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Bobcat E80 Excavator Service Manual (SN AETB11001-AETB99999)

Format: PDF (Printable Document)

File Language: English

File Pages: 893

File Size: 26.48 MB (Speed Download Link)

Brand: Bobcat

Model: E80 Excavator

Book No: 6987194

Serial No: SN AETB11001-AETB99999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat E80 Excavator Service Manual (SN AETB11001-AETB99999)

An E80 is a mid-size mini excavator, good for trenching utilities, footings, and loading trucks where a big machine won't fit. Around my shop, the service manual comes out when something's leaking, dead, or half torn apart and I don't want to guess. Folks buying this are usually out of warranty and trying to cut dealer bills and downtime by doing real repairs themselves.

What this manual helps you do

  • Diagnose hydraulic issues, trace oil flow, and check pressures at the right test ports before you start throwing parts at it
  • Follow step-by-step teardown and reassembly on major components like pumps, drive motors, cylinders, and final drives
  • Troubleshoot electrical problems using wiring diagrams and connector pinouts so you can track down shorts, opens, and sensor faults
  • Set and verify adjustments on things like pilot controls, travel straightness, swing functions, and machine settings after a repair
  • Replace and torque critical hardware on the engine, undercarriage, and upperstructure using the correct sequences and specs

Who this is for

This is for a small contractor, owner-operator, field tech, or shop mechanic who's actually turning wrenches on a Bobcat E80 in the AETB11001-AETB99999 serial range. If you only want basic controls, capacities, and safety info, you want the operator's handbook instead, not this manual.

FAQ

Q: Is this a searchable PDF, and can I read the wiring diagrams clearly?

A: Yes, it's a PDF you can search by keyword, and the wiring diagrams are readable when you zoom in on a laptop or tablet.

Q: How do I know if it fits my exact E80?

A: Check your machine's serial number plate. If it falls between AETB11001 and AETB99999, this is the right manual.

Q: Is this what I need for real repairs, or just maintenance?

A: This is the service manual, so it's aimed at diagnostics and repair work, not just routine maintenance.

Bottom line: If your E80's serial number is in that AETB11001-AETB99999 window and you're doing your own repairs, this is the manual you want. If the serial doesn't match, skip it.

📘 Show Index

Table of Contents:

  • 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 UNDERCARRIAGE COMPONENTS (STEEL TRACK)
      • 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
      • Guide Plate 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
  • 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

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