Bobcat E17 Compact Excavator Service Manual 7255011 (07-20) – PDF DOWNLOAD

Description

Bobcat E17 Compact Excavator Service Manual 7255011 (07-20) – PDF DOWNLOAD

FILE DETAILS:

Bobcat E17 Compact Excavator Service Manual 7255011 (07-20) – PDF DOWNLOAD

Language : English
Pages : 674
Downloadable : Yes
File Type : PDF
Size:21.1 MB

DESCRIPTION:

Bobcat E17 Compact Excavator Service Manual 7255011 (07-20) – PDF DOWNLOAD

S/N B27H11001 & Above
S/N B4PJ11001 & Above
S/N B4PR11001 & 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.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat E17 Compact Excavator Service Manual 7255011 (07-20) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS / TOPS) 27
Description 27
Cab Door 28
Front Window 29
Front Wiper 30
Window Washer Reservoir 30
Right Side Window 31
Heating And Ventilation Ducting 31
OPERATOR CANOPY (ROPS / TOPS) 33
Description 33
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TAILGATE 37
Opening And Closing 37
Adjusting The Latch 38
SERVICE SCHEDULE 39
Maintenance Intervals 39
AIR CLEANER SERVICE 41
Daily Check 41
Replacing The Filter Elements 41
CAB FILTER 43
Cleaning And Maintenance 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 52
Removing Air From The Fuel System 53
ENGINE LUBRICATION SYSTEM 55
Checking And Adding Engine Oil 55
Engine Oil Chart 55
Removing And Replacing Oil And Filter 56
HYDRAULIC SYSTEM 57
Checking And Adding Hydraulic Fluid 57
Hydraulic / Hydrostatic Fluid Chart 58
Removing And Replacing The Hydraulic Filters 58
Removing And Replacing The Hydraulic Fluid 59
LUBRICATING THE EXCAVATOR 61
Lubrication Locations 61
TRAVEL MOTOR 65
Checking And Adding Fluid 65
Removing And Replacing Fluid 65
SPARK ARRESTER MUFFLER 67
Cleaning Procedure 67
ALTERNATOR BELT 69
Belt Adjustment 69
Belt Replacement 70
SEAT BELT 71
Inspection And Maintenance 71
CONTROL CONSOLE LOCKOUTS 73
Inspection And Maintenance 73
PIVOT PINS 75
Inspection And Maintenance 75
EXCAVATOR STORAGE AND RETURN TO SERVICE 77
Storage 77
Return To Service 77
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 79
Procedure 79
EMERGENCY EXIT 81
Side Or Rear Window 81
Front Window 81
REMOTE START TOOL KIT – MEL1563 83
Remote Start Tool – MEL1563 83
Service Tool Harness Communicator – MEL1566 85
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 87
Description 87
Remote Start Tool (Service Tool) – 7022042 88
Excavator Service Tool Harness – 6689747 89
Computer Service Tool Harness – 6689746 90
HYDRAULIC SYSTEM 91
HYDRAULIC/HYDROSTATIC SCHEMATIC 95
HYDRAULIC SYSTEM INFORMATION 98
Glossary Of Hydraulic / Hydrostatic Symbols 98
Troubleshooting The Hydraulic Circuit 101
Troubleshooting The Cylinder Circuit 102
Troubleshooting The Swing (Upperstructure Slew) Circuit 103
Troubleshooting The Travel Circuit 104
CYLINDER (BOOM) 106
Testing 106
Removal And Installation 108
Parts Identification 110
Disassembly 111
Assembly 113
CYLINDER (ARM) 116
Testing 116
Removal And Installation 118
Parts Identification 120
Disassembly 121
Assembly 123
CYLINDER (BOOM SWING) 126
Testing 126
Removal And Installation 127
Parts Identification (Earlier Models) 129
Disassembly (Earlier Models) 130
Assembly (Earlier Models) 132
Parts Identification (Later Models) 135
Disassembly (Later Models) 136
Assembly (Later Models) 138
CYLINDER (BUCKET) 142
Testing 142
Removal And Installation 144
Parts Identification 145
Disassembly 146
Assembly 148
CYLINDER (BLADE) 152
Testing 152
Removal And Installation 153
Parts Identification (Earlier Models) 155
Disassembly (Earlier Models) 156
Assembly (Earlier Models) 158
Parts Identification (Later Models) 161
Disassembly (Later Models) 162
Assembly (Later Models) 164
CYLINDER (TRACK FRAME EXPANSION) 168
Testing 168
Removal And Installation 169
Parts Identification (Earlier Models) 173
Disassembly (Earlier Models) 174
Assembly (Earlier Models) 176
Parts Identification (Later Models) 179
Disassembly (Later Models) 180
Assembly (Later Models) 182
VALVE (MAIN RELIEF) 186
Description 186
Test Conditions 188
Testing And Adjusting The Main Relief 188
VALVE (PORT RELIEF) 190
Testing And Adjusting 190
VALVE (CROSS PORT RELIEF) 192
Testing 192
Removal And Installation 194
VALVE (PRESSURE REDUCING) 196
Testing And Adjusting 196
HYDRAULIC CONTROL VALVE 198
Description 198
Removal And Installation 198
Parts Identification 204
Disassembly 205
Assembly 210
Right And Left Travel Valve Section Disassembly And Assembly 213
Arm And Bucket Valve Section Disassembly And Assembly 217
Boom Swing And Auxiliary Valve Section Disassembly And Assembly 219
Boom Valve Section Disassembly And Assembly 223
Slew Valve Section Disassembly And Assembly 224
Blade Valve Section Disassembly And Assembly 227
HYDRAULIC PUMP 232
Description 232
Testing The Gear Pump 232
Testing Auxiliary Hydraulic Flow 234
Removal And Installation 235
Parts Identification 237
Disassembly 238
Assembly 241
MANIFOLD ASSEMBLY / ACCUMULATOR 246
Description 246
Removal And Installation 246
Parts Identification (Single Speed Travel Motor) 249
Parts Identification (Two Speed Travel Motor) 250
ACCUMULATOR 256
Removal And Installation 256
TRAVEL MOTOR (SINGLE SPEED) 258
Description 258
Removal And Installation 258
Parts Identification 259
Disassembly 260
Assembly 267
TRAVEL MOTOR (TWO SPEED) 276
Description 276
Removal And Installation 276
Parts Identification 277
Disassembly 278
Assembly 285
SWIVEL JOINT 294
Description 294
Removal And Installation 294
Parts Identification 297
Disassembly 298
Assembly 300
SWING MOTOR 304
Description 304
Removal And Installation 304
Parts Identification 306
Motor Disassembly 307
Motor Assembly 312
Brake Carrier Disassembly And Assembly 319
CONTROL LEVER (JOYSTICK) (RIGHT) 322
Testing 322
Handle Removal And Installation 323
Removal And Installation 325
Parts Identification 328
Disassembly 329
Assembly 333
CONTROL LEVER (JOYSTICK) (LEFT) 338
Testing 338
Handle Removal And Installation 339
Removal and Installation 341
Parts Identification 342
Disassembly 343
Assembly 347
HYDRAULIC FILTER MOUNT 352
Description 352
Removal And Installation 352
HYDRAULIC RESERVOIR 354
Description 354
Removal And Installation 354
OIL COOLER 356
Removal And Installation 356
BLADE / TRACK EXPANSION SOLENOID BLOCK 358
Description 358
Block Removal And Installation 358
Solenoid Removal And Installation 360
Parts Identification 361
Block Disassembly And Assembly 362
UNDERCARRIAGE 364
BLADE 366
Description 366
Extension Removal And Installation 366
Blade Removal And Installation 367
TRACK UNDERCARRIAGE COMPONENTS 368
Description 368
Track Lug Height 368
Checking Tension 369
Adjusting Tension 370
Track Removal And Installation 372
Idler Removal And Installation 373
Track Tensioner Removal And Installation 373
Track Tensioner Disassembly & Assembly 373
Roller Removal And Installation 374
Sprocket Removal And Installation 374
Removal And Installation Of Expandable Track Frame 376
TRACK MAINTENANCE 378
Cutting Of The Steel Cords 378
Causes Of The Damage 378
Abrasion Of Embedded Metals 379
Separation Of Embedded Metals 380
Separation Of Embedded Metals Due To Corrosion 381
Cuts On The Lug Side Rubber 382
Cracks On The Lug Side Rubber Due To Fatigue 383
Lug Abrasion 384
Cracks And Cuts On The Lug Side Rubber 385
Abrasion Of The Track Roller Side 386
Cuts On The Edges Of The Track Roller Side 387
SWING CIRCLE GEAR 390
Removal And Installation 390
UPPERSTRUCTURE & SWING 392
UPPERSTRUCTURE 396
Description 396
Removal 396
Installation 398
ROPS CANOPY 400
Removal And Installation 400
CAB 404
Removal And Installation 404
Door Removal And Installation 408
Front Window Removal And Installation 409
Right Side Sliding Window Removal And Installation 412
Glass Removal 412
Glass Installation 413
SEAT AND SEAT MOUNT 416
Removal And Installation 416
LEFT CONSOLE 418
Console Cover Removal And Installation 418
Gas Spring Removal And Installation 420
Lock Lever Removal And Installation 421
Console Removal And Installation 421
LEFT UPPERSTRUCTURE COVERs 422
Removal And Installation 422
RIGHT UPPERSTRUCTURE COVER 424
Removal And Installation 424
ENGINE SPEED CONTROL 426
Removal And Installation 426
Cable Adjustment 429
BLADE CONTROL 430
Removal And Installation 430
RIGHT PEDAL (BOOM SWING) 432
Removal And Installation 432
Disassembly And Assembly 433
TRAVEL CONTROLS 434
Removal And Installation 434
Disassembly And Assembly 435
LEFT PEDAL (AUXILIARY) 438
Disassembly And Assembly 438
CONTROL LINKAGE ASSEMBLY 440
Removal And Installation 440
Disassembly And Assembly 441
FLOOR MAT AND FLOOR PANELS 444
Description 444
Removal And Installation 444
FUEL TANK 446
Removal And Installation 446
HORN 448
Removal And Installation 448
SWING FRAME 450
Description 450
Removal And Installation 450
Bushing Removal And Installation 452
Swing Frame Bushing Removal 452
Swing Frame Bushing Installation 453
BOOM 454
Description 454
Removal And Installation 454
Boom Bushing Removal And Installation 456
ARM 458
Description 458
Removal And Installation 458
Arm To Boom Bushing Removal And Installation 459
Arm To Bucket And Bucket Link Bushing Removal And Installation 460
BUCKET 462
Removal And Installation 462
TAILGATE 464
Removal And Installation 464
Latch Removal And Installation 465
COUNTERWEIGHT 466
Removal And Installation 466
OPERATOR BONNET 468
Removal And Installation 468
QUICK COUPLER (KLAC™ SYSTEM) 474
Troubleshooting 474
Daily Inspection 474
Removal And Installation 475
Parts Identification 477
Disassembly 478
Assembly 480
QUICK COUPLER (LEHNHOFF® SYSTEM) 482
Troubleshooting 482
Daily Inspection 482
Removal (MS03 And MS08) 483
Installation (MS03 And MS08) 484
Parts Identification (MS03) 485
Disassembly And Assembly (MS03) 486
Parts Identification (MS08) 487
Disassembly (MS08) 488
Assembly (MS08) 491
RIGHT SIDE COVER 496
Removal And Installation 496
TOOL BOX 498
Removal And Installation 498
ELECTRICAL SYSTEM 500
ELECTRICAL SCHECMATICS 502
ELECTRICAL SYSTEM INFORMATION 517
Glossary Of Electrical Symbols 517
Troubleshooting 520
Description 521
Fuse And Relay Location / Identification 521
BATTERY 523
Servicing 523
Removal And Installation 524
Using A Booster Battery (Jump Starting) 525
ALTERNATOR 527
Belt Adjustment 527
Belt Replacement 527
Charging System Inspection 528
Alternator Voltage Testing 529
Removal And Installation 530
Parts Identification 531
STARTER 533
Testing 533
Removal And Installation 534
Parts Identification 535
LIGHTS 537
Boom Light Removal And Installation 537
Boom Light Bulb Replacement 537
Cab Light Removal And Installation 538
Cab Light Bulb Replacement 538
MAGNETIC LOCKOUT SENSOR 539
Removal And Installation 539
TWO-SPEED SWITCH 541
Removal And Installation 541
FUEL LEVEL SENDER 543
Removal And Installation 543
Testing 543
KEY SWITCH 545
Removal And Installation 545
WIPER MOTOR 547
Removal And Installation 547
ENGINE 549
ENGINE INFORMATION 551
Description 551
Specifications 552
Crankshaft Re-Grind Data 556
Torque Values 557
Troubleshooting 558
Engine Removal And Installation 559
Engine Mount Replacement 565
Engine Compression – Testing 566
SPARK ARRESTER MUFFLER 567
Removal And Installation 567
AIR CLEANER 569
Removal And Installation 569
ENGINE COOLING SYSTEM 571
Radiator / Oil Cooler Removal And Installation 571
Fan Removal 573
Water Pump Removal and Installation 574
Thermostat Removal and Installation 575
Thermostat – Testing 575
LUBRICATION SYSTEM 577
Oil Pan Removal And Installation 577
Oil Pump Removal And Installation 578
Oil Pump – Service 578
Engine Oil Pressure – Testing 579
FUEL SYSTEM 581
Fuel Shutoff Solenoid Removal And Installation 581
Fuel Injection Pump – Testing 582
Fuel Injection Pump Removal And Installation 584
Fuel Injection Pump – Timing 586
Fuel Camshaft Removal And Installation 587
Fuel Camshaft Governor 588
Fuel Injector Removal And Installation 588
Fuel Injector Nozzle Pressure – Testing 589
CYLINDER HEAD 591
Glow Plug Removal And Installation 591
Valve Clearance Adjustment 592
Valve Timing – Checking 593
Cylinder Head Removal And Installation 593
Cylinder Head Disassembly And Assembly 595
Cylinder Head – Servicing 596
Cylinder Head Top Clearance 597
Valve Guide – Servicing 597
Valve And Valve Seat Reconditioning 599
Valve Spring 600
Valve Tappets 601
Rocker Arm And Shaft – Servicing 602
CRANKSHAFT AND PISTONS 603
Piston And Connecting Rod Removal And Installation 603
Piston And Connecting Rod Disassembly And Assembly 604
Piston And Connecting Rod – Servicing 605
Cylinder Bore – Measuring 607
Connecting Rod Alignment 608
Crankshaft Gear Removal And Installation 608
Crankshaft And Bearings Removal And Installation 609
Crankshaft And Bearings – Servicing 611
CAMSHAFT AND TIMING GEARS 615
Timing Gearcase Cover Removal And Installation 615
Timing Gears Measuring Backlash 617
Idler Gear And Camshaft Removal And Installation 617
Idler Gear And Shaft – Servicing 620
FLYWHEEL AND HOUSING 621
Flywheel Housing Removal And Installation 621
Hydraulic Pump Coupler Removal And Installation 622
Flywheel Removal 622
Flywheel Installation 623
Rear End Plate Removal And Installation 623
HEATING AND VENTILATION 625
HEATER SYSTEM 627
Description 627
Components 627
REGULAR MAINTENANCE 629
Filter Element Removal And Installation 629
Heater Coil 629
HEATER UNIT 631
Removal And Installation 631
HEATER COIL 633
Removal And Installation 633
HEATER FAN 637
Removal And Installation 637
HEATER VALVE 639
Removal And Installation 639
SPECIFICATIONS 641
EXCAVATOR SPECIFICATIONS 643
Machine Dimensions 643
Performance 645
Controls 645
Engine 646
Hydraulic System 646
Hydraulic Cylinders 647
Hydraulic Cycle Times 647
Electrical 647
Drive System 647
Slew System 648
Undercarriage 648
Capacities 648
Tracks 648
Ground Pressure 648
Environmental 649
Temperature Range 649
TECHNICAL SERVICE GUIDE SPECIFICATIONS 651
Engine 651
Engine Torques 651
Cooling System 651
Excavator Torques 651
TORQUE SPECIFICATIONS FOR BOLTS 653
Torque For General SAE Bolts 653
Torque For General Metric Bolts 654
HYDRAULIC CONNECTION SPECIFICATIONS 655
O-ring Face Seal Connection 655
Straight Thread O-ring Fitting 656
Tubelines And Hoses 656
Flare Fitting 657
Port Seal Fitting 658
HYDRAULIC FLUID SPECIFICATIONS 659
Specifications 659
CONVERSIONS 661
Decimal And Millimeter Equivalent Chart 661
U S To Metric Conversion Chart 661
SERVICE TOOLS REQUIRED 663
Remote Start Tools 663
Hydraulic Tools 664
Engine Tools 667
Electrical Tools 669
General Tools 669
HVAC Tools 670
ALPHABETICAL INDEX 671
SERVICE SCHEDULE SYMBOLS 673

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