Complete repair service manual with Electrical Wiring Diagrams for Bobcat E60, E62, E63, E80 Compact Excavators, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat E60, E62, E63, E80 Compact Excavators workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6987189 (10-09) - E60 Compact Excavator Operation & Maintenance Manual.pdf
6987190 (07-11) - E60 Compact Excavator Service Manual.pdf
6987190 (10-09) - E60 Compact Excavator Service Manual.pdf
6987193 (2-11) - E80 Compact Excavator Operation & Maintenance Manual.pdf
6987194 (2-11) - E80 Excavator Service Manual.pdf
6990613 (06-13) - E63 Compact Excavator Service Manual.pdf
6990617 (06-13) - E85 Excavator Service Manual.pdf
6990794 (09-13) - E62 Compact Excavator Service Manual.pdf

Total Pages: 5,140
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6987189 (10-09) - E60 Compact Excavator Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNING...3
  CONTENTS...5
  FOREWORD...7
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...9
    REGULAR MAINTENANCE ITEMS...9
    SERIAL NUMBER LOCATIONS...10
      Excavator Serial Number...10
      Engine Serial Number...10
    DELIVERY REPORT...10
    EXCAVATOR IDENTIFICATION...11
    FEATURES, ACCESSORIES AND ATTACHMENTS...12
      Standard Items...12
      Options And Accessories...12
      Attachments...12
      Buckets Available...12
      Falling Object Guards (FOGS)...13
      Special Applications Kit...13
      Special Applications Kit Inspection And Maintenance...13
  SAFETY & TRAINING RESOURCES...15
    SAFETY INSTRUCTIONS...17
      Before Operation...17
      Safe Operation Is The Operator’s Responsibility...18
      Safe Operation Needs A Qualified Operator...18
      Avoid Silica Dust...19
    FIRE PREVENTION...19
      Maintenance...19
      Operation...19
      Electrical...19
      Hydraulic System...20
      Fueling...20
      Starting...20
      Spark Arrestor Exhaust System...20
      Welding And Grinding...20
      Fire Extinguishers...20
    PUBLICATIONS AND TRAINING RESOURCES...21
    MACHINE SIGNS (DECALS)...22
  OPERATING INSTRUCTIONS...25
    INSTRUMENT PANEL IDENTIFICATION...29
      Overview...29
      Right Console...30
      Function Icons...31
      STD / ISO Selector Valve...32
      Upperstructure Slew Brake...32
      Raising And Lowering The Console...32
      Two-Speed Travel...33
      Engine Speed Control Dial...33
      Automatic Idle...33
    OPERATOR CANOPY (ROPS / TOPS)...34
      Description...34
    OPERATOR CAB (ROPS / TOPS)...34
      Description...34
      Cab Door...35
      Front Window...36
      Front Wiper...37
      Window Washer Reservoir...37
      Right Side Window...38
      Heating, Ventilation And Air Conditioning Duct...39
    TRAVEL CONTROLS...40
      Description...40
      Forward And Reverse Travel...40
      Turning...40
    EMERGENCY EXITS...42
      Right Rear Side Window...42
      Front Window...42
    MOTION ALARM SYSTEM (IF EQUIPPED)...43
      Operation...43
    HYDRAULIC CONTROLS...44
      Description...44
      STANDARD Control Pattern...44
      ISO Control Pattern...45
      Quick Couplers...46
      Auxiliary Hydraulics (One Way Flow)...47
      Auxiliary Hydraulics (Secondary Auxiliaries)...47
      Auxiliary Hydraulics (Third Auxiliaries) (If Equipped)...47
      Relieve Hydraulic Pressure - One Way Flow (Excavator And Attachment)...48
      Relieve Hydraulic Pressure - Secondary Auxiliaries (If Equipped) (Excavator And Attachment)...48
      Relieve Hydraulic Pressure - Third Auxiliaries (If Equipped) (Excavator And Attachment)...48
    BLADE CONTROL LEVER...49
      Operation...49
    BOOM SWING PEDAL...49
      Operation...49
    OVERLOAD WARNING...50
      Description...50
      Operation...50
    BOOM LOAD HOLDING VALVE...51
      Description...51
      Lowering Boom With Load Holding Valve...51
    DAILY INSPECTION...52
      Daily Inspection And Maintenance...53
    PRE-STARTING PROCEDURE...54
      Operation & Maintenance Manual And Operator’s Handbook Locations...54
      Entering The Excavator...54
      Seat Adjustment...55
      Seat Belt Adjustment...55
      Control Console...56
      Mirror Adjustment (If Equipped)...56
    STARTING THE ENGINE...57
      Key Switch...57
      Cold Temperature Starting...58
      Warming The Hydraulic System...59
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...60
      Procedure...60
      Emergency Shut Off...60
    ATTACHMENTS...61
      Installing And Removing The Attachment (Pin-On)...61
      Installing And Removing The Attachment (Pin-On X- Change)...63
    OPERATING PROCEDURE...67
      Inspect The Work Area...67
      Basic Operating Instructions...67
      Lowering The Work Equipment (Engine STOPPED)...67
      Lifting A Load...68
      Excavating...69
      Boom Swing...71
      Backfilling...72
      Driving The Excavator...72
      Operating On Slopes...73
      Operating In Water...75
      Avoiding Track Damage...76
    TOWING THE EXCAVATOR...77
      Procedure...77
    LIFTING THE EXCAVATOR...78
      Procedure...78
    TRANSPORTING THE EXCAVATOR ON A TRAILER...79
      Loading And Unloading...79
      Fastening...79
  PREVENTIVE MAINTENANCE...81
    MAINTENANCE SAFETY...85
    SERVICE SCHEDULE...87
      Chart...87
    CONTROL CONSOLE LOCKOUT...88
      Inspection And Maintenance...88
    SEAT BELT...89
      Inspection And Maintenance...89
    MOTION ALARM SYSTEM (IF EQUIPPED)...90
      Description...90
      Inspecting...90
      Adjusting Switch Position...91
    REAR COVER...92
      Opening And Closing...92
    RIGHT SIDE COVER...92
      Opening And Closing...92
      Adjusting The Latch...92
    CAB FILTERS...93
      Cleaning And Maintenance...93
    AIR CLEANER SERVICE...94
      Daily Check...94
      Replacing Filter Elements...94
    FUEL SYSTEM...96
      Biodiesel Blend Fuel...96
      Filling The Fuel Tank...97
      Fuel Filters...98
      Draining The Fuel Tank...99
      Removing Air From The Fuel System...99
    ENGINE LUBRICATION SYSTEM...100
      Checking And Adding Engine Oil...100
      Engine Oil Chart...100
      Removing And Replacing Oil And Filter...101
    ENGINE COOLING SYSTEM...102
      Cleaning...102
      Checking Level...102
      Removing And Replacing Coolant...103
    ELECTRICAL SYSTEM...104
      Description...104
      Fuse And Relay Location / Identification...104
      Battery Maintenance...106
      Using A Booster Battery (Jump Starting)...107
      Removing And Installing Battery...108
    HYDRAULIC SYSTEM...109
      Checking And Adding Fluid...109
      Hydraulic Fluid Chart...110
      Removing And Replacing Hydraulic Filters...111
      Removing And Replacing Hydraulic Fluid...114
      Removing And Replacing Hydraulic Fluid...115
    SPARK ARRESTOR MUFFLER...116
      Cleaning Procedure...116
    TRACK TENSION...117
      Adjusting...117
    TRAVEL MOTOR...119
      Checking And Adding Oil...119
      Removing And Replacing Oil...119
    ALTERNATOR BELT...120
      Belt Adjustment...120
      Belt Replacement...120
    AIR CONDITIONING BELT...121
      Belt Adjustment...121
      Belt Replacement...122
    ATTACHMENT...123
      Pin-On Inspection And Maintenance...123
      Pin-On X-Change And Attachment Inspection And Maintenance...123
    TRACK ROLLER AND IDLER LUBRICATION...124
      Procedure...124
    BUCKET...125
      Bucket Teeth Removal And Installation...125
    LUBRICATING THE EXCAVATOR...127
      Lubrication Locations...127
    PIVOT PINS...130
      Inspection And Maintenance...130
    EXCAVATOR STORAGE AND RETURN TO SERVICE...131
      Storage...131
      Return to Service...131
  SYSTEM SETUP & ANALYSIS...133
    DIAGNOSTIC SERVICE CODES...135
      Service Codes List...135
    FLASHING PATTERNS OF ENGINE CHECK LAMP...138
  MACHINE SIGN TRANSLATIONS...139
    MACHINE SIGN TRANSLATIONS...141
      Service Schedule (7189180)...141
      Lift Chart (7176311)...144
      X-Change (7102651)...147
      Warning (6808185)...150
      Warning (7168995)...151
      Warning (6804114)...154
      Warning (6577754)...154
      Warning (6804233)...154
      Warning (6809832)...154
      Warning (7169006)...155
      Joystick Control Pattern Selector (7176312)...156
      Motion Alarm (7167994)...157
      Low Sulfur (7152748)...158
      EG Coolant (7157847)...158
  SPECIFICATIONS...159
    (E60) EXCAVATOR SPECIFICATIONS...161
      Machine Dimensions...161
      Performance...163
      Controls...163
      Engine...163
      Hydraulic System...164
      Hydraulic Cylinders...164
      Hydraulic Cycle Times...165
      Electrical...165
      Instrumentation...165
      Drive System...165
      Slew System...165
      Undercarriage...165
      Crawler Track Design...165
      Capacities...165
      Fuel Tank...165
      Track...166
      Type...166
      Ground Pressure...166
  WARRANTY...167
    WARRANTY...169
  ALPHABETICAL INDEX...171
6987190 (07-11) - E60 Compact Excavator Service Manual...173
  MAINTENANCE SAFETY...175
  CONTENTS...177
  FOREWORD...179
    FOREWORD...181
    SAFETY INSTRUCTIONS...184
    FIRE PREVENTION...186
      Maintenance...186
      Operation...186
      Electrical...186
      Hydraulic System...186
      Fueling...186
      Starting...186
      Spark Arrester Exhaust System...186
      Welding And Grinding...187
      Fire Extinguishers...187
    SERIAL NUMBER LOCATIONS...188
      Excavator Serial Number...188
      Engine Serial Number...188
    DELIVERY REPORT...189
    EXCAVATOR IDENTIFICATION...190
  SAFETY & MAINTENANCE...191
    LIFTING AND BLOCKING THE EXCAVATOR...193
      Procedure...193
    LIFTING THE EXCAVATOR...195
      Procedure...195
    OPERATOR CAB (ROPS / TOPS)...197
      Description...197
      Cab Door...197
      Front Window...198
      Front Wiper...199
      Window Washer Reservoir...199
      Right Side Window...200
      Heating, Ventilation And Air Conditioning Duct...201
    TRANSPORTING THE EXCAVATOR ON A TRAILER...203
      Loading And Unloading...203
      Fastening...204
    RIGHT SIDE COVER...205
      Opening And Closing...205
      Adjusting The Latch...205
    REAR COVER...207
      Opening And Closing...207
    SERVICE SCHEDULE...209
      Chart...209
    AIR CLEANER SERVICE...211
      Daily Check...211
      Replacing The Filters...211
    CAB FILTER...213
      Cleaning And Maintenance...213
    ENGINE COOLING SYSTEM...215
      Cleaning...215
      Checking Level...215
      Removing And Replacing Coolant...216
    FUEL SYSTEM...217
      Fuel Specifications...217
      Biodiesel Blend Fuel...217
      Filling The Fuel Tank...218
      Fuel Filters...219
      Draining The Fuel Tank...220
      Removing Air From The Fuel System...220
    ENGINE LUBRICATION SYSTEM...221
      Checking And Adding Engine Oil...221
      Engine Oil Chart...221
      Removing And Replacing Oil And Filter...222
    HYDRAULIC SYSTEM...225
      Checking And Adding Fluid...225
      Hydraulic Fluid Chart...226
      Removing And Replacing Hydraulic Filters...226
      Removing And Replacing Hydraulic Fluid...230
      Removing Air From Hydraulic Pump...231
    LUBRICATING THE EXCAVATOR...233
      Lubrication Locations...233
    PIVOT PINS...237
      Inspection And Maintenance...237
    TRAVEL MOTOR...239
      Checking And Adding Oil...239
      Removing And Replacing Oil...239
    SPARK ARRESTER MUFFLER...241
      Cleaning Procedure...241
    ALTERNATOR BELT...243
      Belt Adjustment...243
      Belt Replacement...243
    AIR CONDITIONING BELT...245
      Belt Adjustment...245
      Belt Replacement...246
    EMERGENCY EXIT...247
      Right Rear Side Window...247
      Front Window...247
    SEAT BELT...249
      Inspection And Maintenance...249
    CAB TILT PROCEDURE...251
      Tilting The Cab...251
    CONTROL CONSOLE LOCKOUTS...253
      Inspection And Maintenance...253
    TOWING THE EXCAVATOR...255
      Procedure...255
  HYDRAULIC SYSTEM...257
    HYDRAULIC / HYDROSTATIC SCHEAMTICS...261
    HYDRAULIC SYSTEM INFORMATION...269
      Glossary Of Hydraulic / Hydrostatic Symbols...269
      Troubleshooting The Hydraulic Circuit...272
      Troubleshooting The Cylinder Circuit...273
      Troubleshooting The Swing (Slew) Circuit...274
      Troubleshooting The Travel Circuit...275
      Description...277
    CYLINDER (BOOM)...279
      Testing...279
      Removal And Installation...281
      Parts Identification...284
      Disassembly...285
      Assembly...292
    CYLINDER (ARM)...299
      Testing...299
      Removal And Installation...301
      Parts Identification...303
      Disassembly...304
      Assembly...311
    CYLINDER (BOOM SWING)...319
      Testing...319
      Removal And Installation...320
      Parts Identification...323
      Disassembly...324
      Assembly...331
    CYLINDER (BUCKET)...339
      Testing...339
      Removal And Installation...339
      Parts Identification...343
      Disassembly...344
      Assembly...351
    CYLINDER (BLADE)...359
      Testing...359
      Removal And Installation...360
      Parts Identification...363
      Disassembly...364
      Assembly...369
    VALVES (MAIN RELIEF)...375
      Testing And Adjusting The Main Relief Valves...375
    VALVES (PORT RELIEF)...379
      Testing And Adjusting Port Relief Valve Pressure...379
    VALVE (PRESSURE REDUCING)...381
      Description...381
      Testing And Adjusting...381
    HYDRAULIC CONTROL VALVE...383
      Removal And Installation...383
      Parts Identification...386
      Disassembly And Assembly...387
      Inlet Valve Section Disassembly And Assembly...392
      Blade And Upperstructure Swing Valve Section Disassembly And Assembly...395
      Boom Swing And 2nd Auxiliary Valve Section Disassembly And Assembly...397
      Boom 2 / Auxiliary And Arm 1 Valve Section Disassembly And Assembly...400
      Left Travel, Inlet And Right Travel Valve Section Disassembly And Assembly...403
      Boom 1 Disassembly And Assembly...405
      Arm 2 and Bucket Valve Section Disassembly And Assembly...409
    HYDRAULIC PUMP...411
      Testing Information...411
      Torque Adjustment...412
      Testing The Piston Pump...413
      Testing The Gear Pump...415
      Removal And Installation...417
      Gear Pump Parts Identification...420
      Gear Pump Disassembly And Assembly...421
      Solenoid Valve Parts Identification...426
      Solenoid Valve Disassembly And Assembly...427
      Piston Pump Parts Identification...429
      Piston Pump Disassembly And Assembly...430
    ACCUMULATOR...439
      Description...439
      Removal And Installation...439
    TRAVEL MOTOR...441
      Removal And Installation...441
      Parts Identification Hydraulic Motor...442
      Parts Identification Gear Reduction Hub...443
      Disassembly...444
      Assembly...460
    SWIVEL JOINT...477
      Removal And Installation...477
      Parts Identification...480
      Disassembly...481
      Assembly...482
    SWING MOTOR...485
      Removal And Installation...485
      Parts Identification...487
      Disassembly And Assembly...488
    SWING MOTOR (DRIVE CARRIER)...497
      Removal And Installation...497
      Parts Identification...498
      Disassembly And Assembly...499
    CONTROL PATTERN SELECTOR VALVE...503
      Removal And Installation...503
      Parts Identification...504
      Disassembly...505
      Assembly...507
    RIGHT CONTROL LEVER (JOYSTICK)...509
      Testing...509
      Handle Removal And Installation...510
      Joystick Assembly Removal And Installation...511
      Parts Identification...513
      Disassembly And Assembly...514
    LEFT CONTROL LEVER (JOYSTICK)...519
      Testing...519
      Handle Removal And Installation...520
      Joystick Assembly Removal And Installation...521
      Parts Identification...523
      Disassembly And Assembly...524
    BLADE CONTROL VALVE...529
      Removal And Installation...529
      Parts Identification...530
      Disassembly And Assembly...531
    HYDRAULIC RESERVOIR...535
      Removal And Installation...535
    OIL COOLER...539
      Removal And Installation...539
    AUXILIARY HYDRAULIC BREAKER VALVE...541
      Removal And Installation...541
      Disassembly And Assembly...542
    SWING MOTOR BRAKE SHUTTLE VALVE...545
      Removal And Installation...545
      Parts Identification...546
      Disassembly And Assembly...547
    BOOM SWING VALVE...549
      Removal And Installation...549
      Parts Identification...550
      Disassembly And Assembly...551
    AUXILIARY HYDRAULIC VALVE...555
      Removal And Installation...555
      Parts Identification...556
      Disassembly And Assembly...557
    TRAVEL CONTROL VALVE...561
      Removal And Installation...561
      Parts Identification...563
      Disassembly And Assembly...564
  UNDERCARRIAGE...569
    BLADE...571
      Removal And Installation...571
    TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)...573
      Description...573
      Track Lug Height...573
      Checking Tension...574
      Adjusting Tension...575
      Track Removal And Installation...575
      Idler Removal And Installation...578
      Idler Parts Identification...579
      Idler Disassembly...580
      Idler Assembly...583
      Tensioner Removal And Installation...588
      Track Tensioner Parts Identification...589
      Track Tensioner Disassembly And Assembly...590
      Roller Removal And Installation...591
      Roller Parts Identification...592
      Roller Disassembly...593
      Roller Assembly...596
      Sprocket Removal And Installation...600
    TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)...601
      Description...601
      Checking Tension...602
      Adjusting Tension...603
      Track Removal...604
      Track Installation...606
      Idler Removal And Installation...607
      Idler Parts Identification...608
      Idler Disassembly...609
      Idler Assembly...612
      Track Tensioner Removal And Installation...617
      Track Tension Parts Identification...618
      Track Tensioner Disassembly And Assembly...619
      Roller Removal And Installation...620
      Roller Parts Identification...621
      Roller Disassembly...622
      Roller Assembly...625
      Sprocket Removal And Installation...629
      Guide Plate Removal And Installation...629
    TRACK MAINTENANCE...631
      Track Damage Identification...631
    SWING CIRCLE GEAR...643
      Swing Bearing Removal...643
      Swing Bearing Installation...643
  UPPERSTRUCTURE AND SWING SECTION...645
    UPPERSTRUCTURE...647
      Removal...647
      Installation...649
    CAB...651
      Removal And Installation...651
      Door Removal And Installation...666
      Front Window Removal And Installation...667
      Lower Front Window Removal And Installation...668
      Glass Installation...669
      Front Window Strut Removal And Installation...673
      Front Window Slide Bar Removal And Installation...674
      Cab Tilt Assembly Removal And Installation...675
      Cab Tilt Parts Identification...676
      Cab Tilt Assembly Disassembly And Assembly...677
      Headliner Removal And Installation...677
    SEAT AND SEAT MOUNT...683
      Seat Removal And Installation...683
      Seat Mount Removal And Installation...684
    RIGHT CONSOLE...687
      Console Cover Removal And Installation...687
    LEFT CONSOLE...689
      Upper Console Cover Removal And Installation...689
      Lower Console Cover Removal And Installation...690
      Gas Strut Removal And Installation...691
      Lock Lever Removal And Installation...692
      Lock Lever Disassembly And Assembly...693
      Console Removal And Installation...694
    LEFT UPPERSTRUCTURE COVER...695
      Removal And Installation...695
    RIGHT UPPERSTRUCTURE COVER...697
      Removal And Installation...697
    COUNTER WEIGHT...699
      Removal And Installation...699
    FLOOR MAT...701
      Removal And Installation...701
    FUEL TANK...703
      Removal And Installation...703
    HORN...705
      Removal And Installation...705
    SWING FRAME...707
      Removal And Installation...707
      Bushing Removal...711
      Bushing Installation...712
    BOOM...713
      Removal And Installation...713
      Bushing Removal And Installation...714
    ARM (STANDARD AND LONG)...715
      Removal And Installation...715
      Arm To Boom Bushing Removal And Installation...716
      Bucket And Link Bushing Removal And Installation...717
    BUCKET...719
      Bucket Teeth Removal And Installation...719
      Bucket Side Cutting Edge Removal And Installation...720
    REAR COVER...721
      Removal And Installation...721
    QUICK COUPLER (KLAC™ SYSTEM)...723
      Troubleshooting...723
      Daily Inspection...723
      Removal And Installation...724
      Parts Identification...726
      Disassembly...727
      Assembly...729
    QUICK COUPLER (LEHNHOFF® SYSTEM)...731
      Troubleshooting...731
      Daily Inspection...731
      Removal (MS03 And MS08)...732
      Installation (MS03 And MS08)...733
      Parts Identification (MS03)...734
      Disassembly And Assembly (MS03)...735
      Parts Identification (MS08)...736
      Disassembly (MS08)...737
      Assembly (MS08)...741
    RIGHT SIDE COVER...745
      Removal And Installation...745
  ELECTRICAL SYSTEM & ANALYSIS...747
    ELECTRICAL SCHEMATICS...749
    ELECTRICAL SYSTEM INFORMATION...750
      Troubleshooting Chart...750
      Description...751
      Fuse And Relay Location / Identification...751
      Engine Control Unit (ECU)...753
    BATTERY...754
      Servicing...754
      Removal And Installation...755
      Using A Booster Battery (Jump Starting)...756
    ALTERNATOR...758
      Belt Adjustment...758
      Removal And Installation...758
      Charging System Check...760
      Alternator Voltage Test...763
      Low Voltage Test...763
      High Voltage Test...764
      Alternator Regulator Test...765
      Parts Identification...766
      Disassembly And Assembly...767
      Stator Continuity Test...767
      Stator Ground Test...767
      Rotor Continuity Test...767
      Rotor Ground Test...768
    STARTER...770
      Testing...770
      Removal And Installation...771
      Parts Identification...773
    LIGHTS...774
      Boom Light Removal And Installation...774
      Boom Light Bulb Replacement...774
    CONSOLE LOCKOUT SWITCH...776
      Testing / Adjustment...776
      Removal And Installation...777
    FUEL LEVEL SENDER...778
      Removal And Installation...778
    DIAGNOSTIC SERVICE CODE...780
      Service Codes List...780
      Flashing Patterns Of Engine Check Lamp...784
    DIAGNOSTIC TOOL...786
      Software Installation...786
      Installation...788
      Code Retrieval...791
    INSTRUMENT PANEL...796
      Removal And Installation...796
      Disassembly And Assembly...797
    KEY SWITCH...800
      Removal And Installation...800
    RIGHT CONSOLE SWITCH COVER...802
      Removal And Installation...802
      Rocker Switch Removal And Installation...803
      Speed Control Removal And Installation...804
      Engine Emergency Stop Switch Removal And Installation...804
      Auxiliary Power Outlet Removal And Installation...805
    WIPER MOTOR...806
      Removal And Installation...806
    MOTION ALARM SYSTEM (IF EQUIPPED)...808
      Description...808
      Inspecting...808
      Adjusting Switch Position...809
    FUEL TRANSFER PUMP...810
      Removal And Installation...810
  ENGINE SERVICE...812
    ENGINE INFORMATION...814
      Description...814
      Specifications...815
      Troubleshooting...821
      Engine Removal And Installation...822
      Compression - Testing...829
    ENGINE SPEED CONTROL...832
      Adjustment...832
    ENGINE SPEED CONTROL (Cont’d)...833
    MUFFLER...834
      Removal And Installation...834
    AIR CLEANER...836
      Housing Removal And Installation...836
    ENGINE COOLING SYSTEM...838
      Radiator Removal And Installation...838
      Radiator Disassembly And Assembly...845
      Fan Removal And Installation...847
      Fuel Cooler Removal And Installation...848
      Water Pump Removal And Installation...849
      Water Pump Parts Identification...850
      Thermostat Removal And Installation...851
      Temperature Switch Testing...851
      Temperature Sensor Testing...852
      Thermostat Testing...852
      Radiator Cap Testing...853
    LUBRICATION SYSTEM...854
      Oil Pan Removal And Installation...854
      Oil Pump Removal And Installation...855
      Oil Pump Inspection...857
      Engine Oil Pressure - Testing...859
    FUEL SYSTEM...860
      Fuel Injection Pump Removal And Installation...860
      Fuel Injection Pump - Timing...865
      Fuel Injector Removal And Installation...869
      Fuel Injector Pressure - Testing...871
      Nozzle Spray Condition...871
    CYLINDER HEAD...874
      Valve Clearance Adjustment...874
      Cylinder Head Removal And Installation...876
      Cylinder Head Disassembly And Assembly...877
      Cylinder Head - Servicing...878
      Valve Guide - Inspection...879
      Intake And Exhaust Valve - Inspection...880
      Valve Stem Bend - Inspection...880
      Valve Face And Seat...881
      Valve Spring - Inspection...881
      Push Rod - Inspection...882
      Rocker Arm - Inspection...882
      Valve Bridge - Inspection...883
    CRANKSHAFT AND PISTONS...884
      Piston And Connecting Rod Removal And Installation...884
      Piston And Connecting Rod - Servicing...885
      Cylinder Bore - Inspection...887
      Crankshaft End Play...887
      Crankshaft And Bearings Removal And Installation...888
      Crankshaft And Bearings - Servicing...889
    CAMSHAFT AND TIMING GEARS...890
      Timing Gear Case Cover Removal And Installation...890
      Timing Gear Backlash - Inspection...891
      Idler Gear And Camshaft Removal And Installation...892
      Camshaft - Servicing...893
      Idler Gear And Shaft - Servicing...894
    COLD START DEVICE...896
      Description...896
      Testing...896
      Removal And Installation...896
    EXHAUST GAS RECIRCULATION VALVE (EGR)...898
      Description...898
      Testing...898
      Removal And Installation...899
    MANIFOLD AIR HEATER...900
      Description...900
      Testing...900
      Removal And Installation...900
    ENGINE FLYWHEEL...902
      Hydraulic Pump Coupler Removal And Installation...902
      Flywheel Removal And Installation...903
      Flywheel Ring Gear Removal And Installation...903
  HEATING, VENTILATION & AIR CONDITIONING...904
    AIR CONDITIONING SYSTEM FLOW...906
      Description...906
      Chart...907
      Components...908
      Safety Equipment...911
    REGULAR MAINTENANCE...912
      Filters...912
      Belt Adjustment...912
      Belt Replacement...912
      Condenser...912
      Air Conditioning Service Chart...913
      Evaporator / Heater Coil...914
    TROUBLESHOOTING...916
      Blower Motor Does Not Operate...916
      Blower Motor Operates Normally, But Air Flow Is Insufficient...916
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...916
      The Compressor Operates Improperly Or Not At All...916
      Gauge Pressure Related Troubleshooting...917
      Temperature / Pressure Chart...919
      Poor A/C Performance...920
      HVAC Repair And Leaks...921
    SYSTEM CHARGING AND RECLAMATION...922
      Reclamation And Charging With Recovery / Charging Unit...922
      Charging With A Manifold Gauge Set...925
    COMPRESSOR...928
      Removal And Installation...928
      Oil...930
      Oil Check...931
    CONDENSER...934
      Removal And Installation...934
    RECEIVER / DRIER...936
      Receiver / Drier Removal And Installation...936
      Pressure Switch Removal And Installation...937
    EVAPORATOR / HEATER UNIT...938
      Removal And Installation...938
    THERMOSTAT...940
      Inspection...940
    EXPANSION VALVE...942
      Removal And Installation...942
    BLOWER FAN...944
      Removal And Installation...944
    HEATER VALVE...946
      Removal And Installation...946
    HVAC CONTROLLER...948
      Removal And Installation...948
  SPECIFICATIONS...950
    E60 SPECIFICATIONS...952
      Machine Dimensions...952
      Machine Dimensions With Standard Arm...953
      Machine Dimensions With Long Arm...954
      Performance...955
      Controls...955
      Engine...955
      Hydraulic System...956
      Hydraulic Cylinders...956
      Hydraulic Cycle Times...957
      Electrical...957
      Drive System...957
      Slew System...957
      Undercarriage...957
      Capacities...957
      Tracks...958
      Ground Pressure...958
    TORQUE SPECIFICATIONS FOR BOLTS...960
      Torque For General SAE Bolts...960
      Torque For General Metric Bolts...961
    HYDRAULIC CONNECTION SPECIFICATIONS...962
      O-ring Face Seal Connection...962
      Straight Thread O-ring Fitting...963
      Tubelines And Hoses...963
      Flare Fitting...964
      Port Seal Fitting...965
      BSPP Swivel Nut...965
    HYDRAULIC FLUID SPECIFICATIONS...966
      Specifications...966
    CONVERSIONS...968
      Decimal And Millimeter Equivalents...968
      U.S. To Metric Conversion...969
  ALPHABETICAL INDEX...970
  SERVICE MANUAL REVISION...972
    Revision No: E60-1...972
    Revision No: E60-2...974
    Revision No: E60-3...976
    Revision No: E60-4...978
6987190 (10-09) - E60 Compact Excavator Service Manual...980
  MAINTENANCE SAFETY...982
  ALPHABETICAL INDEX...984
  CONTENTS...986
    FOREWORD...988
    SAFETY INSTRUCTIONS...991
    FIRE PREVENTION...993
      Maintenance...993
      Operation...993
      Electrical...993
      Hydraulic System...993
      Fueling...993
      Starting...993
      Spark Arrestor Exhaust System...993
      Welding And Grinding...994
      Fire Extinguishers...994
    SERIAL NUMBER LOCATIONS...996
      Excavator Serial Number...996
      Engine Serial Number...996
    DELIVERY REPORT...996
    BOBCAT EXCAVATOR IDENTIFICATION...997
  SAFETY AND MAINTENANCE...998
    LIFTING AND BLOCKING THE EXCAVATOR...1000
      Procedure...1000
    LIFTING THE EXCAVATOR...1002
      Procedure...1002
    OPERATOR CAB (ROPS / TOPS)...1004
      Description...1004
      Cab Door...1004
      Front Window...1005
      Front Wiper...1006
      Window Washer Reservoir...1006
      Right Side Window...1007
      Heating, Ventilation And Air Conditioning Duct...1008
    TRANSPORTING THE EXCAVATOR...1010
      Loading And Unloading...1010
      Fastening...1011
    RIGHT SIDE COVER...1012
      Opening And Closing...1012
      Adjusting The Latch...1012
    REAR COVER...1014
      Opening And Closing...1014
    SERVICE SCHEDULE...1016
      Chart...1016
    AIR CLEANER SERVICE...1018
      Daily Check...1018
      Replacing The Filters...1018
    CAB FILTER...1020
      Cleaning And Maintenance...1020
    ENGINE COOLING SYSTEM...1022
      Cleaning...1022
      Checking Level...1022
      Removing And Replacing Coolant...1023
    FUEL SYSTEM...1024
      Fuel Specifications...1024
      Biodiesel Blend Fuel...1024
      Filling The Fuel Tank...1025
      Fuel Filters...1026
      Draining The Fuel Tank...1027
      Removing Air From The Fuel System...1027
    ENGINE LUBRICATION SYSTEM...1028
      Checking And Adding Engine Oil...1028
      Engine Oil Chart...1028
      Removing And Replacing Oil And Filter...1029
    HYDRAULIC SYSTEM...1030
      Checking And Adding Fluid...1030
      Hydraulic Fluid Chart...1031
      Removing And Replacing Hydraulic Filters...1031
      Removing And Replacing Hydraulic Fluid...1035
      Removing Air From Hydraulic Pump...1036
    LUBRICATING THE EXCAVATOR...1038
      Lubrication Locations...1038
    TRAVEL MOTOR...1042
      Checking And Adding Oil...1042
      Removing And Replacing Oil...1042
    SPARK ARRESTOR MUFFLER...1044
      Cleaning Procedure...1044
    ALTERNATOR BELT...1046
      Belt Adjustment...1046
      Belt Replacement...1046
    AIR CONDITIONING BELT...1048
      Belt Adjustment...1048
      Belt Replacement...1049
    SEAT BELT...1050
      Inspection And Maintenance...1050
    PIVOT PINS...1052
      Inspection And Maintenance...1052
    CAB TILT PROCEDURE...1054
      Tilting The Cab...1054
  HYDRAULIC SYSTEM...1056
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1060
    HYDRAULIC SYSTEM INFORMATION...1062
      Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...1062
      Troubleshooting Chart...1065
      Description...1070
    BOOM CYLINDER...1072
      Testing...1072
      Removal And Installation...1074
      Parts Identification...1077
      Disassembly...1078
      Assembly...1085
    ARM CYLINDER...1092
      Testing...1092
      Removal And Installation...1094
      Parts Identification...1096
      Disassembly...1097
      Assembly...1104
    BOOM SWING CYLINDER...1112
      Testing...1112
      Removal And Installation...1113
      Parts Identification...1116
      Disassembly...1117
      Assembly...1124
    BUCKET CYLINDER...1132
      Testing...1132
      Removal And Installation...1132
      Parts Identification...1136
      Disassembly...1137
      Assembly...1144
    BLADE CYLINDER...1152
      Testing...1152
      Removal And Installation...1153
      Parts Identification...1156
      Disassembly...1157
      Assembly...1162
    MAIN RELIEF VALVES...1168
      Testing And Adjusting The Main Relief Valves...1168
    PORT RELIEF VALVES...1172
      Testing And Adjusting Port Relief Valve Pressure...1172
    PRESSURE REDUCING VALVE...1174
      Description...1174
      Testing And Adjusting...1174
    HYDRAULIC CONTROL VALVE...1176
      Removal And Installation...1176
      Parts Identification...1179
      Disassembly And Assembly...1180
      Inlet Valve Section Disassembly And Assembly...1185
      Blade And Upperstructure Swing Valve Section Disassembly And Assembly...1188
      Boom Swing And Tilting Valve Section Disassembly And Assembly...1190
      Boom 2/Auxiliary And Arm 1 Valve Section Disassembly And Assembly...1193
      Left Travel, Inlet And Right Travel Valve Section Disassembly And Assembly...1196
      Boom 1 Disassembly And Assembly...1198
      Arm 2 and Bucket Valve Section Disassembly And Assembly...1202
    HYDRAULIC PUMP...1204
      Testing Information...1204
      Torque Adjustment...1205
      Testing The Piston Pump...1206
      Testing The Gear Pump...1208
      Removal And Installation...1210
      Gear Pump Parts Identification...1213
      Gear Pump Disassembly And Assembly...1214
      Solenoid Valve Parts Identification...1219
      Solenoid Valve Disassembly And Assembly...1220
      Piston Pump Parts Identification...1222
      Piston Pump Disassembly And Assembly...1223
    GEAR PUMP...1232
      Testing Information...1232
      Testing...1232
      Removal And Installation...1234
      Disassembly And Assembly...1236
    ACCUMULATOR...1240
      Description...1240
      Removal And Installation...1240
    TRAVEL MOTOR...1242
      Removal And Installation...1242
      Parts Identification...1243
    SWIVEL JOINT...1246
      Removal And Installation...1246
      Parts Identification...1249
      Disassembly...1250
      Assembly...1251
    SWING MOTOR...1254
      Removal And Installation...1254
      Parts Identification...1256
      Disassembly And Assembly...1257
    SWING MOTOR DRIVE CARRIER...1266
      Removal And Installation...1266
      Parts Identification...1267
      Disassembly And Assembly...1268
    CONTROL PATTERN SELECTOR VALVE...1272
      Removal And Installation...1272
      Parts Identification...1273
      Disassembly...1274
      Assembly...1276
    RIGHT CONTROL LEVER (JOYSTICK)...1278
      Testing...1278
      Handle Removal And Installation...1279
      Joystick Assembly Removal And Installation...1280
      Parts Identification...1282
      Disassembly And Assembly...1283
    LEFT CONTROL LEVER (JOYSTICK)...1288
      Testing...1288
      Handle Removal And Installation...1289
      Joystick Assembly Removal And Installation...1290
      Parts Identification...1292
      Disassembly And Assembly...1293
    BLADE CONTROL VALVE...1298
      Removal And Installation...1298
      Parts Identification...1299
      Disassembly And Assembly...1300
    HYDRAULIC RESERVOIR...1304
      Removal And Installation...1304
    OIL COOLER...1308
      Removal And Installation...1308
    DIRECT TO TANK VALVE...1310
      Removal And Installation...1310
      Disassembly And Assembly...1311
    AUXILIARY BREAKER VALVE...1314
      Description...1314
      Removal And Installation...1314
      Parts Identification...1315
      Disassembly And Assembly...1316
    BOOM SWING VALVE...1318
      Removal And Installation...1318
      Parts Identification...1319
      Disassembly And Assembly...1320
    AUXILIARY HYDRAULIC VALVE...1324
      Removal And Installation...1324
      Parts Identification...1325
      Disassembly And Assembly...1326
    TRAVEL CONTROL VALVE...1330
      Removal And Installation...1330
      Parts Identification...1332
      Disassembly And Assembly...1333
  UNDERCARRIAGE...1338
    BLADE...1340
      Removal And Installation...1340
    TRACKS...1342
      Track Lug Height...1342
      Adjustment...1342
      Rubber Track Removal And Installation...1345
      Steel Track Removal And Installation...1348
    TRACK FRAME...1350
      Disassembly And Assembly...1350
      Recoil Spring Cylinder...1353
    TRACK DAMAGE IDENTIFICATION...1356
      Cutting Of Steel Cords...1356
      Abrasion Of Embedded Metals...1357
      Separation Of Embedded Metals...1358
      Separation Of Embedded Metals Due To Corrosion...1360
      Cuts On The Lug Side Rubber...1361
      Cracks On The Lug Side Rubber Due To Fatigue...1362
      Lug Abrasion...1363
      Cracks And Cuts On The Lug Side Rubber...1364
      Abrasion Of The Track Roller Side...1365
      Cuts On The Edges Of Track Roller Side...1366
    TRACK IDLER...1368
      Parts Identification...1368
      Disassembly...1369
      Assembly...1372
    TRACK ROLLER...1378
      Parts Identification...1378
      Disassembly...1379
      Assembly...1382
    LOWER STEEL TRACK ROLLER...1386
      Parts Identification...1386
      Disassembly...1387
      Assembly...1390
    UPPER ROLLER...1396
      Parts Identification...1396
      Disassembly And Assembly...1397
  UPPERSTRUCTURE & SWING SECTION...1400
    UPPERSTRUCTURE...1402
      Removal...1402
      Installation...1404
    LEFT UPPERSTRUCTURE SIDE COVER...1406
      Removal And Installation...1406
    RIGHT UPPERSTRUCTURE SIDE COVER...1408
      Removal And Installation...1408
    CAB...1410
      Removal And Installation...1410
      Door Removal And Installation...1425
      Front Window Removal And Installation...1426
      Lower Front Window Removal And Installation...1427
      Glass Installation...1428
      Front Window Strut Removal And Installation...1432
      Front Window Slide Bar Removal And Installation...1433
      Cab Tilt Assembly Removal And Installation...1434
      Cab Tilt Parts Identification...1435
      Cab Tilt Assembly Disassembly And Assembly...1436
      Headliner Removal And Installation...1436
    SEAT AND SEAT MOUNT...1442
      Seat Removal And Installation...1442
      Seat Mount Removal And Installation...1443
    RIGHT CONSOLE...1446
      Console Cover Removal And Installation...1446
    LEFT CONSOLE...1448
      Upper Console Cover Removal And Installation...1448
      Lower Console Cover Removal And Installation...1449
      Gas Strut Removal And Installation...1450
      Lock Lever Removal And Installation...1451
      Lock Lever Disassembly And Assembly...1452
      Console Removal And Installation...1453
    FLOORMAT...1454
      Removal And Installation...1454
    FUEL TANK...1456
      Removal And Installation...1456
    HORN...1458
      Removal And Installation...1458
    SWING FRAME...1460
      Removal And Installation...1460
      Bushing Removal...1464
      Bushing Installation...1465
    BOOM...1466
      Removal And Installation...1466
      Bushing Removal And Installation...1467
    ARM...1468
      Removal And Installation...1468
      Arm To Boom Bushing Removal And Installation...1469
      Bucket And Link Bushing Removal And Installation...1470
    ATTACHMENTS...1472
      Installing And Removing The Attachment (Pin-On Attachment)...1472
      Pin-On Inspection...1474
      Installing And Removing The Attachment (Pin-On X- Change Attachment)...1475
      Installing And Removing The Attachment (Bobcat Quick Coupler (BQC) Type SW)...1479
      Quick Coupler (BQC) Type SW And Attachment Inspection...1481
      Installing And Removing The Attachment (Bobcat Quick Coupler (BQC) Type K)...1482
      Quick Coupler (BQC) Type K And Attachment Inspection...1486
    BUCKET...1488
      Bucket Teeth Removal And Installation...1488
      Bucket Side Cutting Edge Removal And Installation...1489
    RIGHT SIDE COVER...1490
      Removal And Installation...1490
    COUNTER WEIGHT...1492
      Removal And Installation...1492
    REAR COVER...1494
      Removal And Installation...1494
  ELECTRICAL SYSTEM AND ANALYSIS...1496
    ELECTRICAL SCHEMATICS...1498
    ELECTRICAL SYSTEM INFORMATION...1499
      Troubleshooting Chart...1499
      Description...1500
      Fuse And Relay Location / Identification...1500
    BATTERY...1503
      Servicing...1503
      Removal And Installation...1504
      Using A Booster Battery (Jump Starting)...1505
    ALTERNATOR...1507
      Belt Adjustment...1507
      Removal And Installation...1507
      Charging System Check...1509
      Alternator Voltage Test...1512
      Low Voltage Test...1512
      High Voltage Test...1513
      Alternator Regulator Test...1514
      Parts Identification...1515
      Disassembly And Assembly...1516
      Stator Continuity Test...1516
      Stator Ground Test...1516
      Rotor Continuity Test...1516
      Rotor Ground Test...1517
    STARTER...1519
      Removal And Installation...1519
      Parts Identification...1521
      Disassembly...1522
      Inspection And Repair...1527
      Assembly...1530
    LIGHTS...1535
      Boom Light Removal And Installation...1535
      Boom Light Bulb Replacement...1535
    CONSOLE LOCKOUT SWITCH...1537
      Testing / Adjustment...1537
      Removal And Installation...1538
    FUEL LEVEL SENDER...1539
      Removal And Installation...1539
    DIAGNOSTIC SERVICE CODE...1541
      Service Codes List...1541
      Flashing Patterns Of Engine Check Lamp...1545
    DIAGNOSTIC TOOL...1547
      Software Installation...1547
      Installation...1549
      Code Retrieval...1552
    KEY SWITCH...1557
      Removal And Installation...1557
    INSTRUMENT PANEL...1559
      Removal And Installation...1559
      Disassembly And Assembly...1560
    RIGHT CONSOLE SWITCH COVER...1563
      Removal And Installation...1563
      Rocker Switch Removal And Installation...1564
      Speed Control Removal And Installation...1565
      Engine Emergency Stop Switch Removal And Installation...1565
      Auxiliary Power Outlet Removal And Installation...1566
    WIPER MOTOR...1567
      Removal And Installation...1567
    FUEL TRANSFER PUMP...1569
      Removal And Installation...1569
  ENGINE SERVICE...1571
    TROUBLESHOOTING...1573
      Chart...1573
    MUFFLER...1575
      Removal And Installation...1575
    AIR CLEANER...1577
      Removal And Installation...1577
    RADIATOR / OIL COOLER...1579
      Removal And Installation...1579
      Disassembly And Assembly...1585
    FUEL COOLER...1587
      Removal And Installation...1587
    ENGINE COMPONENTS AND TESTING...1589
      Engine Compression Checking...1589
      Fuel Injection Pump Removal And Installation...1591
      Fuel Injection Pump Timing...1596
      Fuel Injector Removal And Installation...1600
      Fuel Injector Testing...1602
      Valve Clearance Adjustment...1604
      Cold Start Device Description...1606
      Cold Start Device Testing...1606
      Cold Start Device Removal And Installation...1606
      EGR Valve Description...1607
      EGR Valve Testing...1607
      EGR Valve Removal And Installation...1608
      Manifold Air Heater Description...1609
      Manifold Air Heater Testing...1609
      Manifold Air Heater Removal And Installation...1609
    ENGINE...1611
      Removal And Installation...1611
    ENGINE FLYWHEEL...1619
      Hydraulic Pump Coupler Removal And Installation...1619
      Flywheel Removal And Installation...1620
      Flywheel Ring Gear Removal And Installation...1620
    RECONDITIONING THE ENGINE...1621
      Cylinder Head Removal And Installation...1621
      Cylinder Head Disassembly And Assembly...1622
      Cylinder Head Servicing...1623
      Valve Guide Inspection...1624
      Intake And Exhaust Valve Inspection...1625
      Valve Stem Bend...1625
      Valve Face And Seat...1626
      Valve Spring Inspection...1626
      Push Rod Inspection...1627
      Rocker Arm Inspection...1627
      Valve Bridge Inspection...1628
      Remove Of Timing Gear Case Cover...1628
      Checking Timing Gear Backlash...1629
      Removal Of The Timing Gears...1630
      Camshaft Removal...1631
      Oil Pan Removal And Installation...1633
      Gear Case Removal And Installation...1633
      Crankshaft End Play...1634
      Crankshaft Removal And Installation...1634
      Cylinder Block Inspection...1636
      Piston And Connecting Rod...1636
      Fan Removal And Installation...1639
  HEATING, VENTILATION, AIR CONDITIONING...1641
    EVAPORATOR / HEATER COIL...1643
      Removal And Installation...1643
    HEATER / AC FAN...1645
      Removal And Installation...1645
    HEATER VALVE...1647
      Removal And Installation...1647
    AIR CONDITIONING SYSTEM FLOW...1650
      Principals...1650
      Chart...1651
    COMPONENTS...1653
      Identification...1653
    SAFETY...1657
      Safety Equipment...1657
    REGULAR MAINTENANCE...1659
      Heater Air Filter...1659
      Compressor Belt Inspection...1659
      Cleaning The Condenser...1659
    BASIC TROUBLESHOOTING...1661
      Poor A/C Performance...1661
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1663
      Compressor Oil...1663
      Compressor Oil Check...1664
      Component Replacement And Refrigeration Leaks...1666
    SYSTEM TROUBLESHOOTING CHART...1667
      Blower Motor Does Not Operate...1667
      Blower Motor Operates Normally, But Air Flow Is Insufficient...1667
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...1667
      The Compressor Operates Improperly Or Not At All...1667
      Gauge Pressure Related Troubleshooting...1668
    TEMPERATURE/PRESSURE...1671
      Chart...1671
    AIR CONDITIONING SERVICE...1673
      Chart...1673
    SYSTEM CHARGING AND RECLAMATION...1675
      Reclamation Procedure...1675
      Charging Procedure With A Manifold Gauge Set...1678
    COMPRESSOR...1683
      Removal And Installation...1683
    CONDENSER...1687
      Removal And Installation...1687
    RECEIVER / DRIER...1689
      Removal And Installation...1689
    PRESSURE SWITCH...1691
      Removal And Installation...1691
    EVAPORATOR / HEATER UNIT...1693
      Removal And Installation...1693
    THERMOSTAT...1695
      Inspection...1695
    EXPANSION VALVE...1697
      Removal And Installation...1697
    HVAC CONTROLLER...1699
      Removal And Installation...1699
  SPECIFICATIONS...1701
    SPECIFICATIONS...1703
      E60 Excavator Dimensions...1703
      E60 Excavator Dimensions With Standard Arm...1704
      E60 Excavator Dimensions With Long Arm...1705
      Performance...1706
      Controls...1706
      Engine...1706
      Hydraulic System...1707
      Hydraulic Cylinders...1707
      Hydraulic Cycle Times...1708
      Drive System...1708
      Undercarriage...1708
      Electrical...1708
      Slew System...1708
      Capacities...1708
      Track...1709
      Ground Pressure...1709
    ENGINE SPECIFICATIONS...1711
      Fuel Injection Nozzles...1711
      Fuel Injection Pump...1711
      Cylinder Head...1711
      Valves...1711
      Valve Springs...1712
      Rocker Arm And Shaft...1712
      Camshaft...1712
      Tappet...1713
      Push Rod...1713
      Cylinders...1713
      Piston Rings...1713
      Pistons...1714
      Connecting Rods...1714
      Oil Pump...1714
      Crankshaft...1715
      Thrust Bearing...1715
      Timing Gear Backlash...1715
      Idler Gear Shaft And Bushing...1716
      Engine Bolt Torque...1716
    TORQUE SPECIFICATIONS FOR BOLTS...1717
      Torque For General SAE Bolts...1717
      Torque For General Metric Bolts...1718
    HYDRAULIC CONNECTION SPECIFICATIONS...1719
      O-Ring Face Seal Connection...1719
      Straight Thread O-Ring Fitting...1720
      Tubelines And Hoses...1720
      Flare Fitting...1721
      Port Seal Fitting...1722
      BSPP Swivel Nut...1722
    HYDRAULIC FLUID SPECIFICATIONS...1723
      Specifications...1723
    CONVERSIONS...1725
      Decimal And Millimeter Equivalents...1725
      U.S. To Metric Conversion...1726
  SERVICE MANUAL REVISION...1727
    Revision No: E60-1...1727
    Revision No: E60-2...1729
    Revison No: E60-3...1731
6987193 (2-11) - E80 Compact Excavator Operation & Maintenance Manual...1733
  OPERATOR SAFETY WARNING...1735
  CONTENTS...1737
  FOREWORD...1739
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...1741
    REGULAR MAINTENANCE ITEMS...1741
    SERIAL NUMBER LOCATIONS...1743
      Excavator Serial Number...1743
      Engine Serial Number...1743
    DELIVERY REPORT...1743
    EXCAVATOR IDENTIFICATION...1744
    FEATURES, ACCESSORIES AND ATTACHMENTS...1745
      Standard Items...1745
      Options And Accessories...1745
      Attachments...1745
      Buckets Available...1745
      Falling Object Guards (FOGS)...1746
      Falling Object Guards Kit Inspection And Maintenance...1746
  SAFETY & TRAINING RESOURCES...1747
    SAFETY INSTRUCTIONS...1749
      Before Operation...1749
      Safe Operation Is The Operator’s Responsibility...1750
      Safe Operation Needs A Qualified Operator...1750
      Avoid Silica Dust...1751
    FIRE PREVENTION...1751
      Maintenance...1751
      Operation...1751
      Electrical...1751
      Hydraulic System...1752
      Fueling...1752
      Starting...1752
      Spark Arrestor Exhaust System...1752
      Welding And Grinding...1752
      Fire Extinguishers...1752
    MACHINE SIGNS (DECALS)...1753
    PUBLICATIONS AND TRAINING RESOURCES...1755
  OPERATING INSTRUCTIONS...1757
    INSTRUMENTS AND CONSOLES...1761
      Cab Interior Light...1761
      Left Console...1761
      Right Console...1762
      Function Icons...1763
      STD / ISO Selector Valve...1764
      Integrated Slew Brake...1764
      Raising And Lowering The Console...1764
      Two-Speed Travel...1765
      Engine Speed Control Dial...1765
      Automatic Idle Feature...1765
    OPERATOR CAB...1766
      Description...1766
      Cab Door...1766
      Front Window...1767
      Front Wiper...1768
      Window Washer Reservoir...1768
      Right Side Window...1769
      Heating, Ventilation And Air Conditioning Duct...1770
    TRAVEL CONTROLS...1771
      Description...1771
      Forward And Reverse Travel...1771
      Turning...1771
    EMERGENCY EXITS...1773
      Right Rear Side Window...1773
      Front Window...1773
    MOTION ALARM SYSTEM (IF EQUIPPED)...1774
      Operation...1774
    HYDRAULIC CONTROLS...1775
      Description...1775
      STANDARD Control Pattern...1775
      ISO Control Pattern...1776
      Quick Couplers...1777
      Direct To Tank Valve...1778
      Auxiliary Hydraulics (One Way Flow)...1779
      Auxiliary Hydraulics (Primary Auxiliaries)...1779
      Auxiliary Hydraulics (Secondary Auxiliaries) (If Equipped)...1779
      Relieve Auxiliary Hydraulic Pressure (Excavator And Attachment)...1779
    BLADE CONTROL LEVER...1780
      Operation...1780
    BOOM SWING PEDAL...1780
      Operation...1780
    OVERLOAD WARNING...1781
      Description...1781
      Operation...1781
    BOOM LOAD HOLDING VALVE...1782
      Description...1782
      Lowering Boom With Load Holding Valve...1782
    DAILY INSPECTION...1783
      Daily Inspection And Maintenance...1784
    PRE-STARTING PROCEDURE...1785
      Operation & Maintenance Manual And Operator’s Handbook Locations...1785
      Entering The Excavator...1785
      Seat Adjustment...1786
      Seat Belt Adjustment...1786
      Control Console...1787
      Mirror Adjustment (If Equipped)...1787
    STARTING THE ENGINE...1788
      Key Switch...1788
      Cold Temperature Starting...1789
      Warming The Hydraulic System...1790
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...1791
      Procedure...1791
      Emergency Shut Off...1791
    ATTACHMENTS...1792
      Installing And Removing The Attachment (Pin-On Attachment)...1792
      Installing And Removing The Attachment (Manual Spring Loaded Coupler)...1794
    OPERATING PROCEDURE...1797
      Inspect The Work Area...1797
      Basic Operating Instructions...1797
      Lowering The Work Equipment (Engine STOPPED)...1797
      Lifting A Load...1798
      Excavating...1799
      Boom Swing...1801
      Backfilling...1802
      Driving The Excavator...1802
      Operating On Slopes...1803
      Operating In Water...1805
      Avoiding Track Damage...1806
    TOWING THE EXCAVATOR...1807
      Procedure...1807
    LIFTING THE EXCAVATOR...1808
      Procedure...1808
    TRANSPORTING THE EXCAVATOR ON A TRAILER...1809
      Loading And Unloading...1809
      Fastening...1809
  PREVENTIVE MAINTENANCE...1811
    MAINTENANCE SAFETY...1815
    SERVICE SCHEDULE...1817
      Chart...1817
    CONTROL CONSOLE LOCKOUT...1818
      Inspection And Maintenance...1818
    SEAT BELT...1819
      Inspection And Maintenance...1819
    MOTION ALARM SYSTEM (IF EQUIPPED)...1820
      Description...1820
      Inspecting...1820
      Adjusting Switch Position...1821
    REAR COVER...1822
      Opening And Closing...1822
    CENTER COVER...1822
      Opening And Closing...1822
    RIGHT SIDE COVER...1822
      Opening And Closing...1822
      Adjusting The Latch...1822
    CAB FILTERS...1823
      Cleaning And Maintenance...1823
    AIR CLEANER SERVICE...1824
      Daily Check...1824
      Replacing Filter Elements...1824
    FUEL SYSTEM...1826
      Biodiesel Blend Fuel...1826
      Filling The Fuel Tank...1827
      Fuel Filters...1828
      Draining The Fuel Tank...1829
      Removing Air From The Fuel System...1829
    ENGINE LUBRICATION SYSTEM...1830
      Checking And Adding Engine Oil...1830
      Engine Oil Chart...1830
      Removing And Replacing Oil And Filter...1831
    ENGINE COOLING SYSTEM...1832
      Cleaning...1832
      Checking Level...1832
      Removing And Replacing Coolant...1833
    ELECTRICAL SYSTEM...1834
      Description...1834
      Fuse And Relay Location / Identification...1834
      Battery Maintenance...1836
      Using A Booster Battery (Jump Starting)...1837
      Removing And Installing Battery...1838
    HYDRAULIC SYSTEM...1839
      Checking And Adding Fluid...1839
      Hydraulic Fluid Chart...1840
      Removing And Replacing Hydraulic Filters...1841
      Removing And Replacing Hydraulic Fluid...1844
      Checking Swing Motor Gear Box Fluid Level...1845
      Removing And Replacing Swing Motor Gear Box Fluid...1845
    SPARK ARRESTER MUFFLER...1846
      Cleaning Procedure...1846
    TRACK TENSION...1847
      Adjusting...1847
    TRAVEL MOTOR...1849
      Checking And Adding Oil...1849
      Removing And Replacing Oil...1849
    ALTERNATOR BELT...1850
      Belt Adjustment...1850
      Belt Replacement...1850
    AIR CONDITIONING BELT...1851
      Belt Adjustment...1851
      Belt Replacement...1852
    ATTACHMENT...1853
      Pin-On Inspection And Maintenance...1853
      Manual Spring Loaded Coupler And Attachment Inspection And Maintenance...1853
    TRACK ROLLER AND IDLER LUBRICATION...1854
      Procedure...1854
    BUCKET...1855
      Bucket Teeth Removal And Installation...1855
    LUBRICATING THE EXCAVATOR...1856
      Lubrication Locations...1856
    PIVOT PINS...1859
      Inspection And Maintenance...1859
    EXCAVATOR STORAGE AND RETURN TO SERVICE...1860
      Storage...1860
      Return To Service...1860
  SYSTEM SETUP & ANALYSIS...1861
    DIAGNOSTIC SERVICE CODE...1863
      Service Codes List...1863
    FLASHING PATTERNS OF ENGINE CHECK LAMP...1866
  MACHINE SIGN TRANSLATIONS...1867
    MACHINE SIGN TRANSLATIONS...1869
      Warning (6808185)...1869
      Lift Chart (7168999)...1870
      Service Schedule (7189180)...1873
      Warning (7168995)...1876
      Warning (6804114)...1879
      Warning (6804233)...1879
      Warning (6809832)...1879
      Warning (7169006)...1880
      Joystick Control Pattern Selector (7169008)...1881
      Motion Alarm (6810004)...1882
      Low Sulfur (7152748)...1883
      Eg Coolant (7157847)...1883
  SPECIFICATIONS...1885
    EXCAVATOR SPECIFICATIONS...1887
      Dimensions...1887
      Performance...1889
      Controls...1889
      Engine...1889
      Hydraulic System...1890
      Hydraulic Cylinders...1890
      Hydraulic Cycle Times...1891
      Electrical...1891
      Drive System...1891
      Slew System...1891
      Undercarriage...1891
      Crawler Track Design...1891
      Capacities...1891
      Fuel Tank...1891
      Track...1892
      Type...1892
      Ground Pressure...1892
  WARRANTY...1893
    WARRANTY...1895
  ALPHABETICAL INDEX...1897
6987194 (2-11) - E80 Excavator Service Manual...1899
  MAINTENANCE SAFETY...1901
  CONTENTS...1903
  FOREWORD...1905
    FOREWORD...1907
    SAFETY INSTRUCTIONS...1910
    FIRE PREVENTION...1912
      Maintenance...1912
      Operation...1912
      Electrical...1912
      Hydraulic System...1912
      Fueling...1912
      Starting...1912
      Spark Arrestor Exhaust System...1912
      Welding And Grinding...1913
      Fire Extinguishers...1913
    SERIAL NUMBER LOCATIONS...1914
      Excavator Serial Number...1914
      Engine Serial Number...1914
    DELIVERY REPORT...1915
    BOBCAT EXCAVATOR IDENTIFICATION...1916
  SAFETY & MAINTENANCE...1917
    LIFTING AND BLOCKING THE EXCAVATOR...1919
      Procedure...1919
    LIFTING THE EXCAVATOR...1921
      Procedure...1921
    OPERATOR CAB...1923
      Description...1923
      Cab Door...1923
      Front Window...1924
      Front Wiper...1925
      Window Washer Reservoir...1925
      Right Side Window...1926
      Heating, Ventilation And Air Conditioning Duct...1927
    TRANSPORTING THE EXCAVATOR ON A TRAILER...1929
      Loading And Unloading...1929
      Fastening...1929
    RIGHT SIDE COVER...1931
      Opening And Closing...1931
      Adjusting The Latch...1931
    REAR COVER...1933
      Opening And Closing...1933
    CENTER COVER...1935
      Opening And Closing...1935
    SERVICE SCHEDULE...1937
      Chart...1937
    AIR CLEANER SERVICE...1939
      Daily Check...1939
      Replacing The Filters...1939
    CAB FILTER...1941
      Cleaning And Maintenance...1941
    ENGINE COOLING SYSTEM...1943
      Cleaning...1943
      Checking Level...1943
      Removing And Replacing Coolant...1944
    FUEL SYSTEM...1945
      Fuel Specifications...1945
      Biodiesel Blend Fuel...1945
      Filling The Fuel Tank...1946
      Fuel Filters...1947
      Draining The Fuel Tank...1948
      Removing Air From The Fuel System...1948
    ENGINE LUBRICATION SYSTEM...1949
      Checking And Adding Engine Oil...1949
      Engine Oil Chart...1949
      Removing And Replacing Oil And Filter...1950
    HYDRAULIC SYSTEM...1951
      Checking And Adding Fluid...1951
      Hydraulic Fluid Chart...1952
      Removing And Replacing Hydraulic Filters...1952
      Removing And Replacing Hydraulic Fluid...1956
      Checking Swing Motor Gear Box Fluid Level...1957
      Removing And Replacing Swing Motor Gear Box Fluid...1958
    LUBRICATING THE EXCAVATOR...1959
      Lubrication Locations...1959
    PIVOT PINS...1963
      Inspection And Maintenance...1963
    TRAVEL MOTOR...1965
      Checking And Adding Oil...1965
      Removing And Replacing Oil...1965
    SPARK ARRESTER MUFFLER...1967
      Cleaning Procedure...1967
    EMERGENCY EXIT...1969
      Right Rear Side Window...1969
      Front Window...1969
    SEAT BELT...1971
      Inspection And Maintenance...1971
    CAB TILT PROCEDURE...1973
      Tilting The Cab...1973
    CONTROL CONSOLE LOCKOUTS...1975
      Inspection And Maintenance...1975
    TOWING THE EXCAVATOR...1977
      Procedure...1977
  HYDRAULIC SYSTEM...1979
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1983
    HYDRAULIC SYSTEM INFORMATION...1987
      Glossary Of Hydraulic / Hydrostatic Symbols...1987
      Troubleshooting The Hydraulic Circuit...1990
      Troubleshooting The Cylinder Circuit...1991
      Troubleshooting The Swing (Slew) Circuit...1992
      Troubleshooting The Travel Circuit...1993
      Description...1995
    CYLINDER (BOOM)...1997
      Testing...1997
      Removal And Installation...2000
      Parts Identification...2003
      Disassembly...2004
      Assembly...2012
    CYLINDER (ARM)...2021
      Testing...2021
      Removal And Installation...2023
      Parts Identification...2026
      Disassembly...2027
      Assembly...2035
    CYLINDER (BOOM SWING)...2043
      Testing...2043
      Removal And Installation...2044
      Parts Identification...2047
      Disassembly...2048
      Assembly...2055
    CYLINDER (BUCKET)...2063
      Testing...2063
      Removal And Installation...2063
      Parts Identification...2066
      Disassembly...2067
      Assembly...2076
    CYLINDER (BLADE)...2085
      Testing...2085
      Removal And Installation...2086
      Parts Identification...2089
      Disassembly...2090
      Assembly...2098
    CYLINDER (ARTICULATED BOOM) (OPTIONAL)...2107
      Testing...2107
      Removal And Installation...2109
      Parts Identification...2111
      Disassembly...2112
      Assembly...2118
    VALVES (RELIEF)...2125
      Description...2125
    VALVES (PORT RELIEF)...2127
      Testing And Adjusting The Port Relief Valve Pressure...2127
    VALVE (PILOT PRESSURE RELIEF)...2129
      Testing And Adjusting The Pressure Reducing Valve...2129
    HYDRAULIC CONTROL VALVE...2131
      Description...2131
      Removal And Installation...2131
      Parts Identification...2133
      Disassembly And Assembly...2134
      Inlet Valve Section Disassembly And Assembly...2139
      Boom, Arm And Bucket Valve Section Disassembly And Assembly...2142
      Left Travel, Right Travel And Blade Valve Section Disassembly And Assembly...2146
      Auxiliary And Slew Valve Section Disassembly And Assembly...2150
      Boom Swing Valve Section Disassembly And Assembly...2154
      Articulated Boom Valve Section Disassembly And Assembly...2157
    PUMP (HYDRAULIC PISTON)...2161
      Hydraulic Pump Work Sheet...2161
      Testing Information...2164
      Pump Testing...2166
      Removal And Installation...2174
      Torque Limiter Valve Parts Identification...2176
      Torque Limiter Valve Removal And Installation...2177
      Torque Limiter Valve Disassembly...2178
      Torque Limiter Valve Assembly...2182
      Initial Torque Limiter Valve Setting...2186
      Pump Control Parts Identification...2188
      Pump Control Removal And Installation...2189
      Pump Control Disassembly And Assembly...2190
      Parts Identification...2195
      Disassembly...2196
      Assembly...2204
    PUMP (GEAR)...2213
      Testing Information...2213
      Pump Testing...2213
      Removal And Installation...2215
      Disassembly And Assembly...2217
    MANIFOLD ASSEMBLY / ACCUMULATOR...2221
      Description...2221
      Removal And Installation...2221
      Disassembly And Assembly...2222
    TRAVEL MOTOR...2225
      Removal And Installation...2225
      Parts Identification...2226
      Parts Identification Gear Reduction Hub...2227
      Disassembly...2228
      Assembly...2242
    SWIVEL JOINT...2257
      Removal And Installation...2257
      Parts Identification...2260
      Disassembly...2261
      Assembly...2262
    SWING MOTOR...2265
      Removal And Installation...2265
      Parts Identification...2267
      Disassembly And Assembly...2268
    SWING MOTOR (DRIVE CARRIER)...2277
      Removal And Installation...2277
      Parts Identification...2278
      Disassembly And Assembly...2279
    CONTROL PATTERN SELECTOR VALVE...2283
      Removal And Installation...2283
      Parts Identification...2284
      Disassembly...2285
      Assembly...2287
    RIGHT CONTROL LEVER (JOYSTICK)...2289
      Testing...2289
      Handle Removal And Installation...2290
      Joystick Assembly Removal And Installation...2291
      Parts Identification...2293
      Disassembly And Assembly...2294
    LEFT CONTROL LEVER (JOYSTICK)...2299
      Testing...2299
      Handle Removal And Installation...2300
      Joystick Assembly Removal And Installation...2301
      Parts Identification...2303
      Disassembly And Assembly...2304
    BLADE CONTROL VALVE...2309
      Removal And Installation...2309
      Parts Identification...2310
      Disassembly And Assembly...2311
    HYDRAULIC RESERVOIR...2315
      Removal And Installation...2315
    OIL COOLER...2321
      Removal And Installation...2321
    DIRECT TO TANK VALVE...2323
      Removal And Installation...2323
      Disassembly And Assembly...2324
    AUXILIARY BREAKER VALVE...2325
      Description...2325
      Removal And Installation...2325
      Parts Identification...2326
      Disassembly And Assembly...2327
    BOOM SWING VALVE...2329
      Removal And Installation...2329
      Parts Identification...2330
      Disassembly And Assembly...2331
    AUXILIARY HYDRAULIC VALVE...2335
      Removal And Installation...2335
      Parts Identification...2336
      Disassembly And Assembly...2337
    ARTICULATED BOOM VALVE (OPTIONAL)...2341
      Removal And Installation...2341
      Parts Identification...2342
      Disassembly And Assembly...2343
    TRAVEL CONTROL VALVE...2347
      Removal And Installation...2347
      Parts Identification...2349
      Disassembly And Assembly...2350
    AUTO IDLE VALVE...2355
      Testing And Adjusting...2355
      Removal And Installation...2356
  UNDERCARRIAGE...2359
    BLADE...2361
      Removal And Installation...2361
    TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)...2363
      Track Lug Height...2363
      Checking Tension...2364
      Adjusting Tension...2365
      Track Removal And Installation...2366
      Idler Removal And Installation...2368
      Idler Parts Identification...2369
      Idler Disassembly...2370
      Idler Assembly...2373
      Track Tensioner Removal And Installation...2378
      Track Tensioner Parts Identification...2379
      Track Tensioner Disassembly And Assembly...2380
      Roller Removal And Installation...2382
      Lower Roller Parts Identification...2384
      Lower Roller Disassembly...2385
      Lower Roller Assembly...2388
      Upper Roller Parts Identification...2394
      Upper Roller Disassembly And Assembly...2395
      Sprocket Removal And Installation...2398
    TRACK MAINTENANCE...2399
      Track Damage Identification...2399
    SWING CIRCLE GEAR...2411
      Swing Bearing Removal...2411
      Swing Bearing Installation...2412
    LOWER TRACK ROLLER...2413
      Parts Identification...2413
      Disassembly...2414
      Assembly...2417
    UPPER TRACK ROLLER...2423
      Parts Identification...2423
      Disassembly And Assembly...2424
    SWING CIRCLE GEAR...2427
      Swing Bearing Removal...2427
      Swing Bearing Installation...2428
  UPPERSTRUCTURE & SWING SECTION...2429
    UPPERSTRUCTURE...2433
      Removal...2433
      Installation...2435
    UPPERSTRUCTURE SIDE COVER (LEFT)...2437
      Removal And Installation...2437
    UPPERSTRUCTURE SIDE COVER (RIGHT)...2439
      Removal And Installation...2439
    CAB...2441
      Removal And Installation...2441
      Door Removal And Installation...2455
      Front Window Removal And Installation...2456
      Lower Front Window Removal And Installation...2457
      Glass Installation...2458
      Front Window Strut Removal And Installation...2463
      Front Window Slide Bar Removal And Installation...2464
      Cab Tilt Assembly Removal And Installation...2465
      Cab Tilt Parts Identification...2466
      Cab Tilt Assembly Disassembly And Assembly...2467
      Headliner Removal And Installation...2468
    SEAT...2473
      Seat Removal And Installation...2473
      Seat Mount Removal And Installation...2474
    RIGHT CONSOLE...2477
      Console Cover Removal And Installation...2477
    LEFT CONSOLE...2479
      Lower Console Cover Removal And Installation...2479
      Upper Console Cover Removal And Installation...2480
      Gas Strut Removal And Installation...2481
      Lock Lever Removal And Installation...2482
      Lock Lever Disassembly And Assembly...2483
      Console Removal And Installation...2484
    CENTER COVER...2485
      Removal And Installation...2485
    CENTER ACCESS COVER...2487
      Removal And Installation...2487
    COUNTERWEIGHT...2489
      Removal And Installation...2489
    FLOOR MAT...2493
      Removal And Installation...2493
    FUEL TANK...2495
      Removal And Installation...2495
    HORN...2499
      Removal And Installation...2499
    SWING FRAME...2501
      Removal And Installation...2501
      Bushing Removal...2505
      Bushing Installation...2506
    BOOM...2507
      Removal And Installation...2507
      Bushing Removal And Installation...2508
    BOOM (ARTICULATED) (OPTIONAL)...2509
      Removal And Installation...2509
    ARM...2511
      Removal And Installation...2511
      Arm To Boom Bushing Removal And Installation...2512
      Bucket And Link Bushing Removal And Installation...2513
    QUICK COUPLER (KLAC SYSTEM™)...2515
      Troubleshooting...2515
      Daily Inspection...2515
      Removal And Installation...2516
      Parts Identification...2518
      Disassembly...2519
      Assembly...2521
    QUICK COUPLER (LEHNHOFF SYSTEM®)...2523
      Troubleshooting...2523
      Daily Inspection...2523
      Removal (MS03 And MS08)...2524
      Installation (MS03 And MS08)...2525
      Parts Identification (MS03)...2526
      Disassembly And Assembly (MS03)...2527
      Parts Identification (MS08)...2528
      Disassembly (MS08)...2529
      Assembly (MS08)...2533
    BUCKET...2537
      Bucket Teeth Removal And Installation...2537
      Bucket Side Cutting Edge Removal And Installation...2538
    RIGHT SIDE COVER...2539
      Removal And Installation...2539
      Latch Adjustment...2541
    REAR COVER...2543
      Removal And Installation...2543
  ELECTRICAL SYSTEM & ANALYSIS...2545
    ELECTRICAL SCHEMATICS...2547
    ELECTRICAL SYSTEM INFORMATION...2548
      Troubleshooting Chart...2548
      Description...2549
      Fuse And Relay Location / Identification...2549
    BATTERY...2552
      Servicing...2552
      Removal And Installation...2553
      Using A Booster Battery (Jump Starting)...2554
    ALTERNATOR...2556
      Belt Adjustment...2556
      Belt Replacement...2556
      Charging System Inspection...2557
      Alternator Voltage Testing...2559
      Low Voltage Testing...2560
      High Voltage Testing...2560
      Alternator Regulator Testing...2561
      Removal And Installation...2562
      Parts Identification...2564
    STARTER...2566
      Testing...2566
      Removal And Installation...2567
      Parts Identification...2569
    LIGHTS...2570
      Boom Light Removal And Installation...2570
      Boom Light Bulb Replacement...2570
    CONSOLE LOCKOUT SWITCH...2572
      Testing / Adjustment...2572
      Removal And Installation...2573
    FUEL LEVEL SENDER...2574
      Removal And Installation...2574
    DIAGNOSTIC SERVICE CODE...2576
      Service Codes List...2576
      Flashing Patterns Of Engine Check Lamp...2579
    DIAGNOSTIC TOOL...2580
      Software Installation...2580
      Installation...2582
      Code Retrieval...2585
    INSTRUMENT PANEL...2590
      Removal And Installation...2590
      Disassembly And Assembly...2591
    KEY SWITCH...2594
      Removal And Installation...2594
    RIGHT CONSOLE SWITCH COVER...2596
      Removal And Installation...2596
      Rocker Switch Removal And Installation...2597
      Speed Control Removal And Installation...2598
      Engine Emergency Stop Switch Removal And Installation...2598
      Auxiliary Power Outlet Removal And Installation...2599
    WIPER MOTOR...2600
      Removal And Installation...2600
    MOTION ALARM SYSTEM (IF EQUIPPED)...2602
      Description...2602
      Inspecting...2602
      Adjusting Switch Position...2603
    FUEL TRANSFER PUMP...2604
      Removal And Installation...2604
    AUTO IDLE PRESSURE SWITCH...2606
      Removal And Installation...2606
  ENGINE SERVICE...2608
    ENGINE INFORMATION...2610
      Description...2610
      Specifications...2611
      Troubleshooting...2617
      Engine Removal And Installation...2618
      Compression - Testing...2625
    ENGINE SPEED CONTROL...2628
      Adjustment...2628
    MUFFLER...2630
      Removal And Installation...2630
    AIR CLEANER...2632
      Housing Removal And Installation...2632
    ENGINE COOLING SYSTEM...2634
      Radiator Removal And Installation...2634
      Radiator Disassembly And Assembly...2641
      Fan Removal And Installation...2643
      Fuel Cooler Removal And Installation...2644
      Water Pump Removal And Installation...2645
      Water Pump Parts Identification...2646
      Thermostat Removal And Installation...2647
      Temperature Switch - Testing...2647
      Temperature Sensor - Testing...2648
      Thermostat - Testing...2648
    LUBRICATION SYSTEM...2650
      Oil Pan Removal And Installation...2650
      Oil Pump Removal And Installation...2651
      Oil Pump Inspection...2653
      Engine Oil Pressure - Testing...2655
    FUEL SYSTEM...2656
      Fuel Injection Pump Removal And Installation...2656
      Fuel Injection Pump - Timing...2661
      Fuel Injector Removal And Installation...2665
      Fuel Injector Pressure - Testing...2667
      Nozzle Spray Condition...2667
    CYLINDER HEAD...2670
      Valve Clearance Adjustment...2670
      Cylinder Head Removal And Installation...2672
      Cylinder Head Disassembly And Assembly...2673
      Cylinder Head - Servicing...2674
      Valve Guide - Inspection...2675
      Intake And Exhaust Valve - Inspection...2676
      Valve Stem Bend - Inspection...2676
      Valve Face And Seat...2677
      Valve Spring - Inspection...2677
      Push Rod - Inspection...2678
      Rocker Arm - Inspection...2678
      Valve Bridge - Inspection...2679
    CRANKSHAFT AND PISTONS...2680
      Piston And Connecting Rod Removal And Installation...2680
      Piston And Connecting Rod - Servicing...2681
      Cylinder Bore - Inspection...2683
      Crankshaft End Play...2683
      Crankshaft And Bearings Removal And Installation...2684
      Crankshaft And Bearings - Servicing...2685
    CAMSHAFT AND TIMING GEARS...2686
      Timing Gear Case Cover Removal And Installation...2686
      Timing Gear Backlash - Inspection...2687
      Idler Gear And Camshaft Removal And Installation...2688
      Camshaft - Servicing...2689
      Idler Gear And Shaft - Servicing...2690
    COLD START DEVICE...2692
      Description...2692
      Testing...2692
      Removal And Installation...2692
    EXHAUST GAS RECIRCULATION VALVE (EGR)...2694
      Description...2694
      Testing...2694
      Removal And Installation...2695
    MANIFOLD AIR HEATER...2696
      Description...2696
      Testing...2696
      Removal And Installation...2696
    ENGINE FLYWHEEL...2698
      Hydraulic Pump Coupler Removal And Installation...2698
      Flywheel Removal And Installation...2699
      Flywheel Ring Gear Removal And Installation...2699
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...2700
    AIR CONDITIONING SYSTEM FLOW...2702
      Description...2702
      Chart...2703
      Components...2704
      Safety Equipment...2707
    REGULAR MAINTENANCE...2708
      Filters...2708
      Belt Adjustment...2708
      Belt Replacement...2709
      Condenser...2710
      Air Conditioning Service Chart...2711
      Evaporator / Heater Coil...2712
    TROUBLESHOOTING...2714
      Blower Motor Does Not Operate...2714
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2714
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...2714
      The Compressor Operates Improperly Or Not At All...2714
      Gauge Pressure Related Troubleshooting...2715
      Temperature / Pressure Chart...2717
      Poor A/C Performance...2718
      HVAC Repair And Leaks...2719
    SYSTEM CHARGING AND RECLAMATION...2720
      Reclamation And Charging With Recovery / Charging Unit...2720
      Charging With A Manifold Gauge Set...2723
    COMPRESSOR...2726
      Removal And Installation...2726
      Oil...2728
      Oil Check...2729
    CONDENSER...2732
      Removal And Installation...2732
    RECEIVER / DRIER...2734
      Receiver / Drier Removal And Installation...2734
      Pressure Switch Removal And Installation...2735
    EVAPORATOR / HEATER UNIT...2736
      Removal And Installation...2736
    THERMOSTAT...2738
      Inspection...2738
    EXPANSION VALVE...2740
      Removal And Installation...2740
    BLOWER FAN...2742
      Removal And Installation...2742
    HEATER VALVE...2744
      Removal And Installation...2744
    HVAC CONTROLLER...2746
      Removal And Installation...2746
  SPECIFICATIONS...2748
    E80 EXCAVATOR SPECIFICATIONS...2750
      Machine Dimensions...2750
      Machine Dimensions (Articulated Boom)...2751
      Machine Dimensions (Standard Arm)...2753
      Machine Dimensions (Long Arm)...2754
      Performance...2755
      Controls...2755
      Engine...2755
      Hydraulic System...2756
      Hydraulic Cylinders...2756
      Hydraulic Cycle Times...2757
      Electrical...2757
      Drive System...2757
      Slew System...2757
      Undercarriage...2757
      Capacities...2757
      Tracks...2758
      Ground Pressure...2758
    TORQUE SPECIFICATIONS FOR BOLTS...2760
      Torque For General SAE Bolts...2760
      Torque For General Metric Bolts...2761
    HYDRAULIC CONNECTION SPECIFICATIONS...2762
      O-ring Face Seal Connection...2762
      Straight Thread O-ring Fitting...2763
      Tubelines And Hoses...2763
      Flare Fitting...2763
      Port Seal Fitting...2764
    HYDRAULIC FLUID SPECIFICATIONS...2766
      Specifications...2766
    CONVERSIONS...2768
      Decimal And Millimeter Equivalent Chart...2768
      U.S. To Metric Conversion Chart...2768
  ALPHABETICAL INDEX...2770
  SERVICE MANUAL REVISION...2772
    Revision No: E80 - 1...2772
    Revision No: E80 - 2...2774
    Revision No: E80 - 3...2776
6990613 (06-13) - E63 Compact Excavator Service Manual...2778
  MAINTENANCE SAFETY...2780
  CONTENTS...2782
  FOREWORD...2784
    FOREWORD...2786
    SAFETY INSTRUCTIONS...2788
    FIRE PREVENTION...2790
      Maintenance...2790
      Operation...2790
      Electrical...2790
      Hydraulic System...2790
      Fueling...2790
      Starting...2790
      Spark Arrester Exhaust System...2790
      Welding And Grinding...2791
      Fire Extinguishers...2791
    SERIAL NUMBER LOCATIONS...2792
      Excavator Serial Number...2792
      Engine Serial Number...2792
    DELIVERY REPORT...2793
    EXCAVATOR IDENTIFICATION...2794
  SAFETY AND MAINTENANCE...2796
    LIFTING AND BLOCKING THE EXCAVATOR...2798
      Procedure...2798
    LIFTING THE EXCAVATOR...2800
      Procedure...2800
    OPERATOR CAB...2802
      Description...2802
      Cab Door...2802
      Front Window...2803
      Front Wiper...2804
      Window Washer Reservoir...2804
      Right Side Window...2805
      Heating, Ventilation And Air Conditioning Duct...2806
    TRANSPORTING THE EXCAVATOR ON A TRAILER...2808
      Loading And Unloading...2808
      Fastening...2809
    RIGHT SIDE COVER...2810
      Opening And Closing...2810
      Adjusting The Latch...2810
    REAR COVER...2812
      Opening And Closing...2812
    SERVICE SCHEDULE...2814
      Maintenance Intervals...2814
    AIR CLEANER SERVICE...2816
      Daily Check...2816
      Replacing The Filters...2817
    CAB FILTER...2818
      Cleaning And Maintenance...2818
    ENGINE COOLING SYSTEM...2820
      Cleaning...2820
      Checking Level...2820
      Removing And Replacing Coolant...2821
    FUEL SYSTEM...2822
      Fuel Specifications...2822
      Biodiesel Blend Fuel...2822
      Filling The Fuel Tank...2823
      Fuel Filters...2824
      Draining The Fuel Tank...2826
      Removing Air From The Fuel System...2826
    ENGINE LUBRICATION SYSTEM...2828
      Checking And Adding Engine Oil...2828
      Engine Oil Chart...2828
      Removing And Replacing Oil And Filter...2829
    HYDRAULIC SYSTEM...2832
      Checking And Adding Fluid...2832
      Hydraulic Fluid Chart...2833
      Removing And Replacing Hydraulic Filters...2833
      Removing And Replacing Hydraulic Fluid...2837
      Removing Air From Hydraulic Pump...2838
    LUBRICATING THE EXCAVATOR...2840
      Lubrication Locations...2840
    PIVOT PINS...2844
      Inspection And Maintenance...2844
    TRAVEL MOTOR...2846
      Checking And Adding Oil...2846
      Removing And Replacing Oil...2846
    DIESEL PARTICULATE FILTER (DPF) SYSTEM...2848
      Description...2848
      Remote Parked Regeneration...2848
      Service Regeneration...2850
      DPF Cleaning...2850
    EMERGENCY EXIT...2852
      Right Rear Side Window...2852
      Front Window...2852
    SEAT BELT...2854
      Inspection And Maintenance...2854
    CAB TILT PROCEDURE...2856
      Tilting The Cab...2856
    CONTROL CONSOLE LOCKOUTS...2858
      Inspection And Maintenance...2858
    TOWING THE EXCAVATOR...2860
      Procedure...2860
  HYDRAULIC SYSTEM...2862
    HYDRAULIC / HYDROSTATIC SCHEMATICS...2866
    HYDRAULIC SYSTEM INFORMATION...2868
      Glossary Of Hydraulic / Hydrostatic Symbols...2868
      Troubleshooting The Hydraulic Circuit...2871
      Troubleshooting The Cylinder Circuit...2872
      Troubleshooting The Swing (Slew) Circuit...2873
      Troubleshooting The Travel Circuit...2874
    CYLINDER (BOOM)...2876
      Testing...2876
      Removal And Installation...2878
      Parts Identification...2881
      Disassembly...2882
      Assembly...2889
    CYLINDER (ARM)...2896
      Testing...2896
      Removal And Installation...2898
      Parts Identification...2900
      Disassembly...2901
      Assembly...2908
    CYLINDER (BOOM SWING)...2916
      Testing...2916
      Removal And Installation...2917
      Parts Identification...2920
      Disassembly...2921
      Assembly...2928
    CYLINDER (BUCKET)...2936
      Testing...2936
      Removal And Installation...2936
      Parts Identification...2940
      Disassembly...2941
      Assembly...2948
    CYLINDER (BLADE)...2956
      Testing...2956
      Removal And Installation...2957
      Parts Identification...2960
      Disassembly...2961
      Assembly...2966
    VALVES (MAIN RELIEF)...2972
      Testing And Adjusting...2972
    VALVES (PORT RELIEF)...2974
      Testing And Adjusting The Port Relief Valve Pressure...2974
    VALVE (PILOT PRESSURE RELIEF)...2976
      Testing And Adjusting The Pressure Reducing Valve...2976
    HYDRAULIC CONTROL VALVE...2978
      Removal And Installation...2978
    HYDRAULIC PUMP...2982
      Removal And Installation...2982
    MANIFOLD ASSEMBLY / ACCUMULATOR...2984
      Description...2984
      Removal And Installation...2984
      Disassembly And Assembly...2985
    TRAVEL MOTOR...2988
      Removal And Installation...2988
      Parts Identification Hydraulic Motor...2989
      Parts Identification Gear Reduction Hub...2990
      Disassembly...2991
      Assembly...3007
    SWIVEL JOINT...3024
      Removal And Installation...3024
      Parts Identification...3027
      Disassembly...3028
      Assembly...3029
    SWING MOTOR...3032
      Removal And Installation...3032
      Parts Identification...3034
      Disassembly And Assembly...3035
    SWING MOTOR (DRIVE CARRIER)...3044
      Removal And Installation...3044
      Parts Identification...3045
      Disassembly And Assembly...3046
    CONTROL PATTERN SELECTOR VALVE...3050
      Removal And Installation...3050
      Disassembly And Assembly...3051
    RIGHT CONTROL LEVER (JOYSTICK)...3054
      Testing...3054
      Handle Removal And Installation...3055
      Joystick Assembly Removal And Installation...3056
      Parts Identification...3058
      Disassembly And Assembly...3059
    LEFT CONTROL LEVER (JOYSTICK)...3064
      Testing...3064
      Handle Removal And Installation...3065
      Joystick Assembly Removal And Installation...3066
      Parts Identification...3068
      Disassembly And Assembly...3069
    BLADE CONTROL VALVE...3074
      Removal And Installation...3074
      Parts Identification...3075
      Disassembly And Assembly...3076
    HYDRAULIC RESERVOIR...3080
      Removal And Installation...3080
    OIL COOLER...3084
      Removal And Installation...3084
    DIRECT TO TANK VALVE...3086
      Removal And Installation...3086
      Disassembly And Assembly...3087
    SWING MOTOR BRAKE SHUTTLE VALVE...3088
      Removal And Installation...3088
      Parts Identification...3089
      Disassembly And Assembly...3090
    PILOT VALVE...3092
      Description...3092
      Removal And Installation...3092
      Parts Identification...3093
      Disassembly And Assembly...3094
    FORCED REGENERATION VALVE...3096
      Removal And Installation...3096
      Disassembly And Assembly...3096
    TRAVEL CONTROL VALVE...3098
      Removal And Installation...3098
      Parts Identification...3100
      Disassembly And Assembly...3101
    AUTO IDLE...3106
      Description...3106
  UNDERCARRIAGE...3108
    BLADE...3110
      Removal And Installation...3110
    TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)...3112
      Description...3112
      Track Lug Height...3112
      Checking Tension...3113
      Adjusting Tension...3114
      Track Removal And Installation...3115
      Idler Removal And Installation...3117
      Idler Parts Identification...3118
      Idler Disassembly...3119
      Idler Assembly...3122
      Tensioner Removal And Installation...3127
      Track Tensioner Parts Identification...3128
      Track Tensioner Disassembly And Assembly...3129
      Roller Removal And Installation...3130
      Roller Parts Identification...3131
      Roller Disassembly...3132
      Roller Assembly...3135
      Sprocket Removal And Installation...3139
    TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)...3140
      Description...3140
      Checking Tension...3141
      Adjusting Tension...3142
      Track Removal...3143
      Track Installation...3145
      Idler Removal And Installation...3146
      Idler Parts Identification...3147
      Idler Disassembly...3148
      Idler Assembly...3151
      Track Tensioner Removal And Installation...3156
      Track Tension Parts Identification...3157
      Track Tensioner Disassembly And Assembly...3158
      Roller Removal And Installation...3159
      Roller Parts Identification...3160
      Roller Disassembly...3161
      Roller Assembly...3164
      Sprocket Removal And Installation...3168
      Guide Plate Removal And Installation...3168
    TRACK MAINTENANCE...3170
      Track Damage Identification...3170
    SWING CIRCLE GEAR...3182
      Swing Bearing Removal...3182
      Swing Bearing Installation...3182
  UPPERSTRUCTURE AND SWING SECTION...3184
    UPPERSTRUCTURE...3186
      Removal...3186
      Installation...3188
    CAB...3190
      Removal And Installation...3190
      Door Removal And Installation...3200
      Front Window Removal And Installation...3201
      Lower Front Window Removal And Installation...3202
      Glass Installation...3203
      Front Window Strut Removal And Installation...3208
      Front Window Slide Bar Removal And Installation...3209
      Cab Tilt Assembly Removal And Installation...3210
      Cab Tilt Parts Identification...3211
      Cab Tilt Assembly Disassembly And Assembly...3212
      Headliner Removal And Installation...3213
    SEAT...3218
      Seat Removal And Installation...3218
      Seat Mount Removal And Installation...3219
    RIGHT CONSOLE...3222
      Console Cover Removal And Installation...3222
    LEFT CONSOLE...3224
      Lower Console Cover Removal And Installation...3224
      Upper Console Cover Removal And Installation...3225
      Gas Strut Removal And Installation...3226
      Lock Lever Removal And Installation...3227
      Lock Lever Disassembly And Assembly...3228
      Console Removal And Installation...3229
    LEFT UPPERSTRUCTURE COVER...3230
      Removal And Installation...3230
    RIGHT UPPERSTRUCTURE COVER...3232
      Removal And Installation...3232
    COUNTER WEIGHT...3234
      Removal And Installation...3234
    FLOOR MAT...3236
      Removal And Installation...3236
    FUEL TANK...3238
      Removal And Installation...3238
    HORN...3240
      Removal And Installation...3240
    SWING FRAME...3242
      Removal And Installation...3242
      Bushing Removal...3246
      Bushing Installation...3247
    BOOM...3248
      Removal And Installation...3248
      Bushing Removal And Installation...3249
    ARM (STANDARD AND LONG)...3250
      Removal And Installation...3250
      Arm To Boom Bushing Removal And Installation...3251
      Bucket And Link Bushing Removal And Installation...3252
    BUCKET...3254
      Bucket Teeth Removal And Installation...3254
      Bucket Side Cutting Edge Removal And Installation...3255
    REAR COVER...3256
      Removal And Installation...3256
    QUICK COUPLER (KLAC™ SYSTEM)...3258
      Troubleshooting...3258
      Daily Inspection...3258
      Removal And Installation...3259
      Parts Identification...3261
      Disassembly...3262
      Assembly...3264
    QUICK COUPLER (LEHNHOFF® SYSTEM)...3266
      Troubleshooting...3266
      Daily Inspection...3266
      Removal (MS03 And MS08)...3267
      Installation (MS03 And MS08)...3268
      Parts Identification (MS03)...3269
      Disassembly And Assembly (MS03)...3270
      Parts Identification (MS08)...3271
      Disassembly (MS08)...3272
      Assembly (MS08)...3276
    RIGHT SIDE COVER...3280
      Removal And Installation...3280
  ELECTRICAL SYSTEM AND ANALYSIS...3282
    ELECTRICAL SCHEMATIC...3284
    ELECTRICAL SYSTEM INFORMATION...3285
      Troubleshooting Chart...3285
      Description...3286
      Fuse And Relay Location / Identification...3286
      Engine Control Unit (ECU)...3288
    BATTERY...3289
      Battery Maintenance...3289
      Using A Booster Battery (Jump Starting)...3290
      Removing And Installing Battery...3291
    ALTERNATOR...3293
      Belt Adjustment...3293
      Belt Replacement...3293
      Charging System Inspection...3294
      Alternator Voltage Testing...3296
      Removal And Installation...3297
    STARTER...3299
      Testing...3299
      Removal And Installation...3300
      Parts Identification...3302
    LIGHTS...3303
      Boom Light Removal And Installation...3303
      Boom Light Bulb Replacement...3303
    CONSOLE LOCKOUT SWITCH...3305
      Testing / Adjustment...3305
      Removal And Installation...3306
    FUEL LEVEL SENDER...3307
      Removal And Installation...3307
    DIAGNOSTIC SERVICE CODE...3309
      Service Codes List...3309
      Flashing Patterns Of Engine Check Lamp...3315
    DIAGNOSTIC TOOL...3317
      Software Installation...3317
      Installation...3319
      Code Retrieval...3322
    INSTRUMENT PANEL...3327
      Removal And Installation...3327
    KEY SWITCH...3329
      Removal And Installation...3329
    RIGHT CONSOLE SWITCH COVER...3331
      Removal And Installation...3331
      Rocker Switch Removal And Installation...3332
      Speed Control Removal And Installation...3333
      Engine Emergency Stop Switch Removal And Installation...3333
      Auxiliary Power Outlet Removal And Installation...3334
    WIPER MOTOR...3335
      Removal And Installation...3335
    MOTION ALARM SYSTEM...3337
      Description...3337
      Inspecting...3337
      Adjusting Switch Position...3338
    FUEL TRANSFER PUMP...3339
      Removal And Installation...3339
    AUTO IDLE PRESSURE SWITCH...3341
      Removal And Installation...3341
  ENGINE SERVICE...3343
    ENGINE INFORMATION...3345
      Description...3345
      Specifications...3346
      Sensor Location...3352
      Troubleshooting...3354
      Engine Removal And Installation...3355
      Compression - Testing...3362
    ENGINE SPEED CONTROL...3365
      Adjustment...3365
    DIESEL PARTICULATE FILTER (DPF) SYSTEM...3367
      Description...3367
      Removal And Installation...3368
    AIR CLEANER...3371
      Housing Removal And Installation...3371
    ENGINE COOLING SYSTEM...3373
      Radiator Removal And Installation...3373
      Radiator Disassembly And Assembly...3377
      Fan Removal And Installation...3379
      Fuel Cooler Removal And Installation...3380
      Water Pump Removal And Installation...3381
      Water Pump Parts Identification...3382
      Thermostat Removal And Installation...3383
      Temperature Switch - Testing...3383
      Temperature Sensor - Testing...3384
      Thermostat - Testing...3384
    LUBRICATION SYSTEM...3385
      Oil Pan Removal And Installation...3385
      Oil Pump Removal And Installation...3386
      Oil Pump Inspection...3387
      Engine Oil Pressure - Testing...3388
      Crankcase Ventilation Filter Removal And Installation...3389
    FUEL SYSTEM...3391
      Electronic Fuel Injection Schematic - Components...3391
      Fuel Supply Pump Removal And Installation...3392
      Fuel Rail Assembly Removal And Installation...3397
      Fuel Injector Removal And Installation...3399
    CYLINDER HEAD...3401
      Valve Clearance Adjustment...3401
      Cylinder Head Removal And Installation...3403
      Cylinder Head Disassembly And Assembly...3405
      Cylinder Head - Servicing...3408
      Valve Guide - Inspection...3408
      Intake And Exhaust Valve - Inspection...3409
      Valve Stem Bend - Inspection...3410
      Valve Face And Seat...3410
      Valve Spring - Inspection...3411
      Push Rod - Inspection...3411
      Rocker Arm - Inspection...3412
    CRANKSHAFT AND PISTONS...3413
      Piston And Connecting Rod Removal And Installation...3413
      Piston And Connecting Rod - Servicing...3417
      Cylinder Bore - Inspection...3420
      Crankshaft End Play...3421
      Crankshaft And Bearings Removal And Installation...3421
      Crankshaft And Bearings - Servicing...3422
    CAMSHAFT AND TIMING GEARS...3425
      Timing Gear Case Cover Removal And Installation...3425
      Timing Gear Backlash - Inspection...3426
      Idler Gear And Camshaft Removal And Installation...3427
      Valve Tappet - Servicing...3428
      Camshaft - Servicing...3429
      Idler Gear And Shaft - Servicing...3430
    EXHAUST GAS RECIRCULATION (EGR) VALVE...3431
      Description...3431
      Removal And Installation...3432
      EGR Valve Testing And Cleaning...3433
      Lead (Reed) Valve Cleaning...3433
      EGR Cooler Cleaning...3434
      Intake Throttle...3435
    GLOW PLUGS...3437
      Testing...3437
      Removal And Installation...3438
    ENGINE FLYWHEEL...3439
      Hydraulic Pump Coupler Removal And Installation...3439
      Flywheel Removal And Installation...3440
      Flywheel Ring Gear Removal And Installation...3440
  HEATING, VENTILATION AND AIR CONDITIONING...3441
    AIR CONDITIONING SYSTEM FLOW...3443
      Description...3443
      Chart...3444
      Components...3445
      Safety Equipment...3448
    REGULAR MAINTENANCE...3449
      Filters...3449
      Belt Adjustment...3449
      Belt Replacement...3450
      Condenser...3451
      Air Conditioning Service Chart...3452
      Evaporator / Heater Coil...3453
    TROUBLESHOOTING...3455
      Blower Motor Does Not Operate...3455
      Blower Motor Operates Normally, But Air Flow Is Insufficient...3455
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...3455
      The Compressor Operates Improperly Or Not At All...3455
      Gauge Pressure Related Troubleshooting...3456
      Temperature / Pressure Chart...3458
      Poor A/C Performance...3459
      HVAC Repair And Leaks...3460
    SYSTEM CHARGING AND RECLAMATION...3461
      Reclamation And Charging With Recovery / Charging Unit...3461
      Charging With A Manifold Gauge Set...3464
    COMPRESSOR...3467
      Removal And Installation...3467
      Oil...3469
      Oil Check...3470
    CONDENSER...3473
      Removal And Installation...3473
    RECEIVER / DRIER...3475
      Receiver / Drier Removal And Installation...3475
      Pressure Switch Removal And Installation...3476
    EVAPORATOR / HEATER UNIT...3477
      Removal And Installation...3477
    THERMOSTAT...3479
      Inspection...3479
    EXPANSION VALVE...3481
      Removal And Installation...3481
    BLOWER FAN...3483
      Removal And Installation...3483
    HEATER VALVE...3485
      Removal And Installation...3485
    HVAC CONTROLLER...3487
      Removal And Installation...3487
  SPECIFICATIONS...3489
    EXCAVATOR SPECIFICATIONS...3491
      Dimensions...3491
      Performance...3493
      Controls...3493
      Engine...3493
      Hydraulic System...3494
      Hydraulic Cylinders...3494
      Hydraulic Cycle Times...3495
      Electrical...3495
      Drive System...3495
      Slew System...3495
      Undercarriage...3495
      Crawler Track Design...3495
      Capacities...3495
      Fuel Tank...3495
      Track...3496
      Type...3496
      Ground Pressure...3496
    TORQUE SPECIFICATIONS FOR BOLTS...3497
      Torque For General SAE Bolts...3497
      Torque For General Metric Bolts...3498
    HYDRAULIC CONNECTION SPECIFICATIONS...3499
      O-ring Face Seal Connection...3499
      Straight Thread O-ring Fitting...3500
      Tubelines And Hoses...3500
      Flare Fitting...3501
      Port Seal Fitting...3502
      BSPP Swivel Nut...3502
    HYDRAULIC FLUID SPECIFICATIONS...3503
      Specifications...3503
    CONVERSIONS...3505
      Decimal And Millimeter Equivalent Chart...3505
      U.S. To Metric Conversion Chart...3506
    SERVICE TOOLS REQUIRED...3507
      Remote Start Tools...3507
      Hydraulic Tools...3508
      Engine Tools...3510
      HVAC Tools...3511
  ALPHABETICAL INDEX...3513
6990617 (06-13) - E85 Excavator Service Manual...3515
  MAINTENANCE SAFETY...3517
  CONTENTS...3519
  FOREWORD...3521
    FOREWORD...3523
    SAFETY INSTRUCTIONS...3525
    FIRE PREVENTION...3527
      Maintenance...3527
      Operation...3527
      Electrical...3527
      Hydraulic System...3527
      Fueling...3527
      Starting...3527
      Spark Arrestor Exhaust System...3527
      Welding And Grinding...3528
      Fire Extinguishers...3528
    SERIAL NUMBER LOCATIONS...3529
      Excavator Serial Number...3529
      Engine Serial Number...3529
    DELIVERY REPORT...3530
    EXCAVATOR IDENTIFICATION...3531
  SAFETY AND MAINTENANCE...3533
    LIFTING AND BLOCKING THE EXCAVATOR...3537
      Procedure...3537
    LIFTING THE EXCAVATOR...3539
      Procedure...3539
    OPERATOR CAB...3541
      Description...3541
      Cab Door...3541
      Front Window...3542
      Front Wiper...3543
      Window Washer Reservoir...3543
      Right Side Window...3544
      Heating, Ventilation And Air Conditioning Duct...3545
    TRANSPORTING THE EXCAVATOR ON A TRAILER...3547
      Loading And Unloading...3547
      Fastening...3547
    RIGHT SIDE COVER...3549
      Opening And Closing...3549
      Adjusting The Latch...3549
    REAR COVER...3551
      Opening And Closing...3551
    CENTER COVER...3553
      Opening And Closing...3553
    SERVICE SCHEDULE...3555
      Maintenance Intervals...3555
    AIR CLEANER SERVICE...3557
      Daily Check...3557
      Replacing The Filters...3558
    CAB FILTER...3559
      Cleaning And Maintenance...3559
    ENGINE COOLING SYSTEM...3561
      Cleaning...3561
      Checking Level...3561
      Removing And Replacing Coolant...3562
    FUEL SYSTEM...3563
      Fuel Specifications...3563
      Biodiesel Blend Fuel...3563
      Filling The Fuel Tank...3564
      Fuel Filters...3565
      Replacing Elements...3565
      Draining The Fuel Tank...3567
      Removing Air From The Fuel System...3567
    ENGINE LUBRICATION SYSTEM...3569
      Checking And Adding Engine Oil...3569
      Engine Oil Chart...3569
      Removing And Replacing Oil And Filter...3570
    HYDRAULIC SYSTEM...3571
      Checking And Adding Fluid...3571
      Hydraulic Fluid Chart...3572
      Removing And Replacing Hydraulic Filters...3572
      Removing And Replacing Hydraulic Fluid...3576
      Checking Swing Motor Gear Box Fluid Level...3578
      Removing And Replacing Swing Motor Gear Box Fluid...3578
    LUBRICATING THE EXCAVATOR...3579
      Lubrication Locations...3579
    PIVOT PINS...3583
      Inspection And Maintenance...3583
    TRAVEL MOTOR...3585
      Checking And Adding Oil...3585
      Removing And Replacing Oil...3585
    DIESEL PARTICULATE FILTER (DPF) SYSTEM...3587
      Description...3587
      Remote Parked Regeneration...3587
      Service Regeneration...3589
      DPF Cleaning...3589
    EMERGENCY EXIT...3591
      Right Rear Side Window...3591
      Front Window...3591
    SEAT BELT...3593
      Inspection And Maintenance...3593
    CAB TILT PROCEDURE...3595
      Raising And Lowering...3595
    CONTROL CONSOLE LOCKOUTS...3597
      Inspection And Maintenance...3597
    TOWING THE EXCAVATOR...3599
      Procedure...3599
  HYDRAULIC SYSTEM...3601
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3605
    HYDRAULIC SYSTEM INFORMATION...3609
      Glossary Of Hydraulic / Hydrostatic Symbols...3609
      Troubleshooting The Hydraulic Circuit...3612
      Troubleshooting The Cylinder Circuit...3613
      Troubleshooting The Swing (Slew) Circuit...3614
      Troubleshooting The Travel Circuit...3615
      Description...3617
    CYLINDER (BOOM)...3619
      Testing...3619
      Removal And Installation...3621
      Parts Identification...3624
      Disassembly...3625
      Assembly...3633
    CYLINDER (ARM)...3641
      Testing...3641
      Removal And Installation...3643
      Parts Identification...3646
      Disassembly...3647
      Assembly...3655
    CYLINDER (BOOM SWING)...3663
      Testing...3663
      Removal And Installation...3664
      Parts Identification...3667
      Disassembly...3668
      Assembly...3675
    CYLINDER (BUCKET)...3683
      Testing...3683
      Removal And Installation...3683
      Parts Identification...3686
      Disassembly...3687
      Assembly...3696
    CYLINDER (BLADE)...3705
      Testing...3705
      Removal And Installation...3706
      Parts Identification...3709
      Disassembly...3710
      Assembly...3718
    CYLINDER (ARTICULATED BOOM) (OPTIONAL)...3727
      Testing...3727
      Removal And Installation...3729
      Parts Identification...3731
      Disassembly...3732
      Assembly...3738
    VALVES (RELIEF)...3745
      Description...3745
    VALVES (PORT RELIEF)...3747
      Testing And Adjusting The Port Relief Valve Pressure...3747
    VALVE (PILOT PRESSURE RELIEF)...3749
      Testing And Adjusting The Pressure Reducing Valve...3749
    HYDRAULIC CONTROL VALVE...3751
      Description...3751
      Removal And Installation...3751
      Parts Identification...3753
      Disassembly And Assembly...3754
      Inlet Valve Section Disassembly And Assembly...3759
      Boom, Arm And Bucket Valve Section Disassembly And Assembly...3762
      Left Travel, Right Travel And Blade Valve Section Disassembly And Assembly...3766
      Auxiliary And Slew Valve Section Disassembly And Assembly...3770
      Boom Swing Valve Section Disassembly And Assembly...3774
      Articulated Boom Valve Section Disassembly And Assembly...3777
    PUMP (HYDRAULIC PISTON)...3781
      Hydraulic Pump Work Sheet...3781
      Testing Information...3784
      Pump Testing...3786
      Removal And Installation...3793
      Torque Limiter Valve Parts Identification...3795
      Torque Limiter Valve Removal And Installation...3796
      Torque Limiter Valve Disassembly...3797
      Torque Limiter Valve Assembly...3801
      Initial Torque Limiter Valve Setting...3805
      Pump Control Parts Identification...3807
      Pump Control Removal And Installation...3808
      Pump Control Disassembly And Assembly...3809
      Parts Identification...3814
      Disassembly...3815
      Assembly...3823
    PUMP (GEAR)...3833
      Testing Information...3833
      Pump Testing...3833
      Removal And Installation...3835
      Disassembly And Assembly...3837
    MANIFOLD ASSEMBLY / ACCUMULATOR...3841
      Description...3841
      Removal And Installation...3841
      Disassembly And Assembly...3842
    TRAVEL MOTOR...3845
      Removal And Installation...3845
      Parts Identification...3846
      Parts Identification Gear Reduction Hub...3847
      Disassembly...3848
      Assembly...3862
    SWIVEL JOINT...3877
      Removal And Installation...3877
      Parts Identification...3880
      Disassembly...3881
      Assembly...3882
    SWING MOTOR...3885
      Removal And Installation...3885
      Parts Identification...3887
      Disassembly And Assembly...3888
    SWING MOTOR (DRIVE CARRIER)...3897
      Removal And Installation...3897
      Parts Identification...3898
      Disassembly And Assembly...3899
    CONTROL PATTERN SELECTOR VALVE...3903
      Removal And Installation...3903
      Disassembly And Assembly...3904
    RIGHT CONTROL LEVER (JOYSTICK)...3907
      Testing...3907
      Handle Removal And Installation...3908
      Joystick Assembly Removal And Installation...3909
      Parts Identification...3911
      Disassembly And Assembly...3912
    LEFT CONTROL LEVER (JOYSTICK)...3917
      Testing...3917
      Handle Removal And Installation...3918
      Joystick Assembly Removal And Installation...3919
      Parts Identification...3921
      Disassembly And Assembly...3922
    BLADE CONTROL VALVE...3927
      Removal And Installation...3927
      Parts Identification...3928
      Disassembly And Assembly...3929
    HYDRAULIC RESERVOIR...3933
      Removal And Installation...3933
    OIL COOLER...3939
      Removal And Installation...3939
    DIRECT TO TANK VALVE...3941
      Removal And Installation...3941
      Disassembly And Assembly...3942
    AUXILIARY BREAKER VALVE...3943
      Description...3943
      Removal And Installation...3943
      Parts Identification...3944
      Disassembly And Assembly...3945
    PILOT VALVE...3947
      Description...3947
      Removal And Installation...3947
      Parts Identification...3948
      Disassembly And Assembly...3949
    FORCED REGENERATION VALVE...3951
      Removal And Installation...3951
      Disassembly And Assembly...3952
    TRAVEL CONTROL VALVE...3953
      Removal And Installation...3953
      Parts Identification...3955
      Disassembly And Assembly...3956
    AUTO IDLE...3961
      Description...3961
    HYDRAULIC PILOT PRESSURE FILTER ASSEMBLY...3963
      Removal And Installation...3963
  UNDERCARRIAGE...3965
    BLADE...3967
      Removal And Installation...3967
    TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)...3969
      Track Lug Height...3969
      Checking Tension...3970
      Adjusting Tension...3971
      Track Removal And Installation...3971
      Idler Removal And Installation...3973
      Idler Parts Identification...3974
      Idler Disassembly...3975
      Idler Assembly...3978
      Track Tensioner Removal And Installation...3983
      Track Tensioner Parts Identification...3984
      Track Tensioner Disassembly And Assembly...3985
      Roller Removal And Installation...3987
      Lower Roller Parts Identification...3989
      Lower Roller Disassembly...3990
      Lower Roller Assembly...3993
      Upper Roller Parts Identification...3999
      Upper Roller Disassembly And Assembly...4000
      Sprocket Removal And Installation...4003
    TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)...4005
      Checking Tension...4005
      Adjusting Tension...4006
      Track Removal...4007
      Track Installation...4009
      Idler Removal And Installation...4010
      Idler Parts Identification...4011
      Idler Disassembly...4012
      Idler Assembly...4015
      Track Tensioner Removal And Installation...4020
      Track Tensioner Parts Identification...4021
      Track Tensioner Disassembly And Assembly...4022
      Roller Removal And Installation...4024
      Guide Plate Removal And Installation...4026
      Lower Roller Parts Identification...4027
      Lower Roller Disassembly...4028
      Lower Roller Assembly...4031
      Upper Roller Parts Identification...4037
      Upper Roller Disassembly And Assembly...4038
      Sprocket Removal And Installation...4041
    TRACK MAINTENANCE...4043
      Track Damage Identification...4043
    SWING CIRCLE GEAR...4055
      Swing Bearing Removal...4055
      Swing Bearing Installation...4056
    LOWER TRACK ROLLER...4057
      Parts Identification...4057
      Disassembly...4058
      Assembly...4061
    UPPER TRACK ROLLER...4067
      Parts Identification...4067
      Disassembly And Assembly...4068
  UPPERSTRUCTURE AND SWING SECTION...4071
    UPPERSTRUCTURE...4075
      Removal...4075
      Installation...4077
    UPPERSTRUCTURE SIDE COVER (LEFT)...4079
      Removal And Installation...4079
    UPPERSTRUCTURE SIDE COVER (RIGHT)...4081
      Removal And Installation...4081
    CAB...4083
      Removal And Installation...4083
      Door Removal And Installation...4093
      Front Window Removal And Installation...4094
      Lower Front Window Removal And Installation...4095
      Glass Installation...4096
      Front Window Strut Removal And Installation...4101
      Front Window Slide Bar Removal And Installation...4102
      Cab Tilt Assembly Removal And Installation...4103
      Cab Tilt Parts Identification...4104
      Cab Tilt Assembly Disassembly And Assembly...4105
      Headliner Removal And Installation...4106
    SEAT...4111
      Seat Removal And Installation...4111
      Seat Mount Removal And Installation...4112
    RIGHT CONSOLE...4115
      Console Cover Removal And Installation...4115
    LEFT CONSOLE...4117
      Lower Console Cover Removal And Installation...4117
      Upper Console Cover Removal And Installation...4118
      Gas Strut Removal And Installation...4119
      Lock Lever Removal And Installation...4120
      Lock Lever Disassembly And Assembly...4121
      Console Removal And Installation...4122
    CENTER COVER...4123
      Removal And Installation...4123
    CENTER ACCESS COVER...4125
      Removal And Installation...4125
    COUNTERWEIGHT...4127
      Removal And Installation...4127
    FLOOR MAT...4129
      Removal And Installation...4129
    FUEL TANK...4131
      Removal And Installation...4131
    HORN...4135
      Removal And Installation...4135
    SWING FRAME...4137
      Removal And Installation...4137
      Bushing Removal...4141
      Bushing Installation...4142
    BOOM...4143
      Removal And Installation...4143
      Bushing Removal And Installation...4144
    BOOM (ARTICULATED) (OPTIONAL)...4145
      Removal And Installation...4145
    ARM...4147
      Removal And Installation...4147
      Arm To Boom Bushing Removal And Installation...4148
      Bucket And Link Bushing Removal And Installation...4149
    QUICK COUPLER (KLAC™ SYSTEM)...4151
      Troubleshooting...4151
      Daily Inspection...4151
      Removal And Installation...4152
      Parts Identification...4154
      Disassembly...4155
      Assembly...4157
    QUICK COUPLER (LEHNHOFF® SYSTEM)...4159
      Troubleshooting...4159
      Daily Inspection...4159
      Removal (MS03 And MS08)...4160
      Installation (MS03 And MS08)...4161
      Parts Identification (MS03)...4162
      Disassembly And Assembly (MS03)...4163
      Parts Identification (MS08)...4164
      Disassembly (MS08)...4165
      Assembly (MS08)...4169
    BUCKET...4173
      Bucket Teeth Removal And Installation...4173
      Bucket Side Cutting Edge Removal And Installation...4174
    RIGHT SIDE COVER...4175
      Removal And Installation...4175
      Latch Adjustment...4176
    REAR COVER...4177
      Removal And Installation...4177
  ELECTRICAL SYSTEM AND ANALYSIS...4179
    ELECTRICAL SCHEMATICS...4181
    ELECTRICAL SYSTEM INFORMATION...4182
      Troubleshooting Chart...4182
      Description...4183
      Fuse And Relay Location / Identification...4183
    BATTERY...4186
      Battery Maintenance...4186
      Using A Booster Battery (Jump Starting)...4187
      Removing And Installing Battery...4188
    ALTERNATOR...4190
      Belt Adjustment...4190
      Belt Replacement...4190
      Charging System Inspection...4191
      Alternator Voltage Testing...4193
      Removal And Installation...4194
    STARTER...4196
      Testing...4196
      Removal And Installation...4197
      Parts Identification...4199
    STARTER RELAY...4200
      Removal And Installation...4200
    LIGHTS...4202
      Boom Light Removal And Installation...4202
      Boom Light Bulb Replacement...4202
    CONSOLE LOCKOUT SWITCH...4204
      Testing / Adjustment...4204
      Removal And Installation...4205
    FUEL LEVEL SENDER...4206
      Removal And Installation...4206
    DIAGNOSTIC SERVICE CODE...4208
      Service Codes List...4208
      Flashing Patterns Of Engine Check Lamp...4215
    DIAGNOSTIC TOOL...4216
      Software Installation...4216
      Installation...4218
      Code Retrieval...4221
    INSTRUMENT PANEL...4226
      Removal And Installation...4226
    KEY SWITCH...4228
      Removal And Installation...4228
    RIGHT CONSOLE SWITCH COVER...4230
      Removal And Installation...4230
      Rocker Switch Removal And Installation...4231
      Speed Control Removal And Installation...4232
      Engine Emergency Stop Switch Removal And Installation...4232
      Auxiliary Power Outlet Removal And Installation...4233
    WIPER MOTOR...4234
      Removal And Installation...4234
    MOTION ALARM SYSTEM...4236
      Description...4236
      Inspecting...4236
      Adjusting Switch Position...4237
    FUEL TRANSFER PUMP...4238
      Removal And Installation...4238
    AUTO IDLE PRESSURE SWITCH...4240
      Removal And Installation...4240
    ENGINE CONTROL UNIT (ECU)...4242
      Description...4242
      Removal And Installation...4243
  ENGINE SERVICE...4246
    ENGINE INFORMATION...4248
      Description...4248
      Specifications...4249
      Sensor Location...4255
      Troubleshooting...4257
      Engine Removal And Installation...4258
      Compression - Testing...4265
    ENGINE SPEED CONTROL...4268
      Adjustment...4268
    DIESEL PARTICULATE FILTER (DPF) SYSTEM...4270
      Description...4270
      Removal And Installation...4271
    AIR CLEANER...4274
      Housing Removal And Installation...4274
    ENGINE COOLING SYSTEM...4276
      Radiator Removal And Installation...4276
      Radiator Disassembly And Assembly...4280
      Fan Removal And Installation...4282
      Fuel Cooler Removal And Installation...4283
      Water Pump Removal And Installation...4284
      Water Pump Parts Identification...4285
      Thermostat Removal And Installation...4286
      Temperature Switch - Testing...4286
      Temperature Sensor - Testing...4287
      Thermostat - Testing...4287
    LUBRICATION SYSTEM...4288
      Oil Pan Removal And Installation...4288
      Oil Pump Removal And Installation...4289
      Oil Pump Inspection...4290
      Engine Oil Pressure - Testing...4291
      Crankcase Ventilation Filter Removal And Installation...4292
    FUEL SYSTEM...4294
      Electronic Fuel Injection Schematic - Components...4294
      Fuel Supply Pump Removal And Installation...4295
      Fuel Rail Assembly Removal And Installation...4300
      Fuel Injector Removal And Installation...4302
    CYLINDER HEAD...4304
      Valve Clearance Adjustment...4304
      Cylinder Head Removal And Installation...4306
      Cylinder Head Disassembly And Assembly...4308
      Cylinder Head - Servicing...4311
      Valve Guide - Inspection...4311
      Intake And Exhaust Valve - Inspection...4312
      Valve Stem Bend - Inspection...4313
      Valve Face And Seat...4313
      Valve Spring - Inspection...4314
      Push Rod - Inspection...4314
      Rocker Arm - Inspection...4315
    CRANKSHAFT AND PISTONS...4316
      Piston And Connecting Rod Removal And Installation...4316
      Piston And Connecting Rod - Servicing...4320
      Cylinder Bore - Inspection...4323
      Crankshaft End Play...4324
      Crankshaft And Bearings Removal And Installation...4324
      Crankshaft And Bearings - Servicing...4325
    CAMSHAFT AND TIMING GEARS...4328
      Timing Gear Case Cover Removal And Installation...4328
      Timing Gear Backlash - Inspection...4329
      Idler Gear And Camshaft Removal And Installation...4330
      Valve Tappet - Servicing...4331
      Camshaft - Servicing...4332
      Idler Gear And Shaft - Servicing...4333
    EXHAUST GAS RECIRCULATION (EGR) VALVE...4334
      Description...4334
      Removal And Installation...4335
      EGR Valve Testing And Cleaning...4336
      Lead (Reed) Valve Cleaning...4336
      EGR Cooler Cleaning...4337
      Intake Throttle...4338
    GLOW PLUGS...4340
      Testing...4340
      Removal And Installation...4341
    ENGINE FLYWHEEL...4342
      Hydraulic Pump Coupler Removal And Installation...4342
      Flywheel Removal And Installation...4343
      Flywheel Ring Gear Removal And Installation...4343
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...4344
    AIR CONDITIONING SYSTEM FLOW...4346
      Description...4346
      Chart...4347
      Components...4348
      Safety Equipment...4351
    REGULAR MAINTENANCE...4352
      Filters...4352
      Belt Adjustment...4352
      Belt Replacement...4353
      Condenser...4354
      Air Conditioning Service Chart...4355
      Evaporator / Heater Coil...4356
    TROUBLESHOOTING...4358
      Blower Motor Does Not Operate...4358
      Blower Motor Operates Normally, But Air Flow Is Insufficient...4358
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...4358
      The Compressor Operates Improperly Or Not At All...4358
      Gauge Pressure Related Troubleshooting...4359
      Temperature / Pressure Chart...4361
      Poor A/C Performance...4362
      HVAC Repair And Leaks...4363
    SYSTEM CHARGING AND RECLAMATION...4364
      Reclamation And Charging With Recovery / Charging Unit...4364
      Charging With A Manifold Gauge Set...4367
    COMPRESSOR...4370
      Removal And Installation...4370
      Oil...4372
      Oil Check...4373
    CONDENSER...4376
      Removal And Installation...4376
    RECEIVER / DRIER...4378
      Receiver / Drier Removal And Installation...4378
      Pressure Switch Removal And Installation...4379
    EVAPORATOR / HEATER UNIT...4380
      Removal And Installation...4380
    THERMOSTAT...4382
      Inspection...4382
    EXPANSION VALVE...4384
      Removal And Installation...4384
    BLOWER FAN...4386
      Removal And Installation...4386
    HEATER VALVE...4388
      Removal And Installation...4388
    HVAC CONTROLLER...4390
      Removal And Installation...4390
  SPECIFICATIONS...4392
    EXCAVATOR SPECIFICATIONS...4394
      Dimensions...4394
      Performance...4396
      Controls...4396
      Engine...4396
      Hydraulic System...4397
      Hydraulic Cylinders...4397
      Hydraulic Cycle Times...4398
      Electrical...4398
      Drive System...4398
      Slew System...4398
      Undercarriage...4398
      Crawler Track Design...4398
      Capacities...4398
      Fuel Tank...4398
      Track...4399
      Type...4399
      Ground Pressure...4399
    TORQUE SPECIFICATIONS FOR BOLTS...4400
      Torque For General SAE Bolts...4400
      Torque For General Metric Bolts...4401
    HYDRAULIC CONNECTION SPECIFICATIONS...4402
      O-ring Face Seal Connection...4402
      Straight Thread O-ring Fitting...4403
      Tubelines And Hoses...4403
      Flare Fitting...4403
      Port Seal Fitting...4404
    HYDRAULIC FLUID SPECIFICATIONS...4406
      Specifications...4406
    CONVERSIONS...4408
      Decimal And Millimeter Equivalent Chart...4408
      U.S. To Metric Conversion Chart...4408
    SERVICE TOOLS REQUIRED...4410
      Remote Start Tools...4410
      Hydraulic Tools...4411
      Engine Tools...4413
      HVAC Tools...4414
  ALPHABETICAL INDEX...4416
6990794 (09-13) - E62 Compact Excavator Service Manual...4418
  MAINTENANCE SAFETY...4420
  CONTENTS...4422
  FOREWORD...4424
    FOREWORD...4426
    SAFETY INSTRUCTIONS...4428
    FIRE PREVENTION...4430
      Maintenance...4430
      Operation...4430
      Electrical...4430
      Hydraulic System...4430
      Fueling...4430
      Starting...4430
      Welding And Grinding...4431
      Fire Extinguishers...4431
    SERIAL NUMBER LOCATIONS...4432
      Excavator Serial Number...4432
      Engine Serial Number...4432
    DELIVERY REPORT...4433
    EXCAVATOR IDENTIFICATION...4434
  SAFETY AND MAINTENANCE...4436
    LIFTING AND BLOCKING THE EXCAVATOR...4438
      Procedure...4438
    LIFTING THE EXCAVATOR...4440
      Procedure...4440
    OPERATOR CAB...4442
      Description...4442
      Cab Door...4442
      Front Window...4443
      Front Wiper...4444
      Window Washer Reservoir...4444
      Right Side Window...4445
      Heating, Ventilation And Air Conditioning Duct...4446
    TRANSPORTING THE EXCAVATOR ON A TRAILER...4448
      Loading And Unloading...4448
      Fastening...4449
    RIGHT SIDE COVER...4450
      Opening And Closing...4450
      Adjusting The Latch...4450
    REAR COVER...4452
      Opening And Closing...4452
    SERVICE SCHEDULE...4454
      Maintenance Intervals...4454
    AIR CLEANER SERVICE...4456
      Daily Check...4456
      Replacing The Filters...4457
    CAB FILTER...4458
      Cleaning And Maintenance...4458
    ENGINE COOLING SYSTEM...4460
      Cleaning...4460
      Checking Level...4460
      Removing And Replacing Coolant...4461
    FUEL SYSTEM...4462
      Fuel Specifications...4462
      Biodiesel Blend Fuel...4462
      Filling The Fuel Tank...4463
      Fuel Filters...4464
      Draining The Fuel Tank...4466
      Removing Air From The Fuel System...4466
    ENGINE LUBRICATION SYSTEM...4468
      Checking And Adding Engine Oil...4468
      Engine Oil Chart...4468
      Removing And Replacing Oil And Filter...4469
    HYDRAULIC SYSTEM...4472
      Checking And Adding Fluid...4472
      Hydraulic Fluid Chart...4473
      Removing And Replacing Hydraulic Filters...4473
      Removing And Replacing Hydraulic Fluid...4477
    LUBRICATING THE EXCAVATOR...4480
      Lubrication Locations...4480
    PIVOT PINS...4484
      Inspection And Maintenance...4484
    TRAVEL MOTOR...4486
      Checking And Adding Oil...4486
      Removing And Replacing Oil...4486
    SPARK ARRESTER MUFFLER...4488
      Cleaning Procedure...4488
    AIR CONDITIONING BELT...4490
      Belt Adjustment...4490
      Belt Replacement...4491
    EMERGENCY EXIT...4492
      Right Rear Side Window...4492
      Front Window...4492
    SEAT BELT...4494
      Inspection And Maintenance...4494
    CAB TILT PROCEDURE...4496
      Tilting The Cab...4496
    CONTROL CONSOLE LOCKOUTS...4498
      Inspection And Maintenance...4498
    TOWING THE EXCAVATOR...4500
      Procedure...4500
  HYDRAULIC SYSTEM...4502
    HYDRAULIC / HYDROSTATIC SCHEMATICS...4506
    HYDRAULIC SYSTEM INFORMATION...4508
      Glossary Of Hydraulic / Hydrostatic Symbols...4508
      Troubleshooting The Hydraulic Circuit...4511
      Troubleshooting The Cylinder Circuit...4512
      Troubleshooting The Swing (Slew) Circuit...4513
      Troubleshooting The Travel Circuit...4514
    CYLINDER (BOOM)...4516
      Testing...4516
      Removal And Installation...4518
      Parts Identification...4521
      Disassembly...4522
      Assembly...4529
    CYLINDER (ARM)...4536
      Testing...4536
      Removal And Installation...4538
      Parts Identification...4540
      Disassembly...4541
      Assembly...4548
    CYLINDER (BOOM SWING)...4556
      Testing...4556
      Removal And Installation...4557
      Parts Identification...4560
      Disassembly...4561
      Assembly...4568
    CYLINDER (BUCKET)...4576
      Testing...4576
      Removal And Installation...4576
      Parts Identification...4580
      Disassembly...4581
      Assembly...4588
    CYLINDER (BLADE)...4596
      Testing...4596
      Removal And Installation...4597
      Parts Identification...4600
      Disassembly...4601
      Assembly...4606
    VALVES (MAIN RELIEF)...4612
      Testing And Adjusting...4612
    VALVES (PORT RELIEF)...4614
      Testing And Adjusting The Port Relief Valve Pressure...4614
    VALVE (PILOT PRESSURE RELIEF)...4616
      Testing And Adjusting The Pressure Reducing Valve...4616
    HYDRAULIC CONTROL VALVE...4618
      Removal And Installation...4618
    HYDRAULIC PUMP...4622
      Removal And Installation...4622
    MANIFOLD ASSEMBLY / ACCUMULATOR...4624
      Description...4624
      Removal And Installation...4624
      Disassembly And Assembly...4625
    TRAVEL MOTOR...4628
      Removal And Installation...4628
      Parts Identification Hydraulic Motor...4629
      Parts Identification Gear Reduction Hub...4630
      Disassembly...4631
      Assembly...4647
    SWIVEL JOINT...4664
      Removal And Installation...4664
      Parts Identification...4667
      Disassembly...4668
      Assembly...4669
    SWING MOTOR...4672
      Removal And Installation...4672
      Parts Identification...4674
      Disassembly And Assembly...4675
    SWING MOTOR (DRIVE CARRIER)...4684
      Removal And Installation...4684
      Parts Identification...4685
      Disassembly And Assembly...4686
    CONTROL PATTERN SELECTOR VALVE...4690
      Removal And Installation...4690
      Disassembly And Assembly...4691
    RIGHT CONTROL LEVER (JOYSTICK)...4694
      Testing...4694
      Handle Removal And Installation...4695
      Joystick Assembly Removal And Installation...4696
      Parts Identification...4698
      Disassembly And Assembly...4699
    LEFT CONTROL LEVER (JOYSTICK)...4704
      Testing...4704
      Handle Removal And Installation...4705
      Joystick Assembly Removal And Installation...4706
      Parts Identification...4708
      Disassembly And Assembly...4709
    BLADE CONTROL VALVE...4714
      Removal And Installation...4714
      Parts Identification...4715
      Disassembly And Assembly...4716
    HYDRAULIC RESERVOIR...4720
      Removal And Installation...4720
    OIL COOLER...4724
      Removal And Installation...4724
    DIRECT TO TANK VALVE...4726
      Removal And Installation...4726
      Disassembly And Assembly...4727
    SWING MOTOR BRAKE SHUTTLE VALVE...4728
      Removal And Installation...4728
      Parts Identification...4729
      Disassembly And Assembly...4730
    PILOT VALVE...4732
      Description...4732
      Removal And Installation...4732
      Parts Identification...4733
      Disassembly And Assembly...4734
    TRAVEL CONTROL VALVE...4736
      Removal And Installation...4736
      Parts Identification...4738
      Disassembly And Assembly...4739
    AUTO IDLE...4744
      Description...4744
  UNDERCARRIAGE...4746
    BLADE...4748
      Removal And Installation...4748
    TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)...4750
      Description...4750
      Track Lug Height...4750
      Checking Tension...4751
      Adjusting Tension...4752
      Track Removal And Installation...4753
      Idler Removal And Installation...4755
      Idler Parts Identification...4756
      Idler Disassembly...4757
      Idler Assembly...4760
      Tensioner Removal And Installation...4765
      Track Tensioner Parts Identification...4766
      Track Tensioner Disassembly And Assembly...4767
      Roller Removal And Installation...4768
      Roller Parts Identification...4769
      Roller Disassembly...4770
      Roller Assembly...4773
      Sprocket Removal And Installation...4777
    TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)...4778
      Description...4778
      Checking Tension...4779
      Adjusting Tension...4780
      Track Removal...4781
      Track Installation...4783
      Idler Removal And Installation...4784
      Idler Parts Identification...4785
      Idler Disassembly...4786
      Idler Assembly...4789
      Track Tensioner Removal And Installation...4794
      Track Tension Parts Identification...4795
      Track Tensioner Disassembly And Assembly...4796
      Roller Removal And Installation...4797
      Roller Parts Identification...4798
      Roller Disassembly...4799
      Roller Assembly...4802
      Sprocket Removal And Installation...4806
      Guide Plate Removal And Installation...4806
    TRACK MAINTENANCE...4808
      Track Damage Identification...4808
    SWING CIRCLE GEAR...4820
      Swing Bearing Removal...4820
      Swing Bearing Installation...4820
  UPPERSTRUCTURE AND SWING SECTION...4822
    UPPERSTRUCTURE...4824
      Removal...4824
      Installation...4826
    CAB...4828
      Removal And Installation...4828
      Door Removal And Installation...4838
      Front Window Removal And Installation...4839
      Lower Front Window Removal And Installation...4840
      Glass Installation...4841
      Front Window Strut Removal And Installation...4846
      Front Window Slide Bar Removal And Installation...4847
      Cab Tilt Assembly Removal And Installation...4848
      Cab Tilt Parts Identification...4849
      Cab Tilt Assembly Disassembly And Assembly...4850
      Headliner Removal And Installation...4851
    SEAT...4856
      Seat Removal And Installation...4856
      Seat Mount Removal And Installation...4857
    RIGHT CONSOLE...4860
      Console Cover Removal And Installation...4860
    LEFT CONSOLE...4862
      Lower Console Cover Removal And Installation...4862
      Upper Console Cover Removal And Installation...4863
      Gas Strut Removal And Installation...4864
      Lock Lever Removal And Installation...4865
      Lock Lever Disassembly And Assembly...4866
      Console Removal And Installation...4867
    LEFT UPPERSTRUCTURE COVER...4868
      Removal And Installation...4868
    RIGHT UPPERSTRUCTURE COVER...4870
      Removal And Installation...4870
    COUNTER WEIGHT...4872
      Removal And Installation...4872
    FLOOR MAT...4874
      Removal And Installation...4874
    FUEL TANK...4876
      Removal And Installation...4876
    HORN...4878
      Removal And Installation...4878
    SWING FRAME...4880
      Removal And Installation...4880
      Bushing Removal...4884
      Bushing Installation...4885
    BOOM...4886
      Removal And Installation...4886
      Bushing Removal And Installation...4887
    ARM (STANDARD AND LONG)...4888
      Removal And Installation...4888
      Arm To Boom Bushing Removal And Installation...4889
      Bucket And Link Bushing Removal And Installation...4890
    BUCKET...4892
      Bucket Teeth Removal And Installation...4892
      Bucket Side Cutting Edge Removal And Installation...4893
    REAR COVER...4894
      Removal And Installation...4894
    QUICK COUPLER (KLAC™ SYSTEM)...4896
      Troubleshooting...4896
      Daily Inspection...4896
      Removal And Installation...4897
      Parts Identification...4899
      Disassembly...4900
      Assembly...4902
    QUICK COUPLER (LEHNHOFF® SYSTEM)...4904
      Troubleshooting...4904
      Daily Inspection...4904
      Removal (MS03 And MS08)...4905
      Installation (MS03 And MS08)...4906
      Parts Identification (MS03)...4907
      Disassembly And Assembly (MS03)...4908
      Parts Identification (MS08)...4909
      Disassembly (MS08)...4910
      Assembly (MS08)...4914
    RIGHT SIDE COVER...4918
      Removal And Installation...4918
  ELECTRICAL SYSTEM AND ANALYSIS...4920
    ELECTRICAL SCHEMATICS...4922
    ELECTRICAL SYSTEM INFORMATION...4923
      Troubleshooting Chart...4923
      Description...4924
      Fuse And Relay Location / Identification...4924
      Engine Control Unit (ECU)...4926
    BATTERY...4927
      Battery Maintenance...4927
      Using A Booster Battery (Jump Starting)...4928
      Removing And Installing Battery...4929
    ALTERNATOR...4931
      Belt Adjustment...4931
      Belt Replacement...4931
      Charging System Inspection...4932
      Alternator Voltage Testing...4934
      Removal And Installation...4935
    STARTER...4937
      Testing...4937
      Removal And Installation...4938
      Parts Identification...4940
    LIGHTS...4941
      Boom Light Removal And Installation...4941
      Boom Light Bulb Replacement...4941
    CONSOLE LOCKOUT SWITCH...4943
      Testing / Adjustment...4943
      Removal And Installation...4944
    FUEL LEVEL SENDER...4945
      Removal And Installation...4945
    DIAGNOSTIC SERVICE CODE...4947
      Service Codes List...4947
      Flashing Patterns Of Engine Check Lamp...4954
    DIAGNOSTIC TOOL...4955
      Software Installation...4955
      Installation...4957
      Code Retrieval...4960
    INSTRUMENT PANEL...4965
      Removal And Installation...4965
    KEY SWITCH...4967
      Removal And Installation...4967
    RIGHT CONSOLE SWITCH COVER...4969
      Removal And Installation...4969
      Rocker Switch Removal And Installation...4970
      Speed Control Removal And Installation...4971
      Engine Emergency Stop Switch Removal And Installation...4971
      Auxiliary Power Outlet Removal And Installation...4972
    WIPER MOTOR...4973
      Removal And Installation...4973
    MOTION ALARM SYSTEM...4975
      Description...4975
      Inspecting...4975
      Adjusting Switch Position...4976
    FUEL TRANSFER PUMP...4977
      Removal And Installation...4977
    AUTO IDLE PRESSURE SWITCH...4979
      Removal And Installation...4979
  ENGINE SERVICE...4981
    ENGINE INFORMATION...4983
      Description...4983
      Specifications...4984
      Troubleshooting...4990
      Engine Removal And Installation...4991
      Compression - Testing...4998
    ENGINE SPEED CONTROL...5001
      Adjustment...5001
    MUFFLER...5003
      Removal And Installation...5003
    AIR CLEANER...5005
      Housing Removal And Installation...5005
    ENGINE COOLING SYSTEM...5007
      Radiator Removal And Installation...5007
      Radiator Disassembly And Assembly...5014
      Fan Removal And Installation...5016
      Fuel Cooler Removal And Installation...5017
      Water Pump Removal And Installation...5018
      Water Pump Parts Identification...5019
      Thermostat Removal And Installation...5020
      Temperature Switch Testing...5020
      Temperature Sensor Testing...5021
      Thermostat Testing...5021
      Radiator Cap Testing...5022
    LUBRICATION SYSTEM...5023
      Oil Pan Removal And Installation...5023
      Oil Pump Removal And Installation...5024
      Oil Pump Inspection...5026
      Engine Oil Pressure - Testing...5028
    FUEL SYSTEM...5029
      Fuel Injection Pump Removal And Installation...5029
      Fuel Injection Pump - Timing...5034
      Fuel Injector Removal And Installation...5038
      Fuel Injector Pressure - Testing...5040
      Nozzle Spray Condition...5040
    CYLINDER HEAD...5043
      Valve Clearance Adjustment...5043
      Cylinder Head Removal And Installation...5045
      Cylinder Head Disassembly And Assembly...5046
      Cylinder Head - Servicing...5047
      Valve Guide - Inspection...5048
      Intake And Exhaust Valve - Inspection...5049
      Valve Stem Bend - Inspection...5049
      Valve Face And Seat...5050
      Valve Spring - Inspection...5050
      Push Rod - Inspection...5051
      Rocker Arm - Inspection...5051
      Valve Bridge - Inspection...5052
    CRANKSHAFT AND PISTONS...5053
      Piston And Connecting Rod Removal And Installation...5053
      Piston And Connecting Rod - Servicing...5054
      Cylinder Bore - Inspection...5056
      Crankshaft End Play...5056
      Crankshaft And Bearings Removal And Installation...5057
      Crankshaft And Bearings - Servicing...5058
    CAMSHAFT AND TIMING GEARS...5059
      Timing Gear Case Cover Removal And Installation...5059
      Timing Gear Backlash - Inspection...5060
      Idler Gear And Camshaft Removal And Installation...5061
      Camshaft - Servicing...5062
      Idler Gear And Shaft - Servicing...5063
    COLD START DEVICE...5065
      Description...5065
      Testing...5065
      Removal And Installation...5065
    EXHAUST GAS RECIRCULATION VALVE (EGR)...5067
      Description...5067
      Testing...5067
      Removal And Installation...5068
    MANIFOLD AIR HEATER...5069
      Description...5069
      Testing...5069
      Removal And Installation...5069
    ENGINE FLYWHEEL...5071
      Hydraulic Pump Coupler Removal And Installation...5071
      Flywheel Removal And Installation...5072
      Flywheel Ring Gear Removal And Installation...5072
  HEATING, VENTILATION AND AIR CONDITIONING...5073
    AIR CONDITIONING SYSTEM FLOW...5075
      Description...5075
      Chart...5076
      Components...5077
      Safety Equipment...5080
    REGULAR MAINTENANCE...5081
      Filters...5081
      Belt Adjustment...5081
      Belt Replacement...5082
      Condenser...5083
      Air Conditioning Service Chart...5084
      Evaporator / Heater Coil...5085
    TROUBLESHOOTING...5087
      Blower Motor Does Not Operate...5087
      Blower Motor Operates Normally, But Air Flow Is Insufficient...5087
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...5087
      The Compressor Operates Improperly Or Not At All...5087
      Gauge Pressure Related Troubleshooting...5088
      Temperature / Pressure Chart...5090
      Poor A/C Performance...5091
      HVAC Repair And Leaks...5092
    SYSTEM CHARGING AND RECLAMATION...5093
      Reclamation And Charging With Recovery / Charging Unit...5093
      Charging With A Manifold Gauge Set...5096
    COMPRESSOR...5099
      Removal And Installation...5099
      Oil...5101
      Oil Check...5102
    CONDENSER...5105
      Removal And Installation...5105
    RECEIVER / DRIER...5107
      Receiver / Drier Removal And Installation...5107
      Pressure Switch Removal And Installation...5108
    EVAPORATOR / HEATER UNIT...5109
      Removal And Installation...5109
    THERMOSTAT...5111
      Inspection...5111
    EXPANSION VALVE...5113
      Removal And Installation...5113
    BLOWER FAN...5115
      Removal And Installation...5115
    HEATER VALVE...5117
      Removal And Installation...5117
    HVAC CONTROLLER...5119
      Removal And Installation...5119
  SPECIFICATIONS...5121
    EXCAVATOR SPECIFICATIONS...5123
      Dimensions...5123
      Dimensions - Standard Arm...5124
      Dimensions - Long Arm...5125
      Rated Lift Capacity - Standard Arm...5126
      Rated Lift Capacity - Long Arm...5127
      Performance...5128
      Controls...5128
      Engine...5128
      Hydraulic System...5129
      Hydraulic Cylinders...5129
      Hydraulic Cycle Times...5130
      Electrical...5130
      Drive System...5130
      Slew System...5130
      Undercarriage...5130
      Crawler Track Design...5130
      Capacities...5130
      Fuel Tank...5130
      Track...5131
      Type...5131
      Ground Pressure...5131
      Fuel Consumption...5131
      Environmental...5131
      Temperature Range...5131
    TORQUE SPECIFICATIONS FOR BOLTS...5133
      Torque For General SAE Bolts...5133
      Torque For General Metric Bolts...5134
    HYDRAULIC CONNECTION SPECIFICATIONS...5135
      O-ring Face Seal Connection...5135
      Straight Thread O-ring Fitting...5136
      Tubelines And Hoses...5136
      Flare Fitting...5137
      Port Seal Fitting...5138
      BSPP Swivel Nut...5138
    HYDRAULIC FLUID SPECIFICATIONS...5139
      Specifications...5139
    CONVERSIONS...5141
      Decimal And Millimeter Equivalent Chart...5141
      U.S. To Metric Conversion Chart...5142
    SERVICE TOOLS REQUIRED...5143
      Remote Start Tools...5143
      Hydraulic Tools...5144
      Engine Tools...5146
      HVAC Tools...5147
  ALPHABETICAL INDEX...5149

Bobcat E60, E62, E63, E80 Compact Excavators Repair Service Manuals