Bobcat E32i Compact Excavator Service Manual SN AUYJ11001 & Above – PDF DOWNLOAD

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Bobcat E32i Compact Excavator Service Manual SN AUYJ11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat E32i Compact Excavator Service Manual SN AUYJ11001 & Above – PDF DOWNLOAD

Language : English
Pages : 895
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat E32i Compact Excavator Service Manual SN AUYJ11001 & Above – PDF DOWNLOAD

S/N AUYJ11001 & Above

FOREWORD

This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

•  The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bobcat E32i Compact Excavator Service Manual SN AUYJ11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS / TOPS) 27
Description 27
Cab Door 28
Front Window 29
Front Wiper 30
Window Washer Reservoir 30
Right Side Window 31
OPERATOR CANOPY (ROPS / TOPS) 33
Description 33
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 36
TAILGATE 37
Opening And Closing 37
Adjusting The Latch 37
RIGHT SIDE COVER 39
Opening And Closing 39
SERVICE SCHEDULE 41
Maintenance Intervals 41
AIR CLEANER SERVICE 43
Daily Check 43
Replacing The Filters 44
CAB FILTERS 47
Cleaning And Maintenance 47
ENGINE COOLING SYSTEM 49
Cleaning 49
Checking Level 50
Removing And Replacing Coolant 51
FUEL SYSTEM 53
Fuel Specifications 53
Biodiesel Blend Fuel 53
Filling The Fuel Tank 54
Fuel Filters 55
Draining The Fuel Tank 55
Removing Air From The Fuel System 56
ENGINE LUBRICATION SYSTEM 57
Checking And Adding Engine Oil 57
Engine Oil Chart 57
Removing And Replacing Oil And Filter 58
HYDRAULIC SYSTEM 59
Checking And Adding Hydraulic Fluid 59
Hydraulic / Hydrostatic Fluid Chart 60
Removing And Replacing Hydraulic Filters 61
Removing And Replacing The Hydraulic Fluid 63
LUBRICATION OF THE HYDRAULIC EXCAVATOR 65
Lubrication Locations 65
PIVOT PINS 69
Inspection And Maintenance 69
TRAVEL MOTOR 71
Checking And Adding Oil 71
Removing And Replacing Oil 71
SPARK ARRESTER MUFFLER 73
Cleaning Procedure 73
EMERGENCY EXIT 75
Right Side Rear Window 75
Front Window 75
SEAT BELT 77
Inspection And Maintenance 77
CONTROL CONSOLE LOCKOUTS 79
Inspection And Maintenance 79
TOWING THE EXCAVATOR 81
Procedure 81
REMOTE START TOOL KIT – MEL1563 83
Remote Start Tool Kit – MEL1563 83
Service Tool Harness Control – MEL1565 84
Service Tool Harness Communicator – MEL1566 85
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 87
Description 87
Remote Start Tool (Service Tool) – 7022042 88
Excavator Service Tool Harness – 6689747 89
Computer Service Tool Harness – 6689746 90
HYDRAULIC SYSTEM 91
HYDRAULIC / HYDROSTATIC SCHEMATICS 97
HYDRAULIC SYSTEM INFORMATION 99
Glossary Of Hydraulic / Hydrostatic Symbols 99
Troubleshooting The Hydraulic Circuit 102
Troubleshooting The Cylinder Circuit 103
Troubleshooting The Swing (Upperstructure Slew) Circuit 104
Troubleshooting The Travel Circuit 105
CYLINDER (BOOM) 107
Testing 107
Removal And Installation 109
Parts Identification 112
Disassembly 113
Assembly 116
CYLINDER (ARM) 121
Testing 121
Removal And Installation 123
Parts Identification 125
Disassembly 126
Assembly 128
CYLINDER (BOOM SWING) 133
Testing 133
Removal And Installation 135
Parts Identification 138
Disassembly 139
Assembly 141
CYLINDER (BUCKET) 145
Testing 145
Removal And Installation 147
Parts Identification 149
Disassembly 150
Assembly 152
CYLINDER (BLADE) 155
Testing 155
Removal And Installation 157
Parts Identification 158
Disassembly 159
Assembly 161
CYLINDER (CLAMP) 165
Testing 165
Removal And Installation 166
Parts Identification 168
Disassembly 169
Assembly 172
CYLINDER (EXTENDABLE ARM) 177
Testing 177
Parts Identification 179
Disassembly 180
Assembly 183
VALVE (MAIN RELIEF) 187
Description 187
VALVE (PORT RELIEF) 189
Testing And Adjusting Port Relief Valve Pressure 189
VALVE (CROSS PORT RELIEF) 191
Testing 191
Removal And Installation 193
Cross Port Relief Valve Disassembly And Assembly 193
VALVE (PILOT PRESSURE RELIEF) 195
Testing And Adjusting The Pilot Pressure Relief Valve 195
HYDRAULIC CONTROL VALVE 197
Description 197
Removal And Installation 198
Parts Identification 202
Disassembly 203
Assembly 209
Inlet Valve Section Disassembly And Assembly 213
Boom Swing Valve Section Disassembly And Assembly 215
Slew Valve Section Disassembly And Assembly 218
Blade Valve Section Disassembly And Assembly 219
Right And Left Travel Valve Section Disassembly And Assembly 222
Boom Valve Section Disassembly And Assembly 224
Auxiliary, Arm, Bucket And Angle Blade Valve Section Disassembly And Assembly 228
Outlet Valve Section Disassembly And Assembly 230
HYDRAULIC PUMP 233
Hydraulic Pump Work Sheet 233
Pump Testing 235
Description 243
Removal And Installation 243
Coupler Removal And Installation 244
Hydraulic Pump Startup 245
Gear Pump Disassembly And Assembly 246
Piston Pump Parts Identification 248
Piston Pump Disassembly And Assembly 249
MANIFOLD ASSEMBLY / ACCUMULATOR 261
Description 261
Removal And Installation 261
Parts Identification 263
Disassembly And Assembly 264
TRAVEL MOTOR 271
Removal And Installation 271
Parts Identification Hydraulic Motor 272
Parts Identification Gear Reduction Hub 273
Disassembly 274
Assembly 288
SWIVEL JOINT 305
Removal And Installation 305
Parts Identification 307
Disassembly And Assembly 308
SWING MOTOR 311
Removal And Installation 311
Parts Identification 312
Disassembly And Assembly 313
SWING MOTOR (DRIVE CARRIER) 319
Removal And Installation 319
Parts Identification 320
Disassembly And Assembly 321
CONTROL PATTERN SELECTOR VALVE 327
Removal And Installation 327
Parts Identification 328
Disassembly And Assembly 329
RIGHT CONTROL LEVER (JOYSTICK) 331
Testing 331
Handle Removal And Installation 332
Joystick Assembly Removal And Installation 334
Parts Identification 335
Disassembly 336
Assembly 341
LEFT CONTROL LEVER (JOYSTICK) 347
Testing 347
Handle Removal And Installation 348
Joystick Assembly Removal And Installation 350
Parts Identification 351
Disassembly 352
Assembly 357
HYDRAULIC FILTER MOUNT 363
Removal And Installation 363
HYDRAULIC RESERVOIR 365
Removal And Installation 365
OIL COOLER 367
Removal And Installation 367
DIRECT TO TANK VALVE 369
Removal And Installation 369
BLADE CONTROL LEVER 371
Handle Removal And Installation 371
Removal And Installation 373
Parts Identification 375
Disassembly And Assembly 376
CASE DRAIN FILTER MOUNT 381
Removal And Installation 381
TRAVEL CONTROL VALVE 383
Removal And Installation 383
Parts Identification 384
Disassembly And Assembly 385
REMOVING AIR FROM THE HYDRAULIC SYSTEM 391
Procedure 391
HYDRAULIC X-CHANGE MANIFOLD (EARLIER MODELS) 393
Removal And Installation 393
Parts Identification 394
Disassembly And Assembly 395
HYDRAULIC X-CHANGE MANIFOLD (LATER MODELS) 399
Removal And Installation 399
Parts Identification 400
Disassembly And Assembly 401
SECONDARY AUXILIARY VALVE (EARLIER MODELS) 407
Removal And Installation 407
Parts Identification 409
Disassembly And Assembly 410
SECONDARY AUXILIARY VALVE (LATER MODELS) 415
Removal And Installation 415
Parts Identification 417
Disassembly And Assembly 418
VALVE (BOOM LOCK) 421
Removal And Installation 421
VALVE (ARM LOCK) 423
Removal And Installation 423
UNDERCARRIAGE 425
BLADE 427
Removal And Installation 427
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 429
Description 429
Track Lug Height 429
Checking Tension 430
Adjusting Tension 431
Track Removal And Installation 433
Idler Removal And Installation 434
Parts Identification 435
Idler Disassembly 436
Idler Assembly 438
Track Tensioner Removal And Installation 441
Track Tensioner Parts Identification 442
Track Tensioner Disassembly And Assembly 443
Roller Removal And Installation 445
Sprocket Removal And Installation 446
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 447
Description 447
Checking Tension 448
Adjusting Tension 449
Track Removal And Installation 450
Idler Removal And Installation 454
Idler Parts Identification 455
Idler Disassembly 456
Idler Assembly 458
Track Tensioner Disassembly And Assembly 461
Track Tensioner Parts Identification 462
Track Tensioner Disassembly And Assembly 463
Roller Removal And Installation 465
Sprocket Removal And Installation 466
Guide Plate Removal And Installation 466
TRACK MAINTENANCE 467
Track Damage Identification 467
SWING CIRCLE GEAR 479
Swing Bearing Removal 479
Swing Bearing Installation 480
UPPERSTRUCTURE AND SWING SECTION 481
UPPERSTRUCTURE 485
Removal 485
Installation 487
ROPS CANOPY 489
Removal And Installation 489
CAB 493
Removal And Installation 493
Door Removal And Installation 496
Front Window Removal And Installation 497
Front Window Disassembly And Assembly 498
Front Window Adjustment 499
Right Side Rear Sliding Window Removal And Installation 501
Right Side Front Sliding Window Removal And Installation 501
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 502
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 502
Glass Removal 503
Glass Installation 504
SEAT 509
Removal And Installation 509
Seat Mount Removal And Installation 510
RIGHT CONSOLE 511
Console Cover Removal And Installation 511
LEFT CONSOLE 517
Lower Console Cover Removal And Installation 517
Upper Console Cover Removal And Installation 517
Compression Spring Removal And Installation 520
Lock Lever Removal And Installation 522
Console Removal And Installation 522
LEFT UPPERSTRUCTURE COVER 523
Removal And Installation 523
RIGHT UPPERSTRUCTURE COVER 525
Removal And Installation 525
COUNTERWEIGHT 527
Removal And Installation 527
Long Arm Counterweight Removal And Installation 530
TRAVEL LEVERS AND PEDALS 531
Removal And Installation 531
Disassembly And Assembly 532
FLOOR MAT 533
Removal And Installation 533
FUEL TANK 535
Removal And Installation (Canopy Equipped Excavator) 535
Removal And Installation (Cab Equipped Excavator) 536
Fuel Tank Fitting Removal And Installation 538
HORN 539
Removal And Installation 539
SWING FRAME 541
Removal And Installation 541
Boom Swing Frame Hose Routing 544
Bushing Removal 545
Bushing Installation 546
BOOM 547
Removal And Installation 547
ARM (STANDARD AND LONG) 549
Removal And Installation 549
Arm To Boom Bushing Removal And Installation 550
Arm To Bucket And Bucket Link Bushing Removal And Installation 551
ARM (EXTENDABLE) 553
Removal And Installation 553
Arm To Boom Bushing Removal And Installation 554
Arm To Bucket Bushing Removal And Installation 555
Disassembly And Assembly 556
Shimming Procedure 564
BUCKET 565
Bucket Teeth Removal And Installation 565
Bucket Side Cutting Edge Removal And Installation 566
CLAMP 567
Removal And Installation 567
TAILGATE 569
Removal And Installation 569
Latch Removal And Installation 570
X-CHANGE 571
Removal And Installation 571
Disassembly 572
Assembly 573
X-CHANGE (HYDRAULIC) 575
Removal And Installation 575
Parts Identification 577
Disassembly 578
Assembly 583
QUICK COUPLER (KLAC™ SYSTEM) 591
Troubleshooting 591
Daily Inspection 591
Removal And Installation 592
Parts Identification 594
Disassembly 595
Assembly 596
QUICK COUPLER (LEHNHOFF® SYSTEM) 599
Troubleshooting 599
Daily Inspection 599
Removal (MS03 And MS08) 600
Installation (MS03 And MS08) 601
Parts Identification (MS03) 602
Disassembly And Assembly (MS03) 603
Parts Identification (MS08) 604
Disassembly (MS08) 605
Assembly (MS08) 608
QUICK COUPLER (PIN GRABBER) 613
Troubleshooting 613
Daily Inspection 614
Removal And Installation 615
Parts Identification 616
Disassembly And Assembly 617
RIGHT SIDE COVER 621
Removal And Installation 621
Latch Removal And Installation 622
Latch Adjustment 623
TOOL BOX 625
Removal And Installation 625
ELECTRICAL SYSTEM AND ANALYSIS 627
ELECTRICAL SCHEMATICS 629
ELECTRICAL SYSTEM INFORMATION 636
Troubleshooting Chart 636
Description 637
Fuse And Relay Location / Identification 637
BATTERY 640
Servicing 640
Removal and Installation 641
Using A Booster Battery (Jump Starting) 642
ALTERNATOR 644
Belt Adjustment 644
Belt Replacement 644
Charging System Inspection 644
Alternator Voltage Testing 645
Low Voltage Testing 646
High Voltage Testing 646
Removal And Installation 647
Parts Identification 649
STARTER 650
Testing 650
Removal And Installation 651
Parts Identification 652
LIGHTS 654
Removal And Installation 654
Boom Light Removal And Installation 655
Boom Light Bulb Replacement 655
MAGNETIC LOCKOUT SENSOR 656
Removal And Installation 656
FUEL LEVEL SENDER 658
Removal And Installation 658
Testing 659
DIAGNOSTIC SERVICE CODES 660
Viewing Service Codes 660
Service Codes List 661
CONTROL PANEL SETUP 664
Panel Setup (Deluxe Instrument Panel) 664
Password Setup (Keyless Start Panel) 670
Password Setup (Deluxe Instrument Panel) 671
Maintenance Clock 674
INSTRUMENT PANEL 680
Removal And Installation 680
CONTROLLER 682
Description 682
Gateway Controller Removal And Installation 682
Auxiliary Controller Removal And Installation 684
KEY SWITCH 686
Removal And Installation 686
WIPER MOTOR 688
Removal And Installation 688
MOTION ALARM SYSTEM 690
Description 690
Inspecting 690
Adjusting Switch Position 691
SERVICE PC (LAPTOP COMPUTER) 692
Connecting The Remote Start Tool 692
Connecting Remote Start Tool (Service Tool) 692
SHUT-OFF SWITCH 694
Description 694
Removal And Installation 695
TRAVEL MOTOR AUTO-SHIFT 698
Auto-Shift Drive System (If Equipped) 698
Troubleshooting 699
ENGINE SERVICE 702
ENGINE INFORMATION 704
Description 704
Specifications 705
Crankshaft Re-Grind Data 711
Torque For Kubota Metric Bolts 712
Troubleshooting 713
Engine Removal And Installation 714
Compression – Testing 721
ENGINE SPEED CONTROL 722
Removal And Installation 722
Auto Idle Controller Removal And Installation 723
Calibration 724
Actuator Removal And Installation 727
MUFFLER 730
Removal And Installation 730
AIR CLEANER 732
Removal And Installation 732
ENGINE COOLING SYSTEM 734
Radiator Removal And Installation 734
Fan Removal And Installation 737
Water Pump Removal And Installation 738
Water Pump Disassembly And Assembly 738
Thermostat Housing Removal And Installation 739
Thermostat – Testing 739
LUBRICATION SYSTEM 740
Oil Pan Removal And Installation 740
Oil Pump Removal And Installation 741
Oil Pump Inspection 741
Engine Oil Pressure – Testing 742
FUEL SYSTEM 744
Fuel Shutoff Solenoid – Testing 744
Fuel Shut-off Solenoid Removal And Installation 745
Fuel Injection Pump – Testing 746
Fuel Injection Pump Removal And Installation 747
Fuel Injection Pump – Timing 750
Fuel Camshaft Removal And Installation 752
Fuel Camshaft Governor 753
Fuel Injector Removal And Installation 754
Fuel Injector Nozzle Pressure – Testing 757
Nozzle Spray Condition 758
Valve Seat Tightness 758
CYLINDER HEAD 760
Glow Plugs – Testing 760
Glow Plugs Removal And Installation 761
Valve Clearance Adjustment 762
Valve Timing – Inspecting 762
Cylinder Head Removal And Installation 763
Cylinder Head Disassembly And Assembly 766
Cylinder Head – Servicing 767
Cylinder Head Top Clearance 767
Valve Guide – Inspecting 768
Valve Guide Removal And Installation 769
Reconditioning The Valve And Valve Seat 770
Valve Spring 771
Valve Tappets 772
Rocker Arm And Shaft – Inspecting 773
Push Rod Alignment – Inspecting 773
CRANKSHAFT AND PISTONS 774
Piston And Connecting Rod Removal And Installation 774
Piston And Connecting Rod – Servicing 776
Cylinder Bore – Inspecting 778
Connecting Rod Alignment 779
Crankshaft Gear Removal And Installation 780
Crankshaft And Bearings Removal And Installation 781
Crankshaft And Bearings – Servicing 784
CAMSHAFT AND TIMING GEARS 788
Timing Gearcase Cover Removal And Installation 788
Timing Gears Backlash – Inspecting 791
Idle Gear And Camshaft Removal And Installation 792
Camshaft – Servicing 794
Idle Gear And Shaft – Servicing 795
FLYWHEEL AND HOUSING 796
Hydraulic Pump Coupler Removal And Installation 796
Flywheel Removal And Installation 798
Flywheel Ring Gear 798
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 800
AIR CONDITIONING SYSTEM FLOW 802
Description 802
Chart 803
Components 804
Safety Equipment 807
REGULAR MAINTENANCE 808
Cab Filters 808
Air Conditioning Compressor Belt Adjustment 810
Air Conditioning Compressor Belt Replacement 810
Condenser 812
Air Conditioning Lubrication 813
Evaporator / Heater Coil 813
Air Conditioning Service Chart 814
TROUBLESHOOTING 816
Blower Motor Does Not Operate 816
Blower Motor Operates Normally, But Air Flow Is Insufficient 816
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 816
The Compressor Operates Improperly Or Not At All 816
Gauge Pressure Related Troubleshooting 817
Temperature / Pressure Chart 818
Poor A/C Performance 819
HVAC Repair And Leaks 819
Electrical System 820
Engine Coolant Bypassing The Heater Valve 822
SYSTEM CHARGING AND RECLAMATION 824
Refrigerant Identification 824
Reclamation And Charging With Recovery / Charging Unit 826
COMPRESSOR 828
Removal And Installation 828
Oil 829
Oil Check 830
CONDENSER 832
Removal And Installation 832
RECEIVER / DRIER 834
Receiver / Drier Removal And Installation 834
Pressure Switch Removal And Installation 835
EVAPORATOR / HEATER UNIT 836
Removal And Installation 836
THERMOSTAT 838
Description 838
Removal And Installation 839
EXPANSION VALVE 842
Removal And Installation 842
EVAPORATOR COIL 844
Removal And Installation 844
HEATER COIL 846
Removal And Installation 846
BLOWER FAN 848
Removal And Installation 848
HEATER VALVE 850
Removal And Installation 850
HVAC DUCT 852
Removal And Installation 852
SPECIFICATIONS 854
EXCAVATOR SPECIFICATIONS 856
Machine Dimensions 856
Machine Dimensions (Standard Arm) 857
Machine Dimensions (Long Arm) 858
Machine Dimensions (Extendable Arm) 859
Performance 860
Controls 860
Engine 861
Hydraulic System 861
Hydraulic Cylinders 862
Hydraulic Cycle Times 862
Drive System 862
Slew System 862
Undercarriage 862
Electrical 863
Capacities 863
Tracks 863
Ground Pressure 863
TECHNICAL SERVICE GUIDE SPECIFICATIONS 864
Engine 864
Engine Torques 864
Cooling System 864
Excavator Torques 864
TORQUE SPECIFICATION FOR BOLTS 866
Torque For General SAE Bolts 866
Torque For General Metric Bolts 867
HYDRAULIC CONNECTION SPECIFICATIONS 868
O-ring Face Seal Connection 868
Straight Thread O-ring Fitting 868
Tubelines And Hoses 869
Flare Fitting 869
O-ring Flare Fitting 870
Port Seal Fitting 872
Push To Connect Fittings 873
HYDRAULIC FLUID SPECIFICATIONS 876
Specifications 876
CONVERSIONS 878
Decimal And Millimeter Equivalent Chart 878
U S To Metric Conversion Chart 879
SERVICE TOOLS REQUIRED 880
Remote Start Tools 880
Hydraulic Tools 881
Engine Tools 884
Electrical Tools 886
General Tools 887
HVAC Tools 888
ALPHABETICAL INDEX 890
SERVICE SCHEDULE SYMBOLS 894

Need help? Contact: [email protected]

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M