On Next Page
442 Excavator
40-01 Service Manual
UPPERSTRUCTURE & SWING SECTION (CONT’D)
UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Swing Bearing Removal And Installation . . . . . . . . . . . . . . 40-10-6
442 Excavator
40-02 Service Manual
UPPERSTRUCTURE
Build the service lifting brackets used to remove and install the upperstructure [Figure 40-10-1] & [Figure 40-10-2].
Figure 40-10-1
MS1570
Figure 40-10-2
Spreader Bar
MS1569
442 Excavator
40-10-1 Service Manual
UPPERSTRUCTURE (CONT’D) Mark the track frame to swing bearing (Item 1) [Figure
40-10-3].
Removal And Installation (Cont’d)
Figure 40-10-4
Drain the hydraulic reservoir. (See Replacing The
Hydraulic Oil on Page 10-100-2.)
Drain the fuel tank. (See Draining The Fuel Tank on Page
10-80-8.)
Install the boom pivot pin (Item 1). Install a chain (Item 2)
[Figure 40-10-5] on the pivot pin.
P-40242
442 Excavator
40-10-2 Service Manual
UPPERSTRUCTURE (CONT’D) Figure 40-10-8
Figure 40-10-6
2
1
P-40234
Figure 40-10-7
P-40253
3
442 Excavator
40-10-3 Service Manual
UPPERSTRUCTURE (CONT’D) Figure 40-10-11
Figure 40-10-9
P-40235
NOTE: The cover is located below the air cleaner Figure 40-10-12
mount.
Figure 40-10-10
P-40237
442 Excavator
40-10-4 Service Manual
UPPERSTRUCTURE (CONT’D) Figure 40-10-15
Figure 40-10-13
1
2.0”
(51 mm)
1 P-40248
Figure 40-10-14 1
1
1 1
1
P-40241
442 Excavator
40-10-5 Service Manual
UPPERSTRUCTURE (CONT’D) Figure 40-10-19
P-40249
Mark the swing bearing to upperstructure (Item 1) NOTE: The swing bearing is installed with twenty
[Figure 40-10-17]. seven bolts that are 70 mm in length and three
bolts that are 80 mm in length.
Figure 40-10-18
1 1 1
P-40250
442 Excavator
40-10-6 Service Manual
UPPERSTRUCTURE (CONT’D)
Figure 40-10-20
1 1 1
P-40252
Figure 40-10-21
FRONT OF MACHINE
OUTER RACE
SOFT ZONE IS
AT THE
FILLER PLUG
INNER RACE
SOFT ZONE IS
IDENTIFIED BY
A LETTER S
STAMPED ON
RING
PI-13677A
442 Excavator
40-10-7 Service Manual
442 Excavator
40-10-8 Service Manual
CAB
Build the service lifting brackets used to remove and install the cab [Figure 40-20-1] & [Figure 40-20-2].
Figure 40-20-1
1.0”
(25 mm)
1.250”
(32 mm)
O 0.750”
(19 mm)
O 1.0”
(25 mm)
O 0.750”
(19 mm) Material: 2 X 2-0.187 inch
wall hot rolled angle iron
1.250”
(32 mm)
MS1371
Figure 40-20-2
MS1372
442 Excavator
40-20-1 Service Manual
CAB (CONT’D) Figure 40-20-5
Figure 40-20-3
2 1
2
1
P-32701
Figure 40-20-4
1
1
2
2
1 1
P-33790
442 Excavator
40-20-2 Service Manual
CAB (CONT’D) Figure 40-20-9
Figure 40-20-7
1
1
1
P-33029
2
Remove the two bolts (Item 1) [Figure 40-20-9] and
P-33791 washers from the right arm rest. Remove the arm rest.
Figure 40-20-10
Remove the three screws (Item 1) and remove the cover
(Item 2) [Figure 40-20-7].
Figure 40-20-8
2
1
P-61833
1
442 Excavator
40-20-3 Service Manual
CAB (CONT’D) Figure 40-20-13
Figure 40-20-11
1
1
P-33030
Figure 40-20-14
P-61832
Figure 40-20-12
1
P-33031
2
Remove the two storage compartment bolts (Item 1)
[Figure 40-20-13] & [Figure 40-20-14] and washers.
Remove the storage compartment. (If equipped)
P-61831
442 Excavator
40-20-4 Service Manual
CAB (CONT’D) Figure 40-20-17
Figure 40-20-15
P-33037
Figure 40-20-18
P-61454
P-35013
442 Excavator
40-20-5 Service Manual
CAB (CONT’D) Figure 40-20-20
Figure 40-20-19
2
1
1
1 1
P-35015
Figure 40-20-21
P-33042
P-35014
442 Excavator
40-20-6 Service Manual
CAB (CONT’D) Figure 40-20-24
Figure 40-20-22
P-33793
Figure 40-20-23
P-33795
P-33794
442 Excavator
40-20-7 Service Manual
CAB (CONT’D) Figure 40-20-27
Figure 40-20-25
1
P-36819
Figure 40-20-26
P-36824
442 Excavator
40-20-8 Service Manual
CAB (CONT’D) Figure 40-20-30
Figure 40-20-28
2 P-40674
1
Use a small blade screw driver to depress the wire
P-40734 terminal tabs (Item 1) [Figure 40-20-30].
P-40735
P-40736
442 Excavator
40-20-9 Service Manual
CAB (CONT’D) Figure 40-20-34
Figure 40-20-32
2
1
1
P-40679
Figure 40-20-35
P-40676
P-40681
442 Excavator
40-20-10 Service Manual
CAB (CONT’D) Figure 40-20-38
Figure 40-20-36
2
1
1
P-40685
Figure 40-20-39
Remove the wire (Item 1) from the wire harness (Item 2)
[Figure 40-20-36].
1
4
Figure 40-20-37
3
1
P-40687
442 Excavator
40-20-11 Service Manual
CAB (CONT’D) Figure 40-20-42
Figure 40-20-40
1 1
P-40684
Figure 40-20-41
P-40688
442 Excavator
40-20-12 Service Manual
CAB (CONT’D)
Figure 40-20-43
P-40691
Figure 40-20-44
1
2
P-40733
442 Excavator
40-20-13 Service Manual
CAB (CONT’D) Figure 40-20-47
P-40724
P-40722
Figure 40-20-46
1
1
P-40725
2
P-40723
442 Excavator
40-20-14 Service Manual
CAB (CONT’D) Figure 40-20-51
Figure 40-20-49 1
P-40728
P-40726 Installation: Install the rubber cord with the rounded side
facing out. Do not stretch or cut the rubber cord during
installation. The cord will shrink to its original length
Remove the lock nut (Item 1), wave washers (Item 2) leaving a gap.
latch (Item 3), and washer (Item 4) [Figure 40-20-49]
(Both Sides) Figure 40-20-52
Figure 40-20-50
1
1
P-40730
P-40727
Remove the window (Item 1) [Figure 40-20-52].
442 Excavator
40-20-15 Service Manual
CAB (CONT’D)
Figure 40-20-53
P-40731
Figure 40-20-54
P-40732
442 Excavator
40-20-16 Service Manual
CAB (CONT’D) Figure 40-20-57
Figure 40-20-55
P-40718
1
Pivot the retainer (Item 1) away from the gas strut (Item
2
2) [Figure 40-20-57]. (Both Sides)
Figure 40-20-58
P-40716
Pivot the retainer (Item 1) away from the gas strut (Item
2) [Figure 40-20-55]. (Both Sides)
1
Figure 40-20-56
2
2
1
P-40719
442 Excavator
40-20-17 Service Manual
CAB (CONT’D)
Figure 40-20-59
P-40720
Figure 40-20-60
1
2
P-40721
442 Excavator
40-20-18 Service Manual
CAB (CONT’D) Figure 40-20-63
Figure 40-20-61 1
P-40805
P-40802
Figure 40-20-62
P-40803
442 Excavator
40-20-19 Service Manual
CAB (CONT’D) Figure 40-20-66
The procedure is the same for all the windows. The lower
door window is shown.
Figure 40-20-64
1 P-40808
P-40807
Figure 40-20-65
P-40812
442 Excavator
40-20-20 Service Manual
CAB (CONT’D) Figure 40-20-69
The procedure is the same for all the windows. The lower
door window is shown.
Figure 40-20-67 1
P-40812
1
Figure 40-20-70
P-40808
Figure 40-20-68
P-40814
1
P-40811
442 Excavator
40-20-21 Service Manual
CAB (CONT’D)
Figure 40-20-71
1
1
P-40807
442 Excavator
40-20-22 Service Manual
CAB (CONT’D)
Figure 40-20-72
P-40955
Figure 40-20-73
1 2
1
P-40953
442 Excavator
40-20-23 Service Manual
CAB (CONT’D)
Figure 40-20-74
P-40954
442 Excavator
40-20-24 Service Manual
SEAT AND SEAT MOUNT Figure 40-30-3
Figure 40-30-1 1
P-36822
Figure 40-30-2
P-36821
442 Excavator
40-30-1 Service Manual
SEAT AND SEAT MOUNT (CONT’D)
Figure 40-30-4
P-36823
442 Excavator
40-30-2 Service Manual
RIGHT CONSOLE
Description
442 Excavator
40-40-1 Service Manual
442 Excavator
40-40-2 Service Manual
LEFT CONSOLE Figure 40-50-7
Figure 40-50-5
1 2
P-61458
Lower the console and remove the two screws (Item 1).
Remove the cover (Item 2) [Figure 40-50-7].
1
1 Figure 40-50-8
P-61456
Figure 40-50-6 1
P-61459
1
P-61457
442 Excavator
40-50-1 Service Manual
LEFT CONSOLE (CONT’D) Figure 40-50-11
1
P-61462
1
Figure 40-50-10
1
1
P-61463
442 Excavator
40-50-2 Service Manual
LEFT CONSOLE (CONT’D) Figure 40-50-15
Figure 40-50-13
1
1
1
P-61466
Figure 40-50-16
Mark and remove the battery cables (Item 1) [Figure 40-
50-13] from the battery disconnect switch.
Figure 40-50-14
1 P-61467
442 Excavator
40-50-3 Service Manual
LEFT CONSOLE (CONT’D) Figure 40-50-19
Figure 40-50-17
2
1
P-61471
Figure 40-50-18
1
P-61472
442 Excavator
40-50-4 Service Manual
LEFT CONSOLE (CONT’D)
Figure 40-50-21
P-61473
442 Excavator
40-50-5 Service Manual
LEFT CONSOLE (CONT’D) Figure 40-50-24
Figure 40-50-22
2
P-61476
1
Remove the two bolts (Item 1) and remove the arm rest
(Item 2) [Figure 40-50-22].
Figure 40-50-23
1
2 1
1
2
3
2
P-61477
1
Remove the four bolts (Item 1), four washers (Item 2) and
four nylon washers (Item 3) [Figure 40-50-25].
P-61475
442 Excavator
40-50-6 Service Manual
LEFT CONSOLE (CONT’D) Figure 40-50-28
Figure 40-50-26
1
2
P-61480
Figure 40-50-27
1
1
2
1
P-61481
Remove the bolt (Item 1), washer, and nut from the gas
strut (Item 2) [Figure 40-50-29].
P-61479
Remove the gas strut.
442 Excavator
40-50-7 Service Manual
LEFT CONSOLE (CONT’D) Console Lockout Switch Removal And Installation
Disassembly And Assembly (Cont’d) The cab is shown removed for photo clarity.
P-61482 P-61485
Remove the nut (Item 1) from the bumper (Item 2) Disconnect the wire harness (Item 1) [Figure 40-50-32].
[Figure 40-50-30].
Figure 40-50-33
Remove the bumper.
Figure 40-50-31
1
2
1
P-61486
P-61483 Remove the nut (Item 1) from the console switch (Item 2)
[Figure 40-50-33].
Remove the bushing (Item 1) [Figure 40-50-31] from Remove the console lockout switch.
both sides of the console.
442 Excavator
40-50-8 Service Manual
ENGINE SPEED CONTROL Figure 40-60-3
1
2
P-63445
1
Remove the 4 screws (Item 1) and cover (Item 2) [Figure
40-60-3].
2
3 P-63474 Figure 40-60-4
Remove the nut (Item 1). Loosen the nut (Item 2) [Figure
40-60-1].
Remove all tie straps from the speed control cable (Item
3) [Figure 40-60-1]. 3
2
Figure 40-60-2
1
1 1 1
P-63447
Remove the 3 bolts and nuts (Item 1), knob (Item 2) and
plate (Item 3) [Figure 40-60-4].
P-63444
442 Excavator
40-60-1 Service Manual
ENGINE SPEED CONTROL (CONT’D)
Figure 40-60-5
P-63473
442 Excavator
40-60-2 Service Manual
ENGINE SPEED CONTROL (CONT’D) Figure 40-60-8
Figure 40-60-6
1
1
P-63478
Figure 40-60-7
1
P-63479
442 Excavator
40-60-3 Service Manual
ENGINE SPEED CONTROL (CONT’D)
Figure 40-60-10
2
1 P-63480
442 Excavator
40-60-4 Service Manual
CONTROL LEVERS
Description
442 Excavator
40-70-1 Service Manual
442 Excavator
40-70-2 Service Manual
FUEL TANK Figure 40-80-3
Drain the fuel tank. (See Draining The Fuel Tank on Page
10-80-8.)
Figure 40-80-4
P-38628
Figure 40-80-2
P-40145
1
Remove the bolt (Item 1) [Figure 40-80-4] and washer
from the electrical connector mount bracket.
P-38629
442 Excavator
40-80-1 Service Manual
FUEL TANK (CONT’D) Figure 40-80-7
Figure 40-80-5
P-40148
Figure 40-80-6
1
1
1 2
P-40150
P-40147
Mark and disconnect the wires (Item 1) [Figure 40-80-8]
from the sending unit.
Remove the bolt (Item 1) [Figure 40-80-6] and washer
from the front of the support bracket. Remove the tie strap (Item 2) [Figure 40-80-8].
442 Excavator
40-80-2 Service Manual
FUEL TANK (CONT’D) Figure 40-80-11
2 2
P-40153
Figure 40-80-12
Mark and remove the hoses (Item 1) [Figure 40-80-9].
Figure 40-80-10
1
1
P-40154
442 Excavator
40-80-3 Service Manual
442 Excavator
40-80-4 Service Manual
HORN
Figure 40-90-1
P-40465
Figure 40-90-2
P-40466
442 Excavator
40-90-1 Service Manual
442 Excavator
40-90-2 Service Manual
SWING FRAME Figure 40-100-3
Figure 40-100-1
P-33701
1
Remove the pin (Item 1) [Figure 40-100-3].
Figure 40-100-4
P-33699
1
Remove the bolt (Item 1) [Figure 40-100-1] and washer.
Figure 40-100-2
P-38468
1
Remove the two return to tank hose bracket bolts (Item 1)
[Figure 40-100-4].
P-33700
442 Excavator
40-100-1 Service Manual
SWING FRAME (CONT’D) Figure 40-100-7
Figure 40-100-5 1
3
1
2
P-38471
Figure 40-100-8
Mark the hoses (Item 1) [Figure 40-100-5] for correct
length and orientation.
Remove the two bolts (Item 2), washers and clamp (Item
3) [Figure 40-100-5].
1
Figure 40-100-6
2
1
1
P-38472
P-38470
442 Excavator
40-100-2 Service Manual
SWING FRAME (CONT’D) Figure 40-100-11
2 1
P-38475
1
Use a porta power (Item 1) to remove the top pin (Item 2)
P-38473 [Figure 40-100-11].
Figure 40-100-12
Install the boom cylinder pin (Item 1) [Figure 40-100-9].
Figure 40-100-10
1
1
P-38476
P-38474
442 Excavator
40-100-3 Service Manual
SWING FRAME (CONT’D) Figure 40-100-15
Figure 40-100-13
1
1
1
P-38479
2
1
1 2
1
P-38480
P-38478
442 Excavator
40-100-4 Service Manual
SWING FRAME (CONT’D)
Figure 40-100-17
P-38482
Figure 40-100-18
P-38481
442 Excavator
40-100-5 Service Manual
442 Excavator
40-100-6 Service Manual
FLOOR MAT
Figure 40-110-1
P-32701
442 Excavator
40-110-1 Service Manual
442 Excavator
40-110-2 Service Manual
BOOM Figure 40-120-3
Figure 40-120-1
1
P-33401
P-33396
1
Remove the bolt (Item 1) [Figure 40-120-1] from the rod
end retaining pin.
Figure 40-120-2
P-33403
P-33399
442 Excavator
40-120-1 Service Manual
BOOM (CONT’D) Figure 40-120-7
Figure 40-120-5
1
P-38247
Figure 40-120-8
Lower the chain hoist until the boom is on the ground
[Figure 40-120-5].
1
IMPORTANT 1
P-38248
Figure 40-120-6
P-33391
Remove the load sense line (Item 1) and two pilot hoses
(Item 2) [Figure 40-120-6].
442 Excavator
40-120-2 Service Manual
BOOM (CONT’D) Figure 40-120-11
Figure 40-120-9
1
P-38251
Figure 40-120-10
1
1 P-38252
442 Excavator
40-120-3 Service Manual
BOOM (CONT’D) Figure 40-120-15
Figure 40-120-13
1
P-38255
Figure 40-120-16
Remove the hoses (Item 1) [Figure 40-120-13] from the
base and rod end of the arm cylinder.
Figure 40-120-14
1
P-38256
442 Excavator
40-120-4 Service Manual
BOOM (CONT’D) Figure 40-120-19
Figure 40-120-17
1
1
1
1
1 P-38259
Figure 40-120-20
Raise the cylinder and remove the pin (Item 1) [Figure
40-120-17].
Figure 40-120-18
1
2
1
3
3
1 1
P-38260
Mark the hoses (Item 1) and remove the bolts (Item 2),
P-38258 washers and hose guides (Item 3) [Figure 40-120-20].
442 Excavator
40-120-5 Service Manual
BOOM (CONT’D) Figure 40-120-23
3
1
2
4
2
P-38263
P-38264
2 P-38262
442 Excavator
40-120-6 Service Manual
BOOM (CONT’D) Figure 40-120-27
Figure 40-120-25
1 P-38265
Figure 40-120-28
Figure 40-120-26
P-38266
P-38268
442 Excavator
40-120-7 Service Manual
BOOM (CONT’D)
Figure 40-120-29
P-38267
Figure 40-120-30
P-38270
442 Excavator
40-120-8 Service Manual
ARM Figure 40-170-3
Figure 40-170-1
P-38236
P-382733
With the engine off, the start key in the run position and
the left console lowered, move the joysticks to relieve
hydraulic pressure.
Figure 40-170-2
P-38237
442 Excavator
40-130-1 Service Manual
ARM (CONT’D) Remove the bolt (Item 1) [Figure 40-170-5] and washer
from the rod end of the arm cylinder.
Removal And Installation (Cont’d)
Figure 40-170-6
Figure 40-170-4
P-38239
P-38235
Figure 40-170-5
P-38238
442 Excavator
40-130-2 Service Manual
ARM (CONT’D) Figure 40-170-9
Figure 40-170-7 1
P-38242
1
Remove the shims (Item 1) [Figure 40-170-9] from both
P-38240 sides of the cylinder rod end.
Figure 40-170-10
Place a block (item 1) [Figure 40-170-7] under the arm
cylinder.
Figure 40-170-8
1
P-38243
442 Excavator
40-130-3 Service Manual
ARM (CONT’D) Figure 40-170-13
Figure 40-170-11
P-38271
Figure 40-170-12
P-38245
Move the arm away from the boom. Remove the shims
(Item 1) [Figure 40-170-12] from both sides of the arm.
442 Excavator
40-130-4 Service Manual
BUCKET Figure 40-140-3
1
1
P-32832
1
Remove the pins (Item 1) [Figure 40-140-3].
Retract the bucket link (Item 2) and raise the arm (Item 3)
[Figure 40-140-3].
P-32913
Figure 40-140-4
Figure 40-140-2
1 2
1
1
1 P-32833
442 Excavator
40-140-1 Service Manual
442 Excavator
40-140-2 Service Manual
REAR COVER Figure 40-150-3
Figure 40-150-1
P-36384
1
Figure 40-150-2
P-36386
442 Excavator
40-150-1 Service Manual
REAR COVER (CONT’D) Figure 40-150-6
Figure 40-150-4
1
P-36389
Figure 40-150-7
P-36387
Figure 40-150-5
1
1
P-36390
Remove the cotter pin (Item 1) [Figure 40-150-4] & Remove the cover
[Figure 40-150-5] and washer from the left and right
hinge pins.
442 Excavator
40-150-2 Service Manual
RIGHT SIDE COVER Figure 40-160-10
Figure 40-160-8
1
P-35017
Figure 40-160-11
P-35016
Figure 40-160-9
1
P-35018
442 Excavator
40-160-1 Service Manual
RIGHT SIDE COVER (CONT’D) Figure 40-160-14
Figure 40-160-12
P-35159
Figure 40-160-15
P-35156
Figure 40-160-13
P-35158
Remove the cotter pin (Item 1) [Figure 40-160-12] & Remove the cover.
[Figure 40-160-13] from the front and rear hinge pins.
442 Excavator
40-160-2 Service Manual
RIGHT SIDE COVER (CONT’)
Figure 40-160-16
1
1
P-40595
Remove the four bolts (Item 1) and washers from the dust
seal (Item 2) [Figure 40-160-16].
Figure 40-160-17
P-40593
442 Excavator
40-160-3 Service Manual
442 Excavator
40-160-4 Service Manual
COUNTERWEIGHT
Figure 40-170-1
COUNTERWEIGHT BRACKET
MS1571
Figure 40-170-2
P-40148
442 Excavator
40-170-1 Service Manual
COUNTERWEIGHT (CONT’D) Figure 40-170-5
Figure 40-170-3 1
P-40182
1
1
P-40186 P-40183
Use two bolts (Item 2) [Figure 40-170-3] 16 mm x 35 mm Remove the lock nut (Item 1) [Figure 40-170-6] washers
MC Grade 8,8 and one bolt (Item 1) [Figure 40-170-4] 20 and bolt from the bottom of the counterweight.
mm x 35 mm MC Grade 8,8 to fasten the lifting bracket to
the counterweight.
442 Excavator
40-170-2 Service Manual
COUNTERWEIGHT (CONT’D)
Figure 40-170-7
P-40184
Figure 40-170-8
P-40181
442 Excavator
40-170-3 Service Manual
442 Excavator
40-170-4 Service Manual
ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-18 SAFETY &
Capacitor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-17 MAINTENANCE
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-8
Removal And Installation (S/N 522311001 & Above) . . . . . . . . . . . 50-30-1
Removal And Installation (S/N 528911001 & Above And 528611001 &
Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3 DRIVE
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-16 SYSTEM
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-17
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-16
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-16 ELECTRICAL
SYSTEM AND
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 ANALYSIS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 ELECTRICAL
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . 50-20-4 SYSTEM &
ANALYSIS
BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
ENGINE
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 50-10-1 SERVICE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Fuse And Relay Location (S/N 522311001 & Above) . . . . . . . . . . . 50-10-3
Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 &
Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5 SPECIFICATIONS
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
442 Excavator
50-01 Service Manual50-0
ELECTRICAL SYSTEM AND ANALYSIS (CONT’D)
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-1
Assembly (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-14
Disassembly (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4
Inspection And Repair (All Models) . . . . . . . . . . . . . . . . . . . . . . . . 50-40-12
Parts Identification (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Removal And Installation (S/N 522311001 & Above). . . . . . . . . . . . 50-40-1
Removal And Installation (S/N 528911001 & Above And S/N 528611001 &
Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
442 Excavator
50-02 Service Manual
WIRING SCHEMATIC
442 EXCAVATOR (Sheet 1 of 4)
(S/N 522311001 AND ABOVE)
[C] (PRINTED APRIL 2005)
Sheet
2 of 4 V-0173
1 9 8 7 6 5 4 3 2 1
2 30 sw 2,5ø sw 2,5ø
15 rt 2,5ø
/2.2 /3.4
[F] [D]
0 15 /3.3
FB
FA FA
FB I Sheet 2/3.1
& 3 of 4 Sheet/1.6
1 of 4
II 104
K01 II 15
I F1 F2 F5 F6 F7 133
ge ge
sw 4,0ø
ge
gn/sw
1,0ø sw
K3 K2 K1
ge
30 54
19 10 5 B1 A4 S3
HR32-E01 ø 133 S11
ge
ge
17 5 S16 2
S1 ,
2 ø 1.15
[D]
lb ø 0 IIIII I 0 6
50A 0 ,
1 131
Sheet/4.7 ø 9 A2 3
[B] /
w ,1 5 1
C1 A3 A1 6 XK1
,
1 of 4 [E] 5ø
ø ø s e 2 5 6
Sheet 0 tr g
0 ,
4 t/r Sheet 2, rt 7
[A] ,
4 Thermostat 31
2/2.4
of 4 rt
w 5 3 of 4 rt 9 5
gn/sw
Sheet s 120 8 7 6
10 XK1
gn/gr
X2
gn/sw
2 /2.4
of 4 X2 X2 X2 gn/vi
5
gn/bl
ge
4 ø 3 1 2
100 5
ø ,
bl/rt
0 2
, l
bl/sw
gn/vi
4 b
tr /
w
bl
s 86 30
12 11 7 6
1
XM1 5 XM2 XM1 XB1 K3
ge
XM1 XM2
2 B2
Fuses FA FB 5 1 12 7 6 10
sw
XMNT 85 87 87a
2 9 10
Item Ampere Assigned to ø ø
ge
0 5 8 9 4 3 2
, ,
2 13 XB1 XK1 XK1 XK1
4 XK1
l
b 7
F1 15 Interior light, radio, rt / 8 4 3 2
ge/gn
w XRADIO B3
s 13
immobilizer, rotating beacon B10 4
ø XRADIO
0
gn/sw
, rt ø L+ R+
6
F2 20 Socket, refueling pump, 5
gn/gr
bl/sw
w
gn/vi
7 ,
2 15 30 L- R-
gn/bl
s 1 2
rt rt
bl
additional heating (option) XMGE XMGE XMNT e 15
br/gn
g B1
bl/rt
1 /t XM2
2 7 r
15
F3 15 Working floodlight, front ø
5
31
XRADIO
ge/gn
,
2 8
F4 15 Working floodlight, rear rt M5 +
sw 4,0ø M
G+
D+ 50a 1 243
B+
F5 10 Horn, switch light, immobilizer + 30 M
3 1
Y1
1
1 3 -
50b M
E21 X1 S12 M6
br 2,5ø
br 2,5ø
F6 15 Heater fan G1
B- 31 M1 2 M7 + S30
G2 2 M 2 1
F7 10 Wish/wash system
Wiper/washer system -
M
- 1 M4
F8 5 Control module signal input ø
0 Y10 XK1
1
XK1
11
XK1
12
,
6 2 4 1 11 12
rb
F9 - Additional heating (option) 2
Additional heatingheating
(option)
br/ws
Seat with electrical
gn
1
Working floodlight(s) (option)
(option) S0
ø
5
,
2 2
Working floodlight(s) (option) r
b ø
5
1
,
2 1 X0
br 2,5ø
br 2,5ø
r r r r
br
br
FA 30 Main fuse b b b b
br
br
br
ø YMK
br
br
br
0
,6
rb
FB 60 Pre-heating
31 HR32-E02 HR32-E03
Relay
Position Function Desig- Desig-
Desig- Device Desig- Device Device Device
nation nation nation nation
K 01 Pre-heat
relay Power supply Shut-off Horn M6 Heater fan
G1 Generator Y1 Shut-off F5 Fuse S3 Heater fan switch
K1 Working
floodlight FA Fuse Interior light B10 Horn Wash/ wipe system
, front FB Fuse F1 Fuse S12 Fuse, horn button M5 Washer pump
G2 Battery E21 Interior light Y10 Solenoid valve, immobilizer S11 Wash/ wipe switch
K2 Working
floodlight SO Battery disconnecting switch Socket, refueling pump Heater fan/ air conditioner F7 Fuse
, rear Start-up system F2 Fuse S16 Air conditioner switch M4 Wiper motor
K3 not
Air S1 Pre-heat/ starter switch M7 Refueling pump K3 Relay Radio
Conditione
assigned
r M1 Starter X1 Socket S30 Pressure switch air B1 Radio
conditioner
YMK Magnetic coupling compressor B2 Loudspeaker
V-0173 (3-21-05) F6 Fuse B3 Loudspeaker
WIRING SCHEMATIC
442 EXCAVATOR (Sheet 2 of 4)
(S/N 522311001 AND ABOVE)
(PRINTED APRIL 2005)
V-0173
ge 1,0ø
ge 1,0ø 11 11
ge 1,0ø
bl
2 XB1
S33 S31 S32 S30
rt
sw
10 5 10 5 10 5 10 5 10 5
bl 0,5ø
S8
rt/sw
rt/ws
rt/gn
S9 S5
S5A S6 S15
rt/bl
X1:2 9 1 9 1 9 1 9 1 9 1
X1:3 31 31 31 31 31
X1:1 X1:5
br/ge 0,5ø
gn/rt 0,5ø
bl/rt 0,5ø
BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1
rt/ge 0,5ø
gn 0,5ø
X3:18 X2:6 X3:20 X3:3 X3:4 X3:5 X3:19 X3:17 X3:6 X3:36
2 3 4 5
XB1 XB1
XB1 XB1
2 3 4 5
ge 1,0ø
ge 1,0ø
gn/ge 0,5ø
gn/rt 0,5ø
sw/vi 0,5ø
rt/sw 0,5ø
BE1 BE1 BE1 BE1 BE1
rt/gn 0,5ø
rt/ws 0,5ø
bl/ws 0,5ø
rt/ws 0,5ø
rt/bl 0,5ø
X1:4 X3:9 X3:16 X3:25 X3:12
gn/ws/vi 0,5ø
BE1 X3:14
gn 0,5ø
vi/ws
XM2
rt/ws
sw 6,0ø
sw/vi
bl/ws
8
vi/ws
6
gn
ge
X2:3 X2:5 X2:4 X2:2
86 30 6
gn/rt
3
K01
br/ge
XMNT XMNT
bl/rt
6 3
gn
85 87
rt
rt/ws
sw 6,0ø
gn
7 9 3 14
XB1 XM2 XM2 XB1
7 9 3 14
1
br/ge
1 1 1 1 2
bl/rt
1 Q
gn
B2 B1 3
S5 S4 S7 B20
rt
R1 3
B7
2 2 2 2 2 1
2 1 1 1
1
br Y5 H10 Y11 Y4
br
br
br
br
br
br
br
br
br
2 2 2 2
br
br
br
br
HR32-E04 HR32-E05 HR32-E06
V-0173 (3-21-05)
WIRING SCHEMATIC (Sheet 3 of 4)
442 EXCAVATOR
(S/N 522311001 AND ABOVE)
(PRINTED APRIL 2005)
V-0173
[E]
Sheet
F1
1 of 4 131
F9 F3 F4 [F] 131 1.6
ge 1,0ø 11 11 ge 1,0ø 3 ge 1,0ø 1 ge 1,0ø 1 ge 1,0ø Sheet
ge 2,5ø
XB1 10 5 1 of 4 104
S29 S25
ge
S17 104 1.10
2 110
S21 9 1 /4.9
rt
2 1 2 15 ge
XB1
bl/ge
bl/rt
10 86 3 10 5
rt/bl
bl/sw
rt/sw
S10 S4
/6.2 II I 0
5 7 12 16 3 9 2 1 9 1
XB2 XB1
5 7 XB2 12
XB1
16 3 XB2
31
bl/sw 0,5ø
rt/sw 0,5ø
bl/ge 0,5ø
rt/bl 0,5ø
bl/rt 0,5ø
31
GRN/YEL
BE1 BE1 BE1 BE1 BE1
gr/sw 0,5ø
X3:31 X3:32 X3:11 X3:26 X3:30
gr/rt 0,5ø
rt 2,5ø
rt 2,5ø
vi/ws
gr/rt
XB1 14
XM2 17
86 30 86 30
K1 K2
X 87a 85 87 87a
85 87
gr/sw
gr/rt
gr/sw
gr/rt
BE1 BE1 BE1 BE1 BE1
X2:7 X2:8 X2:1 X2:13 X2:10
Y
bl/sw
bl/ge
rt/sw
rt/bl
bl/rt
vi/ws
gr/sw
gr/sw
16 18 13 13
gr/rt
gr/rt
gr/rt
bl/sw
bl/ge
rt/sw
bl/rt
BRN
1 1 1 1 1 1 1 1 1
E4 E5 E6 E8 E7 E3
Y18 Y19 Y3 Y12 2 2 2 2 2
2
2 2 2 2
br
br
br
br
br
br
br
br
br
br
br
br
br
HR32-E07 HR32-E08
Desig-nation
Designation Device Desig- Device Desig- Device Desig- Device
nation nation nation
Joystick High torque swing drive Working floodlights K2 Relay
S21S21 Pushbutton S25 High torque swing drive F9 Fuse E6 Working floodlight rear
additional control circuit S10 Working floodlights E8 Working floodlight rear
Y18Y18 Valve additional control circuit Y12 Valve high torque swing K1 Relay E7 Boom-mounted work.
drive
floodlight
Y19Y19 Valve additional control circuit Option
E4 Working floodlight front S4 Switch rotating beacon
Working hydraulics S17 Option
F3 Fuse E3 Rotating beacon
S29S29 Armrest switch
E5 Working floodlight front X ISO/STD Valve Solenoid
Y3 Y3 Working hydraulics
F4 Fuse Y ISO/STD Valve Solenoid
V-0173 (3-21-05)
Control module WIRING SCHEMATIC
442 EXCAVATOR (Sheet 4 of 4)
(S/N 522311001 AND ABOVE)
(PRINTED APRIL 2005)
13 High torque swing drive V-0173
14 Valve additional control circuit 2
Cable colors Terminal Significance
15 -- black 30/49 Battery, positive, reverse, flasher
16 -- red 15 Glow starter, positive
17 -- brown 31 Ground, negative
18 -- blue D+/61 Generator, working hour meter
white 56a High beam
yellow 15 Switched positive output
X3 Signal inlets green Oil pressure - engine
1 -- grey Switch forward - rectifier
2 -- beige Board check system
3 Oil pressure switch black / red 54 Brake lights, stop light switch
black / blue Additional valve
4 Air filter contamination black / white L Flasher left, flasher check, terminal C
5 Hydraulic oil filter contamination black / green R Flasher right
6 Hydraulic oil level switch black / yellow Parking brake - charge indicator light
7 -- black / white / green 49a Flasher switch
black / grey C2 Flasher indicator light
8 --
black / violet G Fuel level gauge
9 Load warning switch black / brown Warning buzzer
10 -- red / black Axle lock
11 Armrest switch red / white Temperature indicator
12 Breaker switch red / yellow Hand brake switch - cabin lamp
red / blue Steering inversion
HR32-E15 13 --
red / green 4-wheel steering - crab
X1 Power supply 14 Quick – slow switch red / brown 4-wheel steering - round
1 Power supply terminal 30 15 -- brown / red Hydr.oil cooler / transmitter / engine
16 Back-up alarm switch brown / white 17/31b Warning lamp pre-glow / wiper
2 Power supply terminal 30
motor
3 Power supply terminal 30 17 Tank transmitter
brown / yellow V-belt check, valve-breaker
4 Ground 18 Ground brown / green Horn
5 Power supply terminal 15 19 Coolant temperature blue / red Hydraulic pressure
6 -- 20 Load control blue / brown Diesel fuel heat., charge press. (fuel)
21 Pressure switch travel forward left blue / white Air filter check
7 -- blue / yellow Armrest switch - pilot control
8 -- 22 Pressure switch travel reverse left
blue / black Electr. engine shut-off, wiper motor
9 -- 23 Pressure switch travel forward right white / yellow 56b Low beam
24 Pressure switch travel reverse right white / grey 3 Light switch
25 Float position switch yellow / black Heater fan switch - motor
X2 Signal outlets
26 High torque swing drive
yellow / green Hydr. filter clogging indicator
1 Working hydraulics green / red Engine oil temperature light (Deutz)
2 Breaker 27 Proximity switch boom green / white Hydraulic oil temperature
3 Quick – slow 28 Proximity switch intermediate boom green / violet Windscreen wiper
4 Float position 29 Option green / grey Heater fan
30 Option green / blue Heater fan
5 Back-up alarm
green / black Heater fan
6 Pre-glow 31 Additional control circuit – pushbutton
grey / black Side marker lamp left
7 Valve additional control circuit 32 Additional control circuit – pushbutton grey / red Side marker lamp right, panel lamps
8 Valve additional control circuit 33 -- / working floodlights
34 -- violet / white Rotating beacon
9 ---
35 -- green / white / red Cooling water level
10 Option green / black / white Engine oil level
36 Load warning signal green / white / violet Hydraulic oil level
11 Boom cut-off
37 -- orange Slew limitation
12 Intermediate boom cut-off blue / green Wiper switch
blue / yellow / green Steering lock angle rear
X4 Interface Unassigned !!!
V-0173 (3-21-05)
WIRING SCHEMATIC
442 EXCAVATOR
(S/N 528611001 AND ABOVE)
(S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007)
V-0616
Sheet 1 of 5 X30 3 X30 4 X30 5
BLK BLK
RED RED
Fuse [B]
F1 See Page 5 of 5
Boom
10A Load [C]
Fuel Temperature Indicator See Page 3 of 5
[A] RED Gauge Gauge Gauge
See Page 2 of 5
30 GRY
/BLU
BRN
86 30 BLK
BLK
BLK
BLK
Key 15 15 15
K02 58 58 58
Switch o 3
Switch Q t p
Start
Off
Glow
Run
Power 31 31 31
50A 17 19 54 15 P1 P1 P1
85 87 31
31 BRN
BLK
RED RED 31
WHT
BRN
WHT
WHT
BLK
BLK/BLU
BLK
RED
BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1
BE1
X3:20
BE1
YEL
8 7 X2:6 5
X2 X2 X2
4 3 1
1
VIO/WHT
BLU
X30
BLK/BLU
RED
GRN/WHT/VIO
XM1 XM1 XM1 XM1
BLU/WHT
RED/WHT
2 5 1 6
YEL/GRN
BLK/VIO
GRN
VIO/WHT
RED
3 1 4 4 2 6 5
XM1 XM2 XM2 XM1 XM2 XM2 XM2
3 1 4 4 2 6 5
Fuse Fuse
86 30 86 30
BLK/BLU
FA FB
40A K02 K03
50A
RED/WHT
GRN
Starter Engine
BLU/WHT
BLK/VIO
Heater
GRN/WHT/VIO
85 87 85 87
BLU
YEL
BLK
BLK
RED
RED
YEL/GRN
BLK
6
BRN
BRN
BRN
BRN
2 10 9 7 XMO
XMOT XMOT XMOT XMOT
2 9 7 T 6
10
BLK
+ W
GRN
BLK
D+ B+
Battery 30 50a Fuel Engine
12 Volt M Rack Fuel Intake Oil Air Fuel Q Hyd.
Q
50b Shut-off Heater Pressure P Filter P Level Oil P
Alternator Advanc Engine
B- Starter 31 Solenoi Switch Switch Sender Filter
_ e Temperature Hyd.
d Switch
Solenoi Switch Oil
BLK
d Level
BRN
BRN
BRN
BRN
Battery
BRN
Disconnect
BRN
Switch
X31 1 X31 2 X31 3 X31 4 X31 5 X31 2 X31 3 X31 5 X31 6 X31 7 X31 8
BRN
V-0616 (10-15-07)
WIRING SCHEMATIC
442 EXCAVATOR
(S/N 528611001 AND ABOVE)
(S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007)
V-0617
30 BLK
Sheet 2 of 5
15 RED
Fuse Fuse Fuse
Fuse [D] Fuse
F2 F7 F8
F6 See Page 3 of 5 F9
15A 10A 15A
15A 15A
[A] YEL
See Page 1 of 5
YEL
YEL
YEL
YEL
YEL
Heater
Wiper
A/C Motor
B1 Washer
ON/OFF A4 Switch
Switch
10 6 5 Switch 5 3
10
Off
Hi
Med
Low
C1 A3 A2
RED/YEL
9 8 2 7 1 A1 9 7 6 2
BLU/RED
GRN/BLK
YEL
YEL
YEL
RED
RED
BRN/BLK
BLU/BLK
GRN/VIO
GRN/GRY
GRN/BLU
GRN/BLK
BLU
86 30
YEL/BLK
+ Power 6
BLK
YEL
A/C
Plug X2
_ K3 Relay
12 V 2
85 87 87a
BLU/RED
X31 20 X31 21
XM2 XM1
GRN
YEL/GRN
11 15
BRN
BRN
10
XM1 XB1
7 10
13 12 1 9 4 3 1 2 5 6 11 12
8 9 15 XB1
XB2 XK1 XK1 XK1 XK1 XK1 XK1 XK1 XK1
XK1 XM2 XB2 XB2 XM2
13 12 1 9 4 3 1 2 6 11 12
8 9 15 5
8
XB1
8
Speaker
B6
(Optional)
Horn 1
BRN/BLK
BLU/BLK
GRN/VIO
1
RED/YEL
Switch Pressure
YEL
BLU
GRN/GRY
GRN/BLU
GRN/BLK
Switch
2
S12
BLK
YEL
BRN
Speaker
2 B7 (Optional)
BRN
YEL
GRN
GRN
BRN
BRN/GRN
31b
Thermostat Compressor 4 53
+ Switch Clutch + 53a
Interior 1 2 3 7 4 34 5 6
E21 Light M Fuel M Heater M Washer M Wiper
M7 B10 B1 Radio
And Pump T YMK Fan M5 Pump Pump
Horn M6 (Optional)
BRN
BRN
Switch Motor
_ 1 _ M4
2 31 8
S34
BRN
BRN
BRN
BRN
BRN
BRN
BRN
X31 1 X31 4 X31 9 X31 1 X31 7 X31 18 X31 2 X31 2 X31 3 X31 4 X31 5 X31 6
BRN
V-0617 (10-15-07)
WIRING SCHEMATIC
442 EXCAVATOR
(S/N 528611001 AND ABOVE)
(S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007)
V-0618
Sheet 3 of 5
30 BLK
15 RED
Fuse Fuse Fuse
F11 F10 F12
5A [C] 5A 5A
See Page 1 of 5
YEL
[D] [D] [D] [D] [D]
See Page 2 of 5 See Page 2 of 5 See Page 2 of 5 See Page 2 of 5 See Page 2 of 5
YEL
10 5 10 5 10 5 10 5 10 5
Load
Two Travel Float Breaker
S9 Warning
S5 Speed S6 Alarm S8 Position S15 Switch
Device
9 1 9 1 Switch 9 1 Switch 9 1 Switch 9 1
Switch
BLU/RED
BRN/YEL
RED/YEL
GRN/RED
GRN
YEL
YEL
BLU/YEL
YEL
BE1 BE1 BE1 BE1 BE1 BE1
BE1 BE1 BE1 BE1
X3:36 X2:3 X2:5 X2:4 X2:2 X2:1
X3:21 X3:22 X3:23 X3:24
BRN/YEL
BLU/YEL
GRN/RED
BLU/RED
RED/WHT
RED/GRN
RED
RED/BLU
RED/BLK
GRN
7 8 7 9 3 14 13 12 11
1 2 3 4 5 XB1 XB1 XB1
XM2 XM2 XB1 XM2 XM2 XB1
XB1 XB1 XB1 XB1 XB1
7 8 7 9 3 14 13 12 11
1 2 3 4 5
BLU/RED
BRN/YEL
BLU/YEL
RED/WHT
RED/GRN
RED/BLK
YEL
RED/BLU
BLU/YEL
RED
YEL
GRN/RED
GRN
YEL
2 1 Two 1 Float 1 1 1
2 2 2 2 1 Breaker Armrest
B7 P Speed Travel Position S29
U 3 Y5 Y11 Y4 Solenoid Y3 Switch
P P P P Load Solenoid Alarm Solenoid Auxiliary
1 1 2 2 2 2 2 2
1 1 1 Warning
H10 Hydraulics
Pressure Pressure Pressure Pressure Sensor
BRN
Solenoid
BRN
BRN
BRN
Switch Switch Switch Switch
BRN
BRN
Forward Reverse Forward Reverse
Left Left Right Right
X31 10 X31 3 X31 11 X31 12 X31 4 X31 5
BRN
V-0618 (10-15-07)
WIRING SCHEMATIC
442 EXCAVATOR
(S/N 528611001 AND ABOVE)
(S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007)
V-0619
30 Sheet 4 of 5
BLK
15
RED
Fuse
F13
5A
YEL
3 1 3 1 1
Additional Additional
10 5
Control Control High
YEL
YEL
BLU/GRN
RED/BLU
BLU/RED
GRN/BLK
BLU/WHT
RED/BLK
BLU/BLK
RED/BLK
16
XB2
16 5 18 11 13 1 3
7 XB2 16
XB2 XB2 XB1 XB2 XB2 XB1 XB2 XM2 XB1
5 18 11 13 1 3 20 17
7 16
RED/BLU
RED/BLK
BLU/WHT
BLU/GRN
GRN/BLK
BLU/RED
RED/BLU
RED/BLK
BLU/BLK
GRN/YEL
BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1
BE1 X2:8 X2:9 X2:11 X2:12 X2:14 X2:13 X2:10 X2:15
X2:7
BLU/GRN
YEL/BLK
GRN/BLK
BLU/WHT
RED/BLK
RED/BLK
RED/BLU
BLU/RED
BLU/BLK
16 19 1 2 17 22 21 14
18 XM2 17
XM2 XM2 XM2 XM3 XM3 XB2 XM2 XM2 XM2
16 1 2 17 22
18 17
RED/BLK
BLU/WHT
BLU/GRN
BLU/RED
RED/BLU
BLU/BLK
RED/BLK
BRN
BRN
BRN
V-0619 (10-15-07)
WIRING SCHEMATIC
442 EXCAVATOR
(S/N 528611001 AND ABOVE)
(S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007)
V-0620
30
Sheet 5 of 5
BLK
15
RED
Fuse Fuse Fuse Fuse
F14 F3 F4 F5
10A 5A 15A 15A
[D]
[D] See Page 2 of 5
See Page 2 of 5 [D]
See Page 2 of 5
RED
YEL
10 5 10 8 6 3
Light
YEL
YEL
S4 Beacon
Light Switch
9 1 9 2 1
2
XB2
2
YEL
GRN/RED
RED
86 30 86 30
10 5
GRN/BLK
Reach
RED
S18 K8 K9
GRN/RED
Limit
[B]
Switch 85 87 85 87 See Page 1 of 5
9 1 87a 87a
GRN/BLU
BRN/RED
YEL/RED
BRN
GRN/RED
GRN/YEL
BRN/YEL
86 30 Front 86 30
Rear
VIO/WHT
Light
K9 Relay K9 Light
4 6 10 12 14 Relay
15 87a 85 87
XB2 85 87 87a
XB2 XB2 XB2 XB2 XB2
4 6 10 12 14
GRN/BLK
GRN/BLK
BRN/RED
GRN/RED
GRN/RED
GRN/RED
YEL/RED
GRN/YEL
BRN/YEL
7 14 10 9 10
5 4 3 6 8 7
XM3 XK1 XK1 XK1 XK1
XM3 XM3 XM3 XM3 XK1 XK1
5 4 7 14 10 9 10
3 6 8 7
GRN/RED
GRN/BLK
GRN/BLK
VIO/WHT
BRN/RED
GRN/RED
GRN/YEL
YEL/RED
GRN/RED
GRN/RED
BRN/YEL
YEL/RED
_ _
_ Boom
BRN
Rear Light
Arm Arm Lights
BRN
BRN
BRN
BRN
Front
BRN
BRN
BRN
BRN
BRN
Solenoid
BRN
X31 20 Lights
X31 6 X31 21 X31 22 X31 23 X31 7 X31 8 X31 8 X31 9 X31 9 X31 10 X31 19
BRN
V-0620 (10-15-07)
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
442 Excavator
50-10-1 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Description
WARNING
Figure 50-10-1
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
P-32706
Figure 50-10-2
P-32701
442 Excavator
50-10-2 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 50-10-5
Figure 50-10-3
B-16658
2
The location and sizes are shown below and [Figure 50-
P-32706 10-4] & [Figure 50-10-5].
To check or replace the fuses in the right console, REF. DESCRIPTION AMPERAGE.
remove the three screws (Item 1) and remove the cover
1 Interior light, radio 5
(Item 2) [Figure 50-10-3].
2 Auxiliary power outlet 20
Figure 50-10-4 3 Front lights 15
4 Rear work lights 15
5 Horn 10
6 Heater fan motor 15
7 Wiper/Washer 10
8 Control module signal input 5
9 Optional work lights and heating
K1 Front work lights relay
K2 Rear work lights relay
K3 Air conditioning relay
P-32707
442 Excavator
50-10-3 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 50-10-8
P-32705
Figure 50-10-7
B-16659
442 Excavator
50-10-4 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 50-10-12
Figure 50-10-10
2
1
B-23196
AMPER
REF. DESCRIPTION
AGE
To check or replace the fuses in the right console,
remove the screws (Item 1) and remove the cover (Item 1 Key switch, interior light, security 10A
2) [Figure 50-10-10]. ignition (If equipped)
2 Aux power outlet, radio, heater 15A
Figure 50-10-11
3 Rotating beacon (If equipped) 10A
4 Flood light (Front) 15S
5 Flood light (Back) 15A
6 Fuel pump 15A
7 Horn, panel light, security ignition (If 10A
equipped)
8 Heater fan 15A
9 Wiper/washer, radio 15A
10 Hyd. oil level, hyd functions, overload 5A
warning
11 Travel pressure switch 5A
12 Main hyd. system 5A
P-58260
13 Left and right joystick 5A
14 Air conditioning box 10A
K1 Flood light (Front) Relay
K2 Flood light (Rear) Relay
K3 Open Relay
K01 Switch power Relay
442 Excavator
50-10-5 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 50-10-15
Figure 50-10-13 1
2
1
P-32705
Figure 50-10-14
B-23197
1
The location and sizes are shown below (Item 1) [Figure
50-10-15] & [Figure 50-10-16].
P-32702
REF. DESCRIPTION AMPERAGE
Remove the battery compartment cover (Item 1) [Figure 1 (FA) Main fuse 40
50-10-14]. 2 (FB) Pre-Heat 40
3 (K03) Intake air heat relay
442 Excavator
50-10-6 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Figure 50-10-17
P-56417
Figure 50-10-18
P-56416
442 Excavator
50-10-7 Service Manual
442 Excavator
50-10-8 Service Manual
BATTERY Figure 50-20-3
Servicing
1
The battery is located under the cab floor.
Figure 50-20-1
P-32703
Figure 50-20-2
P-32702
442 Excavator
50-20-1 Service Manual
BATTERY (CONT’D) Removal And Installation
Figure 50-20-4
P-32701
P9590
Pull up on and remove the floormat (Item 1) [Figure 50-
20-5].
Clean the battery terminals and cable ends even when
installing a new battery [Figure 50-20-4]. Figure 50-20-6
P-32702
442 Excavator
50-20-2 Service Manual
BATTERY (CONT’D) Figure 50-20-8
1
P-32704
Disconnect the positive (+) cable (Item 2) [Figure 50-20- Install the battery. Install the hold down clamp and tighten
7]. the bolts.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
442 Excavator
50-20-3 Service Manual
BATTERY (CONT’D)
Be sure the key switch is OFF. The booster battery must In case of acid contact, wash immediately with water.
be 12 volt. In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
Figure 50-20-9 minutes.
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
P-32701
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
Pull up on and remove the floor mat (Item 1) [Figure 50- connecting to a charger. Unplug charger before
20-9]. connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Figure 50-20-10
Battery gas can explode and cause serious injury.
W-2066-1296
P-32702
442 Excavator
50-20-4 Service Manual
BATTERY (CONT’D)
P-32708
Start the engine. After the engine has started, remove the
ground (-) cable first (Item 2) [Figure 50-20-11].
IMPORTANT
If jump starting the excavator from a second
machine:
442 Excavator
50-20-5 Service Manual
442 Excavator
50-20-6 Service Manual
ALTERNATOR Figure 50-30-3
Figure 50-30-1 1
P-36917
Figure 50-30-4
1
P-36915
1
Remove the clamp (Item 1) [Figure 50-30-1].
Figure 50-30-2
P-36918
P-36916
442 Excavator
50-30-1 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-7
Figure 50-30-5
2
1
P-36919
B-16596
1
1
P-36920
442 Excavator
50-30-2 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-10
Figure 50-30-8
P-63300
Figure 50-30-11
P-63298
Figure 50-30-9
P-63301
P-63299
442 Excavator
50-30-3 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-14
Figure 50-30-12
1
2 1
P-63453
Figure 50-30-15
Disconnect the wire connector (Item 1) [Figure 50-30-12]
from the alternator.
Figure 50-30-13 2
1
P-58799
1
Remove the 2 bolts (Item 1) from the alternator (Item 2)
[Figure 50-30-15].
442 Excavator
50-30-4 Service Manual
ALTERNATOR (CONT’D)
Parts Identification
1. Nut
2. Wave Washer
3. Bushing
4. Screw
5. Bracket
6. Bearing
7. Cover
8. Rotor
9. Slip Ring
10. Cover
11. Stator
12. Rectifier
13. Cover
14. Washer
15. Nut 10
16. Brushes 6
17. Regulator 9
18. Capacitor
15
7 1514
5 14
4 6
3
15
8 14
15
4 13 3
14
3 1
2 12
1 4 14 16 4
4 17
11
4
4
18
B23285
442 Excavator
50-30-5 Service Manual
ALTERNATOR (CONT’D) ALTERNATOR (CONT'D)
Figure 50-30-16
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
1 I-2023-1285
The alternator contains field diodes (Item 1) [Figure 50- Make sure all wiring harness leads are connected. Turn
30-16] a capacitor (Item 1) and brush holder (Item 2) all accessories OFF
[Figure 50-30-17].
442 Excavator
50-30-6 Service Manual
Figure 50-30-18 ALTERNATOR (CONT’D)
2
WARNING
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F. (16°C.) before
3
connecting to a charger. Unplug charger before
1 connecting or disconnecting cables to battery. Never
P-63302
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-1296
Connect the positive lead from the voltmeter to the B+
terminal (Item 1) on the alternator. Connect the negative
lead from the voltmeter to the alternator housing (ground) Figure 50-30-19
(Item 2) [Figure 50-30-18]. If the reading on the
voltmeter is lower than battery voltage or has a zero
reading, check and make repairs to the wiring between
the B+ terminal of the alternator and the battery.
1
Connect the positive lead from the voltmeter to the D+
terminal (Item 3). Connect the negative lead from the
voltmeter to the alternator housing (ground) (Item 2)
[Figure 50-30-18]. If the reading on the voltmeter is zero
check the alternator.
2
WARNING P-32703
442 Excavator
50-30-7 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-22
Figure 50-30-20
P-63613
Figure 50-30-23
Unsolder the stator coil at the connections (Item 1) to the
rectifier bridge. Remove the stator (Item 2) [Figure 50-
30-20].
Figure 50-30-21
1
1 P-63615
442 Excavator
50-30-8 Service Manual
ALTERNATOR (CONT'D)
Figure 50-30-24
P-63614
442 Excavator
50-30-9 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-27
Disassembly
Figure 50-30-25
P-63380
Figure 50-30-26
P-63381
442 Excavator
50-30-10 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-31
Disassembly (Cont’d)
Figure 50-30-29
P-63384
Figure 50-30-30
P-63385
442 Excavator
50-30-11 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-35
Disassembly (Cont’d)
Figure 50-30-33
1
1
P-63388
1
Remove the 3 nuts (Item 1) [Figure 50-30-35].
P-63386
Figure 50-30-36
Disconnect the wire (Item 1). Remove the bolt (Item 2).
Remove the capacitor (Item 3) [Figure 50-30-33].
Figure 50-30-34
2 1
1 P-63389
1
Remove the washers (Item 1) [Figure 50-30-36].
P-63387
442 Excavator
50-30-12 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-39
Disassembly (Cont’d)
Figure 50-30-37
1
1
1
P-63392
Figure 50-30-38
1
P-63395
Align the notch with the tab on the cover (Item 1) [Figure
P-63391 50-30-40].
442 Excavator
50-30-13 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-43
Disassembly (Cont’d)
Figure 50-30-41 2
P-63397
Figure 50-30-44
Remove the rotor (Item 1) [Figure 50-30-41].
Figure 50-30-42
P-63398
442 Excavator
50-30-14 Service Manual
ALTERNATOR (CONT'D) Figure 50-30-47
Disassembly (Cont’d)
Figure 50-30-45
2
1
P-63399
Figure 50-30-46
P-63400
P-63402
Remove the bushing (Item 1) [Figure 50-30-48].
442 Excavator
50-30-15 Service Manual
ALTERNATOR (CONT'D) Stator Ground Test
Figure 50-30-49
P-63529
P-63401
Touch one probe to a bare stator lead and the other
probe to the bare metal surface of the stator [Figure 50-
Remove the bushing (Item 1) [Figure 50-30-49]. 30-51].
Use an ohmmeter to test the stator. Replace the stator if there is continuity.
Figure 50-30-52
P-63528
P-63307
Touch the probes to two of the bare stator wires [Figure
50-30-50].
Touch the probes to the slip rings [Figure 50-30-52].
Move one of the probes to the third wire.
The ohmmeter should read between 3.0 - 4.0 ohms.
The readings should be the same.
If there is no continuity replace the rotor.
If there is no continuity, replace the stator.
442 Excavator
50-30-16 Service Manual
ALTERNATOR (CONT’D)
Figure 50-30-53
P-63308
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 50-30-53].
Figure 50-30-54
2 1
P-63610
442 Excavator
50-30-17 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-57
Assembly
Figure 50-30-55
1
2
P-63399
Figure 50-30-58
Install the bushing (Item 1) [Figure 50-30-55].
Figure 50-30-56
1
P-63402
442 Excavator
50-30-18 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-61
Assembly (Cont’d)
Figure 50-30-59 1
1
2
P-63397
Figure 50-30-62
Install the stator (Item 1) [Figure 50-30-59].
Figure 50-30-60
P-63396
442 Excavator
50-30-19 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-65
Assembly (Cont’d)
1
Figure 50-30-63
P-63392
1
Align the tab on the cover (Item 1) with the notch in the
rectifier (Item 2) [Figure 50-30-63].
Figure 50-30-64
1 1
P-63404
P-63394
442 Excavator
50-30-20 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-69
Assembly (Cont’d)
Figure 50-30-67 1
1
1 P-63388
Figure 50-30-68
1 2
P-63387
442 Excavator
50-30-21 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-73
Assembly (Cont’d)
Figure 50-30-71
1
P-63384
1
3
Install the washer (Item 1) [Figure 50-30-73].
P-63386
Figure 50-30-74
Figure 50-30-72
P-63383
P-63385
442 Excavator
50-30-22 Service Manual
ALTERNATOR (CONT’D) Figure 50-30-77
Assembly (Cont’d)
Figure 50-30-75
P-63380
Figure 50-30-76
1
1
P-63379
442 Excavator
50-30-23 Service Manual
ALTERNATOR (CONT’D)
Assembly (Cont’d)
Figure 50-30-79
P-63378
442 Excavator
50-30-24 Service Manual
442 Excavator
50-30-25 Service Manual
442 Excavator
50-30-26 Service Manual
STARTER STARTER (CONT’D)
Removal And Installation (S/N 522311001 & Above) Removal And Installation (S/N 528911001 & Above
And S/N 528611001 & Above)
The engine is shown removed for photo clarity.
Remove the muffler. ((See MUFFLER (S/N 528911001 &
Shut off the battery disconnect switch. (See Servicing on ABOVE AND S/N 528611001 & ABOVE) on Page 60-21-
Page 50-20-1.) 1.).)
Remove the muffler. ((See MUFFLER (S/N 522311001 & Disconnect the battery. (See Servicing on Page 50-20-1.)
ABOVE) on Page 60-20-1.).)
Figure 50-40-2
Figure 50-40-1
1
2
1
1
2
2
P-61453
P-38196
P-61452
442 Excavator
50-40-1 Service Manual
Figure 50-40-4
P-61451
442 Excavator
50-40-2 Service Manual
STARTER (CONT’D)
16
18
3 2 18
2 16
14 15
1
2 24
2 18 23 11
13
5 16 16
3 4
17 22
7 2 7
12 16
6 11
11
10
9 21
8 2 20
1. Magnetic Switch 19
2. Washer
3. Nut
13
4. Clamp
5. Screw
6. Bearing
7. Bolt
8. Housing
9. Snap Ring
10. Collar
11. Bushing
12. Pinion
13. Plate
14. Yoke
15. Pivot
16. Seal
17. Shaft
18. Gear
19. Armature
20. Frame
21. Brush Holder
22. Retainer
23. Cover
24. Cap B-23284
442 Excavator
50-40-3 Service Manual
STARTER (CONT’D) Figure 50-40-7
P-63314
Figure 50-40-8
Remove the cable (Item 1) [Figure 50-40-5] from the
magnetic switch.
Figure 50-40-6
P-63315
1
P-63313
442 Excavator
50-40-4 Service Manual
STARTER (CONT’D) Figure 50-40-11
Figure 50-40-9
1
1
P-63318
Figure 50-40-12
Remove the retainer (Item 1) [Figure 50-40-9] and
washer.
Figure 50-40-10
2
1
P-63319
442 Excavator
50-40-5 Service Manual
STARTER (CONT’D) Figure 50-40-15
Figure 50-40-13
3
2
1
1 P-63324
1
Figure 50-40-16
Remove the screws (Item 1) [Figure 50-40-13] from the
housing.
Figure 50-40-14
P-63327
442 Excavator
50-40-6 Service Manual
STARTER (CONT’D) Figure 50-40-19
Figure 50-40-17
1
P-63333
1
Figure 50-40-20
Remove the pinion (Item 1) [Figure 50-40-17].
Figure 50-40-18
2
1
1.5”
(38 mm)
P-63334
0.675”
(17 mm) Press the collar (Item 1) down to gain access to the snap
P-63335
ring (Item 2) [Figure 50-40-20].
In order to remove the snap ring from the pinion shaft, a Remove the snap ring.
tube 0.675 inches (17 mm) in diameter by 1.5 inches (38
mm) in length is needed [Figure 50-40-18].
442 Excavator
50-40-7 Service Manual
STARTER (CONT’D) Figure 50-40-23
Figure 50-40-21
2
1
P-63339
2
1 Press down on the over running clutch (Item 1) [Figure
P-63337 50-40-23].
Figure 50-40-22
4
3
2
1
1 P-63340
P-63338
Remove the snap ring retainer (Item 1), yoke retainer
(Item 2), spring retainer (Item 3) and spring (Item 4)
Remove the yoke (Item 1) [Figure 50-40-22]. [Figure 50-40-24].
442 Excavator
50-40-8 Service Manual
STARTER (CONT’D) Figure 50-40-27
Figure 50-40-25
1 P-63341
Figure 50-40-26
1
1
P-63345
442 Excavator
50-40-9 Service Manual
STARTER (CONT’D) Figure 50-40-31
Figure 50-40-29
P-63348
2
Remove the washer (Item 1) [Figure 50-40-31].
P-63344
Figure 50-40-32
Figure 50-40-30
P-63349
P-63347
442 Excavator
50-40-10 Service Manual
STARTER (CONT’D) Figure 50-40-35
Figure 50-40-33
1
1
P-63364
Figure 50-40-34
1
P-63377
442 Excavator
50-40-11 Service Manual
STARTER (CONT’D) Figure 50-40-39
Figure 50-40-37
P-63368
Figure 50-40-38
B-14458
442 Excavator
50-40-12 Service Manual
STARTER (CONT’D) Figure 50-40-42
Figure 50-40-41
P-63369
Check all the connections for clean and tight solder joints.
P-63375
442 Excavator
50-40-13 Service Manual
STARTER (CONT’D) Figure 50-40-46
Figure 50-40-44
1
P-63377
Figure 50-40-45
P-63364
1
P-63332
442 Excavator
50-40-14 Service Manual
STARTER (CONT’D) Figure 50-40-50
Figure 50-40-48
1
1
P-63348
Figure 50-40-49
1
1
P-63348
442 Excavator
50-40-15 Service Manual
STARTER (CONT’D) Figure 50-40-54
Figure 50-40-52
1 P-63345
Figure 50-40-53
P-63341
P-63344
442 Excavator
50-40-16 Service Manual
STARTER (CONT’D) Figure 50-40-58
Figure 50-40-56 1
2
3
4
1
1
P-63340
Install the spring (Item 1), spring retainer (Item 2), yoke
P-63343 retainer (Item 3) and snap ring retainer (Item 4) [Figure
50-40-58].
Figure 50-40-57
1
P-63339
P-63342
Press down on the snap ring retainer (Item 1) and install
the snap ring (Item 2) [Figure 50-40-59].
Install the plate (Item 1) [Figure 50-40-57].
442 Excavator
50-40-17 Service Manual
STARTER (CONT’D) Figure 50-40-62
Figure 50-40-60
1
P-63334
1
Install the snap ring (Item 1) [Figure 50-40-62].
P-63338
Figure 50-40-63
Figure 50-40-61
1
P-63332
1
2 Install the collar (Item 1) [Figure 50-40-63] over the snap
P-63337 ring.
442 Excavator
50-40-18 Service Manual
STARTER (CONT’D) Figure 50-40-66
Figure 50-40-64
1
2
3
1
P-63324
Align the notch (Item 1) with the tab (Item 2). Install the
pinion (Item 3) [Figure 50-40-64].
Figure 50-40-65
P-63327
442 Excavator
50-40-19 Service Manual
STARTER (CONT’D) Figure 50-40-69
Figure 50-40-67
1
1
P-63322
Figure 50-40-70
Figure 50-40-68
1
1 1
1
P-63321
P-63325
442 Excavator
50-40-20 Service Manual
STARTER (CONT’D) Figure 50-40-73
Figure 50-40-71
2
2
1
P-63376
Figure 50-40-74
Solder the wire (Item 1) [Figure 50-40-71] if the brush
holder assembly has been replaced.
Figure 50-40-72
1
P-63317
442 Excavator
50-40-21 Service Manual
STARTER (CONT’D) Figure 50-40-77
1 P-63314
Figure 50-40-76
1
P-63313
1
Install the bolts (Item 1) [Figure 50-40-78].
P-63315
442 Excavator
50-40-22 Service Manual
STARTER (CONT’D)
Figure 50-40-79
1 P-63312
442 Excavator
50-40-23 Service Manual
442 Excavator
50-40-24 Service Manual
STARTER (S/N 528911001 & ABOVE & S/N 528611001 Figure 50-41-82
& ABOVE)
Figure 50-41-80
P-61451
1
Remove the two bolts (Item 1) [Figure 50-41-82] from
the starter.
P-61453
Figure 50-41-81
P-61452
442 Excavator
50-41-1 Service Manual
442 Excavator
50-41-2 Service Manual
FRONT CAB LIGHT Figure 50-50-2
Figure 50-50-1
1
P-36367
Figure 50-50-3
P-36352
P-36368
442 Excavator
50-50-1 Service Manual
FRONT CAB LIGHT (CONT’D) Disassembly And Assembly
Figure 50-50-4
1 1
P-36354
P-36353
Remove the two bushings (Item 1) [Figure 50-50-5].
1
1
P-36356
442 Excavator
50-50-2 Service Manual
FRONT CAB LIGHT (CONT’D) Figure 50-50-9
Figure 50-50-7
P-36360
Figure 50-50-10
Remove the four screws (Item 1) and cover (Item 2)
[Figure 50-50-7].
1
Figure 50-50-8
P-36362
2
Remove the bulb (Item 1) [Figure 50-50-10].
P-36359
NOTE: Do not touch the bulb. If the bulb needs to be
cleaned use a clean lint free cloth. Any dirt or
Disconnect the red wire (Item 1) from the white wire (Item oil on the bulb will shorten the service life of
2). Remove the black wire (Item 3) [Figure 50-50-8] from the bulb.
the housing.
442 Excavator
50-50-3 Service Manual
FRONT CAB LIGHT (CONT’D)
Figure 50-50-11
2
P-36363
Figure 50-50-12
P-36364
442 Excavator
50-50-4 Service Manual
TWO SPEED SWITCH Figure 50-60-3
Figure 50-60-1
2
P-63442
Figure 50-60-2
P-63443
1 P-63441
442 Excavator
50-60-1 Service Manual
442 Excavator
50-60-2 Service Manual
FUEL LEVEL SENDER
Figure 50-70-1
P-33730
Figure 50-70-2
P-33729
442 Excavator
50-70-1 Service Manual
442 Excavator
50-70-2 Service Manual
WIPER MOTOR Figure 50-80-3
Figure 50-80-1
1
P-36373
1
Remove the wiper arm (Item 1) [Figure 50-80-3].
P-36371
Figure 50-80-4
Figure 50-80-2
1 2
1 P-36374
442 Excavator
50-80-1 Service Manual
WIPER MOTOR (CONT’D) Figure 50-80-7
Figure 50-80-5
P-36378
Figure 50-80-6
P-36379
P-36380
442 Excavator
50-80-2 Service Manual
BATTERY DISCONNECT SWITCH Figure 50-90-3
Figure 50-90-1
1 P-35921
1
Mark and remove the six hoses (Item 1) [Figure 50-90-
3]. Install caps and plugs.
Figure 50-90-2
2
1
1
P-40672
P-35920
442 Excavator
50-90-1 Service Manual
BATTERY DISCONNECT SWITCH (CONT’D)
Figure 50-90-5
P-40673
Figure 50-90-6
P-40660
442 Excavator
50-90-2 Service Manual
INSTRUMENT PANEL Figure 50-100-3
Figure 50-100-1
P-40667
Figure 50-100-4
Remove the screw (Item 1) [Figure 50-100-1].
Figure 50-100-2
1
1 1 1
P-40666
Tip the instrument panel back and remove the gauge Remove the instrument panel.
light harness connectors (Item 1) [Figure 50-100-2].
442 Excavator
50-100-1 Service Manual
INSTRUMENT PANEL (CONT’D)
E-Prom Information
Figure 50-100-5
P-40664
Figure 50-100-6
P-40665
442 Excavator
50-100-2 Service Manual
ENGINE SERVICE
ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . 60-61-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61-1
442 Excavator
60-01 Service Manual
ENGINE SERVICE (CONT’D)
FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . .60-71-1
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-1
MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . . 60-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21-1
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 &
ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
Hydraulic Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . 60-41-5
Hydraulic Check Valve Disassembly And Assembly . . . . . . . . . . . . . . . . 60-41-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
442 Excavator
60-02 Service Manual
ENGINE SERVICE (CONT’D)
442 Excavator
60-03 Service Manual
ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 &
ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-9
Camshaft Bearing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-29
Camshaft Bearing, Removal And Installation. . . . . . . . . . . . . . . . . . . . . 60-81-30
Connecting Rod, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-41
Control Rod Guide Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-33
Control Rod Guide Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-31
Crankshaft, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-39
Crankshaft Gear Mounting Bolt Torque Procedure . . . . . . . . . . . . . . . . 60-81-72
Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-28
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-51
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-48
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-2
Deutz Engine Tools Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1
Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-60
Front Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-54
Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-44
Piston Installation On The Connecting Rod . . . . . . . . . . . . . . . . . . . . . . 60-81-47
Piston Pin, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-45
Piston Rings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-46
Rear Cover Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-81-38
Rocker Arm And Bracket, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-53
Turbo Charger Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-81-70
Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-49
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-50
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
442 Excavator
60-04 Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12,13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 46, 47
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 45, 48
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
Vibration. 2, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47
Too much crankcase pressure. 22, 27, 29, 46
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49
Start and stop 9, 10, 11
442 Excavator
60-10-1 Service Manual
TROUBLESHOOTING (CONT’D)
Chart (Cont’d)
442 Excavator
60-10-2 Service Manual
MUFFLER (S/N 522311001 & ABOVE) Figure 60-20-3
Figure 60-20-1
1
P-35232
P-35231
Figure 60-20-2
P-38128
Figure 60-20-5
P-35231
1
Loosen the clamp (Item 1) [Figure 60-20-2]. Rotate the
clamp to provide clearance to the suction fitting bolts.
P-38129
442 Excavator
60-20-1 Service Manual
MUFFLER (S/N 522311001 & ABOVE) (CONT’D) Figure 60-20-8
Figure 60-20-6
2
P-40472
Figure 60-20-9
P-40474
P-40471
P-40473
442 Excavator
60-20-2 Service Manual
MUFFLER (S/N 522311001 & ABOVE) (CONT’D) Figure 60-20-12
Figure 60-20-10
1 P-40467
1
Figure 60-20-13
P-40469
Figure 60-20-11
2
1 1
3 P-40468
3
Remove the four bolts (Item 1) [Figure 60-20-12] &
[Figure 60-20-13] and washers.
442 Excavator
60-20-3 Service Manual
442 Excavator
60-20-4 Service Manual
MUFFLER (S/N 528911001 & ABOVE AND S/N Figure 60-21-3
528611001 & ABOVE)
Figure 60-21-1
P-58447
1
Figure 60-21-2
P-58446
442 Excavator
60-21-1 Service Manual
MUFFLER (S/N 528911001 & ABOVE AND S/N
528611001 & ABOVE) (CONT’D)
Figure 60-21-4
P-58448
Figure 60-21-5
P-58449
442 Excavator
60-21-2 Service Manual
AIR CLEANER Figure 60-30-3
1 2
3 4
2 P-33726
Figure 60-30-4
5
P-33724
Figure 60-30-2
Slide the air cleaner (Item 1) [Figure 60-30-3] & [Figure
60-30-4] out the front of the excavator.
P-33725
442 Excavator
60-30-1 Service Manual
442 Excavator
60-30-2 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) NOTE: The plug is located next to the alternator
mount bracket.
Removal And Installation
Drain the coolant from the engine.
Drain the hydraulic reservoir. (See Replacing The
Hydraulic Oil on Page 10-100-2.) Figure 60-40-3
Figure 60-40-1
2 1 1
1 P-36921
Figure 60-40-4
1 1
P-38640
Figure 60-40-2 1
P-36922
442 Excavator
60-40-1 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Position the hose and bracket (Item 2) [Figure 60-40-6]
(CONT’D) towards the rear of the excavator.
Removal And Installation (Cont’d) Reinstall the bolt (Item 1) [Figure 60-40-6].
2
1
P-36923
P-36925
Remove the hose (Item 1) [Figure 60-40-5]. Remove the bottom oil hose (Item 1) [Figure 60-40-7].
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 60-40-6
2 1
P-36924
442 Excavator
60-40-2 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Figure 60-40-10
(CONT’D)
Figure 60-40-8
2 P-36928
1
Install a lifting chain and hoist on the lifting brackets
[Figure 60-40-10].
P-36926
Figure 60-40-9
2
1
P-36927
442 Excavator
60-40-3 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Remove the three bolts (Item 1) [Figure 60-40-11],
(CONT’D) [Figure 60-40-12] & [Figure 60-40-13] and washers.
Figure 60-40-11
1
P-36930
P-36932
Figure 60-40-15
Figure 60-40-12
P-36929
P-36933
Remove the two radiator mount bolts (Item 1) [Figure 60-
40-14] & [Figure 60-40-15] and washers.
Figure 60-40-13
P-36934
442 Excavator
60-40-4 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Figure 60-40-18
(CONT’D)
Figure 60-40-16 2
P-36936
Figure 60-40-17
P-36937
442 Excavator
60-40-5 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Figure 60-40-21
(CONT’D)
Figure 60-40-19
P-36940
1
Raise the hoist and slide the radiator towards the front of
the excavator. Remove the fan guard (Item 1) [Figure
P-36938 60-40-21].
P-36939
442 Excavator
60-40-6 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Figure 60-40-24
(CONT’D)
Figure 60-40-22
1
1
P-38010
1
1 1 1 1
P-36942
P-38011
442 Excavator
60-40-7 Service Manual
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE)
(CONT’D)
Figure 60-40-26
P-38012
442 Excavator
60-40-8 Service Manual
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE Figure 60-41-3
AND S/N 528611001 & ABOVE)
Figure 60-41-1
2 1 P-58451
1
1 1 1
IMPORTANT
P-38640 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Remove the eleven bolts (Item 1) [Figure 60-41-1] and tubelines and ports to keep dirt out. Dirt can quickly
washers. damage the system.
I-2003-0888
Remove the cover (Item 2) [Figure 60-41-1].
Figure 60-41-2
P-58450
442 Excavator
60-41-1 Service Manual
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE Figure 60-41-6
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-41-4
P-58453
1
Remove the bolt (Item 1) and clamp. Remove the lower
3 hydraulic cooler hose (Item 2) [Figure 60-41-6].
P-58452
Figure 60-41-7
Install the plug and washer. Remove the drain hose after
the radiator is drained.
1
Remove the upper hydraulic cooler hose (Item 2) and
upper radiator hose (Item 3) [Figure 60-41-4].
Figure 60-41-5
1
1
P-58455
P-58454
Remove the tie strap (Item 1). Remove the lower radiator
hose (Item 2) [Figure 60-41-5].
442 Excavator
60-41-2 Service Manual
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE Figure 60-41-10
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-41-8
4
2
1
P-58459
Figure 60-41-11
Remove the top bolt (Item 1) and washer. Remove the
washer (Item 2) [Figure 60-41-8] from between the
mount and bracket.
Figure 60-41-9
P-58460
1
1
P-58458
442 Excavator
60-41-3 Service Manual
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE Figure 60-41-14
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-41-12
1 P-58464
Tilt the fan shroud forward and remove the fan (Item 1)
[Figure 60-41-12].
Figure 60-41-13
P-58462
442 Excavator
60-41-4 Service Manual
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE Figure 60-41-16
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-41-15
P-58465
IMPORTANT 1
442 Excavator
60-41-5 Service Manual
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-41-18
P-58467
Figure 60-41-19
5 4 3 2 1
P-58468
Remove the spring seat (Item 1), spring (Item 2), check
valve (Item 3), and O-ring (Item 4) from the check valve
body (Item 5) [Figure 60-41-19].
442 Excavator
60-41-6 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-2
522311001 & ABOVE)
P-63087
IMPORTANT
Remove the valve cover [Figure 60-50-2].
Do not bend the high pressure fuel injection tubes
when removing or installing them. Installation: Tighten the bolts to 6-7 ft.-lb. (8-10 N•m)
I-2029-0289
torque.
P-63086 P-63089
Disconnect the wire harness (Item 1) [Figure 60-50-1] Remove the fuel injector lines from the fuel pump and
from the fuel shut off solenoid. fuel injector [Figure 60-50-3].
442 Excavator
60-50-1 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-6
522311001 & ABOVE) (CONT’D)
Figure 60-50-4
P-63091
Figure 60-50-5
P-63092
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 seconds
P-63090 each time and take the average reading.
442 Excavator
60-50-2 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
522311001 & ABOVE) (CONT’D)
442 Excavator
60-50-3 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
522311001 & ABOVE) (CONT’D)
Figure 60-50-8
P-63087
Figure 60-50-9
P-61843
442 Excavator
60-50-4 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
522311001 & ABOVE) (CONT’D)
442 Excavator
60-50-5 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-12
522311001 & ABOVE) (CONT’D)
Figure 60-50-10
P-61950
P-63086 Installation: Press and hold the control rod in the stop
position. Install the solenoid.
Figure 60-50-11
P-61951
442 Excavator
60-50-6 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Remove the fuel injector lines from the fuel pump and
522311001 & ABOVE) (CONT’D) fuel injectors [Figure 60-50-14].
Fuel Injection Pump Removal Installation: Preload the injector cap nuts to 4 ft.-lb. (5
N•m). Final tighten the bolts to 18-21 ft.-lb. (25-28,5 N•m)
torque.
Figure 60-50-15
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Figure 60-50-13
P-63093
P-63087
Figure 60-50-14
P-63089
442 Excavator
60-50-7 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-18
522311001 & ABOVE) (CONT’D)
Figure 60-50-16
P-61849
P-63094
Figure 60-50-17
P-63101
442 Excavator
60-50-8 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-21
522311001 & ABOVE) (CONT’D)
Figure 60-50-19
P-61922
Turn the locking tool. Move the control rod to the stop
position by pressing in on the setscrew [Figure 60-50-
P-61920 21].
Figure 60-50-22
Install the control rod locking tool (MEL-XXX) [Figure 60-
50-19].
Figure 60-50-20
P-61923
442 Excavator
60-50-9 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-25
522311001 & ABOVE) (CONT’D)
Figure 60-50-23
P-61926
Figure 60-50-24
P-61927
P-61925
442 Excavator
60-50-10 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-29
522311001 & ABOVE) (CONT’D)
Figure 60-50-27
P-61930
Figure 60-50-30
P-61928
Figure 60-50-28
P-61931
P-61929
442 Excavator
60-50-11 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-33
522311001 & ABOVE) (CONT’D)
Figure 60-50-31
P-61934
Position the tappet, of the injector pump to be timed, on Example: -116.26 mm-
the base circle. Turn the crankshaft 180° opposite the
direction of engine rotation [Figure 60-50-31].
Figure 60-50-32
P-61933
442 Excavator
60-50-12 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-35
522311001 & ABOVE) (CONT’D)
Figure 60-50-34
P-61935
Figure 60-50-36
P-61937
Example: -8°-
442 Excavator
60-50-13 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-39
522311001 & ABOVE) (CONT’D)
Figure 60-50-37
P-63102
Procedure:
Read the code for injection pump length -A- [Figure 60-
50-37]. Enter in Table 1 [Figure 60-50-34 on Page 13]. Read off EP code for cylinder 3 from nameplate under
column “EP”, e.g. 070. (Reading sequence: line 1=cyl 1,
Example: -53- line 2=cyl 2, etc.
Ts = Ek-(Lo+A/100)
Ts = 111.725 mm - (109 mm +53/100 mm)
Ts = 2.195 mm = Ss 2.2 mm
P-63098
442 Excavator
60-50-14 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-42
522311001 & ABOVE) (CONT’D)
Figure 60-50-40
P-63101
Figure 60-50-41
P-63094
442 Excavator
60-50-15 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-46
522311001 & ABOVE) (CONT’D)
Figure 60-50-44
P-63097
Figure 60-50-45
P-63093
Initial torque60°
P-63096 Second stage torque5 ft.-lb. (7 N•m)
Third stage torque7 ft.-lb. (10 N•m)
Final stage torque22 ft.-lb. (30 N•m)
Loosen the bolts 60° [Figure 60-50-45].
NOTE: Alternately torque the bolts starting with the
outer bolt.
442 Excavator
60-50-16 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-50
522311001 & ABOVE) (CONT’D)
Figure 60-50-48
P-61955
Figure 60-50-49
P-61954
Installation: Preload the cap nuts to 4 ft.-lb. (5 N•m) NOTE: Do not rebend or reuse the fuel injector lines.
torque. Tighten the cap nuts to 18-21 ft.-lb. (25-28,5 N•m)
torque.
442 Excavator
60-50-17 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Fuel Injector, Checking
522311001 & ABOVE) (CONT’D)
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
P-61953 Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
Remove the fuel injector clamps and bolts [Figure 60-50- from a physician familiar with this injury.
52]. W-2072-0496
Figure 60-50-53
The tools listed will be needed to do the following
procedure:
P-61952
442 Excavator
60-50-18 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-57
522311001 & ABOVE) (CONT’D)
Figure 60-50-55 1
2
3
4
5
6
CD-15333
Figure 60-50-56
CD-15334
Remove the nozzle cap nut [Figure 60-50-56]. When the nozzle body is held in the upright position, the
needle should by its own weight slide slowly and
smoothly on its seat [Figure 60-50-58].
442 Excavator
60-50-19 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
522311001 & ABOVE) (CONT’D)
Figure 60-50-59
CD-15335
442 Excavator
60-50-20 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-62
522311001 & ABOVE) (CONT’D)
Figure 60-50-60
CD-15338
Figure 60-50-61
CD-15339
CD-15337
442 Excavator
60-50-21 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-66
522311001 & ABOVE) (CONT’D)
Figure 60-50-64
CD-15342
Figure 60-50-65
CD-15341
442 Excavator
60-50-22 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-50-69
522311001 & ABOVE) (CONT’D)
CRANKSHAFT POSITION CRANKSHAFT POSITION
Valve Clearance Adjustment ONE TWO
Turn crankshaft until valves of Turn crankshaft further by
cylinder No. 1 Over lap one complete revolution
Make the valve clearance adjustment with the engine
(360°)
stopped and cold.
DO NOT ADJUST ADJUST
Remove the valve cover and crankcase breather.
Figure 60-50-67
MC-2174
Figure 60-50-70
When installing the valve cover bolts, tighten the bolts to
6-7 ft.-lb. (8-10 N•m) torque [Figure 60-50-67].
Figure 60-50-68
P-63103
Loosen the locknut and turn the set screw until the
P-63104 clearance is correct [Figure 60-50-70].
442 Excavator
60-50-23 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
522311001 & ABOVE) (CONT’D)
Thermostat
Figure 60-50-71
P-63105
442 Excavator
60-50-24 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
Figure 60-51-1
P-58312
P-58310
Installation: Tighten the bolt to 16 ft.-lb. (21 N•m) torque.
Figure 60-51-2
P-58311
442 Excavator
60-51-1 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-6
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-4
1 P-56716
Figure 60-51-5
1
P-56717
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 seconds
Install the compression adapter tool MEL-1433 [Figure
each time and take the average reading.
60-51-5].
The correct compression of the engine is 319 - 392 PSI
(22 - 27 bar) with no more than 15% difference between
the cylinders.
442 Excavator
60-51-2 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-9
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-8 1
P-58328
442 Excavator
60-51-3 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-12
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-10
P-58330
1
Remove the copper washer (Item 1) [Figure 60-51-12].
P-58327
Figure 60-51-11
P-58329
442 Excavator
60-51-4 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-13
P-58310
Figure 60-51-14
P-58316
442 Excavator
60-51-5 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-17
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
2
1
3
P-58318
P-58317
Cut and remove the cable tie (Item 1). Remove the two
bolts (Item 2) and remove the solenoid (Item 3) [Figure
60-51-16].
442 Excavator
60-51-6 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-19
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Figure 60-51-20
3 3
2 2
1
P5282
P5281
Remove the fuel tubeline (Item 1) to the fuel injection
pumps (Item 2) [Figure 60-51-18].
Remove the two mounting nuts (Item 1) [Figure 60-51-
Disconnect the respective high pressure fuel line (Item 3) 20] from the injection pump.
[Figure 60-51-18] from the injection pump to be removed
and fuel injector.
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
442 Excavator
60-51-7 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-23
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-21
1
2
P-56990
P5283
Figure 60-51-22
P5279
442 Excavator
60-51-8 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Measured Depth 2.29 inch. (58.16 mm)
528911001 & ABOVE AND S/N 528611001 & ABOVE) Difference0.070 inch. (1,78 mm)
(CONT’D)
Determine the number of shim(s) needed to get the
Fuel Injection Pump Timing
correct installation height.
The fuel injection pump does not need to be timed if the
Figure 60-51-26
tappet, shim(s) and the camshaft are not changed.
Figure 60-51-24
P-56994
Figure 60-51-25
Tappet
MC-2175
EXAMPLE:
Specifications:
Installation Depth2.36 inch. (60 mm)
442 Excavator
60-51-9 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-29
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-27
1
1 P-56995
Figure 60-51-28
B-23275
442 Excavator
60-51-10 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-33
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-31
P-56999
Figure 60-51-34
P-56997
Figure 60-51-32
P-58000
P-56998
442 Excavator
60-51-11 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-37
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-35
P5285
P-58001 Install the fuel line on the injection pumps and tighten to
20-23 ft.-lb. (27-31 N•m) torque.
Install the plug [Figure 60-51-35]. Tighten the plug to 14
ft.-lb. (18 N•m) torque.
Figure 60-51-36
P-58311
442 Excavator
60-51-12 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-39
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-38
1
P-58312
Figure 60-51-40
Remove the high pressure fuel line (Item 1) [Figure 60-
51-38] from fuel injector to be removed and fuel injection
pump.
IMPORTANT 1
442 Excavator
60-51-13 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-42
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-41
B-8971
P-58314 Operate the test pump until the nozzle valve opens:
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
442 Excavator
60-51-14 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-45
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
CD-15333
Figure 60-51-44
CD-15334
442 Excavator
60-51-15 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-47
CD-15335
442 Excavator
60-51-16 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-50
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-48
CD-15338
Figure 60-51-49
CD-15339
CD-15337
442 Excavator
60-51-17 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-54
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-52
CD-15342
Figure 60-51-53
CD-15341
442 Excavator
60-51-18 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-56
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
To do the following procedure you need the following tool: Check the timing belt, sprockets and tensioner for wear,
cracks or damage [Figure 60-51-56].
ME-1552 - Torx Bit
Check the timing belt in detail for the following conditions,
Figure 60-51-55 replace as needed.
1. Oil deposits
2. Hardened back rubber surfaces
3. Cracked
4. Badly worn teeth
1 5. Missing tooth
6. Side of belt badly worn
7. Side of belt cracked
2
P-58315
442 Excavator
60-51-19 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-58
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-57
1
2
1
P-58800
2
Remove the bolts (Item 1) from the V-belt pulley (Item 2) Remove the nuts and wire harness (Item 2) [Figure 60-
[Figure 60-51-57]. 51-59].
442 Excavator
60-51-20 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-62
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-60
1 1
P-58802
Figure 60-51-61
P-58801
442 Excavator
60-51-21 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-65
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-63
1
P-58805
Figure 60-51-64
B-14401
P-58804
442 Excavator
60-51-22 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-69
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-67
P5630
Figure 60-51-68
P5632
442 Excavator
60-51-23 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-73
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D) 1
Timing Belt Installation (Cont'd)
Figure 60-51-71
2
N-18866
Figure 60-51-74
Install the belt tension tool MEL-1460 (Item 1) [Figure
60-51-71].
Figure 60-51-72
N-18864
N-18867
442 Excavator
60-51-24 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-77
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-75
2
N-18865
N-18853
P-58801
442 Excavator
60-51-25 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-81
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-79
1
2 P-58798
Figure 60-51-82
P-58799
Figure 60-51-80
P-58797
1 1
P-58800
442 Excavator
60-51-26 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-83
P-58315
442 Excavator
60-51-27 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-86
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-84
P-56712
Loosen the locknut and turn the set screw until the
clearance is correct [Figure 60-51-86].
P-56714
Figure 60-51-85
CRANKSHAFT POSITION CRANKSHAFT POSITION
ONE TWO
Turn crankshaft Turn crankshaft further by
until valves one complete revolution
of cylinder No. 1 Overlap (360)°
F F
L L
Y Y
W W
H H
E E
E E
L L MC-2174
442 Excavator
60-51-28 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-89
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-87
P-56710
1
Figure 60-51-88
1
P-58320
442 Excavator
60-51-29 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-91
P-58444
If the timing tool can not be turned into the crankcase the
required turns, the camshaft (valve timing) setting will
have to be redone.
442 Excavator
60-51-30 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Figure 60-51-94
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
1
Thermostat, Oil Pressure Control Valves & Heater
Connections
Figure 60-51-92 2
3
1 5
6
B-14310
442 Excavator
60-51-31 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Installation: See “Thermostat, Oil Pressure Control
528911001 & ABOVE AND S/N 528611001 & ABOVE) Valves & Heater Connections” on page 31. [Figure 60-
(CONT’D) 51-94] for location on the engine block.
Thermostat, Oil Pressure Control Valves & Heater
Figure 60-51-97
Connections (Cont'd)
Figure 60-51-95 1
2
3
2
1
N-18871
N-18868 Replace the O-ring (Item 1). Remove the spring (Item 2)
from the oil pressure control valve (Item 3) [Figure 60-
51-97].
Remove the thermostat spring (Item 1) from the
thermostat (Item 2) [Figure 60-51-95], inspect all parts
The spring is marked with a red mark, for proper
and replace as needed.
installation. If the red mark is missing, the spring coil
diameter is 0.055 inch (1,4 mm).
Installation: See “Thermostat, Oil Pressure Control
Valves & Heater Connections” on page 31. [Figure 60-
Installation: See “Thermostat, Oil Pressure Control
51-94 on Page 31] for location on the engine block.
Valves & Heater Connections” on page 31. [Figure 60-
51-94 on Page 31] for location on the engine block.
Figure 60-51-96
1
2
N-18869
442 Excavator
60-51-32 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Figure 60-51-98
N-18872
442 Excavator
60-51-33 Service Manual
ENGINE COMPONENTS AND TESTING (S/N
528911001 & ABOVE AND S/N 528611001 & ABOVE)
(CONT’D)
Aneroid Device
WARNING
Description Rotating fan blade can cause serious injury or death.
Keep away from fan and moving parts. Do not
The aneroid device is used to control exhaust smoke operate with guard removed.
during acceleration or when a sudden load is placed on a
turbo-charged engine. This is accomplished by delaying Hot surfaces can cause injury. Do not touch. Allow to
the fuel control rack from moving into the higher fuel cool before servicing.
setting until the turbo-charger has time to provided W-2521-0106
sufficient intake manifold pressure to assure the correct
“air fuel mixture” to the combustion chambers. If the
intake manifold pressure is low, the fuel delivery will be The following components will be needed for testing the
reduced to prevent exhaust smoke. Once the intake aneroid device for proper function:
manifold pressure has reached a predetermined
pressure, the aneroid device will allow the injection pump Fuel Pressure Gauge - 0 - 30 PSI (0 - 60” HG)
control rack to move to a higher fuel setting and enable
the engine to produce more power, while controlling Boost Pressure Gauge (must also fabricate an
exhaust smoke output. adapter to go from the gauge threads to fit into the
manifold threads)
The only time the aneroid device should be tested or
adjusted is if excessive loss of engine RPM is evident Infrared Heat Sensor [must read a minimum 1000° F.
when a hydraulic pump load is applied to the engine. This (538 ° C.)]
condition can occur when two hydraulic functions are
required at the same time (one of these functions must
Photo tach
work the gear pump). Example: engaging the swing
circuit and the blade circuit at the same time.
Testing
Figure 60-51-99
Use the following information to determine if the aneroid
needs adjustment:
Turbochargers, operate at high speed and high Install an adapter and the Boost Pressure Gauge into the
temperatures. Keep fingers, tools and other objects manifold heater opening.
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
442 Excavator
60-51-34 Service Manual
ENGINE COMPONENTS AND TESTING (S/N 1. Bring the engine to high idle (approximately 2400
528911001 & ABOVE AND S/N 528611001 & ABOVE) RPM) and verify the engine speed with the photo
(CONT’D) tach.
Aneroid Device (Cont’d)
2. Check fuel pressure, the fuel pressure should be
between 8 - 12 PSI (0,55 - 0,82 bar). This will be
Testing (Cont’d)
difficult to read as the pressure gauge will be pulsing
due to the transfer pump.
Figure 60-51-100
3. Read the intake manifold pressure. The reading
should be between 9 - 12 PSI (0,62 - 0,82 bar) or 20
- 24” HG. If these readings can be obtained, the
engine is operating properly, continue to step 4. If
these readings can not be obtained, further engine
evaluation is needed to determine fuel restrictions, air
1 restrictions, etc..
5. Have the operator in the cab raise the boom and the
P-56410A
blade fully until both the relief valves goes over relief.
Disconnect the fuel line (Item 1) [Figure 60-51-98] at the 6. The second person should note the manifold
filter and install the fuel pressure gauge at this location. pressure, the fuel pressure and monitor the engine
RPM.
This test must be done with the engine and the hydraulic
fluid at operating temperature, 150° F. (66° C.). 7. If the manifold pressure starts to drop off and the
engine RPM starts to fall, and black exhaust smoke is
present, this is an indication that an adjustment to the
aneroid is needed. (IF the engine pulls down for a
short period of time and then start to recover without
WARNING producing black smoke, the aneroid is set correctly.)
Turbochargers, operate at high speed and high 8. Decrease engine RPM, lower boom fully and lower
temperatures. Keep fingers, tools and other objects blade to the ground. Stop the engine and remove the
away from the inlet and outlet ports. Avoid contact key.
with hot surfaces.
W-2257-1196 9. If aneroid adjustment is needed, proceed to the
adjustment procedure. If no adjustment is needed,
remove the gauges and reinstall all the existing
components.
WARNING
Rotating fan blade can cause serious injury or death.
Keep away from fan and moving parts. Do not
operate with guard removed.
442 Excavator
60-51-35 Service Manual
ENGINE COMPONENTS AND TESTING (S/N Once the correct adjustment has been reached, the
528911001 & ABOVE AND S/N 528611001 & ABOVE) engine will pull down for a short period of time and will
(CONT’D) start to recover without producing black smoke.
Aneroid Device (Cont’d)
Adjustment
When adjustment is complete: remove all test equipment
and reinstall all the original components that were
The aneroid is located in the fuel filter housing. There are
previously removed.
two lock nuts and adjustment screws on the filter
housing. Make sure you are adjusting the correct screw
Start the engine and run at high idle for a few minutes.
as shown below.
Return engine to low idle and stop the engine. Check for
leaks and repair or replace as necessary.
Figure 60-51-101
1
2
P-56410B
442 Excavator
60-51-36 Service Manual
ENGINE (S/N 522311001 & ABOVE) Figure 60-60-2
Figure 60-60-1
1 1
1 2
1
1
P-36937
P-38639
Remove the two bottom condenser mount bolts (Item 1)
[Figure 60-60-3] and washers.
Remove the eleven bolts (Item 1) and bottom panel (Item
2) [Figure 60-60-1].
442 Excavator
60-60-1 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-6
Figure 60-60-4
P-35232
Figure 60-60-5 1
P-38128
1 Figure 60-60-8
P-35231
P-38129
442 Excavator
60-60-2 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-11
Figure 60-60-9
P-38134
1
P-38138
Remove the test fitting (Item 1) and hose (Item 2) [Figure IMPORTANT
60-60-9] from the gear pump.
When repairing hydrostatic and hydraulic systems,
Figure 60-60-10 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1 I-2003-0888
Figure 60-60-12
1
2
2
P-38139
Remove the top bolt (Item 1) and two bottom bolts (Item
2) [Figure 60-60-10].
Slide the pump away from the engine. Remove the bolt (Item 1) [Figure 60-60-12].
442 Excavator
60-60-3 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-15
Figure 60-60-13
2
4
3
1 P-38135
1
1
P-32849 P-38136
Remove the plug (Item 1) [Figure 60-60-14] from the Disconnect the two wiring connectors (Item 1) Remove
back side of the engine block. the bottom heater hose (Item 2) [Figure 60-60-16].
442 Excavator
60-60-4 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-19
Figure 60-60-17
2
2
P-38141
Figure 60-60-18
3
2
P-38142
Remove the two bolts (Item 1) and remove the right side
1 cover striker (Item 2) [Figure 60-60-20].
P-38140
442 Excavator
60-60-5 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-23
Figure 60-60-21
2
1
1
P-38145
Figure 60-60-24
Remove the bolt (Item 1) from the fuel line/engine speed
control cable (Item 2) [Figure 60-60-21].
Figure 60-60-22
1
2 1
2
1
P-36915
442 Excavator
60-60-6 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-27
Figure 60-60-25
1
1
P-38152
Figure 60-60-26
P-38151
442 Excavator
60-60-7 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D) Figure 60-60-30
Figure 60-60-28
1
1
1
P-38150
Figure 60-60-31
Remove the front two engine mount bolts (Item 1)
[Figure 60-60-28].
Figure 60-60-29
1 P-38153
P-38148
442 Excavator
60-60-8 Service Manual
ENGINE (S/N 522311001 & ABOVE) (CONT’D)
Figure 60-60-32
P-38154
442 Excavator
60-60-9 Service Manual
442 Excavator
60-60-10 Service Manual
ENGINE (S/N 528911001 & ABOVE AND S/N Figure 60-61-3
528611001 & ABOVE)
1
1 2
1
1
1 P-58672
P-58669
P-58670
Figure 60-61-5 1
1
2 3
P-56395
Figure 60-61-6
1
1
2
P-58675
1
Remove the speed control cable retainer (Item 1).
1 Loosen the nut (Item 2) and remove the cable (Item 3)
[Figure 60-61-8].
P-58674
442 Excavator
60-61-2 Service Manual
ENGINE (S/N 528911001 & ABOVE AND S/N Figure 60-61-11
528611001 & ABOVE) (CONT’D)
1
Removal And Installation (Cont’d)
Figure 60-61-9
3
2
P-58677
1
Figure 60-61-12
Remove the cable tie (Item 1) [Figure 60-61-9] from the
A/C hoses.
Figure 60-61-10
P-58679
442 Excavator
60-61-3 Service Manual
ENGINE (S/N 528911001 & ABOVE AND S/N Figure 60-61-15
528611001 & ABOVE) (CONT’D)
Figure 60-61-13
2
2
2
1 1
2
2
2
2
P-58682
Loosen the clamps (Item 1) and remove the air intake Figure 60-61-16
hose. Remove the cable ties (Item 2) [Figure 60-61-13].
Figure 60-61-14
1
1
P-58684
442 Excavator
60-61-4 Service Manual
ENGINE (S/N 528911001 & ABOVE AND S/N Figure 60-61-19
528611001 & ABOVE) (CONT’D)
Figure 60-61-17
1
P-58687
1
Install lifting brackets (Item 1) [Figure 60-61-19] on the
rear of the engine.
P-58683
Figure 60-61-20
Figure 60-61-18
P-58688
1
Install a hoist on the lifting brackets [Figure 60-61-20].
P-58686
442 Excavator
60-61-5 Service Manual
ENGINE (S/N 528911001 & ABOVE AND S/N
528611001 & ABOVE) (CONT’D)
Figure 60-61-21
1 1
P-58689
442 Excavator
60-61-6 Service Manual
FLYWHEEL (S/N 522311001 & ABOVE) Figure 60-70-3
P-38181
1
1
Remove the plugs (Item 1) [Figure 60-70-3].
1
Mark the flywheel to crankshaft.
1
1
Figure 60-70-4
P-38272
1
1
Figure 60-70-2 1
1
P-38180
11. 60°
Remove the bolts (Item 1) and pump coupler (Item 2) Remove the flywheel.
[Figure 60-70-2].
442 Excavator
60-70-1 Service Manual
FLYWHEEL (S/N 522311001 & ABOVE) (CONT’D)
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-1285
Figure 60-70-5
P-38179
Fit the ring gear over the flywheel. Make sure the gear is
seated correctly.
442 Excavator
60-70-2 Service Manual
FLYWHEEL (S/N 528911001 & ABOVE AND S/N Installation: Apply thread adhesive (Loctite™ 242) to the
528611001 & ABOVE) bolt threads. Tighten the bolts to 15-18 ft.-lb. (20-25 N•m)
torque.
Removal And Installation
Mark the flywheel to crankshaft.
Remove the muffler and muffler mount. (See MUFFLER
(S/N 528911001 & ABOVE AND S/N 528611001 & Figure 60-71-3
ABOVE) on Page 60-21-1).
Figure 60-71-1
1
1
P-58649
Remove the eight bolts (Item 1) [Figure 60-71-1]. Remove the flywheel.
Figure 60-71-2
P-58648
442 Excavator
60-71-1 Service Manual
FLYWHEEL (S/N 528911001 & ABOVE AND S/N
528611001 & ABOVE) (CONT’D)
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-1285
Figure 60-71-4
P-38179
Fit the ring gear over the flywheel. Make sure the gear is
seated correctly.
442 Excavator
60-71-2 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE)
B-23276
442 Excavator
60-80-1 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-1
ABOVE) (CONT’D)
Disassembly
Remove the oil cooler. Remove the push rods [Figure 60-80-2].
P-61846
442 Excavator
60-80-2 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-6
ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-80-4
P-61849
Figure 60-80-5
P-61850
P-61848
442 Excavator
60-80-3 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-10
ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-80-8
P-61853
Figure 60-80-9
P-61854
P-61852
442 Excavator
60-80-4 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-14
ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-80-12
P-61857
Remove the connecting rod bolts [Figure 60-80-12]. Remove the flywheel. (See Removal And Installation on
Page 60-70-1.)
Remove all the piston/connecting rod assemblies from
the engine block. Figure 60-80-15
Figure 60-80-13
P-61858
P-61856 To install a new rear seal and inspect the cover. See
“Rear Cover Seal Removal And Installation” on page 54.
442 Excavator
60-80-5 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-18
ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-80-16
P-61861
Figure 60-80-19
P-61859
Figure 60-80-17
P-61862
P-61860
442 Excavator
60-80-6 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-22
ABOVE)
Disassembly (Cont'd)
Figure 60-80-20
P-61865
Figure 60-80-21
P-61866
P-61864
442 Excavator
60-80-7 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-26
ABOVE)
Disassembly (Cont'd)
Figure 60-80-24
P-61869
P-61867
Figure 60-80-25
P-61868
442 Excavator
60-80-8 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-29
ABOVE) (CONT’D)
Assembly
Figure 60-80-27
P-61872
Figure 60-80-28
P-61873
P-61871
442 Excavator
60-80-9 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-33
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-31
P-56920
Figure 60-80-34
P-61874
Install the other main bearing half into the main bearing
caps [Figure 60-80-31].
Figure 60-80-32
P-56921
Specifications:
Journal Width Std. . . . . . . . . . . . . . . . . .1.417-1.419 inch.
P-61875 (36,0-36,04 mm)
Limit for O/S . . . . . . . . . . . . . . . . 1.435 inch. (36,44 mm)
Install the thrust bearings halves on the main bearing cap Determine the end play for the crankshaft.
[Figure 60-80-32].
Specifications:
Measure the width of the thrust washers/main bearing Std. End Play. . . . . . . . . . . . . . . . . . . . .0.004-0.012 inch.
cap [Figure 60-80-32]. (0,10-0,30 mm)
Use new thrust washers as needed to get the correct end
play.
442 Excavator
60-80-10 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-37
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-35
P-61878
Figure 60-80-36
P-61879
442 Excavator
60-80-11 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & If the engine is equipped with balancing shafts use Figure
ABOVE) (CONT’D) 60-80-41 through Figure 60-80-63.
Figure 60-80-39
P-61882
P-61880
Remove the plugs [Figure 60-80-41].
Figure 60-80-40
P-61883
442 Excavator
60-80-12 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-45
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-43
P-61886
Figure 60-80-44
P-61887
442 Excavator
60-80-13 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-49
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-47
P-61890
NOTE: The teeth on the idler gear must mesh with the
teeth on the crankshaft gear.
Figure 60-80-48
P-61891
Turn the crankshaft until the bores are in line [Figure 60-
80-50].
P-61889
442 Excavator
60-80-14 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-53
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-51
P-61894
P-61892 NOTE: Install the weights toward the oil pan sealing
surface.
Figure 60-80-52
P-61895
442 Excavator
60-80-15 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-57
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-55
P-61898
Figure 60-80-58
Install the thrust washer [Figure 60-80-55].
Figure 60-80-56
P-61899
P-61897
442 Excavator
60-80-16 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-61
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-59
P-61902
Figure 60-80-60
P-61903
P-61901
442 Excavator
60-80-17 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-65
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-63
P-61906
Figure 60-80-66
Install and tighten the bolt to 15 ft.-lb. (21 N•m) torque
[Figure 60-80-63].
Figure 60-80-64
P-61907
442 Excavator
60-80-18 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-69
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-67
P-61910
Figure 60-80-68
P-61911
P-61908 Use the grease to install the gasket on the front cover
[Figure 60-80-70].
442 Excavator
60-80-19 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-73
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-71
P-61913
P-61914
P-61915
Install the front cover [Figure 60-80-72]. Install the connecting rod bearing halves into the
connecting rod [Figure 60-80-74].
442 Excavator
60-80-20 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-77
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-75
P-61917
Figure 60-80-76
P-61918
442 Excavator
60-80-21 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-80
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-79
P-61939
Check that the connecting rods can be easily moved First tightening angle:
back and forth on the crank pin [Figure 60-80-79]. 60 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
80 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Install the flywheel. (See Removal And Installation on
Page 60-70-1.) Second tightening angle:
60 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Install the injection pump. (See Fuel Injection Pump 80 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Installation on Page 60-50-15.)
442 Excavator
60-80-22 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-83
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-81 1
Put spacers on sealing surface of the engine block and Figure 60-80-84
set dial indicator gauge to 0 [Figure 60-80-81]. See
“Deutz Engine Tools Identification Chart” on page 1.
Figure 60-80-82
P-61942
442 Excavator
60-80-23 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-87
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-85
P-61945
Figure 60-80-86
P-61946
P-61944
442 Excavator
60-80-24 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-91
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-89
P-61949
Figure 60-80-92
P-61947
Figure 60-80-90
MS2062
442 Excavator
60-80-25 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-95
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-93
P-61952
Figure 60-80-96
P-61950
Figure 60-80-94
P-61953
Install the clamps and start the bolts. Do not tighten the
bolts at this time [Figure 60-80-96].
P-61951
442 Excavator
60-80-26 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-99
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-97
P-61956
Figure 60-80-98
P-61957
Install the fuel return lines through the seal and on the
injector [Figure 60-80-100].
P-61955
442 Excavator
60-80-27 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-103
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-101
P-61960
Figure 60-80-102
P-61961
P-61959
442 Excavator
60-80-28 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-107
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-105
P-61964
Figure 60-80-108
Apply anti-seize to the studs. Install the nuts on the
exhaust manifold studs and tighten to 17-20 ft.-lb. (22,5-
27,5 N•m) torque [Figure 60-80-105].
Figure 60-80-106
P-61965
Install a new gasket on the oil cooler. Install the oil cooler
[Figure 60-80-108].
P-61963
442 Excavator
60-80-29 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-111
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-109
P-61968
Figure 60-80-110
P-61969
Lightly oil the oil filter gasket. Install the oil filter. Hand
tighten the oil filter [Figure 60-80-112].
P-61967
Lightly oil the fuel filter gasket. Install the fuel filter.
442 Excavator
60-80-30 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-115
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-113
P-61972
Figure 60-80-114
P-61973
442 Excavator
60-80-31 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-119
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-117
P-61976
Figure 60-80-120
Install and tighten the coolant pump bolts to 14-17 ft.-lb.
(19-23 N•m) torque [Figure 60-80-117].
Figure 60-80-118
P-61977
Install new seals on the fuel lines. Install the fuel lines
P-61975 [Figure 60-80-120].
442 Excavator
60-80-32 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-123
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-121
P-61980
Turn the engine 180°. Install a new gasket. Install the oil
suction pipe and retainer [Figure 60-80-121].
Figure 60-80-122
P-61981
P-61979
Tighten the flange bolts first then the retainer bolts to 14-
17 ft.-lb. (19-23 N•m) torque [Figure 60-80-122].
442 Excavator
60-80-33 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Sheet Meal Oil Pan
ABOVE) (CONT’D)
Figure 60-80-127
Assembly (Cont'd)
Figure 60-80-125
P-61984
P-61982 Install the sheet metal oil pan and tighten the bolts to 14-
17 ft.-lb. (19-23 N•m) torque [Figure 60-80-127].
P-61983
P-61985
Put sealing compound on the sealing surface of the oil Align the cast iron oil pan with the timing cover tighten the
pan gasket [Figure 60-80-126]. bolts to 20-23 ft.-lbs (27-31 N•m) torque [Figure 60-80-
128].
442 Excavator
60-80-34 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-131
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-129
P-61988
Figure 60-80-132
Clean and dry the sealing surface of the governor. Apply
a 0.06-0.07 in. (1,5-2,0 mm) bead of sealing compound
to the sealing surface of the governor [Figure 60-80-
129].
Figure 60-80-130
P-61989
P-61987
442 Excavator
60-80-35 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-135
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-133
P-61992
Install the cover and tighten the bolts to 14-17 ft.-lb. (19-
23 N•m) torque [Figure 60-80-133].
Figure 60-80-134
P-61993
442 Excavator
60-80-36 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-139
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-137
P-61996
Figure 60-80-138
P-61997
442 Excavator
60-80-37 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-143
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-141
P-63000
Figure 60-80-144
P-61998
Figure 60-80-142
P-63001
Install the breather and tighten the bolts to 7-9 ft.-lb. (10-
12 N•m) torque [Figure 60-80-144].
P-61992
442 Excavator
60-80-38 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-147
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-145
P-63004
Figure 60-80-146
P-63005
442 Excavator
60-80-39 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-151
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-149
P-63008
Figure 60-80-150
P-63009
442 Excavator
60-80-40 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-155
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-153
P-63012
Figure 60-80-154
P-63013
442 Excavator
60-80-41 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-159
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-157
P-63015
Figure 60-80-158
P-63017
P-63016
Install a new seal on the plug. Install the plug and tighten
to 28-31 ft.-lb. (38-42 N•m) torque [Figure 60-80-158].
442 Excavator
60-80-42 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-163
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-161
P-63020
Figure 60-80-162
P-63021
P-63019
442 Excavator
60-80-43 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-167
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-165
P-63024
Figure 60-80-166
P-63025
442 Excavator
60-80-44 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-171
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-169
P-63028
Install the adjusting bracket with bushings and bolts Figure 60-80-172
[Figure 60-80-169].
Figure 60-80-170
P-63029
P-63027
442 Excavator
60-80-45 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-175
ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-80-173
P-63032
Figure 60-80-174
P-63033
442 Excavator
60-80-46 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-179
ABOVE) (CONT’D)
Cylinder, Checking
b 1
Clean the engine block and inspect for damage.
Figure 60-80-177 2
a 1 2
B-14697
P-63034 Specifications:
Cylinder Bore . . . . . . . . . . . . . . . . . 3.7008 - 3.7016 inch.
(94 - 94.02 mm)
Install the main bearing caps [Figure 60-80-177]. Wear Limit . . . . . . . . . . . . . . . . . . . . 3.59 inch. (94.1 mm)
Figure 60-80-178
P-63035
442 Excavator
60-80-47 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-180
b
a
1 2
B-14698
Figure 60-80-181
P-63036
442 Excavator
60-80-48 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-184
ABOVE) (CONT’D)
Figure 60-80-182
P-63039
Figure 60-80-185
Remove all the camshaft bearing bushings using a
camshaft bushing removal tool as needed [Figure 60-80-
182].
Figure 60-80-183
P-63040
442 Excavator
60-80-49 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-186
1 2
B-14698
Figure 60-80-187
P-63041
442 Excavator
60-80-50 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-190
ABOVE) (CONT’D)
Figure 60-80-188
P-63044
Figure 60-80-189
P-63043
442 Excavator
60-80-51 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-193
ABOVE) (CONT’D)
Figure 60-80-191
P-63047
Using the tool, drive the guide bushing out [Figure 60-
80-191].
Figure 60-80-192
P-63048
442 Excavator
60-80-52 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-195
P-63049
442 Excavator
60-80-53 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-198
ABOVE) (CONT’D)
Figure 60-80-196
P-63052
Figure 60-80-197
P-63053
442 Excavator
60-80-54 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-200
P-63054
Use the seal driver tool and install to the correct depth
[Figure 60-80-200]. See “Deutz Engine Tools
Identification Chart” on page 1.
Figure 60-80-201
P-63055
442 Excavator
60-80-55 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-203
ABOVE) (CONT’D)
Crankshaft, Checking
Specifications:
Specifications:
Figure 60-80-204
P-56760
Specifications:
Specifications:
442 Excavator
60-80-56 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-205
P-63056
442 Excavator
60-80-57 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-208
ABOVE) (CONT’D)
Figure 60-80-206
b
a
1 2
P-63057
P-56774
P-56770
Specifications:
442 Excavator
60-80-58 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-212
ABOVE) (CONT’D)
Figure 60-80-210
P-63060
Specifications:
I.D. of Small End Bushing . . . . . . . . . . 1.338-1.340 inch.
(33.975 - 34.035 mm)
Figure 60-80-211
P-63059
442 Excavator
60-80-59 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-213
CD-15454
Specifications:
Big End I.D. . . . . . . . . . . . . . . . . . . . 2.425 + 0.0008 inch
(61,6 + 0,02 mm)
Specifications:
Parallel Check-Tolerance . . . . . . . 0.002 inch. (0,05 mm)
Over a Distance of . . . . . . . . . . . . . . 3.94 inch. (100 mm)
Squareness Check-Tolerance . . . . 0.002 inch. (0,05 mm)
442 Excavator
60-80-60 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-216
ABOVE) (CONT’D)
Piston, Checking
Figure 60-80-214
P-63064
Figure 60-80-215
P-56782
442 Excavator
60-80-61 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Piston Pin, Checking
ABOVE) (CONT’D)
Figure 60-80-218
Piston, Checking (Cont’d)
Figure 60-80-217
B-8230
Specifications:
Using new rings, measure the ring grooves using a feeler Pin O.D. . . . . . 1.3383-1.3386 inch. (33,994-34,0 mm)
gauge [Figure 60-80-217].
Specifications:
Wear Limit
1st Ring. . . . . . . . . . . . . . . . . . . . . . . Keystone Groove
2nd Ring . . . . . . . . . . . . . . . . . . . 0.007 inch. (0.17 mm)
3rd Ring . . . . . . . . . . . . . . . . . . . 0.004 inch. (0.10 mm)
442 Excavator
60-80-62 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-219
P-56789
Figure 60-80-220
3
TS-1928A
442 Excavator
60-80-63 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-223
ABOVE) (CONT’D)
Figure 60-80-221
P-63062
Figure 60-80-224
Install the snap ring [Figure 60-80-221].
Figure 60-80-222
P-63063
Install the piston on the rod. Install the piston pin [Figure
60-80-222].
442 Excavator
60-80-64 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-227
ABOVE) (CONT’D)
Figure 60-80-225
P-63067
P-63069
Figure 60-80-226
P-63066
442 Excavator
60-80-65 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Valve seat angle:
ABOVE) (CONT’D) Specifications:
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valves, Checking Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
P-56793
P-63070
Measure the valve stem diameter [Figure 60-80-228]. Measure the valve seat width [Figure 60-80-230].
Specifications:
Std. Intake Valve . . . . . . . . . . . . . . . . 0.308-0.0006 inch. Width (Intake) . . . . . 0.106 ± 0.016 inch. (1,27 ± 0,4 mm)
(7,98-0,015 mm) (Exhaust) . . . . . 0.083 ± 0.016 inch. (2,1 ± 0,4 mm)
Figure 60-80-229
Thickness Angle
P-63068
Diameter P-56794 Install the valves and measure the valve stem clearance
[Figure 60-80-231].
442 Excavator
60-80-66 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-232
P-63071
Figure 60-80-233
Inclination
Free Length
Square
B-8208
Specifications:
Valve Spring Free Length . . . . . . . . . 2.323±0.08 inch.
(59±1,9 mm)
442 Excavator
60-80-67 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-236
ABOVE) (CONT’D)
Figure 60-80-234
P-63074
Use the valve spring tool, install the valve spring locks
[Figure 60-80-236].
P-63072
Repeat the procedure to install all the valves.
Install the valve into the cylinder head and install the Figure 60-80-237
valve stem seal [Figure 60-80-234].
Figure 60-80-235
P-63069
442 Excavator
60-80-68 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-240
ABOVE) (CONT’D)
Figure 60-80-238
P-63077
Check the oil passages that they are open and clean
[Figure 60-80-240].
P-63075
Install the rocker arms on the bracket.
Disassemble the rocker arms from the bracket [Figure Figure 60-80-241
60-80-238].
Figure 60-80-239
P-63078
Journals
Adjusting Bolt
Rocker Arm Contact Face
Bore
442 Excavator
60-80-69 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-244
ABOVE) (CONT’D)
Figure 60-80-242
P-63081
Figure 60-80-243
P-63080
442 Excavator
60-80-70 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-247
ABOVE) (CONT’D)
Figure 60-80-245
P-63084
Figure 60-80-248
Inspect the front cover for damage [Figure 60-80-245].
Figure 60-80-246
P-63085
442 Excavator
60-80-71 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-251
ABOVE) (CONT’D)
Figure 60-80-249
1 P-63019
P-63021
Figure 60-80-252
Figure 60-80-250
1
2
P-63018
Remove the elbow (Item 1) [Figure 60-80-250]. Tighten the bolt (Item 2) to 26-32 ft.-lb. (35-43 N•m)
torque.
442 Excavator
60-80-72 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 & Figure 60-80-255
ABOVE) (CONT’D)
Figure 60-80-253
P-63014
P-63017
Installation: Apply anti-seize to the studs. Tighten the
nuts to 14-17 ft.-lb. (19-23 N•m) torque.
Figure 60-80-254
P-63016
442 Excavator
60-80-73 Service Manual
RECONDITIONING THE ENGINE (S/N 522311001 &
ABOVE) (CONT’D)
Figure 60-80-256
P-63013
Drain the engine oil from the crankcase and replace the
engine oil and filter. (See Replacing Oil And Filter on
Page 10-90-2.)
442 Excavator
60-80-74 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
B-16718
442 Excavator
60-81-1 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-2
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly
Remove the turbocharger. See “Turbo Charger Removal Remove the push rods [Figure 60-81-2].
and Installation” on page 70.
Figure 60-81-3
Remove the fuel injectors. (See Fuel Injector Removal
And Installation on Page 60-51-13.)
Figure 60-81-1
P-56872
P-56870
442 Excavator
60-81-2 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-6
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-81-4
P-56875
Figure 60-81-5
P-56876
P-56874
442 Excavator
60-81-3 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-10
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
1
Figure 60-81-8
P-56884
Figure 60-81-9
P-56885
Remove the front cover and timing belt. See “Front Cover
Assembly” on page 60.
442 Excavator
60-81-4 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-14
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-81-12
P-56889
Figure 60-81-13
P-56890
P-56887
442 Excavator
60-81-5 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-18
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-81-16
P-56893
Remove the oil pan [Figure 60-81-16]. To check the piston/connecting rod assembly. See
“Piston Installation On The Connecting Rod” on page 47.
Figure 60-81-17
Figure 60-81-19
P-56892
P-56894
442 Excavator
60-81-6 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-22
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-81-20
P-56901
Figure 60-81-21
1 P-56902
442 Excavator
60-81-7 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Disassembly (Cont'd)
Figure 60-81-24
P-56903
442 Excavator
60-81-8 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-27
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly
1
Figure 60-81-25
P-56907
Figure 60-81-28
1
P-56905
2
Install the plug and tighten to 82 ft.-lb. (111 N•m) torque.
[Figure 60-81-26].
P-56908
442 Excavator
60-81-9 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-31
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-29
P-56912
Figure 60-81-32
Install and tighten the plug to 37 ft.-lb. (50 N•m) torque
[Figure 60-81-29].
Figure 60-81-30
P-56913
442 Excavator
60-81-10 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-35
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-33
P-56900
P-56915
P-56917
442 Excavator
60-81-11 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-39
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-37
P-56920
Figure 60-81-40
P-56918
Install the other main bearing half into the main bearing
caps [Figure 60-81-37].
Figure 60-81-38
P-56921
Specifications:
Journal Width Std. . . . . . . . . . . . . . . . . .1.378-1.379 inch.
P-56919 (35,0-35,04 mm)
Limit for O/S . . . . . . . . . . . . . . . . 1.395 inch. (35,44 mm)
Install the thrust bearings halves on the main bearing cap Determine the end play for the crankshaft.
[Figure 60-81-38].
Specifications:
Measure the width of the thrust washers/main bearing Std. End Play. . . . . . . . . . . . . . . . . . . . .0.004-0.010 inch.
cap [Figure 60-81-38]. (0,1-0,273 mm)
Wear Limit . . . . . . . . . . . . . . . . . . . . 0.016 inch. (0,4 mm)
442 Excavator
60-81-12 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-43
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-41
P-56924
Figure 60-81-42
P-56925
442 Excavator
60-81-13 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-47
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-45
P-56927
Figure 60-81-46
P-56928
442 Excavator
60-81-14 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-51
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-49
P-56930
Figure 60-81-50
A B
CD-15560
Specifications:
Piston Class A . . . . . . . . . . . . . . . . . . . 7.732-7.736 inch.
(196,39-196,49 mm)
Piston Class B . . . . . . . . . . . . . . . . . . . 7.736-7.744 inch.
(196,491-196,69 mm)
442 Excavator
60-81-15 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-55
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-53
P-56932
Install the piston/connecting rod assembly in the engine NOTE: If the connecting rod bolts are still serviceable,
block [Figure 60-81-53]. do not reuse the bolts more than five times.
Figure 60-81-54
CD-15564
442 Excavator
60-81-16 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-59
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-57
CD-15567
Figure 60-81-58
P-56935
Make sure the mating surfaces are clean and free of oil
and install the crankshaft gear on the crankshaft [Figure
60-81-60].
P-56934
Install the front cover with the new shaft seals on the
engine block [Figure 60-81-58].
442 Excavator
60-81-17 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-63
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-61
P-56939
Figure 60-81-62
P-56886
442 Excavator
60-81-18 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-67
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-65
P-56943
Figure 60-81-66
P-56944
442 Excavator
60-81-19 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-71
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-69
P-56947
Tighten the bolt finger tight. The gear must turn freely
[Figure 60-81-69].
Figure 60-81-70
CD-15472
442 Excavator
60-81-20 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-75
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-73 1
Put spacers on sealing surface of the engine block and Figure 60-81-76
set dial indicator gauge to 0 [Figure 60-81-73]. See
“Deutz Engine Tools Identification Chart” on page 1.
Figure 60-81-74
P-56970
442 Excavator
60-81-21 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-79
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-77
P-56973
Figure 60-81-80
Make sure the dowel pins are installed in the engine
block [Figure 60-81-77].
8 6 4 5 9
Figure 60-81-78 10 3 1 2 7
CD-15479
442 Excavator
60-81-22 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-83
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-81
P-56974
CD-15483
P-56870
442 Excavator
60-81-23 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-87
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-85
P-56979
Figure 60-81-86
P-56980
P-56978
442 Excavator
60-81-24 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-91
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-89
P-58013
Figure 60-81-90
P-58014
P-58012
442 Excavator
60-81-25 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-95
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-93
P-58017
Figure 60-81-96
P-58015
P-58016
442 Excavator
60-81-26 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-99
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Assembly (Cont'd)
Figure 60-81-97
CD-15490
B-14696
CD-15489
Install the oil pan bolts and tighten to 15 ft.-lb. (21 N•m)
torque as shown in [Figure 60-81-100].
Install the oil suction pipe and tighten the bolts to 15 ft.-lb.
(21 N•m) torque [Figure 60-81-98]. Install the oil pan plug and tighten to 40 ft.-lb. (55 N•m)
torque.
442 Excavator
60-81-27 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-103
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Cylinder, Checking
b 1
Clean the engine block and inspect for damage.
Figure 60-81-101 2
a 1 2
B-14697
P-56722 Specifications:
Cylinder Bore. . . . . . . . . . . . . . . . . .3.7008 - 3.7016 inch.
(94 - 94.02 mm)
Install the main bearing caps [Figure 60-81-101]. Wear Limit . . . . . . . . . . . . . . . . . . . . 3.59 inch. (94.1 mm)
Figure 60-81-102
P-56723
442 Excavator
60-81-28 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-104
b
a
1 2
B-14698
Figure 60-81-105
P-56724
442 Excavator
60-81-29 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-108
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-106
CD-15383
Figure 60-81-109
Remove all the camshaft bearing bushings using a
camshaft bushing removal tool as needed [Figure 60-81-
106].
Figure 60-81-107
0.019±0.012 inch
(118.9±0.3 mm)
(228.1±0.3 mm)
(117.1±0.3 mm)
4.61±0.012 inch
4.681±0.11 inch
0.098±0.12 inch
8.98±0.012 inch
(0.5±0.3 mm)
(25±.3mm)
0
P-56728
A B
Install the new camshaft bushings using a camshaft
bushing installation tool [Figure 60-81-109].
B-14699
442 Excavator
60-81-30 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-112
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-110
P-56731
Figure 60-81-111
P-56732
Drill a 7/32 inch (5,5 mm) hole on one side of the pipe
[Figure 60-81-113].
P-56730
NOTE: Carefully clean the engine block after drilling.
442 Excavator
60-81-31 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-116
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-114
P-56735
Install the puller into the bore until the pin engages
[Figure 60-81-114].
Figure 60-81-115
P-56734
Install the spacer tool in position. Pull the pipe from the
lower press fit [Figure 60-81-115].
442 Excavator
60-81-32 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-119
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-117
P-56738
Using the tool, drive the guide bushing out [Figure 60-
81-117].
Figure 60-81-118
P-56739
442 Excavator
60-81-33 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-123
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-121
P-56742
Figure 60-81-122
P-56743
442 Excavator
60-81-34 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-127
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-125
P-56746
Figure 60-81-126
P-56747
P-56745
442 Excavator
60-81-35 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-131
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-129
P-56750
Install the new cover flush with the engine block [Figure
60-81-131].
P-56748
Figure 60-81-132
Install the new pipe in the block as far as it will go with the
arbor assembly [Figure 60-81-129].
Figure 60-81-130
P-56751
Install the control rod with starter spring into the guide
bushings [Figure 60-81-132].
P-56749
NOTE: The control rod must move freely.
442 Excavator
60-81-36 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-133
P-56752
442 Excavator
60-81-37 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-136
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
0.803±0.008 inch
(20.4±0.2 mm)
Figure 60-81-134
B-14700
Figure 60-81-135
P-56757
Use the seal driver tool and install to the correct depth
CD-15439 [Figure 60-81-137]. See “Deutz Engine Tools
Identification Chart” on page 1.
442 Excavator
60-81-38 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-139
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Crankshaft, Checking
Specifications:
Specifications:
Figure 60-81-140
P-56760
Specifications:
Specifications:
442 Excavator
60-81-39 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-141
P-56763
442 Excavator
60-81-40 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-144
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-142
b
a
1 2
P-56773
P-56774
P-56770
Specifications:
442 Excavator
60-81-41 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-148
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-146
P-56768
Specifications:
I.D. of Small End Bushing . . . . . . . . . . 1.181-1.182 inch.
(30.025 - 30.035 mm)
Figure 60-81-147
2908 2908
CD-15451
442 Excavator
60-81-42 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-149
CD-15454
Specifications:
Big End I.D. . . . . . . . . . . . . . . . . . . . 2.303 + 0.0008 inch
(58,5 + 0,02 mm)
Specifications:
Parallel Check-Tolerance. . . . . . . .0.118 inch. (0.03 mm)
Over a Distance of . . . . . . . . . . . . . . 3.94 inch. (100 mm)
Squareness Check-Tolerance . . . .0.002 inch. (0,05 mm)
442 Excavator
60-81-43 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-152
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Piston, Checking
Figure 60-81-150
P-56783
Figure 60-81-151
P-56782
442 Excavator
60-81-44 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Piston Pin, Checking
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-154
Piston, Checking (Cont’d)
Figure 60-81-153
B-8230
Specifications:
Using new rings, measure the ring grooves using a feeler Pin O.D. . . . . . . .1.180-1.181 inch. (29.995-30.0 mm)
gauge [Figure 60-81-153].
Specifications:
Wear Limit
1st Ring. . . . . . . . . . . . . . . . . . . . . . . . Trapezoidal Slot
2nd Ring . . . . . . . . . . . . . . . . . . . . 0.0078 in (0.20 mm)
3rd Ring . . . . . . . . . . . . . . . . . . . . 0.0059 in (0.15 mm)
442 Excavator
60-81-45 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-155
P-56789
Figure 60-81-156
3
TS-1928A
442 Excavator
60-81-46 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-159
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-157
2908 2908
CD-15451
Figure 60-81-160
P-56780
1
Figure 60-81-158
3
1 P13908
442 Excavator
60-81-47 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-161
P-56791
Figure 60-81-162
P-56792
442 Excavator
60-81-48 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Valve seat angle:
ABOVE AND S/N 528611001 & ABOVE) (CONT’D) Specifications:
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30°
Valves, Checking Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45°
P-56793
P-56795
Measure the valve stem diameter [Figure 60-81-163]. Measure the valve seat width [Figure 60-81-165].
Specifications:
Std. Intake Valve . . . . . . . . . . . . . . . . . . .0.3134-0.314 in Width (Intake) . . . . . 0.062 ± 0.016 inch. (1,58 ± 0,4 mm)
(7,97-7,98 mm) (Exhaust) . . . . . 0.067 ± 0.016 inch. (1,7 ± 0,4 mm)
Figure 60-81-164
Thickness Angle
P-56796
Diameter P-56794 Install the valves and measure the valve stem clearance
[Figure 60-81-166].
442 Excavator
60-81-49 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-167
P-56797
Figure 60-81-168
Inclination
Free Length
Square
B-8208
Specifications:
Valve Spring Diameter . . . . . . . . 0.132 inch. (3,35 mm)
Free Length . . . . . . . . . . . . . . . . . 1.53 inch. (38.9 mm)
Valve Spring Diameter . . . . . . . . 0.134 inch. (3,40 mm)
Free Length . . . . . . . . . . . . . . . . 1.547 inch. (39,3 mm)
Inclination . . . . . . . . . . . . . . . . . . . 0.126 inch. (3,2 mm)
442 Excavator
60-81-50 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-171
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-169
P-56805
Use the tool and press the valve stem as far as it will go
[Figure 60-81-171]. See “Deutz Engine Tools
P-56803 Identification Chart” on page 1.
Figure 60-81-172
Install the valve into the cylinder head and install the
protective sleeve or masking tape on the valve stem
grooves [Figure 60-81-169].
Figure 60-81-170
P-56806
P-56804
442 Excavator
60-81-51 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-173
P-56791
Use the valve spring tool, install the valve spring tool
[Figure 60-81-173].
442 Excavator
60-81-52 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-176
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-174
P-56810
Check the oil passages that they are open and clean
[Figure 60-81-176].
P-56808
Install the rocker arms on the bracket.
Disassembly the rocker arms from the bracket [Figure Figure 60-81-177
60-81-174].
Figure 60-81-175
P-56811
Journals
Adjusting Bolt
Rocker Arm Contact Face
Bore
442 Excavator
60-81-53 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-180
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-178
P-56813
Figure 60-81-181
CD-15343
Figure 60-81-179
P-56814
CD-15344
442 Excavator
60-81-54 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-184
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-182
P-56817
Figure 60-81-183
P-56818
P-56816
442 Excavator
60-81-55 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-188
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-186
P-56821
Figure 60-81-187
P-56822
442 Excavator
60-81-56 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-192
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-190
P-56825
Figure 60-81-191
P-56826
442 Excavator
60-81-57 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-196
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-194
P-56829
Figure 60-81-197
Remove the speed control lever and spacer bushing
[Figure 60-81-194].
Figure 60-81-195
P-56830
442 Excavator
60-81-58 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-198
P-56831
442 Excavator
60-81-59 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & If the torque control was disassembled, do the following
ABOVE AND S/N 528611001 & ABOVE) (CONT’D) procedure to assemble:
Figure 60-81-199
1 2 3
6
P-56839
P-56832
Turn (Item 1) into (Item 2) until lightly bottomed, back
(Item 1) [Figure 60-81-201] out 1-1/2 turns.
Inspect the front cover for damage [Figure 60-81-199].
Tighten the lock nut (Item 3) [Figure 60-81-201] to 12 ft.-
Replace the front cover as needed. lb. (16 N•m) torque.
Figure 60-81-200 Turn (Item 4) as far as it will go into (Item 5) [Figure 60-
81-201]. Turn back one full turn.
Figure 60-81-202
P-56838
Install the torque control into the front cover [Figure 60-
81-202].
442 Excavator
60-81-60 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-205
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-203
P-56843
Specifications:
Press the camshaft seal into the front cover [Figure 60-
81-206]. See “Deutz Engine Tools Identification Chart” on
page 1.
CD-15374
442 Excavator
60-81-61 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-209
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-207
P-56847-
Figure 60-81-208
P-56848
Install the stop bolt and nut. The nut must be flush with
the end of the bolt [Figure 60-81-208].
442 Excavator
60-81-62 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-213
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-211
P-56851
Figure 60-81-212
P-56852
Install the shut down lever and dowel pin [Figure 60-81-
214].
P-56850
442 Excavator
60-81-63 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-217
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-215
P-56855
Figure 60-81-216
P-56856
Install the dowel pin into the speed control lever [Figure
60-81-218].
P-56854
Install the speed control lever into the front cover [Figure
60-81-216].
442 Excavator
60-81-64 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-221
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-219
CD-15392
Figure 60-81-222
Drive the pin into the lever [Figure 60-81-219].
Figure 60-81-220
P-56858
CD-15391
442 Excavator
60-81-65 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-225
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-223
CD-15396
Figure 60-81-224
CD-15397
CD-15395
442 Excavator
60-81-66 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-229
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-227
P-56860
Assemble the roller lever with the idling lever and shaft
[Figure 60-81-229].
CD-15398
Install the complete governor lever shaft assembly into
the front cover.
Measure the ball bearing by lightly pressing the roller
lever [Figure 60-81-227]. Figure 60-81-230
Figure 60-81-228
P-56861A
442 Excavator
60-81-67 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-233
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-231
P-56864
Figure 60-81-232
P-56865
Install the shut down solenoid into the front cover [Figure
P-56863 60-81-234].
442 Excavator
60-81-68 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-237
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-235
P-56868
Figure 60-81-236
P-56867
Install the breather vent into the front cover. Tighten the
bolts to 75 in.-lb. (8,5 N•m) torque [Figure 60-81-236].
442 Excavator
60-81-69 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-240
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-238
1 P-56984
P-56986
Figure 60-81-241
Figure 60-81-239
1
1
P-56983
P-56985
442 Excavator
60-81-70 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-242
P-56982
Drain the engine oil from the crankcase and replace the
engine oil and filter. (See Replacing Oil And Filter on
Page 10-90-2)
442 Excavator
60-81-71 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 & Figure 60-81-245
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-243
P13135
Figure 60-81-246
P5292 1
Figure 60-81-244
1
P13136
P13135A
442 Excavator
60-81-72 Service Manual
RECONDITIONING THE ENGINE (S/N 528911001 &
ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Figure 60-81-247
P13137
Figure 60-81-248
P13135
442 Excavator
60-81-73 Service Manual
442 Excavator
60-81-74 Service Manual
HEATING, VENTILATION, AIR CONDITIONING
442 Excavtor
70-01 Service Manual
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
442 Excavator
70-02 Service Manual
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-190-1
442 Excavtor
70-03 Service Manual
442 Excavator
70-04 Service Manual
EVAPORATOR/HEATER UNIT (S/N 522311001 & Figure 70-10-3
ABOVE)
Figure 70-10-1
P-36826
Figure 70-10-4
1
P-36828
P-36827
442 Excavator
70-10-1 Service Manual
442 Excavator
70-10-2 Service Manual
EVAPORATOR/HEATER UNIT (S/N 528911001 & Figure 70-11-3
ABOVE AND 528611001 & ABOVE)
Figure 70-11-1
2
2
1
1
P-63541
1
1
Loosen the clamp (Item 1). Remove the hose (Item 2)
[Figure 70-11-3].
P-61833
Figure 70-11-4
Figure 70-11-2
1
2
P-63593
Remove the seat and seat mount. (See SEAT AND SEAT
MOUNT on Page 40-30-1)
442 Excavator
70-11-1 Service Manual
EVAPORATOR/HEATER UNIT (S/N 528911001 & Figure 70-11-7
ABOVE AND 528611001 & ABOVE) (CONT’D)
1
P-63538
2
Loosen the clamp (Item 1). Remove the hose (Item 2)
[Figure 70-11-7].
P-63592
Figure 70-11-8
Figure 70-11-6 1
1
1
P-63589
P-63601
442 Excavator
70-11-2 Service Manual
EVAPORATOR/HEATER UNIT (S/N 528911001 & Figure 70-11-11
ABOVE AND 528611001 & ABOVE) (CONT’D)
Figure 70-11-9
1
1
1
P-63579
1
Remove the 2 bolts (Item 1) from the retainer (Item 2)
[Figure 70-11-9].
Figure 70-11-10
P-63578
P-63580
442 Excavator
70-11-3 Service Manual
EVAPORATOR/HEATER UNIT (S/N 528911001 & EVAPORATOR/HEATER UNIT (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D) ABOVE AND 528611001 & ABOVE) (CONT’D)
1
1 2
1 1 1
1
P-63577 P-63575
Remove the 4 bolts (Item 1) [Figure 70-11-13] and The heater unit is shown removed in [Figure 70-11-15]
washers. and [Figure 70-11-16] for photo clarity.
Figure 70-11-14
P-63576
1
P-63584
Loosen the clamps (Item 1). Remove the hoses (Item 2)
[Figure 70-11-15] from the 2 vents (Item 1) [Figure 70-
Loosen the clamps. Remove the 3 hoses (Item 1) 11-16].
[Figure 70-11-14].
442 Excavator
70-11-4 Service Manual
Figure 70-11-17 EVAPORATOR/HEATER UNIT (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D)
Figure 70-11-19
P-63587
1
Figure 70-11-18
P-63566
Figure 70-11-20
P-63599 1
P-63567
442 Excavator
70-11-5 Service Manual
Figure 70-11-21 EVAPORATOR/HEATER UNIT (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D)
1 1
P-63559 1
Figure 70-11-24
1
P-63560
442 Excavator
70-11-6 Service Manual
Figure 70-11-25 EVAPORATOR/HEATER UNIT (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D)
1 Figure 70-11-27
2
P-63564
2
Remove the screw (Item 1) from the blower (Item 2)
[Figure 70-11-25].
P-63570
Remove the blower.
Figure 70-11-26 Raise the evaporator (Item 1). Remove the thermostat
wire (Item 2) [Figure 70-11-27].
1
Figure 70-11-28
1 1
P-63568
442 Excavator
70-11-7 Service Manual
Figure 70-11-29 EVAPORATOR/HEATER UNIT (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D)
Figure 70-11-31
1
1
P-63572
Figure 70-11-32
P-63573
1
Remove the thermostat (Item 1) [Figure 70-11-30].
P-63552
442 Excavator
70-11-8 Service Manual
Figure 70-11-33 EVAPORATOR/HEATER UNIT (S/N 528911001 &
ABOVE AND 528611001 & ABOVE) (CONT’D)
1 Disassembly And Assembly (Cont’d)
Figure 70-11-35
1 1
P-63553
Figure 70-11-36
1
1
P-63554
P-63556
442 Excavator
70-11-9 Service Manual
Figure 70-11-37
P-63557
Figure 70-11-38
1 2
P-63558
442 Excavator
70-11-10 Service Manual
HEATER/AC FAN Figure 70-20-3
Figure 70-20-4
1 1
P-40350
P-40355
442 Excavator
70-20-1 Service Manual
HEATER/AC FAN (CONT’D) Figure 70-20-7
Figure 70-20-5
1 1 1
P-40363
Figure 70-20-8
Remove the four screws (Item 1) and bracket (Item 2)
[Figure 70-20-5].
Figure 70-20-6 1
1
P-40364
442 Excavator
70-20-2 Service Manual
HEATER/AC FAN (CONT’D)
Remove the seat and seat mount. (See SEAT AND SEAT
MOUNT on Page 40-30-1.)
Figure 70-20-9
P-40368
Figure 70-20-10
1 1
P-40369
442 Excavator
70-20-3 Service Manual
442 Excavator
70-20-4 Service Manual
HEATER VALVE Figure 70-30-3
Figure 70-30-1
1 1
1 1
P-40343
2
Figure 70-30-4
P-40346
P-40344
P-40347
442 Excavator
70-30-1 Service Manual
HEATER VALVE (CONT’D)
Figure 70-30-5
P-40345
442 Excavator
70-30-2 Service Manual
442 Excavator
70-40-1 Service Manual
AIR CONDITIONING SYSTEM FLOW The expansion valve meters the amount of refrigerant
into the evaporator coil (Item 5). As the refrigerant passes
Principles through the expansion valve, it again changes its physical
state. It becomes a low temperature, low-pressure liquid
In an air conditioning system the refrigerant is circulated and saturated vapor. The low pressure liquid immediately
under pressure through five major components in a starts to boil and vaporize as it enters the evaporator. The
closed circuit. At these five points in the system the hot humid air of the machine’s cab is drawn through or
refrigerant goes through pressure and temperature blown into the evaporator by the evaporator fan (Item 6)
changes. [Figure 70-40-1 on Page 3]. Since the refrigerant is
colder than the air, it absorbs the heat from the air and
The compressor (Item 1) takes in heated, low pressure produces cooled air, which is pushed into the cab by the
refrigerant gas through the suction valve (low pressure fan. The moisture in the air condenses on the evaporator
side) and as the name indicates, pressurizes the heated coil and drips into the drain pan, which directs the water
refrigerant and forces it through the discharge valve (high out of the cab.
pressure side) on the condenser (Item 2) [Figure 70-40-
1 on Page 3]. The refrigerant cycle is completed when the heated low
pressure gas is again drawn into the compressor
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.
442 Excavator
70-40-2 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT’D)
Chart
Figure 70-40-1
5
4 Evaporator
Expansion Valve
Blower 6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
STATUS OF R134A
b-16691
442 Excavator
70-40-3 Service Manual
442 Excavator
70-40-4 Service Manual
COMPONENTS (S/N 522311001 & ABOVE) Figure 70-50-3
Identification
Figure 70-50-1
1
2
P-36870
Figure 70-50-2
1
1
P-40349
442 Excavator
70-50-1 Service Manual
COMPONENTS (S/N 522311001 & ABOVE) (CONT’D) Figure 70-50-6
Identification (Cont’d)
Figure 70-50-5
2
1
6
1 2
5
5
P-32714
Expansion Valve: The expansion valve (Item 1) [Figure A/C Switch: The rocker switch (Item 2) [Figure 70-50-6]
70-50-5] controls the amount of refrigerant entering the will be illuminated when the A/C is engaged.
evaporator coil.
Temperature Control Lever: Push the lever (Item 3)
Thermostat: The thermostat (Item 2) [Figure 70-50-5] [Figure 70-50-6] forward to increase the cab
controls the temperature of the evaporator coil. temperature; backward to decrease temperature
442 Excavator
70-50-2 Service Manual
COMPONENTS (S/N 528911001 & ABOVE AND Figure 70-51-3
52864001 & ABOVE)
Identification
Figure 70-51-1
P-63305
1
Receiver/Drier: The receiver/drier (Item 1) [Figure 70-51-
3] is the unit that receives the liquid refrigerant from the
P-63303 condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
extra liquid refrigerant until it is needed by the evaporator.
Compressor: The compressor (Item 1) [Figure 70-51-1]
is the pump that circulates the refrigerant throughout the Pressure Switch: The pressure switch (Item 2) [Figure
system. It raises the pressure of the refrigerant for heat 70-51-3] will disengage the compressor clutch at high
transfer through the condenser and evaporator. pressure readings on the high side, or at low pressure on
the high side, which indicates loss of refrigerant.
NOTE: The A/C system (compressor) is
recommended to be turned on for at least five Figure 70-51-4
minutes weekly throughout the year to
lubricate the internal components.
Figure 70-51-2
1
1
P-63306
442 Excavator
70-51-1 Service Manual
COMPONENTS (S/N 528911001 & ABOVE AND Heater Valve: The heater valve (Item 1) [Figure 70-51-6]
52864001 & ABOVE) is used to control the amount of engine coolant that flows
to the heater coil.
Identification (Cont’d)
Figure 70-51-7
Figure 70-51-5
3 2
1 1
P-32714
P-63561
Figure 70-51-6
P-63536
442 Excavator
70-51-2 Service Manual
COMPONENTS (S/N 528911001 & ABOVE AND
52864001 & ABOVE)
Identification (Cont’d)
Figure 70-51-8
1
2
3
P-61549
442 Excavator
70-51-3 Service Manual
442 Excavator
70-51-4 Service Manual
SAFETY Figure 70-60-2
Safety Equipment
Figure 70-60-1
P16399
442 Excavator
70-60-1 Service Manual
442 Excavator
70-60-2 Service Manual
REGULAR MAINTENANCE Air Conditioning Compressor Belt
Remove the Heat/AC filter. (See FRESH AIR FILTER (S/ Figure 70-70-3
N 522311001 & ABOVE) on Page 10-61-1 or See
FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/ S/N 522311001 & Above
N 528611001 & ABOVE) on Page 10-62-1.)
Replace the filter two to four times per year under normal
operating conditions, up to weekly under extremely dusty
operating conditions.
1
P-56413
Figure 70-70-4
S/N 528911001 & Above
S/N 528611001 & Above
P-40348
442 Excavator
70-70-1 Service Manual
REGULAR MAINTENANCE (CONT’D)
Figure 70-70-5
P-63304
442 Excavator
70-70-2 Service Manual
BASIC TROUBLESHOOTING Figure 70-80-8
Figure 70-80-6
EARLY MODELS
N-22411
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. ((See Cleaning The A/C Evaporator Coil &
P-58141 Heater Coil (S/N 522311001 & Above) on Page 70-80-2.)
or (See Cleaning The A/C Evaporator Coil And Heater
Coil (S/N 528911001 & Above And 528611001 & Above)
on Page 70-80-3.).)
442 Excavator
70-80-1 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Cleaning The A/C Evaporator Coil & Heater Coil (S/N
522311001 & Above)
Compressor Drive Belt Inspection
Remove the seat and seat mount. ((See SEAT AND
Figure 70-80-9 SEAT MOUNT on Page 40-30-1.).)
Figure 70-80-10
1 2
1
1
P-63303
3
P-36826
Inspect and adjust the compressor drive belt (Item 1)
[Figure 70-80-9] every 100 hours of operation. ((See AIR
CONDITIONING COMPRESSOR BELT (S/N 522311001 Remove the bolts (Item 1) [Figure 70-80-10].
& ABOVE) on Page 10-150-1.) or (See AIR
CONDITIONING COMPRESSOR BELT (S/N 528911001 Remove the cover (Item 2) [Figure 70-80-10].
& ABOVE AND S/N 528611001 & ABOVE) on Page 10-
151-1.).) Clean the evaporator coil and heater coil (Item 3) [Figure
70-80-10] with low pressure air or water.
442 Excavator
70-80-2 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-12
Later Models
Evaporator/Heater Unit Remove the filter (Item 1) clean the evaporator coil (Item
2) and heater coil (Item 3) [Figure 70-80-12] with low
Figure 70-80-11 pressure air or water.
1 1 1
2
1
1
1
1
2
P-63559
442 Excavator
70-80-3 Service Manual
BASIC TROUBLESHOOTING (CONT’D)
Figure 70-80-14
1
P-61549
442 Excavator
70-80-4 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-16
Figure 70-80-15
1
1
B-16658
1
Figure 70-80-17
P-32706
B-23196
442 Excavator
70-80-5 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-19
Figure 70-80-18
1
3
1
P-63619
With a multimeter, check the voltage at the excavator A/C Check to see if the compressor clutch is engaging.
relay connector terminals [Figure 70-80-18].
With a person in the operator seat and the cab door
The voltage at Pin 30 (Item 1) [Figure 70-80-18] (Yellow open, turn the key switch to RUN, without starting the
Wire) should be 12 volts at all times. excavator.
442 Excavator
70-80-6 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-22
Figure 70-80-20
1
Early Models
2
P-32705
Figure 70-80-23
P-56399
Figure 70-80-21
Later Models
1
1 2
P-32702
Push the A/C switch (Item 1) [Figure 70-80-20] or Replace the fuse if burned out.
[Figure 70-80-21] to the ON position.
442 Excavator
70-80-7 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-26
Figure 70-80-24
P-63620
1
1
P-61567
442 Excavator
70-80-8 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-30
Figure 70-80-28
1 P-63624
Early Models
Figure 70-80-31
1
P-63623
P-63616
442 Excavator
70-80-9 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-34
Figure 70-80-32
P-63625
Figure 70-80-35
P-63625
1
Check the wire harness (Item 1) [Figure 70-80-33] for
voltage. The voltage should be approximately 12 volts,
from Pin A4 (yellow wire) to ground.
If there is voltage at the wiring harness, check the Disconnect the wire harness (Item 1) [Figure 70-80-35].
thermostat for resistance.
442 Excavator
70-80-10 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-37
Figure 70-80-36
P-63626
Check the wire harness (Item 1) [Figure 70-80-36] for Check the resistance between Pin 2 (brown wire) and Pin
voltage to the blower fan. 10 (blue wire).
In the cab, place the blower switch in position 1. Check Check the resistance between Pin 2 (brown wire) and Pin
for voltage at the harness connector (Item 1) [Figure 70- 9 (black wire).
80-36], Pin 10. (Green/blue wire). The voltage should be
12 volts. Check the resistance between Pin 2 (brown wire) and Pin
8 (red wire).
In the cab, place the blower switch in position 2. Check
for voltage at the harness connector (Item 1) [Figure 70- If there is no resistance value at any of these pins,
80-36], Pin 9. (green/gray wire). The voltage should be replace the blower fan. ((See HEATER/AC FAN on Page
12 volts. 70-20-1.).)
In the cab, place the blower switch in position 3. Check If there is resistance value at any of the pins, check the
for voltage at the harness connector (Item 1) [Figure 70- climate controls at the control panel inside the excavator
80-36], Pin 8. (Green/black wire). The voltage should be cab.
12 volts.
442 Excavator
70-80-11 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-40
Figure 70-80-38
1
P-63630
Figure 70-80-39
1
P-63629
442 Excavator
70-80-12 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-42
P-63628
A1
A4 Remove the switch panel (Item 1) [Figure 70-80-42].
A2 A3
P-63631
Figure 70-80-43
442 Excavator
70-80-13 Service Manual
BASIC TROUBLESHOOTING (CONT’D)
Figure 70-80-44
P-63635
Figure 70-80-45
1
2
3 4
P-63636
442 Excavator
70-80-14 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 70-80-47
Engine Coolant By-Passing The Heater Valve S/N 522311001 & Above
1
Figure 70-80-46
1
2
3 P-36826
Figure 70-80-48
P-32714
S/N 528911001 & Above And
S/N 528611001 & Above
Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to the High Speed position., Turn
the temperature control (Item 3) [Figure 70-80-46] to the 1
High A/C position, with the key switch OFF.
Start the excavator and run at high idle, for ten minutes.
P-63536
442 Excavator
70-80-15 Service Manual
442 Excavator
70-80-16 Service Manual
GENERAL AIR CONDITIONING SERVICE Compressor Oil Check
GUIDELINES
The compressor oil should be checked as follows when
Compressor Oil oil is being added to an in service excavator.
442 Excavator
70-90-1 Service Manual
GENERAL AIR CONDITIONING SERVICE Figure 70-90-52
GUIDELINES (CONT'D)
Figure 70-90-50
1
P-63472
Remove the oil drain plug (Item 1) [Figure 70-90-50] and NOTE: The suction port on the compressor is marked
drain the oil through the connectors and the oil drain with an L and is the larger port on the
hole. compressor.
Figure 70-90-51
1 P-63471
442 Excavator
70-90-2 Service Manual
GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Figure 70-90-53
P-63305
442 Excavator
70-90-3 Service Manual
442 Excavator
70-90-4 Service Manual
SYSTEM TROUBLESHOOTING CHART
442 Excavator
70-100-1 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT’D)
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater than the low side pressure.
442 Excavator
70-100-2 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT’D)
442 Excavator
70-100-3 Service Manual
442 Excavator
70-100-4 Service Manual
TEMPERATURE/PRESSURE
Chart
Condenser
442 Excavator
70-110-1 Service Manual
442 Excavator
70-110-2 Service Manual
AIR CONDITIONING SERVICE
Chart
442 Excavator
70-120-1 Service Manual
442 Excavator
70-120-2 Service Manual
SYSTEM CHARGING AND RECLAMATION Figure 70-130-55
Reclamation Procedure
1
Figure 70-130-54
2
1
P-23024A
442 Excavator
70-130-1 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D)
N-22291
442 Excavator
70-130-2 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-130-59
Figure 70-130-57
N-22381
Figure 70-130-58 Add 1 oz of Pag oil to the system when a A/C component
has been replaced. The compressor comes from the
factory pre-filled with oil.
N-22292
442 Excavator
70-130-3 Service Manual
442 Excavator
70-130-4 Service Manual
COMPRESSOR (S/N 522311001 & ABOVE) Figure 70-140-3
Figure 70-140-1
1 1
P-40478
1 Remove the bolt (Item 1) and nut. Remove the belt (Item
2) [Figure 70-140-3] from the pulley and remove the
compressor.
P-40476
Figure 70-140-2
2
1
P-40477
442 Excavator
70-140-1 Service Manual
442 Excavator
70-140-2 Service Manual
COMPRESSOR (S/N 528911001 & ABOVE AND S/N Figure 70-141-3
528611001 & ABOVE)
Figure 70-141-1
1 1
1
P-61569
1
Remove the two bolts (Item 1) [Figure 70-141-3],
washers and nuts
Figure 70-141-4
P-61567
Figure 70-141-2
1
2
P-61570
2 3
Remove the two bolts (Item 1), washers and nuts.
4
Remove the belt (Item 2) [Figure 70-141-4].
Remove the tiestrap (Item 1), bolt (Item 2), washer, and
nut. Remove the ground wire (Item 3) and disconnect the
wire harness (Item 4) [Figure 70-141-2].
442 Excavator
70-141-1 Service Manual
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONT’D)
Parts Identification
442 Excavator
70-141-2 Service Manual
COMPRESSOR (S/N 528911001 & ABOVE AND S/N Figure 70-141-7
528611001 & ABOVE) (CONT’D)
Figure 70-141-5 1
P-61574
Figure 70-141-6
P-61582
442 Excavator
70-141-3 Service Manual
COMPRESSOR (S/N 528911001 & ABOVE AND S/N Figure 70-141-11
528611001 & ABOVE) (CONT’D)
P-61576
Figure 70-141-10 1
P-61577
442 Excavator
70-141-4 Service Manual
COMPRESSOR (S/N 528911001 & ABOVE AND S/N Figure 70-141-15
528611001 & ABOVE) (CONT’D)
P-61580
Remove the bolt (Item 1) [Figure 70-141-13] from the Remove the coil from the compressor.
shaft.
The compressor is not serviceable and must be replaced
Figure 70-141-14 as a complete unit.
P-61579
442 Excavator
70-141-5 Service Manual
442 Excavator
70-141-6 Service Manual
CONDENSER (S/N 522311001 & ABOVE) Figure 70-150-2
Figure 70-150-1
P-36867
1
Remove the bolt (Item 1) [Figure 70-150-2] and washer.
Figure 70-150-3
P-36866
1
Remove the top hose (Item 1) [Figure 70-150-1].
WARNING P-36868
442 Excavator
70-150-1 Service Manual
CONDENSER (S/N 522311001 & ABOVE)
Figure 70-150-4
P-36869
442 Excavator
70-150-2 Service Manual
CONDENSOR (S/N 528911001 & ABOVE AND S/N Figure 70-151-2
528611001 & ABOVE)
Figure 70-151-1
1
P-63454
1
Remove the bottom hose (Item 1) [Figure 70-151-2].
Figure 70-151-3
P-63455
1
WARNING P-63457
442 Excavator
70-151-1 Service Manual
CONDENSOR (S/N 528911001 & ABOVE AND S/N
528611001 & ABOVE) (CONT’D)
Figure 70-151-4
1
1
P-63456
442 Excavator
70-151-2 Service Manual
RECEIVER/DRYER (S/N 522311001 & ABOVE) Figure 70-160-2
Figure 70-160-1
1 P-36871
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
442 Excavator
70-160-1 Service Manual
442 Excavator
70-160-2 Service Manual
RECEIVER/DRYER (S/N 528911001 & ABOVE AND Figure 70-161-2
528611001 & ABOVE))
Figure 70-161-1
P-63460
1
Loosen the clamp (Item 1) [Figure 70-161-2].
P-63458
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
442 Excavator
70-161-1 Service Manual
442 Excavator
70-161-2 Service Manual
PRESSURE SWITCH (S/N 522311001 & ABOVE) Figure 70-170-2
Figure 70-170-1
1
2 P-40464
Disconnect the wire harness (Item 1) [Figure 70-170-1] With a tire valve core removal tool, remove the valve
core.
Remove the switch (Item 2) [Figure 70-170-1] from the
receiver/drier. Replace with a new core.
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
442 Excavator
70-170-1 Service Manual
442 Excavator
70-170-2 Service Manual
PRESSURE SWITCH (S/N 528911001 & ABOVE AND Figure 70-171-2
528611001 & ABOVE)
Figure 70-171-1 1
P-40464
1
Remove the switch (Item 2) [Figure 70-171-1] from the Replace with a new core.
receiver/drier.
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
442 Excavator
70-171-1 Service Manual
442 Excavator
70-171-2 Service Manual
HEATER COIL/EVAPORATOR Figure 70-180-3
Figure 70-180-1 Remove the two screws (Item 1) [Figure 70-180-3] from
both ends.
Figure 70-180-4
2 1
2
P-40350
Figure 70-180-2 Cut and remove the cable ties (Item 1) [Figure 70-180-4]
P-40355
442 Excavator
70-180-1 Service Manual
HEATER COIL/EVAPORATOR (CONT’D) Figure 70-180-7
Figure 70-180-5
1
1 1
P-40363
Figure 70-180-8
Remove the four screws (Item 1) and bracket (Item 2)
[Figure 70-180-5].
Figure 70-180-6
1
P-40366
442 Excavator
70-180-2 Service Manual
THERMOSTAT Figure 70-190-3
Remove the seat and seat mount. (See SEAT AND SEAT
MOUNT on Page 40-30-1.) 1
Figure 70-190-1
P-40351
P-40352
1
Remove the thermostat probe (Item 1) [Figure 70-190-1]
from the evaporator.
Figure 70-190-2
P-40354
P-40353
442 Excavator
70-190-1 Service Manual
THERMOSTAT (CONT’D)
Figure 70-190-5
P-40367
442 Excavator
70-190-2 Service Manual
EXPANSION VALVE Figure 70-200-2
WARNING P-40371
In the event of a leakage, wear safety goggles. Remove the clamp (Item 1) [Figure 70-200-2].
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives Loosen the nut (Item 2) and remove the expansion valve
a toxic gas. (Item 3) [Figure 70-200-2].
W-2371-0500
Figure 70-200-1
P-40370
442 Excavator
70-200-1 Service Manual
442 Excavator
70-200-2 Service Manual
UPGRADED AIR CONDITIONING SYSTEM Figure 70-210-4
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
1
a toxic gas.
W-2371-0500 P-32701
HFC 134A refrigerant can be dangerous if not Remove the floormat (Item 1) [Figure 70-210-4].
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious Figure 70-210-5
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air. 1
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration 1
equipment.
W-2373-0500 2
Figure 70-210-3 1
P-33790
P-32712
442 Excavator
70-210-1 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D) Figure 70-210-8
Figure 70-210-6
1
1
P-49638
2
Figure 70-210-9
Remove the screws (Item 1) and the cover (Item 2)
[Figure 70-210-6].
Figure 70-210-7
3
1
P-48719
Remove the yellow wire (Item 1), green wire (Item 2) and
P-32707 red wire (Item 3) [Figure 70-210-9] from the wire harness
connector.
442 Excavator
70-210-2 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D) Figure 70-210-12
1
P-49613
Figure 70-210-13
Remove the wire harnesses (Item 1) [Figure 70-210-10]
from the right console.
Figure 70-210-11
1
1
2 P-49592
Remove the two bolts (Item 1) [Figure 70-210-11] and Lift and remove the evaporator unit (Item 3) [Figure 70-
washers from the right arm rest. Remove the arm rest. 210-13].
Remove the seat and seat mount. (See SEAT AND SEAT
MOUNT on Page 40-30-1.)
442 Excavator
70-210-3 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D) Figure 70-210-16
2
1
P-61542
Figure 70-210-17
P-61540
Figure 70-210-15
1
1
P-61543
P-61541
442 Excavator
70-210-4 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D) Figure 70-210-20
Figure 70-210-18
1
1
1
P-61546
1
1 Remove the cover (Item 1) [Figure 70-210-20].
1 P-61544
Figure 70-210-21
Figure 70-210-19
1
1
1 1
P-61547
442 Excavator
70-210-5 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D)
Figure 70-210-22
1 1 1
1 1
P-61548
442 Excavator
70-210-6 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D) Evaporator Removal And Installation
Figure 70-210-23
1 P-61550
1
Remove the evaporator (Item 1) [Figure 70-210-24].
2 Figure 70-210-25
P-61549
P-61551
442 Excavator
70-210-7 Service Manual
UPGRADED AIR CONDITIONING SYSTEM (CONT’D) Figure 70-210-28
Figure 70-210-26
1
1
P-61554
Figure 70-210-29
1
1 2
P-61553
1
P-61555
Mark and remove the wires (Item 1) [Figure 70-210-27].
Remove the tiestraps (Item 2) [Figure 70-210-27]. Remove the switches (Item 1) [Figure 70-210-29].
442 Excavator
70-210-8 Service Manual
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-2 SAFETY &
MAINTENANCE
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE) . . . . . . . . . . . . . SPEC-30-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 &
ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-31-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-31-1
DRIVE
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) . . . . . . . . . . . SPEC-20-1 SYSTEM
Camshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft And Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Cylinder Head and Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Engine Balancing Shaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 ELECTRICAL
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6 SYSTEM &
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6 ANALYSIS
Piston And Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Valve, Valve Guide and Seat Insert . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
ENGINE
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & SERVICE
ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
Camshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-6
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Crankshaft And Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-5 SPECIFICATIONS
Cylinder Head and Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-6
Piston And Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3
Valve, Valve Guide and Seat Insert . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2
442 Excavator
SPEC-01 Service Manual
SPECIFICATIONS (CONT’D)
442 Excavator
SPEC-02 Service Manual
HYDRAULIC EXCAVATOR SPECIFICATIONS
Machine Dimensions
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards. Specifications are subject to change without
notice.
243”
(6170)
1710”
(9340)
205”
(5195)
107”
(272)
104”
(2639)
167”
(4250)
286”
B-16806
(7260)
442 Excavator
SPEC-10-1 Service Manual
HYDRAULIC EXCAVATOR SPECIFICATIONS
(CONT’D)
Performance
Operating Weight w/Cab 16534 lbs (7500 Kg)
24” Bucket, rubber tracks)
Travel Speed
Low 1.7 MPH (2,7 km/hr.)
High 3.2 MPH (5,2 km/hr.)
Controls
Vehicle Two Hand or Foot Levers control speed & direction. RH console switch controls
2 speed travel.
Excavator Functions Right and left joysticks control boom, arm, bucket, arm and swing. RH thumb
switch controls auxiliary hyd. LH foot pedal controls boom swing Separate hand
lever controls blade.
Make Deutz
Model BF4M 1012E
Fuel Diesel/Liquid (Antifreeze mixture)
Horsepower (SAE NET) 71 HP (53 kW) @ 2000 RPM
Maximum Governed RPM (Full Load) NA
Maximum Torque NA
High Idle RPM 2300 RPM
Low Idle RPM 650 RPM
No. of Cylinders Four
Displacement 210 cu.in. (3450 cm)
Bore x Stroke 3.7 inch (94 mm) x 4.5 inch (115 mm)
Lubrication Forced
Filter Cartridge Type - Full Flow
Air Cleaner Dry replaceable paper cartridge, dual element
442 Excavator
SPEC-10-2 Service Manual
HYDRAULIC EXCAVATOR SPECIFICATIONS
(CONT’D)
Engine (S/N 528911001 & Above And S/N 528611001 & Above)
Make Deutz
Model BF4M 2011
Fuel Diesel/Liquid (Oil cooled)
Horsepower 73 HP (54 kW) @ 2200 RPM
Maximum Governed RPM (Full Load) NA
Maximum Torque NA
High Idle RPM 2200
Low Idle RPM 900
No. of Cylinders Four
Displacement 190 cu.in. (3108 cm)
Bore x Stroke 3.7 (94 mm) X 4.4 (112 mm)
Lubrication Pressure System W/Filter
Filter Cartridge type - Full Flow
Air Cleaner Dry replaceable paper cartridge, dual element
Electrical
442 Excavator
SPEC-10-3 Service Manual
HYDRAULIC EXCAVATOR SPECIFICATIONS
(CONT’D)
Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above)
Swing System
Hydraulic Cylinders
Cylinder Bore Dia. in. (mm) Rod Dia. in. (mm) Stroke in. (mm)
Boom 4.7” (120 mm) 2.4” (60 mm) 33.5” (850 mm)
Arm 4.5” (115 mm) 2.8” (70 mm) 26.4” (670 mm)
Bucket 3.5” (90 mm) 2.4” (60 mm) 28.3” (720 mm)
Boom Swing 4.1” (105 mm) 2.4” (60 mm) 24.6” (625 mm)
Blade 3.9” (100 mm) 2.0” (50 mm) 7.9” (200 mm)
442 Excavator
SPEC-10-4 Service Manual
HYDRAULIC EXCAVATOR SPECIFICATIONS
(CONT’D)
Drive System
Travel NA
Service & Parking NA
Swing NA
Service Spring loaded multi disc brake applied when control lever is in neutral
Parking NA
Undercarriage
442 Excavator
SPEC-10-5 Service Manual
HYDRAULIC EXCAVATOR SPECIFICATIONS
(CONT’D)
Capacities (S/N 528911001 & Above And S/N 528611001 & Above)
Digging Force
Arm NA
Bucket NA
442 Excavator
SPEC-10-6 Service Manual
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General
Fuel System
442 Excavator
SPEC-20-1 Service Manual
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
(CONT’D)
442 Excavator
SPEC-20-2 Service Manual
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
(CONT’D)
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Piston Diameter NA
I.D. for Piston Pin NA
Piston Pin Diameter 1.338-1.339 (33,994-34,0)
Piston Ring Groove-1st NA
Piston Ring Groove-2nd NA
Piston Ring Groove-3rd NA
Piston Ring Clearance-1st NA
Wear Limit Keystone Groove
Piston Ring Clearance-2nd NA
Wear Limit 0.007 (0,17)
Piston Ring Clearance-3rd NA
Wear Limit 0.004 (0,10)
Piston Ring Gap-1st 0.031 (0,8) Maximum
Wear Limit-1st NA
Piston Ring Gap-2nd 0.098 (2,5) Maximum
Wear Limit-2nd NA
Piston Ring Gap-3rd 0.045 (1,15) Maximum
Wear Limit-3rd NA
Bore for Piston Pin Bushing NA
Piston Pin Bushing O.D. NA
Piston Pin Bushing I.D. (pressed in) NA
Wear Limit NA
442 Excavator
SPEC-20-3 Service Manual
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
(CONT’D)
Connecting Rod
442 Excavator
SPEC-20-4 Service Manual
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
(CONT’D)
442 Excavator
SPEC-20-5 Service Manual
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)
(CONT’D)
Oil Pump
Governor
442 Excavator
SPEC-20-6 Service Manual
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General
Fuel System
442 Excavator
SPEC-21-1 Service Manual
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
442 Excavator
SPEC-21-2 Service Manual
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
442 Excavator
SPEC-21-3 Service Manual
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Connecting Rod
442 Excavator
SPEC-21-4 Service Manual
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
442 Excavator
SPEC-21-5 Service Manual
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Oil Pump
442 Excavator
SPEC-21-6 Service Manual
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE)
Specifications
Ft.-lb. (Nm)
Adaptor Housing Mount Bolts (M-12) 66-80 (89-109)
(M-16) 161-198 (218-268)
Air Intake Manifold Bolts 7-9 (10-12)
Alternator Bracket Mount Bolts 14-17 (19-23)
Alternator Mount Bolts 22 (30)
Breather Bolts 7-9 (10-12)
Camshaft Bolt NA
Camshaft Thrust Washer Bolts NA
Compressor Drive Gear Mount Nut 147-184 (200-250)
Connecting Rod Cap Bolts 22 (30)
Plus 60 degrees, 30 degrees = 90 degrees
Coolant Pipe Mount Bolts 14-17 (19-23)
Coolant Pump Mount Bolts 14-17 (19-23)
Crankcase Breather Mount Bolts 6-7 (7,5-9,5)
Crankcase Screw Plugs NA
Crankshaft Gear Mount Bolt NA
Crankshaft Bearing Cap Bolt 22 (30)
Plus 60 degrees, 30 degrees = 90 degrees
Cylinder Head Bolts Step 1 22 (30)
Step 2 59 (80)
Step 3 Plus 90 degrees
Engine Lift Bracket Mount Bolts 32-38 (43-51)
Engine Mount Bolt 48-55 (65-75)
Exhaust Manifold Nuts 17-20 (22,5-27,5)
Exhaust Turbocharger Nuts NA
Flywheel Bolts - Step 1 30-45 mm Long 15-22 (20-30)
50-85 mm long 22-30 (30-40)
Step 2 60 degrees
Step 3 30 mm long 30 degrees
35-85 mm long 60 degrees
Flywheel Pulley Mount Bolts
Step 1 29-37 (40-50)
Step 2 - 60 mm long 60 degrees
- 80 mm long 60 degrees
Step 3 - 60 mm long 30 degrees
- 80 mm long 60 degrees
Front Cover Bolts 14-17 (19-23)
Fuel Filter Bracket Bolts NA
Fuel Filter Line Fittings 33-41 (45-55)
442 Excavator
SPEC-30-1 Service Manual
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE)
(CONT’D)
Specifications (Cont’d)
Ft.-lb. (Nm)
Fuel Clamping Plate Pump Bolts 15-18 (20-24)
Fuel Shut Off Solenoid Bolts 15 (21)
Glow Plugs 13-16 (18-22)
Governor Control Rod Bolts 7-9 (10-12)
Governor Drive Gear Mount Bolt 16 (21)
Governor Mount Bolts 11-14 (15,5-18,5)
Governor Mount Bolt Retaining Plate Bolts 14-17 (19-23)
Idler Pulley Mount Nut 14-17 (19-23)
Injector Clamping Pad Bolts 12-15 (16-21)
Injector Line Cap Nut 18-21 (25-28,5)
Injector Pump Mount Bolts
Step 1 5 (7)
Step 2 7 (10)
Step 3 22 (30)
Main Bearing Cap Bolts 22 (30)
Plus 60 degrees, 60 degrees = 120 degrees
Oil Cooler Collar Screws (Initial) 59 (80)
(Final) 118 (160)
Oil Cooler Mount Bolts 14-17 (19-23)
Oil Cooler Plugs 59 (80)
Oil Pan Mount Bolts (Steel) 14-17 (19-23)
(Cast) 20-23 (27-31)
Oil Pan Drain Plug 6-7 (8-9)
Oil Pump Mount Bolts 6-7 (8-9)
Oil Pressure Control Valve 27-32 (36-44)
Oil Pressure Pipe (Top) 19-24 (26-32)
(Bottom) 26-32 (35-43)
Oil Pressure Switch 12-15 (16-20)
Oil Return Line Cap Nut NA
Oil Return Pipe 28-31 (38-42)
Oil Suction Pipe 14-17 (19-23)
Oil Temperature Switch N.A
Overflow Valve 22 (30)
Rocker Arm Cylinder Head Bolts 15 (21)
Rocker Arm Bolts NA
Rocker Arm Set Screw Locknut 13-16 (18-22)
Starter Collar Nut 30 (40)
Starter Mount Bolts 52 (70)
442 Excavator
SPEC-30-2 Service Manual
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE)
(CONT’D)
Specifications (Cont’d)
Ft.-lb. (Nm)
Speed Sensor 6-7 (8-10)
Timing Belt Tensioner Pulley Nut NA
Timing Cover Mount Bolts 14-17 (19-23)
Turbocharger Mount Bolts 14-17 (19-23)
Turbocharger Cover Mount Bolts 7 (9)
Turbocharger Rotor And Pulley Mount Nut 89 (120)
Valve Adjustment Locknut 13-16 (18-22)
Valve Cover Bolts 6-7 (8-10)
V-Belt Pulley Bolts 16 (21)
Vibration Damper Pulley Mount Bolts NA
Step 1 30-37 (40-50)
Step 2 - 60 mm long 60 degrees
80 mm long 60 degrees
Step 3 - 60 mm long 30 degrees
80 mm long 60 degrees
Water Pump Mount Bolts 14-17 (19-23)
Water Temperature Sensor 12-15 (16-20)
442 Excavator
SPEC-30-3 Service Manual
442 Excavator
SPEC-30-4 Service Manual
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
Specifications
Ft.-lb. (Nm)
Air Intake Manifold Bolts 15 (21)
Alternator Bracket Mount Bolts N/A
Alternator Mount Bolts N/A
Breather Pipe Bolts 6 (8,5)
Camshaft Bolt
Step 1 22 (30)
Step 2 Plus 210 Degrees
Camshaft Gear Mount Bolt 22 (30) Plus 210 Degrees
Camshaft Thrust Washer Bolts 15 (21)
Connecting Rod Cap Bolts 22 (30)
Plus 60 degrees, 60 degrees = 120 degrees
Crankshaft Gear Mount Bolt 96 (130) plus 210 degrees
Crankshaft Bearing Cap Bolt 37 (50)
Plus 60 degrees, 45 degrees = 105 degrees
Cylinder Head Bolts
Step 1 22 (30)
Step 2 59 (80)
Step 3 118 (160)
Step 4 Plus 90 degrees
Engine Mount Bolts 48-55 (65-75)
Exhaust Manifold Bolts 41 (55)
Exhaust Turbocharger Nuts N/A
Flywheel Bolts
Step 1 22 (30)
Step 2 60 degrees
Step 3 30 degrees
Flywheel Pulley Mount Bolts
Step 1 22 (30)
Step 2 60 degrees
Step 3 30 degrees
Front Cover Bolts 15 (21)
Front Cover Stop Nut 3 (4,5)
Fuel Filter Bracket Bolts 15 (21)
Fuel Line Bolts 20-23 (27-31)
442 Excavator
SPEC-31-1 Service Manual
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Specifications (Cont’d)
Ft.-lb. (Nm)
Fuel Lift Pump Bolts 15 (21)
Fuel Shut Off Solenoid Bolts 10-12 (13,5-16,3)
Governor Lever Shaft Bolts 7 (9,2)
Governor Cover Bolts 3 (4,5)
Governor Mount Bolts 7 (9,2)
Idle Speed Bolts 3-4 (4,2-5)
Idler Pulley Mount Bolts 33 (45)
Injector Clamping Pad Bolts 16 (21)
Injector Line Cap Nut 10-12 (13,5-16,5)
Injector Line Clamping Pad Bolts 16 (21)
Injector Nozzle Cap Nut 29-37 (40-50)
Injector Pump Mount Bolts 15 (21)
Main Bearing Cap Bolts 37 (50)
Plus 60 degrees, 45 degrees = 105 degrees
Minimum Speed Screw Lock Nut 3 (4,5)
Oil Pan Mount Bolts (Steel) 15 (21)
(Cast) 30 mm long) 16 (21)
(Cast 55 mm long) 16 (21)
Oil Pan Drain Plug 40 (55)
Oil Pump Mount Bolts 14-17 (18,9-23,1)
Oil Pressure Pipe 82 (111)
Oil Pressure Switch 8-11 (11,5-14,5)
Oil Return Clamping Pad 6 (8,5)
Oil Return Pipe 30 (40)
Oil Suction Pipe 15 (21)
Oil Temperature Sensor 17-20 (22,5-27,5)
Oil Temperature Switch 17-21 (22,5-27,5)
Rear Cover Bolts 15 (21)
Rocker Arm Bracket Bolts 15 (21)
Starter Mount Bolts 32 (43,5)
442 Excavator
SPEC-31-2 Service Manual
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE
AND S/N 528611001 & ABOVE) (CONT’D)
Specifications (Cont’d)
Ft.-lb. (Nm)
Thermostat 55 (75)
Timing Belt Tensioner Pulley Nut 14-17 (19-23)
Torque Control Clamp Nut 7 (10)
Torque Control Locknut 12 (16)
Turbocharger Carrier Mount Bolts 15 (21))
Turbocharger Vent Pipe Bolts
Step 1 6 (8,5)
Step 2 9 (12,5)
Turbocharger Oil Line Bolt 21 (29)
V-Belt Pulley Bolts 28-34 (38-46)
Valve Adjustment Lock Nut 13-16 (18-22)
Valve Cover Bolts 6 (8,5)
442 Excavator
SPEC-31-3 Service Manual
442 Excavator
SPEC-31-4 Service Manual
EXCAVATOR BOLT TORQUE
Specifications
S/N 522311001 & Above S/N 528911001 & Above
S/N 528611001 & Above
Ft.-lb. (Nm) Ft.-lb. (Nm)
Air Cleaner Mount Bolts 18-19 (24-26) 18-19 (24-26)
Backup Relief Valve 52 (70) 52 (70)
Control Valve Mount Bolts (6 spool) 48-55 (65-75) 48-55 (65-75)
(3 spool) 32-35 (43-47) 32-35 (43-47)
Drive Sprockets 177-203 (240-275) 177-203 (240-275)
Engine Mount Bolts 48-55 (65-75) 48-55 (65-75)
Exhaust Pipe To Exhaust Manifold Mount Bolts NA NA
Filter Housing Mount Bolts NA NA
Front Panel Bolts NA NA
Hydraulic Pump Drive Coupler Mount Bolts 36 (49) 15-18 (20-25)
Hydraulic Pump Mount Bolts (Piston Pump) 125-140 (170-190) 125-140 (170-190)
(Gear Pump) 22-26 (30-35) 48-55 (65-75)
Hydraulic Reservoir Mount Bolts NA NA
Main Relief Valve 46-57 (63-77) 46-57 (63-77)
Load Sense Relief Valve 18 (25) 18 (25)
Operator Cab Mount Bolts/ Nuts (Front And Rear) 81-92 (110-125) 81-92 (110-125)
(Side Bolts) 48-55 (65-75) 48-55 (65-75)
Pivot Pin NA NA
Seat Belt Mount Bolts NA NA
Seat Mount Bolts NA NA
442 Excavator
SPEC-40-1 Service Manual
442 Excavator
SPEC-40-2 Service Manual
TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
442 Excavator
SPEC-50-1 Service Manual
442 Excavator
SPEC-50-2 Service Manual
HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the excavator must be kept in a warm building.
Specifications Extra warm-up time must be used each time the
excavator is started during cold temperature conditions.
Use Bobcat hydraulic fluid (P/N 6903117 - 2, 2 1/2 Gal.), Cold fluid will not flow easily and it makes action of the
(P/N 6903118 - 5 Gal.), (P/N 6903119 - 55 Gal.). hydraulic function slower. Loss of fluid flow to the
hydraulic system can cause damage in less than 60
seconds.
WARNING
During cold weather 32°F (0°C) and below, do not
operate machine until the engine has run for at least
five (5) minutes at less than half throttle. This warm-
up period is necessary for foot pedal operation and
safe stopping. Do not operate controls during warm-
up period. When temperatures are below -20°F
(30°C), the hydrostatic oil must be heated or kept
warm. The hydrostatic system will not get enough oil
at low temperatures. Park the machine in an area
DO NOT use automatic transmission fluids in the where the temperature will be above 0°F (-18°C), if
excavator or permanent damage to the hydraulic system possible.
will result. W-2027-1285
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece or cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
442 Excavator
SPEC-60-1 Service Manual
442 Excavator
SPEC-60-2 Service Manual
FUEL, COOLANT AND LUBRICANTS
Use this chart for correct selection of Fuel, Coolant and Lubricants.
442 Excavator
SPEC-70-1 Service Manual
**ENGINE OIL SPECIFICATIONS
442 Excavator
SPEC-70-2 Service Manual
FUEL, COOLANT AND LUBRICANTS (CONT’D)
Chart (S/N 528911001 & Above And S/N 528611001 & Above)
Use this chart for correct selection of Fuel, Coolant and Lubricants.
442 Excavator
SPEC-70-3 Service Manual
**ENGINE OIL SPECIFICATIONS
442 Excavator
SPEC-70-4 Service Manual
CONVERSIONS
442 Excavator
SPEC-80-1 Service Manual
CONVERSIONS (CONT’D)
442 Excavator
SPEC-80-2 Service Manual
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60-20-1, 60-20-2 60-20-1 through 60-20-4 Text change
70-01, 70-02 70-01, 70-02 Text change
70-20-1, 70-20-2 70-20-1 through 70-20-4 Text change
70-30-1, 70-30-2 70-30-1, 70-30-2 Text change
70-40-1 through 70-40-4 70-40-1 through 70-40-4 Text change
70-50-1, 70-50-2 70-50-1, 70-50-2 Text change
70-170-1, 70-170-2 70-170-1, 70-170-2 Text change
70-180-1, 70-180-2 70-180-1, 70-180-2 Text change
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2 Operation & Maintenance Manual
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70-200-1, 70-200-2 70-200-1, 70-200-2 Text change
442 Excavator
2 Service Manual
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20-53 Added Section
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20-61 Added Section
20-101 20-101 Text Change
20-102 Added Section
20-160 20-160 Text Change
20-170 20-170 Text Change
20-171 Added Section
442 Excavator
2 Service Manual
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NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Please discard your old 442 Bobcat Excavator Service Manual (P/N 6901801) Dated 9-02 and replace it
with the revised 442 Bobcat Excavator Service Manual (P/N 6901801) Dated 4-05.
Printed in U.S.A.
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442 Service Manual (P/N 6901801) Dated (2-06) contains updated service information which
replaces the previous 442 Service Manual (P/N 6901801) Dated (4-05)
Printed in U.S.A.
2
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Cover
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20-52
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20-80
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. COVER
ALPHABETICAL INDEX
FOREWORD
ELECTRICAL SCHEMATICS
Section 60-01
Section 60-51
Printed in U.S.A.
2