Bobcat 116 Excavator Service Manual – 6570484 (4-87)

This workshop repair service manual PDF download for the 116 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 116

TABLE OF CONTENTS :

10 ENGINE
12 TESTING AND ADJUSTING
13 DISASSEMBLY AND ASSEMBLY

20 POWER TRAIN
21 STRUCTURE AND FUNCTION
23 DISASSEMBLY AND ASSEMBLY
24 MAINTENANCE STANDARD

30 UNDERCARRIAGE
31 STRCTURE AND FUNCTION
33 DISASSEMBLY AND ASSEMBLY
34 MAINTENANCE STANDARD

60 HYDRAULIC SYSTEM
61 STRUCTURE AND FUNCTION
62 TESTING AND ADJUSTING
63 DISASSEMBLY AND ASSEMBLY
64 MAINTENANCE STANDARD

70 WORK EQUIPMENT
71 STRUCTURE AND FUNCTION
73 DISASSEMBLY AND ASSEMBLY
74 MAINTENANCE STANDARD

80 ELECTRICAL SYSTEM
81 STRUCTURE AND FUNCTION

SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6570484 (4-87)-5C
Total Pages : 212

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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CONTENTS
SAFETY
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
PRECAUTIONS DURING WORK

STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
TIGHTENING TORQUE FOR NUTS OF FLARED

COATING MATERIALS

ELECTRICAL WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE

WEIGHT TABLE

TABLE OF OIL AND COOLANT QUANTITIES

ENGINE TESTING AND ADJUSTING
TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING TOOL LIST
LUBRICATION SYSTEM
LUBRICATION SYSTEM CHART
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FAN BELT TENSION
BLEEDING AIR FROM FUEL LINE

ENGINE DISASSEMBLY AND ASSEMBLY
REMOVAL OF STARTING MOTOR ASSEMBLY
INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL OF ALTERNATOR ASSEMBLY
INSTALLATION OF ALTERNATOR ASSEMBLY
REMOVAL OF FAN PULLEY ASSEMBLY
INSTALLATION OF FAN PULLEY ASSEMBLY
REMOVAL OF WATER PUMP ASSEMBLY
INSTALLATION OF WATER PUMP ASSEMBLY
REMOVAL OF THERMOSTAT ASSEMBLY
INSTALLATION OF THERMOSTAT ASSEMBLY
REMOVAL OF NOZZLE HOLDER ASSEMBLY
INSTALLATION OF NOZZLE HOLDER ASSEMBLY
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
REMOVAL OF CYLINDER HEAD ASSEMBLY
REMOVAL OF RADIATOR ASSEMBLY
INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL OF ENGINE ASSEMBLY
INSTALLATION OF ENGINE ASSEMBLY

POWER TRAIN STRUCTURE AND FUNCTION
POWER TRAIN (S/N 11999 & Below)
POWER TRAIN (S/N 12001 & Above)
SWING CIRCLE (S/N 11999 & Below)
SWING CIRCLE (S/N 12001 & Above)
SWING MACHINERY (S/N 11999 & Below)
SWING MACHINERY (S/N 12001 & Above)
SPROCKET (S/N 11999 & Below)
SPROCKET (S/N 12001 & Below)
TRACK FRAME AND RECOIL SPRING (S/N 12001 & Above)
IDLER (S/N 12001 & Above)
TRACK ROLLER
TRACK SHOE (S/N 12001 & Above)

POWER TRAIN DISASSEMBLY AND ASSEMBLY
REMOVAL OF SWING CIRCLE ASSEMBLY
INSTALLATION OF SWING CIRCLE ASSEMBLY
REMOVAL OF SWING MACHINERY ASSEMBLY
INSTALLATION OF SWING MACHINERY ASSEMBLY
DISASSEMBLY OF SWING MACHINERY ASSEMBLY
ASSEMBLY OF SWING MACHINERY ASSEMBLY
POWER TRAIN MAINTENANCE STANDARD
SWING CIRCLE (S/N 11999 & Below)
SWING CIRCLE (S/N 12001 & Above)
SWING MACHINERY (S/N 11999 & Below)
SWING MACHINERY (S/N 12001 & Above)
SPROCKET (S/N 11999 & Below)
SPROCKET (S/N 12001 & Above)

UNDERCARRIAGE STRUCTURE AND FUNCTION
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER
TRACK SHOE

UNDERCARRIAGE DISASSEMBLY AND ASSEMBLY
REMOVAL OF RECOIL SPRING ASSEMBLY
INSTALLATION OF RECOIL SPRING ASSEMBLY
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
ASSEMBLY OF RECOIL SPRING ASSEMBLY
REMOVAL OF TRACK SHOE ASSEMBLY
INSTALLATION OF TRACK SHOE ASSEMBLY

UNDERCARRIAGE MAINTENANCE STANDARD
TRACK FRAME AND RECOIL SPRING (S/N 11999 & Below)
TRACK FRAME AND RECOIL SPRING (S/N 12001 & Above)
TRACK ROLLER (S/N 11999 & Below)
TRACK ROLLER (S/N 12001 & Above)
TRACK SHOE (S/N 11999 & Below)
TRACK SHOE (S/N 12001 & Above)
IDLER (S/N 11999 & Below)
IDLER (S/N 12001 & Above)

HYDRAULIC CONTROL STRUCTURE AND FUNCTION
HYDRAULIC PIPING
HYDRAULIC CIRCUIT SCHEMATICS
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT SCHEMATICS (S/N 12001 & Above)
HYDRAULIC CIRCUIT DIAGRAM (S/N 11999 & Below)
HYDRAULIC CIRCUIT DIAGRAM (S/N 12001 & Above)
HYDRAULIC TANK (S/N 11999 & Below)
HYDRAULIC TANK (S/N 12001 & Above)
6-SPOOL CONTROL VALVE (S/N 11999 & Below)
6-SPOOL CONTROL VALVE (S/N 12001 & Above)
4-SPOOL CONTROL VALVE (S/N 12001 & Above)
3-SPOOL CONTROL VALVE (S/N 11999 & Below)
HYDRAULIC TRIPLE GEAR PUMP (S/N 11999 & Below)
CENTER SWIVEL JOINT (S/N 11999 & Above)
CENTER SWIVEL JOINT (S/N 12001 & Above)
SWING MOTOR (S/N 11999 & Below)
SWING MOTOR (S/N 12001 & Above)
TRAVEL MOTOR (with reduction gear) (S/N 11999 & Below)
BRAKE VALVE
VALVE CONTROL (S/N 11999 & Below)
VALVE CONTROL (S/N 12001 & Above)

HYDRAULIC SYSTEM TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TESTING AND ADJUSTING TOOL
TESTING OPERATING FORCE OF CONTROL LEVER
TESTING TRAVEL OF CONTROL LEVER
TESTING TRAVEL OF CONTROL VALVE SPOOL
TESTING AND ADJUSTING HYDRAULIC PRESSURE
MEASURING DELIVERY OF PUMP
116 HYDRAULIC PUMP CHECK
Checking the Output of the Hydraulic Pump at the Boom Cylinder
Adjusting the Main Relief Valve
Checking the Output of the Hydraulic Pump at the Arm Cylinder
Adjusting the Main Relief Valve
Checking the Output of the Hydraulic Pump at the Blade Cylinder
Adjusting the Main Relief Valve
116 PORT RELIEF VALVE CHECK
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR
MEASURING OIL LEAKAGE FROM CYLINDER

HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
REMOVAL OF 6-SPOOL CONTROL VALVE ASSEMBLY
INSTALLATION OF 6-SPOOL CONTROL VALVE ASSEMBLY
REMOVAL OF 3-SPOOL CONTROL VALVE ASSEMBLY
INSTALLATION OF 3-SPOOL CONTROL VALVE ASSEMBLY
DISASSEMBLY OF CONTROL VALVE ASSEMBLY
ASSEMBLY OF CONTROL VALVE ASSEMBLY
REMOVAL OF MAIN RELIEF VALVE ASSEMBLY
INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL OF SWING MOTOR ASSEMBLY
INSTALLATION OF SWING MOTOR ASSEMBLY
REMOVAL OF TRAVEL MOTOR ASSEMBLY
INSTALLATION OF TRAVEL MOTOR ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY
INSTALLATION OF BOOM CYLINDER ASSEMBLY
REMOVAL OF ARM CYLINDER ASSEMBLY
INSTALLATION OF ARM CYLINDER ASSEMBLY
REMOVAL OF BUCKET CYLINDER ASSEMBLY
INSTALLATION OF BUCKET CYLINDER ASSEMBLY
REMOVAL OF BLADE CYLINDER ASSEMBLY
INSTALLATION OF BLADE CYLINDER ASSEMBLY
REMOVAL OF BOOM SWING CYLINDER ASSEMBLY
INSTALLATION OF BOOM SWING CYLINDER ASSEMBLY
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY

HYDRAULIC SYSTEM MAINTENANCE STANDARD
SWING MOTOR (S/N 12001 & Above)
6-SPOOL CONTROL VALVE (S/N 11999 & Below)
6-SPOOL CONTROL VALVE (S/N 12001 & Above)
4-SPOOL CONTROL VALVE (S/N 12001 & Above)
3-SPOOL CONTROL VALVE (S/N 11999 & Below)
HYDRAULIC CYLINDER (S/N 11999 & Below)
HYDRAULIC CYLINDER (S/N 12001 & Above)
TRIPLE GEAR PUMP (S/N 11999 & Below)
TRIPLE GEAR PUMP (S/N 12001 & Above)

WORK EQUIPMENT STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT (S/N 12001 & Above)

WORK EQUPMENT DISASSEMBLY AND ASSEMBLY
REMOVAL OF WORK EQUIPMENT ASSEMBLY
INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL OF BLADE ASSEMBLY
INSTALLATION OF BLADE ASSEMBLY
REMOVAL OF ARM AND BUCKET ASSEMBLY
INSTALLATION OF ARM AND BUCKET ASSEMBLY
REMOVAL OF BUCKET ASSEMBLY
INSTALLATION OF BUCKET ASSEMBLY
REMOVAL OF ARM ASSEMBLY
INSTALLATION OF ARM ASSEMBLY
REMOVAL OF BOOM ASSEMBLY
INSTALLATION OF BOOM ASSEMBLY
REMOVAL OF FLOOR FRAME ASSEMBLY
INSTALLATION OF FLOOR FRAME ASSEMBLY

WORK EQUIPMENT MAINTENANCE STANDARD
WORK EQUIPMENT

ELECTRICAL SYSTEM STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM (S/N 12001 & Above)

SERVICE MANUAL REVISION
116-1
116-2

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