Bobcat E85 Excavator Service Manual 6990617 (01-20) – PDF DOWNLOAD

Description

Bobcat E85 Excavator Service Manual 6990617 (01-20) – PDF DOWNLOAD

FILE DETAILS:

Bobcat E85 Excavator Service Manual 6990617 (01-20) – PDF DOWNLOAD

Language : English
Pages : 922
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E85 Excavator Service Manual 6990617 (01-20) – PDF DOWNLOAD

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 E85 Excavator Service Manual 6990617 (01-20) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB 27
Description 27
Cab Door 27
Front Window 28
Front Wiper 29
Window Washer Reservoir 29
Right Side Window 30
Heating, Ventilation And Air Conditioning Duct 31
TRANSPORTING THE EXCAVATOR ON A TRAILER 33
Loading And Unloading 33
Fastening 33
RIGHT SIDE COVER 35
Opening And Closing 35
Adjusting The Latch 35
REAR COVER 37
Opening And Closing 37
CENTER COVER 39
Opening And Closing 39
SERVICE SCHEDULE 41
Maintenance Intervals 41
AIR CLEANER SERVICE 43
Daily Check 43
Replacing The Filters 44
CAB FILTERS 45
Cleaning And Maintenance 45
ENGINE COOLING SYSTEM 47
Cleaning 47
Checking Level 48
Removing And Replacing Coolant 49
FUEL SYSTEM 51
Fuel Specifications 51
Biodiesel Blend Fuel 51
Filling The Fuel Tank 52
Fuel Filters 53
Replacing Elements 53
Draining The Fuel Tank 55
Removing Air From The Fuel System 56
ENGINE LUBRICATION SYSTEM 57
Checking And Adding Engine Oil 57
Engine Oil Chart 57
Removing And Replacing Oil And Filter 58
HYDRAULIC SYSTEM 59
Checking And Adding Fluid 59
Hydraulic Fluid Chart 60
Removing And Replacing Hydraulic Filters 60
Removing And Replacing Hydraulic Fluid 64
Checking Swing Motor Gear Box Fluid Level 66
Removing And Replacing Swing Motor Gear Box Fluid 66
LUBRICATING THE EXCAVATOR 67
Lubrication Locations 67
PIVOT PINS 71
Inspection And Maintenance 71
TRAVEL MOTOR 73
Checking And Adding Oil 73
Removing And Replacing Oil 73
DIESEL PARTICULATE FILTER (DPF) SYSTEM 75
Description 75
Forced (Stationary) Regeneration 75
Service Regeneration 78
DPF Ash Cleaning 78
EMERGENCY EXITS 79
Right Rear Side Window 79
Front Window 80
SEAT BELT 81
Inspection And Maintenance 81
CAB TILT PROCEDURE 83
Raising And Lowering 83
CONTROL CONSOLE LOCKOUT 85
Inspection And Maintenance 85
TOWING THE EXCAVATOR 87
Procedure 87
HYDRAULIC SYSTEM 89
HYDRAULIC / HYDROSTATIC SCHEMATICS 93
HYDRAULIC SYSTEM INFORMATION 99
Glossary Of Hydraulic / Hydrostatic Symbols 99
Troubleshooting The Hydraulic Circuit 102
Troubleshooting The Cylinder Circuit 103
Troubleshooting The Swing (Slew) Circuit 104
Troubleshooting The Travel Circuit 105
Description 107
CYLINDER (BOOM) 109
Testing 109
Removal And Installation 112
Parts Identification 115
Disassembly 116
Assembly 124
CYLINDER (ARM) 133
Testing 133
Removal And Installation 135
Parts Identification 138
Disassembly 139
Assembly 147
CYLINDER (BOOM SWING) 155
Testing 155
Removal And Installation 156
Parts Identification 159
Disassembly 160
Assembly 167
CYLINDER (BUCKET) 175
Testing 175
Removal And Installation 175
Parts Identification 178
Disassembly 179
Assembly 188
CYLINDER (BLADE) 197
Testing 197
Removal And Installation 198
Parts Identification 201
Disassembly 202
Assembly 210
CYLINDER (ARTICULATED BOOM) 219
Testing 219
Removal And Installation 221
Parts Identification 223
Disassembly 224
Assembly 230
VALVES (RELIEF) 237
Description 237
VALVES (PORT RELIEF) 239
Testing And Adjusting The Port Relief Valve Pressure 239
VALVE (PRESSURE REDUCING RELIEF) 241
Testing And Adjusting The Pressure Reducing Valve 241
HYDRAULIC CONTROL VALVE 243
Description 243
Removal And Installation 243
Parts Identification 245
Disassembly And Assembly 246
Inlet Valve Section Disassembly And Assembly 251
Boom, Arm And Bucket Valve Section Disassembly And Assembly 254
Left Travel, Right Travel And Blade Valve Section Disassembly And Assembly 258
Auxiliary And Slew Valve Section Disassembly And Assembly 262
Boom Swing Valve Section Disassembly And Assembly 266
Articulated Boom Valve Section Disassembly And Assembly 269
PUMP (HYDRAULIC PISTON) 273
Hydraulic Pump Work Sheet 273
Testing Information 276
Pump Testing 278
Removal And Installation 285
Torque Limiter Valve Parts Identification 287
Torque Limiter Valve Removal And Installation 288
Torque Limiter Valve Disassembly 289
Torque Limiter Valve Assembly 293
Initial Torque Limiter Valve Setting 297
Pump Control Parts Identification 299
Pump Control Removal And Installation 300
Pump Control Disassembly And Assembly 301
Parts Identification 305
Disassembly 306
Assembly 314
PUMP (GEAR) 323
Testing Information 323
Pump Testing 323
Removal And Installation 325
Disassembly And Assembly 327
MANIFOLD ASSEMBLY / ACCUMULATOR 331
Description 331
Removal And Installation 331
Disassembly And Assembly 332
TRAVEL MOTOR 335
Removal And Installation 335
Parts Identification 336
Parts Identification Gear Reduction Hub 337
Disassembly 338
Assembly 352
SWIVEL JOINT 367
Removal And Installation 367
Parts Identification 370
Disassembly 371
Assembly 372
SWING MOTOR 375
Removal And Installation 375
Parts Identification 377
Disassembly And Assembly 378
SWING MOTOR (DRIVE CARRIER) 387
Removal And Installation 387
Parts Identification 388
Disassembly And Assembly 389
CONTROL PATTERN SELECTOR VALVE 393
Removal And Installation 393
Disassembly And Assembly 394
RIGHT CONTROL LEVER (JOYSTICK) 397
Testing 397
Handle Removal And Installation 398
Joystick Assembly Removal And Installation 399
Parts Identification 401
Disassembly And Assembly 402
LEFT CONTROL LEVER (JOYSTICK) 407
Testing 407
Handle Removal And Installation 408
Joystick Assembly Removal And Installation 410
Parts Identification 411
Disassembly And Assembly 412
BLADE CONTROL VALVE 417
Removal And Installation 417
Parts Identification 418
Disassembly And Assembly 419
HYDRAULIC RESERVOIR 423
Removal And Installation 423
OIL COOLER 429
Removal And Installation 429
DIRECT TO TANK VALVE 431
Removal And Installation 431
Disassembly And Assembly 432
SWING MOTOR BRAKE RELEASE 433
Description 433
Removal And Installation 433
Parts Identification 434
Disassembly And Assembly 435
EPPR VALVE 437
Description 437
Removal And Installation 437
Parts Identification 438
Disassembly And Assembly 439
FORCED REGENERATION VALVE 441
Removal And Installation 441
Disassembly And Assembly 442
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 457
Description 457
HYDRAULIC PILOT PRESSURE FILTER ASSEMBLY 459
Removal And Installation 459
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 503
Track Installation 505
Idler Removal And Installation 506
Idler Parts Identification 507
Idler Disassembly 508
Idler Assembly 511
Track Tensioner Removal And Installation 516
Track Tensioner Parts Identification 517
Track Tensioner Disassembly And Assembly 518
Roller Removal And Installation 520
Guide Plate Removal And Installation 522
Lower Roller Parts Identification 523
Lower Roller Disassembly 524
Lower Roller Assembly 527
Upper Roller Parts Identification 533
Upper Roller Disassembly And Assembly 534
Sprocket Removal And Installation 537
TRACK MAINTENANCE 539
Track Damage Identification 539
SWING CIRCLE GEAR 551
Swing Bearing Removal 551
Swing Bearing Installation 552
LOWER TRACK ROLLER 553
Parts Identification 553
Disassembly 554
Assembly 557
UPPER TRACK ROLLER 563
Parts Identification 563
Disassembly And Assembly 564
UPPERSTRUCTURE AND SWING SECTION 567
UPPERSTRUCTURE 571
Removal 571
Installation 573
UPPERSTRUCTURE SIDE COVER (LEFT) 575
Removal And Installation 575
UPPERSTRUCTURE SIDE COVER (RIGHT) 577
Removal And Installation 577
CAB 579
Removal And Installation 579
Door Removal And Installation 589
Front Window Removal And Installation 590
Lower Front Window Removal And Installation 591
Glass Installation 592
Front Window Strut Removal And Installation 597
Front Window Slide Bar Removal And Installation 598
Cab Tilt Assembly Removal And Installation 599
Cab Tilt Parts Identification 600
Cab Tilt Assembly Disassembly And Assembly 601
Headliner Removal And Installation 602
SEAT 607
Seat Removal And Installation 607
Seat Mount Removal And Installation 608
RIGHT CONSOLE 611
Console Cover Removal And Installation 611
LEFT CONSOLE 613
Lower Console Cover Removal And Installation 613
Upper Console Cover Removal And Installation 614
Gas Strut Removal And Installation 615
Lock Lever Removal And Installation 616
Lock Lever Disassembly And Assembly 617
Console Removal And Installation 618
CENTER COVER 619
Removal And Installation 619
CENTER ACCESS COVER 621
Removal And Installation 621
COUNTERWEIGHT 623
Removal And Installation 623
FLOOR MAT 625
Removal And Installation 625
FUEL TANK 627
Removal And Installation 627
HORN 631
Removal And Installation 631
SWING FRAME 633
Removal And Installation 633
Bushing Removal 637
Bushing Installation 638
BOOM 639
Removal And Installation 639
Bushing Removal And Installation 640
BOOM (ARTICULATED) (OPTIONAL) 641
Removal And Installation 641
ARM 643
Removal And Installation 643
Arm To Boom Bushing Removal And Installation 644
Bucket And Link Bushing Removal And Installation 645
QUICK COUPLER (KLAC™ SYSTEM) 647
Troubleshooting 647
Daily Inspection 647
Removal And Installation 648
Parts Identification 650
Disassembly 651
Assembly 653
QUICK COUPLER (LEHNHOFF® SYSTEM) 655
Troubleshooting 655
Daily Inspection 655
Removal (MS03 And MS08) 656
Installation (MS03 And MS08) 657
Parts Identification (MS03) 658
Disassembly And Assembly (MS03) 659
Parts Identification (MS08) 660
Disassembly (MS08) 661
Assembly (MS08) 665
BUCKET 669
Bucket Teeth Removal And Installation 669
Bucket Side Cutting Edge Removal And Installation 670
RIGHT SIDE COVER 671
Removal And Installation 671
Latch Adjustment 672
REAR COVER 673
Removal And Installation 673
ELECTRICAL SYSTEM AND ANALYSIS 675
ELECTRICAL SCHEMATICS 677
ELECTRICAL SYSTEM INFORMATION 679
Troubleshooting Chart 679
Description 680
Fuse And Relay Location / Identification 680
Master Disconnect Switch 681
BATTERY 683
Battery Maintenance 683
Using A Booster Battery (Jump Starting) 684
Removing And Installing Battery 685
ALTERNATOR 687
Belt Adjustment 687
Belt Replacement 687
Charging System Inspection 688
Alternator Voltage Testing 690
Removal And Installation 691
STARTER 693
Testing 693
Removal And Installation 694
Parts Identification 696
STARTER RELAY 697
Removal And Installation 697
LIGHTS 699
Boom Light Removal And Installation 699
Boom Light Bulb Replacement 699
CONSOLE LOCKOUT SWITCH 701
Testing / Adjustment 701
Removal And Installation 702
FUEL LEVEL SENDER 703
Removal And Installation 703
DIAGNOSTIC SERVICE CODES 705
Service Codes List 705
Failure Mode Indicator Information 711
Code Retrieval Through The Dash 712
DIAGNOSTIC TOOL 715
Installation 715
INSTRUMENT PANEL 717
Removal And Installation 717
Setting The Operator Four Digit Password 718
KEY SWITCH 721
Removal And Installation 721
RIGHT CONSOLE SWITCH COVER 723
Removal And Installation 723
Rocker Switch Removal And Installation 725
Speed Control Removal And Installation 725
Auxiliary Power Outlet Removal And Installation 726
WIPER MOTOR 727
Removal And Installation 727
MOTION ALARM SYSTEM 729
Description 729
Inspecting 729
Adjusting Switch Position 730
FUEL TRANSFER PUMP 731
Removal And Installation 731
AUTO IDLE PRESSURE SWITCH 733
Removal And Installation 733
ENGINE CONTROL UNIT (ECU) 735
Description 735
Removal And Installation 736
VEHICLE CONTROL UNIT (VCU) 739
Removal And Installation 739
ENGINE SERVICE 741
ENGINE INFORMATION 743
Description 743
Specifications 744
Sensor Location 750
Troubleshooting 752
Engine Removal And Installation 753
Compression – Testing 760
ENGINE SPEED CONTROL 763
Adjustment 763
DIESEL PARTICULATE FILTER (DPF) SYSTEM 765
Description 765
Removal And Installation 766
AIR CLEANER 769
Housing Removal And Installation 769
ENGINE COOLING SYSTEM 771
Radiator Removal And Installation 771
Radiator Disassembly And Assembly 775
Fan Removal And Installation 777
Fuel Cooler Removal And Installation 778
Water Pump Removal And Installation 779
Water Pump Parts Identification 780
Thermostat Removal And Installation 781
Temperature Switch – Testing 781
Temperature Sensor – Testing 782
Thermostat – Testing 782
LUBRICATION SYSTEM 783
Oil Pan Removal And Installation 783
Oil Pump Removal And Installation 784
Oil Pump Inspection 785
Engine Oil Pressure – Testing 786
Crankcase Ventilation Filter Removal And Installation 787
FUEL SYSTEM 789
Electronic Fuel Injection Schematic – Components 789
Fuel Supply Pump Removal And Installation 790
Fuel Rail Assembly Removal And Installation 795
Fuel Injector Removal And Installation 797
CYLINDER HEAD 799
Valve Clearance Adjustment 799
Cylinder Head Removal And Installation 801
Cylinder Head Disassembly And Assembly 803
Cylinder Head – Servicing 806
Valve Guide – Inspection 806
Intake And Exhaust Valve – Inspection 807
Valve Stem Bend – Inspection 808
Valve Face And Seat 808
Valve Spring – Inspection 809
Push Rod – Inspection 809
Rocker Arm – Inspection 810
CRANKSHAFT AND PISTONS 811
Piston And Connecting Rod Removal And Installation 811
Piston And Connecting Rod – Servicing 815
Cylinder Bore – Inspection 818
Crankshaft End Play 819
Crankshaft And Bearings Removal And Installation 819
Crankshaft And Bearings – Servicing 820
CAMSHAFT AND TIMING GEARS 823
Timing Gearcase Cover Removal And Installation 823
Timing Gear Backlash – Inspection 824
Idler Gear And Camshaft Removal And Installation 825
Valve Tappet – Servicing 826
Camshaft – Servicing 827
Idler Gear And Shaft – Servicing 828
EXHAUST GAS RECIRCULATION (EGR) VALVE 829
Description 829
Removal And Installation 830
EGR Valve Testing And Cleaning 831
Lead (Reed) Valve Cleaning 831
EGR Cooler Cleaning 832
Intake Throttle 833
GLOW PLUGS 835
Testing 835
Removal And Installation 836
ENGINE FLYWHEEL 837
Hydraulic Pump Coupler Removal And Installation 837
Flywheel Removal And Installation 838
Flywheel Ring Gear Removal And Installation 838
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 839
AIR CONDITIONING SYSTEM FLOW 841
Description 841
Chart 842
Components 843
Safety Equipment 846
REGULAR MAINTENANCE 847
Filters 847
Belt Adjustment 847
Belt Replacement 848
Condenser 849
Air Conditioning Service Chart 850
Evaporator / Heater Coil 851
TROUBLESHOOTING 853
Blower Motor Does Not Operate 853
Blower Motor Operates Normally, But Air Flow Is Insufficient 853
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 853
The Compressor Operates Improperly Or Not At All 853
Gauge Pressure Related Troubleshooting 854
Temperature / Pressure Chart 856
Poor A/C Performance 857
HVAC Repair And Leaks 858
SYSTEM CHARGING AND RECLAMATION 859
Reclamation And Charging With Recovery / Charging Unit 859
Charging With A Manifold Gauge Set 862
COMPRESSOR 865
Removal And Installation 865
Oil 867
Oil Check 868
CONDENSER 871
Removal And Installation 871
RECEIVER / DRIER 873
Receiver / Drier Removal And Installation 873
Pressure Switch Removal And Installation 874
EVAPORATOR / HEATER UNIT 875
Removal And Installation 875
THERMOSTAT 877
Inspection 877
EXPANSION VALVE 879
Removal And Installation 879
BLOWER FAN 881
Removal And Installation 881
HEATER VALVE 883
Removal And Installation 883
HVAC CONTROLLER 885
Removal And Installation 885
SPECIFICATIONS 887
EXCAVATOR SPECIFICATIONS 889
Dimensions 889
Dimensions – Standard Arm 891
Dimensions – Long Arm 892
Dimensions – Articulated Boom 893
Performance 894
Controls 894
Engine 894
Hydraulic System 895
Hydraulic Cylinders 895
Hydraulic Cycle Times 896
Electrical 896
Drive System 896
Slew System 896
Undercarriage 896
Crawler Track Design 896
Capacities 896
Fuel Tank 896
Track 897
Type 897
Ground Pressure 897
TECHNICAL SERVICE GUIDE SPECIFICATIONS 899
Engine 899
Engine Torques 899
Cooling System 899
Excavator Torques 899
TORQUE SPECIFICATIONS FOR BOLTS 901
Torque For General SAE Bolts 901
Torque For General Metric Bolts 902
HYDRAULIC CONNECTION SPECIFICATIONS 903
O-ring Face Seal Connection 903
Straight Thread O-ring Fitting 904
Tubelines And Hoses 904
Flare Fitting 904
Port Seal Fitting 905
HYDRAULIC FLUID SPECIFICATIONS 907
Specifications 907
CONVERSIONS 909
Decimal And Millimeter Equivalent Chart 909
U S To Metric Conversion Chart 909
SERVICE TOOLS REQUIRED 911
Remote Start Tools 911
Hydraulic Tools 912
Engine Tools 915
Electrical Tools 917
General Tools 917
HVAC Tools 918
ALPHABETICAL INDEX 919

Customer Support: [email protected]

https://vimeo.com/841763864?share=copy

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

S.M