Bobcat E35z Compact Excavator Service Manual SN B3Y411001 & Above – PDF DOWNLOAD

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Bobcat E35z Compact Excavator Service Manual SN B3Y411001 & Above – PDF DOWNLOAD

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Bobcat E35z Compact Excavator Service Manual SN B3Y411001 & Above – PDF DOWNLOAD

Language : English
Pages : 835
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E35z Compact Excavator Service Manual SN B3Y411001 & Above – PDF DOWNLOAD

S/N B3Y411001 & Above

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:

•  The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bobcat E35z Compact Excavator Service Manual SN B3Y411001 & 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
EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS / TOPS / FOPS) 27
Description 27
Cab Door 27
Front Window 28
Front Wiper 30
Window Washer Reservoir 30
Right Side Window 31
OPERATOR CANOPY (ROPS / TOPS / FOPS) 33
Description 33
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 36
TAILGATE 39
Opening And Closing 39
Adjusting The Latch 39
RIGHT SIDE COVER 41
Opening And Closing 41
SERVICE SCHEDULE 43
Maintenance Intervals 43
AIR CLEANER SERVICE 45
Daily Check 45
Replacing The Filter Elements 45
CAB FILTERS 47
Cleaning And Maintenance 47
ENGINE COOLING SYSTEM 49
Cleaning 49
Checking Level 50
Removing And Replacing Coolant 51
FUEL SYSTEM 53
Fuel Specifications 53
Biodiesel Blend Fuel 53
Filling The Fuel Tank 54
Fuel Filters 55
Draining The Fuel Tank 56
Removing Air From The Fuel System 57
ENGINE LUBRICATION SYSTEM 59
Checking And Adding Engine Oil 59
Engine Oil Chart 59
Removing And Replacing Oil And Filter 60
HYDRAULIC SYSTEM 61
Checking And Adding Hydraulic Fluid 61
Hydraulic / Hydrostatic Fluid Chart 62
Removing And Replacing Hydraulic Filters 62
Removing And Replacing Hydraulic Fluid 63
LUBRICATING THE EXCAVATOR 65
Lubrication Locations 65
PIVOT PINS 69
Inspection And Maintenance 69
TRAVEL MOTOR 71
Checking And Adding Oil 71
Removing And Replacing Oil 71
SPARK ARRESTER MUFFLER 73
Cleaning Procedure 73
EMERGENCY EXIT 75
Right Side Rear Window 75
Front Window 75
SEAT BELT 77
Inspection And Maintenance 77
CONTROL CONSOLE LOCKOUTS 79
Inspection And Maintenance 79
TOWING THE EXCAVATOR 81
Procedure 81
REMOTE START TOOL KIT – MEL1563 83
Remote Start Tool Kit – MEL1563 83
Service Tool Harness Control – MEL1565 84
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 97
Glossary Of Hydraulic / Hydrostatic Symbols 97
Troubleshooting The Hydraulic Circuit 100
Troubleshooting The Cylinder Circuit 101
Troubleshooting The Swing (Upperstructure Slew) Circuit 102
Troubleshooting The Travel Circuit 103
CYLINDER (BOOM) 105
Testing 105
Removal And Installation 107
Parts Identification 110
Disassembly 111
Assembly 114
CYLINDER (ARM) 119
Testing 119
Removal And Installation 121
Parts Identification 123
Disassembly 124
Assembly 126
CYLINDER (BOOM SWING) 131
Testing 131
Removal And Installation 133
Parts Identification (Earlier Models) 135
Disassembly (Earlier Models) 136
Assembly 138
Parts Identification (Later Models) 142
Disassembly (Later Models) 143
Assembly (Later Models) 145
CYLINDER (BUCKET) 149
Testing 149
Removal And Installation 150
Parts Identification 152
Disassembly 153
Assembly 155
CYLINDER (BLADE) 159
Testing 159
Removal And Installation 161
Parts Identification (Earlier Models) 162
Disassembly (Earlier Models) 163
Assembly (Earlier Models) 165
Parts Identification (Later Models) 168
Disassembly (Later Models) 169
Assembly (Later Models) 171
CYLINDER (CLAMP) 175
Testing 175
Removal And Installation 176
Parts Identification 178
Disassembly 179
Assembly 182
VALVE (MAIN RELIEF) 187
Description 187
VALVE (PORT RELIEF) 189
Testing And Adjusting Port Relief Valve Pressure 189
VALVE (CROSS PORT RELIEF) 191
Testing 191
Removal And Installation 193
Disassembly And Assembly 194
VALVE (PILOT PRESSURE RELIEF) 195
Testing And Adjusting The Pilot Pressure Relief Valve 195
HYDRAULIC CONTROL VALVE 197
Description 197
Removal And Installation 198
Parts Identification 202
Disassembly 203
Assembly 209
Inlet Valve Section Disassembly And Assembly 212
Boom Swing Valve Section Disassembly And Assembly 214
Slew Valve Section Disassembly And Assembly 217
Blade Valve Section Disassembly And Assembly 218
Right And Left Travel Valve Section Disassembly And Assembly 221
Boom Valve Section Disassembly And Assembly 223
Auxiliary, Arm, Bucket And Angle Blade Valve Section Disassembly And Assembly 227
Outlet Valve Section Disassembly And Assembly 229
HYDRAULIC PUMP 231
Hydraulic Pump Work Sheet 231
Pump Testing 233
Description 241
Removal And Installation 241
Coupler Removal And Installation 242
Hydraulic Pump Startup 243
Gear Pump Disassembly And Assembly 244
Piston Pump Parts Identification 246
Piston Pump Disassembly And Assembly 247
MANIFOLD ASSEMBLY / ACCUMULATOR 259
Description 259
Removal And Installation 259
Parts Identification 261
Disassembly And Assembly 262
TRAVEL MOTOR 269
Description 269
Removal And Installation 269
Parts Identification Hydraulic Motor 270
Parts Identification Gear Reduction Hub 271
Disassembly 272
Assembly 286
SWIVEL JOINT 301
Removal And Installation 301
Parts Identification 303
Disassembly And Assembly 304
SWING MOTOR 307
Removal And Installation 307
Parts Identification 308
Disassembly And Assembly 309
SWING MOTOR (DRIVE CARRIER) 315
Removal And Installation 315
Parts Identification 316
Disassembly And Assembly 317
CONTROL PATTERN SELECTOR VALVE 323
Removal And Installation 323
Parts Identification 324
Disassembly And Assembly 325
RIGHT CONTROL LEVER (JOYSTICK) 327
Testing 327
Handle Removal And Installation 328
Joystick Assembly Removal And Installation 331
Parts Identification 332
Disassembly And Assembly 333
LEFT CONTROL LEVER (JOYSTICK) 335
Testing 335
Handle Removal And Installation 336
Joystick Assembly Removal And Installation 339
Parts Identification 340
Disassembly And Assembly 341
HYDRAULIC FILTER MOUNT 343
Removal And Installation 343
HYDRAULIC RESERVOIR 345
Removal And Installation 345
OIL COOLER 347
Removal And Installation 347
DIRECT TO TANK VALVE 349
Removal And Installation 349
BLADE CONTROL LEVER 351
Handle Removal And Installation 351
Removal And Installation 353
Parts Identification 354
Disassembly And Assembly 355
CASE DRAIN FILTER MOUNT 359
Removal And Installation 359
TRAVEL CONTROL VALVE 361
Removal And Installation 361
Parts Identification 362
Disassembly And Assembly 363
REMOVING AIR FROM THE HYDRAULIC SYSTEM 369
Procedure 369
HYDRAULIC X-CHANGE MANIFOLD 371
Removal And Installation 371
Parts Identification 372
Disassembly And Assembly 373
SECONDARY AUXILIARY VALVE 375
Removal And Installation 375
Parts Identification 377
Disassembly And Assembly 378
VALVE (BOOM LOCK) 381
Removal And Installation 381
VALVE (ARM LOCK) 383
Removal And Installation 383
UNDERCARRIAGE 385
BLADE 387
Removal And Installation 387
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 389
Description 389
Track Lug Height 389
Checking Tension 390
Adjusting Tension 392
Removal And Installation 393
Idler Removal And Installation 395
Idler Parts Identification 396
Idler Disassembly 397
Idler Assembly 399
Track Tensioner Removal And Installation 402
Track Tensioner Parts Identification 403
Track Tensioner Disassembly And Assembly 404
Roller Removal And Installation 406
Sprocket Removal And Installation 406
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 407
Description 407
Checking Tension 408
Adjusting Tension 410
Track Removal And Installation 411
Idler Removal And Installation 414
Idler Parts Identification 415
Idler Disassembly 416
Idler Assembly 418
Track Tensioner Removal And Installation 421
Track Tensioner Parts Identification 422
Track Tensioner Disassembly And Assembly 423
Roller Removal And Installation 425
Sprocket Removal And Installation 426
Guide Plate Removal And Installation 426
TRACK MAINTENANCE 427
Track Damage Identification 427
SWING CIRCLE GEAR 439
Swing Bearing Removal 439
Swing Bearing Installation 440
UPPERSTRUCTURE AND SWING SECTION 441
UPPERSTRUCTURE 445
Removal 445
Installation 447
ROPS CANOPY 449
Removal And Installation 449
CAB 453
Removal And Installation 453
Door Removal And Installation 457
Front Window Removal And Installation 458
Right Side Sliding Window Removal And Installation 460
Glass Removal 463
Glass Installation 464
SEAT 469
Removal And Installation 469
Seat Mount Removal And Installation 470
RIGHT CONSOLE 471
Console Cover Removal And Installation 471
LEFT CONSOLE 475
Lower Console Cover Removal And Installation 475
Upper Console Cover Removal And Installation 476
Compression Spring Removal And Installation 479
Lock Lever Removal And Installation 481
Console Removal And Installation 481
LEFT UPPERSTRUCTURE COVER 483
Removal And Installation 483
RIGHT UPPERSTRUCTURE COVER 485
Removal And Installation 485
COUNTERWEIGHT 487
Removal And Installation 487
Add On Counterweight Removal And Installation 491
TRAVEL LEVERS AND PEDALS 493
Removal And Installation 493
Disassembly And Assembly 493
FLOOR MAT AND FLOORPLATE 495
Removal And Installation 495
FUEL TANK 497
Removal And Installation 497
Fuel Tank Fitting Removal And Installation 498
HORN 499
Removal And Installation 499
SWING FRAME 501
Removal And Installation 501
Boom Swing Frame Hose Routing 504
Bushing Removal 505
Bushing Installation 506
BOOM 507
Removal And Installation 507
ARM (STANDARD AND LONG) 509
Removal And Installation 509
Arm To Boom Bushing Removal And Installation 510
Arm To Bucket And Bucket Link Bushing Removal And Installation 511
BUCKET 513
Bucket Teeth Removal And Installation 513
Bucket Side Cutting Edge Removal And Installation 514
CLAMP 515
Removal And Installation 515
TAILGATE 517
Removal And Installation 517
Disassembly And Assembly 518
QUICK COUPLER (KLAC™ SYSTEM) 521
Troubleshooting 521
Daily Inspection 521
Removal And Installation 522
Parts Identification 524
Disassembly 525
Assembly 527
QUICK COUPLER (PIN GRABBER) 529
Troubleshooting 529
Daily Inspection 530
Removal And Installation 530
Parts Identification 532
Disassembly And Assembly 533
RIGHT SIDE COVER 537
Removal And Installation 537
Latch Removal And Installation 537
LEFT SIDE COVER 539
Removal And Installation 539
TOOL BOX 541
Removal And Installation 541
ELECTRICAL SYSTEM AND ANALYSIS 543
ELECTRICAL SCHEMATICS 545
ELECTRICAL SYSTEM INFORMATION 568
Troubleshooting Chart 568
Description 569
Fuse And Relay Location / Identification 569
BATTERY 572
Servicing 572
Maintaining Battery Charge Level 572
Battery Service During Machine Storage 572
Battery Testing 573
Battery Charging 573
Removal And Installation 574
Using A Booster Battery (Jump Starting) 575
ALTERNATOR 576
Belt Adjustment 576
Belt Replacement 576
Charging System Inspection 577
Alternator Voltage Testing 578
Low Voltage Testing 578
High Voltage Testing 579
Removal And Installation 580
Parts Identification 582
STARTER 584
Testing 584
Removal And Installation 585
Parts Identification 586
LIGHTS 588
Boom Light Removal And Installation 588
Boom Light Bulb Replacement 588
MAGNETIC LOCKOUT SENSOR 590
Removal And Installation 590
FUEL LEVEL SENDER 592
Removal And Installation 592
Testing 593
DIAGNOSTIC SERVICE CODES 594
Viewing Service Codes 594
Number Codes List 595
CONTROL PANEL SETUP 598
Panel Setup (Deluxe Instrument Panel) 598
Password Setup (Keyless Start Panel) 604
Password Setup (Deluxe Instrument Panel) 606
Maintenance Clock 608
INSTRUMENT PANEL 614
Removal And Installation 614
CONTROLLER 616
Description 616
Auxiliary Controller Removal And Installation 616
Gateway Controller Removal And Installation 618
KEY SWITCH 620
Removal And Installation 620
WIPER MOTOR 622
Removal And Installation 622
MOTION ALARM SYSTEM 624
Description 624
Inspecting 624
Adjusting Switch Position 625
SERVICE PC (LAPTOP COMPUTER) 626
Connecting The Remote Start Tool 626
Connecting Remote Start Tool (Service Tool) 626
SHUT-OFF SWITCH 628
Description 628
Removal And Installation 629
TRAVEL MOTOR AUTO-SHIFT 630
Auto-Shift Drive System (If Equipped) 630
Troubleshooting 631
ENGINE SPEED CONTROL 632
Removal And Installation 632
AUTO IDLE PRESSURE SENSOR 634
Description 634
Removal And Installation 635
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 636
Controller Removal And Installation 636
Antenna Removal And Installation 637
ENGINE SERVICE 640
ENGINE INFORMATION 642
Description 642
Specifications 643
Crankshaft Re-grind Data 649
Torque For Kubota® Metric Bolts 650
Troubleshooting 651
Engine Removal And Installation 652
Compression – Testing 659
ENGINE SPEED CONTROL 660
Removal And Installation 660
Calibration 661
Actuator Removal And Installation 664
MUFFLER 666
Removal And Installation 666
AIR CLEANER 668
Removal And Installation 668
ENGINE COOLING SYSTEM 670
Radiator Removal And Installation 670
Fan Removal And Installation 673
Water Pump Removal And Installation 674
Water Pump Disassembly And Assembly 674
Thermostat Housing Removal And Installation 675
Thermostat – Testing 675
LUBRICATION SYSTEM 676
Oil Pan Removal And Installation 676
Oil Pump Removal And Installation 677
Oil Pump Inspection 677
Engine Oil Pressure – Testing 678
FUEL SYSTEM 680
Fuel Shutoff Solenoid – Testing 680
Fuel Shut-off Solenoid Removal And Installation 681
Fuel Injection Pump – Testing 682
Fuel Injection Pump Removal And Installation 683
Fuel Injection Pump – Timing 686
Fuel Camshaft Removal And Installation 688
Fuel Camshaft Governor 689
Fuel Injector Removal And Installation 690
Fuel Injector Nozzle Pressure – Testing 693
Nozzle Spray Condition 694
Valve Seat Tightness 694
CYLINDER HEAD 696
Glow Plugs – Testing 696
Glow Plugs Removal And Installation 697
Valve Clearance Adjustment 698
Valve Timing – Inspecting 698
Cylinder Head Removal And Installation 699
Cylinder Head Disassembly And Assembly 702
Cylinder Head – Servicing 703
Cylinder Head Top Clearance 703
Valve Guide – Inspecting 704
Valve Guide Removal And Installation 705
Reconditioning The Valve And Valve Seat 706
Valve Spring 707
Valve Tappets 708
Rocker Arm And Shaft – Inspecting 709
Push Rod Alignment – Inspecting 709
CRANKSHAFT AND PISTONS 710
Piston And Connecting Rod Removal And Installation 710
Piston And Connecting Rod – Servicing 712
Cylinder Bore – Inspecting 714
Connecting Rod Alignment 714
Crankshaft Gear Removal And Installation 715
Crankshaft And Bearings Removal And Installation 716
Crankshaft And Bearings – Servicing 718
CAMSHAFT AND TIMING GEARS 722
Timing Gearcase Cover Removal And Installation 722
Timing Gears Backlash – Inspecting 725
Idle Gear And Camshaft Removal And Installation 726
Camshaft – Servicing 728
Idle Gear And Shaft – Servicing 729
FLYWHEEL AND HOUSING 730
Hydraulic Pump Coupler Removal And Installation 730
Flywheel Removal And Installation 732
Flywheel Ring Gear 732
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 734
AIR CONDITIONING SYSTEM FLOW 736
Description 736
Chart 737
Components 738
Safety Equipment 741
REGULAR MAINTENANCE 742
Cab Filters 742
Air Conditioning Compressor Belt Adjustment 743
Air Conditioning Compressor Belt Replacement 743
Condenser 744
Air Conditioning Lubrication 744
Evaporator / Heater Coil 744
Air Conditioning Service Chart 746
TROUBLESHOOTING 748
Blower Motor Does Not Operate 748
Blower Motor Operates Normally, But Air Flow Is Insufficient 748
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 748
The Compressor Operates Improperly Or Not At All 748
Gauge Pressure Related Troubleshooting 749
Temperature / Pressure Chart 750
Poor A/C Performance 751
HVAC Repair And Leaks 751
Electrical System 752
Engine Coolant Bypassing The Heater Valve 754
SYSTEM CHARGING AND RECLAMATION 756
Refrigerant Identification 756
Reclamation And Charging With Recovery / Charging Unit 758
COMPRESSOR 760
Removal And Installation 760
Oil 761
Oil Check 762
CONDENSER 764
Removal And Installation 764
RECEIVER / DRIER 766
Receiver / Drier Removal And Installation 766
Pressure Switch Removal And Installation 767
EVAPORATOR / HEATER UNIT 768
Removal And Installation 768
THERMOSTAT 772
Description 772
Removal And Installation 773
EXPANSION VALVE 776
Removal And Installation 776
EVAPORATOR COIL 778
Removal And Installation 778
HEATER COIL 780
Removal And Installation 780
BLOWER FAN 782
Removal And Installation 782
HEATER VALVE 784
Removal And Installation 784
HVAC DUCT 786
Removal And Installation 786
SPECIFICATIONS 788
EXCAVATOR SPECIFICATIONS 790
Machine Dimensions 790
Machine Dimensions – Standard Arm 791
Machine Dimensions – Long Arm 792
Rated Lift Capacity For Standard Arm, Medium Counterweight, And Canopy 793
Rated Lift Capacity For Long Arm, Medium Counterweight, And Canopy 794
Rated Lift Capacity For Standard Arm, Heavy Counterweight, And Canopy 795
Rated Lift Capacity For Standard Arm, Medium Counterweight, And Cab 796
Rated Lift Capacity For Long Arm, Medium Counterweight, And Cab 797
Rated Lift Capacity For Standard Arm, Heavy Counterweight, And Cab 798
Rated Lift Capacity For Long Arm, Heavy Counterweight, And Canopy 799
Rated Lift Capacity For Long Arm, Heavy Counterweight, And Cab 800
Performance 801
Controls 801
Engine 802
Hydraulic System 802
Hydraulic Cycle Times 803
Hydraulic Cylinders 803
Drive System 803
Slew System 803
Undercarriage 803
Electrical 804
Capacities 804
Tracks 804
Ground Pressure 805
Environmental 805
Temperature Range 805
TECHNICAL SERVICE GUIDE SPECIFICATIONS 806
Engine 806
Engine Torques 806
Cooling System 806
Excavator Torques 806
TORQUE SPECIFICATION FOR BOLTS 808
Torque For General SAE Bolts 808
Torque For General Metric Bolts 809
HYDRAULIC CONNECTION SPECIFICATIONS 810
O-ring Face Seal Connection 810
Straight Thread O-ring Fitting 810
Tubelines And Hoses 811
Flare Fitting 811
O-ring Flare Fitting 812
Port Seal Fitting 814
Push To Connect Fittings 815
HYDRAULIC FLUID SPECIFICATIONS 818
Specifications 818
CONVERSIONS 820
Decimal And Millimeter Equivalent Chart 820
U S To Metric Conversion Chart 821
SERVICE TOOLS REQUIRED 822
Remote Start Tools 822
Hydraulic Tools 823
Engine Tools 826
Electrical Tools 828
General Tools 829
HVAC Tools 830
ALPHABETICAL INDEX 832
SERVICE SCHEDULE SYMBOLS 834

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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