Bobcat E85 Excavator Service Manual 7320318 (08-20) – PDF DOWNLOAD

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Bobcat E85 Excavator Service Manual 7320318 (08-20) – PDF DOWNLOAD

FILE DETAILS:

Bobcat E85 Excavator Service Manual 7320318 (08-20) – PDF DOWNLOAD

Language : English
Pages : 952
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E85 Excavator Service Manual 7320318 (08-20) – 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 7320318 (08-20) – 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 (ROPS / TOPS) 27
Description 27
Cab Door 28
Front Window 29
Front Wiper 30
Window Washer Reservoir 30
Right Side Windows 31
OPERATOR CAB (ROPS / TOPS / FOPS) 33
Description 33
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TAILGATE 37
Opening And Closing 37
Adjusting The Latch 37
RIGHT SIDE COVER 39
Opening And Closing 39
CENTER COVER 41
Removal And Installation 41
SERVICE SCHEDULE 43
Maintenance Intervals 43
AIR CLEANER SERVICE 45
Replacing The Filter Elements 45
CAB FILTERS 47
Cleaning And Maintenance 47
ENGINE COOLING SYSTEM 49
Cleaning 49
Checking Level 50
Removing And Replacing Coolant 51
FUEL SYSTEM 53
Fuel Specifications 53
Biodiesel Blend Fuel 53
Filling The Fuel Tank 54
Fuel Filters 55
Removing Air From The Fuel System 56
Replacing The Fuel Tank Breather 56
Draining The Fuel Tank 57
ENGINE LUBRICATION SYSTEM 59
Checking And Adding Engine Oil 59
Engine Oil Chart 59
Removing And Replacing Oil And Filter 60
HYDRAULIC SYSTEM 61
Checking And Adding Hydraulic Oil 61
Hydraulic / Hydrostatic Fluid Chart 62
Removing And Replacing The Hydraulic Filters 62
Removing And Replacing The Hydraulic Fluid 64
Checking Swing Motor Gear Box Fluid Level 65
Removing And Replacing Swing Motor Gear Box Fluid 65
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
EMERGENCY EXIT 75
Right Side Rear Window 75
Front Window 75
SEAT BELT 77
Inspection And Maintenance 77
CONTROL CONSOLE LOCKOUTS 79
Inspection And Maintenance 79
TOWING THE EXCAVATOR 81
Procedure 81
REMOTE START TOOL KIT – MEL1563 83
Remote Start Tool – MEL1563 83
Service Tool Harness Control – MEL1565 84
Service Tool Harness Communicator – MEL1566 85
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 87
Description 87
Remote Start Tool (Service Tool) – 7022042 88
Excavator Service Tool Harness – 6689747 89
Computer Service Tool Harness – 6689746 90
HYDRAULIC SYSTEM 91
HYDRAULIC / HYDROSTATIC SCHEMATICS 95
HYDRAULIC SYSTEM INFORMATION 99
Glossary Of Hydraulic / Hydrostatic Symbols 99
Troubleshooting The Hydraulic Circuit 102
Troubleshooting The Cylinder Circuit 103
Troubleshooting The Swing (Upperstructure Slew) Circuit 104
Troubleshooting The Travel Circuit 105
CYLINDER (BOOM) 107
Testing 107
Removal And Installation 109
Parts Identification 111
Disassembly 112
Assembly 120
CYLINDER (ARM) 129
Testing 129
Removal And Installation 131
Parts Identification 133
Disassembly 134
Assembly 141
CYLINDER (BOOM SWING) 149
Testing 149
Removal And Installation 150
Parts Identification 152
Disassembly 153
Assembly 155
CYLINDER (BUCKET) 159
Testing 159
Removal And Installation 159
Parts Identification 162
Disassembly 163
Assembly 171
CYLINDER (BLADE) 179
Testing 179
Removal And Installation 180
Parts Identification 181
Disassembly 182
Assembly 190
CYLINDER (CLAMP) 197
Testing 197
Removal And Installation 198
Parts Identification 199
Disassembly 200
Assembly 203
VALVES (MAIN RELIEF) 207
Testing And Adjusting 207
VALVES (PORT RELIEF) 209
Testing And Adjusting Port Relief Valve Pressure 209
VALVES (CROSS PORT RELIEF) 211
Testing And Adjusting 211
Removal And Installation 214
VALVES (PRESSURE REDUCING) 215
Testing And Adjusting 215
HYDRAULIC CONTROL VALVE 217
Description 217
Removal And Installation 217
Parts Identification 220
Disassembly And Assembly 221
Inlet Valve Section Disassembly And Assembly 225
Valve Section Disassembly And Assembly 228
HYDRAULIC PUMP 231
Hydraulic Pump Work Sheet 231
Pump Testing 235
Removal And Installation 247
Coupler Removal And Installation 249
Hydraulic Pump Startup 250
Torque Limiter Valve Parts Identification 252
Torque Limiter Valve Removal 253
Torque Limiter Valve Disassembly 254
Torque Limiter Valve Assembly 258
Initial Torque Limiter Valve Setting 261
Torque Limiter Valve Installation 263
Pump Control Parts Identification 264
Pump Control Removal And Installation 265
Pump Control Disassembly And Assembly 266
Parts Identification 271
Disassembly 272
Assembly 281
MANIFOLD ASSEMBLY / ACCUMULATOR 291
Description 291
Removal And Installation 292
Parts Identification 293
Disassembly And Assembly 294
TRAVEL MOTOR 301
Removal And Installation 301
Parts Identification 302
Parts Identification Gear Reduction Hub 303
Disassembly 304
Assembly 315
SWIVEL JOINT 327
Removal And Installation 327
Parts Identification 328
Disassembly And Assembly 329
SWING MOTOR 333
Removal And Installation 333
Parts Identification 335
Disassembly And Assembly 336
SWING MOTOR (DRIVE CARRIER) 345
Removal And Installation 345
Parts Identification 346
Disassembly And Assembly 347
CONTROL PATTERN SELECTOR VALVE 351
Removal And Installation 351
Parts Identification 352
Disassembly And Assembly 353
RIGHT CONTROL LEVER (JOYSTICK) 355
Testing 355
Handle Removal And Installation 356
Joystick Assembly Removal And Installation 358
Parts Identification 359
Disassembly 360
Assembly 365
LEFT CONTROL LEVER (JOYSTICK) 371
Testing 371
Handle Removal And Installation 372
Joystick Assembly Removal And Installation 374
Parts Identification 375
Disassembly 376
Assembly 381
HYDRAULIC FILTER MOUNT 387
Removal And Installation 387
HYDRAULIC RESERVOIR 389
Removal And Installation 389
OIL COOLER 393
Removal And Installation 393
BLADE CONTROL LEVER 395
Handle Removal And Installation 395
Removal And Installation 397
Parts Identification 399
Disassembly And Assembly 400
CASE DRAIN FILTER MOUNT 405
Removal And Installation 405
TRAVEL CONTROL VALVE 407
Removal And Installation 407
Parts Identification 408
Disassembly And Assembly 409
REMOVING AIR FROM THE HYDRAULIC SYSTEM 415
Procedure 415
MANIFOLD (PIN GRABBER) 417
Removal And Installation 417
Parts Identification 418
Disassembly And Assembly 419
SECONDARY AUXILIARY VALVE 421
Removal And Installation 421
Parts Identification 423
Disassembly And Assembly 424
VALVE (BOOM LOCK) 427
Removal And Installation 427
VALVE (ARM LOCK) 429
Removal And Installation 429
UNDERCARRIAGE 431
BLADE 433
Removal And Installation 433
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 435
Description 435
Track Lug Height 435
Checking Tension 436
Adjusting Tension 437
Track Removal And Installation 438
Idler Removal And Installation 440
Idler Parts Identification 441
Idler Disassembly 442
Idler Assembly 445
Track Tensioner Removal And Installation 450
Track Tensioner Parts Identification 451
Track Tensioner Disassembly And Assembly 452
Roller Removal And Installation 453
Lower Roller Parts Identification 454
Lower Roller Disassembly 455
Lower Roller Assembly 458
Upper Roller Parts Identification 464
Upper Roller Disassembly And Assembly 465
Sprocket Removal And Installation 468
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 469
Description 469
Checking Tension 470
Adjusting Tension 471
Track Removal 472
Track Installation 474
Idler Removal And Installation 475
Idler Parts Identification 476
Idler Disassembly 477
Idler Assembly 480
Track Tensioner Removal And Installation 485
Track Tensioner Parts Identification 486
Track Tensioner Disassembly And Assembly 487
Roller Removal And Installation 488
Lower Roller Parts Identification 489
Lower Roller Disassembly 490
Lower Roller Assembly 493
Upper Roller Parts Identification 499
Upper Roller Disassembly And Assembly 500
Sprocket Removal And Installation 503
Guide Plate Removal And Installation 503
TRACK UNDERCARRIAGE COMPONENTS (SEGMENTED TRACK) 505
Description 505
Rubber Pad Removal And Installation 505
Guide Plate Removal And Installation 506
TRACK MAINTENANCE 507
Track Damage Identification 507
SWING CIRCLE GEAR 519
Swing Bearing Removal 519
Swing Bearing Installation 520
UPPERSTRUCTURE AND SWING SECTION 521
UPPERSTRUCTURE 523
Removal 523
Installation 525
CAB 527
Removal And Installation 527
Door Removal And Installation 531
Front Window Removal And Installation 532
Front Window Disassembly And Assembly 533
Front Window Adjustment 535
Glass Removal 538
Glass Installation 539
SEAT 545
Removal And Installation 545
RIGHT CONSOLE 547
Console Cover Removal And Installation 547
LEFT CONSOLE 553
Lower Console Cover Removal And Installation 553
Upper Console Cover Removal And Installation 554
Compression Spring Removal And Installation 557
Lock Lever Removal And Installation 559
Console Removal And Installation 559
LEFT UPPERSTRUCTURE COVER 561
Removal And Installation 561
RIGHT UPPERSTRUCTURE COVER 563
Removal And Installation 563
COUNTERWEIGHT 565
Removal And Installation 565
TRAVEL LEVERS AND PEDALS 567
Removal And Installation 567
Disassembly And Assembly 568
FLOOR MAT 569
Removal And Installation 569
FUEL TANK 571
Removal And Installation 571
Fuel Tank Fitting Removal And Installation 572
HORN 573
Removal And Installation 573
SWING FRAME 575
Removal And Installation 575
Boom Swing Frame Hose Routing 578
Bushing Removal 579
Bushing Installation 580
BOOM 581
Removal And Installation 581
ARM 583
Removal And Installation 583
Arm To Boom Bushing Removal And Installation 584
Arm To Bucket And Bucket Link Bushing Removal And Installation 585
BUCKET 587
Bucket Teeth Removal And Installation 587
Bucket Side Cutting Edge Removal And Installation 588
CLAMP 589
Removal And Installation 589
TAILGATE 591
Removal And Installation 591
Latch Removal And Installation 592
QUICK COUPLER (PIN GRABBER) 593
Troubleshooting 593
Daily Inspection 594
Removal And Installation 595
Parts Identification 596
Disassembly And Assembly 597
RIGHT SIDE COVER 599
Removal And Installation 599
Latch Removal And Installation 600
TOOL BOX 601
Removal And Installation 601
CENTER COVER 603
Removal And Installation 603
ELECTRICAL SYSTEM AND ANALYSIS 605
ELECTRICAL SCHEMATICS 609
ELECTRICAL SYSTEM INFORMATION 667
Troubleshooting Chart 667
Description 668
Fuse And Relay Location / Identification 668
Shut-Off Switch 670
BATTERY 671
Servicing 671
Using A Booster Battery (Jump Starting) 672
Removing And Installing The Battery 673
ALTERNATOR 675
Belt Adjustment 675
Belt Replacement 675
Charging System Inspection 676
Alternator Voltage Testing 677
Low Voltage Testing 677
High Voltage Testing 678
Removal And Installation 679
Parts Identification 681
STARTER 683
Testing 683
Removal And Installation 684
Parts Identification 685
LIGHTS 687
Removal And Installation 687
Boom Light Removal And Installation 688
Boom Light Bulb Replacement 688
MAGNETIC LOCKOUT SENSOR 689
Removal And Installation 689
FUEL LEVEL SENDER 691
Lower Fuel Level Sender Removal And Installation 691
Upper Fuel Level Sender Removal And Installation 691
Testing 692
DIAGNOSTIC SERVICE CODES 693
Viewing Service Codes 693
Service Codes List 694
CONTROL PANEL SETUP 701
Panel Setup (Deluxe Instrument Panel) 701
Password Setup (Keyless Start Panel) 707
Password Setup (Deluxe Instrument Panel) 708
Password Lockout Feature 709
Maintenance Clock 710
INSTRUMENT PANEL 713
Removal And Installation 713
CONTROLLER (GATEWAY AND AUXILIARY) 715
Description 715
Gateway Controller Removal And Installation 715
Auxiliary Controller Removal And Installation 716
CONTROLLER (PIN GRABBER) 717
Removal And Installation 717
ENGINE CONTROL UNIT (ECU) 719
Description 719
Cleaning 720
Removal And Installation 721
KEY SWITCH 723
Removal And Installation 723
WIPER MOTOR 725
Removal And Installation 725
MOTION ALARM SYSTEM 727
Description 727
Inspecting 727
Adjusting Switch Position 728
SERVICE PC (LAPTOP COMPUTER) 729
Connecting The Remote Start Tool 729
Connecting Remote Start Tool (Service Tool) 729
SHUT-OFF SWITCH 731
Removal And Installation 731
TRAVEL MOTOR AUTO-SHIFT 733
Auto-Shift Drive System (If Equipped) 733
Troubleshooting 734
AUTO IDLE PRESSURE SENSOR 737
Description 737
Removal And Installation 738
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 739
Description 739
Controller Removal And Installation 739
Antenna Removal And Installation 742
Procedure 743
ENGINE SERVICE 745
ENGINE INFORMATION 747
Description 747
Specifications 748
Sensor Location 750
Torque Values 756
Troubleshooting 758
Engine Removal And Installation 760
Compression – Testing Using The Glow Plug Adapter 768
Compression – Testing Using The Injector Adapter 770
Injector Signal – Testing 772
Injector Signal – Testing (In-Line) 774
Oil Pressure Testing (At Oil Sensor On Block) 776
Oil Pressure Testing (At Turbocharger Oil Inlet) 779
DIESEL OXIDATION CATALYST (DOC) 781
Removal And Installation 781
AIR CLEANER 783
Housing Removal And Installation 783
ENGINE COOLING SYSTEM 785
Oil Cooler / Radiator Removal And Installation 785
Fan Removal And Installation 788
Water Pump Removal And Installation 789
Thermostat Housing Removal And Installation 790
Testing The Thermostat 791
LUBRICATION SYSTEM 793
Description 793
Oil Pan Removal And Installation 794
Oil Pump Removal And Installation 795
Oil Pump Relief Valve Description 796
Oil Pump Relief Valve Removal And Installation 796
Oil Cooler Removal And Installation 797
Oil Filter Head Removal And Installation 798
Oil Cooler Bypass Description 799
Oil Cooler Bypass Removal And Installation 799
FUEL SYSTEM 801
Description 801
Transfer Pump / High Pressure Pump Removal And Installation 802
Fuel Temperature Sensor Removal And Installation 805
Fuel Cooler Removal And Installation 806
Fuel Recirculation Valve Removal And Installation 807
Fuel Injector Removal And Installation 808
Removing Air From The Fuel System 810
CYLINDER HEAD 811
Glow Plugs Testing 811
Glow Plug Removal And Installation 812
Valve Clearance Adjustment 813
Cylinder Head Removal And Installation 815
Cylinder Head Disassembly And Assembly 819
Cylinder Head Inspection 820
Cylinder Head Top Clearance 821
Valve Step Height 822
Valve Stem Height 822
Valve Guide 823
Valve 823
Valve Spring 824
Rocker Arm Shaft Disassembly And Assembly 825
Rocker Arm Shaft Inspection 826
Push Rod Inspection 826
CRANKSHAFT AND PISTONS 827
Piston And Connecting Rod Removal And Installation 827
Piston And Connecting Rod Inspection 828
Crankshaft Removal And Installation 830
Cylinder Block Inspection 833
Crankshaft Inspection 835
Connecting Rod Inspection 835
Engine Component Class 836
CAMSHAFT 839
Removal And Installation 839
Inspecting 840
GEARCASE 843
Gearcase Cover Removal And Installation 843
Gear Backlash 844
Gear Timing 845
Idle Gear Removal And Installation 846
Idle Gear Inspection 846
TURBOCHARGER 847
Description 847
Removal And Installation 847
Inspection 850
FLYWHEEL AND HOUSING 851
Hydraulic Pump Coupler Removal And Installation 851
Flywheel Removal And Installation 853
Ring Gear Removal And Installation 853
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 855
Removal And Installation 855
HEATING, VENTILATION AND AIR CONDITIONING 859
AIR CONDITIONING SYSTEM FLOW 861
Description 861
Chart 862
Components 863
Safety Equipment 866
REGULAR MAINTENANCE 867
Cab Filters 867
Air Conditioning Compressor Belt Adjustment 868
Air Conditioning Compressor Belt Replacement 868
Condenser 869
Air Conditioning Lubrication 870
Evaporator / Heater Coil 870
Air Conditioning Service Chart 871
TROUBLESHOOTING 873
Blower Motor Does Not Operate 873
Blower Motor Operates Normally, But Air Flow Is Insufficient 873
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 873
The Compressor Operates Improperly Or Not At All 873
Gauge Pressure Related Troubleshooting 874
Temperature / Pressure Chart 875
Poor A/C Performance 876
HVAC Repair And Leaks 877
Electrical System 877
Engine Coolant Bypassing The Heater Valve 879
SYSTEM CHARGING AND RECLAMATION 881
Refrigerant Identification 881
Reclamation And Charging With Recovery / Charging Unit 883
COMPRESSOR 885
Removal And Installation 885
Oil 886
Oil Check 887
CONDENSER 889
Removal And Installation 889
RECEIVER / DRIER 891
Receiver / Drier Removal And Installation 891
Pressure Switch Removal And Installation 892
EVAPORATOR / HEATER UNIT 893
Removal And Installation 893
THERMOSTAT 895
Description 895
Removal And Installation 896
EXPANSION VALVE 899
Removal And Installation 899
EVAPORATOR COIL 901
Removal And Installation 901
HEATER COIL 903
Removal And Installation 903
BLOWER FAN 905
Removal And Installation 905
HEATER VALVE 907
Removal And Installation 907
HVAC DUCT 909
Removal And Installation 909
SPECIFICATIONS 911
EXCAVATOR SPECIFICATIONS 913
Machine Dimensions 913
Performance 915
Controls 915
Engine 916
Hydraulic System 917
Hydraulic Cylinders 917
Hydraulic Cycle Times 918
Drive System 918
Slew System 918
Undercarriage 918
Capacities 918
Electrical 919
Tracks 919
Ground Pressure 919
TECHNICAL SERVICE GUIDE SPECIFICATIONS 921
Engine 921
Engine Torques 921
Cooling System 921
Excavator Torques 921
TORQUE SPECIFICATION FOR BOLTS 923
Torque For General SAE Bolts 923
Torque For General Metric Bolts 924
HYDRAULIC CONNECTION SPECIFICATIONS 925
O-ring Face Seal Connection 925
Straight Thread O-ring Fitting 925
Tubelines And Hoses 926
Flare Fitting 926
O-ring Flare Fitting 927
Port Seal Fitting 929
Push To Connect Fittings 930
HYDRAULIC FLUID SPECIFICATIONS 933
Specifications 933
CONVERSIONS 935
Decimal And Millimeter Equivalent Chart 935
U S To Metric Conversion Chart 936
SERVICE TOOLS REQUIRED 937
Remote Start Tools 937
Hydraulic Tools 938
Engine Tools 941
Electrical Tools 943
General Tools 944
HVAC Tools 945
ALPHABETICAL INDEX 947
SERVICE SCHEDULE SYMBOLS 951

Customer Support: [email protected]

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M