A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• 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
• Revison No: E60-3