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Bobcat E16 Excavator Service Manual (SN AHLL11001-AHLL99999)

Format: PDF (Printable Document)

File Language: English

File Pages: 689

File Size: 19.71 MB (Speed Download Link)

Brand: Bobcat

Model: E16 Excavator

Book No: 6989424

Serial No: SN AHLL11001-AHLL99999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat E16 Excavator Service Manual (SN AHLL11001-AHLL99999)

A Bobcat E16 is a small compact excavator that spends its life trenching, loading, and working in tight spots where a big machine won't fit. The people who reach for this service manual are the ones actually turning wrenches: shop mechanics, field techs, and owner-operators who don't want downtime. They're looking for teardown order, torque sequences, test-port locations, and wiring logic so they can fix it once and move on to the next job. If you're rebuilding or diagnosing an out-of-warranty E16 in that serial range, this is the book you keep open on the bench.

What this manual helps you do

  • Trace hydraulic circuits and check pressures on the boom, arm, and auxiliary functions.
  • Follow step-by-step procedures to remove, rebuild, and reinstall cylinders, drive motors, and control valves.
  • Diagnose electrical issues using wiring diagrams, connector callouts, and test procedures.
  • Replace engine and hydrostatic components correctly, with the right sequences and adjustment points.
  • Set and verify machine adjustments after repairs so travel, swing, and work functions operate within spec.

Who this is for

This is for anyone maintaining or repairing a Bobcat E16 in a shop or rental yard, or an owner-operator doing their own heavier work. If you just need basic controls, safety, and daily checks, you want the operator's handbook instead, not this service manual.

FAQ

Q: Is this a searchable PDF, and can I zoom in on wiring diagrams?

A: Yes, it's typically a searchable PDF and the wiring diagrams are made to stay readable when you zoom in on a laptop or tablet.

Q: Will this cover my E16 with serial number in the AHLL range?

A: It's written for E16 machines with serial numbers from AHLL11001 through AHLL99999. If your tag falls in that range, you're covered.

Q: Is this the right document if I'm chasing hydraulic or electrical faults?

A: Yes, this is the workshop-level service manual, which is what you want for diagnostics, teardown, and reassembly work.

Bottom line: If you own or service a Bobcat E16 in that AHLL serial range and need real repair procedures, this is the right manual. If you only want operating tips, skip it.

📘 Show Index

Table of Contents:

  • MAINTENANCE SAFETY
  • CONTENTS
  • FOREWORD
    • FOREWORD
    • SAFETY INSTRUCTIONS
    • FIRE PREVENTION
      • Maintenance
      • Operation
      • Electrical
      • Hydraulic System
      • Fueling
      • Starting
      • Spark Arrester Exhaust System
      • Welding And Grinding
      • Fire Extinguishers
    • SERIAL NUMBER LOCATIONS
      • Excavator Serial Number
      • Engine Serial Number
    • DELIVERY REPORT
    • EXCAVATOR IDENTIFICATION
  • SAFETY AND MAINTENANCE
    • LIFTING AND BLOCKING THE EXCAVATOR
      • Procedure
    • UPPERSTRUCTURE SLEW LOCK
    • LIFTING THE EXCAVATOR
      • Procedure
    • OPERATOR CANOPY (ROPS / TOPS)
      • Description
    • OPERATOR CAB (ROPS / TOPS)
      • Description
      • Cab Door
      • Front Window
      • Front Wiper
      • Window Washer Reservoir
      • Right Side Windows
      • Heater
    • TRANSPORTING THE EXCAVATOR ON A TRAILER
      • Loading And Unloading
      • Fastening – Track Frame Tie Downs
      • Fastening – Upperstructure Tie Downs (Optional)
      • Fastening Arm – All Models
    • TAILGATE
      • Opening And Closing
      • Adjusting The Bumper
      • Adjusting The Latch
    • SERVICE SCHEDULE
      • Chart
      • Inspection Checkbook
    • AIR CLEANER SERVICE
      • Daily Check
      • Replacing The Filter Elements
    • CAB FILTER
      • Cleaning And Maintenance (Early Models Only)
    • 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 Hydraulic Fluid
      • Hydraulic / Hydrostatic Fluid Chart
      • Removing And Replacing The Hydraulic Filter
      • Removing And Replacing The Hydraulic Fluid
    • LUBRICATING THE EXCAVATOR
      • Lubrication Locations
    • TRAVEL MOTOR
      • Checking And Adding Oil
      • Removing And Replacing Oil
    • SPARK ARRESTER MUFFLER
      • Cleaning Procedure
    • ALTERNATOR BELT
      • Belt Adjustment (S/N AHLL11001 – AHLL13119)
      • Belt Adjustment (S/N AHLL13120 & Above)
      • Belt Adjustment (All Models)
      • Belt Replacement
    • SEAT BELT
      • Inspection And Maintenance
    • CONTROL CONSOLE LOCKOUTS
      • Inspection And Maintenance
    • PIVOT PINS
      • Inspection And Maintenance
    • EXCAVATOR STORAGE AND RETURN TO SERVICE
      • Storage
      • Return to Service
    • STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
      • Procedure
    • EMERGENCY EXIT
      • Right Side Rear Window
      • Front Window
    • DE-AERATION
      • Procedure
    • MOTION ALARM SYSTEM
      • Description
      • Inspecting
      • Adjusting Switch Position
    • REMOTE START TOOL KIT – MEL1563
      • Remote Start Tool – MEL1563
      • Service Tool Harness Control – MEL1565
      • Service Tool Harness Communicator – MEL1566
    • REMOTE START TOOL (SERVICE TOOL) KIT – 6689779 / 7003031
      • Description
      • Remote Start Tool (Service Tool) – 6689778 / 7003030
      • Excavator Service Tool Harness – 6689747
      • Computer Service Tool Harness – 6689746
  • HYDRAULIC SYSTEM
    • HYDRAULIC/HYDROSTATIC SCHEMATICS
    • HYDRAULIC SYSTEM INFORMATION
      • Glossary Of Hydraulic / Hydrostatic Symbols
      • Troubleshooting The Hydraulic Circuit
      • Troubleshooting The Cylinder Circuit
      • Troubleshooting The Swing (Upperstructure Slew) Circuit
      • Troubleshooting The Travel Circuit
    • 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 (TRACK FRAME EXPANSION)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • VALVE (MAIN RELIEF)
      • Testing And Adjusting
    • VALVE (PORT RELIEF)
      • Testing And Adjusting
    • VALVE (CROSSPORT RELIEF)
      • Testing And Adjusting
    • VALVE (PRESSURE REDUCING)
      • Testing And Adjusting
    • HYDRAULIC CONTROL VALVE
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Right Travel Valve Section Disassembly And Assembly
      • Boom Swing Valve Section Disassembly And Assembly
      • Arm Valve Section Disassembly And Assembly
      • Bucket Valve Section Disassembly And Assembly
      • Auxiliary Valve Section Disassembly And Assembly
      • Boom Valve Section Disassembly And Assembly
      • Left Travel Valve Section Disassembly And Assembly
      • Swing (Slew) Valve Section Disassembly And Assembly
      • Blade Valve Section Disassembly And Assembly
      • Assembly
    • HYDRAULIC PUMP
      • Description
      • Torque Adjustment
      • Testing The Piston Pump
      • Testing The Gear Pump
      • Testing Auxiliary Hydraulic Flow
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Gear Pump Disassembly
      • Piston Pump Disassembly
      • Piston Pump Assembly
      • Gear Pump Assembly
      • Assembly
    • MANIFOLD ASSEMBLY / ACCUMULATOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • TRAVEL MOTOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • SWIVEL JOINT
      • Description
      • Removal And Installation
      • Parts Identification (S/N AHll11001 to AHLL22003)
      • Parts Identification (AHLL22003 & Above)
      • Disassembly
      • Assembly
    • SWING MOTOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL LEVER (JOYSTICK) (RIGHT)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CONTROL LEVER (JOYSTICK) (LEFT)
      • Description
      • Testing
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • HYDRAULIC FILTER MOUNT
      • Description
      • Removal And Installation
    • HYDRAULIC RESERVOIR
      • Description
      • Removal And Installation
    • OIL COOLER
      • Description
      • Removal And Installation
    • BLADE / TRACK EXPANSION SOLENOID BLOCK (FOR MODEL E16 S/N AHLL11001 – 13119)
      • Description
      • Block Removal And Installation
      • Solenoid Removal And Installation
      • Block Disassembly And Assembly
    • BLADE / TRACK EXPANSION SOLENOID BLOCK (FOR MODEL E16 S/N AHLL13120 & ABOVE)
      • Description
      • Block Removal And Installation
      • Solenoid Removal And Installation
      • Block Disassembly And Assembly
    • SLEW LOCK VALVE
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • REMOVING AIR FROM THE HYDRAULIC SYSTEM
      • Procedure
  • UNDERCARRIAGE
    • BLADE
      • Description
      • Extension Removal And Installation
      • Blade Removal And Installation
    • TRACK UNDERCARRIAGE COMPONENTS
      • Description
      • 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 Assembly Disassembly And Assembly
      • Roller Removal And Installation
      • Roller Parts Identification
      • Disassembly
      • Assembly
    • TRACK MAINTENANCE
      • Track Damage Identification
    • SWING CIRCLE GEAR
      • Removal And Installation
  • UPPERSTRUCTURE AND SWING SECTION
    • UPPERSTRUCTURE
      • Description
      • Removal
      • Installation
    • ROPS CANOPY
      • Removal And Installation
    • CAB
      • Removal And Installation
      • Door Removal And Installation
      • Front Window Removal And Installation
      • Right Side Rear Sliding Window Removal And Installation
      • Right Side Front Sliding Window Removal And Installation
      • Glass Removal
      • Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
      • Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
      • Glass Installation
    • SEAT AND SEAT MOUNT (FOR MODEL E16 S/N AHLL11001 – 13119)
      • Seat Mount Removal And Installation
    • SEAT AND SEAT MOUNT (FOR MODEL E16 S/N AHLL13120 & ABOVE)
      • Seat Mount Removal And Installation
    • RIGHT CONSOLE
      • Description
      • Joystick Console Cover (Bottom) Removal And Installation
      • Joystick Console Cover (Top) Removal And Installation
      • Joystick Console Cover (Top) Disassembly And Assembly
      • Compression Spring Removal And Installation (Canopy Only)
      • Compression Spring Disassembly And Assembly (Canopy Only)
      • Lever Removal And Installation (Canopy Only)
      • Joystick Console Frame Removal And Installation
      • Joystick Console Frame Disassembly And Assembly
      • Right Rear Console Cover Removal And Installation
      • Right Rear Console Cover Disassembly And Assembly
      • Right Rear Console Frame Removal And Installation
    • LEFT CONSOLE
      • Description
      • Joystick Console Cover (Bottom) Removal And Installation
      • Joystick Console Cover (Top) Removal And Installation
      • Compression Spring Removal And Installation
      • Compression Spring Disassembly And Assembly
      • Lever Removal And Installation
      • Joystick Console Frame Removal And Installation
      • Joystick Console Frame Disassembly And Assembly
      • Left Rear Console Cover Removal And Installation
      • Left Rear Console Frame Removal And Installation
    • ENGINE SPEED CONTROL
      • Removal And Installation
      • Cable Removal And Installation
    • BLADE CONTROL
      • Removal And Installation
      • Disassembly And Assembly
      • Cable Removal And Installation
    • UPPERSTRUCTURE SLEW LOCK
      • Removal And Installation
      • Disassembly And Assembly
    • RIGHT PEDAL
      • Removal And Installation
      • Disassembly And Assembly
    • TRAVEL CONTROLS
      • Removal And Installation
      • Disassembly And Assembly
    • LEFT PEDAL
      • Removal And Installation
      • Disassembly And Assembly
    • CONTROL LINKAGE ASSEMBLY
      • Description
      • Removal And Installation
      • Right Half Of Control Linkage Disassembly And Assembly
      • Left Half Of Control Linkage Disassembly And Assembly
      • Bracket Of Control Linkage Disassembly And Assembly
    • FLOOR MAT AND FLOOR PANELS
      • Description
      • Removal And Installation
    • FUEL TANK
      • Removal And Installation
    • HORN
      • Removal And Installation
    • SWING FRAME
      • Description
      • Removal And Installation
      • Bushing Removal And Installation
      • Swing Frame Bushing Removal
      • Swing Frame Bushing Installation
      • Boom Pivot Bushing Removal
      • Boom Pivot Bushing Installation
    • BOOM
      • Description
      • Removal And Installation
      • Boom Bushing Removal And Installation
    • ARM
      • Description
      • Removal And Installation
      • Arm To Boom Bushing Removal And Installation
      • Arm To Bucket And Bucket Link Bushing Removal And Installation
    • BUCKET
      • Removal And Installation
    • TAILGATE
      • Removal And Installation
      • Latch Removal And Installation
  • ELECTRICAL SYSTEM AND ANALYSIS
    • ELECTRICAL SCHEMATICS
    • ELECTRICAL SYSTEM INFORMATION
      • Glossary Of Electrical Symbols
      • Troubleshooting
      • Description
      • Fuse And Relay Location / Identification
      • Fuel Timer And Diode Location / Identification
    • BATTERY
      • Maintenance
      • Removal And Installation
      • Using A Booster Battery (Jump Starting)
    • ALTERNATOR
      • Description
      • Tests
      • Alternator Output Test
      • Full Field Test
      • Alternator Regulator Test
      • Alternator Regulator Test With Voltmeter
      • Removal And Installation
      • Belt Adjustment (S/N AHLL11001 – AHLL13119)
      • Belt Adjustment (S/N AHLL13120 & Above)
      • Belt Adjustment (All Models)
      • Belt Replacement
      • Charging System Inspection
      • Parts Identification
    • STARTER
      • Removal And Installation
      • Parts Identification
      • Cleaning And Inspection
    • LIGHTS
      • Upperstructure Light Removal And Installation
      • Upperstructure Light Disassembly And Assembly
      • Boom Light Removal And Installation
      • Boom Light Disassembly And Assembly
      • Light Switch Removal And Installation
    • MICROSWITCH
      • Testing Left Console Microswitch
      • Left Console Microswitch Removal And Installation
      • Testing Right Console Microswitch
      • Right Console Microswitch Removal And Installation
    • FUEL LEVEL SENDER
      • Removal And Installation
      • Testing
  • ENGINE SERVICE
    • ENGINE INFORMATION
      • Description
      • Specifications
      • Torque Values
      • Troubleshooting
      • Engine Removal And Installation
      • Engine Mount Replacement
      • Compression – Checking
    • SPARK ARRESTER MUFFLER
      • Removal And Installation
    • AIR CLEANER
      • Removal And Installation
    • ENGINE COOLING SYSTEM
      • Radiator Removal And Installation
      • Water Pump Removal And Installation
      • Water Pump Disassembly And Assembly
      • Thermostat Removal And Installation
      • Thermostat – Checking
    • LUBRICATION SYSTEM
      • Oil Pan Removal And Installation
      • Oil Pump Removal And Installation
      • Oil Pump – Service
      • Engine Oil Pressure – Testing
      • Relief Valve
    • FUEL SYSTEM
      • Fuel Shutoff Solenoid – Checking
      • Fuel Shutoff Solenoid Removal And Installation
      • Fuel Shutoff Timer Removal And Installation
      • Fuel Injection Pump – Checking
      • Fuel Injection Pump Removal And Installation
      • Fuel Injection Pump – Timing
      • Fuel Camshaft Removal And Installation
      • Fuel Camshaft Governor
      • Fuel Injector Removal And Installation
      • Fuel Injector Nozzle Pressure – Checking
    • CYLINDER HEAD
      • Glow Plug Removal And Installation
      • Valve Clearance Adjustment
      • Valve Timing – Checking
      • Cylinder Head Removal And Installation
      • Cylinder Head Disassembly And Assembly
      • Cylinder Head – Servicing
      • Cylinder Head Top Clearance
      • Valve Guide – Checking
      • Valve And Valve Seat Reconditioning
      • Valve Seat Tightness
      • Valve Spring
      • Valve Tappets
      • Rocker Arm And Shaft – Checking
    • CRANKSHAFT AND PISTONS
      • Piston And Connecting Rod Removal And Installation
      • Piston And Connecting Rod – Servicing
      • Cylinder Bore – Checking
      • Connecting Rod Alignment
      • Crankshaft Gear Removal And Installation
      • Crankshaft And Bearings Removal And Installation
      • Crankshaft And Bearings – Servicing
    • CAMSHAFT AND TIMING GEARS
      • Timing Gearcase Cover Removal And Installation
      • Timing Gears Checking Backlash
      • Idler Gear And Camshaft Removal And Installation
      • Idler Gear And Shaft – Servicing
    • FLYWHEEL AND HOUSING
      • Flywheel Housing Removal And Installation
      • Hydraulic Pump Coupler Removal And Installation
      • Flywheel Removal
      • Flywheel Installation
      • Rear End Plate Removal And Installation
  • HEATER
    • HEATER SYSTEM
      • Description
      • Components
    • REGULAR MAINTENANCE
      • Filter Element Removal And Installation
      • Heater Coil
    • HEATER UNIT
      • Removal And Installation
      • Louver Removal And Installation
      • Threaded Insert Removal And Installation
    • HEATER COIL
      • Removal And Installation
    • HEATER FAN
      • Removal And Installation
    • HEATER VALVE
      • Removal And Installation
  • SPECIFICATIONS
    • (E16) SPECIFICATIONS
      • Machine Dimensions
      • Machine Dimensions – Standard Arm
      • Machine Dimensions – Long Arm
      • Lift Capacity (Standard Arm)
      • Lift Capacity (Long Arm)
      • Performance
      • Controls
      • Engine
      • Hydraulic System
      • Hydraulic Cylinders
      • Hydraulic Cycle Times
      • Electrical
      • Instrumentation
      • Lights
      • Drive System
      • Slew System
      • Undercarriage
      • Crawler Track Design
      • Tracks
      • Type
      • Ground Pressure
      • Capacities
      • Fuel Tank
      • Fuel Consumption
    • TECHNICAL SERVICE GUIDE SPECIFICATIONS
      • Engine
      • Engine Torques
      • Cooling System
      • Excavator Torques
    • 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 Fittings
    • HYDRAULIC FLUID SPECIFICATIONS
      • Specifications
    • CONVERSIONS
      • Decimal And Millimeter Equivalents
      • U.S. To Metric Conversion Chart
    • SERVICE TOOLS REQUIRED
      • Remote Start Tools
      • Hydraulic Tools
      • Engine Tools
      • HVAC Tools
  • ALPHABETICAL INDEX

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