Bobcat E80 Excavator Service Manual 6987194 (05-16) – PDF DOWNLOAD

Description

Bobcat E80 Excavator Service Manual 6987194 (05-16) – PDF DOWNLOAD

FILE DETAILS:

Bobcat E80 Excavator Service Manual 6987194 (05-16) – PDF DOWNLOAD

Language : English
Pages : 893
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E80 Excavator Service Manual 6987194 (05-16) – PDF DOWNLOAD

S/N AETB11001 & Above
S/N AET311001 & 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 E80 Excavator Service Manual 6987194 (05-16) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 12
FIRE PREVENTION 14
Maintenance 14
Operation 14
Electrical 14
Hydraulic System 14
Fueling 14
Starting 14
Spark Arrestor Exhaust System 14
Welding And Grinding 15
Fire Extinguishers 15
SERIAL NUMBER LOCATIONS 16
Excavator Serial Number 16
Engine Serial Number 16
DELIVERY REPORT 17
BOBCAT EXCAVATOR IDENTIFICATION 18
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
LIFTING THE EXCAVATOR 23
Procedure 23
OPERATOR CAB 25
Description 25
Cab Door 25
Front Window 26
Front Wiper 27
Window Washer Reservoir 27
Right Side Window 28
Heating, Ventilation And Air Conditioning Duct 29
TRANSPORTING THE EXCAVATOR ON A TRAILER 31
Loading And Unloading 31
Fastening 31
RIGHT SIDE COVER 33
Opening And Closing 33
Adjusting The Latch 33
REAR COVER 35
Opening And Closing 35
CENTER COVER 37
Opening And Closing 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Daily Check 41
Replacing The Filters 41
CAB FILTER 43
Cleaning And Maintenance 43
ENGINE COOLING SYSTEM 45
Cleaning 45
Checking Level 45
Removing And Replacing Coolant 46
FUEL SYSTEM 47
Fuel Specifications 47
Biodiesel Blend Fuel 47
Filling The Fuel Tank 48
Fuel Filters 49
Draining The Fuel Tank 50
Removing Air From The Fuel System 50
ENGINE LUBRICATION SYSTEM 51
Checking And Adding Engine Oil 51
Engine Oil Chart 51
Removing And Replacing Oil And Filter 52
HYDRAULIC SYSTEM 53
Checking And Adding Fluid 53
Hydraulic Fluid Chart 54
Removing And Replacing Hydraulic Filters 54
Removing And Replacing Hydraulic Fluid 58
Checking Swing Motor Gear Box Fluid Level 59
Removing And Replacing Swing Motor Gear Box Fluid 60
LUBRICATING THE EXCAVATOR 61
Lubrication Locations 61
PIVOT PINS 65
Inspection And Maintenance 65
TRAVEL MOTOR 67
Checking And Adding Oil 67
Removing And Replacing Oil 67
SPARK ARRESTER MUFFLER 69
Cleaning Procedure 69
EMERGENCY EXIT 71
Right Rear Side Window 71
Front Window 71
SEAT BELT 73
Inspection And Maintenance 73
CAB TILT PROCEDURE 75
Tilting The Cab 75
CONTROL CONSOLE LOCKOUTS 77
Inspection And Maintenance 77
TOWING THE EXCAVATOR 79
Procedure 79
HYDRAULIC SYSTEM 81
HYDRAULIC/HYDROSTATIC SCHEMATICS 85
HYDRAULIC SYSTEM INFORMATION 89
Glossary Of Hydraulic / Hydrostatic Symbols 89
Troubleshooting The Hydraulic Circuit 92
Troubleshooting The Cylinder Circuit 93
Troubleshooting The Swing (Slew) Circuit 94
Troubleshooting The Travel Circuit 95
Description 97
CYLINDER (BOOM) 99
Testing 99
Removal And Installation 102
Parts Identification 105
Disassembly 106
Assembly 114
CYLINDER (ARM) 123
Testing 123
Removal And Installation 125
Parts Identification 128
Disassembly 129
Assembly 137
CYLINDER (BOOM SWING) 145
Testing 145
Removal And Installation 146
Parts Identification 149
Disassembly 150
Assembly 157
CYLINDER (BUCKET) 165
Testing 165
Removal And Installation 165
Parts Identification 168
Disassembly 169
Assembly 178
CYLINDER (BLADE) 187
Testing 187
Removal And Installation 188
Parts Identification 191
Disassembly 192
Assembly 200
CYLINDER (ARTICULATED BOOM) (OPTIONAL) 209
Testing 209
Removal And Installation 211
Parts Identification 213
Disassembly 214
Assembly 220
VALVES (RELIEF) 227
Description 227
VALVES (PORT RELIEF) 229
Testing And Adjusting The Port Relief Valve Pressure 229
VALVE (PILOT PRESSURE RELIEF) 231
Testing And Adjusting The Pressure Reducing Valve 231
HYDRAULIC CONTROL VALVE 233
Description 233
Removal And Installation 233
Parts Identification 235
Disassembly And Assembly 236
Inlet Valve Section Disassembly And Assembly 241
Boom, Arm And Bucket Valve Section Disassembly And Assembly 244
Left Travel, Right Travel And Blade Valve Section Disassembly And Assembly 248
Auxiliary And Slew Valve Section Disassembly And Assembly 252
Boom Swing Valve Section Disassembly And Assembly 256
Articulated Boom Valve Section Disassembly And Assembly 259
PUMP (HYDRAULIC PISTON) 263
Hydraulic Pump Work Sheet 263
Testing Information 266
Pump Testing 268
Removal And Installation 276
Torque Limiter Valve Parts Identification 278
Torque Limiter Valve Removal And Installation 279
Torque Limiter Valve Disassembly 280
Torque Limiter Valve Assembly 284
Initial Torque Limiter Valve Setting 288
Pump Control Parts Identification 290
Pump Control Removal And Installation 291
Pump Control Disassembly And Assembly 292
Parts Identification 297
Disassembly 298
Assembly 306
PUMP (GEAR) 315
Testing Information 315
Pump Testing 315
Removal And Installation 317
Disassembly And Assembly 319
MANIFOLD ASSEMBLY / ACCUMULATOR 323
Description 323
Removal And Installation 323
Disassembly And Assembly 324
TRAVEL MOTOR 327
Removal And Installation 327
Parts Identification 328
Parts Identification Gear Reduction Hub 329
Disassembly 330
Assembly 344
SWIVEL JOINT 359
Removal And Installation 359
Parts Identification 362
Disassembly 363
Assembly 364
SWING MOTOR 367
Removal And Installation 367
Parts Identification 369
Disassembly And Assembly 370
SWING MOTOR (DRIVE CARRIER) 379
Removal And Installation 379
Parts Identification 380
Disassembly And Assembly 381
CONTROL PATTERN SELECTOR VALVE 385
Removal And Installation 385
Parts Identification 386
Disassembly 387
Assembly 389
RIGHT CONTROL LEVER (JOYSTICK) 391
Testing 391
Handle Removal And Installation 392
Joystick Assembly Removal And Installation 393
Parts Identification 395
Disassembly And Assembly 396
LEFT CONTROL LEVER (JOYSTICK) 401
Testing 401
Handle Removal And Installation 402
Joystick Assembly Removal And Installation 403
Parts Identification 405
Disassembly And Assembly 406
BLADE CONTROL VALVE 411
Removal And Installation 411
Parts Identification 412
Disassembly And Assembly 413
HYDRAULIC RESERVOIR 417
Removal And Installation 417
OIL COOLER 423
Removal And Installation 423
DIRECT TO TANK VALVE 425
Removal And Installation 425
Disassembly And Assembly 426
AUXILIARY BREAKER VALVE 427
Description 427
Removal And Installation 427
Parts Identification 428
Disassembly And Assembly 429
BOOM SWING VALVE 431
Removal And Installation 431
Parts Identification 432
Disassembly And Assembly 433
AUXILIARY HYDRAULIC VALVE 437
Removal And Installation 437
Parts Identification 438
Disassembly And Assembly 439
ARTICULATED BOOM VALVE (OPTIONAL) 443
Removal And Installation 443
Parts Identification 444
Disassembly And Assembly 445
TRAVEL CONTROL VALVE 449
Removal And Installation 449
Parts Identification 451
Disassembly And Assembly 452
AUTO IDLE VALVE 457
Testing And Adjusting 457
Removal And Installation 458
UNDERCARRIAGE 461
BLADE 463
Removal And Installation 463
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 465
Track Lug Height 465
Checking Tension 466
Adjusting Tension 467
Track Removal And Installation 467
Idler Removal And Installation 469
Idler Parts Identification 470
Idler Disassembly 471
Idler Assembly 474
Track Tensioner Removal And Installation 479
Track Tensioner Parts Identification 480
Track Tensioner Disassembly And Assembly 481
Roller Removal And Installation 483
Lower Roller Parts Identification 485
Lower Roller Disassembly 486
Lower Roller Assembly 489
Upper Roller Parts Identification 495
Upper Roller Disassembly And Assembly 496
Sprocket Removal And Installation 499
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 501
Checking Tension 501
Adjusting Tension 502
Track Removal And Installation 502
Idler Removal And Installation 504
Idler Parts Identification 505
Idler Disassembly 506
Idler Assembly 509
Track Tensioner Removal And Installation 514
Track Tensioner Parts Identification 515
Track Tensioner Disassembly And Assembly 516
Roller Removal And Installation 518
Guide Plate Removal And Installation 520
Lower Roller Parts Identification 521
Lower Roller Disassembly 522
Lower Roller Assembly 525
Upper Roller Parts Identification 531
Upper Roller Disassembly And Assembly 532
Sprocket Removal And Installation 535
TRACK MAINTENANCE 537
Track Damage Identification 537
SWING CIRCLE GEAR 549
Swing Bearing Removal 549
Swing Bearing Installation 550
UPPERSTRUCTURE & SWING SECTION 551
UPPERSTRUCTURE 555
Removal 555
Installation 557
UPPERSTRUCTURE SIDE COVER (LEFT) 559
Removal And Installation 559
UPPERSTRUCTURE SIDE COVER (RIGHT) 561
Removal And Installation 561
CAB 563
Removal And Installation 563
Door Removal And Installation 577
Front Window Removal And Installation 578
Lower Front Window Removal And Installation 579
Glass Installation 580
Front Window Strut Removal And Installation 585
Front Window Slide Bar Removal And Installation 586
Cab Tilt Assembly Removal And Installation 587
Cab Tilt Parts Identification 588
Cab Tilt Assembly Disassembly And Assembly 589
Headliner Removal And Installation 590
SEAT 595
Seat Removal And Installation 595
Seat Mount Removal And Installation 596
RIGHT CONSOLE 599
Console Cover Removal And Installation 599
LEFT CONSOLE 601
Lower Console Cover Removal And Installation 601
Upper Console Cover Removal And Installation 602
Gas Strut Removal And Installation 603
Lock Lever Removal And Installation 604
Lock Lever Disassembly And Assembly 605
Console Removal And Installation 606
CENTER COVER 607
Removal And Installation 607
CENTER ACCESS COVER 609
Removal And Installation 609
COUNTERWEIGHT 611
Removal And Installation 611
FLOOR MAT 615
Removal And Installation 615
FUEL TANK 617
Removal And Installation 617
HORN 621
Removal And Installation 621
SWING FRAME 623
Removal And Installation 623
Bushing Removal 627
Bushing Installation 628
BOOM 629
Removal And Installation 629
Bushing Removal And Installation 630
BOOM (ARTICULATED) (OPTIONAL) 631
Removal And Installation 631
ARM 633
Removal And Installation 633
Arm To Boom Bushing Removal And Installation 634
Bucket And Link Bushing Removal And Installation 635
QUICK COUPLER (KLAC™ SYSTEM) 637
Troubleshooting 637
Daily Inspection 637
Removal And Installation 638
Parts Identification 640
Disassembly 641
Assembly 643
QUICK COUPLER (LEHNHOFF® SYSTEM) 645
Troubleshooting 645
Daily Inspection 645
Removal (MS03 And MS08) 646
Installation (MS03 And MS08) 647
Parts Identification (MS03) 648
Disassembly And Assembly (MS03) 649
Parts Identification (MS08) 650
Disassembly (MS08) 651
Assembly (MS08) 655
BUCKET 659
Bucket Teeth Removal And Installation 659
Bucket Side Cutting Edge Removal And Installation 660
RIGHT SIDE COVER 661
Removal And Installation 661
Latch Adjustment 663
REAR COVER 665
Removal And Installation 665
ELECTRICAL SYSTEM & ANALYSIS 667
ELECTRICAL SCHEMATICS 669
ELECTRICAL SYSTEM INFORMATION 670
Troubleshooting Chart 670
Description 671
Fuse And Relay Location / Identification 671
BATTERY 674
Servicing 674
Removal And Installation 675
Using A Booster Battery (Jump Starting) 676
ALTERNATOR 678
Belt Adjustment 678
Belt Replacement 678
Charging System Inspection 679
Alternator Voltage Testing 681
Low Voltage Testing 682
High Voltage Testing 682
Alternator Regulator Testing 683
Removal And Installation 684
Parts Identification 686
STARTER 688
Testing 688
Removal And Installation 689
Parts Identification 691
LIGHTS 692
Boom Light Removal And Installation 692
Boom Light Bulb Replacement 692
CONSOLE LOCKOUT SWITCH 694
Testing / Adjustment 694
Removal And Installation 695
FUEL LEVEL SENDER 696
Removal And Installation 696
DIAGNOSTIC SERVICE CODE 698
Service Codes List 698
Flashing Patterns Of Engine Check Lamp 701
DIAGNOSTIC TOOL 702
Software Installation 702
Installation 704
Code Retrieval 707
INSTRUMENT PANEL 712
Removal And Installation 712
Disassembly And Assembly 713
KEY SWITCH 716
Removal And Installation 716
RIGHT CONSOLE SWITCH COVER 718
Removal And Installation 718
Rocker Switch Removal And Installation 719
Speed Control Removal And Installation 720
Engine Emergency Stop Switch Removal And Installation 720
Auxiliary Power Outlet Removal And Installation 721
WIPER MOTOR 722
Removal And Installation 722
MOTION ALARM SYSTEM (IF EQUIPPED) 724
Description 724
Inspecting 724
Adjusting Switch Position 725
FUEL TRANSFER PUMP 726
Removal And Installation 726
AUTO IDLE PRESSURE SWITCH 728
Removal And Installation 728
ENGINE SERVICE 730
ENGINE INFORMATION 732
Description 732
Specifications 733
Troubleshooting 739
Engine Removal And Installation 740
Compression – Testing 747
ENGINE SPEED CONTROL 750
Adjustment 750
MUFFLER 752
Removal And Installation 752
AIR CLEANER 754
Housing Removal And Installation 754
ENGINE COOLING SYSTEM 756
Radiator Removal And Installation 756
Radiator Disassembly And Assembly 763
Fan Removal And Installation 765
Fuel Cooler Removal And Installation 766
Water Pump Removal And Installation 767
Water Pump Parts Identification 768
Thermostat Removal And Installation 769
Temperature Switch – Testing 769
Temperature Sensor – Testing 770
Thermostat – Testing 770
LUBRICATION SYSTEM 772
Oil Pan Removal And Installation 772
Oil Pump Removal And Installation 773
Oil Pump Inspection 775
Engine Oil Pressure – Testing 777
FUEL SYSTEM 778
Fuel Injection Pump Removal And Installation 778
Fuel Injection Pump – Timing 783
Fuel Injector Removal And Installation 787
Fuel Injector Pressure – Testing 789
Nozzle Spray Condition 789
CYLINDER HEAD 792
Valve Clearance Adjustment 792
Cylinder Head Removal And Installation 794
Cylinder Head Disassembly And Assembly 795
Cylinder Head – Servicing 796
Valve Guide – Inspection 797
Intake And Exhaust Valve – Inspection 798
Valve Stem Bend – Inspection 798
Valve Face And Seat 799
Valve Spring – Inspection 799
Push Rod – Inspection 800
Rocker Arm – Inspection 800
Valve Bridge – Inspection 801
CRANKSHAFT AND PISTONS 802
Piston And Connecting Rod Removal And Installation 802
Piston And Connecting Rod – Servicing 803
Cylinder Bore – Inspection 805
Crankshaft End Play 805
Crankshaft And Bearings Removal And Installation 806
Crankshaft And Bearings – Servicing 807
CAMSHAFT AND TIMING GEARS 808
Timing Gear Case Cover Removal And Installation 808
Timing Gear Backlash – Inspection 809
Idler Gear And Camshaft Removal And Installation 810
Camshaft – Servicing 811
Idler Gear And Shaft – Servicing 812
COLD START DEVICE 814
Description 814
Testing 814
Removal And Installation 814
EXHAUST GAS RECIRCULATION VALVE (EGR) 816
Description 816
Testing 816
Removal And Installation 817
MANIFOLD AIR HEATER 818
Description 818
Testing 818
Removal And Installation 818
ENGINE FLYWHEEL 820
Hydraulic Pump Coupler Removal And Installation 820
Flywheel Removal And Installation 821
Flywheel Ring Gear Removal And Installation 821
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 822
AIR CONDITIONING SYSTEM FLOW 824
Description 824
Chart 825
Components 826
Safety Equipment 829
REGULAR MAINTENANCE 830
Filters 830
Belt Adjustment 830
Belt Replacement 831
Condenser 832
Air Conditioning Service Chart 833
Evaporator / Heater Coil 834
TROUBLESHOOTING 836
Blower Motor Does Not Operate 836
Blower Motor Operates Normally, But Air Flow Is Insufficient 836
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 836
The Compressor Operates Improperly Or Not At All 836
Gauge Pressure Related Troubleshooting 837
Temperature / Pressure Chart 839
Poor A/C Performance 840
HVAC Repair And Leaks 841
SYSTEM CHARGING AND RECLAMATION 842
Reclamation And Charging With Recovery / Charging Unit 842
Charging With A Manifold Gauge Set 845
COMPRESSOR 848
Removal And Installation 848
Oil 850
Oil Check 851
CONDENSER 854
Removal And Installation 854
RECEIVER / DRIER 856
Receiver / Drier Removal And Installation 856
Pressure Switch Removal And Installation 857
EVAPORATOR / HEATER UNIT 858
Removal And Installation 858
THERMOSTAT 860
Inspection 860
EXPANSION VALVE 862
Removal And Installation 862
BLOWER FAN 864
Removal And Installation 864
HEATER VALVE 866
Removal And Installation 866
HVAC CONTROLLER 868
Removal And Installation 868
SPECIFICATIONS 870
E80 EXCAVATOR SPECIFICATIONS 872
Machine Dimensions 872
Machine Dimensions (Articulated Boom) 873
Machine Dimensions (Standard Arm) 875
Machine Dimensions (Long Arm) 876
Performance 877
Controls 877
Engine 877
Hydraulic System 878
Hydraulic Cylinders 878
Hydraulic Cycle Times 879
Electrical 879
Drive System 879
Slew System 879
Undercarriage 879
Capacities 879
Tracks 880
Ground Pressure 880
TORQUE SPECIFICATIONS FOR BOLTS 882
Torque For General SAE Bolts 882
Torque For General Metric Bolts 883
HYDRAULIC CONNECTION SPECIFICATIONS 884
O-ring Face Seal Connection 884
Straight Thread O-ring Fitting 885
Tubelines And Hoses 885
Flare Fitting 885
Port Seal Fitting 886
HYDRAULIC FLUID SPECIFICATIONS 888
Specifications 888
CONVERSIONS 890
Decimal And Millimeter Equivalent Chart 890
U S To Metric Conversion Chart 890
ALPHABETICAL INDEX 892

Need help? Contact: [email protected]

https://vimeo.com/841764978?share=copy

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.M