PDF Service Manual Bobcat E145 Compact Excavator - 8 MB
This service manual is the ultimate guide for repairing and maintaining the Bobcat E145 Compact Excavator (S/N B4WU11001 & Above).
It provides detailed, factory-approved procedures for diagnostics, disassembly, and reassembly of all major components.
Technicians will find comprehensive information on the hydraulic and electrical systems, complete with schematics.
Following this manual will ensure that all repairs are done correctly, maximizing the excavator's performance and lifespan.
It's an indispensable tool for any professional Bobcat mechanic.
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Service Manual
Compact Excavator
E145 S/N B4WU11001 & Above
7387076enUS (07-20) (B) Printed in U.S.A. ©2020 Bobcat Company. All rights reserved.
NA T4-B
--- Page 3 ---
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Flying or Falling Objects
On work sites where there is a potential hazard that flying or
falling objects can hit operator's cabin, select and use a guard to
match operating conditions for additional operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards. Contact
your Bobcat dealer for information on available protective
guards. HAOA110L
Figure 2
To prevent bystanders from being struck by flying objects, keep
bystanders out of work area.
HAOA100L
Figure 3
E145 Track Excavator Maintenance Safety
1-1-9
--- Page 4 ---
Work Site
Before starting operations, thoroughly check work area for any
hazards, such as underground utility lines, overhead electrical
lines, unstable ground, excessive slopes, etc.
Before starting engine and moving machine, make sure that no
one is underneath machine, around machine, or on machine.
Know width and length of your machine and work equipment to
maintain proper clearance when you operate machine or work DANGER
equipment near fences or near boundary obstacles. No Entry
EX1403489
Know appropriate work site hand signals and site crew that are Figure 20
authorized to give hand signals. Follow hand signals from only
one person.
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around work site.
Erect barricades or fences, post "No Entry" signs, and take other
steps to prevent bystanders from coming close to or entering
work site. If bystanders come too close to a moving machine,
they may be struck or caught by machine, and this can result in
death or serious injury.
E145 Track Excavator Maintenance Safety
1-1-23
--- Page 5 ---
Engine Stop
Turn engine starter switch to "O" (OFF) position and remove
engine starter switch key.
Before lowering any equipment with engine stopped, clear area
around equipment of all bystanders.
Do not stop engine immediately after the machine has been
operated under load. This can cause overheating and
accelerated wear of engine components.
After the machine is parked, allow engine to run for five minutes
before stopping the engine. This allows hot areas of engine to
cool gradually.
• Do not leave operator's seat when there is a raised load.
Parking Machine
Park machine on firm and level ground away from traffic and
away from high walls, drop-offs and any area of potential water
accumulation or runoff. 120
If parking on inclines is unavoidable, block crawler tracks to
prevent movement. Lower bucket or other working attachment
completely to ground.
Block
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that
passing traffic can see machine clearly. Park machine so
machine, flags, signs and fences do not obstruct traffic.
After front attachment has been lowered to an overnight storage
position and all switches and operating controls are in "OFF"
position, safety lever must be moved to "LOCK" position. This
will disable all pilot control functions.
Unlock
Always close door of operator's cabin and lock all equipment to
prevent any unauthorized person from operating the machine.
Lock EX1403197
Figure 35
The hydraulic system remains pressurized provided the
accumulator is charged even when engine is not running.
Accumulator pressure should decrease in a short time
(approximately one minute). While hydraulic system maintains a
charge, hydraulic work tools and machine controls remain
functional.
Always move safety lever to "LOCK" position before stopping off
engine or immediately after engine stops running.
EX1403198
Figure 36
E145 Track Excavator Maintenance Safety
1-1-37
--- Page 6 ---
Underground Operation
If excavation is in an underground location or in a building, make
sure there is adequate overhead clearance, and adequate
ventilation.
Special equipment and engines may be required in some
countries. Contact your Bobcat dealer for more information.
Check that there is sufficient room for machine and load.
Move slowly.
Make sure that authorities or companies responsible for
underground cables, utilities, and electrical lines have been
contacted and that their instructions are followed. Also check
which rules apply to ground crew regarding exposing cables,
utilities and electrical lines.
EX1403203
Consider all electrical cables as live.
Figure 49
Working in Water
IMPORTANT
Do not exceed maximum permissible water depth. The
water level must not reach higher than centerline of upper
track roller(s) (1, Figure 50).
After working in water, lubricate all lubrication points on 1 EX1403204
undercarriage, which have been underwater so water is Figure 50
removed. Check that no water has entered travel gearboxes and
undercarriage components.
Working in Contaminated Environment
When working within area which is contaminated or where there
is a health risk, check local regulations and contact your Bobcat
dealer for assistance with identifying what additional safety
precautions need to be taken.
E145 Track Excavator Maintenance Safety
1-1-51
--- Page 7 ---
2
1
3
5
4
EX1500578_BCT
Figure 2
Reference Reference
Description Description
Number Number
1 Engine 4 Main Pump
2 Radiator 5 SCR Muffler
3 Air Cleaner
E145 Specifications
2-1-7
--- Page 8 ---
OPERATIONAL PERFORMANCE TEST
Hydraulic Cylinder Cycle Time
Summary
1. Check the overall operational performance of the front
attachment hydraulic system (between the hydraulic
pumps and each cylinder) by measuring the cycle time of
the boom, arm, bucket, and bucket dump (open/close)
cylinders with the empty bucket.
2. Bucket must be empty.
Preparation
1. Maintain the hydraulic oil temperature at 50 ±5 °C
(122 ±41 °F).
Engine Power Mode Auto-idle
Work Mode
Control Dial Switch Switch
Power Plus Digging
High Idle OFF
Mode Mode
2. Position the front attachment as described in the following.
Then, measure the operating time until cylinder reaches
the stroke end by fully moving the control lever.
A. Boom cylinder
1) Boom up speed
Rapidly operate the bucket from the ground,
and measure the time it takes for the boom to
reach the end point.
2) Boom down speed
Rapidly operate the bucket with the boom
reached the end point, and measure the time it
takes for the bucket to reach the ground. EX1403531
3) Measuring available displacement of the Figure 8
cylinder: Measure and record the extension of
the cylinder rod from when the bucket is resting
on the ground to when the boom cylinder is
extended to its maximum length.
E145 Specifications
2-1-21
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General
Maintenance
Instructions
Edition 1
E145 General Maintenance Instructions
3-1-1
--- Page 10 ---
Replace bearing.
Figure 4
Galling
Metal smears on roller ends because of overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper
lubrication.
Figure 5
Abrasive Step Wear
Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts and housings,
check seals and bearings and replace if leaking, rough or
noisy.
Figure 6
E145 General Maintenance Instructions
3-1-15
--- Page 11 ---
TYPE 8 PHOSPHATE COATED HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts, nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
Standard Torque ±10%
Nominal Thread Diameter Kilogram.meter Foot pounds
(kg.m) (ft lb)
1/4" 1,1 8
5/16" 2,2 16
3/8" 3,9 28
7/16" 6,2 45
1/2" 9,7 70
9/16" 13,8 100
5/8" 19,4 140
3/4" 33,2 240
7/8" 53,9 390
1" 80,2 580
1 - 1/8" 113,4 820
1 - 1/4" 160,4 1160
1 - 3/8" 210,2 1520
1 - 1/2" 279,4 2020
1 - 3/4" 347,1 2510
2" 522,8 3780
E145 Standard Torques
3-2-9
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Open Cooling System
Ensure that all cooling drain plugs have been opened. Allow the
coolant to drain. Install the drain plugs. Place a vapor phase
inhibitor into the system.
The coolant system must be sealed once the vapor phase
inhibitor has been introduced. The effect of the vapor phase
inhibitor will be lost if the cooling system is open to the
atmosphere.
Monthly Checks
The crankshaft must be rotated in order to change the spring
loading on the valve train. Rotate the crankshaft more than 180
degrees. Visibly check for damage or corrosion to the engine
and aftertreatment.
Ensure that the engine and aftertreatment are covered
completely before storage. Log the procedure in the record for
the engine.
Aftertreatment
The engine must be allowed to perform a Diesel Exhaust Fluid
(DEF) purge before the battery disconnect switch is turned off.
Disconnecting the battery power too soon may prevent purging
of the DEF fluid system.
The exhaust outlet of the aftertreatment must be capped. In
order to prevent damage to the exhaust outlet connection during
storage, the weight of the CEM must not act on the exhaust
outlet.
DEF in Tank Storage
DEF must be drained and replenished if the application is left
idle for 2 months or longer at 40°C (104°F).
DEF must be drained and replenished if the application is left
idle for 4 months or more at 25°C (77°F).
1. Ensure normal engine shutdown, allow the DEF to be
purged. Disconnecting the battery power too soon may
prevent purging of the DEF fluid system.
2. Ensure that all DEF lines and electrical connection are
connected prior to prevent crystal from forming.
3. Ensure that the DEF filler cap is correctly installed.
E145 Engine
4-1-19
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22. Use the suitable lifting device to lift cylinder head (34)
2 6 10 7 3
carefully off the cylinder block.
NOTE: Do not use a lever to separate the cylinder head
from the cylinder block. Take care not to
damage the machined surfaces of the cylinder
head during the removal procedure.
1 5 9 8 4
Figure 32 EX1500813
35
IMPORTANT
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
23. Remove cylinder head gasket (36).
24. Note the position of dowels (35) in the cylinder block.
25. If necessary, remove water temperature regulator from the
cylinder head. Refer to "Water Temperature Regulator -
Remove" or the correct procedure.
36 EX1500817
Figure 33
E145 Engine
4-1-33
--- Page 15 ---
Parts List
Flywheel
4
5
1
1-1
EX1501082
Figure 55
Reference Reference
Description Description
Number Number
1 Flywheel Assembly 4 Screw
1-1 Gear; Starter Ring 5 Washer
E145 Engine
4-1-47
--- Page 16 ---
Piston and Rings - Specification
1. Top compression ring (1, Figure 80) 1
• The shape of the top compression ring: Keystone 2
• Ring gap: 0.25 ~ 0.35 mm (0.00984 ~ 0.01378 inch)
NOTE: When you install a new top compression ring,
make sure that the word "TOP" is facing the top
of the piston. New top piston rings have a black
identification mark. The identification mark must
3
be on the left of the ring end gap when the top
piston ring is installed on an upright piston.
2. Intermediate compression ring (2, Figure 80) EX1500854
• The shape of the intermediate compression ring: Figure 80
Internal bevel in the bottom edge with a tapered face
• Width of intermediate compression ring:
2.47 ~ 2.495 mm (0.0972 ~ 0.0982 inch)
• The clearance between a new intermediate
compression ring and the piston groove in a new
piston: 0.065 ~ 0.110 mm (0.00256 ~ 0.00433 inch)
• Ring gap: 0.65 ~ 0.85 mm (0.0256 ~ 0.0335 inch)
NOTE: When you install a new intermediate
compression ring, make sure that the word
"TOP" is facing the top of the piston. New
intermediate rings have a blue identification
mark. The identification mark must be on the left
of the ring end gap when the top piston ring is
installed on an upright piston.
3. The oil control ring (3, Figure 80)
• Width of oil control ring: 2.79 ~ 3.00 mm (0.10984 ~
0.11811 inch)
• The clearance between a new oil control ring and the
groove in a new piston: 0.05 ~ 0.10 mm (0.00197 ~
0.00394 inch)
• Ring gap: 0.30 ~ 0.55 mm (0.0118 ~ 0.0216 inch)
NOTE: When you install a new oil control ring, make
sure that the word "TOP" is facing the top of the
piston. New oil control rings have a red
identification mark. The identification mark must
be on the left of the ring end gap when the top
piston ring is installed on an upright piston. The
oil control ring is a twopiece ring that is spring
loaded. A pin is used in order to hold both ends
of the spring of the oil control ring in position.
The ends of the spring of the oil control ring
must be installed opposite the end gap of the oil
control ring.
NOTE: Ensure that the ring end gaps of the piston rings
are spaced 120 degrees from each other.
E145 Engine
4-1-61
--- Page 17 ---
Crankshaft - Specification
• Maximum permissible temperature of the gear for
installation on the crankshaft: 180°C (356°F) 1 2 3 4 5
• The end play of a new crankshaft:
0.1 ~ 0.41 mm (0.00394 ~ 0.01614 inch)
• Standard thickness of thrust washer:
2.69 ~ 2.75 mm (0.10591 ~ 0.10827 inch)
• Oversize thickness of thrust washer:
EX1500870
2.89 ~ 2.95 mm (0.11378 ~ 0.11614 inch) Figure 98
Refer to table for the run out of the crankshaft journals.
Journal Run Out of the Journals
1 Mounting
2 0.08 mm (0.0031 inch)
3 0.15 mm (0.0059 inch)
4 0.08 mm (0.0031 inch)
5 Mounting
Inspect the crankshaft for wear or for damage. For more
information regarding the servicing of the crankshaft, contact the
Global Technical Support Center.
Refer to "Connecting Rod Bearing Journal" for more information
on the connecting rod bearing journals and connecting rod
bearings.
Refer to "Main Bearing Journal" for information on the main
bearing journals and for information on the main bearings.
E145 Engine
4-1-75
--- Page 18 ---
Bearing Clearance - Check
IMPORTANT
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTE: Bobcat does not recommend the checking of the
actual clearances of the bearing shells particularly on
small engines. Checking of the actual clearances of
the bearing shells is because of the possibility of
obtaining inaccurate results and of damaging the
bearing shell or the journal surfaces. Each bearing
shell is quality checked for specific wall thickness.
NOTE: The measurements must be within specifications and
the correct bearings must be used. If the crankshaft
journals and the bores for the block and the rods
were measured during disassembly, no further
checks are necessary.
However, if the technician still wants to measure the
bearing clearances, a suitable tool is an acceptable
method.
IMPORTANT
Lead wire, shim stock or a dial bore gauge can damage the
bearing surfaces.
The technician must use tools correctly. The following points
must be remembered:
• Ensure that the backs of the bearings and the bores are
clean and dry.
• Ensure that the bearing locking tabs are properly seated in
the tab grooves.
• The crankshaft must be free of oil at the contact points of
tools.
1. Put a piece of tool on the crown of the bearing that is in the
cap.
NOTE: Do not allow tool to extend over the edge of the
bearing.
E145 Engine
4-1-89
--- Page 19 ---
6. Use a suitable tool in order to loosen threaded inserts (5)
on all rocker arms (6). Unscrew threaded inserts (5) on all
rocker arms (6) until all valves are fully closed. 5
NOTE: Failure to ensure that ALL threaded inserts are
fully unscrewed can result in contact between
the valves and pistons.
6
EX1501000
Figure 149
7. Mark plate (8) in order to show orientation.
NOTE: Identification will ensure that the plate can be
installed in the original orientation.
8. Remove bolts (7).
9. Remove plate (8).
10. Remove assembly of idler gear (4). 4
11. Remove hub (9) from the recess in the front housing. 7
8
Figure 150 EX1501001
4
9
EX1501002
Figure 151
E145 Engine
4-1-103
--- Page 20 ---
Camshaft - Remove
Start By:
Remove rocker shaft and pushrods. Refer to "Rocker shaft and
Pushrod - Remove" for the correct procedure.
Remove front housing. Refer to "Housing (Front) - Remove" for
the correct procedure.
IMPORTANT
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. The engine must be mounted on a suitable stand and
placed in the inverted position.
2. Remove thrust washer (1) from the cylinder block. 1
Do not remove dowel (2) from the cylinder block unless the
dowel is damaged
NOTE: The thrust washer can have one or two Slots
(X).
X
2 EX1501026
Figure 182
IMPORTANT 3
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
3. Carefully remove camshaft (3) from the cylinder block.
4. If necessary, remove key (4) from camshaft (3).
4
EX1501027
Figure 183
E145 Engine
4-1-117
--- Page 21 ---
1. Make an identification mark on each rocker arm assembly
in order to show the location.
NOTE: The components must be reinstalled in the
original location. Do not interchange
components.
2. Remove Torx screws from the rocker shaft assembly. Note
position of different length Torx screws for assembly 1
purposes.
3. Remove retaining clip (2) from rocker shaft (6).
Remove spring (3) from the rocker shaft. 2 3
4. Remove rocker arm assembly (4) for the inlet valve from
rocker shaft (6). Remove rocker arm assembly (5) for the
exhaust valve from rocker shaft (6).
NOTE: The rocker arm assembly for the inlet valve is
longer than the rocker arm assembly for the 4 5
exhaust valve.
5. Remove retaining clip (7) from rocker shaft (6).
Remove spring (8) from the rocker shaft.
6. Remove rocker arm assembly (4) for the exhaust valve
from rocker shaft (6). Remove rocker arm assembly (5) for
the inlet valve from rocker shaft (6).
6 7 8 4 5
7. Repeat Step 5 through Step 6 in order to remove EX1501039
remaining rocker arms from rocker shaft (6). Figure 207
8. If necessary, follow Step 8.A. through Step 8.B. in order to
remove threaded inserts (1) from the rocker arms.
A. Make a temporary identification mark on each
threaded inserts (1) in order to show the location.
NOTE: The components must be reinstalled in the
original location. Do not interchange
components.
B. Remove threaded inserts (1) from the rocker arms.
E145 Engine
4-1-131
--- Page 22 ---
Reference Reference
Description Description
Number Number
1 Pan, Oil 20-2 Clip
2 Gasket; Sump 20-3 Dipstick
3 Piece; Bridge 20-4 Seal, O-ring
4 Screw 21 Bracket
5 Screw 22 Screw
6 Screw 23 Seal, O-ring
7 Screw 24 Plug
10 Pipe; Oil Suction 30 Plug
11 Gasket 31 Seal, O-ring
12 Screw 32 Plug
20 Dipstick Assembly 33 Plug; O-ring
20-1 Tube
E145 Engine
4-1-145
--- Page 23 ---
6 7
5
2
1
4
3
EX1501071
Figure 253
Water Pump - Inspect
1. Inspect the water pump for leaks at vent hole. The water
pump seal is lubricated by coolant in the cooling system.
A normal condition is for a small amount of leakage to
occur as the engine cools down and the parts contract.
2. Refer to "Water Pump - Remove", "Water Pump - Install"
for the correct procedures to remove and install the water
pump.
3. Inspect the water pump shaft for unusual noise, excessive
looseness and/or vibration of the bearings.
E145 Engine
4-1-159
--- Page 24 ---
High-pressure Fuel System
The fuel injection pump (1) feeds fuel to the high-pressure fuel manifold (rail) (6). The fuel is at a pressure of
2,000 bar (29,000 psi). A pressure sensor (4) in the high-pressure fuel manifold (rail) (6) monitors the fuel
pressure in the high-pressure fuel manifold (rail) (6). The ECM controls a suction control valve (3) in the fuel
injection pump (1) in order to maintain the actual pressure in the high-pressure fuel manifold (6) at the desired
level. The high-pressure fuel is continuously available at each injector.
The ECM determines the correct time for activation of the correct electronic unit injector (5) which allows fuel to be
injected into the cylinder. The leak off fuel from each injector passes into a drilling which runs along the inside of
the cylinder head. A pipe is connected to the rear of the cylinder head in order to return the leak off fuel to the fuel
tank.
5
6
4