Bobcat E17 B27H11001, B4PJ11001, B4PR11001 & Up 7255011 (07-20) (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
EXCAVATOR IDENTIFICATION
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS)
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
Heating And Ventilation Ducting
OPERATOR CANOPY (ROPS / TOPS)
Description
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
TAILGATE
Opening And Closing
Adjusting The Latch
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Daily Check
Replacing The Filter Elements
CAB FILTER
Cleaning And Maintenance
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Draining The Fuel Tank
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing The Hydraulic Filters
Removing And Replacing The Hydraulic Fluid
LUBRICATING THE EXCAVATOR
Lubrication Locations
TRAVEL MOTOR
Checking And Adding Fluid
Removing And Replacing Fluid
SPARK ARRESTER MUFFLER
Cleaning Procedure
ALTERNATOR BELT
Belt Adjustment
Belt Replacement
SEAT BELT
Inspection And Maintenance
CONTROL CONSOLE LOCKOUTS
Inspection And Maintenance
PIVOT PINS
Inspection And Maintenance
EXCAVATOR STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
Procedure
EMERGENCY EXIT
Side Or Rear Window
Front Window
REMOTE START TOOL KIT – MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Communicator – MEL1566
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
Description
Remote Start Tool (Service Tool) – 7022042
Excavator Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATIC
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
CYLINDER (BOOM)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (ARM)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOOM SWING)
Testing
Removal And Installation
Parts Identification (Earlier Models)
Disassembly (Earlier Models)
Assembly (Earlier Models)
Parts Identification (Later Models)
Disassembly (Later Models)
Assembly (Later Models)
CYLINDER (BUCKET)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BLADE)
Testing
Removal And Installation
Parts Identification (Earlier Models)
Disassembly (Earlier Models)
Assembly (Earlier Models)
Parts Identification (Later Models)
Disassembly (Later Models)
Assembly (Later Models)
CYLINDER (TRACK FRAME EXPANSION)
Testing
Removal And Installation
Parts Identification (Earlier Models)
Disassembly (Earlier Models)
Assembly (Earlier Models)
Parts Identification (Later Models)
Disassembly (Later Models)
Assembly (Later Models)
VALVE (MAIN RELIEF)
Description
Test Conditions
Testing And Adjusting The Main Relief
VALVE (PORT RELIEF)
Testing And Adjusting
VALVE (CROSS PORT RELIEF)
Testing
Removal And Installation
VALVE (PRESSURE REDUCING)
Testing And Adjusting
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
Right And Left Travel Valve Section Disassembly And Assembly
Arm And Bucket Valve Section Disassembly And Assembly
Boom Swing And Auxiliary Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
HYDRAULIC PUMP
Description
Testing The Gear Pump
Testing Auxiliary Hydraulic Flow
Removal And Installation
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR
Description
Removal And Installation
Parts Identification (Single Speed Travel Motor)
Parts Identification (Two Speed Travel Motor)
ACCUMULATOR
Removal And Installation
TRAVEL MOTOR (SINGLE SPEED)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR (TWO SPEED)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR
Description
Removal And Installation
Parts Identification
Motor Disassembly
Motor Assembly
Brake Carrier Disassembly And Assembly
CONTROL LEVER (JOYSTICK) (RIGHT)
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
CONTROL LEVER (JOYSTICK) (LEFT)
Testing
Handle Removal And Installation
Removal and Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER MOUNT
Description
Removal And Installation
HYDRAULIC RESERVOIR
Description
Removal And Installation
OIL COOLER
Removal And Installation
BLADE / TRACK EXPANSION SOLENOID BLOCK
Description
Block Removal And Installation
Solenoid Removal And Installation
Parts Identification
Block Disassembly And Assembly
UNDERCARRIAGE
BLADE
Description
Extension Removal And Installation
Blade Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS
Description
Track Lug Height
Checking Tension
Adjusting Tension
Track Removal And Installation
Idler Removal And Installation
Track Tensioner Removal And Installation
Track Tensioner Disassembly & Assembly
Roller Removal And Installation
Sprocket Removal And Installation
Removal And Installation Of Expandable Track Frame
TRACK MAINTENANCE
Cutting Of The Steel Cords
Causes Of The Damage
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Abrasion Of The Track Roller Side
Cuts On The Edges Of The Track Roller Side
SWING CIRCLE GEAR
Removal And Installation
UPPERSTRUCTURE & SWING
UPPERSTRUCTURE
Description
Removal
Installation
ROPS CANOPY
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Right Side Sliding Window Removal And Installation
Glass Removal
Glass Installation
SEAT AND SEAT MOUNT
Removal And Installation
LEFT CONSOLE
Console Cover Removal And Installation
Gas Spring Removal And Installation
Lock Lever Removal And Installation
Console Removal And Installation
LEFT UPPERSTRUCTURE COVERs
Removal And Installation
RIGHT UPPERSTRUCTURE COVER
Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
Cable Adjustment
BLADE CONTROL
Removal And Installation
RIGHT PEDAL (BOOM SWING)
Removal And Installation
Disassembly And Assembly
TRAVEL CONTROLS
Removal And Installation
Disassembly And Assembly
LEFT PEDAL (AUXILIARY)
Disassembly And Assembly
CONTROL LINKAGE ASSEMBLY
Removal And Installation
Disassembly And Assembly
FLOOR MAT AND FLOOR PANELS
Description
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Description
Removal And Installation
Bushing Removal And Installation
Swing Frame Bushing Removal
Swing Frame Bushing Installation
BOOM
Description
Removal And Installation
Boom Bushing Removal And Installation
ARM
Description
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
BUCKET
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
COUNTERWEIGHT
Removal And Installation
OPERATOR BONNET
Removal And Installation
QUICK COUPLER (KLAC™ SYSTEM)
Troubleshooting
Daily Inspection
Removal And Installation
Parts Identification
Disassembly
Assembly
QUICK COUPLER (LEHNHOFF® SYSTEM)
Troubleshooting
Daily Inspection
Removal (MS03 And MS08)
Installation (MS03 And MS08)
Parts Identification (MS03)
Disassembly And Assembly (MS03)
Parts Identification (MS08)
Disassembly (MS08)
Assembly (MS08)
RIGHT SIDE COVER
Removal And Installation
TOOL BOX
Removal And Installation
ELECTRICAL SYSTEM
ELECTRICAL SCHECMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting
Description
Fuse And Relay Location / Identification
BATTERY
Servicing
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
LIGHTS
Boom Light Removal And Installation
Boom Light Bulb Replacement
Cab Light Removal And Installation
Cab Light Bulb Replacement
MAGNETIC LOCKOUT SENSOR
Removal And Installation
TWO-SPEED SWITCH
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
KEY SWITCH
Removal And Installation
WIPER MOTOR
Removal And Installation
ENGINE
ENGINE INFORMATION
Description
Specifications
Crankshaft Re-Grind Data
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Engine Compression – Testing
SPARK ARRESTER MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
ENGINE COOLING SYSTEM
Radiator / Oil Cooler Removal And Installation
Fan Removal
Water Pump Removal and Installation
Thermostat Removal and Installation
Thermostat – Testing
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump – Service
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump – Testing
Fuel Injection Pump Removal And Installation
Fuel Injection Pump – Timing
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Testing
CYLINDER HEAD
Glow Plug Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Servicing
Valve And Valve Seat Reconditioning
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Servicing
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Disassembly And Assembly
Piston And Connecting Rod – Servicing
Cylinder Bore – Measuring
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Measuring Backlash
Idler Gear And Camshaft Removal And Installation
Idler Gear And Shaft – Servicing
FLYWHEEL AND HOUSING
Flywheel Housing Removal And Installation
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal
Flywheel Installation
Rear End Plate Removal And Installation
HEATING AND VENTILATION
HEATER SYSTEM
Description
Components
REGULAR MAINTENANCE
Filter Element Removal And Installation
Heater Coil
HEATER UNIT
Removal And Installation
HEATER COIL
Removal And Installation
HEATER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
SPECIFICATIONS
EXCAVATOR SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Capacities
Tracks
Ground Pressure
Environmental
Temperature Range
TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Cooling System
Excavator Torques
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Engine Tools
Electrical Tools
General Tools
HVAC Tools
ALPHABETICAL INDEX
SERVICE SCHEDULE SYMBOLS
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