Bobcat E26 Compact Excavator Service Manual SN B4S911001 & Above – PDF DOWNLOAD

Description

Bobcat E26 Compact Excavator Service Manual SN B4S911001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E26 Compact Excavator Service Manual SN B4S911001 & Above – PDF DOWNLOAD

Language : English
Pages : 821
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E26 Compact Excavator Service Manual SN B4S911001 & Above – 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:

TABLE OF CONTENTS:

Bobcat E26 Compact Excavator Service Manual SN B4S911001 & Above – 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
SAFETY AND MAINTENANCE 19
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, Ventilation, And Air Conditioning 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
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 106
CYLINDER (ARM) 111
Testing 111
Removal And Installation 113
Parts Identification 115
Disassembly 116
Assembly 117
CYLINDER (BOOM SWING) 121
Testing 121
Removal And Installation 123
Parts Identification (Earlier Models) 125
Disassembly (Earlier Models) 126
Assembly (Earlier Models) 128
Parts Identification (Later Models) 132
Disassembly (Later Models) 133
Assembly (Later Models) 135
CYLINDER (BUCKET) 139
Testing 139
Removal And Installation 140
Parts Identification 142
Disassembly 143
Assembly 145
CYLINDER (BLADE) 149
Testing 149
Removal And Installation 151
Parts Identification (Earlier Models) 152
Disassembly (Earlier Models) 153
Assembly (Earlier Models) 154
Parts Identification (Later Models) 158
Disassembly (Later Models) 159
Assembly (Later Models) 161
CYLINDER (CLAMP) 165
Testing 165
Removal And Installation 166
Parts Identification 168
Disassembly 169
Assembly 172
VALVES (MAIN RELIEF) 177
Testing And Adjusting 177
VALVES (PORT RELIEF) 183
Testing And Adjusting 183
VALVES (CROSS PORT RELIEF) 185
Testing 185
Removal And Installation 187
Disassembly And Assembly 187
VALVES (PILOT PRESSURE RELIEF) 189
Testing And Adjusting 189
HYDRAULIC CONTROL VALVE 191
Removal And Installation 191
Parts Identification 197
Disassembly 209
Auxiliary Valve Section Disassembly And Assembly 211
Arm Valve Section Disassembly And Assembly 215
RH Travel Valve Section Disassembly And Assembly 218
Bucket Valve Section Disassembly And Assembly 221
Boom Valve Section Disassembly And Assembly 224
LH Travel Valve Section Disassembly And Assembly 225
“Priority Valve” Valve Section Disassembly And Assembly 226
Blade Valve Section Disassembly And Assembly 228
Boom Swing Valve Section Disassembly And Assembly 231
Auxiliary 4 Valve Section Disassembly And Assembly 234
Slew Valve Section Disassembly And Assembly 237
Assembly 240
HYDRAULIC PUMP 247
Description 247
Torque Adjustment 248
Testing The Piston Pump P1 249
Testing The Piston Pump P2 251
Testing The Gear Pump P3 252
Testing The Gear Pump P4 254
Testing Auxiliary Hydraulic Flow 256
Removal And Installation 257
Coupler Removal And Installation 258
Hydraulic Pump Startup 259
Gear Pump Disassembly And Assembly 260
Piston Pump Parts Identification 265
Piston Pump Disassembly And Assembly 266
MANIFOLD ASSEMBLY / ACCUMULATOR 277
Description 277
Removal And Installation 278
Parts Identification 280
Disassembly And Assembly 281
TRAVEL MOTOR 287
Description 287
Removal And Installation 287
Parts Identification Hydraulic Motor 288
Parts Identification Gear Reduction Hub 289
Disassembly 290
Assembly 302
SWIVEL JOINT 315
Removal And Installation 315
Parts Identification 317
Disassembly And Assembly 318
SWING MOTOR 321
Removal And Installation 321
Parts Identification 323
Disassembly And Assembly 324
SWING MOTOR (DRIVE CARRIER) 331
Removal And Installation 331
Parts Identification 332
Disassembly And Assembly 333
RIGHT CONTROL LEVER (JOYSTICK) 339
Testing 339
Handle Removal And Installation 340
Joystick Assembly Removal And Installation 343
Parts Identification 344
Disassembly And Assembly 345
LEFT CONTROL LEVER (JOYSTICK) 347
Testing 347
Handle Removal And Installation 348
Joystick Assembly Removal And Installation 351
Parts Identification 352
Disassembly And Assembly 353
HYDRAULIC FILTER MOUNT 355
Removal And Installation 355
HYDRAULIC RESERVOIR 357
Removal And Installation 357
OIL COOLER 359
Removal And Installation 359
BLADE CONTROL LEVER 361
Handle Removal And Installation 361
Removal And Installation 363
Parts Identification 365
Disassembly And Assembly 366
CASE DRAIN FILTER MOUNT 371
Removal And Installation 371
TRAVEL CONTROL VALVE 373
Removal And Installation 373
Parts Identification 374
Disassembly And Assembly 375
REMOVING AIR FROM THE HYDRAULIC SYSTEM 381
Procedure 381
SECONDARY AUXILIARY VALVE 383
Removal And Installation 383
Parts Identification 386
Disassembly And Assembly 387
VALVE (BOOM LOAD HOLDING VALVE) 391
Removal And Installation 391
Inspection 393
Override Function – Emergency Lowering 393
VALVE (ARM LOAD HOLDING VALVE) 395
Removal And Installation 395
Inspection 397
Override Function – Emergency Lowering 397
UNDERCARRIAGE 399
BLADE 401
Removal And Installation 401
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 403
Description 403
Track Lug Height 403
Checking Tension 404
Adjusting Tension 405
Track Removal And Installation 406
Idler Removal And Installation 408
Idler Parts Identification 409
Idler Disassembly 410
Idler Assembly 412
Track Tensioner Removal And Installation 414
Track Tensioner Parts Identification 415
Track Tensioner Disassembly And Assembly 416
Roller Removal And Installation 417
Sprocket Removal And Installation 418
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 419
Description 419
Checking Tension 419
Adjusting Tension 420
Track Removal And Installation 421
Idler Removal And Installation 424
Idler Parts Identification 425
Idler Disassembly 426
Idler Assembly 428
Track Tensioner Removal And Installation 430
Track Tensioner Parts Identification 431
Track Tensioner Disassembly And Assembly 432
Roller Removal And Installation 433
Sprocket Removal And Installation 434
Guide Plate Removal And Installation 434
TRACK MAINTENANCE 435
Track Damage Identification 435
SWING CIRCLE GEAR 447
Swing Bearing Removal 447
Swing Bearing Installation 448
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
ELECTRICAL SYSTEM AND ANALYSIS 545
ELECTRICAL SCHEMATIC 547
ELECTRICAL SYSTEM INFORMATION 564
Glossary Of Electrical Symbols 564
Cab Frame Harness 567
Canopy Harness 568
Main Frame Harness 569
Motion Alarm Harness 570
Secondary Auxiliary Harness 571
Troubleshooting Chart 572
Description 573
Fuse And Relay Location / Identification 573
BATTERY 576
Servicing 576
Maintaining Battery Charge Level 576
Battery Service During Machine Storage 576
Battery Testing 577
Battery Charging 577
Removing And Installation 578
Using A Booster Battery (Jump Starting) 579
ALTERNATOR 580
Belt Adjustment 580
Belt Replacement 580
Charging System Inspection 582
Alternator Voltage Testing 583
Removal And Installation 583
Parts Identification 586
STARTER 588
Testing 588
Removal And Installation 589
Parts Identification 590
LIGHTS 592
Boom Light Removal And Installation 592
Boom Light Bulb Replacement 592
MAGNETIC LOCKOUT SENSOR 594
Removal And Installation 594
FUEL LEVEL SENDER 596
Removal And Installation 596
Testing 597
DIAGNOSTIC SERVICE CODES 598
Viewing Service Codes 598
Number Codes List 599
CONTROL PANEL SETUP 602
Panel Setup (Deluxe Instrument Panel) 602
Password Setup (Keyless Start Panel) 608
Password Setup (Keyless Start Panel) 609
Password Setup (Deluxe Instrument Panel) 610
Maintenance Clock 612
INSTRUMENT PANEL 614
Removal And Installation 614
CONTROLLER (GATEWAY AND AUXILIARY) 616
Description 616
Gateway Controller Removal And Installation 616
Auxiliary Controller Removal And Installation 617
KEY SWITCH 618
Removal And Installation 618
WIPER MOTOR 620
Removal And Installation 620
MOTION ALARM SYSTEM 622
Description 622
Inspecting 622
Adjusting Switch Position 623
SERVICE PC (LAPTOP COMPUTER) 624
Connecting The Remote Start Tool 624
Connecting Remote Start Tool (Service Tool) 624
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 626
Description 626
Controller Removal And Installation 626
Procedure 628
ENGINE SERVICE 630
ENGINE INFORMATION 632
Description 632
Specifications 633
Crankshaft Re-Grind Data 639
Torque For Kubota® Metric Bolts 640
Troubleshooting 641
Engine Removal And Installation 642
Compression Checking 651
ENGINE SPEED CONTROL (DIAL GAUGE) 652
Removal And Installation 652
Calibration 653
Actuator Removal And Installation 656
ENGINE SPEED CONTROL (LEVER) 658
Removal And Installation 658
Calibration 658
MUFFLER 660
Removal 660
Installation 662
AIR CLEANER 664
Removal And Installation 664
ENGINE COOLING SYSTEM 666
Coolant Recovery Tank Removal And Installation 666
Radiator Removal And Installation 667
Fan Removal And Installation 669
Water Pump Removal And Installation 670
Water Pump Disassembly And Assembly 670
Thermostat Housing Removal And Installation 671
Thermostat – Checking 671
LUBRICATION SYSTEM 672
Oil Pan Removal And Installation 672
Oil Pump Removal And Installation 672
Oil Pump Inspection 673
Engine Oil Pressure – Testing 674
FUEL SYSTEM 676
Fuel Shutoff Solenoid – Checking 676
Fuel Shutoff Solenoid Removal And Installation 677
Fuel Injection Pump – Checking 678
Fuel Injection Pump Removal And Installation 679
Fuel Injection Pump – Timing 682
Fuel Camshaft Removal And Installation 684
Fuel Camshaft Governor 684
Fuel Injector Removal And Installation 685
Fuel Injector Nozzle Pressure – Checking 687
Nozzle Spray Condition 688
Valve Seat Tightness 688
CYLINDER HEAD 690
Glow Plugs – Testing 690
Glow Plugs Removal And Installation 690
Valve Clearance Adjustment 691
Valve Timing – Checking 691
Cylinder Head Removal And Installation 692
Cylinder Head Disassembly And Assembly 696
Cylinder Head – Servicing 697
Cylinder Head Top Clearance 697
Valve Guide – Checking 698
Valve Guide Removal And Installation 699
Reconditioning The Valve And Valve Seat 700
Valve Spring 701
Valve Tappets 702
Rocker Arm And Shaft – Checking 703
Push Rod Alignment – Checking 703
CRANKSHAFT AND PISTONS 704
Piston And Connecting Rod Removal And Installation 704
Piston And Connecting Rod – Servicing 706
Cylinder Bore – Checking 708
Connecting Rod Alignment 709
Crankshaft Gear Removal And Installation 710
Crankshaft And Bearings Removal And Installation 711
Crankshaft And Bearings – Servicing 714
CAMSHAFT AND TIMING GEARS 718
Timing Gearcase Cover Removal And Installation 718
Timing Gears Backlash – Checking 720
Idler Gear And Shaft Removal And Installation 720
Camshaft – Servicing 721
Idler Gear And Shaft Servicing 723
FLYWHEEL AND HOUSING 724
Hydraulic Pump Coupler Removal And Installation 724
Flywheel Removal And Installation 726
Flywheel Ring Gear 726
HEATING AND VENTILATION 728
AIR CONDITIONING SYSTEM FLOW 730
Description 730
Chart 731
Components 732
Safety Equipment 735
REGULAR MAINTENANCE 736
Cab Filters 736
Air Conditioning Compressor Belt Adjustment 737
Air Conditioning Compressor Belt Replacement 737
Condenser 738
Air Conditioning Lubrication 738
Evaporator / Heater Coil 738
Air Conditioning Service Chart 740
TROUBLESHOOTING 742
Blower Motor Does Not Operate 742
Blower Motor Operates Normally, But Air Flow Is Insufficient 742
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 742
The Compressor Operates Improperly Or Not At All 742
Gauge Pressure Related Troubleshooting 743
Temperature / Pressure Chart 744
Poor A/C Performance 745
HVAC Repair And Leaks 745
Electrical System 746
Engine Coolant Bypassing The Heater Valve 748
SYSTEM CHARGING AND RECLAMATION 750
Refrigerant Identification 750
Reclamation And Charging With Recovery / Charging Unit 751
COMPRESSOR 754
Removal And Installation 754
Oil 755
Oil Check 756
CONDENSER 758
Removal And Installation 758
RECEIVER / DRIER 760
Receiver / Drier Removal And Installation 760
Pressure Switch Removal And Installation 761
EVAPORATOR / HEATER UNIT 762
Removal And Installation 762
THERMOSTAT 764
Description 764
Removal And Installation 765
EXPANSION VALVE 768
Removal And Installation 768
EVAPORATOR COIL 770
Removal And Installation 770
HEATER COIL 772
Removal And Installation 772
BLOWER FAN 774
Removal And Installation 774
HEATER VALVE 776
Removal And Installation 776
HVAC DUCT 778
Removal And Installation 778
SPECIFICATIONS 780
EXCAVATOR SPECIFICATIONS 782
Machine Dimensions 782
Machine Dimensions – Long Arm 783
Rated Lift Capacity – Canopy With Heavy Counterweight 784
Rated Lift Capacity – Cab With Heavy Counterweight 785
Performance 786
Controls 786
Engine 787
Hydraulic System 788
Hydraulic Cylinders 788
Hydraulic Cycle Times 789
Electrical 789
Drive System 789
Slew System 789
Undercarriage 790
Capacities 790
Tracks 790
Temperature Range 790
TECHNICAL SERVICE GUIDE SPECIFICATIONS 792
Engine 792
Engine Torques 792
Excavator Torques 792
Cooling System 792
TORQUE SPECIFICATION FOR BOLTS 794
Torque For General SAE Bolts 794
Torque For General Metric Bolts 795
HYDRAULIC CONNECTION SPECIFICATIONS 796
O-ring Face Seal Connection 796
Straight Thread O-ring Fitting 796
Tubelines And Hoses 797
Flare Fitting 797
O-ring Flare Fitting 798
Port Seal Fitting 800
Push To Connect Fittings 801
HYDRAULIC FLUID SPECIFICATIONS 804
Specifications 804
CONVERSIONS 806
Decimal And Millimeter Equivalent Chart 806
U S To Metric Conversion Chart 807
SERVICE TOOLS REQUIRED 808
Remote Start Tools 808
Hydraulic Tools 809
Engine Tools 812
Electrical Tools 814
General Tools 815
HVAC Tools 816
ALPHABETICAL INDEX 818
SERVICE SCHEDULE SYMBOLS 820

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