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Bobcat E32i Excavator Service Manual (SN AUYJ11001-AUYJ99999)

Format: PDF (Printable Document)

File Language: English

File Pages: 895

File Size: 30.69 MB (Speed Download Link)

Brand: Bobcat

Model: E32i Excavator

Book No: 7243979

Serial No: SN AUYJ11001-AUYJ99999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat E32i Excavator Service Manual (SN AUYJ11001-AUYJ99999)

On an E32i compact excavator, this is the book you grab when the boom is drifting down, a drive motor is acting weak, or a wiring fault is killing your workday. The service manual is what I use in the rental yard when a tech needs specs or a step-by-step to keep turnaround tight. Owners and small contractors reach for it when the machine is out of warranty and they want to fix it right the first time instead of guessing.

What this manual helps you do

  • Diagnose hydraulic issues, check pressures, and trace leaks in the implement and travel circuits
  • Follow teardown and reassembly steps for components like cylinders, drive motors, and swing gearboxes
  • Troubleshoot electrical problems using wiring diagrams, connector pinouts, and test procedures
  • Set and verify adjustments on controls, tracks, slew brakes, and other machine systems after repairs
  • Perform scheduled service at 50/250/500 hour intervals with the correct sequences and spec references

Who this is for

This manual is for anyone maintaining or repairing a Bobcat E32i in the AUYJ11001-AUYJ99999 serial range: small contractors, owner-operators, field techs, and rental fleet shops. If you only need to learn how to run the machine or daily checks, you want the operator's handbook instead, not this manual.

FAQ

Q: Is this a searchable PDF and are the wiring diagrams readable?

A: Yes, these manuals are usually in searchable PDF format and the schematics are laid out so you can zoom in and read wire colors and labels.

Q: How do I know if it fits my exact E32i?

A: Check your serial plate. If your E32i serial number falls between AUYJ11001 and AUYJ99999, this is the correct service manual.

Q: Is this what I need for real repairs, not just basic maintenance?

A: Yes, this is the workshop-level service manual, meant for actual diagnostics and repairs, not just basic operation.

Bottom line: If your E32i serial is in that AUYJ range and you're doing your own repairs or running a shop, 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
    • LIFTING THE EXCAVATOR
      • Procedure
    • OPERATOR CAB (ROPS / TOPS)
      • Description
      • Cab Door
      • Front Window
      • Front Wiper
      • Window Washer Reservoir
      • Right Side Window
    • OPERATOR CANOPY (ROPS / TOPS)
      • Description
    • TRANSPORTING THE EXCAVATOR ON A TRAILER
      • Loading And Unloading
      • Fastening
    • TAILGATE
      • Opening And Closing
      • Adjusting The Latch
    • RIGHT SIDE COVER
      • Opening And Closing
    • SERVICE SCHEDULE
      • Maintenance Intervals
    • AIR CLEANER SERVICE
      • Daily Check
      • Replacing The Filters
    • CAB FILTERS
      • 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 Hydraulic Fluid
      • Hydraulic / Hydrostatic Fluid Chart
      • Removing And Replacing Hydraulic Filters
      • Removing And Replacing The Hydraulic Fluid
    • LUBRICATION OF THE HYDRAULIC 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 Side Rear Window
      • Front Window
    • SEAT BELT
      • Inspection And Maintenance
    • CONTROL CONSOLE LOCKOUTS
      • Inspection And Maintenance
    • TOWING THE EXCAVATOR
      • Procedure
    • REMOTE START TOOL KIT – MEL1563
      • Remote Start Tool Kit – MEL1563
      • Service Tool Harness Control – MEL1565
      • Service Tool Harness Communicator – MEL1566
    • REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
      • Description
      • Remote Start Tool (Service Tool) – 7022042
      • 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 (CLAMP)
      • Testing
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • CYLINDER (EXTENDABLE ARM)
      • Testing
      • Parts Identification
      • Disassembly
      • Assembly
    • VALVE (MAIN RELIEF)
      • Description
    • VALVE (PORT RELIEF)
      • Testing And Adjusting Port Relief Valve Pressure
    • VALVE (CROSS PORT RELIEF)
      • Testing
      • Removal And Installation
      • Cross Port Relief Valve Disassembly And Assembly
    • VALVE (PILOT PRESSURE RELIEF)
      • Testing And Adjusting The Pilot Pressure Relief Valve
    • HYDRAULIC CONTROL VALVE
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
      • Inlet Valve Section Disassembly And Assembly
      • Boom Swing Valve Section Disassembly And Assembly
      • Slew Valve Section Disassembly And Assembly
      • Blade Valve Section Disassembly And Assembly
      • Right And Left Travel Valve Section Disassembly And Assembly
      • Boom Valve Section Disassembly And Assembly
      • Auxiliary, Arm, Bucket And Angle Blade Valve Section Disassembly And Assembly
      • Outlet Valve Section Disassembly And Assembly
    • HYDRAULIC PUMP
      • Hydraulic Pump Work Sheet
      • Pump Testing
      • Description
      • Removal And Installation
      • Coupler Removal And Installation
      • Hydraulic Pump Startup
      • Gear Pump Disassembly And Assembly
      • Piston Pump Parts Identification
      • Piston Pump Disassembly And Assembly
    • MANIFOLD ASSEMBLY / ACCUMULATOR
      • Description
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • TRAVEL MOTOR
      • Removal And Installation
      • Parts Identification Hydraulic Motor
      • Parts Identification Gear Reduction Hub
      • Disassembly
      • Assembly
    • SWIVEL JOINT
      • Removal And Installation
      • Parts Identification
      • Disassembly And 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 And Assembly
    • RIGHT CONTROL LEVER (JOYSTICK)
      • Testing
      • Handle Removal And Installation
      • Joystick Assembly Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • LEFT CONTROL LEVER (JOYSTICK)
      • Testing
      • Handle Removal And Installation
      • Joystick Assembly Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • HYDRAULIC FILTER MOUNT
      • Removal And Installation
    • HYDRAULIC RESERVOIR
      • Removal And Installation
    • OIL COOLER
      • Removal And Installation
    • DIRECT TO TANK VALVE
      • Removal And Installation
    • BLADE CONTROL LEVER
      • Handle Removal And Installation
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • CASE DRAIN FILTER MOUNT
      • Removal And Installation
    • TRAVEL CONTROL VALVE
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • REMOVING AIR FROM THE HYDRAULIC SYSTEM
      • Procedure
    • HYDRAULIC X-CHANGE MANIFOLD (EARLIER MODELS)
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • HYDRAULIC X-CHANGE MANIFOLD (LATER MODELS)
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • SECONDARY AUXILIARY VALVE (EARLIER MODELS)
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • SECONDARY AUXILIARY VALVE (LATER MODELS)
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • VALVE (BOOM LOCK)
      • Removal And Installation
    • VALVE (ARM LOCK)
      • Removal And Installation
  • UNDERCARRIAGE
    • BLADE
      • Removal And Installation
    • TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
      • Description
      • Track Lug Height
      • Checking Tension
      • Adjusting Tension
      • Track Removal And Installation
      • Idler Removal And Installation
      • Parts Identification
      • Idler Disassembly
      • Idler Assembly
      • Track Tensioner Removal And Installation
      • Track Tensioner Parts Identification
      • Track Tensioner Disassembly And Assembly
      • Roller Removal And Installation
      • Sprocket Removal And Installation
    • TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)
      • Description
      • Checking Tension
      • Adjusting Tension
      • Track Removal And Installation
      • Idler Removal And Installation
      • Idler Parts Identification
      • Idler Disassembly
      • Idler Assembly
      • Track Tensioner Disassembly And Assembly
      • Track Tensioner Parts Identification
      • Track Tensioner Disassembly And Assembly
      • Roller Removal And Installation
      • Sprocket Removal And Installation
      • Guide Plate Removal And Installation
    • TRACK MAINTENANCE
      • Track Damage Identification
    • SWING CIRCLE GEAR
      • Swing Bearing Removal
      • Swing Bearing Installation
  • UPPERSTRUCTURE AND SWING SECTION
    • UPPERSTRUCTURE
      • Removal
      • Installation
    • ROPS CANOPY
      • Removal And Installation
    • CAB
      • Removal And Installation
      • Door Removal And Installation
      • Front Window Removal And Installation
      • Front Window Disassembly And Assembly
      • Front Window Adjustment
      • Right Side Rear Sliding Window Removal And Installation
      • Right Side Front Sliding Window Removal And Installation
      • 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 Removal
      • Glass Installation
    • 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
      • Compression Spring Removal And Installation
      • Lock Lever Removal And Installation
      • Console Removal And Installation
    • LEFT UPPERSTRUCTURE COVER
      • Removal And Installation
    • RIGHT UPPERSTRUCTURE COVER
      • Removal And Installation
    • COUNTERWEIGHT
      • Removal And Installation
      • Long Arm Counterweight Removal And Installation
    • TRAVEL LEVERS AND PEDALS
      • Removal And Installation
      • Disassembly And Assembly
    • FLOOR MAT
      • Removal And Installation
    • FUEL TANK
      • Removal And Installation (Canopy Equipped Excavator)
      • Removal And Installation (Cab Equipped Excavator)
      • Fuel Tank Fitting Removal And Installation
    • HORN
      • Removal And Installation
    • SWING FRAME
      • Removal And Installation
      • Boom Swing Frame Hose Routing
      • Bushing Removal
      • Bushing Installation
    • BOOM
      • Removal And Installation
    • ARM (STANDARD AND LONG)
      • Removal And Installation
      • Arm To Boom Bushing Removal And Installation
      • Arm To Bucket And Bucket Link Bushing Removal And Installation
    • ARM (EXTENDABLE)
      • Removal And Installation
      • Arm To Boom Bushing Removal And Installation
      • Arm To Bucket Bushing Removal And Installation
      • Disassembly And Assembly
      • Shimming Procedure
    • BUCKET
      • Bucket Teeth Removal And Installation
      • Bucket Side Cutting Edge Removal And Installation
    • CLAMP
      • Removal And Installation
    • TAILGATE
      • Removal And Installation
      • Latch Removal And Installation
    • X-CHANGE
      • Removal And Installation
      • Disassembly
      • Assembly
    • X-CHANGE (HYDRAULIC)
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • 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)
    • QUICK COUPLER (PIN GRABBER)
      • Troubleshooting
      • Daily Inspection
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • RIGHT SIDE COVER
      • Removal And Installation
      • Latch Removal And Installation
      • Latch Adjustment
    • TOOL BOX
      • Removal And Installation
  • ELECTRICAL SYSTEM AND 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
      • Removal And Installation
      • Parts Identification
    • STARTER
      • Testing
      • Removal And Installation
      • Parts Identification
    • LIGHTS
      • Removal And Installation
      • Boom Light Removal And Installation
      • Boom Light Bulb Replacement
    • MAGNETIC LOCKOUT SENSOR
      • Removal And Installation
    • FUEL LEVEL SENDER
      • Removal And Installation
      • Testing
    • DIAGNOSTIC SERVICE CODES
      • Viewing Service Codes
      • Service Codes List
    • CONTROL PANEL SETUP
      • Panel Setup (Deluxe Instrument Panel)
      • Password Setup (Keyless Start Panel)
      • Password Setup (Deluxe Instrument Panel)
      • Maintenance Clock
    • INSTRUMENT PANEL
      • Removal And Installation
    • CONTROLLER
      • Description
      • Gateway Controller Removal And Installation
      • Auxiliary Controller Removal And Installation
    • KEY SWITCH
      • Removal And Installation
    • WIPER MOTOR
      • Removal And Installation
    • MOTION ALARM SYSTEM
      • Description
      • Inspecting
      • Adjusting Switch Position
    • SERVICE PC (LAPTOP COMPUTER)
      • Connecting The Remote Start Tool
      • Connecting Remote Start Tool (Service Tool)
    • SHUT-OFF SWITCH
      • Description
      • Removal And Installation
    • TRAVEL MOTOR AUTO-SHIFT
      • Auto-Shift Drive System (If Equipped)
      • Troubleshooting
  • ENGINE SERVICE
    • ENGINE INFORMATION
      • Description
      • Specifications
      • Crankshaft Re-Grind Data
      • Torque For Kubota Metric Bolts
      • Troubleshooting
      • Engine Removal And Installation
      • Compression – Testing
    • ENGINE SPEED CONTROL
      • Removal And Installation
      • Auto Idle Controller Removal And Installation
      • Calibration
      • Actuator Removal And Installation
    • MUFFLER
      • Removal And Installation
    • AIR CLEANER
      • Removal And Installation
    • ENGINE COOLING SYSTEM
      • Radiator Removal And Installation
      • Fan Removal And Installation
      • Water Pump Removal And Installation
      • Water Pump Disassembly And Assembly
      • Thermostat Housing Removal And Installation
      • Thermostat – Testing
    • LUBRICATION SYSTEM
      • Oil Pan Removal And Installation
      • Oil Pump Removal And Installation
      • Oil Pump Inspection
      • Engine Oil Pressure – Testing
    • FUEL SYSTEM
      • Fuel Shutoff Solenoid – Testing
      • Fuel Shut-off Solenoid Removal And Installation
      • Fuel Injection Pump – Testing
      • 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 – Testing
      • Nozzle Spray Condition
      • Valve Seat Tightness
    • CYLINDER HEAD
      • Glow Plugs – Testing
      • Glow Plugs Removal And Installation
      • Valve Clearance Adjustment
      • Valve Timing – Inspecting
      • Cylinder Head Removal And Installation
      • Cylinder Head Disassembly And Assembly
      • Cylinder Head – Servicing
      • Cylinder Head Top Clearance
      • Valve Guide – Inspecting
      • Valve Guide Removal And Installation
      • Reconditioning The Valve And Valve Seat
      • Valve Spring
      • Valve Tappets
      • Rocker Arm And Shaft – Inspecting
      • Push Rod Alignment – Inspecting
    • CRANKSHAFT AND PISTONS
      • Piston And Connecting Rod Removal And Installation
      • Piston And Connecting Rod – Servicing
      • Cylinder Bore – Inspecting
      • 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 Backlash – Inspecting
      • Idle Gear And Camshaft Removal And Installation
      • Camshaft – Servicing
      • Idle Gear And Shaft – Servicing
    • FLYWHEEL AND HOUSING
      • Hydraulic Pump Coupler Removal And Installation
      • Flywheel Removal And Installation
      • Flywheel Ring Gear
  • HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
    • AIR CONDITIONING SYSTEM FLOW
      • Description
      • Chart
      • Components
      • Safety Equipment
    • REGULAR MAINTENANCE
      • Cab Filters
      • Air Conditioning Compressor Belt Adjustment
      • Air Conditioning Compressor Belt Replacement
      • Condenser
      • Air Conditioning Lubrication
      • Evaporator / Heater Coil
      • Air Conditioning Service Chart
    • 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
      • Electrical System
      • Engine Coolant Bypassing The Heater Valve
    • SYSTEM CHARGING AND RECLAMATION
      • Refrigerant Identification
      • Reclamation And Charging With Recovery / Charging Unit
    • 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
      • Description
      • Removal And Installation
    • EXPANSION VALVE
      • Removal And Installation
    • EVAPORATOR COIL
      • Removal And Installation
    • HEATER COIL
      • Removal And Installation
    • BLOWER FAN
      • Removal And Installation
    • HEATER VALVE
      • Removal And Installation
    • HVAC DUCT
      • Removal And Installation
  • SPECIFICATIONS
    • EXCAVATOR SPECIFICATIONS
      • Machine Dimensions
      • Machine Dimensions (Standard Arm)
      • Machine Dimensions (Long Arm)
      • Machine Dimensions (Extendable Arm)
      • Performance
      • Controls
      • Engine
      • Hydraulic System
      • Hydraulic Cylinders
      • Hydraulic Cycle Times
      • Drive System
      • Slew System
      • Undercarriage
      • Electrical
      • Capacities
      • Tracks
      • Ground Pressure
    • TECHNICAL SERVICE GUIDE SPECIFICATIONS
      • Engine
      • Engine Torques
      • Cooling System
      • Excavator Torques
    • TORQUE SPECIFICATION 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
      • O-ring Flare Fitting
      • Port Seal Fitting
      • Push To Connect Fittings
    • HYDRAULIC FLUID SPECIFICATIONS
      • Specifications
    • CONVERSIONS
      • Decimal And Millimeter Equivalent Chart
      • U.S. To Metric Conversion Chart
    • SERVICE TOOLS REQUIRED
      • Remote Start Tools
      • Hydraulic Tools
      • Engine Tools
      • Electrical Tools
      • General Tools
      • HVAC Tools
  • ALPHABETICAL INDEX
  • SERVICE SCHEDULE SYMBOLS

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