(S/N: AG3411001 & Above – S/N: AHHB11001 & Above)
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This workshop repair service manual PDF download for the E42 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Excavator E42
S/N: AG3411001 & Above
S/N: AHHB11001 & Above
TABLE OF CONTENTS :
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE AND SWING SECTION
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION & AIR CONDITIONING
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE MANUAL REVISION
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 6989433 (8-10)
Total Pages : 826
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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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
EXCAVATOR IDENTIFICATION
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS)
Emergency Exit
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
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
Chart
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 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 ARRESTOR MUFFLER
Cleaning Procedure
ALTERNATOR BELT
Belt Adjustment
Belt Replacement
AIR CONDITIONING COMPRESSOR BELT
Belt Adjustment
Belt Replacement
SEAT BELT
Inspection And Maintenance
CONTROL CONSOLE LOCKOUTS
Inspection And Maintenance
TOWING THE EXCAVATOR
Procedure
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
Description
Remote Start Tool (Service Tool) – 6689778
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) (S/N AG3411031 & ABOVE, AHHB11002 & ABOVE)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOOM) (S/N AG3411030 & BELOW, AHHB11001 & BELOW)
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 (ANGLE BLADE)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
VALVE (MAIN RELIEF)
Testing And Adjusting
VALVES (PORT RELIEF)
Testing And Adjusting Port Relief Valve Pressure
VALVES (CROSS PORT RELIEF)
Testing
Removal And Installation
Cross Port Relief Valve Disassembly And Assembly
VALVE (PRESSURE REDUCING)
Testing And Adjusting
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Parts Identification
Disassembly And 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
Angle Blade, Boom, Auxiliary, Arm and Bucket Valve Section Disassembly And Assembly
HYDRAULIC PUMP
Hydraulic Pump Work Sheet
Pump Testing
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Startup
Torque Limiter Assembly Parts Identification
Torque Limiter Assembly Removal And Installation
Torque Limiter Valve Assembly Disassembly And Assembly
Pump Control Parts Identification
Pump Control Removal And Installation
Pump Control Disassembly And Assembly
Parts Identification
Disassembly And Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR (WITHOUT ANGLE BLADE)
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR (WITH ANGLE BLADE)
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
TRAVEL MOTOR
Removal And Installation
Parts Identification
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
Removal And Installation
Parts Identification
Disassembly And Assembly
SECONDARY AUXILIARY VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
VALVE (BOOM LOCK) (S/N AHHB11001 & ABOVE)
Removal And Installation
VALVE (ARM LOCK) (S/N AHHB11001 & ABOVE)
Removal And Installation
UNDERCARRIAGE
BLADE
Removal And Installation
BLADE (ANGLE)
Removal And Installation
Cutting Edge Removal And Installation
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
Description
Track Lug Height
Checking Tension
Adjusting Tension
Track Removal And Installation
Idler Removal And Installation
Idler Parts Identification
Track Idler Disassembly
Track Idler Assembly
Track Tensioner Removal And Installation
Track Tensioner Cylinder 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
Track Idler Disassembly
Track Idler Assembly
Track Tensioner Disassembly And Assembly
Track Tensioner Cylinder 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
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)
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Boom Swing Frame Hose Routing
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
STANDARD AND LONG ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
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
RIGHT SIDE COVER
Removal And Installation
Latch Removal And Installation
Latch Adjustment
TOOL BOX
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
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
DIAGNOSTICS SERVICE CODES
Number Codes List
DELUXE INSTRUMENT PANEL SETUP
Passwords
Password Entry (For Starting And Operating The Machine)
Changing The Operator Password
Password Lockout Feature
Job Clock
RPM
INSTRUMENT PANEL / CONTROLLER
Removal And Installation
KEY SWITCH
Removal And Installation
WIPER MOTOR
Removal And Installation
MOTION ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Adjusting Switch Position
SERVICE PC (LAPTOP COMPUTER)
Connecting The Remote Start Tool
Connecting Remote Start Tool (Service Tool)
Operation
SHUT-OFF SWITCH
Description
Removal And Installation
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Pushrod
Cylinders
Piston Rings
Pistons
Connecting Rods
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Bolt Torque
Crankshaft Re-Grind Data
Torque For Kubota Metric Bolts
Troubleshooting
Removal And Installation
Compression Checking
ENGINE SPEED CONTROL
Removal And Installation
Auto Idle Controller Removal And Installation
Calibration
Actuator Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing 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 – Checking
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid – Checking
Fuel Shut-off Solenoid 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
Nozzle Spray Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs 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 Guide Removal And Installation
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Push Rod Alignment – 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 Backlash – Checking
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 & AIR CONDITIONING
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 Relief Valve 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
E42 EXCAVATOR SPECIFICATIONS
Machine Dimensions
Machine Dimensions (Standard Arm)
Machine Dimensions (Long Arm)
Machine Dimensions (Angle Blade)
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Capacities
Tracks
Ground Pressure
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
ALPHABETICAL INDEX
SERVICE MANUAL REVISION
Revision No: E42 – 1
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Bobcat E42 Compact Excavator Repair Service Manual – 6989433.pdf
Source : Sitelux.com
