Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001

Description

Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001

This Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001 is written for the shop mechanic who services the E80 after daily operator work is finished. Publication 6987194 (2-11), printed in the U.S.A. and dated 2011 by Bobcat Company, gathers lifting and blocking rules, hydraulic cylinder and pump overhaul, rubber and steel track work, upperstructure removal, electrical analysis with wiring schematics, Yanmar 4TNV98-ESDB8 engine rebuild data, HVAC charging steps, and the full E80 specification set. The cover range is S/N AETB11001 & Above and S/N AET311001 & Above. Later cab notes split ROPS / TOPS protection at S/N AETB11235 & Above and S/N AET311235 & Above, so serial confirmation on the swing-frame plate remains the first shop step.

File Details

• Manual type: Service Manual
• Brand / model: Bobcat E80 excavator
• Document number: 6987194 (2-11)
• Date / copyright: 2011, Bobcat Company
• Language: English
• Page count: 879
• File format: PDF
• Serial coverage: S/N AETB11001 & Above; S/N AET311001 & Above

Who This E80 Service Book Is For

The foreword states the book is for the Bobcat excavator mechanic and that operating start-up, daily checks, and routine owner tasks live in the separate Operation & Maintenance Manual. After any repair the same foreword lists a return-to-service inspection: ROPS / TOPS / FOPS condition and hardware, seat belt, decals, travel and control levers returning to neutral, work lights, enclosure latches, attachment locking pins, safety treads, indicator lamps, fluid levels, leaks, lubrication, battery and charging system, air cleaner, tracks and tension, loose hardware, unfinished field modifications, control-console interlocks, X-Change wear, and option function. That close-out list is the practical standard this Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001 expects after shop work.

Serial plates are documented with photos. The excavator plate sits on the swing frame at the front of the upperstructure. The number is explained as a four-digit model / engine combination module plus a five-digit production sequence. The engine serial number is on the top cover. Delivery-report completion and machine identification drawings name boom, arm, bucket and blade cylinders, auxiliary quick couplers, cab, covers, tracks, lift points and tie-downs so parts conversations stay tied to the correct E80.

Chapters Covered

• Safety & Maintenance — lifting and blocking; lifting the excavator; operator cab (door, front window, wiper, washer reservoir, right side window, HVAC ducts); trailer transport; right side, rear and center covers; service schedule; air cleaner; cab filter; engine cooling system; fuel system including biodiesel blend notes; engine lubrication; hydraulic fluid and filters; swing motor gearbox fluid; lubrication points; pivot pins; travel motor oil; spark arrester muffler; emergency exit; seat belt; cab tilt; control console lockouts; towing
• Hydraulic System — circuit glossary and troubleshooting; boom, arm, boom swing, bucket, blade and optional articulated-boom cylinders; relief, port relief and pilot pressure-reducing valves; hydraulic control valve sections; piston pump with torque limiter and pump control; gear pump; manifold / accumulator; travel motor and gear-reduction hub; swivel joint; swing motor and drive carrier; control pattern selector; left and right joysticks; blade control valve; reservoir; oil cooler; direct-to-tank, auxiliary breaker, boom swing, auxiliary hydraulic, articulated boom, travel control and auto idle valves
• Undercarriage — blade; rubber-track components (lug height, tension, removal, idler, tensioner, rollers, sprocket); steel-track components; track maintenance; swing circle gear; lower and upper track rollers
• Upperstructure & Swing Section — upperstructure removal and installation; left and right side covers; cab; floor mat and related interior items; horn; swing frame; boom, arm, bucket and related structural work as presented in the section
• Electrical System & Analysis — troubleshooting chart, fuses and relays; battery and jump starting; alternator belt, voltage and regulator tests; starter; boom lights; console lockout switch; fuel level sender; diagnostic service codes and engine check-lamp flash patterns; diagnostic tool software and code retrieval; instrument panel; key switch; right console switches including speed control and emergency stop; wiper motor; motion alarm; fuel transfer pump; auto idle pressure switch; full wiring schematic
• Engine Service — engine information, specifications, troubleshooting, removal and compression test; speed-control adjustment; muffler; air cleaner housing; radiator, fan, fuel cooler, water pump and thermostat; lubrication system and oil-pressure test; fuel injection pump timing and injector testing; cylinder head and valve service; crankshaft and pistons; camshaft and timing gears; cold start device; EGR valve; manifold air heater; flywheel and hydraulic pump coupler
• Heating, Ventilation and Air Conditioning (HVAC) — system description, troubleshooting, charging and reclamation, compressor, evaporator / heater unit, thermostat, HVAC controller and related components
• Specifications — machine dimensions for standard, long-arm and articulated-boom layouts; performance, controls, engine, hydraulics, cylinders, cycle times, electrical, drive, slew, undercarriage, capacities, tracks and ground pressure; SAE and metric bolt torque; hydraulic connection specs; hydraulic fluid specs; conversion charts
• Alphabetical Index

Taken together, those divisions give a technician a complete shop path on one compact excavator rather than a parts catalog or an operator handbook. Hydraulic work runs from leak-down cylinder tests through 12-spool closed-centre valve section rebuilds and piston-pump margin, backup-relief and torque-limiter settings. Undercarriage work covers both 450 mm rubber and steel tracks with five rollers per side. Electrical diagnosis includes service codes, E-ECU lamp patterns and a machine wiring schematic dated February 2011. Engine work goes past filters into injection timing, valve and bottom-end service on the Yanmar 4TNV98-ESDB8. HVAC pages cover R134a pressures and system charging. The specification chapter then locks dimensions, pressures, flows and fill quantities used throughout the procedures.

Safety, Daily Service and Shop Access

Opening chapters of the Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001 keep lift, block and fire-prevention rules next to the service schedule. Jackstands go under the blade and rear corners of the undercarriage before anyone works beneath the machine. One side can be raised about 101.6 mm (4 in) with boom and arm before stands take the weight. Whole-machine lifting uses fully extended bucket, arm and boom cylinders, a raised blade, chains at the blade ends and boom, protection against cab contact, and a maximum 45° angle between front and rear chains, with no operator on board and no swing during the lift.

Cab pages distinguish earlier cabs from S/N AETB11235 & Above and S/N AET311235 & Above, which list ROPS / TOPS to ISO 12117-2:2008 and ISO 12117:2000 and require the seat belt for that protection. Front-window latch pins, right-side window latch, seven adjustable air vents, washer reservoir location ahead of the radiator, and cab-tilt warnings (never work under the cab without an approved support) sit in the same section as trailer loading: metal ramps, angle not over 15°, auto idle off, two-speed travel in low range, blade forward, and chains at both blade corners plus the rear track-frame tie-down loop.

The service chart spaces coolant, engine oil, air filter, hydraulic fluid and filters, swing gearbox oil, travel-motor oil, grease fittings and spark-arrester muffler cleaning across 50 / 100 / 250 / 500 / 1000 / 2000 hour marks. Fuel pages specify clean Grade No. 2 or Grade No. 1 diesel with a cetane number of 45 or higher and limit biodiesel blends; more than five percent biodiesel is called out as a risk to hoses, injectors and seals. After a run-dry event the electric fuel pump is used with the key ON for 10–15 seconds to purge air. Hydraulic sight-glass checks are made with arm and bucket retracted, bucket and blade on the ground.

Hydraulics, Travel and Swing Work

Hydraulic system information states two separate circuits, with the piston-pump circuit feeding the control valve that contains boom, bucket, arm, blade, auxiliary, left and right travel, boom swing and upperstructure swing sections. Separate troubleshooting tables cover the main circuit, cylinders, slew and travel. Each work cylinder chapter follows the same shop rhythm: relieve residual pressure with the engine off and key ON, test for internal leakage, remove and install, then identify, disassemble and assemble parts. Optional articulated-boom cylinders and valve sections are included for machines so equipped.

Pump work is measurement-heavy. Piston-pump testing is done with oil at 50–60°C (122–140°F) after high idle is confirmed. Recorded targets in the test sequences include pilot / pressure-reducing values around 3200 kPa (32 bar) (464 psi), pump-margin and load-sense settings, backup relief near 34000 kPa (340 bar) (4931 psi), load-sense relief near 28000 kPa (280 bar) (4060 psi), and free flow of 144 L/min (38 U.S. gpm) used while setting the torque limiter. Gear-pump free flow on a new pump is given as 21.9 L/min (5.8 U.S. gpm) at 2200 engine rpm. Dual hydraulic / hydrostatic schematics printed August 2010 serve S/N AETB11001 and above (V-1315) and S/N AET311001 and above (V-1315EMEA), including optional third-auxiliary, breaker, motion-alarm and articulated-boom circuits.

Travel motors are independently driven axial-piston units with two-stage planetary reduction; the manual separates motor removal from gear-reduction-hub parts identification, disassembly and assembly. Swing work covers the axial-piston slew motor, drive carrier and the single-row shear-type ball bearing with internal gear. Joystick testing, control-pattern selector service, accumulator description (short-term reserve pressure with engine off and key in run), and auto-idle valve test and adjustment close the hydraulic book for day-to-day control complaints.

Undercarriage, Electrical Diagnosis and Engine Rebuild

Rubber-track service measures lug height, sets grease-cylinder tension, and walks idler, tensioner, roller and sprocket R&I with floating-seal assembly using alcohol on the O-ring and a light oil film only on the metal seal faces. Steel-track pages add shoe-count and tension checks for the 39-shoe, 450 mm (17.7 in) chain. Track-maintenance text explains rubber-track damage modes so a worn or cut belt is not treated as a simple tension problem. Swing-circle bearing removal is tied to full upperstructure lift-off, with alignment pins and match marks required on reassembly.

Electrical system analysis starts with a cause-and-correction chart for no-charge and no-crank complaints, then fuse and relay maps. Battery jump-starting routes the ground to a flywheel-cover bolt. Alternator pages cover belt tension, regulator checks and a 12 V, 60 A open-frame unit with internal regulator. Starter testing precedes gear-reduction starter R&I. Diagnostic service codes list sensor, rack-actuator, overspeed and oil-pressure failures with the resulting engine behavior and the flash pattern of the engine check lamp. A diagnostic-tool chapter covers software install, PC connection and code retrieval. The wiring schematic on the analysis section is titled for both S/N AETB11001 and S/N AET311001 ranges and dated February 2011 (V-1316).

Engine service identifies a Yanmar direct-injected 4TNV98-ESDB8 four-cylinder diesel, 3.319 L (202.5 in³), 98 x 110 mm (3.85 x 4.33 in) bore and stroke, counter-clockwise rotation from the flywheel, closed crankcase ventilation and dual dry air cartridges. The specification chapter lists SAE Gross 40.7 kW (54.6 hp), torque 223–243 N·m (164.5–179.1 ft-lb) at 1300 rpm, low idle 1050 rpm and high idle 2150 rpm. Shop procedures include engine R&I, compression testing with kit MEL10630 (3330 kPa class values at 250 rpm cranking), injection-pump timing using the pump index and flywheel TDC / BTDC marks, injector spray and pressure tests, valve clearance, head and guide service, piston and crankshaft limits, camshaft and idler-gear backlash, cold-start device operation below 5°C (41°F), EGR coil tests, manifold air heater preheat and flywheel / pump-coupler work. Oil-pressure limits include 60 kPa (0.6 bar) (8.7 psi) or more at idle.

IMAGES PREVIEW

Capacities, Pressures and Machine Figures Used in the Shop

Keep these published figures beside the work order when using this Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001. Operating weight with cab, steel tracks and a 610 mm (24 in) bucket is 8380 kg (18475 lb); add 60 kg (133 lb) for the long arm or 920 kg (2028 lb) for the articulated-boom option. Travel speed is 2.9 km/h (1.8 mph) low and 4.6 km/h (2.9 mph) high. Digging force per ISO 6015 is 40855 N (9185 lbf) on the standard or articulated-boom arm, 34068 N (7659 lbf) on the long arm, and 54623 N (12280 lbf) at the bucket. Boom offset is 70° left and 55° right. Slew speed is 9.6 rpm. Ground pressure is 39 kPa (0.39 bar) (5.66 psi).

Hydraulic hardware is an engine-driven variable-displacement dual piston pump with pressure-compensating, load-sensing and torque-limiter controls plus two gear pumps. Piston capacity is listed as 2 @ 70 L/min (18.5 U.S. gpm); gear pumps 70 L/min (18.5 U.S. gpm) and 9.9 L/min (2.6 U.S. gpm); auxiliary flow 120 L/min (31.7 U.S. gpm). System relief on travel, slew, boom swing, blade and primary work circuits is 30000 kPa (300 bar) (4278 psi). Port reliefs on arm, boom, bucket and optional articulated boom are 31000 kPa (310 bar) (4496 psi). Joystick control pressure is 2940 kPa (29.4 bar) (427 psi). Cylinder bore / rod / stroke tables cover boom 115 / 75 / 775 mm, arm 100 / 65 / 866 mm, bucket 85 / 55 / 690 mm, boom swing 110 / 60 / 738 mm, blade 100 / 60 / 149 mm and optional articulated boom 100 / 55 / 370 mm. Cycle times include boom raise 3.2 s / lower 3.0 s, arm retract 3.8 s / extend 2.9 s and bucket curl 3.3 s / dump 2.1 s.

Fill quantities: fuel tank 78 L (20.6 U.S. gal); hydraulic reservoir to sight-glass center 87 L (23.0 U.S. gal); hydraulic system with reservoir 127 L (35.5 U.S. gal); cooling system 10.0 L (10.6 qt); engine oil and filter 11.6 L (12.25 qt); each final drive 1.4 L (1.5 qt). Electrical specification is a 12 V, 750 CCA battery at -18°C (0°F), 60 A alternator and 3.0 kW (4.0 hp) gear-reduction starter, with air-intake heater as the starting aid. Dimension plates give overall layouts for standard arm, long arm and articulated boom, including transport height and reach figures used when planning lifts or trailer loads.

Use This Manual on the Job, Then Keep a Copy on Any Device

With the Bobcat E80 Compact Excavator Service Manual 6987194 (2011) S/N AETB11001 & AET311001 a technician can block and lift the machine, change planned-interval fluids and filters, test and rebuild boom through blade cylinders, set piston-pump margin and torque limiter, overhaul travel and swing motors, replace rubber or steel tracks and rollers, lift the upperstructure off the swing bearing, trace no-charge or no-crank faults, read E-ECU codes, time and test the 4TNV98-ESDB8 injection system, service head and bottom end, and charge the HVAC circuit to the pressures shown in the HVAC chapter. Matching those procedures to the printed relief settings, cylinder sizes, idle speeds and fill quantities is what keeps a compact excavator from coming back with the same leak, drift or derate. After purchase the file is delivered as an instant PDF with no shipping wait, opens on a shop computer, tablet or phone, and can be printed for the bench or service truck.