Bobcat E20z Compact Excavator Service Manual 7359012(07-20) – PDF DOWNLOAD

Description

Bobcat E20z Compact Excavator Service Manual 7359012(07-20) – PDF DOWNLOAD

FILE DETAILS:

Bobcat E20z Compact Excavator Service Manual 7359012(07-20) – PDF DOWNLOAD

Language : English
Pages : 701
Downloadable : Yes
File Type : PDF
Size:22.5 MB

DESCRIPTION:

Bobcat E20z Compact Excavator Service Manual 7359012(07-20) – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader 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 E20z Compact Excavator Service Manual 7359012(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 / FOPs) 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
RIGHT SIDE COVER 39
Opening And Closing Right Side Cover 39
SERVICE SCHEDULE 41
Maintenance Intervals 41
Inspection Checkbook 42
AIR CLEANER SERVICE 43
Daily Check 43
Replacing The Filter Elements 43
CAB FILTER 45
Cleaning And Maintenance 45
ENGINE COOLING SYSTEM 47
Cleaning 47
Checking Level 48
Removing And Replacing Coolant 49
FUEL SYSTEM 51
Fuel Specifications 51
Biodiesel Blend Fuel 51
Filling The Fuel Tank 52
Fuel Filters 53
Draining The Fuel Tank 54
Removing Air From The Fuel System 55
ENGINE LUBRICATION SYSTEM 57
Checking And Adding Engine Oil 57
Engine Oil Chart 57
Removing And Replacing Oil And Filter 58
HYDRAULIC SYSTEM 59
Checking And Adding Hydraulic Oil 59
Hydraulic / Hydrostatic Fluid Chart 60
Removing And Replacing The Hydraulic Filters 60
Removing And Replacing The Hydraulic Oil 61
LUBRICATING THE EXCAVATOR 63
Lubrication Locations 63
TRAVEL MOTOR 67
Checking And Adding Oil 67
Removing And Replacing Oil 67
SPARK ARRESTER MUFFLER 69
Cleaning Procedure 69
ALTERNATOR BELT 71
Belt Adjustment 71
Belt Replacement 71
SEAT BELT 73
Inspection And Maintenance 73
CONTROL CONSOLE LOCKOUTS 75
Inspection And Maintenance 75
PIVOT PINS 77
Inspection And Maintenance 77
TOWING THE EXCAVATOR 79
Procedure 79
EXCAVATOR STORAGE AND RETURN TO SERVICE 81
Storage 81
Return To Service 81
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 83
Procedure 83
EMERGENCY EXIT 85
Side Or Rear Window 85
Front Window 85
REMOTE START TOOL KIT – MEL1563 87
Remote Start Tool – MEL1563 87
Service Tool Harness Communicator – MEL1566 89
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 91
Description 91
Remote Start Tool (Service Tool) – 7022042 92
Excavator Service Tool Harness – 6689747 93
Computer Service Tool Harness – 6689746 94
HYDRAULIC SYSTEM 95
HYDRAULIC / HYDROSTATIC SCHEMATICS 99
HYDRAULIC SYSTEM INFORMATION 103
Glossary Of Hydraulic / Hydrostatic Symbols 103
Troubleshooting The Hydraulic Circuit 106
Troubleshooting The Cylinder Circuit 107
Troubleshooting The Swing (Upperstructure Slew) Circuit 108
Troubleshooting The Travel Circuit 109
CYLINDER (BOOM) 111
Testing 111
Removal And Installation 113
Parts Identification 115
Disassembly 116
Assembly 118
CYLINDER (ARM) 121
Testing 121
Removal And Installation 123
Parts Identification 125
Disassembly 126
Assembly 128
CYLINDER (BOOM SWING) 131
Testing 131
Removal And Installation 132
Parts Identification (Earlier Models) 134
Disassembly (Earlier Models) 135
Assembly (Earlier Models) 137
Parts Identification (Later Models) 140
Disassembly (Later Models) 141
Assembly (Later Models) 143
CYLINDER (BUCKET) 147
Testing 147
Removal And Installation 149
Parts Identification 150
Disassembly 151
Assembly 153
CYLINDER (BLADE) 157
Testing 157
Removal And Installation 158
Parts Identification (Earlier Models) 160
Disassembly (Earlier Models) 161
Assembly (Earlier Models) 163
Parts Identification (Later Models) 166
Disassembly (Later Models) 167
Assembly (Later Models) 169
CYLINDER (TRACK FRAME EXPANSION) 173
Testing 173
Removal And Installation 174
Parts Identification (Earlier Models) 178
Disassembly (Earlier Models) 179
Assembly (Earlier Models) 181
Parts Identification (Later Models) 184
Disassembly (Later Models) 185
Assembly (Later Models) 187
VALVE (MAIN RELIEF) 191
Description 191
Test Conditions 193
Testing And Adjusting Main Relief At Manifold 194
Testing And Adjusting Main Relief At Hydraulic Control Valve 195
VALVE (PORT RELIEF) 197
Testing And Adjusting 197
VALVE (CROSS PORT RELIEF) 199
Testing 199
Removal And Installation 201
VALVE (PRESSURE REDUCING) 203
Testing And Adjusting 203
HYDRAULIC CONTROL VALVE 205
Description 205
Removal And Installation 205
Parts Identification 211
Disassembly 212
Assembly 218
Right And Left Travel Valve Section Disassembly And Assembly 221
Arm And Bucket Valve Section Disassembly And Assembly 225
Boom Swing And Auxiliary Valve Section Disassembly And Assembly 227
Boom Valve Section Disassembly And Assembly 231
Slew Valve Section Disassembly And Assembly 232
Blade Valve Section Disassembly And Assembly 235
HYDRAULIC PUMP 239
Description 239
Torque Adjustment 239
Testing The Piston Pump 240
Testing The Gear Pump 242
Testing Auxiliary Hydraulic Flow 243
Removal And Installation 245
Parts Identification 247
Disassembly And Assembly 248
Gear Pump Disassembly 249
Gear Pump Assembly 251
Piston Pump Disassembly 253
Piston Pump Assembly 263
MANIFOLD ASSEMBLY / ACCUMULATOR 273
Description 273
Removal And Installation 273
Parts Identification 276
ACCUMULATOR 283
Removal And Installation 283
TRAVEL MOTOR 285
Description 285
Removal And Installation 285
Parts Identification 286
Disassembly 287
Assembly 294
SWIVEL JOINT 303
Description 303
Removal And Installation 303
Parts Identification 306
Disassembly 307
Assembly 309
SWING MOTOR 313
Description 313
Removal And Installation 313
Parts Identification 315
Disassembly And Assembly 316
Motor Disassembly 317
Motor Assembly 321
Brake Carrier Disassembly And Assembly 328
CONTROL LEVER (JOYSTICK) (RIGHT) 331
Testing 331
Handle Removal And Installation 332
Joystick Assembly Removal And Installation 334
Parts Identification 337
Disassembly 338
Assembly 342
CONTROL LEVER (JOYSTICK) (LEFT) 347
Testing 347
Handle Removal And Installation 348
Joystick Assembly Removal And Installation 350
Parts Identification 351
Disassembly 352
Assembly 356
HYDRAULIC FILTER MOUNT 361
Description 361
Removal And Installation 361
HYDRAULIC RESERVOIR 363
Description 363
Removal And Installation 363
OIL COOLER 365
Removal And Installation 365
BLADE / TRACK EXPANSION SOLENOID BLOCK 367
Description 367
Block Removal And Installation 367
Solenoid Removal And Installation 369
Block Disassembly And Assembly 370
UNDERCARRIAGE 373
BLADE 375
Description 375
Extension Removal And Installation 375
Blade Removal And Installation 376
TRACK UNDERCARRIAGE COMPONENTS 377
Description 377
Track Lug Height 377
Checking Tension 378
Adjusting Tension 379
Track Removal And Installation 381
Idler Removal And Installation 382
Track Tensioner Removal And Installation 382
Track Tensioner Disassembly And Assembly 383
Roller Removal And Installation 383
Sprocket Removal And Installation 384
Track Frame Guide Inspection 385
Removal And Installation Of Expandable Track Frame 386
TRACK MAINTENANCE 387
Track Damage Identification 387
SWING CIRCLE GEAR 399
Removal And Installation 399
UPPERSTRUCTURE & SWING 401
UPPERSTRUCTURE 405
Description 405
Removal 405
Installation 407
ROPS CANOPY 409
Removal And Installation 409
CAB 413
Removal And Installation 413
Door Removal And Installation 417
Front Window Removal And Installation 418
Right Side Sliding Window Removal And Installation 421
Glass Removal 421
Glass Installation 422
SEAT AND SEAT MOUNT 425
Removal And Installation 425
LEFT CONSOLE 427
Console Cover Removal And Installation 427
Gas Spring Removal And Installation 429
Lock Lever Removal And Installation 430
Console Removal And Installation 430
LEFT UPPERSTRUCTURE COVER 431
Removal And Installation 431
RIGHT UPPERSTRUCTURE COVER 433
Removal And Installation 433
ENGINE SPEED CONTROL 435
Removal And Installation 435
Cable Adjustment 437
BLADE CONTROL 439
Removal And Installation 439
RIGHT PEDAL (BOOM SWING) 441
Removal And Installation 441
Disassembly And Assembly 442
TRAVEL CONTROLS 443
Removal And Installation 443
Disassembly And Assembly 444
LEFT PEDAL (AUXILIARY) 447
Disassembly And Assembly 447
CONTROL LINKAGE ASSEMBLY 449
Removal And Installation 449
Disassembly And Assembly 450
FLOOR MAT AND FLOOR PANELS 453
Description 453
Removal And Installation 453
FUEL TANK 455
Removal And Installation 455
HORN 457
Removal And Installation 457
SWING FRAME 459
Description 459
Removal And Installation 459
Bushing Removal And Installation 461
Swing Frame Bushing Removal 461
Swing Frame Bushing Installation 462
BOOM 463
Description 463
Removal And Installation 463
Boom Bushing Removal And Installation 465
ARM 467
Description 467
Removal And Installation 467
Arm To Boom Bushing Removal And Installation 468
Arm To Bucket And Bucket Link Bushing Removal And Installation 469
BUCKET 471
Removal And Installation 471
TAILGATE 473
Removal And Installation 473
Latch Removal And Installation 473
COUNTERWEIGHT 475
Removal And Installation 475
OPERATOR BONNET 477
Removal And Installation 477
QUICK COUPLER (KLAC™ SYSTEM) 483
Troubleshooting 483
Daily Inspection 483
Removal And Installation 484
Parts Identification 486
Disassembly 487
Assembly 488
QUICK COUPLER (LEHNHOFF® SYSTEM) 491
Troubleshooting 491
Daily Inspection 491
Removal (MS03 And MS08) 492
Installation (MS03 And MS08) 493
Parts Identification (MS03) 494
Disassembly And Assembly (MS03) 495
Parts Identification (MS08) 496
Disassembly (MS08) 497
Assembly (MS08) 500
RIGHT SIDE COVER 505
Removal And Installation 505
ELECTRICAL SYSTEM 507
ELECTRICAL SCHEMATICS 509
ELECTRICAL SYSTEM INFORMATION 524
Glossary Of Electrical Symbols 524
Troubleshooting Chart 527
Description 528
Fuse And Relay Location / Identification 528
BATTERY 530
Location 530
Servicing 530
Maintaining Battery Charge Level 531
Battery Service During Machine Storage 531
Battery Testing 532
Battery Charging 532
Removal And Installation 533
Using A Booster Battery (Jump Starting) 534
ALTERNATOR 536
Belt Adjustment 536
Belt Replacement 536
Charging System Inspection 537
Alternator Voltage Testing 538
Parts Identification 539
Removal And Installation 540
STARTER 542
Testing 542
Removal And Installation 543
Parts Identification 544
LIGHTS 546
Boom Light Removal And Installation 546
Boom Light Bulb Replacement 546
Cab Light Removal And Installation 547
Cab Light Bulb Replacement 547
MAGNETIC LOCKOUT SENSOR 548
Removal And Installation 548
TWO-SPEED SWITCH 550
Removal And Installation 550
FUEL LEVEL SENDER 552
Removal And Installation 552
Testing 552
DIAGNOSTIC SERVICE CODES 554
Viewing Service Codes 554
Number Codes List 555
CONTROL PANEL SETUP 558
Password Setup (Keyless Start Panel) 558
Maintenance Clock 560
KEY SWITCH 562
Removal And Installation 562
WIPER MOTOR 564
Removal And Installation 564
MOTION ALARM SYSTEM 566
Description 566
Inspecting 566
Adjusting Switch Position 567
ENGINE 568
ENGINE INFORMATION 570
Description 570
Specifications 571
Crankshaft Re-Grind Data 575
Torque Values 576
Troubleshooting 577
Engine Removal And Installation 578
Engine Mount Replacement 583
Engine Compression – Testing 584
SPARK ARRESTER MUFFLER 586
Removal And Installation 586
AIR CLEANER 588
Removal And Installation 588
ENGINE COOLING SYSTEM 590
Radiator / Oil Cooler Removal And Installation 590
Fan Removal 592
Water Pump Removal And Installation 593
Thermostat Housing Removal And Installation 595
Thermostat – Testing 595
LUBRICATION SYSTEM 596
Oil Pan Removal And Installation 596
Oil Pump Removal And Installation 597
Oil Pump – Service 597
Engine Oil Pressure – Testing 598
FUEL SYSTEM 600
Fuel Shutoff Solenoid Removal And Installation 600
Fuel Injection Pump – Testing 601
Fuel Injection Pump Removal And Installation 603
Fuel Injection Pump – Timing 605
Fuel Camshaft Removal And Installation 606
Fuel Camshaft Governor 607
Fuel Injector Removal And Installation 607
Fuel Injector Nozzle Pressure – Testing 608
CYLINDER HEAD 610
Glow Plug Removal And Installation 610
Valve Clearance Adjustment 611
Valve Timing – Checking 612
Cylinder Head Removal And Installation 612
Cylinder Head Disassembly And Assembly 614
Cylinder Head – Servicing 615
Cylinder Head Top Clearance 616
Valve Guide – Servicing 616
Valve And Valve Seat Reconditioning 618
Valve Spring 619
Valve Tappets 620
Rocker Arm And Shaft – Servicing 621
CRANKSHAFT AND PISTONS 622
Piston And Connecting Rod Removal And Installation 622
Piston And Connecting Rod – Servicing 624
Cylinder Bore – Measuring 626
Connecting Rod Alignment 627
Crankshaft Gear Removal And Installation 627
Crankshaft And Bearings Removal And Installation 628
Crankshaft And Bearings – Servicing 630
CAMSHAFT AND TIMING GEARS 634
Timing Gearcase Cover Removal And Installation 634
Timing Gears Measuring Backlash 636
Idler Gear And Camshaft Removal And Installation 636
Idler Gear And Shaft – Servicing 639
FLYWHEEL AND HOUSING 640
Flywheel Housing Removal And Installation 640
Hydraulic Pump Coupler Removal And Installation 641
Flywheel Removal 641
Flywheel Installation 642
Rear End Plate Removal And Installation 642
HEATING AND VENTILATION 644
HEATER SYSTEM 646
Description 646
Components 646
REGULAR MAINTENANCE 648
Filter Element Removal And Installation 648
Heater Coil 649
HEATER UNIT 650
Removal And Installation 650
HEATER COIL 652
Removal And Installation 652
HEATER FAN 656
Removal And Installation 656
HEATER VALVE 658
Removal And Installation 658
SPECIFICATIONS 660
EXCAVATOR SPECIFICATIONS 662
Machine Dimensions 662
Machine Dimensions (Standard Arm) 663
Machine Dimensions (Long Arm) 664
Rated Lift Capacity – With Standard Arm And Canopy (No Demolition Kit) 665
Rated Lift Capacity – With Standard Arm And Canopy (With Demolition Kit) 666
Rated Lift Capacity – With Standard Arm And Cab (No Demolition Kit) 667
Rated Lift Capacity – With Standard Arm And Cab (With Demolition Kit) 668
Rated Lift Capacity – With Long Arm And Canopy (No Demolition Kit) 669
Rated Lift Capacity – With Long Arm And Canopy (With Demolition Kit) 670
Rated Lift Capacity – With Long Arm And Cab (No Demolition Kit) 671
Rated Lift Capacity – With Long Arm And Cab (With Demolition Kit) 672
Performance 673
Controls 673
Engine 674
Hydraulic System 674
Hydraulic Cylinders 675
Hydraulic Cycle Times 675
Electrical 675
Drive System 675
Slew System 676
Undercarriage 676
Capacities 676
Tracks 676
Ground Pressure 676
Environmental 677
Temperature Range 677
TECHNICAL SERVICE GUIDE SPECIFICATIONS 678
Engine 678
Engine Torques 678
Cooling System 678
Excavator Torques 678
TORQUE SPECIFICATIONS FOR BOLTS 680
Torque For General SAE Bolts 680
Torque For General Metric Bolts 681
HYDRAULIC CONNECTION SPECIFICATIONS 682
O-ring Face Seal Connection 682
Straight Thread O-ring Fitting 683
Tubelines And Hoses 683
Flare Fitting 684
Port Seal Fitting 685
HYDRAULIC FLUID SPECIFICATIONS 686
Specifications 686
CONVERSIONS 688
Decimal And Millimeter Equivalent Chart 688
U S To Metric Conversion Chart 688
SERVICE TOOLS REQUIRED 690
Remote Start Tools 690
Hydraulic Tools 691
Engine Tools 694
Electrical Tools 696
General Tools 696
HVAC Tools 697
ALPHABETICAL INDEX 698
SERVICE SCHEDULE SYMBOLS 700

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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