Bobcat E35z Compact Excavator Service Manual SN B4S511001 & Above – PDF DOWNLOAD

Description

Bobcat E35z Compact Excavator Service Manual SN B4S511001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E35z Compact Excavator Service Manual SN B4S511001 & Above – PDF DOWNLOAD

Language : English
Pages : 857
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E35z Compact Excavator Service Manual SN B4S511001 & Above – PDF DOWNLOAD

S/N B4S511001 & 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 B4S511001 & 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 97
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 112
Disassembly 113
Assembly 116
CYLINDER (ARM) 121
Testing 121
Removal And Installation 123
Parts Identification 125
Disassembly 126
Assembly 128
CYLINDER (BOOM SWING) 133
Testing 133
Removal And Installation 135
Parts Identification (Earlier Models) 137
Disassembly (Earlier Models) 138
Assembly (Earlier Models) 140
Parts Identification (Later Models) 144
Disassembly (Later Models) 145
Assembly (Later Models) 147
CYLINDER (BUCKET) 151
Testing 151
Removal And Installation 152
Parts Identification 154
Disassembly 155
Assembly 157
CYLINDER (BLADE) 161
Testing 161
Removal And Installation 163
Parts Identification (Earlier Models) 164
Disassembly (Earlier Models) 165
Assembly (Earlier Models) 167
Parts Identification (Later Models) 170
Disassembly (Later Models) 171
Assembly (Later Models) 173
CYLINDER (CLAMP) 177
Testing 177
Removal And Installation 178
Parts Identification 180
Disassembly 181
Assembly 184
VALVE (MAIN RELIEF) 189
Description 189
VALVE (PORT RELIEF) 191
Testing And Adjusting Port Relief Valve Pressure 191
VALVE (CROSS PORT RELIEF) 193
Testing 193
Removal And Installation 195
Disassembly And Assembly 196
VALVE (PILOT PRESSURE RELIEF) 197
Testing And Adjusting The Pilot Pressure Relief Valve 197
HYDRAULIC CONTROL VALVE 199
Description 199
Removal And Installation 199
Parts Identification 204
Disassembly 205
Assembly 211
Inlet Valve Section Disassembly And Assembly 214
Boom Swing Valve Section Disassembly And Assembly 216
Slew Valve Section Disassembly And Assembly 219
Blade Valve Section Disassembly And Assembly 220
Right And Left Travel Valve Section Disassembly And Assembly 223
Boom Valve Section Disassembly And Assembly 225
Auxiliary, Arm, Bucket And Angle Blade Valve Section Disassembly And Assembly 229
Outlet Valve Section Disassembly And Assembly 231
HYDRAULIC PUMP 233
Hydraulic Pump Work Sheet 233
Pump Testing 235
Description 243
Removal And Installation 243
Coupler Removal And Installation 244
Hydraulic Pump Startup 245
Gear Pump Disassembly And Assembly 246
Piston Pump Parts Identification 248
Piston Pump Disassembly And Assembly 249
MANIFOLD ASSEMBLY / ACCUMULATOR 261
Description 261
Removal And Installation 261
Parts Identification 263
Disassembly And Assembly 264
MANIFOLD ASSEMBLY / ACCUMULATOR (WITH ANGLE BLADE) 271
Description 271
Removal And Installation 271
Parts Identification 273
Disassembly And Assembly 274
TRAVEL MOTOR 281
Description 281
Removal And Installation 281
Parts Identification Hydraulic Motor 282
Parts Identification Gear Reduction Hub 283
Disassembly 284
Assembly 298
SWIVEL JOINT 313
Removal And Installation 313
Parts Identification 315
Disassembly And Assembly 316
SWING MOTOR 319
Removal And Installation 319
Parts Identification 320
Disassembly And Assembly 321
SWING MOTOR (DRIVE CARRIER) 327
Removal And Installation 327
Parts Identification 328
Disassembly And Assembly 329
CONTROL PATTERN SELECTOR VALVE 335
Removal And Installation 335
Parts Identification 336
Disassembly And Assembly 337
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
DIRECT TO TANK VALVE 361
Removal And Installation 361
BLADE CONTROL LEVER 363
Handle Removal And Installation 363
Removal And Installation 365
Parts Identification 366
Disassembly And Assembly 367
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
HYDRAULIC X-CHANGE MANIFOLD 383
Removal And Installation 383
Parts Identification 384
Disassembly And Assembly 385
SECONDARY AUXILIARY VALVE 387
Removal And Installation 387
Parts Identification 389
Disassembly And Assembly 390
VALVE (BOOM LOCK) 393
Removal And Installation 393
VALVE (ARM LOCK) 395
Removal And Installation 395
UNDERCARRIAGE 397
BLADE 399
Removal And Installation 399
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 401
Description 401
Track Lug Height 401
Checking Tension 402
Adjusting Tension 404
Removal And Installation 405
Idler Removal And Installation 407
Idler Parts Identification 408
Idler Disassembly 409
Idler Assembly 411
Track Tensioner Removal And Installation 414
Track Tensioner Parts Identification 415
Track Tensioner Disassembly And Assembly 416
Roller Removal And Installation 418
Sprocket Removal And Installation 418
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 419
Description 419
Checking Tension 420
Adjusting Tension 422
Track Removal And Installation 423
Idler Removal And Installation 426
Idler Parts Identification 427
Idler Disassembly 428
Idler Assembly 430
Track Tensioner Removal And Installation 433
Track Tensioner Parts Identification 434
Track Tensioner Disassembly And Assembly 435
Roller Removal And Installation 437
Sprocket Removal And Installation 438
Guide Plate Removal And Installation 438
TRACK MAINTENANCE 439
Track Damage Identification 439
SWING CIRCLE GEAR 451
Swing Bearing Removal 451
Swing Bearing Installation 452
UPPERSTRUCTURE AND SWING SECTION 453
UPPERSTRUCTURE 457
Removal 457
Installation 459
ROPS CANOPY 461
Removal And Installation 461
CAB 465
Removal And Installation 465
Door Removal And Installation 469
Front Window Removal And Installation 470
Right Side Sliding Window Removal And Installation 472
Glass Removal 475
Glass Installation 476
SEAT 481
Removal And Installation 481
Seat Mount Removal And Installation 482
RIGHT CONSOLE 483
Console Cover Removal And Installation 483
LEFT CONSOLE 487
Lower Console Cover Removal And Installation 487
Upper Console Cover Removal And Installation 488
Compression Spring Removal And Installation 491
Lock Lever Removal And Installation 493
Console Removal And Installation 493
LEFT UPPERSTRUCTURE COVER 495
Removal And Installation 495
RIGHT UPPERSTRUCTURE COVER 497
Removal And Installation 497
COUNTERWEIGHT 499
Removal And Installation 499
Add On Counterweight Removal And Installation 503
TRAVEL LEVERS AND PEDALS 505
Removal And Installation 505
Disassembly And Assembly 505
FLOOR MAT AND FLOORPLATE 507
Removal And Installation 507
FUEL TANK 509
Removal And Installation 509
Fuel Tank Fitting Removal And Installation 510
HORN 511
Removal And Installation 511
SWING FRAME 513
Removal And Installation 513
Boom Swing Frame Hose Routing 516
Bushing Removal 517
Bushing Installation 518
BOOM 519
Removal And Installation 519
ARM (STANDARD AND LONG) 521
Removal And Installation 521
Arm To Boom Bushing Removal And Installation 522
Arm To Bucket And Bucket Link Bushing Removal And Installation 523
ARM (EXTENDABLE) 525
Removal And Installation 525
Arm To Boom Bushing Removal And Installation 526
Arm To Bucket Bushing Removal And Installation 527
Disassembly And Assembly 528
Shimming Procedure 536
BUCKET 537
Bucket Teeth Removal And Installation 537
Bucket Side Cutting Edge Removal And Installation 538
CLAMP 539
Removal And Installation 539
TAILGATE 541
Removal And Installation 541
Disassembly And Assembly 542
QUICK COUPLER (KLAC™ SYSTEM) 545
Troubleshooting 545
Daily Inspection 545
Removal And Installation 546
Parts Identification 548
Disassembly 549
Assembly 551
QUICK COUPLER (PIN GRABBER) 553
Troubleshooting 553
Daily Inspection 554
Removal And Installation 554
Parts Identification 556
Disassembly And Assembly 557
RIGHT SIDE COVER 561
Removal And Installation 561
Latch Removal And Installation 561
LEFT SIDE COVER 563
Removal And Installation 563
TOOL BOX 565
Removal And Installation 565
ELECTRICAL SYSTEM AND ANALYSIS 567
ELECTRICAL SCHEMATICS 569
ELECTRICAL SYSTEM INFORMATION 592
Troubleshooting Chart 592
Description 593
Fuse And Relay Location / Identification 593
BATTERY 596
Servicing 596
Maintaining Battery Charge Level 596
Battery Service During Machine Storage 596
Battery Testing 597
Battery Charging 597
Removal And Installation 598
Using A Booster Battery (Jump Starting) 599
ALTERNATOR 600
Belt Adjustment 600
Belt Replacement 600
Charging System Inspection 601
Alternator Voltage Testing 602
Low Voltage Testing 602
High Voltage Testing 603
Removal And Installation 604
Parts Identification 606
STARTER 608
Testing 608
Removal And Installation 609
Parts Identification 610
LIGHTS 612
Boom Light Removal And Installation 612
Boom Light Bulb Replacement 612
MAGNETIC LOCKOUT SENSOR 614
Removal And Installation 614
FUEL LEVEL SENDER 616
Removal And Installation 616
Testing 617
DIAGNOSTIC SERVICE CODES 618
Viewing Service Codes 618
Number Codes List 619
CONTROL PANEL SETUP 622
Panel Setup (Deluxe Instrument Panel) 622
Password Setup (Keyless Start Panel) 628
Password Setup (Keyless Start Panel) 629
Password Setup (Deluxe Instrument Panel) 630
Maintenance Clock 632
INSTRUMENT PANEL 638
Removal And Installation 638
CONTROLLER 640
Description 640
Auxiliary Controller Removal And Installation 640
Gateway Controller Removal And Installation 642
KEY SWITCH 644
Removal And Installation 644
WIPER MOTOR 646
Removal And Installation 646
MOTION ALARM SYSTEM 648
Description 648
Inspecting 648
Adjusting Switch Position 649
SERVICE PC (LAPTOP COMPUTER) 650
Connecting The Remote Start Tool 650
Connecting Remote Start Tool (Service Tool) 650
SHUT-OFF SWITCH 652
Description 652
Removal And Installation 653
TRAVEL MOTOR AUTO-SHIFT 654
Auto-Shift Drive System (If Equipped) 654
Troubleshooting 655
ENGINE SPEED CONTROL 656
Removal And Installation 656
AUTO IDLE PRESSURE SENSOR 658
Description 658
Removal And Installation 659
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 660
Controller Removal And Installation 660
Antenna Removal And Installation 661
ENGINE SERVICE 664
ENGINE INFORMATION 666
Description 666
Specifications 667
Crankshaft Re-grind Data 673
Torque For Kubota® Metric Bolts 674
Troubleshooting 675
Engine Removal And Installation 676
Compression – Testing 683
ENGINE SPEED CONTROL 684
Removal And Installation 684
Calibration 685
Actuator Removal And Installation 688
MUFFLER 690
Removal And Installation 690
AIR CLEANER 692
Removal And Installation 692
LUBRICATION SYSTEM 694
Oil Pan Removal And Installation 694
Oil Pump Removal And Installation 695
Oil Pump Inspection 695
Engine Oil Pressure – Testing 696
ENGINE COOLING SYSTEM 698
Radiator Removal And Installation 698
Fan Removal And Installation 701
Water Pump Removal And Installation 702
Water Pump Disassembly And Assembly 702
Thermostat Housing Removal And Installation 703
Thermostat – Testing 703
FUEL SYSTEM 704
Fuel Shutoff Solenoid – Testing 704
Fuel Shut-off Solenoid Removal And Installation 705
Fuel Injection Pump – Testing 706
Fuel Injection Pump Removal And Installation 707
Fuel Injection Pump – Timing 710
Fuel Camshaft Removal And Installation 712
Fuel Camshaft Governor 713
Fuel Injector Removal And Installation 714
Fuel Injector Nozzle Pressure – Testing 717
Nozzle Spray Condition 718
Valve Seat Tightness 718
CYLINDER HEAD 720
Glow Plugs – Testing 720
Glow Plugs Removal And Installation 721
Valve Clearance Adjustment 722
Valve Timing – Inspecting 722
Cylinder Head Removal And Installation 723
Cylinder Head Disassembly And Assembly 726
Cylinder Head – Servicing 727
Cylinder Head Top Clearance 727
Valve Guide – Inspecting 728
Valve Guide Removal And Installation 729
Reconditioning The Valve And Valve Seat 730
Valve Spring 731
Valve Tappets 732
Rocker Arm And Shaft – Inspecting 733
Push Rod Alignment – Inspecting 733
CRANKSHAFT AND PISTONS 734
Piston And Connecting Rod Removal And Installation 734
Piston And Connecting Rod – Servicing 736
Cylinder Bore – Inspecting 738
Connecting Rod Alignment 738
Crankshaft Gear Removal And Installation 739
Crankshaft And Bearings Removal And Installation 740
Crankshaft And Bearings – Servicing 742
CAMSHAFT AND TIMING GEARS 746
Timing Gearcase Cover Removal And Installation 746
Timing Gears Backlash – Inspecting 749
Idle Gear And Camshaft Removal And Installation 750
Camshaft – Servicing 752
Idle Gear And Shaft – Servicing 753
FLYWHEEL AND HOUSING 754
Hydraulic Pump Coupler Removal And Installation 754
Flywheel Removal And Installation 756
Flywheel Ring Gear 756
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 758
AIR CONDITIONING SYSTEM FLOW 760
Description 760
Chart 761
Components 762
Safety Equipment 765
REGULAR MAINTENANCE 766
Cab Filters 766
Air Conditioning Compressor Belt Adjustment 767
Air Conditioning Compressor Belt Replacement 767
Condenser 768
Air Conditioning Lubrication 768
Evaporator / Heater Coil 768
Air Conditioning Service Chart 770
TROUBLESHOOTING 772
Blower Motor Does Not Operate 772
Blower Motor Operates Normally, But Air Flow Is Insufficient 772
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 772
The Compressor Operates Improperly Or Not At All 772
Gauge Pressure Related Troubleshooting 773
Temperature / Pressure Chart 774
Poor A/C Performance 775
HVAC Repair And Leaks 775
Electrical System 776
Engine Coolant Bypassing The Heater Valve 778
SYSTEM CHARGING AND RECLAMATION 780
Refrigerant Identification 780
Reclamation And Charging With Recovery / Charging Unit 782
COMPRESSOR 784
Removal And Installation 784
Oil 785
Oil Check 786
CONDENSER 788
Removal And Installation 788
RECEIVER / DRIER 790
Receiver / Drier Removal And Installation 790
Pressure Switch Removal And Installation 791
EVAPORATOR / HEATER UNIT 792
Removal And Installation 792
THERMOSTAT 796
Description 796
Removal And Installation 797
EXPANSION VALVE 800
Removal And Installation 800
EVAPORATOR COIL 802
Removal And Installation 802
HEATER COIL 804
Removal And Installation 804
BLOWER FAN 806
Removal And Installation 806
HEATER VALVE 808
Removal And Installation 808
HVAC DUCT 810
Removal And Installation 810
SPECIFICATIONS 812
EXCAVATOR SPECIFICATIONS 814
Machine Dimensions 814
Machine Dimensions – Standard Arm 815
Machine Dimensions – Long Arm 816
Rated Lift Capacity For Standard Arm, Medium Counterweight, And Canopy 817
Rated Lift Capacity For Standard Arm, Medium Counterweight, And Cab 818
Rated Lift Capacity For Long Arm, Heavy Counterweight, And Canopy 819
Rated Lift Capacity For Long Arm, Heavy Counterweight, And Cab 820
Performance 821
Controls 821
Engine 822
Hydraulic System 822
Hydraulic Cycle Times 823
Hydraulic Cylinders 823
Drive System 823
Slew System 823
Undercarriage 823
Electrical 824
Capacities 824
Tracks 824
Ground Pressure 825
Temperature Range 825
TECHNICAL SERVICE GUIDE SPECIFICATIONS 826
Engine 826
Engine Torques 826
Cooling System 826
Excavator Torques 826
TORQUE SPECIFICATION FOR BOLTS 828
Torque For General SAE Bolts 828
Torque For General Metric Bolts 829
HYDRAULIC CONNECTION SPECIFICATIONS 830
O-ring Face Seal Connection 830
Straight Thread O-ring Fitting 830
Tubelines And Hoses 831
Flare Fitting 831
O-ring Flare Fitting 832
Port Seal Fitting 834
Push To Connect Fittings 835
HYDRAULIC FLUID SPECIFICATIONS 838
Specifications 838
CONVERSIONS 840
Decimal And Millimeter Equivalent Chart 840
U S To Metric Conversion Chart 841
SERVICE TOOLS REQUIRED 842
Remote Start Tools 842
Hydraulic Tools 843
Engine Tools 846
Electrical Tools 848
General Tools 849
HVAC Tools 850
ALPHABETICAL INDEX 852
SERVICE SCHEDULE SYMBOLS 856

Customer Support: [email protected]

https://vimeo.com/841773306?share=copy

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

S.M