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 !!!! 

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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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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