Bobcat E63 B34R11001 & Up 6990613 (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
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
Heating, Ventilation And Air Conditioning Duct
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
RIGHT SIDE COVER
Opening And Closing
Adjusting The Latch
REAR COVER
Opening And Closing
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Daily Check
Replacing The Filters
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 Fluid
Hydraulic Fluid Chart
Removing And Replacing Hydraulic Filters
Removing And Replacing Hydraulic Fluid
Removing Air From Hydraulic Pump
LUBRICATING THE EXCAVATOR
Lubrication Locations
PIVOT PINS
Inspection And Maintenance
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
DIESEL PARTICULATE FILTER (DPF) SYSTEM
Description
Remote Parked Regeneration
Service Regeneration
DPF Cleaning
EMERGENCY EXITS
Right Rear Side Window
Front Window
SEAT BELT
Inspection And Maintenance
CAB TILT PROCEDURE
Tilting The Cab
CONTROL CONSOLE LOCKOUT
Inspection And Maintenance
TOWING THE EXCAVATOR
Procedure
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATIC
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Swing (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
VALVES (MAIN RELIEF)
Testing And Adjusting
VALVES (PORT RELIEF)
Testing And Adjusting The Port Relief Valve Pressure
VALVE (PRESSURE REDUCING)
Testing And Adjusting
HYDRAULIC CONTROL VALVE
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
Boom, Auxiliary, Arm And Bucket Valve Section Disassembly And Assembly
HYDRAULIC PUMP
Hydraulic Pump Work Sheet
Pump Testing
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
Parts Identification
Disassembly And Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR
Description
Removal And Installation
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
Disassembly
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
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
BLADE CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
DIRECT TO TANK VALVE
Removal And Installation
Disassembly And Assembly
SWING MOTOR BRAKE RELEASE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
EPPR VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
FORCED REGENERATION VALVE
Removal And Installation
Disassembly And Assembly
TRAVEL CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
AUTO IDLE
Description
UNDERCARRIAGE
BLADE
Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
Description
Track Lug Height
Checking Tension
Adjusting Tension
Track Removal And Installation
Idler Removal And Installation
Idler Parts Identification
Idler Disassembly
Idler Assembly
Tensioner Removal And Installation
Track Tensioner Parts Identification
Track Tensioner Disassembly And Assembly
Roller Removal And Installation
Roller Parts Identification
Roller Disassembly
Roller Assembly
Sprocket Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)
Description
Checking Tension
Adjusting Tension
Track Removal
Track Installation
Idler Removal And Installation
Idler Parts Identification
Idler Disassembly
Idler Assembly
Track Tensioner Removal And Installation
Track Tension Parts Identification
Track Tensioner Disassembly And Assembly
Roller Removal And Installation
Roller Parts Identification
Roller Disassembly
Roller Assembly
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
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Lower Front Window Removal And Installation
Glass Installation
Front Window Strut Removal And Installation
Front Window Slide Bar Removal And Installation
Cab Tilt Assembly Removal And Installation
Cab Tilt Parts Identification
Cab Tilt Assembly Disassembly And Assembly
Headliner Removal And Installation
SEAT
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
Gas Strut Removal And Installation
Lock Lever Removal And Installation
Lock Lever Disassembly And Assembly
Console Removal And Installation
LEFT UPPERSTRUCTURE COVER
Removal And Installation
RIGHT UPPERSTRUCTURE COVER
Removal And Installation
COUNTER WEIGHT
Removal And Installation
FLOOR MAT
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
Bushing Removal And Installation
ARM (STANDARD AND LONG)
Removal And Installation
Arm To Boom Bushing Removal And Installation
Bucket And Link Bushing Removal And Installation
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
REAR COVER
Removal And Installation
QUICK COUPLER (KLAC™ SYSTEM)
Troubleshooting
Daily Inspection
Removal And Installation
Parts Identification
Disassembly
Assembly
QUICK COUPLER (LEHNHOFF® SYSTEM)
Troubleshooting
Daily Inspection
Removal (MS03 And MS08)
Installation (MS03 And MS08)
Parts Identification (MS03)
Disassembly And Assembly (MS03)
Parts Identification (MS08)
Disassembly (MS08)
Assembly (MS08)
RIGHT SIDE COVER
Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location / Identification
Engine Control Unit (ECU)
Master Disconnect Switch
BATTERY
Servicing
Using A Booster Battery (Jump Starting)
Removal and Installation
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Voltage Testing
Removal And Installation
STARTER
Testing
Removal And Installation
Parts Identification
LIGHTS
Boom Light Removal And Installation
Boom Light Bulb Replacement
CONSOLE LOCKOUT SWITCH
Testing / Adjustment
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
DIAGNOSTIC SERVICE CODE
Service Codes List
Failure Mode Indicator Information
Code Retrieval Through The Dash
DIAGNOSTIC TOOL
Installation
INSTRUMENT PANEL
Removal And Installation
Setting The Operator Four Digit Password
KEY SWITCH
Removal And Installation
RIGHT CONSOLE SWITCH COVER
Removal And Installation
Rocker Switch Removal And Installation
Speed Control Removal And Installation
Auxiliary Power Outlet Removal And Installation
WIPER MOTOR
Removal And Installation
MOTION ALARM SYSTEM
Description
Inspecting
Adjusting Switch Position
FUEL TRANSFER PUMP
Removal And Installation
AUTO IDLE PRESSURE SWITCH
Removal And Installation
VEHICLE CONTROL UNIT (VCU)
Removal And Installation
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Sensor Location
Troubleshooting
Engine Removal And Installation
Compression – Testing
ENGINE SPEED CONTROL
Adjustment
DIESEL PARTICULATE FILTER (DPF) SYSTEM
Description
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Radiator Disassembly And Assembly
Fan Removal And Installation
Fuel Cooler Removal And Installation
Water Pump Removal And Installation
Water Pump Parts Identification
Thermostat Removal And Installation
Temperature Switch – Testing
Temperature Sensor – Testing
Thermostat – Testing
Radiator Cap Testing
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
Crankcase Ventilation Filter Removal And Installation
FUEL SYSTEM
Electronic Fuel Injection Schematic – Components
Fuel Supply Pump Removal And Installation
Fuel Rail Assembly Removal And Installation
Fuel Injector Removal And Installation
CYLINDER HEAD
Valve Clearance Adjustment
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Valve Guide – Inspection
Intake And Exhaust Valve – Inspection
Valve Stem Bend – Inspection
Valve Face And Seat
Valve Spring – Inspection
Push Rod – Inspection
Rocker Arm – Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Inspection
Crankshaft End Play
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gear Case Cover Removal And Installation
Timing Gear Backlash – Inspection
Idler Gear And Camshaft Removal And Installation
Valve Tappet – Servicing
Camshaft – Servicing
Idler Gear And Shaft – Servicing
EXHAUST GAS RECIRCULATION (EGR) VALVE
Description
Removal And Installation
EGR Valve Testing And Cleaning
Lead (Reed) Valve Cleaning
EGR Cooler Cleaning
Intake Throttle
GLOW PLUGS
Testing
Removal And Installation
ENGINE FLYWHEEL
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Belt Adjustment
Belt Replacement
Condenser
Air Conditioning Service Chart
Evaporator / Heater Coil
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
SYSTEM CHARGING AND RECLAMATION
Reclamation And Charging With Recovery / Charging Unit
Charging With A Manifold Gauge Set
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
Inspection
EXPANSION VALVE
Removal And Installation
BLOWER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
HVAC CONTROLLER
Removal And Installation
SPECIFICATIONS
EXCAVATOR SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Crawler Track Design
Capacities
Fuel Tank
Track
Type
Ground Pressure
TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Cooling System
Excavator Torques
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
BSPP Swivel Nut
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
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