Bobcat E80 Compact Excavator Repair Service Manual - 6987194


(S/N: AETB11001 & Above - S/N: AET311001 & Above)
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This workshop repair service manual PDF download for the E80 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Bobcat Excavator E80
S/N: AETB11001 & Above
S/N: AET311001 & Above


TABLE OF CONTENTS :

SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6987194 (2-11)
Total Pages : 879


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
Heating, Ventilation And Air Conditioning Duct
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
RIGHT SIDE COVER
Opening And Closing
Adjusting The Latch
REAR COVER
Opening And Closing
CENTER COVER
Opening And Closing
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing The Filters
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 Filters
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 Fluid
Hydraulic Fluid Chart
Removing And Replacing Hydraulic Filters
Removing And Replacing Hydraulic Fluid
Checking Swing Motor Gear Box Fluid Level
Removing And Replacing Swing Motor Gear Box Fluid
LUBRICATING THE EXCAVATOR
Lubrication Locations
PIVOT PINS
Inspection And Maintenance
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
SPARK ARRESTER MUFFLER
Cleaning Procedure
EMERGENCY EXIT
Right Rear Side Window
Front Window
SEAT BELT
Inspection And Maintenance
CAB TILT PROCEDURE
Tilting The Cab
CONTROL CONSOLE LOCKOUTS
Inspection And Maintenance
TOWING THE EXCAVATOR
Procedure

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Swing (Slew) Circuit
Troubleshooting The Travel Circuit
Description
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
Disassembly
Assembly
CYLINDER (BUCKET)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BLADE)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (ARTICULATED BOOM) (OPTIONAL)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
VALVES (RELIEF)
Description
VALVES (PORT RELIEF)
Testing And Adjusting The Port Relief Valve Pressure
VALVE (PILOT PRESSURE RELIEF)
Testing And Adjusting The Pressure Reducing Valve
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
Inlet Valve Section Disassembly And Assembly
Boom, Arm And Bucket Valve Section Disassembly And Assembly
Left Travel, Right Travel And Blade Valve Section Disassembly And Assembly
Auxiliary And Slew Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Articulated Boom Valve Section Disassembly And Assembly
PUMP (HYDRAULIC PISTON)
Hydraulic Pump Work Sheet
Testing Information
Pump Testing
Removal And Installation
Torque Limiter Valve Parts Identification
Torque Limiter Valve Removal And Installation
Torque Limiter Valve Disassembly
Torque Limiter Valve Assembly
Initial Torque Limiter Valve Setting
Pump Control Parts Identification
Pump Control Removal And Installation
Pump Control Disassembly And Assembly
Parts Identification
Disassembly
Assembly
PUMP (GEAR)
Testing Information
Pump Testing
Removal And Installation
Disassembly And Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR
Description
Removal And Installation
Disassembly And Assembly
TRAVEL MOTOR
Removal And Installation
Parts Identification
Parts Identification Gear Reduction Hub
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly And Assembly
SWING MOTOR (DRIVE CARRIER)
Removal And Installation
Parts Identification
Disassembly And Assembly
CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly
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
BLADE CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
DIRECT TO TANK VALVE
Removal And Installation
Disassembly And Assembly
AUXILIARY BREAKER VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
BOOM SWING VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
AUXILIARY HYDRAULIC VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
ARTICULATED BOOM VALVE (OPTIONAL)
Removal And Installation
Parts Identification
Disassembly And Assembly
TRAVEL CONTROL VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
AUTO IDLE VALVE
Testing And Adjusting
Removal And Installation

UNDERCARRIAGE
BLADE
Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
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
Lower Roller Parts Identification
Lower Roller Disassembly
Lower Roller Assembly
Upper Roller Parts Identification
Upper Roller Disassembly And Assembly
Sprocket Removal And Installation
TRACK MAINTENANCE
Track Damage Identification
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing Installation
LOWER TRACK ROLLER
Parts Identification
Disassembly
Assembly
UPPER TRACK ROLLER
Parts Identification
Disassembly And Assembly
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing Installation

UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Removal
Installation
UPPERSTRUCTURE SIDE COVER (LEFT)
Removal And Installation
UPPERSTRUCTURE SIDE COVER (RIGHT)
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Lower Front Window Removal And Installation
Glass Installation
Front Window Strut Removal And Installation
Front Window Slide Bar Removal And Installation
Cab Tilt Assembly Removal And Installation
Cab Tilt Parts Identification
Cab Tilt Assembly Disassembly And Assembly
Headliner Removal And Installation
SEAT
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
Gas Strut Removal And Installation
Lock Lever Removal And Installation
Lock Lever Disassembly And Assembly
Console Removal And Installation
CENTER COVER
Removal And Installation
CENTER ACCESS COVER
Removal And Installation
COUNTERWEIGHT
Removal And Installation
FLOOR MAT
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
Bushing Removal And Installation
BOOM (ARTICULATED) (OPTIONAL)
Removal And Installation
ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Bucket And Link Bushing Removal And Installation
QUICK COUPLER (KLAC SYSTEMâ„¢)
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)
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
RIGHT SIDE COVER
Removal And Installation
Latch Adjustment
REAR COVER
Removal And Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
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
Low Voltage Testing
High Voltage Testing
Alternator Regulator Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
LIGHTS
Boom Light Removal And Installation
Boom Light Bulb Replacement
CONSOLE LOCKOUT SWITCH
Testing / Adjustment
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
DIAGNOSTIC SERVICE CODE
Service Codes List
Flashing Patterns Of Engine Check Lamp
DIAGNOSTIC TOOL
Software Installation
Installation
Code Retrieval
INSTRUMENT PANEL
Removal And Installation
Disassembly And Assembly
KEY SWITCH
Removal And Installation
RIGHT CONSOLE SWITCH COVER
Removal And Installation
Rocker Switch Removal And Installation
Speed Control Removal And Installation
Engine Emergency Stop Switch Removal And Installation
Auxiliary Power Outlet Removal And Installation
WIPER MOTOR
Removal And Installation
MOTION ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Adjusting Switch Position
FUEL TRANSFER PUMP
Removal And Installation
AUTO IDLE PRESSURE SWITCH
Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Troubleshooting
Engine Removal And Installation
Compression - Testing
ENGINE SPEED CONTROL
Adjustment
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Radiator Disassembly And Assembly
Fan Removal And Installation
Fuel Cooler Removal And Installation
Water Pump Removal And Installation
Water Pump Parts Identification
Thermostat Removal And Installation
Temperature Switch - Testing
Temperature Sensor - Testing
Thermostat - Testing
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure - Testing
FUEL SYSTEM
Fuel Injection Pump Removal And Installation
Fuel Injection Pump - Timing
Fuel Injector Removal And Installation
Fuel Injector Pressure - Testing
Nozzle Spray Condition
CYLINDER HEAD
Valve Clearance Adjustment
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head - Servicing
Valve Guide - Inspection
Intake And Exhaust Valve - Inspection
Valve Stem Bend - Inspection
Valve Face And Seat
Valve Spring - Inspection
Push Rod - Inspection
Rocker Arm - Inspection
Valve Bridge - Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod - Servicing
Cylinder Bore - Inspection
Crankshaft End Play
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings - Servicing
CAMSHAFT AND TIMING GEARS
Timing Gear Case Cover Removal And Installation
Timing Gear Backlash - Inspection
Idler Gear And Camshaft Removal And Installation
Camshaft - Servicing
Idler Gear And Shaft - Servicing
COLD START DEVICE
Description
Testing
Removal And Installation
EXHAUST GAS RECIRCULATION VALVE (EGR)
Description
Testing
Removal And Installation
MANIFOLD AIR HEATER
Description
Testing
Removal And Installation
ENGINE FLYWHEEL
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear Removal And Installation

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Belt Adjustment
Belt Replacement
Condenser
Air Conditioning Service Chart
Evaporator / Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Operates Improperly Or Not At All
Gauge Pressure Related Troubleshooting
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
SYSTEM CHARGING AND RECLAMATION
Reclamation And Charging With Recovery / Charging Unit
Charging With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Oil
Oil Check
CONDENSER
Removal And Installation
RECEIVER / DRIER
Receiver / Drier Removal And Installation
Pressure Switch Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Inspection
EXPANSION VALVE
Removal And Installation
BLOWER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
HVAC CONTROLLER
Removal And Installation

SPECIFICATIONS
E80 EXCAVATOR SPECIFICATIONS
Machine Dimensions
Machine Dimensions (Articulated Boom)
Machine Dimensions (Standard Arm)
Machine Dimensions (Long Arm)
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Capacities
Tracks
Ground Pressure
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

ALPHABETICAL INDEX

SERVICE MANUAL REVISION
Revision No: E80 - 1
Revision No: E80 - 2
Revision No: E80 - 3

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