Bobcat E63 Compact Excavator Service Manual SN B34R11001 & Above – PDF DOWNLOAD

Description

Bobcat E63 Compact Excavator Service Manual SN B34R11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E63 Compact Excavator Service Manual SN B34R11001 & Above – PDF DOWNLOAD

Language : English
Pages : 799
Downloadable : Yes
File Type : PDF

DESCRIPTION:

S/N B34R11001 & Above

Bobcat E63 Compact Excavator Service Manual SN B34R11001 & Above – PDF DOWNLOAD

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 E63 Compact Excavator Service Manual SN B34R11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 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 21
Procedure 21
LIFTING THE EXCAVATOR 23
Procedure 23
OPERATOR CAB 25
Description 25
Cab Door 25
Front Window 26
Front Wiper 27
Window Washer Reservoir 27
Right Side Window 28
Heating, Ventilation And Air Conditioning Duct 29
TRANSPORTING THE EXCAVATOR ON A TRAILER 31
Loading And Unloading 31
Fastening 32
RIGHT SIDE COVER 33
Opening And Closing 33
Adjusting The Latch 33
REAR COVER 35
Opening And Closing 35
SERVICE SCHEDULE 37
Maintenance Intervals 37
AIR CLEANER SERVICE 39
Daily Check 39
Replacing The Filters 40
CAB FILTERS 41
Cleaning And Maintenance 41
ENGINE COOLING SYSTEM 43
Cleaning 43
Checking Level 43
Removing And Replacing Coolant 44
FUEL SYSTEM 45
Fuel Specifications 45
Biodiesel Blend Fuel 45
Filling The Fuel Tank 46
Fuel Filters 47
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 Fluid Chart 56
Removing And Replacing Hydraulic Filters 56
Removing And Replacing Hydraulic Fluid 60
Removing Air From Hydraulic Pump 61
LUBRICATING THE EXCAVATOR 63
Lubrication Locations 63
PIVOT PINS 67
Inspection And Maintenance 67
TRAVEL MOTOR 69
Checking And Adding Oil 69
Removing And Replacing Oil 69
DIESEL PARTICULATE FILTER (DPF) SYSTEM 71
Description 71
Remote Parked Regeneration 71
Service Regeneration 73
DPF Cleaning 73
EMERGENCY EXITS 75
Right Rear Side Window 75
Front Window 75
SEAT BELT 77
Inspection And Maintenance 77
CAB TILT PROCEDURE 79
Tilting The Cab 79
CONTROL CONSOLE LOCKOUT 81
Inspection And Maintenance 81
TOWING THE EXCAVATOR 83
Procedure 83
HYDRAULIC SYSTEM 85
HYDRAULIC / HYDROSTATIC SCHEMATIC 89
HYDRAULIC SYSTEM INFORMATION 91
Glossary Of Hydraulic / Hydrostatic Symbols 91
Troubleshooting The Hydraulic Circuit 94
Troubleshooting The Cylinder Circuit 95
Troubleshooting The Swing (Slew) Circuit 96
Troubleshooting The Travel Circuit 97
CYLINDER (BOOM) 99
Testing 99
Removal And Installation 101
Parts Identification 104
Disassembly 105
Assembly 112
CYLINDER (ARM) 119
Testing 119
Removal And Installation 121
Parts Identification 123
Disassembly 124
Assembly 131
CYLINDER (BOOM SWING) 139
Testing 139
Removal And Installation 140
Parts Identification 143
Disassembly 144
Assembly 151
CYLINDER (BUCKET) 159
Testing 159
Removal And Installation 159
Parts Identification 163
Disassembly 164
Assembly 171
CYLINDER (BLADE) 179
Testing 179
Removal And Installation 180
Parts Identification 183
Disassembly 184
Assembly 189
VALVES (MAIN RELIEF) 195
Testing And Adjusting 195
VALVES (PORT RELIEF) 197
Testing And Adjusting The Port Relief Valve Pressure 197
VALVE (PRESSURE REDUCING) 199
Testing And Adjusting 199
HYDRAULIC CONTROL VALVE 201
Removal And Installation 201
Parts Identification 204
Disassembly And Assembly 205
Inlet Valve Section Disassembly And Assembly 208
Boom Swing Valve Section Disassembly And Assembly 212
Slew Valve Section Disassembly And Assembly 215
Blade Valve Section Disassembly And Assembly 219
Right And Left Travel Valve Section Disassembly And Assembly 223
Boom, Auxiliary, Arm And Bucket Valve Section Disassembly And Assembly 225
HYDRAULIC PUMP 229
Hydraulic Pump Work Sheet 229
Pump Testing 232
Removal And Installation 243
Hydraulic Pump Startup 245
Torque Limiter Assembly Parts Identification 246
Torque Limiter Assembly Removal And Installation 247
Torque Limiter Valve Assembly Disassembly And Assembly 247
Pump Control Parts Identification 248
Pump Control Removal And Installation 249
Pump Control Disassembly And Assembly 249
Parts Identification 255
Disassembly And Assembly 256
MANIFOLD ASSEMBLY / ACCUMULATOR 265
Description 265
Removal And Installation 265
Disassembly And Assembly 266
TRAVEL MOTOR 269
Removal And Installation 269
Parts Identification Hydraulic Motor 270
Parts Identification Gear Reduction Hub 271
Disassembly 272
Assembly 288
SWIVEL JOINT 305
Removal And Installation 305
Parts Identification 308
Disassembly 309
Assembly 310
SWING MOTOR 313
Removal And Installation 313
Parts Identification 315
Disassembly And Assembly 316
SWING MOTOR (DRIVE CARRIER) 325
Removal And Installation 325
Parts Identification 326
Disassembly And Assembly 327
CONTROL PATTERN SELECTOR VALVE 331
Removal And Installation 331
Disassembly And Assembly 332
RIGHT CONTROL LEVER (JOYSTICK) 335
Testing 335
Handle Removal And Installation 336
Joystick Assembly Removal And Installation 337
Parts Identification 339
Disassembly And Assembly 340
LEFT CONTROL LEVER (JOYSTICK) 345
Testing 345
Handle Removal And Installation 346
Joystick Assembly Removal And Installation 347
Parts Identification 349
Disassembly And Assembly 350
BLADE CONTROL VALVE 355
Removal And Installation 355
Parts Identification 356
Disassembly And Assembly 357
HYDRAULIC RESERVOIR 361
Removal And Installation 361
OIL COOLER 365
Removal And Installation 365
DIRECT TO TANK VALVE 367
Removal And Installation 367
Disassembly And Assembly 368
SWING MOTOR BRAKE RELEASE 369
Description 369
Removal And Installation 369
Parts Identification 370
Disassembly And Assembly 371
EPPR VALVE 373
Description 373
Removal And Installation 373
Parts Identification 374
Disassembly And Assembly 375
FORCED REGENERATION VALVE 377
Removal And Installation 377
Disassembly And Assembly 377
TRAVEL CONTROL VALVE 379
Removal And Installation 379
Parts Identification 381
Disassembly And Assembly 382
AUTO IDLE 387
Description 387
UNDERCARRIAGE 389
BLADE 391
Removal And Installation 391
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 393
Description 393
Track Lug Height 393
Checking Tension 394
Adjusting Tension 395
Track Removal And Installation 396
Idler Removal And Installation 398
Idler Parts Identification 399
Idler Disassembly 400
Idler Assembly 403
Tensioner Removal And Installation 408
Track Tensioner Parts Identification 409
Track Tensioner Disassembly And Assembly 410
Roller Removal And Installation 411
Roller Parts Identification 412
Roller Disassembly 413
Roller Assembly 416
Sprocket Removal And Installation 420
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 421
Description 421
Checking Tension 422
Adjusting Tension 423
Track Removal 424
Track Installation 426
Idler Removal And Installation 427
Idler Parts Identification 428
Idler Disassembly 429
Idler Assembly 432
Track Tensioner Removal And Installation 437
Track Tension Parts Identification 438
Track Tensioner Disassembly And Assembly 439
Roller Removal And Installation 440
Roller Parts Identification 441
Roller Disassembly 442
Roller Assembly 445
Sprocket Removal And Installation 449
Guide Plate Removal And Installation 449
TRACK MAINTENANCE 451
Track Damage Identification 451
SWING CIRCLE GEAR 463
Swing Bearing Removal 463
Swing Bearing Installation 463
UPPERSTRUCTURE AND SWING SECTION 465
UPPERSTRUCTURE 467
Removal 467
Installation 469
CAB 471
Removal And Installation 471
Door Removal And Installation 481
Front Window Removal And Installation 482
Lower Front Window Removal And Installation 483
Glass Installation 484
Front Window Strut Removal And Installation 489
Front Window Slide Bar Removal And Installation 490
Cab Tilt Assembly Removal And Installation 491
Cab Tilt Parts Identification 492
Cab Tilt Assembly Disassembly And Assembly 493
Headliner Removal And Installation 494
SEAT 499
Seat Removal And Installation 499
Seat Mount Removal And Installation 500
RIGHT CONSOLE 503
Console Cover Removal And Installation 503
LEFT CONSOLE 505
Lower Console Cover Removal And Installation 505
Upper Console Cover Removal And Installation 506
Gas Strut Removal And Installation 507
Lock Lever Removal And Installation 508
Lock Lever Disassembly And Assembly 509
Console Removal And Installation 510
LEFT UPPERSTRUCTURE COVER 511
Removal And Installation 511
RIGHT UPPERSTRUCTURE COVER 513
Removal And Installation 513
COUNTER WEIGHT 515
Removal And Installation 515
FLOOR MAT 517
Removal And Installation 517
FUEL TANK 519
Removal And Installation 519
HORN 521
Removal And Installation 521
SWING FRAME 523
Removal And Installation 523
Bushing Removal 527
Bushing Installation 528
BOOM 529
Removal And Installation 529
Bushing Removal And Installation 530
ARM (STANDARD AND LONG) 531
Removal And Installation 531
Arm To Boom Bushing Removal And Installation 532
Bucket And Link Bushing Removal And Installation 533
BUCKET 535
Bucket Teeth Removal And Installation 535
Bucket Side Cutting Edge Removal And Installation 536
REAR COVER 537
Removal And Installation 537
QUICK COUPLER (KLAC™ SYSTEM) 539
Troubleshooting 539
Daily Inspection 539
Removal And Installation 540
Parts Identification 542
Disassembly 543
Assembly 545
QUICK COUPLER (LEHNHOFF® SYSTEM) 547
Troubleshooting 547
Daily Inspection 547
Removal (MS03 And MS08) 548
Installation (MS03 And MS08) 549
Parts Identification (MS03) 550
Disassembly And Assembly (MS03) 551
Parts Identification (MS08) 552
Disassembly (MS08) 553
Assembly (MS08) 557
RIGHT SIDE COVER 561
Removal And Installation 561
ELECTRICAL SYSTEM AND ANALYSIS 563
ELECTRICAL SCHEMATICS 565
ELECTRICAL SYSTEM INFORMATION 566
Troubleshooting Chart 566
Description 567
Fuse And Relay Location / Identification 567
Engine Control Unit (ECU) 569
Master Disconnect Switch 569
BATTERY 570
Servicing 570
Using A Booster Battery (Jump Starting) 571
Removal and Installation 572
ALTERNATOR 574
Belt Adjustment 574
Belt Replacement 574
Charging System Inspection 575
Alternator Voltage Testing 577
Removal And Installation 578
STARTER 580
Testing 580
Removal And Installation 581
Parts Identification 583
LIGHTS 584
Boom Light Removal And Installation 584
Boom Light Bulb Replacement 584
CONSOLE LOCKOUT SWITCH 586
Testing / Adjustment 586
Removal And Installation 587
FUEL LEVEL SENDER 588
Removal And Installation 588
DIAGNOSTIC SERVICE CODE 590
Service Codes List 590
Failure Mode Indicator Information 596
Code Retrieval Through The Dash 597
DIAGNOSTIC TOOL 600
Installation 600
INSTRUMENT PANEL 602
Removal And Installation 602
Setting The Operator Four Digit Password 603
KEY SWITCH 606
Removal And Installation 606
RIGHT CONSOLE SWITCH COVER 608
Removal And Installation 608
Rocker Switch Removal And Installation 610
Speed Control Removal And Installation 610
Auxiliary Power Outlet Removal And Installation 611
WIPER MOTOR 612
Removal And Installation 612
MOTION ALARM SYSTEM 614
Description 614
Inspecting 614
Adjusting Switch Position 615
FUEL TRANSFER PUMP 616
Removal And Installation 616
AUTO IDLE PRESSURE SWITCH 618
Removal And Installation 618
VEHICLE CONTROL UNIT (VCU) 620
Removal And Installation 620
ENGINE SERVICE 622
ENGINE INFORMATION 624
Description 624
Specifications 625
Sensor Location 631
Troubleshooting 633
Engine Removal And Installation 634
Compression – Testing 641
ENGINE SPEED CONTROL 644
Adjustment 644
DIESEL PARTICULATE FILTER (DPF) SYSTEM 646
Description 646
Removal And Installation 647
AIR CLEANER 650
Housing Removal And Installation 650
ENGINE COOLING SYSTEM 652
Radiator Removal And Installation 652
Radiator Disassembly And Assembly 656
Fan Removal And Installation 658
Fuel Cooler Removal And Installation 659
Water Pump Removal And Installation 660
Water Pump Parts Identification 661
Thermostat Removal And Installation 662
Temperature Switch – Testing 662
Temperature Sensor – Testing 663
Thermostat – Testing 663
Radiator Cap Testing 663
LUBRICATION SYSTEM 664
Oil Pan Removal And Installation 664
Oil Pump Removal And Installation 665
Oil Pump Inspection 666
Engine Oil Pressure – Testing 667
Crankcase Ventilation Filter Removal And Installation 668
FUEL SYSTEM 670
Electronic Fuel Injection Schematic – Components 670
Fuel Supply Pump Removal And Installation 671
Fuel Rail Assembly Removal And Installation 676
Fuel Injector Removal And Installation 678
CYLINDER HEAD 680
Valve Clearance Adjustment 680
Cylinder Head Removal And Installation 682
Cylinder Head Disassembly And Assembly 684
Cylinder Head – Servicing 687
Valve Guide – Inspection 687
Intake And Exhaust Valve – Inspection 688
Valve Stem Bend – Inspection 689
Valve Face And Seat 689
Valve Spring – Inspection 690
Push Rod – Inspection 690
Rocker Arm – Inspection 691
CRANKSHAFT AND PISTONS 692
Piston And Connecting Rod Removal And Installation 692
Piston And Connecting Rod – Servicing 696
Cylinder Bore – Inspection 699
Crankshaft End Play 700
Crankshaft And Bearings Removal And Installation 700
Crankshaft And Bearings – Servicing 701
CAMSHAFT AND TIMING GEARS 704
Timing Gear Case Cover Removal And Installation 704
Timing Gear Backlash – Inspection 705
Idler Gear And Camshaft Removal And Installation 706
Valve Tappet – Servicing 707
Camshaft – Servicing 708
Idler Gear And Shaft – Servicing 709
EXHAUST GAS RECIRCULATION (EGR) VALVE 710
Description 710
Removal And Installation 711
EGR Valve Testing And Cleaning 712
Lead (Reed) Valve Cleaning 712
EGR Cooler Cleaning 713
Intake Throttle 714
GLOW PLUGS 716
Testing 716
Removal And Installation 717
ENGINE FLYWHEEL 718
Hydraulic Pump Coupler Removal And Installation 718
Flywheel Removal And Installation 719
Flywheel Ring Gear Removal And Installation 719
HEATING, VENTILATION AND AIR CONDITIONING 720
AIR CONDITIONING SYSTEM FLOW 722
Description 722
Chart 723
Components 724
Safety Equipment 727
REGULAR MAINTENANCE 728
Filters 728
Belt Adjustment 728
Belt Replacement 729
Condenser 730
Air Conditioning Service Chart 731
Evaporator / Heater Coil 732
TROUBLESHOOTING 734
Blower Motor Does Not Operate 734
Blower Motor Operates Normally, But Air Flow Is Insufficient 734
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 734
The Compressor Operates Improperly Or Not At All 734
Gauge Pressure Related Troubleshooting 735
Temperature / Pressure Chart 737
Poor A/C Performance 738
HVAC Repair And Leaks 739
SYSTEM CHARGING AND RECLAMATION 740
Reclamation And Charging With Recovery / Charging Unit 740
Charging With A Manifold Gauge Set 743
COMPRESSOR 746
Removal And Installation 746
Oil 748
Oil Check 749
CONDENSER 752
Removal And Installation 752
RECEIVER / DRIER 754
Receiver / Drier Removal And Installation 754
Pressure Switch Removal And Installation 755
EVAPORATOR / HEATER UNIT 756
Removal And Installation 756
THERMOSTAT 758
Inspection 758
EXPANSION VALVE 760
Removal And Installation 760
BLOWER FAN 762
Removal And Installation 762
HEATER VALVE 764
Removal And Installation 764
HVAC CONTROLLER 766
Removal And Installation 766
SPECIFICATIONS 768
EXCAVATOR SPECIFICATIONS 770
Dimensions 770
Performance 772
Controls 772
Engine 772
Hydraulic System 773
Hydraulic Cylinders 773
Hydraulic Cycle Times 774
Electrical 774
Drive System 774
Slew System 774
Undercarriage 774
Crawler Track Design 774
Capacities 774
Fuel Tank 774
Track 775
Type 775
Ground Pressure 775
TECHNICAL SERVICE GUIDE SPECIFICATIONS 776
Engine 776
Engine Torques 776
Cooling System 776
Excavator Torques 776
TORQUE SPECIFICATIONS FOR BOLTS 778
Torque For General SAE Bolts 778
Torque For General Metric Bolts 779
HYDRAULIC CONNECTION SPECIFICATIONS 780
O-ring Face Seal Connection 780
Straight Thread O-ring Fitting 781
Tubelines And Hoses 781
Flare Fitting 782
Port Seal Fitting 783
BSPP Swivel Nut 783
HYDRAULIC FLUID SPECIFICATIONS 784
Specifications 784
CONVERSIONS 786
Decimal And Millimeter Equivalent Chart 786
U S To Metric Conversion Chart 787
SERVICE TOOLS REQUIRED 788
Remote Start Tools 788
Hydraulic Tools 789
Engine Tools 792
Electrical Tools 794
HVAC Tools 794
ALPHABETICAL INDEX 796

Customer Support: [email protected]

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PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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