Bobcat E55 Compact Excavator Repair Service Manual - 6990093

(S/N: ARWM11001 & Above - S/N: ASW311001 & Above) 
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This workshop repair service manual PDF download for the E55 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Excavator E55 
S/N: ARWM11001 & Above
S/N: ASW311001 & Above


TABLE OF CONTENTS :

SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM 
UNDERCARRIAGE 
UPPERSTRUCTURE AND SWING SECTION 
ELECTRICAL SYSTEM & ANALYSIS 
ENGINE SERVICE 
HEATING, VENTILATION & AIR CONDITIONING 
SPECIFICATIONS 
ALPHABETICAL INDEX 


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6990093 (6-11)
Total Pages : 848


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Excavator Serial Number
        Engine Serial Number
    DELIVERY REPORT
    EXCAVATOR IDENTIFICATION
    
SAFETY & MAINTENANCE
    LIFTING AND BLOCKING THE EXCAVATOR
        Procedure
    LIFTING THE EXCAVATOR
        Procedure
    OPERATOR CAB (ROPS / TOPS)
        Cab Door
        Front Window
        Front Wiper
        Window Washer Reservoir
        Right Side Windows
    TRANSPORTING THE EXCAVATOR ON A TRAILER
        Loading And Unloading
        Fastening
    TAILGATE
        Opening And Closing
        Adjusting The Latch
    RIGHT SIDE COVER
        Opening And Closing
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Daily Check
        Replacing The Filters
    ENGINE COOLING SYSTEM
        Cleaning
        Checking Level
        Removing And Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Biodiesel Blend Fuel
        Filling The Fuel Tank
        Fuel Filters
        Draining The Fuel Tank
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking And Adding Engine Oil
        Engine Oil Chart
        Removing And Replacing Oil And Filter
    HYDRAULIC SYSTEM
        Checking And Adding Hydraulic Fluid
        Hydraulic / Hydrostatic Fluid Chart
        Removing And Replacing The Hydraulic Filters
        Removing And Replacing The Hydraulic Fluid
    LUBRICATING THE EXCAVATOR
        Lubrication Locations
    PIVOT PINS
        Inspection And Maintenance
    TRAVEL MOTOR
        Checking And Adding Oil
        Removing And Replacing Oil
    SPARK ARRESTER MUFFLER
        Cleaning Procedure
    EMERGENCY EXIT
        Right Side Rear Window
        Front Window
    SEAT BELT
        Inspection And Maintenance
    CONTROL CONSOLE LOCKOUTS
        Inspection And Maintenance
    TOWING THE EXCAVATOR
        Procedure
    REMOTE START TOOL KIT - MEL1563
        Remote Start Tool - MEL1563
        Service Tool Harness Control - MEL1565
        Service Tool Harness Communicator - MEL1566
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031
        Description
        Remote Start Tool (Service Tool) - 7003030
        Excavator Service Tool Harness - 6689747
        Computer Service Tool Harness - 6689746
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary Of Hydraulic / Hydrostatic Symbols
        Troubleshooting The Hydraulic Circuit
        Troubleshooting The Cylinder Circuit
        Troubleshooting The Swing (Upperstructure Slew) Circuit
        Troubleshooting The Travel Circuit
    CYLINDER (BOOM)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (ARM)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (BOOM SWING)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (BUCKET)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (BLADE)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (CLAMP)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (ANGLE BLADE)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    VALVE (MAIN RELIEF)
        Testing And Adjusting
    VALVES (PORT RELIEF)
        Testing And Adjusting Port Relief Valve Pressure
    VALVES (CROSS PORT RELIEF)
        Testing And Adjusting
        Removal And Installation
    VALVE (PRESSURE REDUCING)
        Testing And Adjusting
    HYDRAULIC CONTROL VALVE
        Description
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inlet Valve Section Disassembly And Assembly
        Boom Swing Valve Section Disassembly And Assembly
        Slew Valve Section Disassembly And Assembly
        Blade Valve Section Disassembly And Assembly
        Right And Left Travel Valve Section Disassembly And Assembly
        Angle Blade, Boom, Auxiliary, Arm And Bucket Valve Section Disassembly And Assembly
    HYDRAULIC PUMP
        Hydraulic Pump Work Sheet
        Pump Testing
        Removal And Installation
        Coupler Removal And Installation
        Hydraulic Pump Startup
        Torque Limiter Assembly Parts Identification
        Torque Limiter Assembly Removal And Installation
        Torque Limiter Valve Assembly Disassembly And Assembly
        Pump Control Parts Identification
        Pump Control Removal And Installation
        Pump Control Disassembly And Assembly
        Parts Identification
        Disassembly And Assembly
    MANIFOLD ASSEMBLY / ACCUMULATOR (WITHOUT ANGLE BLADE)
        Description
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    MANIFOLD ASSEMBLY / ACCUMULATOR (WITH ANGLE BLADE)
        Description
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    TRAVEL MOTOR
        Removal And Installation
        Parts Identification Hydraulic Motor
        Parts Identification Gear Reduction Hub
        Disassembly
        Assembly
    SWIVEL JOINT
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    SWING MOTOR
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    SWING MOTOR (DRIVE CARRIER)
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    CONTROL PATTERN SELECTOR VALVE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    RIGHT CONTROL LEVER (JOYSTICK)
        Testing
        Handle Removal And Installation
        Joystick Assembly Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    LEFT CONTROL LEVER (JOYSTICK)
        Testing
        Handle Removal And Installation
        Joystick Assembly Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    HYDRAULIC FILTER MOUNT
        Removal And Installation
    HYDRAULIC RESERVOIR
        Removal And Installation
    OIL COOLER
        Removal And Installation
    DIRECT TO TANK VALVE
        Removal And Installation
    BLADE CONTROL LEVER
        Handle Removal And Installation
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    CASE DRAIN FILTER MOUNT
        Removal And Installation
    TRAVEL CONTROL VALVE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    REMOVING AIR FROM THE HYDRAULIC SYSTEM
        Procedure
    HYDRAULIC X-CHANGE MANIFOLD
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    SECONDARY AUXILIARY VALVE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    VALVE (BOOM LOCK)
        Removal And Installation
    VALVE (ARM LOCK)
        Removal And Installation
        
UNDERCARRIAGE
    BLADE
        Removal And Installation
    BLADE (ANGLE)
        Removal And Installation
        Cutting Edge Removal And Installation
    TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
        Description
        Track Lug Height
        Checking Tension
        Adjusting Tension
        Track Removal And Installation
        Idler Removal And Installation
        Idler Parts Identification
        Track Idler Disassembly
        Track Idler Assembly
        Track Tensioner Removal And Installation
        Track Tensioner Parts Identification
        Track Tensioner Disassembly And Assembly
        Roller Removal And Installation
        Sprocket Removal And Installation
    TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)
        Description
        Checking Tension
        Adjusting Tension
        Track Removal
        Track Installation
        Idler Removal And Installation
        Idler Parts Identification
        Track Idler Disassembly
        Track Idler Assembly
        Track Tensioner Removal And Installation
        Track Tensioner Cylinder Parts Identification
        Track Tensioner Disassembly And Assembly
        Roller Removal And Installation
        Sprocket Removal And Installation
        Guide Plate Removal And Installation
    TRACK MAINTENANCE
        Track Damage Identification
    SWING CIRCLE GEAR
        Swing Bearing Removal
        Swing Bearing Installation
        
UPPERSTRUCTURE AND SWING SECTION
    UPPERSTRUCTURE
        Removal
        Installation
    ROPS CANOPY
        Removal And Installation
    CAB
        Removal And Installation
        Door Removal And Installation
        Front Window Removal And Installation
        Right Side Rear Sliding Window Removal And Installation
        Right Side Front Sliding Window Removal And Installation
        Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
        Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
        Glass Removal
        Glass Installation
    SEAT
        Removal And Installation
        Seat Mount Removal And Installation
    RIGHT CONSOLE
        Console Cover Removal And Installation
    LEFT CONSOLE
        Lower Console Cover Removal And Installation
        Upper Console Cover Removal And Installation
        Compression Spring Removal And Installation
        Lock Lever Removal And Installation
        Console Removal And Installation
    LEFT UPPERSTRUCTURE COVER
        Removal And Installation
    RIGHT UPPERSTRUCTURE COVER
        Removal And Installation
    COUNTERWEIGHT
        Removal And Installation
    COUNTERWEIGHT (LOWER)
        Removal And Installation
    TRAVEL LEVERS AND PEDALS
        Removal And Installation
        Disassembly And Assembly
    FLOOR MAT
        Removal And Installation
    FUEL TANK
        Removal And Installation (Canopy Equipped Excavator)
        Removal And Installation (Cab Equipped Excavator)
    HORN
        Removal And Installation
    SWING FRAME
        Removal And Installation
        Boom Swing Frame Hose Routing
        Bushing Removal
        Bushing Installation
    BOOM
        Removal And Installation
    ARM (STANDARD AND LONG)
        Removal And Installation
        Arm To Boom Bushing Removal And Installation
        Arm To Bucket And Bucket Link Bushing Removal And Installation
    BUCKET
        Bucket Teeth Removal And Installation
        Bucket Side Cutting Edge Removal And Installation
    CLAMP
        Removal And Installation
    TAILGATE
        Removal And Installation
        Latch Removal And Installation
    X-CHANGE
        Removal And Installation
        Disassembly
        Assembly
    X-CHANGE (HYDRAULIC)
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    QUICK COUPLER (KLAC™ SYSTEM)
        Troubleshooting
        Daily Inspection
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    QUICK COUPLER (LEHNHOFF® SYSTEM)
        Troubleshooting
        Daily Inspection
        Removal (MS03 And MS08)
        Installation (MS03 And MS08)
        Parts Identification (MS03)
        Disassembly And Assembly (MS03)
        Parts Identification (MS08)
        Disassembly (MS08)
        Assembly (MS08)
    RIGHT SIDE COVER
        Removal And Installation
        Latch Removal And Installation
        Latch Adjustment
    TOOL BOX
        Removal And Installation
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuse And Relay Location / Identification
    BATTERY
        Servicing
        Removal And Installation
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Belt Adjustment
        Belt Replacement
        Charging System Inspection
        Alternator Voltage Testing
        Low Voltage Testing
        High Voltage Testing
        Removal And Installation
        Parts Identification
    STARTER
        Testing
        Removal And Installation
        Parts Identification
    LIGHTS
        Removal And Installation
        Boom Light Removal And Installation
        Boom Light Bulb Replacement
    MAGNETIC LOCKOUT SENSOR
        Removal And Installation
    FUEL LEVEL SENDER
        Removal And Installation
        Testing
    DIAGNOSTIC SERVICE CODES
        Service Codes List
    DELUXE INSTRUMENT PANEL SETUP
        Passwords
        Password Entry (For Starting And Operating The Machine)
        Changing The Operator Password
        Password Lockout Feature
        Job Clock
        RPM
    INSTRUMENT PANEL / CONTROLLER
        Removal And Installation
    KEY SWITCH
        Removal And Installation
    WIPER MOTOR
        Removal And Installation
    MOTION ALARM SYSTEM
        Description
        Inspecting
        Adjusting Switch Position
    SERVICE PC (LAPTOP COMPUTER)
        Connecting The Remote Start Tool
        Connecting Remote Start Tool (Service Tool)
        Operation
    SHUT-OFF SWITCH
        Description
        Removal And Installation
    TRAVEL MOTOR AUTO-SHIFT
        Auto-Shift Drive System (If Equipped)
        Troubleshooting
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Specifications
        Crankshaft Re-Grind Data
        Torque For Kubota Metric Bolts
        Troubleshooting
        Removal And Installation
        Compression-Checking
    ENGINE SPEED CONTROL
        Removal And Installation
        Auto Idle Description
        Auto Idle Controller Removal And Installation
        Calibration
        Actuator Removal And Installation
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Housing Removal And Installation
    ENGINE COOLING SYSTEM
        Radiator Removal And Installation
        Fan Removal And Installation
        Water Pump Removal And Installation
        Water Pump Disassembly And Assembly
        Thermostat Housing Removal And Installation
        Thermostat - Checking
    LUBRICATION SYSTEM
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Inspection
        Engine Oil Pressure - Testing
    FUEL SYSTEM
        Fuel Shutoff Solenoid - Checking
        Fuel Shut-off Solenoid Removal And Installation
        Fuel Injection Pump - Checking
        Fuel Injection Pump Removal And Installation
        Fuel Injection Pump - Timing
        Fuel Camshaft Removal And Installation
        Fuel Camshaft Governor
        Fuel Injector Removal And Installation
        Fuel Injector Nozzle Pressure - Checking
        Nozzle Spray Condition
        Valve Seat Tightness
    CYLINDER HEAD
        Glow Plugs - Testing
        Glow Plugs Removal And Installation
        Valve Clearance Adjustment
        Valve Timing - Checking
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head - Servicing
        Cylinder Head Top Clearance
        Valve Guide - Checking
        Valve Guide Removal And Installation
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft - Checking
        Push Rod Alignment - Checking
    CRANKSHAFT AND PISTONS
        Piston And Connecting Rod Removal And Installation
        Piston And Connecting Rod - Servicing
        Cylinder Bore - Checking
        Connecting Rod Alignment
        Crankshaft Gear Removal And Installation
        Crankshaft And Bearings Removal And Installation
        Crankshaft And Bearings - Servicing
    CAMSHAFT AND TIMING GEARS
        Timing Gearcase Cover Removal And Installation
        Timing Gears Backlash - Checking
        Idle Gear And Camshaft Removal And Installation
        Camshaft - Servicing
        Idle Gear And Shaft - Servicing
    TURBOCHARGER
        Description
        Testing
        Removal And Installation
    FLYWHEEL AND HOUSING
        Hydraulic Pump Coupler Removal And Installation
        Flywheel Removal And Installation
        Flywheel Ring Gear
        
HEATING, VENTILATION & AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Description
        Chart
        Components
        Safety Equipment
    REGULAR MAINTENANCE
        Cab Filters
        Air Conditioning Compressor Belt Adjustment
        Air Conditioning Compressor Belt Replacement
        Condenser
        Air Conditioning Lubrication
        Evaporator / Heater Coil
        Air Conditioning Service Chart
    TROUBLESHOOTING
        Blower Motor Does Not Operate
        Blower Motor Operates Normally, But Air Flow Is Insufficient
        Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
        The Compressor Operates Improperly Or Not At All
        Gauge Pressure Related Troubleshooting
        Temperature / Pressure Chart
        Poor A/C Performance
        HVAC Repair And Leaks
        Electrical System
        Engine Coolant Bypassing The Heater Valve
    SYSTEM CHARGING AND RECLAMATION
        Refrigerant Identification
        Reclamation And Charging With Recovery / Charging Unit
    COMPRESSOR
        Removal And Installation
        Oil
        Oil Check
    CONDENSER
        Removal And Installation
    RECEIVER / DRIER
        Receiver / Drier Removal And Installation
        Pressure Relief Valve Removal And Installation
        Pressure Switch Removal And Installation
    EVAPORATOR / HEATER UNIT
        Removal And Installation
    THERMOSTAT
        Description
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    EVAPORATOR COIL
        Removal And Installation
    HEATER COIL
        Removal And Installation
    BLOWER FAN
        Removal And Installation
    HEATER VALVE
        Removal And Installation
    HVAC DUCT
        Removal And Installation
        
SPECIFICATIONS
    E55 EXCAVATOR SPECIFICATIONS
        Excavator Machine Dimensions
        Excavator Machine Dimensions - Angle Blade
        Performance
        Controls
        Engine
        Hydraulic System
        Hydraulic Cylinders
        Hydraulic Cycle Times
        Electrical
        Drive System
        Slew System
        Undercarriage
        Capacities
        Tracks
        Ground Pressure
    TORQUE SPECIFICATION FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O-ring Face Seal Connection
        Straight Thread O-ring Fitting
        Tubelines And Hoses
        Flare Fitting
        O-ring Flare Fitting
        Port Seal Fitting
        Push To Connect Fittings
    HYDRAULIC FLUID SPECIFICATIONS
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalent Chart
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

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