Bobcat E35z Excavator B3S511001 & Up 7362211 (01-19) (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
– FOREWORD
– SAFETY INSTRUCTIONS
– FIRE PREVENTION
— Maintenance
— Operation
— Electrical
— Hydraulic System
— Fueling
— Starting
— Spark Arrester Exhaust System
— Welding And Grinding
— Fire Extinguishers
– SERIAL NUMBER LOCATIONS
— Excavator Serial Number
— Engine Serial Number
– DELIVERY REPORT
– EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
– LIFTING AND BLOCKING THE EXCAVATOR
— Procedure
– LIFTING THE EXCAVATOR
— Procedure
– OPERATOR CAB (ROPS / TOPS / FOPS)
— Description
— Cab Door
— Front Window
— Front Wiper
— Window Washer Reservoir
— Right Side Window
– OPERATOR CANOPY (ROPS / TOPS / FOPS)
— Description
– TRANSPORTING THE EXCAVATOR ON A TRAILER
— Loading And Unloading
— Fastening
– TAILGATE
— Opening And Closing
— Adjusting The Latch
– RIGHT SIDE COVER
— Opening And Closing
– SERVICE SCHEDULE
— Maintenance Intervals
– AIR CLEANER SERVICE
— Daily Check
— Replacing The Filter Elements
– CAB FILTERS
— Cleaning And Maintenance
– ENGINE COOLING SYSTEM
— Cleaning
— Checking Level
— Removing And Replacing Coolant
– FUEL SYSTEM
— Fuel Specifications
— Biodiesel Blend Fuel
— Filling The Fuel Tank
— Fuel Filters
— Draining The Fuel Tank
— Removing Air From The Fuel System
– ENGINE LUBRICATION SYSTEM
— Checking And Adding Engine Oil
— Engine Oil Chart
— Removing And Replacing Oil And Filter
– HYDRAULIC SYSTEM
— Checking And Adding Hydraulic Fluid
— Hydraulic / Hydrostatic Fluid Chart
— Removing And Replacing Hydraulic Filters
— Removing And Replacing Hydraulic Fluid
– LUBRICATING THE EXCAVATOR
— Lubrication Locations
– PIVOT PINS
— Inspection And Maintenance
– TRAVEL MOTOR
— Checking And Adding Oil
— Removing And Replacing Oil
– SPARK ARRESTER MUFFLER
— Cleaning Procedure
– EMERGENCY EXIT
— Right Side Rear Window
— Front Window
– SEAT BELT
— Inspection And Maintenance
– CONTROL CONSOLE LOCKOUTS
— Inspection And Maintenance
– TOWING THE EXCAVATOR
— Procedure
– REMOTE START TOOL KIT – MEL1563
— Remote Start Tool Kit – MEL1563
— Service Tool Harness Control – MEL1565
— Service Tool Harness Communicator – MEL1566
– REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
— Description
— Remote Start Tool (Service Tool) – 7022042
— Excavator Service Tool Harness – 6689747
— Computer Service Tool Harness – 6689746
HYDRAULIC SYSTEM
– HYDRAULIC / HYDROSTATIC SCHEMATICS
– HYDRAULIC SYSTEM INFORMATION
— Glossary Of Hydraulic / Hydrostatic Symbols
— Troubleshooting The Hydraulic Circuit
— Troubleshooting The Cylinder Circuit
— Troubleshooting The Swing (Upperstructure Slew) Circuit
— Troubleshooting The Travel Circuit
– CYLINDER (BOOM)
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– CYLINDER (ARM)
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– CYLINDER (BOOM SWING)
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– CYLINDER (BUCKET)
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– CYLINDER (BLADE)
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– CYLINDER (CLAMP)
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– VALVE (MAIN RELIEF)
— Description
– VALVE (PORT RELIEF)
— Testing And Adjusting Port Relief Valve Pressure
– VALVE (CROSS PORT RELIEF)
— Testing
— Removal And Installation
— Disassembly And Assembly
– VALVE (PILOT PRESSURE RELIEF)
— Testing And Adjusting The Pilot Pressure Relief Valve
– HYDRAULIC CONTROL VALVE
— Description
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
— Inlet Valve Section Disassembly And Assembly
— Boom Swing Valve Section Disassembly And Assembly
— Slew Valve Section Disassembly And Assembly
— Blade Valve Section Disassembly And Assembly
— Right And Left Travel Valve Section Disassembly And Assembly
— Boom Valve Section Disassembly And Assembly
— Auxiliary, Arm, Bucket And Angle Blade Valve Section Disassembly And Assembly
— Outlet Valve Section Disassembly And Assembly
– HYDRAULIC PUMP
— Hydraulic Pump Work Sheet
— Pump Testing
— Description
— Removal And Installation
— Coupler Removal And Installation
— Hydraulic Pump Startup
— Gear Pump Disassembly And Assembly
— Piston Pump Parts Identification
— Piston Pump Disassembly And Assembly
– MANIFOLD ASSEMBLY / ACCUMULATOR
— Description
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– MANIFOLD ASSEMBLY / ACCUMULATOR (WITH ANGLE BLADE)
— Description
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– TRAVEL MOTOR
— Description
— Removal And Installation
— Parts Identification Hydraulic Motor
— Parts Identification Gear Reduction Hub
— Disassembly
— Assembly
– SWIVEL JOINT
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– SWING MOTOR
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– SWING MOTOR (DRIVE CARRIER)
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– CONTROL PATTERN SELECTOR VALVE
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– RIGHT CONTROL LEVER (JOYSTICK)
— Testing
— Handle Removal And Installation
— Joystick Assembly Removal And Installation
— Parts Identification
— Disassembly And Assembly
– LEFT CONTROL LEVER (JOYSTICK)
— Testing
— Handle Removal And Installation
— Joystick Assembly Removal And Installation
— Parts Identification
— Disassembly And Assembly
– HYDRAULIC FILTER MOUNT
— Removal And Installation
– HYDRAULIC RESERVOIR
— Removal And Installation
– OIL COOLER
— Removal And Installation
– DIRECT TO TANK VALVE
— Removal And Installation
– BLADE CONTROL LEVER
— Handle Removal And Installation
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– CASE DRAIN FILTER MOUNT
— Removal And Installation
– TRAVEL CONTROL VALVE
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– REMOVING AIR FROM THE HYDRAULIC SYSTEM
— Procedure
– HYDRAULIC X-CHANGE MANIFOLD
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– SECONDARY AUXILIARY VALVE
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– VALVE (BOOM LOCK)
— Removal And Installation
– VALVE (ARM LOCK)
— Removal And Installation
UNDERCARRIAGE
– BLADE
— Removal And Installation
– TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
— Description
— Track Lug Height
— Checking Tension
— Adjusting Tension
— Removal And Installation
— Idler Removal And Installation
— Idler Parts Identification
— Idler Disassembly
— Idler Assembly
— Track Tensioner Removal And Installation
— Track Tensioner Parts Identification
— Track Tensioner Disassembly And Assembly
— Roller Removal And Installation
— Sprocket Removal And Installation
– TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)
— Description
— Checking Tension
— Adjusting Tension
— Track Removal And Installation
— Idler Removal And Installation
— Idler Parts Identification
— Idler Disassembly
— Idler Assembly
— Track Tensioner Removal And Installation
— Track Tensioner Parts Identification
— Track Tensioner Disassembly And Assembly
— Roller Removal And Installation
— Sprocket Removal And Installation
— Guide Plate Removal And Installation
– TRACK MAINTENANCE
— Track Damage Identification
– SWING CIRCLE GEAR
— Swing Bearing Removal
— Swing Bearing Installation
UPPERSTRUCTURE AND SWING SECTION
– UPPERSTRUCTURE
— Removal
— Installation
– ROPS CANOPY
— Removal And Installation
– CAB
— Removal And Installation
— Door Removal And Installation
— Front Window Removal And Installation
— Right Side Sliding Window Removal And Installation
— Glass Removal
— Glass Installation
– SEAT
— Removal And Installation
— Seat Mount Removal And Installation
– RIGHT CONSOLE
— Console Cover Removal And Installation
– LEFT CONSOLE
— Lower Console Cover Removal And Installation
— Upper Console Cover Removal And Installation
— Compression Spring Removal And Installation
— Lock Lever Removal And Installation
— Console Removal And Installation
– LEFT UPPERSTRUCTURE COVER
— Removal And Installation
– RIGHT UPPERSTRUCTURE COVER
— Removal And Installation
– COUNTERWEIGHT
— Removal And Installation
— Add On Counterweight Removal And Installation
– TRAVEL LEVERS AND PEDALS
— Removal And Installation
— Disassembly And Assembly
– FLOOR MAT AND FLOORPLATE
— Removal And Installation
– FUEL TANK
— Removal And Installation
— Fuel Tank Fitting Removal And Installation
– HORN
— Removal And Installation
– SWING FRAME
— Removal And Installation
— Boom Swing Frame Hose Routing
— Bushing Removal
— Bushing Installation
– BOOM
— Removal And Installation
– ARM (STANDARD AND LONG)
— Removal And Installation
— Arm To Boom Bushing Removal And Installation
— Arm To Bucket And Bucket Link Bushing Removal And Installation
– ARM (EXTENDABLE)
— Removal And Installation
— Arm To Boom Bushing Removal And Installation
— Arm To Bucket Bushing Removal And Installation
— Disassembly And Assembly
— Shimming Procedure
– BUCKET
— Bucket Teeth Removal And Installation
— Bucket Side Cutting Edge Removal And Installation
– CLAMP
— Removal And Installation
– TAILGATE
— Removal And Installation
— Disassembly and Assembly
– QUICK COUPLER (KLAC™ SYSTEM)
— Troubleshooting
— Daily Inspection
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– QUICK COUPLER (PIN GRABBER)
— Troubleshooting
— Daily Inspection
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– RIGHT SIDE COVER
— Removal And Installation
— Latch Removal And Installation
– LEFT SIDE COVER
— Removal And Installation
– TOOL BOX
— Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
– ELECTRICAL SCHEMATICS
– ELECTRICAL SYSTEM INFORMATION
— Troubleshooting Chart
— Description
— Fuse And Relay Location / Identification
– BATTERY
— Servicing
— Maintaining Battery Charge Level
— Battery Service During Machine Storage
— Battery Testing
— Battery Charging
— Removal And Installation
— Using A Booster Battery (Jump Starting)
– ALTERNATOR
— Belt Adjustment
— Belt Replacement
— Charging System Inspection
— Alternator Voltage Testing
— Low Voltage Testing
— High Voltage Testing
— Removal And Installation
— Parts Identification
– STARTER
— Testing
— Removal And Installation
— Parts Identification
– LIGHTS
— Boom Light Removal And Installation
— Boom Light Bulb Replacement
– MAGNETIC LOCKOUT SENSOR
— Removal And Installation
– FUEL LEVEL SENDER
— Removal And Installation
— Testing
– DIAGNOSTIC SERVICE CODES
— Viewing Service Codes
— Number Codes List
– CONTROL PANEL SETUP
— Panel Setup (Deluxe Instrument Panel)
— Password Setup (Keyless Start Panel)
— Password Setup (Keyless Start Panel)
— Password Setup (Deluxe Instrument Panel)
— Maintenance Clock
– INSTRUMENT PANEL
— Removal And Installation
– CONTROLLER
— Description
— Auxiliary Controller Removal And Installation
— Gateway Controller Removal And Installation
– KEY SWITCH
— Removal And Installation
– WIPER MOTOR
— Removal And Installation
– MOTION ALARM SYSTEM
— Description
— Inspecting
— Adjusting Switch Position
– SERVICE PC (LAPTOP COMPUTER)
— Connecting The Remote Start Tool
— Connecting Remote Start Tool (Service Tool)
– SHUT-OFF SWITCH
— Description
— Removal And Installation
– TRAVEL MOTOR AUTO-SHIFT
— Auto-Shift Drive System (If Equipped)
— Troubleshooting
– ENGINE SPEED CONTROL
— Removal And Installation
– AUTO IDLE PRESSURE SENSOR
— Description
— Removal And Installation
– BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS
— Controller Removal And Installation
— Antenna Removal And Installation
ENGINE SERVICE
– ENGINE INFORMATION
— Description
— Specifications
— Crankshaft Re-grind Data
— Torque For Kubota® Metric Bolts
— Troubleshooting
— Engine Removal And Installation
— Compression – Testing
– ENGINE SPEED CONTROL
— Removal And Installation
— Calibration
— Actuator Removal And Installation
– MUFFLER
— Removal And Installation
– AIR CLEANER
— Removal And Installation
– LUBRICATION SYSTEM
— Oil Pan Removal And Installation
— Oil Pump Removal And Installation
— Oil Pump Inspection
— Engine Oil Pressure – Testing
– ENGINE COOLING SYSTEM
— Radiator Removal And Installation
— Fan Removal And Installation
— Water Pump Removal And Installation
— Water Pump Disassembly And Assembly
— Thermostat Housing Removal And Installation
— Thermostat – Testing
– FUEL SYSTEM
— Fuel Shutoff Solenoid – Testing
— Fuel Shut-off Solenoid Removal And Installation
— Fuel Injection Pump – Testing
— Fuel Injection Pump Removal And Installation
— Fuel Injection Pump – Timing
— Fuel Camshaft Removal And Installation
— Fuel Camshaft Governor
— Fuel Injector Removal And Installation
— Fuel Injector Nozzle Pressure – Testing
— Nozzle Spray Condition
— Valve Seat Tightness
– CYLINDER HEAD
— Glow Plugs – Testing
— Glow Plugs Removal And Installation
— Valve Clearance Adjustment
— Valve Timing – Inspecting
— Cylinder Head Removal And Installation
— Cylinder Head Disassembly And Assembly
— Cylinder Head – Servicing
— Cylinder Head Top Clearance
— Valve Guide – Inspecting
— Valve Guide Removal And Installation
— Reconditioning The Valve And Valve Seat
— Valve Spring
— Valve Tappets
— Rocker Arm And Shaft – Inspecting
— Push Rod Alignment – Inspecting
– CRANKSHAFT AND PISTONS
— Piston And Connecting Rod Removal And Installation
— Piston And Connecting Rod – Servicing
— Cylinder Bore – Inspecting
— Connecting Rod Alignment
— Crankshaft Gear Removal And Installation
— Crankshaft And Bearings Removal And Installation
— Crankshaft And Bearings – Servicing
– CAMSHAFT AND TIMING GEARS
— Timing Gearcase Cover Removal And Installation
— Timing Gears Backlash – Inspecting
— Idle Gear And Camshaft Removal And Installation
— Camshaft – Servicing
— Idle Gear And Shaft – Servicing
– FLYWHEEL AND HOUSING
— Hydraulic Pump Coupler Removal And Installation
— Flywheel Removal And Installation
— Flywheel Ring Gear
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
– AIR CONDITIONING SYSTEM FLOW
— Description
— Chart
— Components
— Safety Equipment
– REGULAR MAINTENANCE
— Cab Filters
— Air Conditioning Compressor Belt Adjustment
— Air Conditioning Compressor Belt Replacement
— Condenser
— Air Conditioning Lubrication
— Evaporator / Heater Coil
— Air Conditioning Service Chart
– TROUBLESHOOTING
— Blower Motor Does Not Operate
— Blower Motor Operates Normally, But Air Flow Is Insufficient
— Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
— The Compressor Operates Improperly Or Not At All
— Gauge Pressure Related Troubleshooting
— Temperature / Pressure Chart
— Poor A/C Performance
— HVAC Repair And Leaks
— Electrical System
— Engine Coolant Bypassing The Heater Valve
– SYSTEM CHARGING AND RECLAMATION
— Refrigerant Identification
— Reclamation And Charging With Recovery / Charging Unit
– COMPRESSOR
— Removal And Installation
— Oil
— Oil Check
– CONDENSER
— Removal And Installation
– RECEIVER / DRIER
— Receiver / Drier Removal And Installation
— Pressure Switch Removal And Installation
– EVAPORATOR / HEATER UNIT
— Removal And Installation
– THERMOSTAT
— Description
— Removal And Installation
– EXPANSION VALVE
— Removal And Installation
– EVAPORATOR COIL
— Removal And Installation
– HEATER COIL
— Removal And Installation
– BLOWER FAN
— Removal And Installation
– HEATER VALVE
— Removal And Installation
– HVAC DUCT
— Removal And Installation
SPECIFICATIONS
– EXCAVATOR SPECIFICATIONS
— Machine Dimensions
— Machine Dimensions – Standard Arm
— Machine Dimensions – Long Arm
— Rated Lift Capacity For Standard Arm, Medium Counterweight, And Canopy
— Rated Lift Capacity For Standard Arm, Medium Counterweight, And Cab
— Rated Lift Capacity For Long Arm, Heavy Counterweight, And Canopy
— Rated Lift Capacity For Long Arm, Heavy Counterweight, And Cab
— Performance
— Controls
— Engine
— Hydraulic System
— Hydraulic Cycle Times
— Hydraulic Cylinders
— Drive System
— Slew System
— Undercarriage
— Electrical
— Capacities
— Tracks
— Ground Pressure
— Temperature Range
– TECHNICAL SERVICE GUIDE SPECIFICATIONS
— Engine
— Engine Torques
— Cooling System
— Excavator Torques
– TORQUE SPECIFICATION FOR BOLTS
— Torque For General SAE Bolts
— Torque For General Metric Bolts
– HYDRAULIC CONNECTION SPECIFICATIONS
— O-ring Face Seal Connection
— Straight Thread O-ring Fitting
— Tubelines And Hoses
— Flare Fitting
— O-ring Flare Fitting
— Port Seal Fitting
— Push To Connect Fittings
– HYDRAULIC FLUID SPECIFICATIONS
— Specifications
– CONVERSIONS
— Decimal And Millimeter Equivalent Chart
— U.S. To Metric Conversion Chart
– SERVICE TOOLS REQUIRED
— Remote Start Tools
— Hydraulic Tools
— Engine Tools
— Electrical Tools
— HVAC Tools
ALPHABETICAL INDEX
SERVICE SCHEDULE SYMBOLS
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