Bobcat 116 Excavator Repair Service Manual - 6570484

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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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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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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