116 Hydraulic Excavator Service Repair Manual

*bobcat 116 HYDRAULIC EXCAVATOR MELROEcoMPANY · ., 6570484 (4°87)·5C A ·BUSINESS UNIT OF CLIIRK EQUIPMENT COMPANY Printed in U.S.A.

CONTENTS 10 ENGINE No. of page 12 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 13 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 20 POWER TRAIN 21 STRUCTURE AND FUNCTION .................................... 21-1 23 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1 24 MAINTENANCE STAND ARD ............................. _. . . . . . . . 24-1 30 UNDERCARRIAGE 31 STRCTURE AND FUNCTION ..................................... 31-1 33 DISASSEMBLY AND ASSEMBLY .................................. 33-1 34 MAINTENANCE STANDARD ...................................... 34-1 60 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION .................................... 61-1 62 TESTING AND ADJUSTING ...................................... 62-1 63 DISASSEMBLY AND ASSEMBLY .................................. 63-1 64 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-1 70 WORK EQUIPMENT 71 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 -1 73 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-1 7 4 MAINTENANCE STAND ARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4-1 80 ELECTRICAL SYSTEM 81 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 -1

it IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol ffi is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or could possibly arise, first consider safety, and take the necessary actions to deal with the situation. it SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carying out any greasing or repairs, read all the precautions given on the decals which are on the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when using tools. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When welding always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When doing any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 00-1 6.Determine a place in the workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the controi levers and hang warning signs on them. 9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 116 Service Manual

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove all pressure from the cicruit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative(-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 1 7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can start fires. 18. As a general rule, do not use gasoline to wash parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand, your fingers could get caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. 00-2 When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. 116 Service Manual

) STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of "Disassembly and Assembly". Thread diameter Width Ci) Ci) of bolt across flat (mm) (mm) kgm Nm 6 10 1.35±0.15 13.2±1.4 8 13 3.2±0.3 31.4±2.9 10 17 6.7±0.7 65.7±6.8 12 19 11.5± 1.0 112±9.8 14 22 18.0±2.0 177±19 16 24 28.5±3 279±29 18 27 39±4 383±39 20 30 56±6 549±58 22 32 76±8 745±78 24 36 94.5± 10 927±98 27 41 135 ± 15 1320±140 30 46 175±20 1720±190 33 50 225±25 2210±240 36 55 280±30 2750±290 39 60 335±35 3280±340 This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): 1 Nm ::::; 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width of bolt across flats (mm) (mm) kgm 10 14 6.7±0.7 12 17 11.5± 1 16 22 28.5±3 00-3 Tightening torque Nm 65.7±6.8 112±9.8 279±29 11 Si:.rvil'A M<>n• ,,.1

STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. FS0068 Thread diameter Width across flats Tightening torque of nut part of nut part (mm) (mm) kgm Nm 14 19 2.5 ±0.5 24.5±4.9 18 24 5±2 49± 19.6 22 27 8±2 78.5 ± 19.6 24 32 14±3 137.3±29.4 30 36 18±3 176.5±29.4 33 41 20±5 196.1±49 36 46 25 5 245.2±49 42 55 30±5 294.2±49 COATING MATERIALS The recommended coating materials prescribed are listed below. Nomenclature code Applications LT-1A Used to apply rubber pads, rubber gaskets, and cork plugs. LT-1 B Used to apply resin, rubber, metallic and Adhesives non-metallic parts when a fast, strong seal is needed. LT-2" Preventing bolts, nuts and plugs from loosening and leaking oil. LT-3 Provides an airtight, electrically insulating seal. Used for aluminum surfaces LG-1 Used with gaskets and packings to increase sealing effect. LG-3 Heat-resistant gasket for precombustion chambers and exhaust piping. Liquid gasket LG-4 Used by itself on mounting surfaces on the final drive and transmission cases (Thickness after tightening: 0.07 - 0.08 mm) LG-5 Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter. Antitr1ction compound Applied to bearings and taper shafts to facilitate press-fitting and to (Lubricant including LM-P molybdenum disulfide) prevent sticking, burning or rusting. Grease G2-LI Applied to bearings, sliding parts and oil seals for lubrication, rust (Lithium grease) prevention and facilitation of assembling work Vaseline - Used for protecting battery electrode terminals from corrosion. 'L T-2 is also called LOCTITE in the shop manuals 00-4 116 Service Manual

ELECTRIC WIRE CODE ELECTRIC ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Nominal Copper wire Cable O.D. Current rating Applicable circuit number Number Dia. of strands Cross section (mm) (A) strands (mm) (mm~) 01 11 0.32 0.88 2.4 12 Starting, lighting, signal etc. 02 26 0.32 2.09 3.1 20 Lighting, signal etc. 05 65 0.32 5.23 4.6 37 Charging and signal 15 84 0.45 13 36 7.0 59 Starting (Glow plug) 40 85 0.80 42.73 11.4 135 Starting 60 127 0.80 63.84 13.6 178 Starting 100 217 0.80 109.1 17 6 230 Starting CLASSIFICATION BY COLOR AND CODE Priority Starting Charging Lighting Signal Instrument Other n Code B w R G y L 1 Primary Color Black White Red Green Yellow Blue Code BW WR RW GW YR LW 2 Color Black & White White & Red Red & White Green & White Yellow & Red Blue & White Code BY WB RB GR YB LR 3 Color Black & Yellow White & Black Red & Black Green & Red Yellow & Black Blue & Red Auxiliary Code BR WL RY GY YG LY 4 Color Black & Red White & Blue Red & Yellow Green & Yellow Yellow & Green Blue & Yellow Code WY RG GB YL LB 5 Color - White & Yellow Red & Green Green & Black Yellow & Blue Blue & Black Code - WG RL GL YW 6 Color White & Green Red & Blue Green & Blue Yellow & White 00-5 116 Service Manual

WEIGHT TABLE A This weight table is a guide for use when transporting on handling components. Unit: kg Machine model 116 Serial No. 8501 and up Engine assembly 252 Engine (including engine mount) 235 Hydraulic tank (dry) 49 Fuel tank (dry) 22 Operator cab assembly (if equipped) 162 Revolving frame assembly 440 Swing machinery assembly 38 Center swivel joint assembly 32 Travel motor assembly (with reduction gear) 38 X 2 Counterweight 220 Track frame assembly 650 Recoil spring assembly 25 X 2 . Swing circle assembly 62 Track shoe assembly 524 Standard track shoe (400 mm wide) Boom assembly 170 Arm assembly 80 Bucket assembly 100 Boom cylinder assembly 45.5 Arm cylinder assembly 37.5 Bucket cylinder assembly 35 Swing cylinder assembly 39.5 Blade cylinder assembly 26.5 Swing bracket assembly 82 Blade 127 00-6 116 Service Manual

116 Hydraulic Excavator Service Repair Manual

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