Bobcat E27 Compact Excavator Service Manual SN B4BA11001 & Above – PDF DOWNLOAD

Description

Bobcat E27 Compact Excavator Service Manual SN B4BA11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E27 Compact Excavator Service Manual SN B4BA11001 & Above – PDF DOWNLOAD

Language : English
Pages : 751
Downloadable : Yes
File Type : PDF
Size:24.9 MB

DESCRIPTION:

Bobcat E27 Compact Excavator Service Manual SN B4BA11001 & Above – PDF DOWNLOAD

S/N B4BA11001 & Above

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 E27 Compact Excavator Service Manual SN B4BA11001 & 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
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE EXCAVATOR 19
Procedure 19
LIFTING THE EXCAVATOR 21
Procedure 21
OPERATOR CAB (ROPS / TOPS) 23
Description 23
Cab Door 24
Front Window 25
Front Wiper 26
Window Washer Reservoir 26
Right Side Window 27
Heating And Ventilation Ducting 28
OPERATOR CANOPY (ROPS / TOPS) 29
Description 29
TRANSPORTING THE EXCAVATOR ON A TRAILER 31
Loading And Unloading 31
Fastening 32
TAILGATE 35
Opening And Closing 35
Adjusting The Latch 35
RIGHT SIDE COVER 37
Opening And Closing 37
SERVICE SCHEDULE 39
Maintenance Intervals 39
Inspection Checkbook 40
AIR CLEANER SERVICE 41
Replacing The Filter Elements 41
ENGINE COOLING SYSTEM 43
Cleaning 43
Checking 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 49
Removing Air From The Fuel System 50
ENGINE LUBRICATION SYSTEM 51
Checking And Adding Engine Oil 51
Engine Oil Chart 51
Removing And Replacing Oil And Filter 52
HYDRAULIC SYSTEM 53
Checking And Adding Hydraulic Fluid 53
Hydraulic / Hydrostatic Fluid Chart 54
Removing And Replacing Hydraulic Filters 54
Removing And Replacing Hydraulic Fluid 55
LUBRICATION OF THE HYDRAULIC EXCAVATOR 57
Lubrication Locations 57
PIVOT PINS 61
Inspection And Maintenance 61
TRAVEL MOTOR 63
Checking And Adding Oil 63
Removing And Replacing Oil 63
EMERGENCY EXIT 65
Right Rear Side Window 65
Front Window 65
SEAT BELT 67
Inspection And Maintenance 67
CONTROL CONSOLE LOCKOUTS 69
Inspection And Maintenance 69
TOWING THE EXCAVATOR 71
Procedure 71
REMOTE START TOOL KIT – 6987761 73
Remote Start Tool – 6987761 73
Service Tool Harness Control 74
Service Tool Harness Communicator – 6678110 75
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 77
Description 77
Remote Start Tool (Service Tool) – 7022042 78
Excavator Service Tool Harness – 6689747 79
Computer Service Tool Harness – 6689746 80
HYDRAULIC SYSTEM 81
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 104
CYLINDER (ARM) 109
Testing 109
Removal And Installation 111
Parts Identification 113
Disassembly 114
Assembly 115
CYLINDER (BOOM SWING) 119
Testing 119
Removal And Installation 121
Parts Identification (Earlier Models) 123
Disassembly (Earlier Models) 124
Assembly (Earlier Models) 126
Parts Identification (Later Models) 130
Disassembly (Later Models) 131
Assembly (Later Models) 133
CYLINDER (BUCKET) 137
Testing 137
Removal And Installation 138
Parts Identification 140
Disassembly 141
Assembly 143
CYLINDER (BLADE) 147
Testing 147
Removal And Installation 149
Parts Identification (Earlier Models) 150
Disassembly (Earlier Models) 151
Assembly (Earlier Models) 152
Parts Identification (Later Models) 156
Disassembly (Later Models) 157
Assembly (Later Models) 159
CYLINDER (CLAMP) 163
Testing 163
Removal And Installation 164
Parts Identification 166
Disassembly 167
Assembly 170
VALVES (MAIN RELIEF) 175
Testing And Adjusting 175
VALVES (PORT RELIEF) 181
Testing And Adjusting 181
VALVES (CROSS PORT RELIEF) 183
Testing 183
Removal And Installation 185
Disassembly And Assembly 185
VALVES (PILOT PRESSURE RELIEF) 187
Testing And Adjusting 187
HYDRAULIC CONTROL VALVE 189
Removal And Installation 189
Parts Identification 195
Disassembly 207
Auxiliary Valve Section Disassembly And Assembly 209
Arm Valve Section Disassembly And Assembly 213
RH Travel Valve Section Disassembly And Assembly 216
Bucket Valve Section Disassembly And Assembly 219
Boom Valve Section Disassembly And Assembly 221
LH Travel Valve Section Disassembly And Assembly 221
“Priority Valve” Valve Section Disassembly And Assembly 222
Blade Valve Section Disassembly And Assembly 224
Boom Swing Valve Section Disassembly And Assembly 227
Auxiliary 4 Valve Section Disassembly And Assembly 230
Slew Valve Section Disassembly And Assembly 233
Assembly 236
HYDRAULIC PUMP 243
Description 243
Torque Adjustment 244
Testing The Piston Pump P1 245
Testing The Piston Pump P2 247
Testing The Gear Pump P3 248
Testing The Gear Pump P4 250
Testing Auxiliary Hydraulic Flow 252
Removal And Installation 253
Coupler Removal And Installation 254
Hydraulic Pump Startup 255
Gear Pump Disassembly And Assembly 256
Piston Pump Parts Identification 261
Piston Pump Disassembly And Assembly 262
MANIFOLD ASSEMBLY / ACCUMULATOR 273
Description 273
Removal And Installation 273
Parts Identification 276
Disassembly And Assembly 277
TRAVEL MOTOR 283
Description 283
Removal And Installation 283
Parts Identification Hydraulic Motor 284
Parts Identification Gear Reduction Hub 285
Disassembly 286
Assembly 298
SWIVEL JOINT 311
Removal And Installation 311
Parts Identification 313
Disassembly And Assembly 314
SWING MOTOR 317
Removal And Installation 317
Parts Identification 319
Disassembly And Assembly 320
SWING MOTOR (DRIVE CARRIER) 327
Removal And Installation 327
Parts Identification 328
Disassembly And Assembly 329
RIGHT CONTROL LEVER (JOYSTICK) 335
Testing 335
Handle Removal And Installation 336
Joystick Assembly Removal And Installation 339
Parts Identification 340
Disassembly And Assembly 341
LEFT CONTROL LEVER (JOYSTICK) 343
Testing 343
Handle Removal And Installation 344
Joystick Assembly Removal And Installation 347
Parts Identification 348
Disassembly And Assembly 349
HYDRAULIC FILTER MOUNT 351
Removal And Installation 351
HYDRAULIC RESERVOIR 353
Removal And Installation 353
OIL COOLER 355
Removal And Installation 355
BLADE CONTROL LEVER 357
Handle Removal And Installation 357
Removal And Installation 359
Parts Identification 361
Disassembly And Assembly 362
CASE DRAIN FILTER MOUNT 367
Removal And Installation 367
TRAVEL CONTROL VALVE 369
Removal And Installation 369
Parts Identification 370
Disassembly And Assembly 371
REMOVING AIR FROM THE HYDRAULIC SYSTEM 377
Procedure 377
SECONDARY AUXILIARY VALVE 379
Removal And Installation 379
Parts Identification 383
Disassembly And Assembly 384
VALVE (BOOM LOAD HOLDING VALVE) 387
Removal And Installation 387
Inspection 389
Override Function – Emergency Lowering 389
VALVE (ARM LOAD HOLDING VALVE) 391
Removal And Installation 391
Inspection 393
Override Function – Emergency Lowering 393
UNDERCARRIAGE 395
BLADE 397
Removal And Installation 397
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 399
Description 399
Track Lug Height 399
Checking Tension 400
Adjusting Tension 401
Track Removal And Installation 402
Idler Removal And Installation 404
Idler Parts Identification 405
Idler Disassembly 406
Idler Assembly 408
Track Tensioner Removal And Installation 410
Track Tensioner Parts Identification 411
Track Tensioner Disassembly And Assembly 412
Roller Removal And Installation 413
Sprocket Removal And Installation 414
TRACK MAINTENANCE 415
Track Damage Identification 415
SWING CIRCLE GEAR 427
Swing Bearing Removal 427
Swing Bearing Installation 428
UPPERSTRUCTURE AND SWING SECTION 431
UPPERSTRUCTURE 433
Removal 433
Installation 435
ROPS CANOPY 437
Removal And Installation 437
CAB 441
Removal And Installation 441
Door Removal And Installation 445
Front Window Removal And Installation 446
Right Side Sliding Window Removal And Installation 448
Glass Removal 450
Glass Installation 451
SEAT 455
Removal And Installation 455
Seat Mount Removal And Installation 455
RIGHT CONSOLE 457
Console Cover Removal And Installation 457
LEFT CONSOLE 463
Lower Console Cover Removal And Installation 463
Upper Console Cover Removal And Installation 464
Compression Spring Removal And Installation 467
Lock Lever Removal And Installation 469
Console Removal And Installation 469
LEFT UPPERSTRUCTURE COVER 471
Removal And Installation 471
RIGHT UPPERSTRUCTURE COVER 473
Removal And Installation 473
COUNTERWEIGHT 475
Removal And Installation (Standard And Long Arm) 475
TRAVEL LEVERS AND PEDALS 479
Removal And Installation 479
Disassembly And Assembly 480
FLOOR MAT 481
Removal And Installation 481
FUEL TANK 483
Removal And Installation 483
HORN 485
Removal And Installation 485
SWING FRAME 487
Removal And Installation 487
Boom Swing Frame Hose Routing 489
Bushing Removal 490
Bushing Installation 491
BOOM 493
Removal And Installation 493
ARM (STANDARD AND LONG) 495
Removal And Installation 495
Arm To Boom Bushing Removal And Installation 497
Arm To Bucket And Bucket Link Bushing Removal And Installation 498
BUCKET 499
Bucket Teeth Removal And Installation 499
CLAMP 501
Removal And Installation 501
TAILGATE 503
Removal And Installation 503
Latch Removal And Installation 504
QUICK COUPLER (KLAC™ SYSTEM) 505
Removal 505
Installation 506
RIGHT SIDE COVER 509
Removal And Installation 509
TOOL BOX 511
Removal And Installation 511
ELECTRICAL SYSTEM AND ANALYSIS 513
ELECTRICAL SCHEMATICS 515
ELECTRICAL SYSTEM INFORMATION 537
Glossary Of Electrical Symbols 537
Cab Frame Harness 540
Canopy Harness 541
Main Frame Harness 542
Motion Alarm Harness 543
Secondary Auxiliary Harness 544
Troubleshooting Chart 545
Description 546
Fuse And Relay Location / Identification 546
BATTERY 549
Battery Maintenance 549
Maintaining Battery Charge Level 549
Battery Service During Machine Storage 549
Battery Testing 550
Battery Charging 550
Removing And Installing The Battery 551
Using A Booster Battery (Jump Starting) 552
ALTERNATOR 553
Belt Adjustment 553
Belt Replacement 553
Charging System Inspection 555
Alternator Voltage Testing 556
Removal And Installation 556
Parts Identification 559
STARTER 561
Testing 561
Removal And Installation 562
Parts Identification 563
LIGHTS 565
Boom Light Removal And Installation 565
Boom Light Bulb Replacement 566
MAGNETIC LOCKOUT SENSOR 567
Removal And Installation 567
FUEL LEVEL SENDER 569
Removal And Installation 569
Testing 570
DIAGNOSTIC SERVICE CODES 571
Viewing Service Codes 571
Number Codes List 572
CONTROL PANEL SETUP 575
Password Setup (Keyless Start Panel) 575
Maintenance Clock 576
INSTRUMENT PANEL 577
Removal And Installation 577
CONTROLLER (GATEWAY AND AUXILIARY) 579
Description 579
Gateway Controller Removal And Installation 579
Auxiliary Controller Removal And Installation 580
KEY SWITCH 581
Removal And Installation 581
WIPER MOTOR 583
Removal And Installation 583
MOTION ALARM SYSTEM 585
Description 585
Inspecting 585
Adjusting Switch Position 586
SERVICE PC (LAPTOP COMPUTER) 587
Connecting The Remote Start Tool 587
Connecting Remote Start Tool (Service Tool) 587
SHUT-OFF SWITCH 589
Description 589
Removal And Installation 590
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 591
Description 591
Removal And Installation 591
Procedure 593
ENGINE SERVICE 595
ENGINE INFORMATION 597
Description 597
Specifications 598
Crankshaft Re-Grind Data 604
Torque For Kubota® Metric Bolts 605
Troubleshooting 606
Engine Removal And Installation 607
Compression Checking 616
ENGINE SPEED CONTROL (DIAL GAUGE) 617
Removal And Installation 617
Calibration 618
Actuator Removal And Installation 621
ENGINE SPEED CONTROL (LEVER) 623
Removal And Installation 623
Calibration 623
MUFFLER 625
Removal 625
Installation 627
AIR CLEANER 629
Removal And Installation 629
ENGINE COOLING SYSTEM 631
Coolant Recovery Tank Removal And Installation 631
Radiator Removal And Installation 632
Fan Removal And Installation 634
Water Pump Removal And Installation 635
Water Pump Disassembly And Assembly 635
Thermostat Housing Removal And Installation 636
Thermostat – Checking 636
LUBRICATION SYSTEM 637
Oil Pan Removal And Installation 637
Oil Pump Removal And Installation 637
Oil Pump Inspection 638
Engine Oil Pressure – Testing 639
FUEL SYSTEM 641
Fuel Shutoff Solenoid – Checking 641
Fuel Shutoff Solenoid Removal And Installation 642
Fuel Injection Pump – Checking 643
Fuel Injection Pump Removal And Installation 644
Fuel Injection Pump – Timing 647
Fuel Camshaft Removal And Installation 649
Fuel Camshaft Governor 649
Fuel Injector Removal And Installation 650
Fuel Injector Nozzle Pressure – Checking 652
Nozzle Spray Condition 653
Valve Seat Tightness 653
CYLINDER HEAD 655
Glow Plugs – Testing 655
Glow Plugs Removal And Installation 655
Valve Clearance Adjustment 656
Valve Timing – Checking 656
Cylinder Head Removal And Installation 657
Cylinder Head Disassembly And Assembly 661
Cylinder Head – Servicing 662
Cylinder Head Top Clearance 662
Valve Guide – Checking 663
Valve Guide Removal And Installation 664
Reconditioning The Valve And Valve Seat 665
Valve Spring 666
Valve Tappets 667
Rocker Arm And Shaft – Checking 668
Push Rod Alignment – Checking 668
CRANKSHAFT AND PISTONS 669
Piston And Connecting Rod Removal And Installation 669
Piston And Connecting Rod – Servicing 671
Cylinder Bore – Checking 673
Connecting Rod Alignment 674
Crankshaft Gear Removal And Installation 675
Crankshaft And Bearings Removal And Installation 676
Crankshaft And Bearings – Servicing 679
CAMSHAFT AND TIMING GEARS 683
Timing Gearcase Cover Removal And Installation 683
Timing Gears Backlash – Checking 685
Idler Gear And Shaft Removal And Installation 685
Camshaft – Servicing 686
Idler Gear And Shaft Servicing 688
FLYWHEEL AND HOUSING 689
Hydraulic Pump Coupler Removal And Installation 689
Flywheel Removal And Installation 691
Flywheel Ring Gear 691
HEATING AND VENTILATION 693
REGULAR MAINTENANCE 695
Cab Filters 695
TROUBLESHOOTING 697
Blower Motor Does Not Operate 697
Blower Motor Operates Normally, But Air Flow Is Insufficient 697
Electrical System 698
HEATER UNIT 699
Removal And Installation 699
HEATER COIL 701
Removal And Installation 701
BLOWER FAN 703
Removal And Installation 703
HEATER VALVE 705
Removal And Installation 705
HEATING / VENTILATION DUCT 707
Removal And Installation 707
SPECIFICATIONS 709
EXCAVATOR SPECIFICATIONS 711
Machine Dimensions 711
Rated Lift Capacity – Canopy With Medium Counterweight 713
Rated Lift Capacity – Canopy With Heavy Counterweight 714
Rated Lift Capacity – Cab With Medium Counterweight 715
Rated Lift Capacity – Cab With Heavy Counterweight 716
Performance 717
Controls 717
Engine 718
Hydraulic System 718
Hydraulic Cylinders 719
Hydraulic Cycle Times 719
Electrical 719
Drive System 719
Slew System 719
Undercarriage 720
Capacities 720
Tracks 720
Environmental 720
Temperature Range 720
TECHNICAL SERVICE GUIDE SPECIFICATIONS 721
Engine 721
Engine Torques 721
Excavator Torques 721
Cooling System 721
TORQUE SPECIFICATION FOR BOLTS 723
Torque For General SAE Bolts 723
Torque For General Metric Bolts 724
HYDRAULIC CONNECTION SPECIFICATIONS 725
O-ring Face Seal Connection 725
Straight Thread O-ring Fitting 725
Tubelines And Hoses 726
Flare Fitting 726
O-ring Flare Fitting 727
Port Seal Fitting 729
Push To Connect Fittings 730
HYDRAULIC FLUID SPECIFICATIONS 733
Specifications 733
CONVERSIONS 735
Decimal And Millimeter Equivalent Chart 735
U S To Metric Conversion Chart 736
SERVICE TOOLS REQUIRED 737
Remote Start Tools 737
Hydraulic Tools 738
Engine Tools 741
Electrical Tools 743
General Tools 744
HVAC Tools 745
ALPHABETICAL INDEX 747
SERVICE SCHEDULE SYMBOLS 750

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