Bobcat 1600 Wheel Loader Repair Service Manual – 6566906

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This workshop repair service manual PDF download for the 1600 Bobcat Wheel Loader 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 Loader 1600

TABLE OF CONTENTS :

SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT ARTICULATED LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566906 (8-87)
Total Pages : 280

This Bobcat 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
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Procedure
FRAME LOCK
Procedure
TRANSPORTING THE BOBCAT LOADER
Procedure
OPERATOR RESTRAINT SYSTEM
Description
Inspection Of The Operator Restraint System
Serviceing The Operator Restraint System
USING AND EXTRA BATTERY (JUMP STARTING)
Procedure

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM (S/N 12001 & ABOVE)
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Flare Connections
O-Ring Face Seal Connection
Straight Thread O-Ring Fitting
Tubelines And Hoses
LIFT CYLINDER
Checking The Lift Cylinder
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
STEERING CYLINDER
Checking The Steering Cylinder
Removal And Installation
HYDRAULIC CONTROL VALVE
Check The Main Relief Valve
Main Relief Valve Removal And Installation
Removal And Installation
HYDRAULIC PUMP
Checking Output Of The Hydraulic Pump
Removal And Installation
BUCKET POSITION VALVE (S/N 12026 & BELOW)
Removal And Installation
Disassembly And Assembly
BUCKET POSITION VALVE (S/N 12027 & ABOVE)
Removal And Installation
STEERING CONTROL VALVE
Checking Steering Relief Valve
Removal And Installation
Disassembly
Inspection
Assembly
PORT BLOCK
Removal And Installation
Disassembly And Assembly
PRIORITY VALVE
Removal And Installation
Disassembly And Assembly
Adjustment Of Steering Relief Valve
HYDRAULIC / HYDROSTATIC FLUID RESERVOIR
Removal And Installation
HYDRAULIC SYSTEM (S/N 11999 & BELOW)
HYDRAULIC CONTROL VALVE
Checking The Main Relief Valve
Mian relief Valve Removal And Installation
Checking Output Of The Hydraulic Pump
Removal And Installation
STEERING CONTROL VALVE
Checking Steering Relief Valve
PORT BLOCK
Removal And Installation
Cold Weather By-Pass Valve
Servo Relief Valve
Charge Relief Valve
OIL COOLER
Removal And Installation
Oil Cooler Service

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM (S/N 12001 & ABOVE)
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
High Pressure Relief Replenishing Valves Function
CENTERING MECHANISM
Foot Pedal Angle Adjustment
Removal And Installation
Centering Mechanism Spring Replacement
Adjusting The Springs In The Centering Mechanism
Micro Switch Adjustment
HYDROSTATIC MOTOR
Removal And Installation
TWO SPEED VALVE
Removal And Installation
Disassembly And Assembly
HYDROSTATIC PUMP
Checking Charge Pressure
Checking The High Pressure Relief Replenishing Valve
Neutral Adjustment
Removal And Installation
HYDROSTATIC SYSTEM (S/N 11999 & BELOW)
TROUBLESHOOTING
SERVO CONTROL
Neutral Adjustment
Removal And Installation
Disassembly And Assembly
Servo Control Pressure
CENTERING MECHANISM
Removal And Installation
Centering Mechanism Spring Replacement
Adjusting The Springs in The Centering Mechanism
Neutral Safety Switch Adjustment
HYDROSTATIC MOTOR
Removal And Installation
Manifold Block
HYDROSTATIC PUMP
Checking Charge Pressure
Replenishing Valves
Removal And Installation

DRIVE SYSTEM
TROUBLESHOOTING
DRIVE SHAFT
Removal And Installation
AXLE AND DIFFERENTIAL
Rear Axle Removal And Installation
Front Axle Removal And Installation
Wheel RPM
Hub Removal
Hub Installation
Differential Disassembly
Ring Gear Removal
Ring Gear Installation
Pinion Shaft And Drop Gear Removal
Assembly Procedure Explanation
Checking Differential Assembly End Play (Without Pinion Shaft Installed)
Pinion Shaft Installation
Differential Assembly Installation
BRAKE (S/N 12001 & ABOVE)
Removal And Installation
Disassembly And Assembly
BRAKE VALVE
Removal And Installation
Disassembly And Assembly
BRAKE (S/N 11242 – 11999)
Removal And Installation
Disassembly And Assembly
Moving The Loader
BRAKE (S/N 11241 & bELOW)
Removal And Installation
Disassembly And Assembly
Removing Air From The Brake System

MAIN FRAME
OPERATOR CAB
Removal And Installation
REAR DOOR
Door Latch Adjustment
Removal And Installation
LIFT ARMS
Removal And Installation
BOB-TACH
Removal And Installation
FLOOR PANEL
Removal And Installation
SEAT AND SEAT PAN
Removal And Installation
STEERING COLUMN COVER
Removal And Installation
TUBELINE COVER
Removal And Installation
FUEL TANK
Removal And Installation
LOADER FRAME DISASSEMBLY AND ASSEMBLY
Description
Seperating The Front Section From The Center Section
Connecting The Front Section To The Center Section
Seperating The Rear Section From The Center Section (S/N 11999 & Below Only)
Rear Section Service Procedures (S/N 11999 & Below Only)
Connecting The Rear Section To The Center Section (S/N 11999 & Below Only)

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Description
TROUBLESHOOTING
BATTERY
Checking The Battery
Removal And Installation
DIODES
Checking The Diodes
ALTERNATOR (DELCO)
Alternator Belt Adjustment
Checking Alternator Wiring Harness
Checking Alternator Output
Checking Alternator Regulator
Removal And Installation
Disassembly And Assembly
MELROE ALTERNATOR
Checking The Alternator Output
Checking The Alternator Regulator
Removal And Installation
Disassembly And Assembly
STARTER
Checking The Starter
Removal And Installation
Disassembly And Assembly
Inspection
Replacing The Brushes

ENGINE SERVICE
TROUBLESHOOTING
VALVE CLEARANCE
Adjustment
ENGINE COMPRESSION
Checking
FUEL FILTER
Water Trap
Fuel Filter Element
REMOVING AIR FROM THE FUEL SYSTEM
Procedure
ENGINE SHUT-OFF SOLENOID
Removal And Installation
THROTTLE TENSION ADJUSTMENT
Procedure
FUEL INJECTION PUMP
Removal And Installation
Checking The Injection Pump
Timing The Injection Pump
FUEL INJECTOR NOZZLES
Removal And Installation
Checking The Injector Nozzles
GLOW PLUGS
Removal And Installation
Checking The Glow Plug
ENGINE
Removal And Installation
RADIATOR AND OIL COOLER
Removal And Installation
Oil Cooler Removal And Installation
MUFFLER
Removal And Installation
BLOWER HOUSING
Removal And Installation
ENGINE FLYWHEEL AND U-JOINT
Removal And Installation
Flywheel Ring Gear
CYLINDER HEAD
Removal Of The Cylinder Head
Disassembly Of The Cylinder Head
Servicing The Cylinder Head
Assembly Of The Cylinder Head
Installing The Cylinder Head
TIMING GEAR COVER
Removal And Installation
TIMING GEAR, CAMSHAFT AND OIL PUMP
Removal And Installation
Oil Pump Service
Servicing The Camshaft
CRANKSHAFT AND PISTONS
Piston And Crankshaft Removal And Installation
Crankshaft Service
Service The Connecting Rods And Pistons
CYLINDER LINERS
Checking The Cylinder Liners
WATER PUMP
Disassembly And Assembly

TECHNICAL DATA
LOADER SPECIFICATIONS (S/N 11999 & BELOW)
Operation And Performance
Engine
Loader Hydraulics
Electrical
Drive System
Capactities
Tires
LOADER SPECIFICATIONS (S/N 12001 & ABOVE)
Operation And Performance
Engine
Loader Hydraulics
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Pistons
Crankshaft
Oil Pump
Engine Bolt Torque
TORQUE SPECIFICATIONS
Engine Group
Hydrostatic Controls (S/N 11999 & Below)
Hydrostatic System (S/N 12001 & Above)
Hydrostatic System (S/N 11999 & Below)
Hydraulic Controls
Steering Controls And Rear Door
Drive System
Lift Arm & Bob-Tach Group
Frame & Articulation Unit Group
DECIMAL AND MILLIMETER EQUILAVENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

SERVICE MANUAL REVISIONS
1600-1
1600-2
1600-3
1600-4
1600-5

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