Bobcat Compact Excavator E27z Service Manual 7349963 (01-21) – PDF DOWNLOAD

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Bobcat Compact Excavator E27z Service Manual 7349963 (01-21) – PDF DOWNLOAD

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Bobcat Compact Excavator E27z Service Manual 7349963 (01-21) – PDF DOWNLOAD

Language : English
Pages : 798
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat Compact Excavator E27z Service Manual 7349963 (01-21) – PDF DOWNLOAD

S/N B4B911001 & 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 Compact Excavator E27z Service Manual 7349963 (01-21) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
Avoid Silica Dust 11
FIRE PREVENTION 12
Maintenance 12
Operation 12
Electrical 12
Hydraulic System 12
Fueling 12
Starting 12
Spark Arrester Exhaust System 12
Welding And Grinding 13
Fire Extinguishers 13
SERIAL NUMBER LOCATIONS 14
Excavator Serial Number 14
Engine Serial Number 14
DELIVERY REPORT 15
EXCAVATOR IDENTIFICATION 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
LIFTING THE EXCAVATOR 23
Procedure 23
OPERATOR CAB (ROPS / TOPS / FOPS) 25
Description 25
Cab Door 26
Front Window 27
Front Wiper 28
Window Washer Reservoir 28
Right Side Window 29
Heating And Ventilation Ducting 30
OPERATOR CANOPY (ROPS / TOPS / FOPS) 31
Description 31
TRANSPORTING THE EXCAVATOR ON A TRAILER 33
Loading And Unloading 33
Fastening 34
TAILGATE 37
Opening And Closing 37
Adjusting The Latch 37
RIGHT SIDE COVER 39
Opening And Closing 39
SERVICE SCHEDULE 41
Maintenance Intervals 41
Inspection Checkbook 42
AIR CLEANER SERVICE 43
Daily Check 43
Replacing The Filters 43
ENGINE COOLING SYSTEM 45
Cleaning 45
Checking Level 46
Removing And Replacing Coolant 47
FUEL SYSTEM 49
Fuel Specifications 49
Biodiesel Blend Fuel 49
Filling The Fuel Tank 50
Fuel Filter 51
Draining The Fuel Tank 51
Removing Air From The Fuel System 52
ENGINE LUBRICATION SYSTEM 53
Checking And Adding Engine Oil 53
Engine Oil Chart 53
Removing And Replacing Oil And Filter 54
HYDRAULIC SYSTEM 55
Checking And Adding Hydraulic Fluid 55
Hydraulic / Hydrostatic Fluid Chart 56
Removing And Replacing Hydraulic Filters 56
Removing And Replacing Hydraulic Fluid 57
LUBRICATING THE EXCAVATOR 59
Lubrication Locations 59
PIVOT PINS 63
Inspection And Maintenance 63
TRAVEL MOTOR 65
Checking And Adding Oil 65
Removing And Replacing Oil 65
EMERGENCY EXIT 67
Right Side Rear Window 67
Front Window 67
SEAT BELT 69
Inspection And Maintenance 69
CONTROL CONSOLE LOCKOUTS 71
Inspection And Maintenance 71
TOWING THE EXCAVATOR 73
Procedure 73
REMOTE START TOOL KIT – MEL1563 75
Remote Start Tool – MEL1563 75
Service Tool Harness Control – MEL1565 76
Service Tool Harness Communicator – MEL1566 77
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 79
Description 79
Remote Start Tool (Service Tool) – 7022042 80
Excavator Service Tool Harness – 6689747 81
Computer Service Tool Harness – 6689746 82
HYDRAULIC SYSTEM 83
HYDRAULIC / HYDROSTATIC SCHEMATICS 87
HYDRAULIC SYSTEM INFORMATION 89
Glossary Of Hydraulic / Hydrostatic Symbols 89
Troubleshooting The Hydraulic Circuit 92
Troubleshooting The Cylinder Circuit 93
Troubleshooting The Swing (Upperstructure Slew) Circuit 94
Troubleshooting The Travel Circuit 95
CYLINDER (BOOM) 97
Testing 97
Removal And Installation 99
Parts Identification 102
Disassembly 103
Assembly 105
CYLINDER (ARM) 109
Testing 109
Removal And Installation 111
Parts Identification 113
Disassembly 114
Assembly 115
CYLINDER (BOOM SWING) 119
Testing 119
Removal And Installation 121
Parts Identification (Earlier Models) 123
Disassembly (Earlier Models) 124
Assembly (Earlier Models) 126
Parts Identification (Later Models) 130
Disassembly (Later Models) 131
Assembly (Later Models) 133
CYLINDER (BUCKET) 137
Testing 137
Removal And Installation 138
Parts Identification 140
Disassembly 141
Assembly 143
CYLINDER (BLADE) 147
Testing 147
Removal And Installation 149
Parts Identification (Earlier Models) 150
Disassembly (Earlier Models) 151
Assembly 152
Parts Identification (Later Models) 156
Disassembly (Later Models) 157
Assembly (Later Models) 159
CYLINDER (CLAMP) 163
Testing 163
Removal And Installation 164
Parts Identification 166
Disassembly 167
Assembly 170
VALVES (MAIN RELIEF) 175
Testing And Adjusting 175
VALVES (PORT RELIEF) 181
Testing And Adjusting 181
VALVES (CROSS PORT RELIEF) 183
Testing 183
Removal And Installation 185
Disassembly And Assembly 185
VALVES (PILOT PRESSURE RELIEF) 187
Testing And Adjusting 187
HYDRAULIC CONTROL VALVE 189
Removal And Installation 189
Parts Identification 195
Disassembly 207
Auxiliary Valve Section Disassembly And Assembly 209
Arm Valve Section Disassembly And Assembly 213
RH Travel Valve Section Disassembly And Assembly 216
Bucket Valve Section Disassembly And Assembly 219
Boom Valve Section Disassembly And Assembly 222
LH Travel Valve Section Disassembly And Assembly 223
“Priority Valve” Valve Section Disassembly And Assembly 224
Blade Valve Section Disassembly And Assembly 226
Boom Swing Valve Section Disassembly And Assembly 229
Auxiliary 4 Valve Section Disassembly And Assembly 232
Slew Valve Section Disassembly And Assembly 235
Assembly 238
HYDRAULIC PUMP 245
Description 245
Torque Adjustment 246
Testing The Piston Pump P1 247
Testing The Piston Pump P2 249
Testing The Gear Pump P3 250
Testing The Gear Pump P4 252
Testing Auxiliary Hydraulic Flow 254
Removal And Installation 255
Coupler Removal And Installation 256
Hydraulic Pump Startup 257
Gear Pump Disassembly And Assembly 258
Piston Pump Parts Identification 263
Piston Pump Disassembly And Assembly 264
MANIFOLD ASSEMBLY / ACCUMULATOR 275
Description 275
Removal And Installation 276
Parts Identification 278
Disassembly And Assembly 279
TRAVEL MOTOR 285
Description 285
Removal And Installation 285
Parts Identification Hydraulic Motor 286
Parts Identification Gear Reduction Hub 287
Disassembly 288
Assembly 300
SWIVEL JOINT 313
Removal And Installation 313
Parts Identification 315
Disassembly And Assembly 316
SWING MOTOR 319
Removal And Installation 319
Parts Identification 321
Disassembly And Assembly 322
SWING MOTOR (DRIVE CARRIER) 329
Removal And Installation 329
Parts Identification 330
Disassembly And Assembly 331
RIGHT CONTROL LEVER (JOYSTICK) 337
Testing 337
Handle Removal And Installation 338
Joystick Assembly Removal And Installation 341
Parts Identification 342
Disassembly And Assembly 343
LEFT CONTROL LEVER (JOYSTICK) 345
Testing 345
Handle Removal And Installation 346
Joystick Assembly Removal And Installation 349
Parts Identification 350
Disassembly And Assembly 351
HYDRAULIC FILTER MOUNT 353
Removal And Installation 353
HYDRAULIC RESERVOIR 355
Removal And Installation 355
OIL COOLER 357
Removal And Installation 357
BLADE CONTROL LEVER 359
Handle Removal And Installation 359
Removal And Installation 361
Parts Identification 363
Disassembly And Assembly 364
CASE DRAIN FILTER MOUNT 369
Removal And Installation 369
TRAVEL CONTROL VALVE 371
Removal And Installation 371
Parts Identification 372
Disassembly And Assembly 373
REMOVING AIR FROM THE HYDRAULIC SYSTEM 379
Procedure 379
SECONDARY AUXILIARY VALVE 381
Removal And Installation 381
Parts Identification 384
Disassembly And Assembly 385
VALVE (BOOM LOAD HOLDING VALVE) 389
Removal And Installation 389
Inspection 391
Override Function – Emergency Lowering 391
VALVE (ARM LOAD HOLDING VALVE) 393
Removal And Installation 393
Inspection 395
Override Function – Emergency Lowering 395
UNDERCARRIAGE 397
BLADE 399
Removal And Installation 399
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 401
Description 401
Track Lug Height 401
Checking Tension 402
Adjusting Tension 403
Track Removal And Installation 404
Idler Removal And Installation 406
Idler Parts Identification 407
Idler Disassembly 408
Idler Assembly 410
Track Tensioner Removal And Installation 412
Track Tensioner Parts Identification 413
Track Tensioner Disassembly And Assembly 414
Roller Removal And Installation 415
Sprocket Removal And Installation 416
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 417
Description 417
Checking Tension 417
Adjusting Tension 418
Track Removal And Installation 419
Idler Removal And Installation 422
Idler Parts Identification 423
Idler Disassembly 424
Idler Assembly 426
Track Tensioner Removal And Installation 428
Track Tensioner Parts Identification 429
Track Tensioner Disassembly And Assembly 430
Roller Removal And Installation 431
Sprocket Removal And Installation 432
Guide Plate Removal And Installation 432
TRACK MAINTENANCE 433
Track Damage Identification 433
SWING CIRCLE GEAR 445
Swing Bearing Removal 445
Swing Bearing Installation 446
UPPERSTRUCTURE AND SWING SECTION 449
UPPERSTRUCTURE 451
Removal 451
Installation 453
ROPS CANOPY 455
Removal And Installation 455
CAB 459
Removal And Installation 459
Door Removal And Installation 463
Front Window Removal And Installation 464
Right Side Sliding Window Removal And Installation 466
Glass Removal 469
Glass Installation 470
SEAT 475
Removal And Installation 475
Seat Mount Removal And Installation 476
RIGHT CONSOLE 477
Console Cover Removal And Installation 477
LEFT CONSOLE 483
Lower Console Cover Removal And Installation 483
Upper Console Cover Removal And Installation 484
Compression Spring Removal And Installation 487
Lock Lever Removal And Installation 489
Console Removal And Installation 489
LEFT UPPERSTRUCTURE COVER 491
Removal And Installation 491
RIGHT UPPERSTRUCTURE COVER 493
Removal And Installation 493
COUNTERWEIGHT 495
Removal And Installation (Standard And Long Arm) 495
TRAVEL LEVERS AND PEDALS 499
Removal And Installation 499
Disassembly And Assembly 500
FLOOR MAT 501
Removal And Installation 501
FUEL TANK 503
Removal And Installation 503
HORN 505
Removal And Installation 505
SWING FRAME 507
Removal And Installation 507
Boom Swing Frame Hose Routing 509
Bushing Removal 510
Bushing Installation 511
BOOM 513
Removal And Installation 513
ARM (STANDARD AND LONG) 515
Removal And Installation 515
Arm To Boom Bushing Removal And Installation 516
Arm To Bucket And Bucket Link Bushing Removal And Installation 517
BUCKET 519
Bucket Teeth Removal And Installation 519
CLAMP 521
Removal And Installation 521
TAILGATE 523
Removal And Installation 523
Latch Removal And Installation 524
QUICK COUPLER (KLAC™ SYSTEM) 525
Removal 525
Installation 526
QUICK COUPLER (LEHNHOFF ® SYSTEM) 529
Removal 529
Installation 530
QUICK COUPLER (BOBCAT HYDRAULIC PIN GRABBER COUPLER HPG2) 533
Troubleshooting 533
Daily Inspection 534
Removal And Installation 534
Parts Identification 536
Disassembly And Assembly 537
RIGHT SIDE COVER 541
Removal And Installation 541
TOOL BOX 543
Removal And Installation 543
ELECTRICAL SYSTEM AND ANALYSIS 545
ELECTRICAL SCHEMATICS 547
ELECTRICAL SYSTEM INFORMATION 569
Glossary Of Electrical Symbols 569
Cab Frame Harness 572
Canopy Harness 573
Main Frame Harness 574
Motion Alarm Harness 575
Secondary Auxiliary Harness 576
Troubleshooting Chart 577
Description 578
Fuse And Relay Location / Identification 578
BATTERY 581
Servicing 581
Removing And Installation 582
Using A Booster Battery (Jump Starting) 583
ALTERNATOR 585
Belt Adjustment 585
Belt Replacement 585
Charging System Inspection 587
Alternator Voltage Testing 588
Removal And Installation 588
Parts Identification 591
STARTER 593
Testing 593
Removal And Installation 594
Parts Identification 595
LIGHTS 597
Boom Light Removal And Installation 597
Boom Light Bulb Replacement 597
MAGNETIC LOCKOUT SENSOR 599
Removal And Installation 599
FUEL LEVEL SENDER 601
Removal And Installation 601
Testing 602
DIAGNOSTIC SERVICE CODES 603
Viewing Service Codes 603
Service Codes List 604
CONTROL PANEL SETUP 607
Panel Setup (Deluxe Instrument Panel) 607
Password Setup (Keyless Start Panel) 613
Password Setup (Deluxe Instrument Panel) 614
Maintenance Clock 616
INSTRUMENT PANEL 619
Removal And Installation 619
CONTROLLER (GATEWAY AND AUXILIARY) 621
Description 621
Gateway Controller Removal And Installation 621
Auxiliary Controller Removal And Installation 622
KEY SWITCH 623
Removal And Installation 623
WIPER MOTOR 625
Removal And Installation 625
MOTION ALARM SYSTEM 627
Description 627
Inspecting 627
Adjusting Switch Position 628
SERVICE PC (LAPTOP COMPUTER) 629
Connecting The Remote Start Tool 629
Connecting Remote Start Tool (Service Tool) 629
BATTERY DISCONNECT SWITCH 631
Description 631
Removal And Installation 632
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 633
Description 633
Controller Removal And Installation 633
Procedure 635
ENGINE SERVICE 637
ENGINE INFORMATION 639
Description 639
Specifications 640
Crankshaft Re-Grind Data 646
Torque For Kubota® Metric Bolts 647
Troubleshooting 648
Engine Removal And Installation 649
Compression Checking 658
ENGINE SPEED CONTROL (DIAL GAUGE) 659
Removal And Installation 659
Calibration 660
Actuator Removal And Installation 663
ENGINE SPEED CONTROL (LEVER) 665
Removal And Installation 665
Calibration 665
MUFFLER 667
Removal 667
Installation 668
AIR CLEANER 671
Removal And Installation 671
ENGINE COOLING SYSTEM 673
Coolant Recovery Tank Removal And Installation 673
Radiator Removal And Installation 673
Fan Removal And Installation 676
Water Pump Removal And Installation 677
Water Pump Disassembly And Assembly 677
Thermostat Housing Removal And Installation 678
Thermostat – Checking 678
LUBRICATION SYSTEM 679
Oil Pan Removal And Installation 679
Oil Pump Removal And Installation 679
Oil Pump Inspection 680
Engine Oil Pressure – Testing 681
FUEL SYSTEM 683
Fuel Shutoff Solenoid – Checking 683
Fuel Shutoff Solenoid Removal And Installation 684
Fuel Injection Pump – Checking 685
Fuel Injection Pump Removal And Installation 686
Fuel Injection Pump – Timing 689
Fuel Camshaft Removal And Installation 691
Fuel Camshaft Governor 691
Fuel Injector Removal And Installation 692
Fuel Injector Nozzle Pressure – Checking 694
Nozzle Spray Condition 695
Valve Seat Tightness 695
CYLINDER HEAD 697
Glow Plugs – Testing 697
Glow Plugs Removal And Installation 697
Valve Clearance Adjustment 698
Valve Timing – Checking 698
Cylinder Head Removal And Installation 699
Cylinder Head Disassembly And Assembly 703
Cylinder Head – Servicing 704
Cylinder Head Top Clearance 704
Valve Guide – Checking 705
Valve Guide Removal And Installation 706
Reconditioning The Valve And Valve Seat 707
Valve Spring 708
Valve Tappets 709
Rocker Arm And Shaft – Checking 710
Push Rod Alignment – Checking 710
CRANKSHAFT AND PISTONS 711
Piston And Connecting Rod Removal And Installation 711
Piston And Connecting Rod – Servicing 713
Cylinder Bore – Checking 715
Connecting Rod Alignment 716
Crankshaft Gear Removal And Installation 717
Crankshaft And Bearings Removal And Installation 718
Crankshaft And Bearings – Servicing 721
CAMSHAFT AND TIMING GEARS 725
Timing Gearcase Cover Removal And Installation 725
Timing Gears Backlash – Checking 727
Idler Gear And Camshaft Removal And Installation 727
Camshaft – Servicing 728
Idler Gear And Shaft Servicing 730
FLYWHEEL AND HOUSING 731
Hydraulic Pump Coupler Removal And Installation 731
Flywheel Removal And Installation 733
Flywheel Ring Gear 733
HEATING AND VENTILATION 735
REGULAR MAINTENANCE 737
Cab Filters 737
TROUBLESHOOTING 739
Blower Motor Does Not Operate 739
Blower Motor Operates Normally, But Air Flow Is Insufficient 739
Electrical System 740
HEATER UNIT 741
Removal And Installation 741
HEATER COIL 743
Removal And Installation 743
BLOWER FAN 745
Removal And Installation 745
HEATER VALVE 747
Removal And Installation 747
HEATING / VENTILATION DUCT 749
Removal And Installation 749
SPECIFICATIONS 751
EXCAVATOR SPECIFICATIONS 753
Machine Dimensions 753
Machine Dimensions – Standard Arm 754
Machine Dimensions – Long Arm 755
Rated Lift Capacity – Canopy With Standard Arm And Medium Counterweight 756
Rated Lift Capacity – Canopy With Long Arm And Medium Counterweight 757
Rated Lift Capacity – Canopy With Standard Arm And Heavy Counterweight 758
Rated Lift Capacity – Canopy With Long Arm And Heavy Counterweight 759
Rated Lift Capacity – Cab With Standard Arm And Medium Counterweight 760
Rated Lift Capacity – Cab With Long Arm And Medium Counterweight 761
Rated Lift Capacity – Cab With Standard Arm And Heavy Counterweight 762
Rated Lift Capacity – Cab With Long Arm And Heavy Counterweight 763
Performance 764
Controls 764
Engine 765
Hydraulic System 765
Hydraulic Cylinders 766
Hydraulic Cycle Times 766
Electrical 766
Drive System 766
Slew System 767
Undercarriage 767
Capacities 767
Tracks 767
Environmental 767
Temperature Range 767
TECHNICAL SERVICE GUIDE SPECIFICATIONS 769
Engine 769
Engine Torques 769
Excavator Torques 769
Cooling System 769
TORQUE SPECIFICATION FOR BOLTS 771
Torque For General SAE Bolts 771
Torque For General Metric Bolts 772
HYDRAULIC CONNECTION SPECIFICATIONS 773
O-ring Face Seal Connection 773
Straight Thread O-ring Fitting 773
Tubelines And Hoses 774
Flare Fitting 774
O-ring Flare Fitting 775
Port Seal Fitting 777
Push To Connect Fittings 778
HYDRAULIC FLUID SPECIFICATIONS 781
Specifications 781
CONVERSIONS 783
Decimal And Millimeter Equivalent Chart 783
U S To Metric Conversion Chart 784
SERVICE TOOLS REQUIRED 785
Remote Start Tools 785
Hydraulic Tools 786
Engine Tools 789
Electrical Tools 791
General Tools 792
HVAC Tools 793
ALPHABETICAL INDEX 795
SERVICE SCHEDULE SYMBOLS 797

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