Bobcat E85 Excavator B48411001 & Up 7320318 (08-20) (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)
— Description
— Cab Door
— Front Window
— Front Wiper
— Window Washer Reservoir
— Right Side Windows
– OPERATOR CAB (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
– CENTER COVER
— Removal And Installation
– SERVICE SCHEDULE
— Maintenance Intervals
– AIR CLEANER SERVICE
— 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
— Removing Air From The Fuel System
— Replacing The Fuel Tank Breather
— Draining The Fuel Tank
– 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
— Checking Swing Motor Gear Box Fluid Level
— Removing And Replacing Swing Motor Gear Box Fluid
– LUBRICATING THE EXCAVATOR
— Lubrication 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 KIT – MEL1563
— Remote Start Tool – 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
– VALVES (MAIN RELIEF)
— Testing And Adjusting
– VALVES (PORT RELIEF)
— Testing And Adjusting Port Relief Valve Pressure
– VALVES (CROSS PORT RELIEF)
— Testing And Adjusting
— Removal And Installation
– VALVES (PRESSURE REDUCING)
— Testing And Adjusting
– HYDRAULIC CONTROL VALVE
— Description
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
— Inlet Valve Section Disassembly And Assembly
— 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 Valve Parts Identification
— Torque Limiter Valve Removal
— Torque Limiter Valve Disassembly
— Torque Limiter Valve Assembly
— Initial Torque Limiter Valve Setting
— Torque Limiter Valve Installation
— Pump Control Parts Identification
— Pump Control Removal And Installation
— Pump Control Disassembly And Assembly
— Parts Identification
— Disassembly
— Assembly
– MANIFOLD ASSEMBLY / ACCUMULATOR
— Description
— Removal And Installation
— Parts Identification
— Disassembly And Assembly
– TRAVEL MOTOR
— Removal And Installation
— Parts Identification
— 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
— Assembly
– LEFT CONTROL LEVER (JOYSTICK)
— Testing
— Handle Removal And Installation
— Joystick Assembly Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– HYDRAULIC FILTER MOUNT
— Removal And Installation
– HYDRAULIC RESERVOIR
— Removal And Installation
– OIL COOLER
— 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 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
— 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
— Lower Roller Parts Identification
— Lower Roller Disassembly
— Lower Roller Assembly
— Upper Roller Parts Identification
— Upper Roller Disassembly And 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 Tensioner Parts Identification
— Track Tensioner Disassembly And Assembly
— Roller Removal And Installation
— Lower Roller Parts Identification
— Lower Roller Disassembly
— Lower Roller Assembly
— Upper Roller Parts Identification
— Upper Roller Disassembly And Assembly
— Sprocket Removal And Installation
— Guide Plate Removal And Installation
– TRACK UNDERCARRIAGE COMPONENTS (SEGMENTED TRACK)
— Description
— Rubber Pad 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
— Front Window Disassembly And Assembly
— Front Window Adjustment
— Glass Removal
— Glass Installation
– SEAT
— 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
– FLOOR MAT
— 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
— 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
– 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
– TOOL BOX
— Removal And Installation
– CENTER COVER
— Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
– ELECTRICAL SCHEMATICS
– ELECTRICAL SYSTEM INFORMATION
— Troubleshooting Chart
— Description
— Fuse And Relay Location / Identification
— Shut-Off Switch
– BATTERY
— Servicing
— Using A Booster Battery (Jump Starting)
— Removing And Installing The Battery
– 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
— Removal And Installation
— Boom Light Removal And Installation
— Boom Light Bulb Replacement
– MAGNETIC LOCKOUT SENSOR
— Removal And Installation
– FUEL LEVEL SENDER
— Lower Fuel Level Sender Removal And Installation
— Upper Fuel Level Sender Removal And Installation
— Testing
– DIAGNOSTIC SERVICE CODES
— Viewing Service Codes
— Service Codes List
– CONTROL PANEL SETUP
— Panel Setup (Deluxe Instrument Panel)
— Password Setup (Keyless Start Panel)
— Password Setup (Deluxe Instrument Panel)
— Password Lockout Feature
— Maintenance Clock
– INSTRUMENT PANEL
— Removal And Installation
– CONTROLLER (GATEWAY AND AUXILIARY)
— Description
— Gateway Controller Removal And Installation
— Auxiliary Controller Removal And Installation
– CONTROLLER (PIN GRABBER)
— Removal And Installation
– ENGINE CONTROL UNIT (ECU)
— Description
— Cleaning
— 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
— Removal And Installation
– TRAVEL MOTOR AUTO-SHIFT
— Auto-Shift Drive System (If Equipped)
— Troubleshooting
– AUTO IDLE PRESSURE SENSOR
— Description
— Removal And Installation
– BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS
— Description
— Controller Removal And Installation
— Antenna Removal And Installation
— Procedure
ENGINE SERVICE
– ENGINE INFORMATION
— Description
— Specifications
— Sensor Location
— Torque Values
— Troubleshooting
— Engine Removal And Installation
— Compression – Testing Using The Glow Plug Adapter
— Compression – Testing Using The Injector Adapter
— Injector Signal – Testing
— Injector Signal – Testing (In-Line)
— Oil Pressure Testing (At Oil Sensor On Block)
— Oil Pressure Testing (At Turbocharger Oil Inlet)
– DIESEL OXIDATION CATALYST (DOC)
— Removal And Installation
– AIR CLEANER
— Housing Removal And Installation
– ENGINE COOLING SYSTEM
— Oil Cooler / Radiator Removal And Installation
— 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 Removal And Installation
— Oil Filter Head Removal And Installation
— Oil Cooler Bypass Description
— Oil Cooler Bypass Removal And Installation
– FUEL SYSTEM
— Description
— Transfer Pump / High Pressure Pump Removal And Installation
— Fuel Temperature Sensor Removal And Installation
— Fuel Cooler Removal And Installation
— Fuel Recirculation Valve Removal And Installation
— Fuel Injector Removal And Installation
— Removing Air From The Fuel System
– CYLINDER HEAD
— Glow Plugs Testing
— Glow Plug Removal And Installation
— Valve Clearance Adjustment
— 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
— Hydraulic Pump Coupler Removal And Installation
— Flywheel Removal And Installation
— Ring Gear Removal And Installation
– EXHAUST GAS RECIRCULATION (EGR) SYSTEM
— Removal And 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
— 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
— Performance
— Controls
— Engine
— Hydraulic System
— Hydraulic Cylinders
— Hydraulic Cycle Times
— Drive System
— Slew System
— Undercarriage
— Capacities
— Electrical
— Tracks
— Ground Pressure
– 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
SERVICE SCHEDULE SYMBOLS
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