Bobcat Compact Excavator E27z Service Manual 7354905 (01-21) – PDF DOWNLOAD

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Bobcat Compact Excavator E27z Service Manual 7354905 (01-21) – PDF DOWNLOAD

FILE DETAILS:

Bobcat Compact Excavator E27z Service Manual 7354905 (01-21) – PDF DOWNLOAD

Language : English
Pages : 790
Downloadable : Yes
File Type : PDF

DESCRIPTION:

S/N B4R711001 & Above

Bobcat Compact Excavator E27z Service Manual 7354905 (01-21) – 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 Compact Excavator E27z Service Manual 7354905 (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 116
CYLINDER (BOOM SWING) 119
Testing 119
Removal And Installation 121
Parts Identification (Earlier Models) 123
Disassembly (Earlier Models) 124
Assembly 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 275
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 385
Disassembly And Assembly 386
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
LEFT SIDE COVER 545
Removal And Installation 545
ELECTRICAL SYSTEM AND ANALYSIS 547
ELECTRICAL SCHEMATICS 549
ELECTRICAL SYSTEM INFORMATION 565
Glossary Of Electrical Symbols 565
Cab Frame Harness 568
Canopy Harness 569
Main Frame Harness 570
Motion Alarm Harness 571
Secondary Auxiliary Harness 572
Troubleshooting Chart 573
Description 574
Fuse And Relay Location / Identification 574
BATTERY 577
Servicing 577
Removing And Installation 578
Using A Booster Battery (Jump Starting) 579
ALTERNATOR 581
Belt Adjustment 581
Belt Replacement 581
Charging System Inspection 583
Alternator Voltage Testing 584
Removal And Installation 584
Parts Identification 587
STARTER 589
Testing 589
Removal And Installation 590
Parts Identification 591
LIGHTS 593
Boom Light Removal And Installation 593
Boom Light Bulb Replacement 593
MAGNETIC LOCKOUT SENSOR 595
Removal And Installation 595
FUEL LEVEL SENDER 597
Removal And Installation 597
Testing 598
DIAGNOSTIC SERVICE CODES 599
Viewing Service Codes 599
Service Codes List 600
CONTROL PANEL SETUP 603
Panel Setup (Deluxe Instrument Panel) 603
Password Setup (Keyless Start Panel) 609
Password Setup (Deluxe Instrument Panel) 610
Maintenance Clock 612
INSTRUMENT PANEL 615
Removal And Installation 615
CONTROLLER (GATEWAY AND AUXILIARY) 617
Description 617
Gateway Controller Removal and Installation 617
Auxiliary Controller Removal And Installation 618
KEY SWITCH 619
Removal And Installation 619
WIPER MOTOR 621
Removal And Installation 621
MOTION ALARM SYSTEM 623
Description 623
Inspecting 623
Adjusting Switch Position 624
SERVICE PC (LAPTOP COMPUTER) 625
Connecting The Remote Start Tool 625
Connecting Remote Start Tool (Service Tool) 625
BATTERY DISCONNECT SWITCH 627
Description 627
Removal And Installation 628
ENGINE SERVICE 629
ENGINE INFORMATION 631
Description 631
Specifications 632
Crankshaft Re-Grind Data 638
Torque For Kubota® Metric Bolts 639
Troubleshooting 640
Engine Removal And Installation 641
Compression Checking 650
ENGINE SPEED CONTROL (DIAL GAUGE) 651
Removal And Installation 651
Calibration 652
Actuator Removal And Installation 655
ENGINE SPEED CONTROL (LEVER) 657
Removal And Installation 657
Calibration 657
MUFFLER 659
Removal 659
Installation 660
AIR CLEANER 663
Removal And Installation 663
ENGINE COOLING SYSTEM 665
Coolant Recovery Tank Removal And Installation 665
Radiator Removal And Installation 665
Fan Removal And Installation 668
Water Pump Removal And Installation 669
Water Pump Disassembly And Assembly 669
Thermostat Housing Removal And Installation 670
Thermostat – Checking 670
LUBRICATION SYSTEM 671
Oil Pan Removal And Installation 671
Oil Pump Removal And Installation 671
Oil Pump Inspection 672
Engine Oil Pressure – Testing 673
FUEL SYSTEM 675
Fuel Shutoff Solenoid – Checking 675
Fuel Shutoff Solenoid Removal And Installation 676
Fuel Injection Pump – Checking 677
Fuel Injection Pump Removal And Installation 678
Fuel Injection Pump – Timing 681
Fuel Camshaft Removal And Installation 683
Fuel Camshaft Governor 683
Fuel Injector Removal And Installation 684
Fuel Injector Nozzle Pressure – Checking 686
Nozzle Spray Condition 687
Valve Seat Tightness 687
CYLINDER HEAD 689
Glow Plugs – Testing 689
Glow Plugs Removal And Installation 689
Valve Clearance Adjustment 690
Valve Timing – Checking 690
Cylinder Head Removal And Installation 691
Cylinder Head Disassembly And Assembly 695
Cylinder Head – Servicing 696
Cylinder Head Top Clearance 696
Valve Guide – Checking 697
Valve Guide Removal And Installation 698
Reconditioning The Valve And Valve Seat 699
Valve Spring 700
Valve Tappets 701
Rocker Arm And Shaft – Checking 702
Push Rod Alignment – Checking 702
CRANKSHAFT AND PISTONS 703
Piston And Connecting Rod Removal And Installation 703
Piston And Connecting Rod – Servicing 705
Cylinder Bore – Checking 707
Connecting Rod Alignment 708
Crankshaft Gear Removal And Installation 709
Crankshaft And Bearings Removal And Installation 710
Crankshaft And Bearings – Servicing 713
CAMSHAFT AND TIMING GEARS 717
Timing Gearcase Cover Removal And Installation 717
Timing Gears Backlash – Checking 719
Idler Gear And Camshaft Removal And Installation 719
Camshaft – Servicing 720
Idler Gear And Shaft Servicing 722
FLYWHEEL AND HOUSING 723
Hydraulic Pump Coupler Removal And Installation 723
Flywheel Removal And Installation 725
Flywheel Ring Gear 725
HEATING AND VENTILATION 727
REGULAR MAINTENANCE 729
Cab Filters 729
TROUBLESHOOTING 731
Blower Motor Does Not Operate 731
Blower Motor Operates Normally, But Air Flow Is Insufficient 731
Electrical System 732
HEATER UNIT 733
Removal And Installation 733
HEATER COIL 735
Removal And Installation 735
BLOWER FAN 737
Removal And Installation 737
HEATER VALVE 739
Removal And Installation 739
HEATING / VENTILATION DUCT 741
Removal And Installation 741
SPECIFICATIONS 743
EXCAVATOR SPECIFICATIONS 745
Machine Dimensions 745
Machine Dimensions – Standard Arm 746
Machine Dimensions – Long Arm 747
Rated Lift Capacity – Canopy With Standard Arm And Medium Counterweight 748
Rated Lift Capacity – Canopy With Long Arm And Medium Counterweight 749
Rated Lift Capacity – Canopy With Standard Arm And Heavy Counterweight 750
Rated Lift Capacity – Canopy With Long Arm And Heavy Counterweight 751
Rated Lift Capacity – Cab With Standard Arm And Medium Counterweight 752
Rated Lift Capacity – Cab With Long Arm And Medium Counterweight 753
Rated Lift Capacity – Cab With Standard Arm And Heavy Counterweight 754
Rated Lift Capacity – Cab With Long Arm And Heavy Counterweight 755
Performance 756
Controls 756
Engine 757
Hydraulic System 757
Hydraulic Cylinders 758
Hydraulic Cycle Times 758
Electrical 758
Drive System 758
Slew System 759
Undercarriage 759
Capacities 759
Tracks 759
Environmental 759
Temperature Range 759
TECHNICAL SERVICE GUIDE SPECIFICATIONS 761
Engine 761
Engine Torques 761
Excavator Torques 761
Cooling System 761
TORQUE SPECIFICATION FOR BOLTS 763
Torque For General SAE Bolts 763
Torque For General Metric Bolts 764
HYDRAULIC CONNECTION SPECIFICATIONS 765
O-ring Face Seal Connection 765
Straight Thread O-ring Fitting 765
Tubelines And Hoses 766
Flare Fitting 766
O-ring Flare Fitting 767
Port Seal Fitting 769
Push To Connect Fittings 770
HYDRAULIC FLUID SPECIFICATIONS 773
Specifications 773
CONVERSIONS 775
Decimal And Millimeter Equivalent Chart 775
U S To Metric Conversion Chart 776
SERVICE TOOLS REQUIRED 777
Remote Start Tools 777
Hydraulic Tools 778
Engine Tools 781
Electrical Tools 783
General Tools 784
HVAC Tools 785
ALPHABETICAL INDEX 787
SERVICE SCHEDULE SYMBOLS 789

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M