Bobcat E57W B54A11001 & Up 7423170 (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
Other Serial Numbers
DELIVERY REPORT
MANUFACTURING LOCATIONS
EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
UPPERSTRUCTURE SLEW LOCK
Upperstructure Slew Lock
Boom Swing Lock
LIFTING THE EXCAVATOR
Procedure
TRANSPORTING THE EXCAVATOR
Loading And Unloading
Fastening
EMERGENCY EXIT
Right Side Rear Window
Front Window
ENGINE COVER
Opening
Closing
RIGHT SIDE COVER
Opening And Closing
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Daily Check
Replacing Filter Elements
Pre-Cleaner Cleaning
COOLING SYSTEM
Cleaning
Cooling Fan Blade
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 Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Filters
Removing And Replacing Hydraulic Fluid
LUBRICATION OF THE HYDRAULIC EXCAVATOR
Lubrication Locations
PIVOT PINS
Lubrication Locations
Inspection And Maintenance
DRAINING AND REFILLING TRANSMISSION AND AXLE
Checking And Adding Oil – Rear Axle Center Housing
Draining And Refilling Oil – Rear Axle Center Housing
Checking And Adding Oil – Front Axle Center Housing
Draining And Refilling Oil – Front Axle Center Housing
Removing And Replacing Oil – Axle End Housing
Checking And Adding Oil – Transmission
Removing And Replacing Oil – Transmission
ALTERNATOR BELT
Description
Belt Check
Belt Replacement
SEAT BELT
Inspection And Maintenance
LEFT CONSOLE LOCKOUT
Inspection And Maintenance
Left Console Lever Cut-off Switch Inspection
STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
Procedure
Engine Emergency Shut Off
TOWING THE EXCAVATOR
Procedure
Releasing The Parking Brake Manually
Resetting The Parking Brake Function
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting The Hydraulic Control Valve
Troubleshooting The Relief Valve
Troubleshooting The Whole Hydraulic System
Troubleshooting The Swing Motor
Troubleshooting The Brake Supply Valve
Troubleshooting The Solenoid Valve (5 Functions)
Troubleshooting The Cylinders
CYLINDER (BOOM)
Boom Cylinder Natural Drop Test
Parts Identification
Disassembly
Assembly
CYLINDER (ARM)
Arm Cylinder Natural Drop Test
Parts Identification
Disassembly
Assembly
CYLINDER (BOOM SWING)
Parts Identification
Disassembly
Assembly
CYLINDER (BUCKET)
Bucket Cylinder Natural Drop Test
Parts Identification
Disassembly
Assembly
CYLINDER (BLADE)
Blade Cylinder Natural Drop Test
Parts Identification
Disassembly
Assembly
HYDRAULIC CONTROL VALVE
Description
Parts Identification
Boom Swing Section Parts Identification
Boom Swing / Rotating Section Parts Identification
Boom Swing / Rotating / Two-Way Section Parts Identification
Fixed Boom Section Parts Identification
Removal
Installation
Disassembly
Assembly
Inspection
Hoses, Plugs And Fittings Tightening Torques
BRAKE SUPPLY VALVE
Description
Removal And Installation
Hoses, Plugs And Fittings Tightening Torques
Tightening Torques For Bolts
ACCUMULATOR (BRAKE AND PILOT)
Description
TRAVEL MOTOR
Description
Parts Identification
Piston Assembly Parts Identification
Cover Parts Identification
Counterbalance Valve Parts Identification
Removal And Installation
Disassembly
Assembly
Inspection
Seal Nut Replacement
SWIVEL JOINT
Description
Parts Identification
Removal And Installation
Disassembly And Assembly
SWING MOTOR
Description
Parts Identification
Inspection
Precautions
Removal And Installation
Motor Disassembly
Motor Assembly
Reduction Gear Disassembly
Reduction Gear Assembly
Part Replacement Standards For Hydraulic Motor
Part Replacement Standards For Reduction Gear
Standards For Correcting Sliding Surfaces
Tightening Torques For Bolts
Special Tools
ACCELERATOR PEDAL VALVE
Description
Removal And Installation
Disassembly And Assembly
Hoses, Plugs And Fittings Tightening Torques
JOYSTICK
Description
Parts Identification
Removal And Installation
Disassembly And Assembly
HYDRAULIC OIL TANK
Description
Parts Identification
Removal And Installation
OIL COOLER
Parts Identification
Removal And Installation
SOLENOID VALVE (5 FUNCTIONS)
Description
Parts Identification
Removal And Installation
Disassembly And Assembly
Tightening Torques
Hoses, Plugs And Fittings Tightening Torques
STEERING CYLINDER
Removal And Installation
Disassembly
Assembly
STEERING VALVE
Description
Parts Identification
Disassembly
Assembly
Hydraulic Connections
SERVICE BRAKE PEDAL VALVE
Description
Parts Identification
Removal And Installation
Disassembly And Assembly
Hoses, Plugs And Fittings Tightening Torques
BLADE VALVE
Description
Parts Identification
Removal And Installation
Disassembly And Assembly
UNDERCARRIAGE
FRONT AXLE
Removal And Installation
Hoses, Plugs And Fittings Tightening Torques
Housing Parts Identification
Planetary Carrier And Wheel Hub Parts Identification
Planetary Carrier Disassembly
Wheel Hub Disassembly
Steering Parts Identification
Steering Knuckle Disassembly
Brake Group Parts Identification
Brake Group Disassembly
Brake Group Assembly
Differential Parts Identification
Differential Disassembly
Differential Assembly
Steering Knuckle Assembly
Wheel Hub Assembly
Planetary Carrier Assembly
Setting Of The Crown Wheel And Pinion (1)
Setting Of The Crown Wheel And Pinion (2)
AXLE TOE-IN
Adjustment
Special Tools
STEERING ANGLE ADJUSTMENT
Adjustment
Jutting Portion Of The Screw
DRIVE SHAFT
Front Drive Shaft Removal And Installation
Rear Drive Shaft Removal And Installation
REAR AXLE
Removal And Installation
Hoses, Plugs And Fittings Tightening Torques
Housing Parts Identification
Planetary Carrier And Wheel Hub Parts Identification
Planetary Carrier Disassembly
Planetary Carrier Assembly
Brake Group Parts Identification
Brake Group Disassembly
Releasing The Parking Brake Manually
Resetting The Parking Brake Function
Brake Group Assembly
Brake Piston Cap Check
Differential Parts Identification
Differential Disassembly
Differential Assembly
Ring Gear And Pinion Adjusting
Bevel Pinion Disassembly
Bevel Pinion Assembly
Special Tools
TIRES AND WHEELS
Tire Changing Procedure
SWING BEARING
Operating Recommendation
Measuring Swing Bearing Axial Play
Measuring Swing Bearing Lateral Play
Parts Identification
Disassembly And Assembly
TRANSMISSION
Description
Transmission Serial Number
Removal And Installation
Parts Identification
Replacing Speed Sensor
Hydraulic Gear Control Disassembly
Hydraulic Gear Control Assembly
Reduction Gear Disassembly
Reduction Gear Assembly
UPPERSTRUCTURE AND SWING SECTION
CAB
Removal And Installation
LEFT CONSOLE
Left Console Lever
RIGHT CONSOLE
Right Console
FLOOR MAT AND FLOOR PANEL
Removal And Installation
TRAVEL LEVER / PEDALS
Travel Direction Control Lever
Pedals
FUEL TANK
Parts Identification
Removal And Installation
FUEL PUMP
Removal And Installation
HYDROSTATIC PUMP
Description
Parts Identification
Removal And Installation
Disassembly
Assembly
Special Tools
Inspection
Troubleshooting
BOOM
Description
Removal And Installation
ARM
Description
Removal
Installation
BUCKET
Bucket Removal
Bucket Installation
Reversing The Bucket
Bucket O-ring Replacement
Bucket Teeth Inspection And Replacement
ENGINE COVER
Removal And Installation
COUNTERWEIGHT
Removal
Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting
Fuses And Relays Location
Fuses And Relays Identification
Electric Power Circuit Diagram
Wiring Harness Layout
Main Harness
Cabin Harness
Engine And Battery Harness
BATTERY
Battery Maintenance
Using A Booster Battery (Jump Starting)
Removing And Installing Battery
Battery Disconnect Switch
ALTERNATOR
Removal And Installation
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
STARTER
Parts Identification
Removal And Installation
Testing
INSTRUMENT PANEL SETUP
User Menu
PASSWORD SETUP (INSTRUMENT PANEL)
Owner Password Setting
Operator Password Setting
DIAGNOSTIC SERVICE CODES
Service Code At Machine
Service Code At Engine Side
ENGINE CONTROL UNIT (ECU)
Description
Removal And Installation
ENGINE SPEED CONTROL
Adjustment
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Sensor Location
Torque Values
Troubleshooting
Engine Removal And Installation
Compression – Testing (Using Glow Plug Compression Adapter)
Compression – Testing (Using Injector Compression Adapter)
Injector Signal – Testing
Injector Signal – Testing (In-Line)
DIESEL PARTICULATE FILTER (DPF)
Removal And Installation
AIR CLEANER
Removal And Installation
ENGINE COOLING SYSTEM
Description
Fan Removal And Installation
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Testing The Thermostat
LUBRICATION SYSTEM
Description
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Relief Valve Description
Oil Pump Relief Valve Removal And Installation
Oil Cooler / Oil Filter Module Removal And Installation
Oil Cooler / Oil Filter Module Disassembly And Assembly
FUEL SYSTEM
Description
Fuel Return Hose Removal And Installation
Fuel Filter Housing Removal And Installation
Transfer Pump / High Pressure Pump Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Pressure Relief Valve Removal And Installation
Fuel Rail Assembly Removal And Installation
Fuel Injector Removal And Installation
Injector Coding
CYLINDER HEAD
Glow Plugs Testing
Glow Plug Removal And Installation
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Inspection
Cylinder Head Top Clearance
Valve Step Height
Valve Stem Height
Valve Guide
Valve
Valve Spring
Rocker Arm Shaft Disassembly And Assembly
Rocker Arm Shaft Inspection
Push Rod Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Inspection
Crankshaft Removal And Installation
Cylinder Block Inspection
Crankshaft Inspection
Connecting Rod Inspection
Engine Component Class
CAMSHAFT
Removal And Installation
Inspecting
GEARCASE
Gearcase Cover Removal And Installation
Gear Backlash
Gear Timing
Idle Gear Removal And Installation
Idle Gear Inspection
TURBOCHARGER
Description
Removal And Installation
Inspection
FLYWHEEL AND HOUSING
Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Removal And Installation
EXHAUST MANIFOLD
Removal And Installation
INTERCOOLER
Description
Removal And Installation
PRE-CLEANER
Removal And Installation
DRIVE COUPLING (HYDROSTATIC PUMP)
Parts Identification
Disassembly
Assembly
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
REGULAR MAINTENANCE
Cab Filters
Air Conditioning Belt Adjustment
Air Conditioning Belt Replacement
Repair And Replacement Procedure
TROUBLESHOOTING
Self-Diagnosis
Error Codes
Refrigerant Pressure Check
Electrical System
SYSTEM CHARGING AND RECLAMATION
Refrigerant Reclamation
Vacuuming Refrigerant System
Leakage Check
Refrigerant Charging
Inspecting System For Leakage
COMPRESSOR
Description
Belt Check
Belt Replacement
RECEIVER / DRIER
Description
SPECIFICATIONS
(E57W) EXCAVATOR SPECIFICATIONS
Machine Dimensions
Working Range
Lift Capacity – Short Arm ST
Lift Capacity – Short Arm DT
Lift Capacity – Long Arm ST
Lift Capacity – Long Arm DT
Weights
Performance
Engine
Engine Performance Data
Electrical
Fluid Capacities
Hydraulic System
Drive System
Swing System
Function Time
Traction
Hydraulic Cylinders
Environmental
Controls
Instrumentation
ENGINE SPECIFICATIONS
Torque Values
TORQUE SPECIFICATIONS 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
Port Seal Fitting
FLUIDS, LUBRICANTS AND FUEL SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
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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