SOP for Bobcat

STANDRAD OPERATING PROCEUDRE FOR

MAINTENANCE OF
SKID STEER LOADER (BOB CAT)

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SOP for Bobcat

INDEX

1.0

DAILY CHECK UP

2.0

MAINTENANCE PROCEDURES
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26

APM Terminals

Drive chain adjustment

Radiator core cleaning
Quick coupler inspection
Hydraulic Pump (Axial Pump) Servicing
Replacement of Hydraulic cylinder Seals
Replacement of Hydraulic Return Line Filters.
Removal and Maintenance of Accumulators
Replacement of Hydraulic oil
Maintenance of lead acid battery
Replacement of lubricating oil
Servicing and replacement of air breather
Replacement of tires
Checking of Engine Oil level.
Replacement of Alternator Belts.
Replacement/service of Air filter
Replacement of engine oil and oil filter
Replacement of fuel filter
Cleaning/replacement of Crankcase Breather
Replacement of Coolant.
Servicing of Oil Pump of engine
Engine Disassembly Procedure
Assembly of Piston and Connecting Rod
Tappet Setting
Replacement of knuckle pin bearing
Adjustment of loader arm movements
Replacement of wheel bearing

SOP for Bobcat

1 DAILY CHECK UP
1) Check oil level before starting
2) Check the hydraulic oil level
3) Check the coolant level in the radiator
4) Check the coolant level in the coolant reservoir
5) Lubricate the designated locations
6) Drain the water separator
7) check the operation of all switches
8) Check operation of all controls
9) Check level of window washer liquid

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SOP for Bobcat

MAINTENANCE PROCEDURES

2.1

Drive chain adjustment -

Responsibility: In-Charge, Shift Engineer, Work Leader

Purpose:

Description of procedure for adjustment of drive chains.

Scope:

To be done at recommended interval.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box,

There are four drive chains on the skid steer loader that must be checked and adjusted.
1)
2)
3)
4)
5)
6)
7)
8)

9)
10)
11)
12)
13)
14)

Park the machine on level ground and stable ground.

Chock the rear tires.
Use and appropriate floor jack to lift the front of the machine so that the front tires are off of the
ground
Rotate the wheel forward and backward measure total play
Remove the right wheel nuts. Use an appropriate nylon lifting strap and hoist in order to remove
the tire and rim. The weight of the standard tire and rim is 51 kg
Remove bolts and the cover for the drive chain case.
Loosen the eight bolts for the axle housing. Place chain tension adjuster between the axle
housings.
Rotate the axle in order to ensure that the chain is taut below the sprockets. Place a straight
edge across the top of the sprockets. Measure the total amount of movement in the chain. Set
the chain tension so that there is a total of 15 mm movement in the chain. This is equal to
7.5mm of movement above the straight edge and 7.5 mm of movement below the straight edge.
Tighten the bolts for the axle housing in order that is shown above to 16015 N-m. Turn the nuts
an additional 605 in the same order.
Remove the chain tension adjuster.
Install the bolts and the cover for the drive chain case.
Use an appropriate nylon lifting strap and a hoist in order to position the tire and rim to the axle.
The weight of the tire and rim is 51 kg.
Lower the front of the machine to the ground. Repeat the procedure on the opposite side of the
machine it is necessary.
Repeat the adjustment procedure on the rear drive chains if it is necessary.

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SOP for Bobcat

2.2

Radiator core cleaning -

Responsibility:

Work Shop In-Charge, Shift Engineer, Work Leader

Purpose:

Description of procedure for cleaning of radiator core cleaning.

Scope:

To be done at recommended interval or at pump malfunction.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box,

1)
2)
3)
4)
5)
6)

Open the engine access door.

Tilt the radiator guard upward.
Clean the radiator core
Remove any dirt or debris from the fan, the fan hub, the oil cooler, the radiator guard and the
fan guard.
Tilt the radiator guard downward.
Close the engine access door.

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SOP for Bobcat

2.3

Quick coupler inspection -

Responsibility:

Work Shop In-Charge, Shift Engineer, Work Leader

Purpose:

Description of procedure for inspection of quick coupler.

Scope:

To be done at recommended interval or at pump malfunction.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box,

1)
2)
3)
4)
5)
6)
7)
8)

Clean the quick coupler prior to inspection in order to properly inspect the quick coupler.
Tilt the quick coupler all the way forward in order to clean the debris away from the pins
Move the quick coupler levers. Ensure that the levers are not bent or broken.
Make sure that the coupler pins extend through the bottom of the quick coupler assembly.
Check the pins for wear and check the pins for damage.
Check the top edges of the quick coupler assembly for wear or for damage. Check the face of
the quick coupler assembly for wear or damage.
Inspect the components inside the quick coupler for the following problems: loose bolts, oil
leaks, broken parts, missing parts and cracked components.
Inspect the hydraulic lines and the hydraulic fittings for damage or for wear. Repair any worn
components or replace any worn components. Repair any leaking components.
Inspect the steel material of the quick coupler for cracks.

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SOP for Bobcat

2.4

DISASSEMBLY OF HYDRAULIC PUMP (VARIABLE DISP AXIAL PISTON

PUMP)

Responsibility:

Area Manager, Shift Engineer, Technician

Purpose:

For disassembly and servicing of Axial Piston Pump

Scope:
Operating Procedures

TOOLS AND MATERIAL REQUIRED: Prepare the followings:

1)
Clean washing oil(kerosene or light oil) to wash parts
2)
Lithium grease to coat oil seals
3)
The same clean hydraulic fluid as the type used in the machine- for lubrication
Precautions during assembly: A)
General precautions:
1)
Never damage the parts.
2)
Do not dirty the parts (keep the work table clean).
3)
Cover the openings of removed pipes, etc. to prevent entry of foreign objects.
4)
To facilitate assembly later, place the removed parts in their correct order.
B)

Internal Parts:
Handle the cylinder block assembly and the port plate particularly carefully. Because of the
viscous hydraulic fluid, it may take much trouble to remove the piston assembly from the
cylinder block. Do not apply any excessive force but handle them gently with good care.

C)

Parts to be pressed in:

Except for replacement, do not remove the parts pressed in(bearings, oil seals and bushes).
Once removed, they cannot be reused.

Disassembly procedure:1)
Slackening the cover fitting bolts, remove the cover. Take care not to damage the gaskets
between the cover and the housing. Also, be aware that the cover may suddenly be pushed up
by the springs.
Ordinarily, the port plate can be removed together but occasionally it is stuck
on
the cylinder block. Remove it carefully by turning it slowly without causing damage.
2)
Remove the yoke return spring and their rests.
3)
Remove the entire cylinder block assembly (including the cylinder block, the piston assembly,
the slippers retainer, the pivot, the washers, etc.)
4)
Remove the operating piston.
5)
Disassemble the control body fitted on the cover.
6)
Remove the yoke:
A)
Slacken the trunion fitting bolts, and then remove the trunion shafts.

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SOP for Bobcat

B)
C)
7)
A)
B)
C)

Slightly tilt the yoke and remove it from the housing.

Remove the swash plate from the removed yoke. The swash plate may be stuck on the yoke.
Remove them gently taking care not to damage the sliding surfaces.
Remove the shaft:
Remove the key
The seal retainer can be removed by loosening the seal retainer mounting bolt.
Give a light blows to the shaft end on the cover side. The shaft will come out together with the
bearings.

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SOP for Bobcat

2.5

REPLACEMENT OF HYDRAULIC CYLINDER SEALS: -

Responsibility:

Work Shop In-Charge, Shift Engineer, Work Leader

Purpose:

Description of procedure for replacement of Hydraulic Cylinder Seals.

Scope:

To be done at recommended interval or at pump malfunction.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box, seal to be replaced,

7)
Ensure that the equipment is switched off.
8)
Ensure that the cylinder / actuator in question do not contain fluid under pressure.
9)
Provide support to the equipment if necessary.
10)
Remove the hose connections.
11)
Drain the fluids from the actuator
12)
Provide support to the actuator if necessary.
13)
Carefully remove the pins, bolts and nuts that hold the actuator in place.
14)
After removing the actuator from the supports take it to a clean, dust free place for servicing.
15)
Carefully dissemble the cylinder into its sub-components.
16)
Replace the seals and the 'O' rings.
17)
Assemble the actuator taking care to see that no excessive force is used.
18)
Move the actuator back to the site and hoist / prop it as per the requirement for mating it back
onto the equipment.
19)
Fit the pins, nuts and bolts and secure the cylinder.
20)
Reconnect the hoses and other connections.
21)
Remove any lashings and other support that may have been provided.
22)
Clean any oil spillages.

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SOP for Bobcat

2.6

REPLACEMENT OF THE RETURN LINE FILTER: -

Responsibility:

Shift Engineer, Work Leader.

Purpose:

Description of procedure for replacement of Hydraulic Filter

Scope:

To be done along with oil change.

Operating Procedures

TOOLS AND MATERIALS REUIRED: Tool box, cotton waste, replacement filter.
Be alert for procedure when the fault message occurs on the fault display by control system. This fault
message is generated when filter pollution reaches to 75%.
1) Close the shut-off valves on the return flow filter.
2) Loosen the drain screw & permit any air to escape.
3) Unscrew the cover, remove the dirt collecting strainer & filter element by turning to the left &
lifting.
4) Clean the dirt collecting strainer thoroughly with a suitable cleaning aid.
( e.g.
petroleum)
5) Insert the new filter element.
6) Ensure correct oil seating of the seals when re-assembling!
7) Smear the seal beforehand with fresh hydraulic oil.
8) Screw on cover.
9) Re-open the shut-off valves.

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SOP for Bobcat

2.7

REMOVAL AND MAINTENANCE OF HYDRAULIC ACCUMULATORS: -

Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for servicing of Hydraulic Accumulator

Scope:

To be carried out at recommended intervals and when pressure in the

accumulator drops below accepted levels.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Standard Tool boxes, cotton waste

1)
2)
3)
4)
5)
6)

Remove the nuts at the fluid-side end plate in place bend the locking washers to the side.
Push the end plate towards the piston until both halves of locking ring are exposed.
Remove the o-ring and the locking ring halves.
Lift out the end plate.
Remove the gas side end plate.
Ease out the piston.

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SOP for Bobcat

2.8

SOP OF REPLACEMENT OF HYDRAULIC OIL:-

Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for replacement of hydraulic oil.

Scope:

To be carried out at recommended intervals.

Operating Procedures

TOOLS AND MATERIALS REQUIRED: Toolbox with standard tools, replacement oil, collecting tray,
adjustable spanner, hose, pump
DRAINING:
1) Check the hydraulic oil tank, its attachments and connections for external damage, firm seating
and proper sealing.
2) Check the oil level at the tank indicator, before making the engine off dump bucket should be in
maximum up position
3) The oil is drained via a drain below the tank.
4) Connect a drain hose and remove strainer.
5) Ensure the collecting tray has sufficient capacity.
6) When the tank is empty, remove the hose and close the drain plug.
FILLING:
1) Check the hydraulic oil tank, its attachments& connections for external damage, firm seating &
proper sealing.
2) Check the oil level which can be read off the tank indicator. When the dump bucket lifting
cylinder is completely retracted, the oil level must not exceed the max. Marking in the upper
section of the sight glass. If the oil level is too low, top up with the same type of oil or oil must be
changed or oil must be changed on periodic basis regularly.
3) Check whether the drain plug on the exterior below the tank is in closed condition.
4) Now connect the oil pump (which should have capacity of 10 bar), with electric supply.
5) Enter the suction line into hydraulic oil source (hyd. Oil barrel).
6) Now open the filling connection and screw on the pump hose to the filling connection
7) Switch on your pump assembly & fill the tank.
8) The exact oil quantity can be read off the oil level indicator.
9) When the required oil quantity has been filled, switch off your pump assembly.
10) Remove the pump hose.

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SOP for Bobcat

2.9 MAINTENANCE OF LEAD ACID BATTERIES: Responsibility:

Shift Engineer, Work Leader, Auto Electrician

Purpose:

Description of procedure for maintenance of lead-acid batteries.

Scope:

For periodic maintenance af batteries.

Operating Procedures

TOOLS REQUIRED: Open spanner 10-11, 12-13, hydrometer, and multimeter.

PROCEDURE:
1) Before maintenance work is started, it must be ensured that the diesel engine can not be
started.
2) The toggle of the battery main switch is to be removed and taken away, then switch off charger.
3) Check the acid level of the individual battery cell. for this purpose , screw off the respective caps
and check whether the fluid level reaches to the bottom of the control inserts. If not, then top
up with distilled water only.
4) Terminals: clean battery terminals, grease with a plastic brush and check for firm seating.
5) Check the battery blocks for external damage and firm seating in the battery holders. The
battery case must be cleaned & above all , dry.
6) If moisture has penetrated into the battery find the cause and eliminate it.
7) Check the charged status of the individual battery blocks with an appropriate device.

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SOP for Bobcat

2.10 PROCEDURE FOR REPLACEMENT OF LUBRICATING OIL: Responsibility:

Shift Engineer, Work Leader

Purpose:

Procedure for replacement of lubricating and hydraulic fluids.

Scope:

To be done at regular intervals or when fluid condition has deteriorated below

acceptable levels.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box containing ring and fixed spanner set of size from 732mm, hammer, fluid t ob changed, pump, screw driver, cotton waste, barrel for old fluid
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)

If the equipment is mobile secure the wheels using blocks, or if required prop the equipment
with the use of jacks.
Let equipment stay idle for at least 2 hours or till the fluid is max 50 o or sufficiently cool.
Arrange for vessels / container for collection of the spent fluids and accessories.
Keep the necessary fluid / oil handy along with the necessary accessories like pump, filters, etc.
Slightly Open the drain plug located on the bottom of the sump / tank / gear box using proper
tools
Position the vessel for the old fluid.
Completely open the drain plug and allow the fluid to drain out by gravity or by pump.
Allow the fluid to drain completely.
Clean the area around the charging plug.
If there are filters present on that system then dissemble them and clean the old fluid in the
chamber.
Replace the filters and 'O' rings as required and tighten then as required.
Open the necessary plug / port to charge the fresh fluid
Charge the fresh fluid by pump or any manual means.
Observe the level of the fluid in the chamber by regular inspection of the gauges or using the
dip sticks.
When the fluid has reached the desired level shut off the charging process.
Clean any spillages.
Dispose / store the fluids and accessories in the allotted space.

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SOP for Bobcat

2.11 SERVICING AND REPLACEMENT OF THE AIR BREATHER:Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for replacement and service of air breather for

oil sumps and gearboxes.

Scope:

To be done at regular intervals

Operating Procedures

Tools required: Toolbox with standard tools, Replacement filter.

1)
2)
3)
4)

Check the breather for its indicator whether red or green pin is seen.
If the red pin is being seen on the indicator it must be immediately replaced.
Turn the breather to left & remove it.
Install new breather filter by turning it right.

If the breather has a replaceable element, then open the top cover and the replace the Breather
Element.

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SOP for Bobcat

2.12 REPLACEMENT OF TYRE: Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for replacement of tyres

Scope:

To be carried out when tyre has been worn out or damaged.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Box spanner of 24, 27 mm (including socket and T-handle)
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)

Set block around the wheels and jack up of the Equipment.

Check the Tyre and rim assembly for sealing
Deflate Tyre completely
Loosen Mounting bolts.
Use forklift to gently lift and remove the Tyre from the vehicle
Inspect the rim for damage or deformation
Clean the rim of rust and grease.
Tyres to be inflated to 40 lb/in2 to allow the rim to fit onto the Tyre
Inflate the Tyre to the recommended pressure
Fitting of Tyre onto the vehicle using forklift.
Tighten the bolts in staggered sequence with the recommended torque only.
Lower the vehicle from the jack.
Remove the wheel blocks.

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SOP for Bobcat

2.13 CHECKING OF ENGINE OIL LEVEL: -

Responsibility:

DG Operator, Work Leader.

Purpose:

Description of procedure for checking the Engine Oil level.

Scope:

To ensure that the oil levels in the sump is adequate for safe and efficient
operation.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: cotton waste, Engine oil (15W40 CH4)
1)
2)

Check oil level with dipstick oil gauge located on the engine. For accurate readings, oil level
should not be checked for approximately 15 minutes after engine shut down. Keep dipstick with
the oil pan with which it was originally shipped. Keep oil level as near H mark as possible.
If necessary, add oil of the same quality and brand as already in the engine

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2.14 REPLACEMENT OF ALTERNATOR BELT: Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure of replacement of drive belt of an engine.

Scope:

To be done at recommended intervals or when belt failure is eminent.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box, cotton waste,

1)
2)
3)
4)
5)
6)

Loosen the alternator mounting so the distance between pulley be shortened and belt can be
installed without force. Never roll a belt over the pulley and never pry it on with a tool such as a
screwdriver. Either of this method will damage belts or cause early failure.
Belts riding depth should not vary over 1.6 mm on matched belt.
Pulley misalignment must not exceed 1.6 mm for each ft of distance between pulley centers.
Belts should not bottom on pulley grooves or should they protrude over 2.4 mm above top edge
of groove.
Do not allow belts to rub any adjacent parts.
Adjust belts to proper specified tension.

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SOP for Bobcat

2.15

REPLACEMENT / SERVICE OF AIR FILTER: -

Responsibility:

Shift Engineer, Work Leader

Purpose:

Description and Procedure of servicing and replacement of Air Cleaner of

ENGINE

Scope:

To be done at manufacturer recommended intervals or as per indications

received by vacuum indicators

Operating Procedures

Tools and Materials Required: The replacement filter elements, toolbox having all standard tools,
cotton waste, a compressed air source.
1.
2.

If an Air pre-cleaner is used then they have to be cleaned as and when required.
Check the mechanical indicator mounted on the air inlet. If the red indicator nears the danger /
chocked mark the following steps are to be done. Reset the indicator when the necessary
actions have been taken.
3.
Cleaning of air filter elements must be done by compressed air jet and blown from the inside to
the outside. Ensure that the pressure of the air jet is not more than 30 PSI. Do not hold the air
jet too close to the filter paper. Do not impart any mechanical shock to the filter element. Follow
the following steps

Clean only the outer element. Never remove inner element for cleaning.

Only remove the outer element when the vacuum indicator shows the red band.
Holes, loose end seals, dented sealing surfaces and other forms of damaged render the cleaner
inoperative and require immediate replacement of the element.
4.
To change the air filter the following steps are to be followed.

Loosen the clamp assembly which holds the cup assembly to the air cleaner.

Remover the cup assembly

Loosen the wing nut of the outer element and remove it.

Loosen the wing nut of the inner element and remove it.

Assemble the new components in a similar manner.

5.
In case of Heavy duty air pre cleaner.

Clean the pre-cleaner openings of all soot, oil film and any other objects lodged in the opening.
Remove any dust or dirt in the lower portion of the pre-cleaner and aspirator tubing. Inspect the
air cleaner housing for any foreign materials.

Inspect the pre cleaner for soot or oil. If there soot inside the cyclone tubes, check the exhaust
systems for leakages. If the pre cleaner appears oily check for fumes escaping from the
crankcase breather, Excessive oil mist shortens the life of any type of dry type pre cleaner.

Inspect the clamps and the flexible hoses or tubing to be sure of all fittings to be airtight on the
cleaners with exhaust aspirators.
6.
Drain the air tanks and regularly remove the collected residue from the casings.

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2.16

REPLACEMENT OF ENGINE OIL AND OIL FILTER:-

Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for replacement of oil filters

Scope:

To be done when the engine oil is changed.

Operating Procedures

Tools and Materials Required: Toolbox containing standard tools, Replacement Oil and filters. Vessel
for the collection of old oils, cotton waste, auxiliaries like pumps and hoses for the transfer of oils.
OIL CHANGE
1)
2)
3)
4)
5)
6)
7)
8)
9)

Bring the engine to operating temperature. Shut off the engine.

When the engine has cooled sufficiently, position the vessel for the collection of the oils.
If pump is available the use the pump to drain the oil or else remove the drain plug at the
bottom of the sump.
While the oil is drain follow the procedure for the replacement of filters.
Install the drain plug when all the oil has drained out.
Fill the crankcase till the H mark on the dipstick.
Start the engine and check for leaks.
Shut down the engine and allow 15 minutes for the oil to drain back to the sump.
Check with the dipstick and top up if necessary.

FILTER CHANGE
1)
2)
3)
4)
5)
6)

Loosen the cap screws and release the filter and he casing from the head.
Remove the oil filter element and the o ring and dispose of them in a proper manner.
Empty the filter casing of the old oil.
Install the new filter element in the casing and top the casing with oil.
Locate the O rings.
Locate the filter casing to the head and tighten the bolts.

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2.17

REPLACEMENT OF FUEL FILTER: -

Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for replacement of Fuel Filter

Scope:

To be done at every oil change routine or if fuel supply is deficient due to the
high impurities in fuel.

Operating Procedures

Tools and Materials Required: The replacement filter and O rings , toolbox having all standard tools,
cotton waste
1.
2.
3.
4.
5.
6.

Loosen the cap screw which holds the shell to the head.
Discard the O rings and the element.
Install the new element
Place the O rings.
Fill the shell with fuel and replace.
Tighten the holding screws.

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2.18

CLEANING / REPLACEMENT OF CRANKCASE BREATHER: -

Responsibility:

Shift engineer, Work Leader

Purpose:

Description of procedure for servicing and replacement crankcase breather filter.

Scope:

To be done at recommended intervals

Operating Procedures

Tools and Materials Required: The replacement breather, toolbox having all standard tools, cotton
waste
1.
2.
3.
4.
5.
6.
7.

Remove the wing nut, lock washer and the plain washer.
Remove the washer and the gasket.
Lift off the cover and lift out the breather element.
Discard the element, clean the body. Inspect for damage, cracks and breaks.
Install new element.
Inspect the gasket. Replace if necessary. Install the gasket in the cover and position the cover
assembly to the body.
Install the gasket, washers and tighten the wing nut.
In the case of naturally aspirated engines the element is to be replace and cannot be cleaned
and re-installed.
In the case of Turbo-charged engines the baffles are to be cleaned and re-used.

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2.19 REPLACEMENT OF COOLANT: Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for the replacement of engine Coolant

Scope:

To be done at recommended intervals or when performance levels lowered.

Operating Procedures

Tools and Materials Required: The Distilled water, the specified grade of coolant and the quantity to
form a proper ratio, toolbox having all standard tools, vessel to collect the old coolant, cotton waste.
1.
2.
3.
4.
5.
6.
7.

Assemble the vessel in a location to collect the coolant.

Ensure that the temperature of the coolant is at workable levels.
Open the drain plug located at the bottom of the radiator or the heat exchanger.
Let the old coolant drain out. After the coolant has drained Install the plug.
Pour the distilled water and the coolant in the recommended ratio. (for the KTA 50 G3 15:1)
When the coolant has reached the appropriate level stop adding the coolant. Do not Overfill
Run the engine to check for any leakages.

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2.20 SERVICING OF OIL PUMP OF ENGINE: 1.1

Responsibility:

Shift Engineer, Work Leader.

1.2

Purpose:

Description of procedure for servicing of Oil Pump.

1.3

Scope:

To be done at recommended intervals and during overhauls.

1.4

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Tool box, cotton waste, dial gauge with stand
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)

Drain the engine oil in some pan.

Remove the pump
Disconnect the suction pipe along with the strainer.
Remove the delivery pipe.
Unscrew the mounting nuts of the oil pump and remove them.
Unscrew the set screws holding the thrust housing. Remove the thrust housing.
Screw in a bolt on the centre threaded hole of the oil pump driving gear with shaft and lift it out.
Unscrew the setscrews on the oil pump suction branch. Remove suction branch and dismantle
the gears.
Clean all the parts thoroughly and keep them on the work table.
Check the oil pump gear contact surface in oil pump housing and cover for any abnormal wear.
Slight wear on the cover can be rectified by resurfacing the cover over a smooth emery paper
placed on a perfect surface. If the wear found is excess, replace the oil pump housing cover.
Check the gear tooth and shaft for any wear and overheating marks.
Insert the oil pump gears in the housing and check the radial clearance.
Check the backlash between the oil pump gears.
Check the oil pump gears end float. All these values should be up to specification.
Examine the suction pipe strainer. If found disintegrated/damaged replace with new one.
Ensure the oil ways in driving spindle driving gear with shaft and oil pump gear are clean.
Check the bush in the crank case for any excessive wear and replace it necessary.
Check the thrust housing contact surface with oil pump driving gear for any wear. Replace, if
wear is excessive.
Keep the oil pump idler gear along with idler spindle in the pump body and press the idler
spindle.
Press the key on the driving spindle. Fit the oil pump gear aligning its key way with the key on
the driving spindle
Slide down the driving spindle with gear in the oil pump housing.
Check and ensure the backlash; radial clearance, end float with the gears.
Fit the end cover with gasket and tighten the setscrews with spring washer.
Check for smooth rotation of the oil pump gears.
Check the oil pump for performance, preferably in a testing rig before mounting on the engine.

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2.21 ENGINE DISASSEMBLY PROCEDURE:

Responsibility:

Shift Engineer, Work Leader.

Purpose:

Description of procedure for overhauling of a diesel engine.

Scope:

To be done at recommended intervals, or due to failure of internal parts.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Standard Tool box, engine overhauling kit, cotton waste, dial
gauge with stand, engine oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Disconnect the cables from battery terminals.

Drain the cooling system by opening the drain cock at the radiator and in engine block at the
rear LH side.
Drain the engine oil.
Remove the radiator cowl.
Remove the air cleaners.
Disconnects the fuel supply pipes at the feed pump, the injector fuel leak off connection and the
fuel overflow line from dual filter mounted on the engine.
Disconnect the oil pressure gauge pipe and delivery hose from air compressor.
Disconnect the temperature gauge connection at water outlet pipe.
Disconnect the accelerator, connection from pedal to engine.
Disconnect the silencer pipe from the exhaust manifold.
Disconnect the propeller shaft at gear box end and cling it to frame to avoid damage to
universal joints.
With a jib crane or some other arrangement, hold the engine assembly with a support bar
hooked on the two eye bolts mounted on the cylinder head front and rear ends.
By holding the engine assembly with the jib crane, disconnect the front cross member by
removing the securing bolts and nuts on either side.
Pull the jib crane outward along with the engine and front cross member.
Remove the front cross member from the front engine mounting. Keep the engine on a work
stand.
Clean the engine externally
Remove the fuel pipes, feed pump to filter and filter to fuel injection pump.
Remove the air pipe connecting the air compressor and inlet manifold.
Remove the fuel filter assembly
Remove the inlet manifold, exhaust manifold and water outlet pipe from the cylinder head.
Remove the cylinder head covers.
Remove injector overflow pipe.
Remove two clamps securing injector pipes. Disconnect the injector pipes from fuel injection
pump. Cover the FIP delivery valve holder with a polythene paper or Plastic caps to avoid entry
of dust.
Remove the coupling from the pump.
Disconnect the air compressor oil pipe from crank case and remove the air compressor from the
timing back plate.
Remove the FIP and keep it in safe place.

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27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.

Unscrew the rocker shaft bracket mounting bolts on both cylinder Heads and remove the rocker
shaft assemblies.
Remove the valve caps and push rod.
Lift out the injectors and keep it in safe place.
Unscrew the cylinder heads nuts and remove the cylinder heads. Remove cylinder head gasket.
Remove the cap nut on engine oil filter and remove the filter bowl with oil filter element.
Remove the filter from the cylinder block.
Remove the oil pressure relief valve.
Remove the fan assembly from the water pump.
Loosen the alternator/dynamo adjusting link and remove the fan belts and dynamo.
Remove the water pump assembly from crank case after loosening the jubilee clip at impeller
casing.
Release the wire lock and remove the vibration damper from the crank shaft pulley. Do not
hammer the viscous damper while removing.
Unscrew the crankshaft pulley mounting bolt after releasing tab washer lock. Remove the
crankshaft pulley.
Remove the self starter assembly
Release the wire lock and remove the clutch assembly and clutch disc.
Remove flywheel from the crankshaft with the help of three jack screws.
Unscrew the clutch housing mounting bolts after releasing the lock wires. Remove the upper
and lower half of the flywheel housing carefully.
Turn the engine side ways and remove the sump.
Remove the oil sump strainer, delivery pipe and then the oil pump assembly.
Rotate the crankshaft and bring down a pair of connecting rod ends to the bottom dead centre
position. Remove the split pins, nuts and caps of the respective connecting rods.
Push out the connecting rod with piston towards top using a wooden plank, taking care the
bearing shells of the connecting rods is not damaged. Refit the cap to the respective connecting
rod and screw in the nut by hand. Do not interchange the connecting rod caps.
Remove another two pairs of connecting rods in the same manner.
Remove the timing gear housing.
Pull out the crankshaft oil thrower plate.
Remove the split pin, castle nut from the idler gear bolt and withdraw the idle gear along wit h
spindle, bush and thrust washers.
From crank case remove the oil pump thrust housing. Lift out the oil pump drive with shaft by
screwing in a bolt in the centre threaded hole.
Remove the breather and tappet side cover front and rear on RH side and remove the twelve
tappets.
Unscrew the camshaft gear mounting bolts and remove the crankshaft gear.
After removing the locking wire unscrew the camshaft thrust washer mounting bolts and pull out
the camshaft carefully.
Unscrew all the main bearing cap bolts and lift out he caps with special tool.
Lift out the crankshaft from its seat.
Remove the bearing shells from the crank case. Fit back the main bearing caps taking care of
identification marks and hand tight the bolts to avoid misplacement of bearing caps.
Remove LH and RH side covers both front and rear.
Remove the front engine mounting brackets.
Remove the accelerator rod control bracket.
Remove front water inlet cover.
Degrease all the dismantled components thoroughly. Ensure the water ways and oil ways are
clean. Clean the all dismantled parts with diesel.
Replace all unserviceable parts. Renew oil seals and gaskets.

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64.
65.
66.
67.
68.
69.
70.

71.

72.
73.
74.
75.
76.

77.
78.
79.
80.

81.

Ensure the crank case main oil gallery and other oil ways are clean. If possible steams wash
the crack case before starting assembly. Fit the main oil gallery plugs on either side.
Clean the crank case parent bore and cylinder liner bore with a new cloth before fitment to clear
off from the fine dust particles. Check the cylinder liner for any blow hole or crack before and
after fitment using an electrical test lamp with 100 watts bulb.
Lightly smear engine oil in cylinder bore and outer surface of the cylinder liner and place the line
over the crank case.
Check the water ways in the block and ensure cleanliness. Fit the ten brass plugs, which closes
water inspection holes.
Fit the two water jacket plates on LH side of the engine with gasket after applying sealing
compound on either side of the gasket seating surface. Tighten the bolts with plain washer.
Fit the oil pump shaft in the crack case. Take care of the oil hole and the slant edge faces
towards the camshaft gear. This proper fitment ensures the lubrication to the camshaft oil pump
gear.
Fit the camshaft bearings in the crank case squarely using a drift. While fitting 2 nd and 5th
camshaft bearings ensure the bearings oil hole coincides with the crankcase oil ways leading to
rocker shafts. While fitting the first camshaft bearing see that the groove on the collar outer
periphery gets locked in the dowel fitted in the crack case.
With a size drill make a locking hole on the 2nd, 3rd, 4th, 5th and 6th camshaft bearings through
the camshaft bearings locking screw holes. Take care the threads are not damaged. Screw in
the camshaft bearing locking screw with washer and lock the 2 nd, 3rd, 4th, 5th and 6th camshaft
bearings. Remove the burr in the inner bore of the camshaft bearings and ensure the locking
screws are not projecting out from the I.D. of the camshaft bearings. If found projecting replace
with correct size of the locking screw with washer.
Tap in the idler bolt in the crack case and position it using a special tool.
Mount the 2 dowel holes with 2 dowel pins on the crank case, tap it with a plastic/brass hammer
and seat it perfectly.
Tighten the two setscrews by a screw driver on the LH side bottom. Tighten the two bolts near
the idler bolt, on the RH side, wire lock them.
Ensure the oil ways in camshaft are clean. Fit the plugs on either end of the camshaft with
sealing compound using a screw driver. Lock the plug gat two points at its periphery with
camshaft by punchi8ng it hard.
Apply clean engine oil on all the seven camshaft bearings, camshaft journals, lobes and oil
pump drive gear teeth. Insert the camshaft in the crack case gently by rotating and lifting at rear
end inside the crank case. Check for smooth rotation. Fit the camshaft thrust washer with few
shims and tighten the four bolts. Four slots in the camshaft thrust washer should face the crank
case side.
Check the camshaft end play and it should be between 0.004 to .008. Adjust the end play
correctly by adding or deleting the shims of .003 thickness. Then wire up the all four thrust
washer bolt with the single wire.
Keep the felt in clean engine oil for about an hour. Insert it in the upper flywheel housing groove
snugly. Shear off by a knife the projected out felt on either side above the machined surface of
the flywheel housing after seating the felt perfectly.
Gently place the flywheel housing upper over the gasket and tighten the bolts with plain washer
to hand tight.
Reclean with a clean cloth, the crank case main bearing parent bore, main bearing cap, and
main bearings and ensure all are dry. Place the main bearing half shells on the crank case in
their respective seat. The bearing shells in 2nd, 3rd. 5th and 6th journals have identical width and
therefore these bearing shell are interchangeable. 1 st journal has more width and not
interchangeable. 4th and 7th are of same width.
Fit the key on the crankshaft. Fit the timing gear at elevated temperature using a drift and
aligning the key way to the key and seat it properly.

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82.
83.
84.
85.

86.

87.
88.
89.

90.
91.
92.
93.
94.
95.
96.
97.

98.
99.
100.
101.
102.
103.

Check the crankshaft oil ways for cleanliness. Smear clean engine oil on the main bearing
shells and on the crankshaft main journals. Lift and gently place the crankshaft journals on the
bearings.
Insert the crankshaft thrust washer upper on rather side taking care the oil groove on the thrust
washer faces crankshaft. Rotate the crankshaft if necessary to seat the thrust washer.
Check the main bearing cps and bearing shells for cleanliness. Fit the bearings in the
respective bearing caps and ensure that the bearing lug is snugly fitting on the notch.
Apply clean engine oil on the main bearing inner surface. Fit the caps on the crank case taking
care the respective markings punched on the main bearing caps and crankcase coincide. While
fitting the 4th main bearing cap, fit tit along with the thrust washer (lower) on either side. Oil
groove on the thrust washers should face the crankshaft.
Screw in the main bearing cap bolts to hand tight with spanner first. Then with a torque wrench
tighten all the bolts to specified torque value. Check smooth rotation of crankshaft and there
should not be and binding. If found tight first loosen the upper flywheel eight mounting bolts and
it lightly away from the crankshaft journal and check for smooth rotation. Even after that if the
crankshaft rotation is not smooth then remove the caps check where the binding takes place
and rectify.
Check the crankshaft axial play with dial gauge in crankshaft and flywheel section or with feeler
gauge at 4th main bearing cap either side. It should be between .002 to .010. This axial play
must be obtained by replacing over/undersize thrust washer.
Fit the one circlip in one of the piston groove.
Hold the connecting rod firmly in a vice and smear engine oil in the small end bush. Lift and
place the piston in position over the connecting rod taking care the valve pockets on the piston
crown is opposite to the connecting rod bearing lock notches. Push the gudgeon pin and fit the
2nd circlip.
Fit the piston rings in the piston using a piston ring expander.
Fit the bottom most oil scraper oil ring first and then the spring loaded oil ring in the 4 th piston
ring groove.
2nd and 3rd rings are taper faced compression rings. Fit the plain top ring in the first piston
groove.
After the fitment of all the five rings ensure the ring end gaps do not fall in the gudgeon pin axis.
The end gaps of the adjacent rings should be staggered 120 apart.
Ensure all the parts are clean before assembly. Smear the cylinder liner bore, piston and
bearing with clean engine oil.
Remove the connecting rod cap without disturbing the bearing shells in respect of 1 st and 6th
cylinder. Rotate the crankshaft and ring the 1st and 6th crankpin to B.D.C. position.
Using either a piston ring compressor for assembly of piston in the respective cylinder.
Push 1st and 6th pistons with connecting rod form the top of the crankcase. Whole inserting the
piston in the cylinder bore, take care the valve pockets in the piston are in position. It should
face the opposite side of the engine camshaft. For easy reference and correct assembly
camshaft side has been punched on the piston crown.
Fit the cap with bearing shells to the respective connecting rod. Take care the bearing notches
of connecting rod and cap are on the same side.
Screw in the nuts and tighten to the torque specified. Fit the split pin and lock it by folding the
two ends.
On no account must nuts be slackened off to bring the split pin holes into line. If the pin hole do
not line up replace or resurface the nut face evenly. The pins should just nip the nut.
Fit in the same manner 2nd and 5th pistons by rotating and keeping the respective crankshaft pin
at B.D.C. position.
Repeat the procedure to assemble 3rd and 4th piston assembly
Check and ensure the smooth crankshaft rotation without binding of bearing shells.

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104.
105.
106.
107.

108.
109.
110.
111.
112.
113.
114.

115.

116.

117.
118.

119.
120.
121.

Check the connecting rod end play in respective journal using a feeler gauge. The end play
should be within the specified limits.
Check the piston projection with respect to the crankcase, cylinder head parting surface at
T.D.C. position and it should be within the limits specified.
Ensure the oil way and oil hole in the oil pump drive shaft are clean. Apply engine oil over the
shaft, gear and slide it on the crank case rear right hand side. Place the thrust housing with
gasket and tighten the two bolts.
Smear grease on the idler gear wearing washer either side and place it on the crank case in its
position. Fix the thrust washer inner on the greased face of the wearing washer. Fit bush, idler
gear inner bore, and idler gear spindle and thrust washer after applying engine oil over them
and fit the split pin.
Check the smooth rotation of the idler gear and end play.
Rotate the crankshaft and bring 1st cylinder position to T.D.C. Fit the camshaft drive gear taking
care the timing mark punched on the gear face coincides with the timing mark on the timing
back plate. Tighten the camshaft gear mounting for bolt to 60 lb-ft torque.
Tap crankshaft oil thrower plate to its seat using a drift. Fit the damper pulley key on the
crankshaft tapered end after ensuring the tapered surface is clean and even.
Fit the new oil seal evenly on the timing gear housing. Fit the timing gear housing. Apply
Anabond on the timing gear housing gasket seating surface and place the gasket over it. Then
fit the timing gear housing on the timing back plate.
Place the damper pulley on the crankshaft after cleaning its contact surface with crankshaft
thoroughly. Tighten the damper bolt with lock washer to 30kg-m. Tab the lock washer on one
side of the bolt ahead.
Fit the vibration damper on the crankshaft pulley and tighten the sic setscrews with plain washer
and wire them up with single wire. Damper should be free from leakage and if any leakage
noticed replace it.
Lift and fit the flywheel housing lower along with felt oil seal. Ensure the flywheel housing
matching numbers punched on the machined surfaces of the upper and lower housings are
same. Tighten the ten 3/8 BSF bolts to integrate the tow flywheel housings. Then tighten the
flywheel housing eight mounting bolts at lower side to 8 kg-m torque. Wire locks the bolts
heads.
Turn the engine and make it parallel to the ground. Fit the oil pump assembly on the crank case
over the three studs and align the shaft to match with the oil pump driving gear spindle. Then
tighten the three nuts. Check for free rotation of the crankshaft before and after fitting the oil
pump assembly.
Fix the O ring on the connecting pipe. Fit the connecting pipe O ring mounted flange on oil
pump assembly side and the other end to the crank case side with a gasket. Tighten the tow
bolts on oil pump side with spring washers. On the crank case side, after tightening the tow
bolts wire lock them.
Assemble the clean and good oil pump strainer to the suction pipe by tightening the three
setscrews. Fit the other end of the suction pipe to oil pump with a gasket. Tighten the nuts with
double coil spring washer.
Apply Anabond on the crank case sump gasket over it. Over the gasket apply a thin coat of
grease for perfect seating and easy removal of sump in future. Fit the cleaned sump to the
crank case and tighten all the twenty four nuts/setscrews using a double coil spring washer. Fit
the dipstick mounting unit.
Turn the engine upright and clean the crank case parting surface where gasket seats.
Install the two number cylinder head gasket taking care the top punched on the gasket facing
towards the cylinder head side.
Fit the tappets in the crank case after applying clean engine oil over its surface. Then insert the
push rods from cylinder head side after applying grease either side. Fit the RH side cover front
and rear with gasket and tighten the setscrews.

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122.
123.

124.
125.
126.

127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.

140.
141.
142.
143.

Fit the valve caps on the valve with grease applied on it.
Place the rocker shaft assembly on the cylinder head after keeping the support bracket gasket
is not obstructing the oil way from cylinder head. For easy seating of the rocker are against the
spring tension and insert a pin on the rocker shaft rocker bush oil hole. Turn the pin in such a
way the rocker shaft locking slots coincides with the cylinder head studs. Remove the pin out.
Loosen the ball end in rocker arm and make the rocker arm free on the valve cap. Then tighten
the rocker bracket mounting nuts first to hand tight and to the specified torque.
Insert the injector with the brass washer in the bottom sear and rubber D bush on the side.
Seat the rubber D bush on the cylinder head groove. Fit the injector clamps and tighten. Fit the
injector overflow pipe.
Flywheel has timing marks on its periphery. Mount the flywheel on the crankshaft which can be
fitted on only one direction due to out of pitch. Tighten the nuts with three lock plate to the
specified torque and tab the washer. Check the run out of the flywheel face plate. Fit the timing
pointer on the flywheel housing.
Mount the air compressor on the timing back plate with gasket and tighten the setscrew.
Connect the air compressor lubricating oil pipe from crank case to the air compressor.
Rotate the crankshaft and align the timing pointer on the flywheel housing with INJ mark on the
flywheel when the first cylinder piston is on compression stroke. Make the FIP timing pointer
and FIP flywheel marks in line with their respective timing marks.
Fit the dual fuel filter with new filter after connecting fuel pipe.
Fit overflow pipes one to the injector overflow pipe and the other from dual filter and clamp them
at rear left hand side of the engine to have onward connection to the diesel tank.
Fit the oil filter housing with new oil filter and filled with oil to about 0.75 l after keeping the two
O rings in position,
Fir the engine oil pressure relief valve on the crankcase with the gasket. Tighten the four bolts
with spring washer.
Fit the water pump outlet pipe on cylinder head wit gasket and tighten the four bolts with double
coil spring washer.
Fit the exhaust manifold on cylinder head with gaskets metallic face towards the cylinder head
side and tighten the ten brass nuts. Do not over tighten the brass
Mount the inlet manifold with gasket on cylinder head and tighten the ten bots with double coil
spring washer.
Fit the flexible hose on the water pump impeller casing. Mount the water pump assembly on the
engine front end with gasket and tighten the five bolts with spring washer.
Keep the tested thermostat in the water outlet pipe. Fit the hose with hose clip on water outlet
elbow. Mount the water outlet elbow on the water outlet pipe with gasket, connect the hose to
the water pump and tighten the circlip.
Fit the dynamo bracket on the four collar studs, which were projecting from the front RH side
cover. Keep two distance pieces and tighten the two bolts spring washer on the crank case.
Tighten four nuts on the studs with spring washer.
Mount the alternator/dynamo on the alternator bracket with two bolts and simmonds nuts. Fit
the alternator assembly sliding slotted lever on the timing gear housing with a bolt. Insert the
alternator front side bottom bolt with plain washer through the sliding slot hole after keeping the
distance in between sliding lever and alternator. Fit the two fan belts over the damper pulley,
water pump pulley and alternator pulley.
Adjust the fan belt tension by pulling the alternator outwards with a lever and then tighten fully
the three alternator mounting nuts. The fan belt tension is correct if there is approximately 25.4
mm total movement on the longest run of the belt.
Mount the front engine mounting arms on either side or tighten the four nuts with spring washer.
Mount the self starter assembly and tighten the three nuts with washer.
Fit the control bracket on the rear side of the crank case with gasket and tighten the four
mounting bolts with double spring washers.

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SOP for Bobcat

144.
145.
146.
147.
148.
149.
150.

151.
152.

Insert the cross shaft in the control bracket after applying oil over it keeping the lever on the
cross shaft towards the FIP side. Connect the FIP inner lever with the cross shaft lever.
Fit the oil pressure gauge pipe on the RH side of the crank case. Clamp the pipe with sump nut
at tow places and then on the plate projecting outwards from the timing gear housing below the
alternator.
Fit the water drain plugs.
Fit the oil seal housing on the flywheel and tighten the setscrews.
Mount the clutch assembly on the flywheel with clutch disc after aligning it with special tool.
Tighten the mounting bolts and wire locks them.
Adjust the withdrawal plate height with a special gauge.
Rotate the crankshaft and bring the first cylinder piston to T.D.C. compression stroke. Check the
pointer through flywheel housing window, align mark on the flywheel and ensure first cylinder is
in compression. Adjust the first cylinder valves tappet clearance to 0.020 for both inlet and
exhaust. Follow the same procedure for the other five cylinders. For this purpose flywheel is
having TDC marks of the pistons is pairs i.e., (1,6) (2,5) (3,4)
Place the rocker cover with gasket over the cylinder head and tighten the mounting bolts with
double coil spring washer.
Mount the air cleaner assembly and fill the oil up to the level mark.

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SOP for Bobcat

2.22 ASSEMBLY OF PISTON AND CONNECTING ROD: Responsibility:

Shift engineer, Work Leader

Purpose:

Description of procedure for assembly of Connecting Rod and piston.

Scope:

To be done during a engine overhaul.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Standard Tool box, cotton waste, dial gauge with stand
1)
2)

3)
4)
5)
6)
7)
8)
9)
10)

11)
12)
13)
14)
15)
16)
17)
18)

Fit the one circlip in one of the piston groove.

Hold the connecting rod firmly in a vice and smear engine oil in the small end bush. Lift and
place the piston in position over the connecting rod taking care the valve pockets on the piston
crown is opposite to the connecting rod bearing lock notches. Push the gudgeon pin and fit the
2nd circlip.
Fit the piston rings in the piston using a piston ring expander.
Fit the bottom most oil scraper oil ring first and then the spring loaded coil ring in the 4 th piston
ring groove.
2nd and 3rd rings are taper faced compression rings. Fit the plain top ring in the first piston
groove.
After the fitment of all the five rings ensure the ring end gaps do not fall in the gudgeon pin axis.
The end gaps of the adjacent rings should be staggered 120 apart.
Ensure all the parts are clean before assembly. Smear the cylinder liner bore, piston and
bearing with clean engine oil.
Remove the connecting rod cap without disturbing the bearing shells in respect of 1 st and 6th
cylinder. Rotate the crankshaft and ring the 1st and 6th crankpin to B.D.C. position.
Using either a piston ring compressor for assembly of piston in the respective cylinder.
Push 1st and 6th pistons with connecting rod form the top of the crankcase. Whole inserting the
piston in the cylinder bore, take care the valve pockets in the piston are in position. It should
face the opposite side of the engine camshaft. For easy reference and correct assembly
camshaft side has been punched on the piston crown.
Fit the cap with bearing shells to the respective connecting rod. Take care the bearing notches
of connecting rod and cap are on the same side.
Screw in the nuts and tighten to the torque specified. Fit the split pin and lock it by folding the
two ends.
On no account must nuts be slackened off to bring the split pin holes into line. If the pin hole do
not line up replace or resurface the nut face evenly. The pins should just nip the nut.
Fit in the same manner 2nd and 5th pistons by rotating and keeping the respective crankshaft pin
at B.D.C. position.
Repeat the procedure to assemble 3rd and 4th piston assembly
Check and ensure the smooth crankshaft rotation without binding of bearing shells.
Check the connecting rod end play in respective journal using a feeler gauge. The end play
should be within the specified limits.
Check the piston projection with respect to the crankcase, cylinder head parting surface at
T.D.C. position and it should be within the limits specified.

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2.23

TAPPET SETTING: -

Responsibility:

Shift Engineer, Work Leader

Purpose:

Description of procedure for tappet setting.

Scope:

To be done at recommended intervals

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Standard Tool box, cotton waste, dial gauge with stand
1)

2)

Rotate the crankshaft and bring the first cylinder piston to T.D.C. compression stroke. Check the
pointer through flywheel housing window, align mark on the flywheel and ensure first cylinder is
in compression. Adjust the first cylinder valves tappet clearance to 0.020 for both inlet and
exhaust. Follow the same procedure for the other five cylinders. For this purpose flywheel is
having TDC marks of the pistons is pairs i.e., (1,6) (2,5) (3,4)
Place the rocker cover with gasket over the cylinder head and tighten the mounting bolts with
double coil spring washer.

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SOP for Bobcat

2.24

REPLACEMENT OF KNUCKLE PIN BEARING:-

Responsibility:

Work Shop In-Charge, Work Leader.

Purpose:

Description of procedure for replacement of Steering Pin.

Scope:

To be carried out at recommended intervals.

Operating Procedures

TOOLS AND MATERIALS REQUIRED: Standard tool box, trolley or pallet truck for supporting the
wheel.
DISMANTLING:
1.
Jack up the steered wheel end of the truck and block it up in a safe manner.
2.
Remove the retaining ring from the steered wheel and remove the Wheel.
Note: A trolley with rest for holding the wheel securely will be needed for handling purposes.
3. Secure a sling around the hub neck and lift the hub is held in position.
Note: A trolley, or a pallet truck or the likes with a rest
4. Remove the protective cover from the upper bearing of the knuckle bearing.
5. Release the tabs of the tab washer. Remove the upper bearing nut and remove the tab washer and
the plain washer.
7.
Remove the protective cover from the lower bearing, remove the split pin from the bearing nut
and remove the nut. The inner race of the bearing in loose and can be removed.
8.
Remove the knuckle pin by tapping it upwards. The inner race of the upper bearing will
accompany the pin.
9.
Use a trolley to lift out the wheel axle.
10.
Remove the wipers from the steering cradle.
11.
Remove the outer bearing races from the steering cradle by the means of an internal puller.
Note: If a suitable puller is not available, lugs for a pulling tool may be welded to the inner race. The
race will the shrink and will be easier to remove.
ASSEMBLY:
1.
Pack the outer races of the bearing with grease and press them into the steering cradle.
Note: Note that these are taper bearings. Fit the Inner races so that the larger inside diameter faces
outwards.
A round plate should be made for each bearing size for pressing in the races. A heavy hammer can
then be used to hammer the plate for driving in the race. Dont hammer the bearings directly, since they
may not enter straight and may become jammed in the housing.
2.
Fit new wipers to the steering cradle, using a suitable ring to tap them in. Tapping the wipers in
with a hammer will damage them
3.
Lift the wheel axle into position by means of a hand trolley or a hoist.
4.
Insert the Knuckle pin, fit the spacer and the lower bearing inner race. (Packed with grease),
and fir the bearing nut.
5.
Tighten the lower bearing nut to stop and secure it with a split pin.

APM Terminals

SOP for Bobcat

6.
7.
8.
9.
10.

Fit the upper bearing inner race (packed with grease), the plain washer and the tab washer in
position. Grease the tab washer to ensure that it will not be damaged by the bearing nut.
Pack both bearing fully with grease and check that they turn freely.
Tighten the upper bearing nut to stop. Release the lifting device as the nut is tightened to
ensure the lifting device does not preventing tightening.
Turn the heel axle to check that it moves freely.
Coat the covers with sealing compounds, pack them with grease and top up with grease with
the grease nipple when the cover is in position and the sealing compound has dried.

APM Terminals

SOP for Bobcat

2.25 ADJUSTMENT OF LOADER ARM MOVEMENTS:

Responsibility:

Work Shop In-Charge, Work Leader.

Purpose:

Description of procedure for setting of steering control arms.

Scope:

To be carried out at recommended intervals.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Standard Tool boxes, cotton waste,

1)
2)
3)
4)
5)
6)

Connect a manometer with a T connector to the rod side of H13, right front.
Test arm movement, begin with the arms raised and check their movement against the function
description. Each attachment is individually set and therefore has different positions for the
sequential valves and over centre valves.
Lower the right arms halfway. Set the sequential valve H11g to that the arm is swiveled out
completely and thereafter it takes a second or so before the arm begins to move.
With the arm half way lowered, read off the pressure. The valve should be set to open at 1.3
times the measured pressure. The setting must be carried out on the test bench.
Set the over-centre valve H8 so that the arm moves smoothly and evenly without jerking. The
valves gives a counter pressure so that the arm does not lower too quickly thus crating a
vacuum on the piston side of the hydraulic cylinder.
Repeat 1-5 for the left hand arm and thereafter for the rear pair of arms with the equivalent
components

APM Terminals

SOP for Bobcat

2.26 REPLACEMENT OF WHEEL BEARING: Responsibility:

Work Shop In-Charge, Work Leader.

Purpose:

Description of procedure for replacement of Steered Wheel bearing

Scope:

To be carried out at recommended intervals.

Operating Procedures

TOOLS AND MATERIAL REQUIRED: Standard Tool box, cotton waste, Grease, Bearing to be
replaced.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)

Jack up the steered wheel end of the truck and block it up in a safe manner.
Remove the retaining ring from the steered wheel and remove the wheel.
Remove the hub cover.
Secure a lifting sling to the hub, preferably using one of the hub bolts. Fit a nu to secure the
bolt. Use a hand trolley. Pallet truck or the like for lifting the hub.
Remove the tab washer, locknut and bearing nut. The plain washer is loose.
Remove the hub off the wheel axle by means of the hand truck. The inner race of the outer
bearing will accompany the hub.
Withdraw the inner race of the inner bearing from the wheel axle.
Remove the seal, but leave the spacer in position.
Pack the outer races of the bearings with grease and press them into the hub.
Press a new seal into the hub. Use a suitable round plate for this purpose. Tapping the seal with
a hammer will damage it.
Clean the spacer and pack it with grease.
Tap the inner race of the inner bearing onto the wheel axle, using a suitable tube. Pack the
inner race with grease.
Lift the plain washer and bearing nut with the flat surface facing inwards. Tighten the bearing
nut to press the bearing home, and release the nut 1/8 of a turn.
Fit the tab washer and locknut. Grease the tab washer to prevent damage by the nut. Tighten
the locknut and lock both the bearing nut and the locknut with the tabs.
Pack the outer bearing with grease, pack the bearing cover with grease and fit it into position.
Top up with grease through the grease nipple.

APM Terminals