Bobcat E88 Excavator B4NL11001 & Up 7433618 (2022) (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
Avoid Silica Dust
FIRE PREVENTION
Maintenance
Operation
Charging
Electrical
Starting
Battery
Hydraulic System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
Front View
Front View
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Lifting The Machine
OPERATOR CAB (ROPS / TOPS / FOPS)
Description
Opening The Cab Door
Operating The Front Window
Operating The Right Windows
Operating The Cab Interior Light
Operating Windshield Wiper
Window Washer Reservoir
Heating, Ventilation, And Air Conditioning Ducting
TRANSPORTING THE MACHINE
Fastening The Machine To A Trailer
TAILGATE
Opening And Closing The Tailgate
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SERVICE SCHEDULE
Maintenance Intervals
Service Schedule
ENGINE AIR CLEANER
Replacing The Outer Filter Of The Air Cleaner
Replacing The Inner Filter Of The Air Cleaner
CAB FILTERS
Cleaning And Maintaining The Recirculation Filter
Cleaning And Maintaining The Fresh Air Filter
ENGINE COOLING SYSTEM
Cleaning The Engine Cooling System
Checking Coolant Level
Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Using The Fuel Fill Pump
Removing Water From The Fuel Filter
Replacing The Fuel Filter
Replacing The Fuel Pre-Filter
Replacing The Fuel Tank Vent Filter
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Replacing Engine Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Fluid
Hydraulic Fluid Chart
Replacing The Hydraulic Filter
Replacing The Case Drain Filter
Replacing Hydraulic Fluid
Checking The Fluid Level Of the Swing Motor Gear Box
Replacing Swing Motor Gear Box Fluid
MACHINE LUBRICATION
Grease Fitting Locations
Lubricate As Indicated
Remote Lubrication
PIVOT PINS
Pivot Pin Inspection And Maintenance
TRAVEL MOTOR
Checking And Adding Travel Motor Fluid
Replacing Travel Motor Fluid
EMERGENCY EXIT
Emergency Exit Locations
Making An Emergency Exit Through The Front Window
Making An Emergency Exit Through The Right Side Window
SEAT BELT
Inspection And Maintenance
CONTROL CONSOLE LOCKOUTS
Inspecting And Maintaining The Control Console Lockouts
TOWING THE MACHINE
Towing The Machine
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
S/N B4NL11001 & Above
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
Earlier Models
Later Models
Removal And Installation
Earlier Models
Later Models
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
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
JOYSTICK PATTERN SELECTOR
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
Description
Removal And Installation
BLADE CONTROL LEVER
Handle Removal And Installation
Removal And Installation
Parts Identification (Standard Blade)
Parts Identification (4th Auxiliary)
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
CLAMP DIVERTER VALVE
Removal And Installation
UNDERCARRIAGE
BLADE
Removal And Installation
TRACK UNDERCARRIAGE (RUBBER TRACK)
Description
Track Lug Height
Checking / Adjusting Tension
Track Removal And Installation
TRACK UNDERCARRIAGE (STEEL TRACK)
Description
Checking / Adjusting Tension
Track Removal
Track Installation
Steel / Segmented Guide Plate Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS
Idler Removal And Installation
Track Tensioner Removal And Installation
Track Tensioner Parts Identification
Track Tensioner Disassembly And Assembly
Roller Removal And Installation
Sprocket 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
Door Latch Removal And Installation
Hold Open Latch Removal And Installation
Front Window Removal And Installation
Front Window Disassembly And Assembly
Front Window Adjustment
Right Side Rear Sliding Window Removal And Installation
Glass Removal
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 SIDE PANEL COVER
Removal And Installation
RIGHT SIDE PANEL COVER
Removal And Installation
COUNTERWEIGHT
Removal And Installation
Add-On 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
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
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
QUICK COUPLER (KLAC™ SYSTEM)
Troubleshooting
Daily Inspection
Removal And Installation
Parts Identification
Disassembly
Assembly
QUICK COUPLER (GERMAN 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)
HYDRAULIC QUICK COUPLER (QC08)
Hydraulic Schematic
QUICK COUPLER (HYDRAULIC GERMAN SYSTEM)
Hydraulic Schematic
Disassembly
Assembly
RIGHT SIDE COVER
Removal And Installation
Latch Removal And Installation
TOOL BOX
Removal And Installation
CENTER COVER
Removal And Installation
LEFT SIDE GRILLE
Removal And Installation
LEFT SIDE COVER
Removal And Installation
FUEL TRANSFER PUMP
Removal And Installation
LOUVER
Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
S/N B4NM11001 & Above
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Upperstructure Harness Connectors
Motion Alarm Harness Connectors
Cab Frame Harness Connectors
Engine Start Harness Connectors
ECU Harness Connectors
Troubleshooting Chart
Electrical System Description
Fuse And Relay Location / Identification
Battery Disconnect Switch Description
Removal And Installation
BATTERY
Battery Maintenance
Maintaining Battery Charge Level
Battery Service During Machine Storage
Testing The Battery
Battery Charging
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
INSTRUMENTS AND CONSOLES
Left Console
Right Console
Standard Display
Touch Display
Jog Shuttle (Standard Display)
Using The Jog Shuttle With Standard Display
Jog Shuttle (Touch Display)
Using The Jog Shuttle With Touch Display
LIGHTS
Cab Light Removal And Installation
Boom Light Removal And Installation
MAGNETIC LOCKOUT SENSOR
Removal And Installation
FUEL LEVEL SENDER
Lower Fuel Level Sender Removal And Installation
Upper Fuel Level Sender Removal And Installation
Testing
NAVIGATION (STANDARD DISPLAY)
Opening Navigation Bar
Active Shortcuts
VITALS (STANDARD DISPLAY)
Accessing Vital Detail And Machine Performance
SERVICE (STANDARD DISPLAY)
Recording A Service
Viewing Service Codes
SETTINGS (STANDARD DISPLAY)
Managing Operators
Machine Lockout And Quick Start
Password Description
Enabling Machine Lockout And Quick Start
Switching Between English / Metric Units
Software Version
Setting Auto Lock Time
CAMERA (TOUCH DISPLAY)
Operating Rear View Camera
Accessing Vital Detail And Machine Performance
Adjusting Rear View Camera Settings
SERVICE (TOUCH DISPLAY)
Viewing Service Codes
Recording A Service
ATTACHMENTS (TOUCH DISPLAY)
Accessing Attachment Information
GAUGES (TOUCH DISPLAY)
Notification Drawer
Accessing Vital Detail And Machine Performance
SETTINGS (TOUCH DISPLAY)
Setting A Date and Time
Releasing Hydraulic Pressure in Excavator
Setting The Auxiliary Hydraulics Flow
Activating Auto Idle
Password Description
Changing The Owner and Operator Passwords
Adding An Operator
Removing An Operator
Machine Lockout and Quick Start
Enabling Machine Lockout and Quick Start
Setting Auto Lock Time
System Sleep Time At Key Off
Enabling Password Error Lockout
Accessing Operator Statistics
Using The Job Clock
Setting The System Language
Switching Between English / Metric Units
Dealer Information
Software Version
STANDARD DISPLAY
Removal And Installation
TOUCH DISPLAY
Removal And Installation
Controller Display 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
Switch Removal And Installation
SERVICE PC (LAPTOP COMPUTER)
Connecting The Remote Start Tool
Connecting Remote Start Tool (Service Tool)
TRAVEL MOTOR AUTO-SHIFT
Auto-Shift Drive System
Troubleshooting
AUTO IDLE PRESSURE SENSOR
Description
Removal And Installation
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Removal and Installation
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS
Description
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 PARTICULATE FILTER (DPF) SYSTEM
Description
DPF Regeneration Status Icons
DPF Regeneration Tables
Removal And Installation
Automatic Regeneration Operation
Forced Regeneration Operation
Forced Parked Regeneration Operation
Inhibit Mode Operation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
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
Description
Oil Pan Removal And Installation
Oil Pump 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
Fuel Filter Housing Removal And Installation
Fuel Filter Temperature And Pressure Sensor Removal
Fuel Lift Pump Removal And Installation
Fuel Pre-Filter Removal And Installation
Transfer Pump / High Pressure Pump Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Recirculation Valve (FRV) 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 Plug 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
Installing the Rocker Arm Assembly
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
Description
Removal And Installation
EXHAUST MANIFOLD
Removal And Installation
INTERCOOLER
Description
Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Cleaning And Maintaining The Recirculation Filter
Cleaning And Maintaining The Fresh Air Filter
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 Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
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
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 Specifications
Controls Specifications
Engine Specifications
Hydraulic System Specifications
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System Specifications
Slew System Specifications
Undercarriage Specifications
Capacities Specifications
Tracks Specifications
Ground Pressure Specifications
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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