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 SYSTEM™)
        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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