Bobcat E60 Compact Excavator Service Manual – 6987190 (10-09)

(S/N: AGSZ11001 & Above – S/N: AET811001 & Above)
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This workshop repair service manual PDF download for the E60 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 E60
S/N: AGSZ11001 & Above
S/N: AET811001 & Above

TABLE OF CONTENTS :

SAFETY INSTRUCTIONS
FOREWORD
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM AND ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 6987190 (10-09)
Total Pages : 753

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 !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
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
BOBCAT EXCAVATOR IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS)
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
Heating, Ventilation And Air Conditioning Duct
TRANSPORTING THE EXCAVATOR
Loading And Unloading
Fastening
RIGHT SIDE COVER
Opening And Closing
Adjusting The Latch
REAR COVER
Opening And Closing
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing The Filters
CAB FILTER
Cleaning And Maintenance
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 Fluid
Hydraulic Fluid Chart
Removing And Replacing Hydraulic Filters
Removing And Replacing Hydraulic Fluid
Removing Air From Hydraulic Pump
LUBRICATING THE EXCAVATOR
Lubrication Locations
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
SPARK ARRESTOR MUFFLER
Cleaning Procedure
ALTERNATOR BELT
Belt Adjustment
Belt Replacement
AIR CONDITIONING BELT
Belt Adjustment
Belt Replacement
SEAT BELT
Inspection And Maintenance
PIVOT PINS
Inspection And Maintenance
CAB TILT PROCEDURE
Tilting The Cab

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting Chart
Description
BOOM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
ARM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BOOM SWING CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BLADE CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVES
Testing And Adjusting The Main Relief Valves
PORT RELIEF VALVES
Testing And Adjusting Port Relief Valve Pressure
PRESSURE REDUCING VALVE
Description
Testing And Adjusting
HYDRAULIC CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
Inlet Valve Section Disassembly And Assembly
Blade And Upperstructure Swing Valve Section Disassembly And Assembly
Boom Swing And Tilting Valve Section Disassembly And Assembly
Boom 2/Auxiliary And Arm 1 Valve Section Disassembly And Assembly
Left Travel, Inlet And Right Travel Valve Section Disassembly And Assembly
Boom 1 Disassembly And Assembly
Arm 2 and Bucket Valve Section Disassembly And Assembly
HYDRAULIC PUMP
Testing Information
Torque Adjustment
Testing The Piston Pump
Testing The Gear Pump
Removal And Installation
Gear Pump Parts Identification
Gear Pump Disassembly And Assembly
Solenoid Valve Parts Identification
Solenoid Valve Disassembly And Assembly
Piston Pump Parts Identification
Piston Pump Disassembly And Assembly
GEAR PUMP
Testing Information
Testing
Removal And Installation
Disassembly And Assembly
ACCUMULATOR
Description
Removal And Installation
TRAVEL MOTOR
Removal And Installation
Parts Identification
SWIVEL JOINT
Removal And Installation
Parts Identification
Disassembly
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
Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly And Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly And Assembly
BLADE CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
DIRECT TO TANK VALVE
Removal And Installation
Disassembly And Assembly
AUXILIARY BREAKER VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
BOOM SWING VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
AUXILIARY HYDRAULIC VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
TRAVEL CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly

UNDERCARRIAGE
BLADE
Removal And Installation
TRACKS
Track Lug Height
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
TRACK FRAME
Disassembly And Assembly
Recoil Spring Cylinder
TRACK DAMAGE IDENTIFICATION
Cutting Of Steel Cords
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Abrasion Of The Track Roller Side
Cuts On The Edges Of Track Roller Side
TRACK IDLER
Parts Identification
Disassembly
Assembly
TRACK ROLLER
Parts Identification
Disassembly
Assembly
LOWER STEEL TRACK ROLLER
Parts Identification
Disassembly
Assembly
UPPER ROLLER
Parts Identification
Disassembly And Assembly

UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Removal
Installation
LEFT UPPERSTRUCTURE SIDE COVER
Removal And Installation
RIGHT UPPERSTRUCTURE SIDE COVER
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Lower Front Window Removal And Installation
Glass Installation
Front Window Strut Removal And Installation
Front Window Slide Bar Removal And Installation
Cab Tilt Assembly Removal And Installation
Cab Tilt Parts Identification
Cab Tilt Assembly Disassembly And Assembly
Headliner Removal And Installation
SEAT AND SEAT MOUNT
Seat Removal And Installation
Seat Mount Removal And Installation
RIGHT CONSOLE
Console Cover Removal And Installation
LEFT CONSOLE
Upper Console Cover Removal And Installation
Lower Console Cover Removal And Installation
Gas Strut Removal And Installation
Lock Lever Removal And Installation
Lock Lever Disassembly And Assembly
Console Removal And Installation
FLOORMAT
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
Bushing Removal And Installation
ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Bucket And Link Bushing Removal And Installation
ATTACHMENTS
Installing And Removing The Attachment (Pin-On Attachment)
Pin-On Inspection
Installing And Removing The Attachment (Pin-On X- Change Attachment)
Installing And Removing The Attachment (Bobcat Quick Coupler (BQC) Type SW)
Quick Coupler (BQC) Type SW And Attachment Inspection
Installing And Removing The Attachment (Bobcat Quick Coupler (BQC) Type K)
Quick Coupler (BQC) Type K And Attachment Inspection
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
RIGHT SIDE COVER
Removal And Installation
COUNTER WEIGHT
Removal And Installation
REAR COVER
Removal And Installation

ELECTRICAL SYSTEM AND 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
Removal And Installation
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Alternator Regulator Test
Parts Identification
Disassembly And Assembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
STARTER
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
LIGHTS
Boom Light Removal And Installation
Boom Light Bulb Replacement
CONSOLE LOCKOUT SWITCH
Testing / Adjustment
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
DIAGNOSTIC SERVICE CODE
Service Codes List
Flashing Patterns Of Engine Check Lamp
DIAGNOSTIC TOOL
Software Installation
Installation
Code Retrieval
KEY SWITCH
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
Disassembly And Assembly
RIGHT CONSOLE SWITCH COVER
Removal And Installation
Rocker Switch Removal And Installation
Speed Control Removal And Installation
Engine Emergency Stop Switch Removal And Installation
Auxiliary Power Outlet Removal And Installation
WIPER MOTOR
Removal And Installation
FUEL TRANSFER PUMP
Removal And Installation

ENGINE SERVICE
TROUBLESHOOTING
Chart
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR / OIL COOLER
Removal And Installation
Disassembly And Assembly
FUEL COOLER
Removal And Installation
ENGINE COMPONENTS AND TESTING
Engine Compression Checking
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Removal And Installation
Fuel Injector Testing
Valve Clearance Adjustment
Cold Start Device Description
Cold Start Device Testing
Cold Start Device Removal And Installation
EGR Valve Description
EGR Valve Testing
EGR Valve Removal And Installation
Manifold Air Heater Description
Manifold Air Heater Testing
Manifold Air Heater Removal And Installation
ENGINE
Removal And Installation
ENGINE FLYWHEEL
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear Removal And Installation
RECONDITIONING THE ENGINE
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Servicing
Valve Guide Inspection
Intake And Exhaust Valve Inspection
Valve Stem Bend
Valve Face And Seat
Valve Spring Inspection
Push Rod Inspection
Rocker Arm Inspection
Valve Bridge Inspection
Remove Of Timing Gear Case Cover
Checking Timing Gear Backlash
Removal Of The Timing Gears
Camshaft Removal
Oil Pan Removal And Installation
Gear Case Removal And Installation
Crankshaft End Play
Crankshaft Removal And Installation
Cylinder Block Inspection
Piston And Connecting Rod
Fan Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
EVAPORATOR / HEATER COIL
Removal And Installation
HEATER / AC FAN
Removal And Installation
HEATER VALVE
Removal And Installation
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Heater Air Filter
Compressor Belt Inspection
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
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
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
CONDENSER
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Inspection
EXPANSION VALVE
Removal And Installation
HVAC CONTROLLER
Removal And Installation

SPECIFICATIONS
SPECIFICATIONS
E60 Excavator Dimensions
E60 Excavator Dimensions With Standard Arm
E60 Excavator Dimensions With Long Arm
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Drive System
Undercarriage
Electrical
Slew System
Capacities
Track
Ground Pressure
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arm And Shaft
Camshaft
Tappet
Push Rod
Cylinders
Piston Rings
Pistons
Connecting Rods
Oil Pump
Crankshaft
Thrust Bearing
Timing Gear Backlash
Idler Gear Shaft And Bushing
Engine Bolt Torque
TORQUE SPECIFICATIONS 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
Port Seal Fitting
BSPP Swivel Nut
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
Revision No: E60-1
Revision No: E60-2
Revision No: E60-3

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