Bobcat E27z Excavator B4R711001 & Up 7354905 (03-21) (Preview)
MAINTENANCE SAFETY
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
Avoid Silica Dust
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 AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS / FOPS)
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
Heating And Ventilation Ducting
OPERATOR CANOPY (ROPS / TOPS / FOPS)
Description
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
TAILGATE
Opening And Closing
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing
SERVICE SCHEDULE
Maintenance Intervals
Inspection Checkbook
AIR CLEANER SERVICE
Daily Check
Replacing The Filters
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 Hydraulic Filters
Removing And Replacing Hydraulic Fluid
LUBRICATING THE EXCAVATOR
Lubrication Locations
PIVOT PINS
Inspection And Maintenance
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
EMERGENCY EXIT
Right Side Rear Window
Front Window
SEAT BELT
Inspection And Maintenance
CONTROL CONSOLE LOCKOUTS
Inspection And Maintenance
TOWING THE EXCAVATOR
Procedure
REMOTE START TOOL KIT – MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Control – MEL1565
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 SCHEMATICS
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 (CLAMP)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
VALVES (MAIN RELIEF)
Testing And Adjusting
VALVES (PORT RELIEF)
Testing And Adjusting
VALVES (CROSS PORT RELIEF)
Testing
Removal And Installation
Disassembly And Assembly
VALVES (PILOT PRESSURE RELIEF)
Testing And Adjusting
HYDRAULIC CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly
Auxiliary Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
RH Travel Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
LH Travel Valve Section Disassembly And Assembly
“Priority Valve” Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Auxiliary 4 Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Description
Torque Adjustment
Testing The Piston Pump P1
Testing The Piston Pump P2
Testing The Gear Pump P3
Testing The Gear Pump P4
Testing Auxiliary Hydraulic Flow
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Startup
Gear Pump Disassembly And Assembly
Piston Pump Parts Identification
Piston Pump Disassembly And Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
TRAVEL MOTOR
Description
Removal And Installation
Parts Identification Hydraulic Motor
Parts Identification Gear Reduction Hub
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification
Disassembly And Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly And Assembly
SWING MOTOR (DRIVE CARRIER)
Removal And Installation
Parts Identification
Disassembly And Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly And Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
BLADE CONTROL LEVER
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly And Assembly
CASE DRAIN FILTER MOUNT
Removal And Installation
TRAVEL CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
REMOVING AIR FROM THE HYDRAULIC SYSTEM
Procedure
SECONDARY AUXILIARY VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
VALVE (BOOM LOAD HOLDING VALVE)
Removal And Installation
Inspection
Override Function – Emergency Lowering
VALVE (ARM LOAD HOLDING VALVE)
Removal And Installation
Inspection
Override Function – Emergency Lowering
UNDERCARRIAGE
BLADE
Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
Description
Track Lug Height
Checking Tension
Adjusting Tension
Track Removal And Installation
Idler Removal And Installation
Idler Parts Identification
Idler Disassembly
Idler Assembly
Track Tensioner Removal And Installation
Track Tensioner Parts Identification
Track Tensioner Disassembly And Assembly
Roller Removal And Installation
Sprocket Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)
Description
Checking Tension
Adjusting Tension
Track Removal And Installation
Idler Removal And Installation
Idler Parts Identification
Idler Disassembly
Idler Assembly
Track Tensioner Removal And Installation
Track Tensioner Parts Identification
Track Tensioner Disassembly And Assembly
Roller Removal And Installation
Sprocket Removal And Installation
Guide Plate Removal And Installation
TRACK MAINTENANCE
Track Damage Identification
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing Installation
UPPERSTRUCTURE AND SWING SECTION
UPPERSTRUCTURE
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
Removal And Installation
Seat Mount Removal And Installation
RIGHT CONSOLE
Console Cover Removal And Installation
LEFT CONSOLE
Lower Console Cover Removal And Installation
Upper Console Cover Removal And Installation
Compression Spring Removal And Installation
Lock Lever Removal And Installation
Console Removal And Installation
LEFT UPPERSTRUCTURE COVER
Removal And Installation
RIGHT UPPERSTRUCTURE COVER
Removal And Installation
COUNTERWEIGHT
Removal And Installation (Standard And Long Arm)
TRAVEL LEVERS AND PEDALS
Removal And Installation
Disassembly And Assembly
FLOOR MAT
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Boom Swing Frame Hose Routing
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
ARM (STANDARD AND LONG)
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
BUCKET
Bucket Teeth Removal And Installation
CLAMP
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
QUICK COUPLER (KLAC™ SYSTEM)
Removal
Installation
QUICK COUPLER (LEHNHOFF ® SYSTEM)
Removal
Installation
QUICK COUPLER (BOBCAT HYDRAULIC PIN GRABBER COUPLER HPG2)
Troubleshooting
Daily Inspection
Removal And Installation
Parts Identification
Disassembly And Assembly
RIGHT SIDE COVER
Removal And Installation
TOOL BOX
Removal And Installation
LEFT SIDE COVER
Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Frame Harness
Canopy Harness
Main Frame Harness
Motion Alarm Harness
Secondary Auxiliary Harness
Troubleshooting Chart
Description
Fuse And Relay Location / Identification
BATTERY
Servicing
Removing 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
MAGNETIC LOCKOUT SENSOR
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTIC SERVICE CODES
Viewing Service Codes
Service Codes List
CONTROL PANEL SETUP
Panel Setup (Deluxe Instrument Panel)
Password Setup (Keyless Start Panel)
Password Setup (Deluxe Instrument Panel)
Maintenance Clock
INSTRUMENT PANEL
Removal And Installation
CONTROLLER (GATEWAY AND AUXILIARY)
Description
Gateway Controller Removal And Installation
Auxiliary Controller Removal And Installation
KEY SWITCH
Removal And Installation
WIPER MOTOR
Removal And Installation
MOTION ALARM SYSTEM
Description
Inspecting
Adjusting Switch Position
SERVICE PC (LAPTOP COMPUTER)
Connecting The Remote Start Tool
Connecting Remote Start Tool (Service Tool)
BATTERY DISCONNECT SWITCH
Description
Removal And Installation
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Crankshaft Re-Grind Data
Torque For Kubota® Metric Bolts
Troubleshooting
Engine Removal And Installation
Compression Checking
ENGINE SPEED CONTROL (DIAL GAUGE)
Removal And Installation
Calibration
Actuator Removal And Installation
ENGINE SPEED CONTROL (LEVER)
Removal And Installation
Calibration
MUFFLER
Removal
Installation
AIR CLEANER
Removal And Installation
ENGINE COOLING SYSTEM
Coolant Recovery Tank Removal And Installation
Radiator Removal And Installation
Fan Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
Thermostat – Checking
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump – Checking
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 – Checking
Nozzle Spray Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs 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 – Checking
Valve Guide Removal And Installation
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Push Rod Alignment – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
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 Backlash – Checking
Idler Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft Servicing
FLYWHEEL AND HOUSING
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear
HEATING AND VENTILATION
REGULAR MAINTENANCE
Cab Filters
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Electrical System
HEATER UNIT
Removal And Installation
HEATER COIL
Removal And Installation
BLOWER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
HEATING / VENTILATION DUCT
Removal And Installation
SPECIFICATIONS
EXCAVATOR SPECIFICATIONS
Machine Dimensions
Machine Dimensions – Standard Arm
Machine Dimensions – Long Arm
Rated Lift Capacity – Canopy With Standard Arm And Medium Counterweight
Rated Lift Capacity – Canopy With Long Arm And Medium Counterweight
Rated Lift Capacity – Canopy With Standard Arm And Heavy Counterweight
Rated Lift Capacity – Canopy With Long Arm And Heavy Counterweight
Rated Lift Capacity – Cab With Standard Arm And Medium Counterweight
Rated Lift Capacity – Cab With Long Arm And Medium Counterweight
Rated Lift Capacity – Cab With Standard Arm And Heavy Counterweight
Rated Lift Capacity – Cab With Long Arm And Heavy Counterweight
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Capacities
Tracks
Environmental
Temperature Range
TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Excavator Torques
Cooling System
TORQUE SPECIFICATION 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
O-ring Flare Fitting
Port Seal Fitting
Push To Connect Fittings
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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