A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• 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