Bobcat E80 AETB11001, AET311001 & Up 6987194 (2-11) (Preview)
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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