Bobcat E20Z Compact Excavator Service Manual SN B4YC11001 & Above – PDF DOWNLOAD

Description

Bobcat E20Z Compact Excavator Service Manual SN B4YC11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E20Z Compact Excavator Service Manual SN B4YC11001 & Above – PDF DOWNLOAD

Language : English
Pages :691
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E20Z Compact Excavator Service Manual SN B4YC11001 & Above – 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 SN B4YC11001 & Above – 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 & MAINTENANCE 17
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
LIFTING THE EXCAVATOR 23
Procedure 23
OPERATOR CAB (ROPS / TOPS) 25
Description 25
Cab Door 26
Front Window 27
Front Wiper 28
Window Washer Reservoir 28
Right Side Window 29
Heating And Ventilation Ducting 29
OPERATOR CANOPY (ROPS / TOPS) 31
Description 31
TRANSPORTING THE EXCAVATOR ON A TRAILER 33
Loading And Unloading 33
Fastening 34
TAILGATE 35
Opening And Closing 35
Adjusting The Latch 36
Opening And Closing Right Side Cover 36
SERVICE SCHEDULE 37
Maintenance Intervals 37
AIR CLEANER SERVICE 39
Daily Check 39
Replacing The Filter Elements 39
CAB FILTER 41
Cleaning And Maintenance 41
ENGINE COOLING SYSTEM 43
Cleaning 43
Checking Coolant Level 44
Removing And Replacing Coolant 45
FUEL SYSTEM 47
Fuel Specifications 47
Biodiesel Blend Fuel 47
Filling The Fuel Tank 48
Fuel Filter 49
Draining The Fuel Tank 50
Removing Air From The Fuel System 51
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 The Hydraulic Filter 56
Removing And Replacing The Hydraulic Fluid 57
LUBRICATING THE EXCAVATOR 59
Lubrication Locations 59
TRAVEL MOTOR 63
Checking And Adding Fluid 63
Removing And Replacing Fluid 63
SPARK ARRESTER MUFFLER 65
Cleaning Procedure 65
ALTERNATOR BELT 67
Belt Adjustment 67
Belt Replacement 67
SEAT BELT 69
Inspection And Maintenance 69
CONTROL CONSOLE LOCKOUTS 71
Inspection And Maintenance 71
PIVOT PINS 73
Inspection And Maintenance 73
TOWING THE EXCAVATOR 75
Procedure 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
Emergency Exit Locations 81
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 SCHEMATICS 95
HYDRAULIC SYSTEM INFORMATION 99
Glossary Of Hydraulic / Hydrostatic Symbols 99
Troubleshooting The Hydraulic Circuit 102
Troubleshooting The Cylinder Circuit 103
Troubleshooting The Swing (Upperstructure Slew) Circuit 104
Troubleshooting The Travel Circuit 105
CYLINDER (BOOM) 107
Testing 107
Removal And Installation 109
Parts Identification 111
Disassembly 112
Assembly 114
CYLINDER (ARM) 117
Testing 117
Removal And Installation 119
Parts Identification 121
Disassembly 122
Assembly 124
CYLINDER (BOOM SWING) 127
Testing 127
Removal And Installation 128
Parts Identification 130
Disassembly 131
Assembly 133
CYLINDER (BUCKET) 137
Testing 137
Removal And Installation 139
Parts Identification 140
Disassembly 141
Assembly 143
CYLINDER (BLADE) 147
Testing 147
Removal And Installation 148
Parts Identification 150
Disassembly 151
Assembly 153
CYLINDER (TRACK FRAME EXPANSION) 157
Testing 157
Removal And Installation 158
Parts Identification 162
Disassembly 163
Assembly 165
VALVE (MAIN RELIEF) 169
Description 169
Test Conditions 171
Testing And Adjusting Main Relief At Manifold 171
Testing And Adjusting Main Relief at Hydraulic Control Valve 173
VALVE (PORT RELIEF) 175
Testing And Adjusting 175
VALVE (CROSS PORT RELIEF) 177
Testing 177
Removal And Installation 179
VALVE (PRESSURE REDUCING) 181
Testing And Adjusting 181
HYDRAULIC CONTROL VALVE 183
Description 183
Removal And Installation 183
Parts Identification 189
Disassembly 190
Assembly 196
Right And Left Travel Valve Section Disassembly And Assembly 199
Arm And Bucket Valve Section Disassembly And Assembly 203
Boom Swing And Auxiliary Valve Section Disassembly And Assembly 205
Boom Valve Section Disassembly And Assembly 209
Slew Valve Section Disassembly And Assembly 210
Blade Valve Section Disassembly And Assembly 213
HYDRAULIC PUMP 217
Description 217
Torque Adjustment 217
Testing The Piston Pump 218
Testing The Gear Pump 220
Testing Auxiliary Hydraulic Flow 221
Removal And Installation 223
Parts Identification 225
Disassembly And Assembly 226
Gear Pump Disassembly 227
Gear Pump Assembly 229
Piston Pump Disassembly 231
Piston Pump Assembly 241
MANIFOLD ASSEMBLY / ACCUMULATOR 251
Description 251
Removal And Installation 251
Parts Identification 254
ACCUMULATOR 261
Removal And Installation 261
TRAVEL MOTOR 263
Description 263
Removal And Installation 263
Parts Identification 264
Disassembly 265
Assembly 272
SWIVEL JOINT (RUBBER TRACK) 281
Description 281
Removal And Installation 281
Parts Identification 284
Disassembly 285
Assembly 288
SWIVEL JOINT (STEEL TRACK) 291
Description 291
Removal And Installation 291
Parts Identification 295
Disassembly 296
Assembly 299
SWING MOTOR 303
Description 303
Removal And Installation 303
Parts Identification 305
Disassembly And Assembly 306
Motor Disassembly 307
Motor Assembly 311
Brake Carrier Disassembly And Assembly 318
CONTROL LEVER (JOYSTICK) (RIGHT) 321
Testing 321
Handle Removal And Installation 322
Removal And Installation 324
Parts Identification 327
Disassembly 328
Assembly 332
CONTROL LEVER (JOYSTICK) (LEFT) 337
Testing 337
Handle Removal And Installation 338
Joystick Assembly Removal and Installation 340
Parts Identification 341
Disassembly 342
Assembly 346
HYDRAULIC FILTER MOUNT 351
Description 351
Removal And Installation 351
HYDRAULIC RESERVOIR 353
Description 353
Removal And Installation 353
OIL COOLER 355
Removal And Installation 355
BLADE / TRACK EXPANSION SOLENOID BLOCK 357
Description 357
Block Removal And Installation 357
Solenoid Removal And Installation 359
Parts Identification 361
Block Disassembly And Assembly 362
UNDERCARRIAGE 365
BLADE 367
Description 367
Extension Removal And Installation 367
Blade Removal And Installation 368
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 369
Description 369
Track Lug Height 369
Checking Tension 370
Adjusting Tension 371
Track Removal And Installation 372
Idler Removal And Installation 373
Track Tensioner Removal And Installation 373
Track Tensioner Disassembly & Assembly 374
Roller Removal And Installation 374
Sprocket Removal And Installation 375
Track Frame Guide Inspection 375
Removal And Installation Of Expandable Track Frame 376
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 377
Description 377
Checking Tension 378
Adjusting Tension 379
Track Removal And Installation 380
Idler Removal And Installation 383
Track Tensioner Removal And Installation 383
Track Tensioner Disassembly & Assembly 384
Roller Removal And Installation 384
Sprocket Removal And Installation 385
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 474
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 527
Description 528
Fuse And Relay Location / Identification 528
BATTERY 530
Servicing 530
Removal And Installation 531
Using A Booster Battery (Jump Starting) 532
ALTERNATOR 534
Belt Adjustment 534
Belt Replacement 534
Charging System Inspection 535
Alternator Voltage Testing 536
Parts Identification 537
Removal And Installation 538
STARTER 540
Testing 540
Removal And Installation 541
Parts Identification 542
LIGHTS 544
Boom Light Removal And Installation 544
Boom Light Bulb Replacement 545
Cab Light Removal And Installation 545
MAGNETIC LOCKOUT SENSOR 546
Removal And Installation 546
TWO-SPEED SWITCH 548
Removal And Installation 548
FUEL LEVEL SENDER 550
Removal And Installation 550
Testing 550
DIAGNOSTIC SERVICE CODES 552
Viewing Service Codes 552
Number Codes List 553
CONTROL PANEL SETUP 556
Password Setup (Keyless Start Panel) 556
Maintenance Clock 558
KEY SWITCH 560
Removal And Installation 560
MOTION ALARM SYSTEM 562
Description 562
Inspecting 562
Adjusting Switch Position 563
WIPER MOTOR 564
Removal And Installation 564
ENGINE 566
ENGINE INFORMATION 568
Description 568
Specifications 569
Crankshaft Re-Grind Data 573
Torque Values 574
Troubleshooting 575
Engine Removal And Installation 576
Engine Mount Replacement 581
Engine Compression – Testing 582
SPARK ARRESTER MUFFLER 584
Removal And Installation 584
AIR CLEANER 586
Removal And Installation 586
ENGINE COOLING SYSTEM 588
Radiator / Oil Cooler Removal And Installation 588
Fan Removal 590
Water Pump Removal and Installation 591
Thermostat Removal and Installation 593
Thermostat – Testing 593
LUBRICATION SYSTEM 594
Oil Pan Removal And Installation 594
Oil Pump Removal And Installation 595
Oil Pump – Service 595
Engine Oil Pressure – Testing 596
FUEL SYSTEM 598
Fuel Shutoff Solenoid Removal And Installation 598
Fuel Injection Pump – Testing 599
Fuel Injection Pump Removal And Installation 601
Fuel Injection Pump – Timing 603
Fuel Camshaft Removal And Installation 604
Fuel Camshaft Governor 605
Fuel Injector Removal And Installation 605
Fuel Injector Nozzle Pressure – Testing 606
CYLINDER HEAD 608
Glow Plug Removal And Installation 608
Valve Clearance Adjustment 609
Valve Timing – Checking 610
Cylinder Head Removal And Installation 610
Cylinder Head Disassembly And Assembly 612
Cylinder Head – Servicing 613
Cylinder Head Top Clearance 614
Valve Guide – Servicing 614
Valve And Valve Seat Reconditioning 616
Valve Spring 617
Valve Tappets 618
Rocker Arm And Shaft – Servicing 619
CRANKSHAFT AND PISTONS 620
Piston And Connecting Rod Removal And Installation 620
Piston And Connecting Rod – Servicing 622
Cylinder Bore – Measuring 624
Connecting Rod Alignment 625
Crankshaft Gear Removal And Installation 625
Crankshaft And Bearings Removal And Installation 626
Crankshaft And Bearings – Servicing 628
CAMSHAFT AND TIMING GEARS 632
Timing Gearcase Cover Removal And Installation 632
Timing Gears Measuring Backlash 634
Idler Gear And Camshaft Removal And Installation 634
Idler Gear and Shaft – Servicing 637
FLYWHEEL AND HOUSING 638
Flywheel Housing Removal And Installation 638
Hydraulic Pump Coupler Removal And Installation 639
Flywheel Removal 639
Flywheel Installation 640
Rear End Plate Removal And Installation 640
HEATING AND VENTILATION 642
HEATER SYSTEM 644
Description 644
Components 644
REGULAR MAINTENANCE 646
Filter Element Removal And Installation 646
HEATER UNIT 648
Removal And Installation 648
HEATER COIL 650
Removal And Installation 650
HEATER FAN 654
Removal And Installation 654
HEATER VALVE 656
Removal And Installation 656
SPECIFICATIONS 658
EXCAVATOR SPECIFICATIONS 660
Machine Dimensions 660
Performance 662
Controls 662
Engine 663
Hydraulic System 663
Hydraulic Cylinders 664
Hydraulic Cycle Times 664
Electrical 664
Drive System 664
Slew System 665
Undercarriage 665
Capacities 665
Tracks 665
Ground Pressure 665
TECHNICAL SERVICE GUIDE SPECIFICATIONS 666
Engine 666
Engine Torques 666
Cooling System 666
Excavator Torques 666
TORQUE SPECIFICATIONS FOR BOLTS 668
Torque For General SAE Bolts 668
Torque For General Metric Bolts 669
HYDRAULIC CONNECTION SPECIFICATIONS 670
O-ring Face Seal Connection 670
Straight Thread O-ring Fitting 671
Tubelines And Hoses 671
Flare Fitting 672
Port Seal Fitting 673
HYDRAULIC FLUID SPECIFICATIONS 674
Specifications 674
CONVERSIONS 676
Decimal And Millimeter Equivalent Chart 676
U S To Metric Conversion Chart 676
SERVICE TOOLS REQUIRED 678
Remote Start Tools 678
Hydraulic Tools 679
Engine Tools 682
Electrical Tools 684
General Tools 685
HVAC Tools 686
ALPHABETICAL INDEX 688
SERVICE SCHEDULE SYMBOLS 690

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