Bobcat E55z Excavator B4TD11001 & Up 7417473 (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
Front View
Rear View
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 Windows
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
Service Schedule
AIR CLEANER SERVICE
Replacing The Filter Elements
CAB FILTERS
Cleaning And Maintenance
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing Coolant (Cab Models)
Removing And Replacing Coolant (Canopy Models)
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filters
Draining The Fuel Tank
Replacing The Fuel Pre-Filter
Replacing The Fuel Tank Vent Filter
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Oil
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing The Hydraulic Filters
Removing And Replacing The Hydraulic Fluid
MACHINE LUBRICATION
Grease Fitting Locations
PIVOT PINS
Inspection And Maintenance
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
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 (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 (Earlier Models)
Disassembly (Earlier Models)
Assembly (Earlier Models)
Parts Identification (Later Models)
Disassembly (Later Models)
Assembly (Later Models)
CYLINDER (BUCKET)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BLADE)
Testing
Removal And Installation
Parts Identification (Earlier Models)
Disassembly (Earlier Models)
Assembly (Earlier Models)
Parts Identification (Later Models)
Disassembly (Later Models)
Assembly (Later Models)
CYLINDER (CLAMP)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (ANGLE BLADE)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
VALVE (MAIN RELIEF)
Testing And Adjusting
VALVE (PORT RELIEF)
Testing And Adjusting
VALVE (CROSS PORT RELIEF)
Testing And Adjusting
Removal And Installation
VALVE (PRESSURE REDUCING)
Testing And Adjusting
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Parts Identification
Disassembly And 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
Angle Blade / Aux 4 Valve Section Disassembly And Assembly
Boom, Auxiliary, Arm, And Bucket Valve Section Disassembly And Assembly
HYDRAULIC PUMP
Hydraulic Pump Work Sheet
Pump Testing
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Startup
Torque Limiter Assembly Parts Identification
Torque Limiter Assembly Removal And Installation
Torque Limiter Valve Assembly Disassembly And Assembly
Pump Control Parts Identification
Pump Control Removal And Installation
Pump Control Disassembly And Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR (WITHOUT ANGLE BLADE)
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
Removal And Installation
Parts Identification Hydraulic Motor
Parts Identification Gear Reduction Hub
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification Straight Blade Swivel
Disassembly And Assembly
SWIVEL JOINT (WITH ANGLE BLADE)
Removal And Installation
Parts Identification Angle Blade Swivel
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
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
Description
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
MANIFOLD (PIN GRABBER)
Removal And Installation
Parts Identification
Disassembly And Assembly
SECONDARY AUXILIARY
Removal And Installation
Parts Identification
Disassembly And Assembly
FOURTH AUXILIARY VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
VALVE (BOOM LOCK)
Removal And Installation
VALVE (ARM LOCK)
Removal And Installation
VALVE (DIRECT TO TANK (DTT))
Removal And Installation
UNDERCARRIAGE
BLADE
Removal And Installation
BLADE (ANGLE)
Removal And Installation
Cutting Edge Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
Description
Track Lug Height
Checking / 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
TRACK UNDERCARRIAGE COMPONENTS (STEEL / SEGMENTED TRACK)
Description
Checking / Adjusting Tension
Track Removal
Track 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
Door Latch Removal And Installation
Hold Open Latch 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
TRAVEL LEVERS AND PEDALS
Removal And Installation
Disassembly And Assembly
FLOORPLATE
Removal And Installation
FUEL TANK
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
STANDARD AND LONG ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
CLAMP
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
PIN-ON
Removal And Installation
Disassembly
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
GERMAN STYLE (MECHANICAL COUPLER)
Procedure
Disassembly
Assembly
GERMAN STYLE (HYDRAULIC COUPLER)
Procedure
Removal And Installation
Disassembly
Assembly
RIGHT SIDE COVER
Removal And Installation
Latch Removal And Installation
TOOL BOX
Removal And Installation
LEFT SIDE GRILLE
Removal And Installation
LEFT SIDE PANEL
Removal And Installation
RIGHT SIDE GRILLE
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
Removing And Installing
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
MAGNETIC LOCKOUT SENSOR
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTIC SERVICE CODES
Viewing Service Codes
Password Setup (Keyless Start Panel)
Service Codes List
CONTROL PANEL SETUP
Panel Setup (Standard Panel)
Panel Setup (Touch Display)
Display Screen Of Standard Panel
Jog Shuttle (Standard Display)
Using The Jog Shuttle With Standard Display
STANDARD DISPLAY
Removal And Installation
STANDARD PANEL
Removal And Installation
CONTROLLER (GATEWAY AND AUXILIARY)
Description
Gateway Controller Removal And Installation
Auxiliary Controller Removal And Installation
KEY SWITCH
Removal And Installation
WIPER MOTOR
Removal And Installation
MOTION ALARM SYSTEM
Description
Inspecting
Switch Removal And Installation
SERVICE PC (LAPTOP COMPUTER)
Connecting The Remote Start Tool
Connecting Remote Start Tool (Service Tool)
SHUT-OFF SWITCH (IF EQUIPPED)
Description
Removal And Installation
TRAVEL MOTOR AUTO-SHIFT
Auto-Shift Drive System
Troubleshooting
AUTO IDLE PRESSURE SENSOR
Description
Removal And Installation
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS
Description
Controller Removal And Installation
Procedure
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Crankshaft Re-Grind Data
Torque For Kubota® Metric Bolts
Troubleshooting
Removal And Installation
Compression Checking
ENGINE SPEED CONTROL
Removal And Installation
Auto Idle Description
Calibration
Actuator Removal And Installation (Later Model)
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Description
Radiator Cooling Package Removal And Installation
Fan Removal And Installation
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Testing The Thermostat
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid – Checking
Fuel Shut-off Solenoid Removal And Installation
Fuel Injection Pump – Checking
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 – Checking
Nozzle Spray Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Valve Guide Removal And Installation
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Push Rod Alignment – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
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 – Checking
Idle Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idle Gear And Shaft – Servicing
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear
FLYWHEEL RPM SENSOR
Description
Removal
Installation
HEATING, VENTILATION AND AIR CONDITIONING
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
Troubleshooting Tree
Temperature / Pressure Chart
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
AIR SENSOR
Location
Inside And After Air Sensor Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
Removal And Installation
AUTO EVAPORATOR COIL
Removal And Installation
HEATER COIL
Removal And Installation
AUTO HEATER COIL
Removal And Installation
BLOWER FAN
Removal And Installation
AUTO BLOWER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
CONTROL PANEL
Removal And Installation
HVAC DUCT
Removal And Installation
AUTO HVAC
Description
ATM Removal And Installation
ATM Diagnostic Codes
Blower Fan Drive Assembly Removal And Installation
De-Icing Sensor Removal And Installation
Inside And After Coil Sensor Testing
SPECIFICATIONS
EXCAVATOR SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Capacities
Tracks
Ground Pressure
Environmental Specifications
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
General Tools
HVAC Tools
ALPHABETICAL INDEX
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