Bobcat E57W Excavator Service Manual SNB3WU11001 & Above – PDF DOWNLOAD

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Bobcat E57W Excavator Service Manual SNB3WU11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E57W Excavator Service Manual SNB3WU11001 & Above – PDF DOWNLOAD

Language : English
Pages :821
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E57W Excavator Service Manual SNB3WU11001 & Above – PDF DOWNLOAD

S/N B3WU11001 & Above

FOREWORD

This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

•  The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bobcat E57W Excavator Service Manual SNB3WU11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
UPPERSTRUCTURE SLEW LOCK 25
Upperstructure Slew Lock 25
Boom Swing Lock 25
LIFTING THE EXCAVATOR 27
Procedure 27
TRANSPORTING THE EXCAVATOR 29
Loading And Unloading 29
Fastening 30
EMERGENCY EXIT 31
Right Side Rear Window 31
Front Window 31
TAILGATE 33
Opening 33
Closing 33
RIGHT SIDE COVER 35
Opening And Closing 35
SERVICE SCHEDULE 37
Maintenance Intervals 37
AIR CLEANER SERVICE 39
Daily Check 39
Replacing Filter Elements 39
Pre-Cleaner Cleaning 40
COOLING SYSTEM 41
Cleaning 41
Cooling Fan Blade 41
Checking Level 42
Removing And Replacing Coolant 43
FUEL SYSTEM 45
Fuel Specifications 45
Biodiesel Blend Fuel 45
Filling The Fuel Tank 46
Fuel Filters 48
Draining The Fuel Tank 49
Removing Air From The Fuel System 49
ENGINE LUBRICATION SYSTEM 51
Checking And Adding Engine Oil 51
Engine Oil Chart 51
Removing And Replacing Oil And Filter 52
HYDRAULIC SYSTEM 55
Checking And Adding Fluid 55
Hydraulic / Hydrostatic Fluid Chart 56
Removing And Replacing Hydraulic Filters 56
Removing And Replacing Hydraulic Fluid 60
LUBRICATION OF THE HYDRAULIC EXCAVATOR 63
Lubrication Locations 63
PIVOT PINS 69
Lubrication Locations 69
Inspection And Maintenance 69
DRAINING AND REFILLING TRANSMISSION AND AXLE 71
Checking And Adding Oil – Rear Axle Center Housing 71
Draining And Refilling Oil – Rear Axle Center Housing 71
Checking And Adding Oil – Front Axle Center Housing 72
Draining And Refilling Oil – Front Axle Center Housing 72
Checking And Adding Oil – Axle End Housing 73
Draining And Refilling Oil – Axle End Housing 73
Checking And Adding Oil – Transmission 74
Draining And Refilling Oil – Transmission 74
ALTERNATOR BELT 75
Belt Adjustment 75
Belt Replacement 75
SEAT BELT 77
Inspection And Maintenance 77
CONTROL CONSOLE LOCKOUTS 79
Inspection And Maintenance 79
Safety Precautions 79
Left Console Lever 79
EXCAVATOR STORAGE AND RETURN TO SERVICE 81
Storage 81
Return to Service 81
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 83
Procedure 83
Engine Emergency Shut Off 84
TOWING THE EXCAVATOR 85
Procedure 85
Releasing The Parking Brake Manually 85
Resetting The Parking Brake Function 86
HYDRAULIC SYSTEM 87
HYDRAULIC / HYDROSTATIC SCHEMATICS 91
HYDRAULIC SYSTEM INFORMATION 93
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators 93
Troubleshooting The Hydraulic Control Valve 97
Troubleshooting The Relief Valve 98
Troubleshooting The Whole Hydraulic System 98
Troubleshooting The Swing Motor 99
Troubleshooting The Brake Supply Valve 102
Troubleshooting The Solenoid Valve (5 Functions) 103
Troubleshooting The Cylinders 104
CYLINDER (BOOM) 107
Boom Cylinder Natural Drop Test 107
Parts Identification 108
Disassembly 110
Assembly 114
CYLINDER (ARM) 119
Arm Cylinder Natural Drop Test 119
Parts Identification 120
Disassembly 122
Assembly 126
CYLINDER (BOOM SWING) 131
Parts Identification 131
Disassembly 132
Assembly 136
CYLINDER (BUCKET) 141
Bucket Cylinder Natural Drop Test 141
Parts Identification 142
Disassembly 144
Assembly 148
CYLINDER (BLADE) 153
Blade Cylinder Natural Drop Test 153
Parts Identification 154
Disassembly 155
Assembly 159
HYDRAULIC CONTROL VALVE 163
Description 163
Parts Identification 164
Boom Swing Section Parts Identification 167
Boom Swing / Rotating Section Parts Identification 169
Boom Swing / Rotating / Two-Way Section Parts Identification 171
Fixed Boom Section Parts Identification 173
Removal 175
Installation 177
Disassembly 178
Assembly 181
Inspection 184
Hoses, Plugs And Fittings Tightening Torques 185
BRAKE SUPPLY VALVE 189
Description 189
Removal And Installation 190
Hoses, Plugs And Fittings Tightening Torques 192
Tightening Torques For Bolts 193
ACCUMULATOR (BRAKE AND PILOT) 195
Description 195
TRAVEL MOTOR 197
Description 197
Parts Identification 198
Piston Assembly Parts Identification 199
Cover Parts Identification 200
Counterbalance Valve Parts Identification 202
Removal And Installation 204
Disassembly 208
Assembly 214
Inspection 220
Seal Nut Replacement 222
SWIVEL JOINT 223
Description 223
Parts Identification 224
Removal And Installation 226
Disassembly And Assembly 232
SWING MOTOR 235
Description 235
Parts Identification 236
Inspection 239
Precautions 239
Removal And Installation 240
Motor Disassembly 243
Motor Assembly 247
Reduction Gear Disassembly 253
Reduction Gear Assembly 256
Part Replacement Standards For Hydraulic Motor 260
Part Replacement Standards For Reduction Gear 261
Standards For Correcting Sliding Surfaces 262
Tightening Torques For Bolts 263
Special Tools 263
ACCELERATOR PEDAL VALVE 265
Description 265
Removal And Installation 266
Disassembly And Assembly 269
Hoses, Plugs And Fittings Tightening Torques 271
JOYSTICK 273
Description 273
Parts Identification 274
Removal And Installation 275
Disassembly And Assembly 280
HYDRAULIC OIL TANK 283
Description 283
Parts Identification 284
Removal And Installation 285
OIL COOLER 289
Parts Identification 289
Removal And Installation 290
SOLENOID VALVE (5 FUNCTIONS) 291
Description 291
Parts Identification 293
Removal And Installation 294
Disassembly And Assembly 297
Tightening Torques 298
Hoses, Plugs And Fittings Tightening Torques 299
STEERING CYLINDER 301
Removal And Installation 301
Disassembly 303
Assembly 305
STEERING VALVE 309
Description 309
Parts Identification 310
Disassembly 312
Assembly 318
Hydraulic Connections 329
SERVICE BRAKE PEDAL VALVE 331
Description 331
Parts Identification 332
Removal And Installation 333
Disassembly And Assembly 336
Hoses, Plugs And Fittings Tightening Torques 341
BLADE VALVE 343
Description 343
Parts Identification 344
Removal And Installation 345
Disassembly And Assembly 348
UNDERCARRIAGE 351
FRONT AXLE 353
Removal And Installation 353
Hoses, Plugs And Fittings Tightening Torques 356
Housing Parts Identification 357
Planetary Carrier And Wheel Hub Parts Identification 358
Planetary Carrier Disassembly 360
Wheel Hub Disassembly 362
Steering Parts Identification 365
Steering Knuckle Disassembly 366
Brake Group Parts Identification 370
Brake Group Disassembly 372
Brake Group Assembly 378
Differential Parts Identification 388
Differential Disassembly 389
Differential Assembly 393
Steering Knuckle Assembly 397
Wheel Hub Assembly 403
Planetary Carrier Assembly 404
Setting Of The Crown Wheel And Pinion (1) 407
Setting Of The Crown Wheel And Pinion (2) 407
AXLE TOE-IN 411
Adjustment 411
Special Tools 413
STEERING ANGLE ADJUSTMENT 415
Adjustment 415
Jutting Portion Of The Screw 416
DRIVE SHAFT 417
Front Drive Shaft Removal And Installation 417
Rear Drive Shaft Removal And Installation 418
REAR AXLE 419
Removal And Installation 419
Hoses, Plugs And Fittings Tightening Torques 422
Housing Parts Identification 423
Planetary Carrier And Wheel Hub Parts Identification 424
Planetary Carrier Disassembly 426
Planetary Carrier Assembly 431
Brake Group Parts Identification 437
Brake Group Disassembly 440
Releasing The Parking Brake Manually 446
Resetting The Parking Brake Function 446
Brake Group Assembly 447
Brake Piston Cap Check 457
Differential Parts Identification 458
Differential Disassembly 459
Differential Assembly 464
Ring Gear And Pinion Adjusting 469
Bevel Pinion Disassembly 473
Bevel Pinion Assembly 476
Special Tools 482
TIRES AND WHEELS 485
Tire Changing Procedure 485
SWING BEARING 487
Operating Recommendation 487
Measuring Swing Bearing Axial Play 487
Measuring Swing Bearing Lateral Play 487
Parts Identification 488
Disassembly And Assembly 489
TRANSMISSION 491
Description 491
Transmission Serial Number 491
Removal And Installation 492
Parts Identification 494
Replacing Speed Sensor 496
Hydraulic Gear Control Disassembly 497
Hydraulic Gear Control Assembly 501
Reduction Gear Disassembly 506
Reduction Gear Assembly 515
UPPERSTRUCTURE AND SWING SECTION 529
CAB 531
Removal And Installation 531
LEFT CONSOLE 539
Left Console Lever 540
RIGHT CONSOLE 541
FLOOR MAT AND FLOOR PANEL 543
Removal And Installation 543
TRAVEL LEVER / PEDALS 545
Travel Direction Control Lever 545
Pedals 546
FUEL TANK 547
Parts Identification 547
Removal And Installation 549
FUEL PUMP 553
Removal And Installation 553
HYDROSTATIC PUMP 555
Description 555
Parts Identification 556
Removal And Installation 557
Disassembly 559
Assembly 567
Special Tools 580
Inspection 581
Troubleshooting 583
BOOM 587
Description 587
Removal And Installation 587
ARM 589
Description 589
Removal 589
Installation 590
BUCKET 591
Bucket Removal 591
Bucket Installation 591
Reversing The Bucket 592
Bucket O-Ring Replacement 592
Bucket Teeth Inspection And Replacement 594
TAILGATE 595
Removal And Installation 595
COUNTERWEIGHT 597
Removal 597
Installation 598
ELECTRICAL SYSTEM AND ANALYSIS 599
ELECTRICAL SCHEMATIC 601
ELECTRICAL SYSTEM INFORMATION 602
Glossary Of Electrical Symbols 602
Troubleshooting 605
Fuse And Relay Location / Identification 606
Battery Disconnect Switch 609
BATTERY 610
Battery Maintenance 610
Using A Booster Battery (Jump Starting) 611
Removing And Installing Battery 612
ALTERNATOR 614
Electric Power Circuit Diagram 614
Removal And Installation 615
Charging System Inspection 616
Alternator Voltage Testing 617
Low Voltage Testing 617
High Voltage Testing 618
STARTER 620
Parts Identification 620
Removal And Installation 621
Testing 621
INSTRUMENT PANEL SETUP 622
User Menu 622
PASSWORD SETUP (INSTRUMENT PANEL) 632
Owner Password Setting 632
Operator Password Setting 634
DIAGNOSTIC SERVICE CODES 636
Service Code At Machine 636
Service Code At Engine Side 639
INSTRUMENT PANEL SETUP 644
User Menu 644
Password Setup 654
Owner Password Setting 654
Operator Password Setting 656
ENGINE CONTROL UNIT (ECU) 658
Description 658
Removal And Installation 660
ENGINE SERVICE 662
ENGINE INFORMATION 666
Description 666
Sensor Location 667
Troubleshooting The Cooling System 673
Troubleshooting The Lubrication System 674
Troubleshooting The Turbocharger 675
Engine Removal And Installation 678
ENGINE SPEED CONTROL 680
Adjustment 680
DRIVE COUPLING (HYDROSTATIC PUMP) 684
Parts Identification 684
Disassembly 685
Assembly 685
DIESEL OXIDATION CATALYST (DOC) 688
Removal And Installation 688
ENGINE COOLING SYSTEM 690
Description 690
Water Pump Removal And Installation 691
Thermostat Removal And Installation 692
Testing The Thermostat 692
LUBRICATION SYSTEM 694
Description 694
Oil Pump Removal And Installation 695
Oil Pan Removal And Installation 696
Oil Filter Assembly Removal And Installation 697
FUEL SYSTEM 698
Description 698
Fuel Return Hose Removal And Installation 700
Injector Removal And Installation 701
Injector Check 703
Common Rail Removal And Installation 704
Fuel Injection Pump Removal And Installation 705
Fuel Injection Pump Disassembly And Assembly 705
CYLINDER HEAD 706
Cylinder Head Removal And Installation 706
Cylinder Head Disassembly And Assembly 709
Cylinder Head Inspection 710
Glow Plug Removal And Installation 711
Valve Guide Measurement Of Inside Diameter 712
Valve Stem End Measurement 712
Valve Step Height Measurement 713
Gap Between Piston And Valve Measurement 713
Valve Spring Check 714
Rocker Arm Shaft Removal And Installation 715
Rocker Arm Shaft Disassembly And Assembly 715
Rocker Arm Shaft Inspection 715
Push Rod Warpage Inspection 717
CRANKSHAFT AND PISTONS 718
Piston And Connecting Rod Removal And Installation 718
Piston And Connecting Rod Disassembly And Assembly 719
Outside Diameter Of Piston Pin Measurement 720
Inside Diameter Of Piston Pin Bore Measurement 721
Gap Of Piston Ring End Measurement 721
Step Height Of Piston Top Side Measurement 722
Inside Diameter Of Connecting Rod Small-End Measurement 722
Connecting Rod Large-End Bore Measurement 723
Gap Of Connecting Rod Big-End Measurement 723
Crankshaft Removal And Installation 724
Crankshaft Main Journal Diameter Measurement 726
Crankshaft Bearing Gap Measurement 727
Crankshaft Warpage Measurement 727
Cylinder Block Measurement Of Inside Diameter Of Main Bearing Bore 728
Cylinder Block Measurement Of Inside Diameter Of Piston Bore 728
Cylinder Block Measurement Of Inside Diameter Of Camshaft Bearing 729
Engine Component Class 730
CAMSHAFT 732
Removal And Installation 732
Disassembly And Assembly 733
Camshaft Journal Outside Diameter Measurement 734
Camshaft Measurement 734
AIR CLEANER 736
Removal And Installation 736
PRE-CLEANER 738
Removal And Installation 738
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 740
Description 740
Removal 741
Installation 742
GEAR CASE 744
Gear Case Cover Removal And Installation 744
Gear Backlash 745
Gear Timing 746
Idle Gear Removal And Installation 747
Idle Gear Inspection 747
TURBOCHARGER 748
Description 748
Removal And Installation 749
Inspection 751
FLYWHEEL AND HOUSING 754
Removal And Installation 754
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 756
AIR CONDITIONING SYSTEM FLOW 758
Description 758
REGULAR MAINTENANCE 762
Cab Filters 762
Air Conditioning Belt Adjustment 763
Air Conditioning Belt Replacement 764
Repair And Replacement Procedure 765
TROUBLESHOOTING 768
Self-Diagnosis 768
Error Codes 768
Refrigerant Pressure Check 769
Electrical System 771
SYSTEM CHARGING AND RECLAMATION 772
Refrigerant Reclamation 772
Vacuuming Refrigerant System 772
Leakage Check 773
Refrigerant Charging 774
Inspecting System For Leakage 775
COMPRESSOR 776
Belt Adjustment 776
Belt Replacement 777
RECEIVER / DRIER 778
Description 778
SPECIFICATIONS 780
(E57W) EXCAVATOR SPECIFICATIONS 782
Machine Dimensions 782
Working Range 783
Lift Capacity – Short Arm ST 784
Lift Capacity – Short Arm DT 785
Lift Capacity – Long Arm ST 786
Lift Capacity – Long Arm DT 787
Weights 788
Performance 788
Engine 789
Engine Performance Data 790
Electrical 790
Fluid Capacities 790
Hydraulic System 791
Drive System 792
Swing System 794
Function Time 795
Traction 795
Hydraulic Cylinders 796
Environmental 796
Controls 797
Instrumentation 797
ENGINE SPECIFICATIONS 798
Torque Values 800
TORQUE SPECIFICATIONS FOR BOLTS 802
Torque For General SAE Bolts 802
Torque For General Metric Bolts 803
HYDRAULIC CONNECTION SPECIFICATIONS 804
O-Ring Face Seal Connection 804
Straight Thread O-Ring Fitting 804
Tubelines And Hoses 804
Flare Fitting 805
Port Seal Fitting 805
FLUIDS, LUBRICANTS AND FUEL SPECIFICATIONS 806
Specifications 806
CONVERSIONS 808
Decimal And Millimeter Equivalents 808
U S To Metric Conversion Chart 809
SERVICE TOOLS REQUIRED 810
Remote Start Tools 810
Hydraulic Tools 811
Engine Tools 814
Electrical Tools 816
HVAC Tools 816
ALPHABETICAL INDEX 818

Customer Support: [email protected]

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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