Bobcat E25 Compact Excavator Service Manual SN AB8B11001 & Above – PDF DOWNLOAD

Description

Bobcat E25 Compact Excavator Service Manual SN AB8B11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E25 Compact Excavator Service Manual SN AB8B11001 & Above – PDF DOWNLOAD

Language : English
Pages : 838
Downloadable : Yes
File Type : PDF
Size:38.1 MB

DESCRIPTION:

Bobcat E25 Compact Excavator Service Manual SN AB8B11001 & 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 E25 Compact Excavator Service Manual SN AB8B11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
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 AND MAINTENANCE 19
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 30
TRANSPORTING THE EXCAVATOR ON A TRAILER 31
Loading And Unloading 31
Fastening 32
TAILGATE 33
Opening And Closing 33
Adjusting The Latch 33
RIGHT SIDE COVER 35
Opening And Closing 35
SERVICE SCHEDULE 37
Maintenance Intervals 37
AIR CLEANER SERVICE 39
Daily Check 39
Replacing The Filter Elements 39
ENGINE COOLING SYSTEM 41
Cleaning 41
Checking Level 42
Removing And Replacing Coolant 43
FUEL SYSTEM 45
Fuel Specifications 45
Biodiesel Blend Fuel 45
Filling The Fuel Tank 46
Fuel Filter 47
Draining The Fuel Tank 47
Removing Air From The Fuel System 48
ENGINE LUBRICATION SYSTEM 49
Checking And Adding Engine Oil 49
Engine Oil Chart 49
Removing And Replacing Oil And Filter 50
HYDRAULIC SYSTEM 51
Checking And Adding Hydraulic Fluid 51
Hydraulic / Hydrostatic Fluid Chart 52
Removing And Replacing Hydraulic Filters 52
Removing And Replacing Hydraulic Fluid 54
LUBRICATION OF THE HYDRAULIC EXCAVATOR 55
Lubrication Locations 55
PIVOT PINS 59
Inspection And Maintenance 59
TRAVEL MOTOR 61
Checking And Adding Oil 61
Removing And Replacing Oil 61
EMERGENCY EXIT 63
Right Rear Side Window 63
Front Window 63
SEAT BELT 65
Inspection And Maintenance 65
CONTROL CONSOLE LOCKOUTS 67
Inspection And Maintenance 67
TOWING THE EXCAVATOR 69
Procedure 69
REMOTE START TOOL KIT – MEL1563 71
Remote Start Tool – MEL1563 71
Service Tool Harness Control – MEL1565 72
Service Tool Harness Communicator – MEL1566 72
REMOTE START TOOL (SERVICE TOOL) KIT – 6689779 / 7003031 75
Description 75
Remote Start Tool (Service Tool) – 6689778 / 7003030 76
Excavator Service Tool Harness – 6689747 77
Computer Service Tool Harness – 6689746 78
HYDRAULIC SYSTEM 79
HYDRAULIC / HYDROSTATIC SCHEMATICS 85
HYDRAULIC SYSTEM INFORMATION 87
Glossary Of Hydraulic / Hydrostatic Symbols 87
Troubleshooting The Hydraulic Circuit 90
Troubleshooting The Cylinder Circuit 91
Troubleshooting The Swing (Upperstructure Slew) Circuit 92
Troubleshooting The Travel Circuit 93
CYLINDER (BOOM) 95
Testing 95
Removal And Installation 97
Parts Identification 100
Disassembly 101
Assembly 103
CYLINDER (ARM) 107
Testing 107
Removal And Installation 109
Parts Identification 111
Disassembly 112
Assembly 114
CYLINDER (BOOM SWING) 117
Testing 117
Removal And Installation 119
Parts Identification 121
Disassembly 122
Assembly 125
CYLINDER (BUCKET) 129
Testing 129
Removal And Installation 130
Parts Identification 132
Disassembly 133
Assembly 135
CYLINDER (BLADE) 139
Testing 139
Removal And Installation 141
Parts Identification 142
Disassembly 143
Assembly 144
CYLINDER (CLAMP) 149
Testing 149
Removal And Installation 150
Parts Identification 152
Disassembly 153
Assembly 156
VALVES (MAIN RELIEF) 161
Testing And Adjusting 161
VALVES (PORT RELIEF) 167
Testing And Adjusting 167
VALVES (CROSS PORT RELIEF) 169
Testing 169
Removal And Installation 170
Disassembly And Assembly 171
VALVES (PILOT PRESSURE RELIEF) 173
Testing And Adjusting 173
HYDRAULIC CONTROL VALVE 175
Removal And Installation 175
Parts Identification 180
Disassembly 191
Auxiliary Valve Section Disassembly And Assembly 193
Arm Valve Section Disassembly And Assembly 197
RH Travel Valve Section Disassembly And Assembly 200
Bucket Valve Section Disassembly And Assembly 203
Boom Valve Section Disassembly And Assembly 205
LH Travel Valve Section Disassembly And Assembly 205
“Priority Valve” Valve Section Disassembly And Assembly 206
Blade Valve Section Disassembly And Assembly 208
Boom Swing Valve Section Disassembly And Assembly 211
Slew Valve Section Disassembly And Assembly 214
Assembly 217
HYDRAULIC PUMP 223
Description 223
Torque Adjustment 224
Testing The Piston Pump P1 225
Testing The Piston Pump P2 227
Testing The Gear Pump P3 228
Testing The Gear Pump P4 230
Testing Auxiliary Hydraulic Flow 232
Removal And Installation 233
Coupler Removal And Installation 234
Hydraulic Pump Startup 235
Gear Pump Disassembly And Assembly 236
Piston Pump Parts Identification 241
Piston Pump Disassembly And Assembly 242
MANIFOLD ASSEMBLY / ACCUMULATOR 253
Description 253
Removal And Installation 253
Parts Identification 256
Disassembly And Assembly 257
TRAVEL MOTOR 263
Removal And Installation 263
Parts Identification Hydraulic Motor 264
Parts Identification Gear Reduction Hub 265
Disassembly 266
Assembly 278
SWIVEL JOINT (EARLY MODELS) 291
Removal And Installation 291
Parts Identification 293
Disassembly And Assembly 294
SWIVEL JOINT (LATER MODELS) 297
Removal And Installation 297
Parts Identification 299
Disassembly And Assembly 300
SWING MOTOR 303
Removal And Installation 303
Parts Identification 305
Disassembly And Assembly 306
SWING MOTOR (DRIVE CARRIER) 311
Removal And Installation 311
Parts Identification 312
Disassembly And Assembly 313
CONTROL PATTERN SELECTOR VALVE 319
Removal And Installation 319
Parts Identification 320
Disassembly And Assembly 321
RIGHT CONTROL LEVER (JOYSTICK) (S/N AB8B11001 – AB8B11080) 323
Testing 323
Handle Removal And Installation 324
Joystick Assembly Removal And Installation 326
Parts Identification 327
Disassembly 328
Assembly 333
RIGHT CONTROL LEVER (JOYSTICK) (S/N AB8B11081 & ABOVE) 337
Testing 337
Handle Removal And Installation 338
Joystick Assembly Removal And Installation 340
Parts Identification 342
Disassembly 343
Assembly 347
LEFT CONTROL LEVER (JOYSTICK) (S/N AB8B11001 – AB8B11080) 351
Testing 351
Handle Removal And Installation 352
Joystick Assembly Removal And Installation 354
Parts Identification 355
Disassembly 356
Assembly 361
LEFT CONTROL LEVER (JOYSTICK) (S/N AB8B11081 & ABOVE) 365
Testing 365
Handle Removal And Installation 366
Joystick Assembly Removal And Installation 368
Parts Identification 369
Disassembly 370
Assembly 374
HYDRAULIC FILTER MOUNT 379
Removal And Installation 379
HYDRAULIC RESERVOIR 381
Removal And Installation 381
OIL COOLER 385
Removal And Installation 385
DIRECT TO TANK VALVE 387
Removal And Installation 387
BLADE CONTROL LEVER 389
Handle Removal And Installation 389
Removal And Installation 391
Parts Identification 393
Disassembly And Assembly 394
CASE DRAIN FILTER MOUNT 399
Removal And Installation 399
TRAVEL CONTROL VALVE 401
Removal And Installation 401
Parts Identification 402
Disassembly And Assembly 403
REMOVING AIR FROM THE HYDRAULIC SYSTEM 409
Procedure 409
SECONDARY AUXILIARY VALVE (EARLY MODELS) 411
Removal And Installation 411
Parts Identification 414
Disassembly And Assembly 415
SECONDARY AUXILIARY VALVE (LATER MODELS) 421
Removal And Installation 421
Parts Identification 424
Disassembly And Assembly 425
VALVE (BOOM LOCK) 429
Removal And Installation 429
VALVE (ARM LOCK) 431
Removal And Installation 431
UNDERCARRIAGE 433
BLADE 435
Removal And Installation 435
TRACK UNDERCARRIAGE COMPONENTS 437
Description 437
Track Lug Height 437
Checking Tension 438
Adjusting Tension 439
Track Removal And Installation 440
Idler Removal And Installation 442
Idler Parts Identification 443
Track Idler Disassembly 444
Track Idler Assembly 446
Track Tensioner Removal And Installation 448
Track Tensioner Parts Identification 449
Track Tensioner Disassembly And Assembly 450
Top Slider Removal And Installation 451
Roller Removal And Installation 451
Sprocket Removal And Installation 452
TRACK MAINTENANCE 453
Track Damage Identification 453
SWING CIRCLE GEAR 465
Swing Bearing Removal 465
Swing Bearing Installation 466
UPPERSTRUCTURE AND SWING SECTION 469
UPPERSTRUCTURE 471
Removal 471
Installation 473
ROPS CANOPY 475
Removal And Installation 475
CAB 479
Removal And Installation 479
Door Removal And Installation 482
Front Window Removal And Installation 483
Right Side Rear Sliding Window Removal And Installation 484
Right Side Front Sliding Window Removal And Installation 484
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 485
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 485
Glass Removal 486
Glass Installation 487
SEAT 493
Removal And Installation 493
Seat Mount Removal And Installation 494
RIGHT CONSOLE (S/N AB8B11001 – AB8B11999) 495
Console Cover Removal And Installation 495
RIGHT CONSOLE (S/N AB8B12001 & ABOVE) 501
Console Cover Removal And Installation 501
LEFT CONSOLE 507
Lower Console Cover Removal And Installation 507
Upper Console Cover Removal And Installation 507
Compression Spring Removal And Installation 510
Lock Lever Removal And Installation 512
Console Removal And Installation 512
LEFT UPPERSTRUCTURE COVER 513
Removal And Installation 513
RIGHT UPPERSTRUCTURE COVER 515
Removal And Installation 515
COUNTERWEIGHT 517
Removal And Installation 517
Long Arm Counterweight Removal And Installation 520
TRAVEL LEVERS AND PEDALS 521
Removal And Installation 521
Disassembly And Assembly 522
FLOOR MAT 523
Removal And Installation 523
FUEL TANK 525
Removal And Installation 525
HORN 527
Removal And Installation 527
SWING FRAME 529
Removal And Installation 529
Boom Swing Frame Hose Routing 531
Bushing Removal 532
Bushing Installation 533
BOOM 535
Removal And Installation 535
ARM (STANDARD AND LONG) 537
Removal And Installation 537
Arm To Boom Bushing Removal And Installation 538
Arm To Bucket And Bucket Link Bushing Removal And Installation 539
BUCKET 541
Bucket Teeth Removal And Installation 541
Bucket Side Cutting Edge Removal And Installation 542
CLAMP 543
Removal And Installation 543
TAILGATE 545
Removal And Installation 545
Latch Removal And Installation 546
QUICK COUPLER (KLAC™ SYSTEM) 547
Removal 547
Installation 548
QUICK COUPLER (BOBCAT HYDRAULIC PIN GRABBER COUPLER HPG2) 551
Troubleshooting 551
Daily Inspection 552
Removal And Installation 553
Parts Identification 554
Disassembly And Assembly 555
RIGHT SIDE COVER 559
Removal And Installation 559
TOOL BOX 561
Removal And Installation 561
ELECTRICAL SYSTEM AND ANALYSIS 563
ELECTRICAL SCHEMATICS 565
ELECTRICAL SYSTEM INFORMATION 607
Troubleshooting Chart 607
Description 608
Fuse And Relay Location / Identification 608
Shut-Off Switch 610
BATTERY 611
Servicing 611
Removing And Installing The Battery 612
Using A Booster Battery (Jump Starting) 613
ALTERNATOR 615
Belt Adjustment 615
Belt Replacement 615
Charging System Inspection 618
Alternator Voltage Testing 619
Low Voltage Testing 619
High Voltage Testing 620
Removal And Installation 620
Parts Identification 622
STARTER 623
Testing 623
Removal And Installation 624
Parts Identification 625
LIGHTS 627
Removal And Installation 627
Boom Light Removal And Installation 628
Boom Light Bulb Replacement 628
MAGNETIC LOCKOUT SENSOR 629
Removal And Installation 629
FUEL LEVEL SENDER 631
Removal And Installation 631
Testing 632
DIAGNOSTIC SERVICE CODES (S/N AB8B11001 – AB8B11999) 633
Service Codes List 633
DIAGNOSTIC SERVICE CODES (S/N AB8B12001 & ABOVE) 635
Viewing Service Codes 635
Number Codes List 636
DELUXE INSTRUMENT PANEL SETUP (S/N AB8B11001 – AB8B11999) 639
Passwords 639
Password Entry (For Starting And Operating The Machine) 639
Changing The Operator Password 639
Password Lockout Feature 640
Job Clock 640
RPM 640
CONTROL PANEL SETUP (S/N AB8B12001 & ABOVE) 641
Panel Setup (Deluxe Instrument Panel) 641
Password Setup (Keyless Start Panel) 647
Password Setup (Deluxe Instrument Panel) 648
Maintenance Clock 650
INSTRUMENT PANEL / CONTROLLER (S/N AB8B11001 – AB8B11999) 653
Removal And Installation 653
INSTRUMENT PANEL (S/N AB8B12001 & ABOVE) 655
Removal And Installation 655
CONTROLLER (S/N AB8B12001 & ABOVE) (GATEWAY AND AUXILIARY) 657
Description 657
Gateway Controller Removal And Installation 658
Auxiliary Controller Removal And Installation 660
KEY SWITCH 661
Removal And Installation 661
WIPER MOTOR 663
Removal And Installation 663
MOTION ALARM SYSTEM 665
Description 665
Inspecting 665
Adjusting Switch Position 666
SERVICE PC (LAPTOP COMPUTER) 667
Connecting The Remote Start Tool 667
Connecting Remote Start Tool (Service Tool) 667
Operation 668
BATTERY DISCONNECT SWITCH 669
Description 669
Removal And Installation 670
ENGINE SERVICE 671
ENGINE INFORMATION 673
Description 673
Specifications 674
Crankshaft Re-Grind Data 680
Torque For Kubota® Metric Bolts 681
Troubleshooting 682
Engine Removal And Installation 683
Compression Checking 690
ENGINE SPEED CONTROL (DIAL GAUGE) 691
Removal And Installation 691
Auto Idle Controller Removal And Installation 692
Calibration 693
Actuator Removal And Installation 696
ENGINE SPEED CONTROL (LEVER) 699
Removal And Installation 699
Calibration 699
MUFFLER 701
Removal 701
Installation 702
AIR CLEANER 705
Removal And Installation 705
ENGINE COOLING SYSTEM 707
Radiator Removal And Installation 707
Fan Removal And Installation 709
Water Pump Removal And Installation 710
Water Pump Disassembly And Assembly 710
Thermostat Housing Removal And Installation 711
Thermostat – Checking 711
LUBRICATION SYSTEM 713
Oil Pan Removal And Installation 713
Oil Pump Removal And Installation 713
Oil Pump Inspection 714
Engine Oil Pressure – Testing 715
FUEL SYSTEM 717
Fuel Shutoff Solenoid – Checking 717
Fuel Shutoff Solenoid Removal And Installation 718
Fuel Injection Pump – Checking 719
Fuel Injection Pump Removal And Installation 720
Fuel Injection Pump – Timing 723
Fuel Camshaft Removal And Installation 725
Fuel Camshaft Governor 725
Fuel Injector Removal And Installation 726
Fuel Injector Nozzle Pressure – Checking 728
Nozzle Spray Condition 729
Valve Seat Tightness 729
CYLINDER HEAD 731
Glow Plugs – Testing 731
Glow Plugs Removal And Installation 731
Valve Clearance Adjustment 732
Valve Timing – Checking 732
Cylinder Head Removal And Installation 733
Cylinder Head Disassembly And Assembly 737
Cylinder Head – Servicing 738
Cylinder Head Top Clearance 738
Valve Guide – Checking 739
Valve Guide Removal And Installation 740
Reconditioning The Valve And Valve Seat 741
Valve Spring 742
Valve Tappets 743
Rocker Arm And Shaft – Checking 744
Push Rod Alignment – Checking 744
CRANKSHAFT AND PISTONS 745
Piston And Connecting Rod Removal And Installation 745
Piston And Connecting Rod – Servicing 747
Cylinder Bore – Checking 749
Connecting Rod Alignment 749
Crankshaft Gear Removal And Installation 750
Crankshaft And Bearings Removal And Installation 750
Crankshaft And Bearings – Servicing 753
CAMSHAFT AND TIMING GEARS 757
Timing Gearcase Cover Removal And Installation 757
Timing Gears Backlash – Checking 759
Idler Gear And Shaft Removal And Installation 759
Camshaft – Servicing 760
Idler Gear And Shaft Servicing 762
FLYWHEEL AND HOUSING 763
Hydraulic Pump Coupler Removal And Installation 763
Flywheel Removal And Installation 765
Flywheel Ring Gear 765
HEATING, VENTILATION AND AIR 767
REGULAR MAINTENANCE (S/N AB8B110001 – AB8B11999) 769
Cab Filters 769
REGULAR MAINTENANCE (S/N AB8B12001 & ABOVE) 771
Cab Filters 771
TROUBLESHOOTING 773
Blower Motor Does Not Operate 773
Blower Motor Operates Normally, But Air Flow Is Insufficient 773
Electrical System 774
HEATING / VENTILATION UNIT 775
Removal And Installation 775
HEATER COIL (S/N AB8B11001 – AB8B11999) 779
Removal And Installation 779
HEATER COIL (S/N AB8B12001 & ABOVE) 781
Removal And Installation 781
BLOWER FAN (S/N AB8B11001 – AB8B11999) 783
Removal And Installation 783
BLOWER FAN (S/N AB8B12001 & ABOVE) 785
Removal And Installation 785
HEATER VALVE 787
Removal And Installation 787
HEATING / VENTILATION DUCT (S/N AB8B110001 – AB8B11999) 789
Removal And Installation 789
HVAC DUCT (S/N AB8B12001 & ABOVE) 791
Removal And Installation 791
SPECIFICATIONS 793
EXCAVATOR SPECIFICATIONS 795
Machine Dimensions (Standard Arm) 795
Machine Dimensions (Long Arm) 797
Rated Lift Capacity – With Standard Arm 799
Rated Lift Capacity – With Standard Arm With Counterweight 800
Rated Lift Capacity – With Long Arm 801
Rated Lift Capacity – With Long Arm With Counterweight 802
Performance 803
Controls 803
Engine 804
Hydraulic System 804
Hydraulic Cylinders 805
Hydraulic Cycle Times 805
Electrical 805
Drive System 805
Slew System 806
Undercarriage 806
Capacities 806
Tracks 806
Ground Pressure 806
Environmental 807
Temperature Range 807
TECHNICAL SERVICE GUIDE SPECIFICATIONS 809
Engine 809
Engine Torques 809
Excavator Torques 810
Cooling System 810
TORQUE SPECIFICATION FOR BOLTS 811
Torque For General SAE Bolts 811
Torque For General Metric Bolts 812
HYDRAULIC CONNECTION SPECIFICATIONS 813
O-ring Face Seal Connection 813
Straight Thread O-ring Fitting 813
Tubelines And Hoses 814
Flare Fitting 814
O-ring Flare Fitting 815
Port Seal Fitting 817
Push To Connect Fittings 818
HYDRAULIC FLUID SPECIFICATIONS 821
Specifications 821
CONVERSIONS 823
Decimal And Millimeter Equivalent Chart 823
U S To Metric Conversion Chart 824
SERVICE TOOLS REQUIRED 825
Remote Start Tools 825
Hydraulic Tools 826
Engine Tools 829
Electrical Tools 831
HVAC Tools 831
ALPHABETICAL INDEX 833

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• 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]

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