Bobcat Skid-Steer Loaders S150, S160 Repair Service Manuals + Operation & Maintenance Manuals
Complete repair service manual with electrical wiring diagrams for Bobcat S150, S160 Skid-Steer Loaders, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Bobcat Skid-Steer Loaders S150-S160 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
902497 (5-12) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
902497 (12-06) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
902498 (1-13) - S150 Skid-Steer Loader Service Manual.pdf
902498 (3-06) - S150, S160 Turbo Service Manual.pdf
902498 (4-11) - S150 Skid-Steer Loader Service Manual.pdf
902505 (5-12) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual.pdf
902505 (12-06) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual.pdf
902684 (5-12) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
902684 (12-06) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
902686 (5-12) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual.pdf
902686 (12-06) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual.pdf
902730 (5-11) - S150, S160 Turbo Skid-Steer Loader Service Manual.pdf
902730 (10-12) - S150, S160 Turbo Skid-Steer Loader Service Manual.pdf
904124 (4-08) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
904126 (7-09) - S150, S160 Skid-Steer Loader Service Manual.pdf
904128 (4-08) - S160 Skid-Steer Loader Operation & Maintenance Manual.pdf
986566 (7-09) - S150 Skid-Steer Loader Service Manual.pdf
986966 (4-08) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
986979 (2-13) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
986979 (11-10) - S150 Skid-Steer Loader Operation & Maintenance Manual.pdf
986981 (3-08) - S160 Skid-Steer Loader Operation & Maintenance Manual.pdf
987009 (2-13) - S160 Skid-Steer Loader Operation & Maintenance Manual.pdf
987009 (11-10) - S160 Skid-Steer Loader Operation & Maintenance Manual.pdf
987033 (11-10) - S150 Skid-Steer Loader Service Manual.pdf
987033 (12-12) - S150 Skid-Steer Loader Service Manual.pdf
987034 (9-09) - S160 Skid-Steer Loader Service Manual.pdf
987048 (1-13) - S160 Skid-Steer Loader Service Manual.pdf
987048 (11-10) - S160 Skid-Steer Loader Service Manual.pdf
987054 (10-08) - S150 Skid-Steer Loader Service Manual.pdf
989453 (2-13) - S160 Skid-Steer Loader Operation & Maintenance Manual.pdf
989453 (11-10) - S160 Skid-Steer Loader Operation & Maintenance Manual.pdf
Total Pages: 14,302 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
6902497 (12-06) - S150 Skid-Steer Loader Operation & Maintenance Manual....3
OPERATOR SAFETY WARNINGS....5
CONTENTS....7
FOREWORD....9
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....11
REGULAR MAINTENANCE ITEMS....11
MOTOR OIL....11
SERIAL NUMBER LOCATIONS....12
Loader Serial Number....12
Engine Serial Number....12
DELIVERY REPORT....12
MACHINE IDENTIFICATION....13
FEATURES, ACCESSORIES AND ATTACHMENTS....14
Standard Items....14
Options and Accessories....14
Buckets Available....15
Attachments....15
SAFETY....17
SAFETY INSTRUCTIONS....19
Before Operation....19
Safe Operation Is The Operator’s Responsibility....20
Safe Operation Needs A Qualified Operator....20
Fire Prevention....21
MACHINE SIGNS (DECALS)....22
OPERATING INSTRUCTIONS....25
INSTRUMENT PANEL IDENTIFICATION....27
Left Panel....27
Right Panel (Standard - With Key Switch)....28
Right Panel (Deluxe - With Keyless Start)....29
Option And Field Accessory Panels (If Equipped)....31
Cab Light....32
LIFT ARM BY-PASS CONTROL....32
Operation....32
TRACTION LOCK OVERRIDE....32
Operation....32
ENGINE SPEED CONTROL....33
Operation....33
PARKING BRAKE....33
Operation....33
DRIVING AND STEERING THE LOADER....34
Available Controls Configurations....34
Operation (Standard and ACS)....34
STOPPING THE BOBCAT LOADER....34
Using The Steering Levers....34
SEAT BAR RESTRAINT SYSTEM....35
Operation....35
HYDRAULIC CONTROLS....36
Operation....36
Standard Controls (Also ACS in Foot Pedal Mode)....36
Advanced Control System (ACS) in HAND Control Mode....37
Quick Couplers....38
Releasing Hydraulic Pressure (Loader and Attachment)....38
Auxiliary Hydraulics Button - VARIABLE FLOW....38
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....39
Auxiliary Hydraulics Button - DISENGAGE....39
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....39
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....39
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....39
REAR Auxiliary Hydraulics Operation (If Equipped)....40
Attachment Control Device (ACD) (If Equipped)....40
Bucket Position Valve Operation (If Equipped)....40
DAILY INSPECTION....41
Daily Inspection and Maintenance....41
PRE-STARTING PROCEDURES....42
Before Starting The Engine....42
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....44
Procedure....44
STARING THE ENGINE (DELUXE PANEL, KEYLESS START)....46
Procedure....46
Cold Temperature Starting....47
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....47
Procedure....47
STOPPING THE ENGINE....48
Procedure....48
MONITORING THE DISPLAY PANEL....49
Standard Panel....49
Deluxe Panel....49
WARNING and SHUTDOWN....49
ATTACHMENTS AND BUCKETS....50
Choosing The Correct Bucket....50
Pallet Forks....51
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....51
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....53
Power Bob-Tach - Installing The Bucket Or Attachment....54
Power Bob-Tach - Removing The Bucket Or Attachment....55
OPERATING PROCEDURE....56
Operating With A Full Bucket....56
Operating With An Empty Bucket....57
Foot Pedal Machines....58
Hand Control Machines (Includes ACS)....60
PARKING THE BOBCAT LOADER....62
Procedure....62
TRANSPORTING THE BOBCAT LOADER....63
Loading Onto Transport Vehicle....63
Fastening To Transport Vehicle....63
TOWING THE LOADER....64
Towing Procedure....64
PREVENTIVE MAINTENANCE....65
MAINTENANCE SAFETY....67
SERVICE SCHEDULE....69
Chart....69
LIFT ARM SUPPORT DEVICE....70
Engaging The Lift Arm Support Device....70
Disengaging The Lift Arm Support Device....71
OPERATOR CAB....72
Raising The Operator Cab....72
Lowering The Operator Cab....73
Cab Door Sensor....73
Emergency Exit....74
SEAT BELT....75
Inspection and Maintenance....75
SEAT BAR RESTRAINT SYSTEM....76
Inspecting The Seat Bar....76
Maintaining The Seat Bar....76
BOCAT INTERLOCK CONTROL SYSTEM (BICS)....77
Inspecting The BICS Controller (Engine Stopped - Key ON)....77
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....77
Inspecting The Seat Bar Sensor (Engine RUNNING)....77
Inspecting The Traction Lock (Engine RUNNING)....77
Inspecting The Lift Arm By-Pass Control....77
Inspecting Deactivation Of Lift And Tilt Functions (ACS)....77
REAR DOOR....78
Opening And Closing The Rear Door....78
Adjusting The Rear Door Latch....78
REAR GRILL....79
Removing....79
Installing....79
HEATING SYSTEM....79
Cleaning And Maintenance....79
AIR CLEANER SERVICE....80
Replacing Filter Elements....80
FUEL SYSTEM....81
Fuel Specifications....81
Filling The Fuel Tank....81
Fuel Filter....82
Removing Air From The Fuel System....82
ENGINE LUBRICATION SYSTEM....83
Checking Engine Oil....83
Replacing The Oil And Filter....83
ENGINE COOLING SYSTEM....84
Cleaning The Cooling System....84
Checking Coolant Level And Adding Coolant....84
Replacing The Coolant....85
ALTERNATOR BELT....86
Adjusting The Alternator Belt....86
ELECTRICAL SYSTEM....86
Description....86
Cleaning Battery and Terminals....86
Fuse Location....87
Using A Booster Battery (Jump Starting)....88
Removing And Installing The Battery....89
HYDRAULIC / HYDROSTATIC SYSTEM....90
Checking And Adding Fluid....90
Replacing Hydraulic/Hydrostatic Filter....90
Replacing Hydraulic Fluid and Case Drain Filters....91
Hydraulic Breather....92
TIRE MAINTENANCE....93
Wheel Nuts....93
Rotating....93
Mounting....93
FINAL DRIVE TRANSMISSION (CHAINCASE)....94
Checking And Adding Oil....94
Removing Oil From The Chaincase....94
FAN GEARBOX....95
Checking And Maintaining....95
DRIVE BELT....95
Adjusting The Drive Belt....95
Replacing The Drive Belt....95
SPARK ARRESTOR MUFFLER....96
LUBRICATING THE BOBCAT LOADER....97
Lubrication Locations....97
PIVOT PINS....98
Inspection And Maintenance....98
BOB-TACH (hand lever)....99
Inspection And Maintenance....99
BOB-TACH (POWER) (OPTIONAL)....100
Inspection And Maintenance....100
SYSTEM SETUP & ANALYSIS....101
BICS SYSTEM....103
Troubleshooting Guide....103
DIAGNOSTICS SERVICE CODES....104
Display....104
Number Codes List....105
DELUXE INSTRUMENT PANEL SETUP....109
Deluxe Panel Upgrade....109
Deluxe Panel Setup....110
Passwords (Deluxe)....110
SHUTDOWN FEATURE....112
SERVICE CLOCK RESET....112
MACHINE SIGN TRANSLATIONS....113
SERVICE SCHEDULE (6734534)....115
WARNING (6728539)....116
WARNING (6715944)....117
WARNING (6732696)....117
DANGER (6579509)....118
DANGER (6579639)....118
WARNING (6717343)....119
IMPORTANT (6560573)....119
WARNING (6577754)....120
WARNING (6579528)....120
SPECIFICATIONS....121
LOADER SPECIFICATIONS (S150)....123
Machine Dimensions....123
Performance....124
Controls....124
Engine....124
Hydraulic System....125
Electrical....125
Drive System....126
Capacities....126
Tires....126
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....127
WARRANTY....129
6902497 (5-12) - S150 Skid-Steer Loader Operation & Maintenance Manual....131
OPERATOR SAFETY WARNINGS....133
CONTENTS....135
FOREWORD....137
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....139
REGULAR MAINTENANCE ITEMS....139
MOTOR OIL....139
SERIAL NUMBER LOCATIONS....140
Loader Serial Number....140
Engine Serial Number....140
DELIVERY REPORT....140
MACHINE IDENTIFICATION....141
FEATURES, ACCESSORIES AND ATTACHMENTS....142
Standard Items....142
Options and Accessories....142
Buckets Available....143
Attachments....143
SAFETY....145
SAFETY INSTRUCTIONS....147
Before Operation....147
Safe Operation Is The Operator’s Responsibility....148
Safe Operation Needs A Qualified Operator....148
Fire Prevention....149
MACHINE SIGNS (DECALS)....150
OPERATING INSTRUCTIONS....153
INSTRUMENT PANEL IDENTIFICATION....155
Left Panel....155
Right Panel (Standard - With Key Switch)....156
Right Panel (Deluxe - With Keyless Start)....157
Option And Field Accessory Panels (If Equipped)....159
Cab Light....160
LIFT ARM BY-PASS CONTROL....160
Operation....160
TRACTION LOCK OVERRIDE....160
Operation....160
ENGINE SPEED CONTROL....161
Operation....161
PARKING BRAKE....161
Operation....161
DRIVING AND STEERING THE LOADER....162
Available Controls Configurations....162
Operation (Standard and ACS)....162
STOPPING THE BOBCAT LOADER....162
Using The Steering Levers....162
SEAT BAR RESTRAINT SYSTEM....163
Operation....163
HYDRAULIC CONTROLS....164
Operation....164
Standard Controls (Also ACS in Foot Pedal Mode)....164
Advanced Control System (ACS) in HAND Control Mode....165
Quick Couplers....166
Releasing Hydraulic Pressure (Loader and Attachment)....166
Auxiliary Hydraulics Button - VARIABLE FLOW....166
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....167
Auxiliary Hydraulics Button - DISENGAGE....167
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....167
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....167
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....167
REAR Auxiliary Hydraulics Operation (If Equipped)....168
Attachment Control Device (ACD) (If Equipped)....168
Bucket Position Valve Operation (If Equipped)....168
DAILY INSPECTION....169
Daily Inspection and Maintenance....169
PRE-STARTING PROCEDURES....170
Before Starting The Engine....170
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....172
Procedure....172
STARING THE ENGINE (DELUXE PANEL, KEYLESS START)....174
Procedure....174
Cold Temperature Starting....175
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....175
Procedure....175
STOPPING THE ENGINE....176
Procedure....176
MONITORING THE DISPLAY PANEL....177
Standard Panel....177
Deluxe Panel....177
WARNING and SHUTDOWN....177
ATTACHMENTS AND BUCKETS....178
Choosing The Correct Bucket....178
Pallet Forks....179
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....179
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....181
Power Bob-Tach - Installing The Bucket Or Attachment....182
Power Bob-Tach - Removing The Bucket Or Attachment....183
OPERATING PROCEDURE....184
Operating With A Full Bucket....184
Operating With An Empty Bucket....185
Foot Pedal Machines....186
Hand Control Machines (Includes ACS)....188
PARKING THE BOBCAT LOADER....190
Procedure....190
TRANSPORTING THE BOBCAT LOADER....191
Loading Onto Transport Vehicle....191
Fastening To Transport Vehicle....191
TOWING THE LOADER....192
Towing Procedure....192
PREVENTIVE MAINTENANCE....193
MAINTENANCE SAFETY....195
SERVICE SCHEDULE....197
Chart....197
LIFT ARM SUPPORT DEVICE....198
Engaging The Lift Arm Support Device....198
Disengaging The Lift Arm Support Device....199
OPERATOR CAB....200
Raising The Operator Cab....200
Lowering The Operator Cab....201
Cab Door Sensor....201
Emergency Exit....202
SEAT BELT....203
Inspection and Maintenance....203
SEAT BAR RESTRAINT SYSTEM....204
Inspecting The Seat Bar....204
Maintaining The Seat Bar....204
BOCAT INTERLOCK CONTROL SYSTEM (BICS)....205
Inspecting The BICS Controller (Engine Stopped - Key ON)....205
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....205
Inspecting The Seat Bar Sensor (Engine RUNNING)....205
Inspecting The Traction Lock (Engine RUNNING)....205
Inspecting The Lift Arm By-Pass Control....205
Inspecting Deactivation Of Lift And Tilt Functions (ACS)....205
REAR DOOR....206
Opening And Closing The Rear Door....206
Adjusting The Rear Door Latch....206
REAR GRILL....207
Removing....207
Installing....207
HEATING SYSTEM....207
Cleaning And Maintenance....207
AIR CLEANER SERVICE....208
Replacing Filter Elements....208
FUEL SYSTEM....209
Fuel Specifications....209
Filling The Fuel Tank....209
Fuel Filter....210
Removing Air From The Fuel System....210
ENGINE LUBRICATION SYSTEM....211
Checking Engine Oil....211
Replacing The Oil And Filter....211
ENGINE COOLING SYSTEM....212
Cleaning The Cooling System....212
Checking Coolant Level And Adding Coolant....212
Replacing The Coolant....213
ALTERNATOR BELT....214
Adjusting The Alternator Belt....214
ELECTRICAL SYSTEM....214
Description....214
Cleaning Battery and Terminals....214
Fuse Location....215
Using A Booster Battery (Jump Starting)....216
Removing And Installing The Battery....217
HYDRAULIC / HYDROSTATIC SYSTEM....218
Checking And Adding Fluid....218
Replacing Hydraulic/Hydrostatic Filter....218
Replacing Hydraulic Fluid and Case Drain Filters....219
Hydraulic Breather....220
TIRE MAINTENANCE....221
Wheel Nuts....221
Rotating....221
Mounting....221
FINAL DRIVE TRANSMISSION (CHAINCASE)....222
Checking And Adding Oil....222
Removing Oil From The Chaincase....222
FAN GEARBOX....223
Checking And Maintaining....223
DRIVE BELT....223
Adjusting The Drive Belt....223
Replacing The Drive Belt....223
SPARK ARRESTOR MUFFLER....224
LUBRICATING THE BOBCAT LOADER....225
Lubrication Locations....225
PIVOT PINS....226
Inspection And Maintenance....226
BOB-TACH (hand lever)....227
Inspection And Maintenance....227
BOB-TACH (POWER) (OPTIONAL)....228
Inspection And Maintenance....228
SYSTEM SETUP & ANALYSIS....229
BICS SYSTEM....231
Troubleshooting Guide....231
DIAGNOSTICS SERVICE CODES....232
Display....232
Number Codes List....233
DELUXE INSTRUMENT PANEL SETUP....237
Deluxe Panel Upgrade....237
Deluxe Panel Setup....238
Passwords (Deluxe)....238
SHUTDOWN FEATURE....240
SERVICE CLOCK RESET....240
MACHINE SIGN TRANSLATIONS....241
SERVICE SCHEDULE (6734534)....243
WARNING (6728539)....244
WARNING (6715944)....245
WARNING (6732696)....245
DANGER (6579509)....246
DANGER (6579639)....246
WARNING (6717343)....247
IMPORTANT (6560573)....247
WARNING (6577754)....248
WARNING (6579528)....248
SPECIFICATIONS....249
LOADER SPECIFICATIONS (S150)....251
Machine Dimensions....251
Performance....252
Controls....252
Engine....252
Hydraulic System....253
Electrical....253
Drive System....254
Capacities....254
Tires....254
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....255
WARRANTY....257
6902498 (1-13) - S150 Skid-Steer Loader Service Manual....259
MAINTENANCE SAFETY....261
CONTENTS....263
FOREWORD....265
FOREWORD....267
SAFETY INSTRUCTIONS....269
FIRE PREVENTION....271
Maintenance....271
Operation....271
Electrical....271
Hydraulic System....271
Fueling....271
Starting....271
Spark Arrester Exhaust System....271
Welding And Grinding....272
Fire Extinguishers....272
SERIAL NUMBER LOCATIONS....273
Loader Serial Number....273
Engine Serial Number....273
DELIVERY REPORT....274
LOADER IDENTIFICATION....275
SAFETY AND MAINTENANCE....277
LIFTING AND BLOCKING THE LOADER....279
Procedure....279
LIFT ARM SUPPORT DEVICE....281
Installing Lift Arm Support Device....281
Removing Lift Arm Support Device....282
OPERATOR CAB....283
Description....283
Raising The Operator Cab....283
Lowering The Operator Cab....285
Emergency Exit....286
TRANSPORTING THE BOBCAT LOADER....289
Procedure....289
TOWING THE LOADER....291
Procedure....291
REMOTE START TOOL KIT - MEL1563....293
Remote Start Tool - MEL1563....293
Service Tool Harness Control - MEL1565....294
Service Tool Harness Communicator - MEL1566....295
Remote Start Procedure....296
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....299
Description....299
Remote Start Tool (Service Tool) - 7022042....300
Loader Service Tool Harness - 6689747....301
Computer Service Tool Harness - 6689746....302
Remote Start Procedure....303
SERVICE SCHEDULE....307
Chart....307
AIR CLEANER SERVICE....309
Testing....309
Replacing Filter Element(s)....309
ENGINE COOLING SYSTEM....311
Cleaning The Cooling System....311
Checking Coolant Level And Adding Coolant....311
Checking The Coolant Level....312
Replacing the Coolant....312
FUEL SYSTEM....315
Fuel Specifications....315
Filling The Fuel Tank....315
Fuel Filter....316
Removing Air From The Fuel System....317
ENGINE LUBRICATION SYSTEM....319
Checking Engine Oil....319
Engine Oil Chart....319
Replacing Oil And Filter....320
HYDRAULIC / HYDROSTATIC SYSTEM....321
Checking And Adding Fluid....321
Hydraulic / Hydrostatic Fluid Chart....321
Replacing Hydraulic / Hydrostatic Filter....321
Replacing Hydraulic Fluid....322
Breather Cap....323
FINAL DRIVE TRANSMISSION (CHAINCASE)....325
Checking And Adding Oil....325
Removing Oil From The Chaincase....325
FAN GEARBOX....327
Checking And Maintaining....327
BOB-TACH (HAND LEVER)....329
Inspection And Maintenance....329
BOB-TACH (POWER)....331
Inspection And Maintenance....331
LUBRICATION OF THE BOBCAT LOADER....333
Procedure....333
TIRE MAINTENANCE....335
Wheel Nuts....335
Rotating....335
Mounting....335
SPARK ARRESTER MUFFLER....337
Cleaning Procedure....337
SEAT BELT....339
Inspection And Maintenance....339
HYDRAULIC SYSTEM....341
HYDRAULIC / HYDROSTATIC SCHEMATICS....345
HYDRAULIC SYSTEM INFORMATION....349
Glossary Of Hydraulic / Hydrostatic Symbols....349
Tighten Procedures....352
Troubleshooting Chart....352
CYLINDER (LIFT)....353
Testing....353
Removal And Installation....354
Identification....355
Disassembly....356
Assembly....357
CYLINDER (TILT)....361
Testing....361
Removal And Installation....362
Rod End Pivot Pin Bushing And Seal Replacement....363
Base End Pivot Pin Replacement....364
Identification....365
Disassembly....366
Assembly....367
CYLINDER (POWER BOB-TACH)....371
Testing....371
Removal And Installation....372
Identification....373
Disassembly....374
Assembly....375
MAIN RELIEF VALVE....379
Description....379
Testing....379
Adjustment....380
Removal And Installation....380
HYDRAULIC CONTROL VALVE (FOOT CONTROL)....383
Removal And Installation....383
BICS™ Valve Removal And Installation....387
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....389
BICS™ Valve, Check Valve Removal And Installation....390
BICS™ Valve Lock Valve Removal And Installation....391
BICS™ Valve Solenoid Removal And Installation....392
BICS™ Valve Solenoid Testing....393
Identification Chart....394
Load Check Valve....395
Main Relief Valve....396
Port Relief Valve....397
Anti-Cavitation Valve / Port Relief Valve....398
Anti-Cavitation Valve....398
Rubber Boot....399
Lift And Tilt Lock Block Removal And Installation....400
Lift Spool And Detent....400
Tilt Spool Removal And Installation....409
Auxiliary Spool Removal And Installation....411
Auxiliary Electric Solenoid....412
Port-Auxiliary Section....413
Cleaning And Inspection....414
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)....415
Description....415
Removal And Installation....415
BICS™ Valve Removal And Installation....420
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....422
BICS™ Valve, Check Valve Removal And Installation....422
BICS™ Valve Lock Valve Removal And Installation....424
BICS™ Valve Solenoid Removal And Installation....425
BICS™ Valve Solenoid Testing....426
Actuator Removal And Installation....427
Identification Chart (ACS)....428
Lift Base End Restrictor....429
Load Check Valve....429
Main Relief Valve....430
Port Relief Valve....431
Anti-Cavitation Valve / Port Relief Valve....432
Anti-Cavitation Valve....433
Lift Spool Removal And Installation....433
Tilt Spool Removal And Installation....434
Lift And Tilt Spool Disassembly And Assembly....435
Auxiliary Spool Removal And Installation....436
Auxiliary Electric Solenoid....437
Port-Auxiliary Section....438
Cleaning And Inspection....438
LIFT ARM BYPASS CONTROL VALVE....439
Inspecting....439
Removal And Installation....439
Disassembly And Assembly....441
HYDRAULIC PUMP....443
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....443
Check The Output Of The Hydraulic Pump With Power Bob-Tach.....445
Removal And Installation....447
Identification....449
Disassembly And Assembly....450
HYDRAULIC PUMP (HI FLOW)....455
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....455
Check The Output Of The Hydraulic Pump With Power Bob-Tach....457
Removal And Installation....459
Identification....461
Disassembly And Assembly....462
HYDRAULIC FILTER HOUSING....471
Removal And Installation....471
HYDRAULIC FLUID RESERVOIR....473
Fluid Removal....473
Removal And Installation....473
BUCKET POSITION VALVE....477
Solenoid Removal And Installation....477
Solenoid Testing....477
Removal And Installation....478
Disassembly And Assembly....480
HIGH FLOW VALVE....483
Checking The High Flow Relief Valve....483
High Flow Relief Valve Adjustment Procedure....485
Removal And Installation....486
Disassembly And Assembly....488
Solenoid Testing....490
REAR AUXILIARY DIVERTER VALVE....491
Removal And Installation....491
Disassembly And Assembly....494
Solenoid Testing....499
Inspection....499
POWER BOB-TACH BLOCK....501
Removal And Installation....501
Disassembly And Assembly....503
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....507
Removal And Installation....507
Disassembly And Assembly....507
HYDROSTATIC SYSTEM....509
HYDROSTATIC SYSTEM INFORMATION....511
Troubleshooting Chart....511
Replenishing Valve Function....512
HYDROSTATIC MOTOR....513
Removal And Installation....513
Parts Identification....515
Disassembly....516
Assembly....521
Carrier Shaft Seal Replacement....527
Carrier Removal And Installation....529
Carrier Parts Identification....531
Carrier Disassembly....532
Carrier Assembly....533
CHARGE PRESSURE....537
Sender Removal And Installation....537
Testing Charge Pressure....537
Adjusting....538
HYDROSTATIC PUMP....539
Replenishing / High Pressure Relief Valve....539
Removal And Installation....540
Parts Identification (Right Half)....542
Parts Identification (Left Half)....544
Hydraulic Pump Removal And Installation....546
Pump Separation....546
Disassembly....547
Assembly....553
DRIVE BELT....561
Shield Removal And Installation....561
Adjusting....561
Drive Belt Replacement....563
Tensioner Pulley Removal And Installation....564
Tensioner Pulley Parts Identification....565
Tensioner Pulley Disassembly....566
Tensioner Pulley Assembly....567
OIL COOLER....569
Removal And Installation....569
DRIVE SYSTEM....571
BRAKE....573
Disk Removal And Installation....573
Switch Operated Parking Brake....574
DRIVE COMPONENTS....575
Axle Seal Removal And Installation....575
Axle Sprocket And Bearings Removal And Installation....577
Chain Removal And Installation....582
CHAINCASE....585
Checking And Adding Oil....585
Removing The Oil....585
Front Cover Removal And Installation....586
Center Cover Removal And Installation....587
Rear Cover Removal And Installation....588
MAINFRAME....589
SEAT BAR....591
Removal And Installation....591
Assembling Components....592
Compression Spring Disassembly And Assembly....594
OPERATOR CAB....595
Gas Cylinder Removal And Installation....595
Gas Cylinder Disassembly....597
Removal And Installation....598
OPERATOR SEAT....601
Removal And Installation....601
Seat Belt Removal And Installation....601
BOB-TACH....603
Removal And Installation....603
Bob-Tach Lever And Wedge....604
Pivot Pin Bushing And Seal Removal And Installation....605
POWER BOB-TACH....607
Removal And Installation....607
Power Bob-Tach Lever And Wedge....608
Pivot Pin Bushing And Seal Removal And Installation....610
LIFT ARMS....611
Removal And Installation....611
REAR GRILLE....615
Removal And Installation....615
REAR DOOR....617
Removal And Installation....617
Striker Removal And Installation....618
Striker Disassembly And Assembly....618
Adjusting The Striker....618
Latch Removal And Installation....619
FUEL TANK....621
Removal And Installation....621
Fuel Level Sender....622
Fuel Fill Screen....622
CONTROL PEDALS....625
Removal And Installation....625
Pedal Adjustment....625
Crossbar Linkage Removal And Installation....626
Lift Foot Pedal Linkage Removal And Installation....628
Tilt Foot Pedal Linkage Removal And Installation....628
CONTROL PEDALS (ACS)....629
Foot Sensor Removal And Installation....629
Foot Pedal Removal And Installation....630
Foot Pedal Linkage Disassembly And Assembly....631
CONTROL PANEL....633
Removal And Installation....633
Shock Removal And Installation....636
Shaft Removal And Installation....636
Shaft Disassembly And Assembly....637
Linkage Removal And Installation....637
Linkage Adjustment....640
Linkage Neutral Adjustment....643
CONTROL HANDLE....647
Control Lever Removal And Installation....647
Control Lever Boot....647
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL....649
Components Identification....649
Handle Sensor Removal And Installation....649
Control Handle Removal And Installation....652
Control Handle Disassembly And Assembly....653
Control Lever Removal And Installation....654
Control Lever Boot....655
ELECTRICAL SYSTEM AND ANALYSIS....657
ELECTRICAL SCHEMATICS....661
ELECTRICAL SYSTEM INFORMATION....665
Troubleshooting Chart....666
Description....667
Fuse Location....668
Relay Switch Location....668
BATTERY....669
Removal And Installation....669
Servicing....670
Using A Booster Battery (Jump Starting)....671
ALTERNATOR (90 AMP)....673
Adjusting The Alternator Belt....673
Alternator Identification....673
Charging System Check....674
Alternator Voltage Test....675
Low Voltage Test....676
High Voltage Test....676
Removal And Installation....677
Rectifier Continuity (Diode) Test....678
Alternator Regulator Test....679
Disassembly....679
Stator Continuity Test....680
Stator Ground Test....680
Rotor Continuity Test....680
Rotor Ground Test....680
Assembly....681
STARTER....683
Checking....683
Removal And Installation....685
Parts Identification....686
Disassembly And Assembly....687
Inspection And Repair....690
No Load Test....692
INSTRUMENT PANEL....693
Left Panel....693
Right Panel (Standard) (With Key Switch)....694
Right Panel - (Deluxe) (With Keyless Start)....695
Option And Field Accessory Panels....700
Removal And Installation....701
Front Accessory Panel Removal And Installation....702
LIGHTS....703
Front Removal And Installation....703
Rear Removal And Installation....703
BOBCAT CONTROLLER....705
Identification Chart....705
Removal And Installation....707
DIAGNOSTIC SERVICE CODES....709
Display....709
Number Codes List....710
BICS™ SYSTEM....715
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....715
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....715
Inspecting The Seat Bar Sensor (Engine RUNNING)....715
Inspecting The Traction Lock (Engine RUNNING)....715
Inspecting The Lift Arm Bypass Control....715
Troubleshooting Chart....716
Troubleshooting Guide....717
SEAT BAR SENSOR....719
Description....719
Troubleshooting....719
Testing....720
Removal And Installation....721
Bobcat Interlock Control System (BICS™) Circuit Test....724
TRACTION LOCK....727
Troubleshooting Chart....727
Inspecting....728
Solenoid Removal And Installation....728
Guide Removal....731
Guide Installation....732
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL....735
Components Identification....735
Troubleshooting Guide....737
Controller, Connector And Wire Identification....738
ACS Controller Removal And Installation....739
Handle Sensor Connector....740
Switch Handle Removal....741
Switch Handle Installation....743
Actuators Disassembly And Assembly....746
Handle Lock Solenoid Removal And Installation....748
Handle Lock Solenoid Disassembly And Assembly....748
Handle Lock Solenoid Connector....749
Calibration Of The ACS System....750
Switchable Hand / Foot Controls Calibration Procedure....750
Hand Controls Only Calibration Procedure....751
Foot Sensor Disassembly And Assembly....753
Foot Sensor Connector....753
Foot Lock Solenoid Removal And Installation....754
Foot Lock Solenoid Connector....755
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE....757
Controls Identification Chart....757
SERVICE PC (LAPTOP COMPUTER)....759
Connecting Remote Start Tool....759
Connecting Remote Start Tool (Service Tool)....759
ENGINE SERVICE....761
TROUBLESHOOTING....765
Chart....765
ENGINE SPEED CONTROL....767
Removal And Installation....767
Disassembly....768
MUFFLER....769
Removal And Installation....769
AIR CLEANER....771
Removal And Installation....771
RADIATOR....773
Removal And Installation....773
COOLING FAN....777
Drive Tension Pulley Removal And Installation....777
Gearbox / Blower Housing Removal And Installation....778
Blower Housing Grille Removal And Installation....780
Blower Disassembly And Assembly....781
Gearbox Parts Identification....783
Gearbox Disassembly....784
Gearbox Assembly....788
Gearbox Checking Backlash....793
ENGINE COMPONENTS AND TESTING....797
Compression Checking....797
Glow Plugs Checking....798
Glow Plugs Removal And Installation....798
Fuel Shut-Off Solenoid - Checking....799
Fuel Shut-Off Solenoid - Adjusting....799
Fuel Shut-Off Solenoid Removal And Installation....800
Checking....801
Fuel Injection Pump Removal And Installation....801
Timing The Injection Pump....804
Fuel Injector Removal And Installation....806
Fuel Injector - Checking....808
Fuel Injector Disassembly....808
Fuel Injector Assembly....809
Valve Clearance Adjustment....809
Rocker Arm And Shaft - Checking....810
Valve Timing - Checking....810
ENGINE....811
Removal And Installation....811
Engine Mount Replacement....819
FLYWHEEL AND HOUSING....821
Flywheel Removal And Installation....821
Ring Gear Removal And Installation....822
Housing Removal And Installation....822
RPM SENSOR....825
Adjustment....825
RECONDITIONING THE ENGINE-KUBOTA V2203-EB AND V2003T-EB (TURBO)....827
Cylinder Head Removal And Installation....827
Cylinder Head Disassembly And Assembly....828
Cylinder Head Servicing....829
Cylinder Head Top Clearance....829
Checking The Valve Guide....830
Reconditioning The Valve And Valve Seat....831
Valve Spring....832
Rocker Arm And Shaft Checking....833
Timing Gearcase Cover Removal And Installation....833
Idler Gear And Camshaft Removal And Installation....835
Servicing The Camshaft....836
Servicing The Idle Gear And Shaft....838
Timing Gears Checking Backlash....839
Fuel Camshaft Removal And Installation....839
Fuel Camshaft Governor....840
Crankshaft Gear Removal And Installation....840
Oil Pump Removal And Installation....841
Oil Pump Service....841
Checking Engine Oil Pressure....843
Relief Valve....843
Piston And Connecting Rod Removal And Installation....844
Servicing The Piston And Connecting Rod....845
Connecting Rod Alignment....847
Crankshaft And Bearings Removal And Installation....848
Servicing The Crankshaft And Bearings....849
Checking The Cylinder Bore....852
Water Pump Disassembly And Assembly....853
TURBOCHARGER....855
Troubleshooting....855
Description....856
Removal And Installation....856
FLYWHEEL AND HOUSING....859
Flywheel Removal And Installation....859
Ring Gear Removal And Installation....859
Housing Removal And Installation....860
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....861
Description....861
Testing....862
Removal And Installation....865
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....867
AIR CONDITIONING SYSTEM FLOW....869
Principals....869
Chart....870
COMPONENTS....871
Identification....871
SAFETY....875
Safety Equipment....875
REGULAR MAINTENANCE....877
Filter Elements Removal And Installation....877
Compressor Drive Belt Inspection....878
Cleaning The Condenser....879
BASIC TROUBLESHOOTING....881
Poor A/C Performance....881
Cleaning The A/C Evaporator Coil And Heater Coil....881
Compressor Drive Belt Inspection....882
Checking The Electrical System....883
Engine Coolant Bypassing The Heater Valve....890
Heater Valve Not Opening Or Closing....891
GENERAL AIR CONDITIONING SERVICE GUIDELINES....893
Compressor Oil....893
Compressor Oil Check....894
Component Replacement And Refrigeration Leaks....895
SYSTEM TROUBLESHOOTING CHART....897
Gauge Pressure Related Troubleshooting....898
TEMPERATURE / PRESSURE....901
Chart....901
AIR CONDITIONING SERVICE....903
Chart....903
SYSTEM CHARGING AND RECLAMATION....905
Reclamation Procedure....905
Charging Procedure With A Manifold Gauge Set....908
Charging Procedure....909
COMPRESSOR....911
Removal And Installation....911
Compressor Clutch Disassembly....912
CONDENSER....917
Removal And Installation....917
RECEIVER / DRIER....919
Removal And Installation....919
PRESSURE RELIEF VALVE....921
Removal And Installation....921
PRESSURE SWITCH....923
Removal And Installation....923
EVAPORATOR / HEATER UNIT....925
Removal And Installation....925
Disassembly And Assembly....927
THERMOSTAT....929
Removal And Installation....929
EXPANSION VALVE....931
Removal And Installation....931
EVAPORATOR....933
Removal And Installation....933
HEATER COIL....935
Removal And Installation With A/C....935
Removal And Installation Without A/C....936
HEATER / A/C FAN....937
Removal And Installation....937
Disassembly And Assembly....938
Wire Connector Removal And Installation....940
HEATER VALVE....943
Removal And Installation....943
Disassembly And Assembly....943
SPECIFICATIONS....945
LOADER SPECIFICATIONS....947
Machine Dimensions....947
Performance....948
Controls....948
Engine....948
Hydraulic System....949
Electrical....949
Drive System....950
Capacities....950
Tires....950
ENGINE SPECIFICATIONS - KUBOTA V2203-EB....951
Specifications....951
Crankshaft Re-Grind Data....955
ENGINE SPECIFICATIONS - KUBOTA V2003T-EB (TURBO)....957
Specifications....957
Crankshaft Re-Grind Data....961
TORQUE SPECIFICATIONS FOR BOLTS....963
Torque For General SAE Bolts....963
Torque For General Metric Bolts....964
HYDRAULIC CONNECTION SPECIFICATIONS....965
O-ring Face Seal Connection....965
Straight Thread O-ring Fitting....966
Tubelines And Hoses....966
Flare Fitting....966
O-ring Flare Fitting....967
Port Seal Fitting....969
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....971
Specifications....971
CONVERSIONS....973
Decimal And Millimeter Equivalent Chart....973
U.S. To Metric Conversion Chart....973
ALPHABETICAL INDEX....975
SERVICE MANUAL REVISION....977
Revision No: S150, S160 - 1....977
Revision No: S150, S160 - 2....979
Revision No: S150, S160 - 3....981
Revision No: S150, S160 - 4....983
Revision No: S150, S160 - 5....985
6902498 (3-06) - S150, S160 Turbo Service Manual....987
MAINTENANCE SAFETY....989
ALPHABETICAL INDEX....991
CONTENTS....993
FOREWORD....994
SAFETY INSTRUCTIONS....997
Fire Prevention....999
SERIAL NUMBER LOCATIONS....1001
Loader Serial Number....1001
Engine Serial Number....1001
DELIVERY REPORT....1002
BOBCAT LOADER IDENTIFICATION....1003
SAFETY AND MAINTENANCE....1005
LIFTING AND BLOCKING THE LOADER....1007
Procedure....1007
LIFT ARM SUPPORT DEVICE....1009
Installing Lift Arm Support Device....1009
Removing Lift Arm Support Device....1010
OPERATOR CAB....1011
Description....1011
Raising The Operator Cab....1011
Lowering The Operator Cab....1012
Emergency Exit....1013
TRANSPORTING THE BOBCAT LOADER....1015
Procedure....1015
TOWING THE LOADER....1017
Procedure....1017
REMOTE START....1019
Procedure....1019
SERVICE SCHEDULE....1023
Chart....1023
AIR CLEANER SERVICE....1025
Checking....1025
Replacing Filter Element(s)....1025
ENGINE COOLING SYSTEM....1027
Cleaning The Cooling System....1027
Checking The Coolant Level....1028
Replacing the Coolant....1028
FUEL SYSTEM....1031
Fuel Specifications....1031
Filling The Fuel Tank....1031
Fuel Filter....1032
Removing Air From The Fuel System....1032
ENGINE LUBRICATION SYSTEM....1033
Checking Engine Oil....1033
Oil Chart....1033
Replacing Oil And Filter....1033
HYDRAULIC/HYDROSTATIC SYSTEM....1035
Checking And Adding Fluid....1035
Replacing Hydraulic/Hydrostatic Filter....1035
Replacing Hydraulic Fluid....1035
Breather Cap....1037
FINAL DRIVE TRANSMISSION (CHAINCASE)....1039
Checking And Adding Oil....1039
Removing Oil From The Chaincase....1039
FAN GEARBOX....1041
Checking And Maintaining....1041
BOB-TACH....1043
Inspection And Maintenance....1043
POWER BOB-TACH (OPTION)....1045
Inspection And Maintenance....1045
LUBRICATION OF THE BOBCAT LOADER....1047
Procedure....1047
TIRE MAINTENANCE....1049
Wheel Nuts....1049
Rotating....1049
Mounting....1049
SPARK ARRESTOR MUFFLER....1051
Cleaning Procedure....1051
HYDRAULIC SYSTEM....1053
HYDRAULIC/HYDROSTATIC SCHEMATICS....1057
HYDRAULIC SYSTEM INFORMATION....1061
Tighten Procedures....1065
Troubleshooting Chart....1065
CYLINDER (LIFT)....1067
Checking....1067
Removal And Installation....1068
Identification....1069
Disassembly....1070
Assembly....1071
CYLINDER (TILT)....1075
Checking....1075
Removal And Installation....1076
Rod End Pivot Pin Bushing And Seal Replacement....1077
Base End Pivot Pin Replacement....1078
Identification....1079
Disassembly....1080
Assembly....1081
CYLINDER (POWER BOB-TACH)....1085
Checking....1085
Removal And Installation....1086
Identification....1087
Disassembly....1088
Assembly....1089
MAIN RELIEF VALVE....1093
Checking....1093
Adjustment....1094
Removal and Installation....1094
HYDRAULIC CONTROL VALVE (FOOT CONTROL)....1097
Removal And Installation....1097
BICS™ Valve Removal And Installation....1100
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation....1102
BICS™ Valve, Check Valve Removal And Installation....1103
BICS™ Valve Lock Valve Removal And Installation....1104
BICS™ Valve Solenoid Removal And Installation....1105
BICS™ Valve Solenoid Testing....1106
Identification Chart....1107
Load Check Valve....1108
Main Relief Valve....1109
Port Relief Valve....1110
Anti-Cavitation Valve/Port Relief Valve....1111
Anti-Cavitation Valve....1111
Rubber Boot....1112
Lift And Tilt Lock Block Removal And Installation....1113
Lift Spool and Detent....1113
Tilt Spool Removal And Installation....1122
Auxiliary Spool Removal And Installation....1124
Auxiliary Electric Solenoid....1125
Port-Auxiliary Section....1126
Cleaning And Inspection....1127
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)....1129
Description....1129
Removal and Installation....1129
BICS™ Valve Removal And Installation....1133
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation....1135
BICS™ Valve, Check Valve Removal And Installation....1135
BICS™ Valve Lock Valve Removal And Installation....1137
BICS™ Valve Solenoid Removal And Installation....1138
BICS™ Valve Solenoid Testing....1139
Actuator Removal And Installation....1140
Identification Chart (ACS)....1141
Lift Base End Restrictor....1142
Load Check Valve....1142
Main Relief Valve....1143
Port Relief Valve....1144
Anti-Cavitation Valve/Port Relief Valve....1145
Anti-Cavitation Valve....1146
Lift Spool Removal And Installation....1146
Tilt Spool Removal And Installation....1147
Lift and Tilt Spool Disassembly And Assembly....1148
Auxiliary Spool Removal And Installation....1149
Auxiliary Electric Solenoid....1150
Port-Auxiliary Section....1151
Cleaning And Inspection....1151
LIFT ARM BY-PASS CONTROL VALVE....1153
Inspecting....1153
Removal and Installation....1153
Disassembly and Assembly....1154
HYDRAULIC PUMP....1155
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....1155
Check The Output Of The Hydraulic Pump With Power Bob-Tach.....1157
Removal And Installation....1159
Identification....1161
Disassembly And Assembly....1162
HYDRAULIC PUMP (HI FLOW)....1167
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....1167
Check The Output Of The Hydraulic Pump With Power Bob-Tach.....1169
Removal And Installation....1171
Identification....1173
Disassembly And Assembly....1174
HYDRAULIC FILTER HOUSING....1183
Removal and Installation....1183
HYDRAULIC FLUID RESERVOIR....1185
Fluid Removal....1185
Removal And Installation....1185
BUCKET POSITION VALVE....1189
Solenoid Removal And Installation....1189
Solenoid Testing....1189
Removal and Installation....1190
Disassembly And Assembly....1192
HIGH FLOW VALVE....1195
Checking The High Flow Relief Valve....1195
High Flow Relief Valve Adjustment Procedure....1197
Removal And Installation....1198
Disassembly And Assembly....1200
Solenoid Testing....1202
REAR AUXILIARY DIVERTER VALVE....1203
Removal And Installation....1203
Disassembly And Assembly....1206
Solenoid Testing....1211
Inspection....1211
POWER BOB-TACH BLOCK....1213
Removal And Installation....1213
Disassembly And Assembly....1215
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....1219
Removal and Installation....1219
Disassembly And Assembly....1219
HYDROSTATIC SYSTEM....1221
HYDROSTATIC SYSTEM INFORMATION....1223
Troubleshooting Chart....1223
Replenishing Valve Function....1224
HYDROSTATIC MOTOR....1225
Removal And Installation....1225
Parts Identification....1227
Disassembly....1228
Assembly....1233
Carrier Shaft Seal Replacement....1239
Carrier Removal And Installation....1241
Carrier Parts Identification....1243
Carrier Disassembly....1244
Carrier Assembly....1245
CHARGE PRESSURE....1249
Sender Removal And Installation....1249
Checking Charge Pressure....1249
Adjusting....1250
HYDROSTATIC PUMP....1251
Replenishing/High Pressure Relief Valve....1251
Removal And Installation....1252
Parts Identification (Right Half)....1254
Parts Identification (Left Half)....1256
Hydraulic Pump Removal And Installation....1258
Pump Separation....1258
Disassembly....1259
Assembly....1265
DRIVE BELT....1273
Shield Removal And Installation....1273
Adjusting....1273
Drive Belt Replacement....1275
Tensioner Pulley Removal And Installation....1276
Tensioner Pulley Parts Identification....1277
Tensioner Pulley Disassembly....1278
Tensioner Pulley Assembly....1279
OIL COOLER....1281
Removal and Installation....1281
DRIVE SYSTEM....1283
BRAKE....1285
Disk Removal And Installation....1285
Switch Operated Parking Brake....1286
DRIVE COMPONENTS....1287
Axle Seal Removal And Installation....1287
Axle Sprocket And Bearings Removal And Installation....1289
Chain Removal And Installation....1294
CHAINCASE....1297
Checking And Adding Oil....1297
Removing The Oil....1297
Front Cover Removal And Installation....1298
Center Cover Removal And Installation....1299
Rear Cover Removal And Installation....1300
MAIN FRAME....1301
SEAT BAR....1303
Removal And Installation....1303
Assembling Components....1304
Compression Spring Disassembly And Assembly....1306
OPERATOR CAB....1307
Gas Cylinder Removal And Installation....1307
Gas Cylinder Disassembly....1309
Removal And Installation....1310
OPERATOR SEAT....1313
Removal And Installation....1313
Seat Belt Removal And Installation....1313
OPERATOR SEAT (SUSPENSION)....1315
Removal And Installation....1315
Slide Rail Removal And Installation....1316
Cushion Removal And Installation....1316
Back Removal And Installation....1317
Shock Removal And Installation....1318
3-Point Seat Belt Removal And Installation....1319
BOB-TACH....1321
Removal And Installation....1321
Bob-Tach Lever And Wedge....1322
POWER BOB-TACH....1325
Removal And Installation....1325
Power Bob-Tach Lever And Wedge....1326
LIFT ARMS....1329
Removal And Installation....1329
REAR GRILL....1333
Removal And Installation....1333
REAR DOOR....1335
Removal And Installation....1335
Striker Removal and Installation....1336
Striker Disassembly and Assembly....1336
Adjusting The Striker....1336
Latch Removal and Installation....1337
FUEL TANK....1339
Removal And Installation....1339
Fuel Level Sender....1340
Fuel Fill Screen....1340
CONTROL PEDALS....1343
Removal And Installation....1343
Pedal Adjustment....1343
Crossbar Linkage Removal and Installation....1344
Lift Foot Pedal Linkage Removal and Installation....1345
Tilt Foot Pedal Linkage Removal and Installation....1345
CONTROL PEDALS (ACS)....1347
Foot Sensor Removal And Installation....1347
Foot Pedal Removal And Installation....1348
Foot Pedal Linkage Disassembly And Assembly....1349
CONTROL PANEL....1351
Removal and Installation....1351
Shock Removal And Installation....1353
Shaft Removal And Installation....1353
Shaft Disassembly And Assembly....1353
Linkage Removal And Installation....1354
Linkage Adjustment....1357
Linkage Neutral Adjustment....1360
CONTROL HANDLE....1363
Control Lever Removal And Installation....1363
Control Lever Boot....1363
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....1365
Components Identification....1365
Handle Sensor Removal And Installation....1365
Control Handle Removal and Installation....1368
Control Handle Disassembly and Assembly....1369
Control Lever Removal and Installation....1370
Control Lever Boot....1371
ELECTRICAL SYSTEM....1373
ELECTRICAL SCHEMATICS....1377
ELECTRICAL SYSTEM INFORMATION....1381
Troubleshooting Chart....1383
Description....1384
Fuse Location....1385
Relay Switch Location....1385
BATTERY....1387
Removal And Installation....1387
Servicing....1388
Using A Booster Battery (Jump Starting)....1389
ALTERNATOR (90 AMP)....1391
Adjusting The Alternator Belt....1391
Alternator Identification....1391
Charging System Check....1392
Alternator Voltage Test....1393
Low Voltage Test....1394
High Voltage Test....1394
Removal And Installation....1394
Rectifier Continuity (Diode) Test....1395
Alternator Regulator Test....1396
Disassembly....1397
Stator Continuity Test....1398
Stator Ground Test....1398
Rotor Continuity Test....1398
Rotor Ground Test....1398
Assembly....1399
STARTER....1401
Checking....1401
Removal And Installation....1402
Parts Identification....1403
Disassembly and Assembly....1404
Inspection And Repair....1407
No Load Test....1409
INSTRUMENT PANEL....1411
Left Panel....1411
Right Panel (Standard) (With Key Switch)....1412
Right Panel - (Deluxe) (With Keyless Start)....1413
Option and Field Accessory Panels....1418
Removal And Installation....1419
Front Accessory Panel Removal And Installation....1420
LIGHTS....1421
Front Removal And Installation....1421
Rear Removal And Installation....1421
BOBCAT CONTROLLER....1423
Identification Chart....1423
Removal And Installation....1425
DIAGNOSTIC SERVICE CODES....1427
Display....1427
Number Codes List....1428
BICS™ SYSTEM....1433
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....1433
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1433
Inspecting The Seat Bar Sensor (Engine RUNNING)....1433
Inspecting The Traction Lock (Engine RUNNING)....1433
Inspecting The Lift Arm By-Pass Control....1433
Troubleshooting Chart....1434
Troubleshooting Guide....1435
SEAT BAR SENSOR....1437
Troubleshooting Chart....1437
Test....1438
Removal And Installation....1439
BICS™ Circuit Test....1440
TRACTION LOCK....1441
Troubleshooting Chart....1441
Inspecting....1442
Solenoid Removal And Installation....1442
Guide Removal....1445
Guide Installation....1446
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL....1449
Components Identification....1449
Troubleshooting Guide....1451
Controller, Connector And Wire Identification....1452
ACS Controller Removal And Installation....1453
Handle Sensor Connector....1454
Switch Handle Removal....1455
Switch Handle Installation....1457
Actuators Disassembly and Assembly....1460
Handle Lock Solenoid Removal And Installation....1462
Handle Lock Solenoid Disassembly And Assembly....1462
Handle Lock Solenoid Connector....1463
Calibration Of The ACS System....1464
Switchable Hand/Foot Controls Calibration Procedure....1464
Hand Controls Only Calibration Procedure....1465
Foot Sensor Disassembly And Assembly....1467
Foot Sensor Connector....1467
Foot Lock Solenoid Removal And Installation....1468
Foot Lock Solenoid Connector....1469
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE....1471
Controls Identification Chart....1471
ENGINE SERVICE....1473
TROUBLESHOOTING....1475
Chart....1475
ENGINE SPEED CONTROL....1477
Removal And Installation....1477
Disassembly....1477
MUFFLER....1479
Removal And Installation....1479
AIR CLEANER....1481
Removal And Installation....1481
RADIATOR....1483
Removal And Installation....1483
COOLING FAN....1487
Drive Tension Pulley Removal And Installation....1487
Gearbox/Blower Housing Removal And Installation....1488
Blower Housing Grill Removal And Installation....1490
Blower Disassembly And Assembly....1490
Gearbox Parts Identification....1492
Gearbox Disassembly....1493
Gearbox Assembly....1497
Gearbox Checking Backlash....1502
ENGINE COMPONENTS AND TESTING....1505
Compression Checking....1505
Glow Plugs Checking....1506
Glow Plugs Removal And Installation....1506
Fuel Shut-Off Solenoid, Checking....1507
Fuel Shut-Off Solenoid, Adjusting....1507
Fuel Shut-Off Solenoid Removal And Installation....1508
Checking....1509
Fuel Injection Pump Removal And Installation....1509
Timing The Injection Pump....1512
Fuel Injector Removal And Installation....1514
Fuel Injector Checking....1516
Fuel Injector Disassembly....1516
Fuel Injector Assembly....1517
Valve Clearance Adjustment....1517
Rocker Arm And Shaft Checking....1518
Valve Timing, Checking....1518
ENGINE....1519
Removal And Installation....1519
Engine Mount Replacement....1527
FLYWHEEL AND HOUSING....1529
Flywheel Removal And Installation....1529
Ring Gear Removal And Installation....1530
Housing Removal And Installation....1530
RPM SENSOR....1533
Adjustment....1533
RECONDITIONING THE ENGINE-KUBOTA V2203-EB AND V2003T-EB (TURBO)....1535
Cylinder Head Removal And Installation....1535
Cylinder Head Disassembly And Assembly....1536
Cylinder Head Servicing....1537
Cylinder Head Top Clearance....1537
Checking The Valve Guide....1538
Reconditioning The Valve And Valve Seat....1539
Valve Spring....1540
Rocker Arm And Shaft Checking....1541
Timing Gearcase Cover Removal And Installation....1541
Idler Gear And Camshaft Removal And Installation....1543
Servicing The Camshaft....1544
Servicing The Idle Gear And Shaft....1546
Timing Gears Checking Backlash....1547
Fuel Camshaft Removal And Installation....1547
Fuel Camshaft Governor....1548
Crankshaft Gear Removal And Installation....1548
Oil Pump Removal And Installation....1549
Oil Pump Service....1549
Checking Engine Oil Pressure....1551
Relief Valve....1551
Piston And Connecting Rod Removal And Installation....1552
Servicing The Piston And Connecting Rod....1553
Connecting Rod Alignment....1555
Crankshaft And Bearings Removal And Installation....1556
Servicing The Crankshaft And Bearings....1557
Checking The Cylinder Bore....1560
Water Pump Disassembly And Assembly....1561
TURBOCHARGER....1563
Troubleshooting....1563
Description....1564
Removal and Installation....1564
HEATING, VENTILATION, AIR CONDITIONING....1567
AIR CONDITIONING SYSTEM FLOW....1570
Principals....1570
Chart....1571
COMPONENTS....1573
Identification....1573
SAFETY....1577
Safety Equipment....1577
REGULAR MAINTENANCE....1579
Filter Elements Removal And Installation....1579
Compressor Drive Belt Inspection....1580
Cleaning The Condenser....1581
BASIC TROUBLESHOOTING....1583
Poor A/C Performance....1583
Cleaning The A/C Evaporator Coil & Heater Coil....1583
Compressor Drive Belt Inspection....1584
Checking The Electrical System....1585
Engine Coolant By-Passing The Heater Valve....1592
Heater Valve Not Opening Or Closing....1593
GENERAL AIR CONDITIONING SERVICE GUIDELINES....1595
Compressor Oil....1595
Compressor Oil Check....1596
Component Replacement And Refrigeration Leaks....1597
SYSTEM TROUBLESHOOTING CHART....1599
Gauge Pressure Related Troubleshooting....1600
TEMPERATURE/PRESSURE....1603
Chart....1603
AIR CONDITIONING SERVICE....1605
Chart....1605
SYSTEM CHARGING AND RECLAMATION....1607
Reclamation Procedure....1607
Charging Procedure With A Manifold Gauge Set....1610
Charging Procedure....1611
COMPRESSOR....1613
Removal And Installation....1613
Compressor Clutch Disassembly....1614
CONDENSER....1619
Removal And Installation....1619
RECEIVER/DRIER....1621
Removal And Installation....1621
PRESSURE RELIEF VALVE....1623
Removal And Installation....1623
PRESSURE SWITCH....1625
Removal And Installation....1625
EVAPORATOR/HEATER UNIT....1627
Removal And Installation....1627
Disassembly And Assembly....1629
THERMOSTAT....1631
Removal And Installation....1631
EXPANSION VALVE....1633
Removal And Installation....1633
EVAPORATOR....1635
Removal And Installation....1635
HEATER COIL....1637
Removal And Installation With A/C....1637
Removal And Installation Without A/C....1638
HEATER/AC FAN....1639
Removal And Installation....1639
Disassembly And Assembly....1640
Wire Connector Removal and Installation....1642
HEATER VALVE....1645
Removal And Installation....1645
Disassembly And Assembly....1645
SPECIFICATIONS....1647
LOADER SPECIFICATIONS....1649
Machine Dimensions....1649
Performance....1650
Controls....1650
Engine....1650
Hydraulic System....1651
Electrical....1651
Drive System....1652
Capacities....1652
Tires....1652
ENGINE SPECIFICATIONS - KUBOTA V2203-EB....1653
Fuel Injection Nozzles....1653
Fuel Injection Pump....1653
Cylinder Head....1653
Valves....1653
Valve Springs....1654
Valve Timing....1654
Rocker Arms....1654
Camshaft....1654
Tappet....1654
Cylinders....1655
Piston Rings....1655
Pistons....1655
Connecting Rod....1655
Oil Pump....1655
Crankshaft....1656
Timing Gear....1656
Thermostat....1656
Crankshaft Re-Grind Data....1657
ENGINE SPECIFICATIONS - KUBOTA V2003T-EB (TURBO)....1659
Fuel Injection Nozzles....1659
Fuel Injection Pump....1659
Cylinder Head....1659
Valves....1659
Valve Springs....1660
Valve Timing....1660
Rocker Arms....1660
Camshaft....1660
Tappet....1660
Cylinder Liner....1661
Piston Rings....1661
Pistons....1661
Connecting Rod....1661
Oil Pump....1661
Crankshaft....1662
Timing Gear....1662
Thermostat....1662
Crankshaft Re-Grind Data....1663
TORQUE SPECIFICATIONS FOR BOLTS....1665
Torque For General SAE Bolts....1665
Torque For General Metric Bolts....1666
HYDRAULIC CONNECTION SPECIFICATIONS....1667
O-ring Face Seal Connection....1667
Straight Thread O-ring Fitting....1668
Tubelines And Hoses....1668
Flare Fitting....1668
O-ring Flare Fitting....1669
Port Seal Fitting....1671
HYDRAULIC FLUID SPECIFICATIONS....1673
Specifications....1673
CONVERSIONS....1675
Decimal And Millimeter Equivalents....1675
U.S. To Metric Conversion....1675
SMR....1677
Revision No: S150, S160-1....1677
Revision No: S150, S160-2....1679
6902498 (4-11) - S150 Skid-Steer Loader Service Manual....1681
MAINTENANCE SAFETY....1683
ALPHABETICAL INDEX....1685
CONTENTS....1687
FOREWORD....1688
SAFETY INSTRUCTIONS....1691
FIRE PREVENTION....1693
Maintenance....1693
Operation....1693
Electrical....1693
Hydraulic System....1693
Fueling....1693
Starting....1693
Spark Arrestor Exhaust System....1693
Welding And Grinding....1694
Fire Extinguishers....1694
SERIAL NUMBER LOCATIONS....1695
Loader Serial Number....1695
Engine Serial Number....1695
DELIVERY REPORT....1696
BOBCAT LOADER IDENTIFICATION....1697
SAFETY AND MAINTENANCE....1699
LIFTING AND BLOCKING THE LOADER....1701
Procedure....1701
LIFT ARM SUPPORT DEVICE....1703
Installing Lift Arm Support Device....1703
Removing Lift Arm Support Device....1704
OPERATOR CAB....1705
Description....1705
Raising The Operator Cab....1705
Lowering The Operator Cab....1707
Emergency Exit....1708
TRANSPORTING THE BOBCAT LOADER....1709
Procedure....1709
TOWING THE LOADER....1711
Procedure....1711
REMOTE START TOOL KIT - MEL1563....1713
Remote Start Tool - MEL1563....1713
Service Tool Harness Control - MEL1565....1714
Service Tool Harness Communicator - MEL1566....1715
Remote Start Procedure....1716
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....1719
Description....1719
Remote Start Tool (Service Tool) - 7003030....1720
Loader Service Tool Harness - 6689747....1721
Computer Service Tool Harness - 6689746....1722
Remote Start Procedure....1723
SERVICE SCHEDULE....1727
Chart....1727
AIR CLEANER SERVICE....1729
Testing....1729
Replacing Filter Element(s)....1729
ENGINE COOLING SYSTEM....1731
Cleaning The Cooling System....1731
Checking Coolant Level And Adding Coolant....1731
Checking The Coolant Level....1732
Replacing the Coolant....1732
FUEL SYSTEM....1735
Fuel Specifications....1735
Filling The Fuel Tank....1735
Fuel Filter....1736
Removing Air From The Fuel System....1737
ENGINE LUBRICATION SYSTEM....1739
Checking Engine Oil....1739
Engine Oil Chart....1739
Replacing Oil And Filter....1740
HYDRAULIC / HYDROSTATIC SYSTEM....1741
Checking And Adding Fluid....1741
Hydraulic / Hydrostatic Fluid Chart....1741
Replacing Hydraulic / Hydrostatic Filter....1741
Replacing Hydraulic Fluid....1742
Breather Cap....1743
FINAL DRIVE TRANSMISSION (CHAINCASE)....1745
Checking And Adding Oil....1745
Removing Oil From The Chaincase....1745
FAN GEARBOX....1747
Checking And Maintaining....1747
BOB-TACH (HAND LEVER)....1749
Inspection And Maintenance....1749
BOB-TACH (POWER)....1751
Inspection And Maintenance....1751
LUBRICATION OF THE BOBCAT LOADER....1753
Procedure....1753
TIRE MAINTENANCE....1755
Wheel Nuts....1755
Rotating....1755
Mounting....1755
SPARK ARRESTER MUFFLER....1757
Cleaning Procedure....1757
SEAT BELT....1759
Inspection And Maintenance....1759
HYDRAULIC SYSTEM....1761
HYDRAULIC / HYDROSTATIC SCHEMATICS....1765
HYDRAULIC SYSTEM INFORMATION....1769
Tighten Procedures....1772
Troubleshooting Chart....1772
CYLINDER (LIFT)....1773
Testing....1773
Removal And Installation....1774
Identification....1775
Disassembly....1776
Assembly....1777
CYLINDER (TILT)....1781
Testing....1781
Removal And Installation....1782
Rod End Pivot Pin Bushing And Seal Replacement....1783
Base End Pivot Pin Replacement....1784
Identification....1785
Disassembly....1786
Assembly....1787
CYLINDER (POWER BOB-TACH)....1791
Testing....1791
Removal And Installation....1792
Identification....1793
Disassembly....1794
Assembly....1795
MAIN RELIEF VALVE....1799
Description....1799
Testing....1799
Adjustment....1800
Removal And Installation....1800
HYDRAULIC CONTROL VALVE (FOOT CONTROL)....1803
Removal And Installation....1803
BICS™ Valve Removal And Installation....1807
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....1809
BICS™ Valve, Check Valve Removal And Installation....1810
BICS™ Valve Lock Valve Removal And Installation....1811
BICS™ Valve Solenoid Removal And Installation....1812
BICS™ Valve Solenoid Testing....1813
Identification Chart....1814
Load Check Valve....1815
Main Relief Valve....1816
Port Relief Valve....1817
Anti-Cavitation Valve / Port Relief Valve....1818
Anti-Cavitation Valve....1818
Rubber Boot....1819
Lift And Tilt Lock Block Removal And Installation....1820
Lift Spool And Detent....1820
Tilt Spool Removal And Installation....1829
Auxiliary Spool Removal And Installation....1831
Auxiliary Electric Solenoid....1832
Port-Auxiliary Section....1833
Cleaning And Inspection....1834
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)....1835
Description....1835
Removal And Installation....1835
BICS™ Valve Removal And Installation....1840
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....1842
BICS™ Valve, Check Valve Removal And Installation....1842
BICS™ Valve Lock Valve Removal And Installation....1844
BICS™ Valve Solenoid Removal And Installation....1845
BICS™ Valve Solenoid Testing....1846
Actuator Removal And Installation....1847
Identification Chart (ACS)....1848
Lift Base End Restrictor....1849
Load Check Valve....1849
Main Relief Valve....1850
Port Relief Valve....1851
Anti-Cavitation Valve / Port Relief Valve....1852
Anti-Cavitation Valve....1853
Lift Spool Removal And Installation....1853
Tilt Spool Removal And Installation....1854
Lift And Tilt Spool Disassembly And Assembly....1855
Auxiliary Spool Removal And Installation....1856
Auxiliary Electric Solenoid....1857
Port-Auxiliary Section....1858
Cleaning And Inspection....1858
LIFT ARM BYPASS CONTROL VALVE....1859
Inspecting....1859
Removal And Installation....1859
Disassembly And Assembly....1860
HYDRAULIC PUMP....1861
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....1861
Check The Output Of The Hydraulic Pump With Power Bob-Tach.....1863
Removal And Installation....1865
Identification....1867
Disassembly And Assembly....1868
HYDRAULIC PUMP (HI FLOW)....1873
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....1873
Check The Output Of The Hydraulic Pump With Power Bob-Tach....1875
Removal And Installation....1877
Identification....1879
Disassembly And Assembly....1880
HYDRAULIC FILTER HOUSING....1889
Removal And Installation....1889
HYDRAULIC FLUID RESERVOIR....1891
Fluid Removal....1891
Removal And Installation....1891
BUCKET POSITION VALVE....1895
Solenoid Removal And Installation....1895
Solenoid Testing....1895
Removal And Installation....1896
Disassembly And Assembly....1898
HIGH FLOW VALVE....1901
Checking The High Flow Relief Valve....1901
High Flow Relief Valve Adjustment Procedure....1903
Removal And Installation....1904
Disassembly And Assembly....1906
Solenoid Testing....1908
REAR AUXILIARY DIVERTER VALVE....1909
Removal And Installation....1909
Disassembly And Assembly....1912
Solenoid Testing....1917
Inspection....1917
POWER BOB-TACH BLOCK....1919
Removal And Installation....1919
Disassembly And Assembly....1921
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....1925
Removal And Installation....1925
Disassembly And Assembly....1925
HYDROSTATIC SYSTEM....1927
HYDROSTATIC SYSTEM INFORMATION....1929
Troubleshooting Chart....1929
Replenishing Valve Function....1930
HYDROSTATIC MOTOR....1931
Removal And Installation....1931
Parts Identification....1933
Disassembly....1934
Assembly....1939
Carrier Shaft Seal Replacement....1945
Carrier Removal And Installation....1947
Carrier Parts Identification....1949
Carrier Disassembly....1950
Carrier Assembly....1951
CHARGE PRESSURE....1955
Sender Removal And Installation....1955
Testing Charge Pressure....1955
Adjusting....1956
HYDROSTATIC PUMP....1957
Replenishing / High Pressure Relief Valve....1957
Removal And Installation....1958
Parts Identification (Right Half)....1960
Parts Identification (Left Half)....1962
Hydraulic Pump Removal And Installation....1964
Pump Separation....1964
Disassembly....1965
Assembly....1971
DRIVE BELT....1979
Shield Removal And Installation....1979
Adjusting....1979
Drive Belt Replacement....1981
Tensioner Pulley Removal And Installation....1982
Tensioner Pulley Parts Identification....1983
Tensioner Pulley Disassembly....1984
Tensioner Pulley Assembly....1985
OIL COOLER....1987
Removal And Installation....1987
DRIVE SYSTEM....1989
BRAKE....1991
Disk Removal And Installation....1991
Switch Operated Parking Brake....1992
DRIVE COMPONENTS....1993
Axle Seal Removal And Installation....1993
Axle Sprocket And Bearings Removal And Installation....1995
Chain Removal And Installation....2000
CHAINCASE....2003
Checking And Adding Oil....2003
Removing The Oil....2003
Front Cover Removal And Installation....2004
Center Cover Removal And Installation....2005
Rear Cover Removal And Installation....2006
MAINFRAME....2007
SEAT BAR....2009
Removal And Installation....2009
Assembling Components....2010
Compression Spring Disassembly And Assembly....2012
OPERATOR CAB....2013
Gas Cylinder Removal And Installation....2013
Gas Cylinder Disassembly....2015
Removal And Installation....2016
OPERATOR SEAT....2019
Removal And Installation....2019
Seat Belt Removal And Installation....2019
OPERATOR SEAT (SUSPENSION)....2021
Removal And Installation....2021
Slide Rail Removal And Installation....2022
Cushion Removal And Installation....2022
Back Removal And Installation....2023
Shock Removal And Installation....2024
3-Point Seat Belt Removal And Installation....2025
BOB-TACH....2027
Removal And Installation....2027
Bob-Tach Lever And Wedge....2028
Pivot Pin Bushing And Seal Removal And Installation....2029
POWER BOB-TACH....2031
Removal And Installation....2031
Power Bob-Tach Lever And Wedge....2032
Pivot Pin Bushing And Seal Removal And Installation....2034
LIFT ARMS....2035
Removal And Installation....2035
REAR GRILLE....2039
Removal And Installation....2039
REAR DOOR....2041
Removal And Installation....2041
Striker Removal And Installation....2042
Striker Disassembly And Assembly....2042
Adjusting The Striker....2042
Latch Removal And Installation....2043
FUEL TANK....2045
Removal And Installation....2045
Fuel Level Sender....2046
Fuel Fill Screen....2046
CONTROL PEDALS....2049
Removal And Installation....2049
Pedal Adjustment....2049
Crossbar Linkage Removal And Installation....2050
Lift Foot Pedal Linkage Removal And Installation....2052
Tilt Foot Pedal Linkage Removal And Installation....2052
CONTROL PEDALS (ACS)....2053
Foot Sensor Removal And Installation....2053
Foot Pedal Removal And Installation....2054
Foot Pedal Linkage Disassembly And Assembly....2055
CONTROL PANEL....2057
Removal And Installation....2057
Shock Removal And Installation....2060
Shaft Removal And Installation....2060
Shaft Disassembly And Assembly....2061
Linkage Removal And Installation....2061
Linkage Adjustment....2064
Linkage Neutral Adjustment....2067
CONTROL HANDLE....2071
Control Lever Removal And Installation....2071
Control Lever Boot....2071
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL....2073
Components Identification....2073
Handle Sensor Removal And Installation....2073
Control Handle Removal And Installation....2076
Control Handle Disassembly And Assembly....2077
Control Lever Removal And Installation....2078
Control Lever Boot....2079
ELECTRICAL SYSTEM....2081
ELECTRICAL SCHEMATICS....2085
ELECTRICAL SYSTEM INFORMATION....2089
Troubleshooting Chart....2091
Description....2092
Fuse Location....2093
Relay Switch Location....2093
BATTERY....2095
Removal And Installation....2095
Servicing....2096
Using A Booster Battery (Jump Starting)....2097
ALTERNATOR (90 AMP)....2099
Adjusting The Alternator Belt....2099
Alternator Identification....2099
Charging System Check....2100
Alternator Voltage Test....2101
Low Voltage Test....2102
High Voltage Test....2102
Removal And Installation....2103
Rectifier Continuity (Diode) Test....2104
Alternator Regulator Test....2105
Disassembly....2105
Stator Continuity Test....2106
Stator Ground Test....2106
Rotor Continuity Test....2106
Rotor Ground Test....2106
Assembly....2107
STARTER....2109
Checking....2109
Removal And Installation....2110
Parts Identification....2111
Disassembly And Assembly....2112
Inspection And Repair....2115
No Load Test....2117
INSTRUMENT PANEL....2119
Left Panel....2119
Right Panel (Standard) (With Key Switch)....2120
Right Panel - (Deluxe) (With Keyless Start)....2121
Option And Field Accessory Panels....2126
Removal And Installation....2127
Front Accessory Panel Removal And Installation....2128
LIGHTS....2129
Front Removal And Installation....2129
Rear Removal And Installation....2129
BOBCAT CONTROLLER....2131
Identification Chart....2131
Removal And Installation....2133
DIAGNOSTIC SERVICE CODES....2135
Display....2135
Number Codes List....2136
BICS™ SYSTEM....2141
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....2141
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2141
Inspecting The Seat Bar Sensor (Engine RUNNING)....2141
Inspecting The Traction Lock (Engine RUNNING)....2141
Inspecting The Lift Arm Bypass Control....2141
Troubleshooting Chart....2142
Troubleshooting Guide....2143
SEAT BAR SENSOR....2145
Description....2145
Troubleshooting....2145
Testing....2146
Removal And Installation....2147
Bobcat Interlock Control System (BICS™) Circuit Test....2150
TRACTION LOCK....2153
Troubleshooting Chart....2153
Inspecting....2154
Solenoid Removal And Installation....2154
Guide Removal....2157
Guide Installation....2158
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL....2161
Components Identification....2161
Troubleshooting Guide....2163
Controller, Connector And Wire Identification....2164
ACS Controller Removal And Installation....2165
Handle Sensor Connector....2166
Switch Handle Removal....2167
Switch Handle Installation....2169
Actuators Disassembly And Assembly....2172
Handle Lock Solenoid Removal And Installation....2174
Handle Lock Solenoid Disassembly And Assembly....2174
Handle Lock Solenoid Connector....2175
Calibration Of The ACS System....2176
Switchable Hand / Foot Controls Calibration Procedure....2176
Hand Controls Only Calibration Procedure....2177
Foot Sensor Disassembly And Assembly....2179
Foot Sensor Connector....2179
Foot Lock Solenoid Removal And Installation....2180
Foot Lock Solenoid Connector....2181
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE....2183
Controls Identification Chart....2183
ENGINE SERVICE....2185
TROUBLESHOOTING....2187
Chart....2187
ENGINE SPEED CONTROL....2189
Removal And Installation....2189
Disassembly....2190
MUFFLER....2191
Removal And Installation....2191
AIR CLEANER....2193
Removal And Installation....2193
RADIATOR....2195
Removal And Installation....2195
COOLING FAN....2199
Drive Tension Pulley Removal And Installation....2199
Gearbox / Blower Housing Removal And Installation....2200
Blower Housing Grille Removal And Installation....2202
Blower Disassembly And Assembly....2203
Gearbox Parts Identification....2205
Gearbox Disassembly....2206
Gearbox Assembly....2210
Gearbox Checking Backlash....2215
ENGINE COMPONENTS AND TESTING....2219
Compression Checking....2219
Glow Plugs Checking....2220
Glow Plugs Removal And Installation....2220
Fuel Shut-Off Solenoid - Checking....2221
Fuel Shut-Off Solenoid - Adjusting....2221
Fuel Shut-Off Solenoid Removal And Installation....2222
Checking....2223
Fuel Injection Pump Removal And Installation....2223
Timing The Injection Pump....2226
Fuel Injector Removal And Installation....2228
Fuel Injector - Checking....2230
Fuel Injector Disassembly....2230
Fuel Injector Assembly....2231
Valve Clearance Adjustment....2231
Rocker Arm And Shaft - Checking....2232
Valve Timing - Checking....2232
ENGINE....2233
Removal And Installation....2233
Engine Mount Replacement....2241
FLYWHEEL AND HOUSING....2243
Flywheel Removal And Installation....2243
Ring Gear Removal And Installation....2244
Housing Removal And Installation....2244
RPM SENSOR....2247
Adjustment....2247
RECONDITIONING THE ENGINE-KUBOTA V2203-EB AND V2003T-EB (TURBO)....2249
Cylinder Head Removal And Installation....2249
Cylinder Head Disassembly And Assembly....2250
Cylinder Head Servicing....2251
Cylinder Head Top Clearance....2251
Checking The Valve Guide....2252
Reconditioning The Valve And Valve Seat....2253
Valve Spring....2254
Rocker Arm And Shaft Checking....2255
Timing Gearcase Cover Removal And Installation....2255
Idler Gear And Camshaft Removal And Installation....2257
Servicing The Camshaft....2258
Servicing The Idle Gear And Shaft....2260
Timing Gears Checking Backlash....2261
Fuel Camshaft Removal And Installation....2261
Fuel Camshaft Governor....2262
Crankshaft Gear Removal And Installation....2262
Oil Pump Removal And Installation....2263
Oil Pump Service....2263
Checking Engine Oil Pressure....2265
Relief Valve....2265
Piston And Connecting Rod Removal And Installation....2266
Servicing The Piston And Connecting Rod....2267
Connecting Rod Alignment....2269
Crankshaft And Bearings Removal And Installation....2270
Servicing The Crankshaft And Bearings....2271
Checking The Cylinder Bore....2274
Water Pump Disassembly And Assembly....2275
TURBOCHARGER....2277
Troubleshooting....2277
Description....2278
Removal And Installation....2278
HEATING, VENTILATION, AIR CONDITIONING....2281
AIR CONDITIONING SYSTEM FLOW....2284
Principals....2284
Chart....2285
COMPONENTS....2287
Identification....2287
SAFETY....2291
Safety Equipment....2291
REGULAR MAINTENANCE....2293
Filter Elements Removal And Installation....2293
Compressor Drive Belt Inspection....2294
Cleaning The Condenser....2295
BASIC TROUBLESHOOTING....2297
Poor A/C Performance....2297
Cleaning The A/C Evaporator Coil & Heater Coil....2297
Compressor Drive Belt Inspection....2298
Checking The Electrical System....2299
Engine Coolant Bypassing The Heater Valve....2306
Heater Valve Not Opening Or Closing....2307
GENERAL AIR CONDITIONING SERVICE GUIDELINES....2309
Compressor Oil....2309
Compressor Oil Check....2310
Component Replacement And Refrigeration Leaks....2311
SYSTEM TROUBLESHOOTING CHART....2313
Gauge Pressure Related Troubleshooting....2314
TEMPERATURE / PRESSURE....2317
Chart....2317
AIR CONDITIONING SERVICE....2319
Chart....2319
SYSTEM CHARGING AND RECLAMATION....2321
Reclamation Procedure....2321
Charging Procedure With A Manifold Gauge Set....2324
Charging Procedure....2325
COMPRESSOR....2327
Removal And Installation....2327
Compressor Clutch Disassembly....2328
CONDENSER....2333
Removal And Installation....2333
RECEIVER / DRIER....2335
Removal And Installation....2335
PRESSURE RELIEF VALVE....2337
Removal And Installation....2337
PRESSURE SWITCH....2339
Removal And Installation....2339
EVAPORATOR / HEATER UNIT....2341
Removal And Installation....2341
Disassembly And Assembly....2343
THERMOSTAT....2345
Removal And Installation....2345
EXPANSION VALVE....2347
Removal And Installation....2347
EVAPORATOR....2349
Removal And Installation....2349
HEATER COIL....2351
Removal And Installation With A/C....2351
Removal And Installation Without A/C....2352
HEATER / A/C FAN....2353
Removal And Installation....2353
Disassembly And Assembly....2354
Wire Connector Removal And Installation....2356
HEATER VALVE....2359
Removal And Installation....2359
Disassembly And Assembly....2359
SPECIFICATIONS....2361
LOADER SPECIFICATIONS....2363
Machine Dimensions....2363
Performance....2364
Controls....2364
Engine....2364
Hydraulic System....2365
Electrical....2365
Drive System....2366
Capacities....2366
Tires....2366
ENGINE SPECIFICATIONS - KUBOTA V2203-EB....2367
Fuel Injection Nozzles....2367
Fuel Injection Pump....2367
Cylinder Head....2367
Valves....2367
Valve Springs....2368
Valve Timing....2368
Rocker Arms....2368
Camshaft....2368
Tappet....2368
Cylinders....2369
Piston Rings....2369
Pistons....2369
Connecting Rod....2369
Oil Pump....2369
Crankshaft....2370
Timing Gear....2370
Thermostat....2370
Crankshaft Re-Grind Data....2371
ENGINE SPECIFICATIONS - KUBOTA V2003T-EB (TURBO)....2373
Fuel Injection Nozzles....2373
Fuel Injection Pump....2373
Cylinder Head....2373
Valves....2373
Valve Springs....2374
Valve Timing....2374
Rocker Arms....2374
Camshaft....2374
Tappet....2374
Cylinder Liner....2375
Piston Rings....2375
Pistons....2375
Connecting Rod....2375
Oil Pump....2375
Crankshaft....2376
Timing Gear....2376
Thermostat....2376
Crankshaft Re-Grind Data....2377
TORQUE SPECIFICATIONS FOR BOLTS....2379
Torque For General SAE Bolts....2379
Torque For General Metric Bolts....2380
HYDRAULIC CONNECTION SPECIFICATIONS....2381
O-ring Face Seal Connection....2381
Straight Thread O-ring Fitting....2382
Tubelines And Hoses....2382
Flare Fitting....2382
O-ring Flare Fitting....2383
Port Seal Fitting....2385
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....2387
Specifications....2387
CONVERSIONS....2389
Decimal And Millimeter Equivalent Chart....2389
U.S. To Metric Conversion Chart....2389
SERVICE MANUAL REVISION....2391
Revision No: S150, S160-1....2391
Revision No: S150, S160-2....2393
Revision No: S150, S160 - 3....2395
6902505 (12-06) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual....2397
OPERATOR SAFETY WARNINGS....2399
CONTENTS....2401
FOREWORD....2403
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....2405
REGULAR MAINTENANCE ITEMS....2405
MOTOR OIL....2405
SERIAL NUMBER LOCATIONS....2406
Loader Serial Number....2406
Engine Serial Number....2406
DELIVERY REPORT....2406
MACHINE IDENTIFICATION....2407
FEATURES, ACCESSORIES AND ATTACHMENTS....2408
Standard Items....2408
Options and Accessories....2408
Buckets Available....2409
Attachments....2409
SAFETY....2411
SAFETY INSTRUCTIONS....2413
Before Operation....2413
Safe Operation Is The Operator’s Responsibility....2414
Safe Operation Needs A Qualified Operator....2414
Fire Prevention....2415
MACHINE SIGNS (DECALS)....2416
OPERATING INSTRUCTIONS....2419
INSTRUMENT PANEL IDENTIFICATION....2421
Left Panel....2421
Right Panel (Standard - With Key Switch)....2422
Right Panel (Deluxe - With Keyless Start)....2423
Option And Field Accessory Panels (If Equipped)....2425
Cab Light....2426
LIFT ARM BY-PASS CONTROL....2426
Operation....2426
TRACTION LOCK OVERRIDE....2426
Operation....2426
ENGINE SPEED CONTROL....2427
Operation....2427
PARKING BRAKE....2427
Operation....2427
DRIVING AND STEERING THE LOADER....2428
Available Controls Configurations....2428
Operation (Standard and ACS)....2428
STOPPING THE BOBCAT LOADER....2428
Using The Steering Levers....2428
SEAT BAR RESTRAINT SYSTEM....2429
Operation....2429
HYDRAULIC CONTROLS....2430
Operation....2430
Standard Controls (Also ACS in Foot Pedal Mode)....2430
Advanced Control System (ACS) in HAND Control Mode....2431
Quick Couplers....2432
Releasing Hydraulic Pressure (Loader and Attachment)....2432
Auxiliary Hydraulics Button - VARIABLE FLOW....2432
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....2433
Auxiliary Hydraulics Button - DISENGAGE....2433
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....2433
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....2433
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....2433
REAR Auxiliary Hydraulics Operation (If Equipped)....2434
High-Flow Hydraulics Operation (If Equipped)....2434
Attachment Control Device (ACD) (If Equipped)....2435
Bucket Position Valve Operation (If Equipped)....2435
DAILY INSPECTION....2436
Daily Inspection and Maintenance....2436
PRE-STARTING PROCEDURES....2437
Before Starting The Engine....2437
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2439
Procedure....2439
STARING THE ENGINE (DELUXE PANEL, KEYLESS START)....2441
Procedure....2441
Cold Temperature Starting....2442
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2442
Procedure....2442
STOPPING THE ENGINE....2443
Procedure....2443
MONITORING THE DISPLAY PANEL....2444
Standard Panel....2444
Deluxe Panel....2444
WARNING and SHUTDOWN....2444
ATTACHMENTS AND BUCKETS....2445
Choosing The Correct Bucket....2445
Pallet Forks....2446
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2446
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2448
Power Bob-Tach - Installing The Bucket Or Attachment....2449
Power Bob-Tach - Removing The Bucket Or Attachment....2450
OPERATING PROCEDURE....2451
Operating With A Full Bucket....2451
Operating With An Empty Bucket....2452
Foot Pedal Machines....2453
Hand Control Machines (Includes ACS)....2455
PARKING THE BOBCAT LOADER....2457
Procedure....2457
TRANSPORTING THE BOBCAT LOADER....2458
Loading Onto Transport Vehicle....2458
Fastening To Transport Vehicle....2458
TOWING THE LOADER....2459
Towing Procedure....2459
PREVENTIVE MAINTENANCE....2461
MAINTENANCE SAFETY....2463
SERVICE SCHEDULE....2465
Chart....2465
LIFT ARM SUPPORT DEVICE....2466
Engaging The Lift Arm Support Device....2466
Disengaging The Lift Arm Support Device....2467
OPERATOR CAB....2468
Raising The Operator Cab....2468
Lowering The Operator Cab....2469
Cab Door Sensor....2469
Emergency Exit....2470
SEAT BELT....2471
Inspection and Maintenance....2471
SEAT BAR RESTRAINT SYSTEM....2472
Inspecting The Seat Bar....2472
Maintaining The Seat Bar....2472
BOCAT INTERLOCK CONTROL SYSTEM (BICS)....2473
Inspecting The BICS Controller (Engine Stopped - Key ON)....2473
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2473
Inspecting The Seat Bar Sensor (Engine RUNNING)....2473
Inspecting The Traction Lock (Engine RUNNING)....2473
Inspecting The Lift Arm By-Pass Control....2473
Inspecting Deactivation Of Lift And Tilt Functions (ACS)....2473
REAR DOOR....2474
Opening And Closing The Rear Door....2474
Adjusting The Rear Door Latch....2474
REAR GRILL....2475
Removing....2475
Installing....2475
HEATING SYSTEM....2475
Cleaning And Maintenance....2475
AIR CLEANER SERVICE....2476
Replacing Filter Elements....2476
FUEL SYSTEM....2477
Fuel Specifications....2477
Filling The Fuel Tank....2477
Fuel Filter....2478
Removing Air From The Fuel System....2478
ENGINE LUBRICATION SYSTEM....2479
Checking Engine Oil....2479
Replacing The Oil And Filter....2479
ENGINE COOLING SYSTEM....2480
Cleaning The Cooling System....2480
Checking Coolant Level And Adding Coolant....2480
Replacing The Coolant....2481
ALTERNATOR BELT....2482
Adjusting The Alternator Belt....2482
ELECTRICAL SYSTEM....2482
Description....2482
Cleaning Battery and Terminals....2482
Fuse Location....2483
Using A Booster Battery (Jump Starting)....2484
Removing And Installing The Battery....2485
HYDRAULIC / HYDROSTATIC SYSTEM....2486
Checking And Adding Fluid....2486
Replacing Hydraulic/Hydrostatic Filter....2486
Replacing Hydraulic Fluid and Case Drain Filters....2487
Hydraulic Breather....2488
TIRE MAINTENANCE....2489
Wheel Nuts....2489
Rotating....2489
Mounting....2489
FINAL DRIVE TRANSMISSION (CHAINCASE)....2490
Checking And Adding Oil....2490
Removing Oil From The Chaincase....2490
FAN GEARBOX....2491
Checking And Maintaining....2491
DRIVE BELT....2491
Adjusting The Drive Belt....2491
Replacing The Drive Belt....2491
SPARK ARRESTOR MUFFLER....2492
LUBRICATING THE BOBCAT LOADER....2493
Lubrication Locations....2493
PIVOT PINS....2494
Inspection And Maintenance....2494
BOB-TACH (HAND LEVER)....2495
Inspection And Maintenance....2495
BOB-TACH (POWER) (OPTIONAL)....2496
Inspection And Maintenance....2496
SYSTEM SETUP & ANALYSIS....2497
BICS SYSTEM....2499
Troubleshooting Guide....2499
DIAGNOSTICS SERVICE CODES....2500
Display....2500
Number Codes List....2501
DELUXE INSTRUMENT PANEL SETUP....2505
Deluxe Panel Upgrade....2505
Deluxe Panel Setup....2506
Passwords (Deluxe)....2506
SHUTDOWN FEATURE....2508
SERVICE CLOCK RESET....2508
MACHINE SIGN TRANSLATIONS....2509
SERVICE SCHEDULE (6734534)....2511
WARNING (6728539)....2512
DANGER - ACS (6715944)....2513
WARNING (6732696)....2513
DANGER (6579509)....2514
DANGER (6579639)....2514
DANGER (6717343)....2515
IMPORTANT (6560573)....2515
WARNING (6577754)....2515
WARNING (6579528)....2515
SPECIFICATIONS....2517
LOADER SPECIFICATIONS (S160)....2519
Machine Dimensions....2519
Performance....2520
Controls....2520
Engine....2520
Hydraulic System....2521
Electrical....2521
Drive System....2522
Capacities....2522
Tires....2522
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2523
WARRANTY....2525
6902505 (5-12) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual....2527
OPERATOR SAFETY WARNINGS....2529
CONTENTS....2531
FOREWORD....2533
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....2535
REGULAR MAINTENANCE ITEMS....2535
MOTOR OIL....2535
SERIAL NUMBER LOCATIONS....2536
Loader Serial Number....2536
Engine Serial Number....2536
DELIVERY REPORT....2536
MACHINE IDENTIFICATION....2537
FEATURES, ACCESSORIES AND ATTACHMENTS....2538
Standard Items....2538
Options and Accessories....2538
Buckets Available....2539
Attachments....2539
SAFETY....2541
SAFETY INSTRUCTIONS....2543
Before Operation....2543
Safe Operation Is The Operator’s Responsibility....2544
Safe Operation Needs A Qualified Operator....2544
Fire Prevention....2545
MACHINE SIGNS (DECALS)....2546
OPERATING INSTRUCTIONS....2549
INSTRUMENT PANEL IDENTIFICATION....2551
Left Panel....2551
Right Panel (Standard - With Key Switch)....2552
Right Panel (Deluxe - With Keyless Start)....2553
Option And Field Accessory Panels (If Equipped)....2555
Cab Light....2556
LIFT ARM BY-PASS CONTROL....2556
Operation....2556
TRACTION LOCK OVERRIDE....2556
Operation....2556
ENGINE SPEED CONTROL....2557
Operation....2557
PARKING BRAKE....2557
Operation....2557
DRIVING AND STEERING THE LOADER....2558
Available Controls Configurations....2558
Operation (Standard and ACS)....2558
STOPPING THE BOBCAT LOADER....2558
Using The Steering Levers....2558
SEAT BAR RESTRAINT SYSTEM....2559
Operation....2559
HYDRAULIC CONTROLS....2560
Operation....2560
Standard Controls (Also ACS in Foot Pedal Mode)....2560
Advanced Control System (ACS) in HAND Control Mode....2561
Quick Couplers....2562
Releasing Hydraulic Pressure (Loader and Attachment)....2562
Auxiliary Hydraulics Button - VARIABLE FLOW....2562
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....2563
Auxiliary Hydraulics Button - DISENGAGE....2563
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....2563
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....2563
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....2563
REAR Auxiliary Hydraulics Operation (If Equipped)....2564
High-Flow Hydraulics Operation (If Equipped)....2564
Attachment Control Device (ACD) (If Equipped)....2565
Bucket Position Valve Operation (If Equipped)....2565
DAILY INSPECTION....2566
Daily Inspection and Maintenance....2566
PRE-STARTING PROCEDURES....2567
Before Starting The Engine....2567
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2569
Procedure....2569
STARING THE ENGINE (DELUXE PANEL, KEYLESS START)....2571
Procedure....2571
Cold Temperature Starting....2572
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2572
Procedure....2572
STOPPING THE ENGINE....2573
Procedure....2573
MONITORING THE DISPLAY PANEL....2574
Standard Panel....2574
Deluxe Panel....2574
WARNING and SHUTDOWN....2574
ATTACHMENTS AND BUCKETS....2575
Choosing The Correct Bucket....2575
Pallet Forks....2576
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2576
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2578
Power Bob-Tach - Installing The Bucket Or Attachment....2579
Power Bob-Tach - Removing The Bucket Or Attachment....2580
OPERATING PROCEDURE....2581
Operating With A Full Bucket....2581
Operating With An Empty Bucket....2582
Foot Pedal Machines....2583
Hand Control Machines (Includes ACS)....2585
PARKING THE BOBCAT LOADER....2587
Procedure....2587
TRANSPORTING THE BOBCAT LOADER....2588
Loading Onto Transport Vehicle....2588
Fastening To Transport Vehicle....2588
TOWING THE LOADER....2589
Towing Procedure....2589
PREVENTIVE MAINTENANCE....2591
MAINTENANCE SAFETY....2593
SERVICE SCHEDULE....2595
Chart....2595
LIFT ARM SUPPORT DEVICE....2596
Engaging The Lift Arm Support Device....2596
Disengaging The Lift Arm Support Device....2597
OPERATOR CAB....2598
Raising The Operator Cab....2598
Lowering The Operator Cab....2599
Cab Door Sensor....2599
Emergency Exit....2600
SEAT BELT....2601
Inspection and Maintenance....2601
SEAT BAR RESTRAINT SYSTEM....2602
Inspecting The Seat Bar....2602
Maintaining The Seat Bar....2602
BOCAT INTERLOCK CONTROL SYSTEM (BICS)....2603
Inspecting The BICS Controller (Engine Stopped - Key ON)....2603
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2603
Inspecting The Seat Bar Sensor (Engine RUNNING)....2603
Inspecting The Traction Lock (Engine RUNNING)....2603
Inspecting The Lift Arm By-Pass Control....2603
Inspecting Deactivation Of Lift And Tilt Functions (ACS)....2603
REAR DOOR....2604
Opening And Closing The Rear Door....2604
Adjusting The Rear Door Latch....2604
REAR GRILL....2605
Removing....2605
Installing....2605
HEATING SYSTEM....2605
Cleaning And Maintenance....2605
AIR CLEANER SERVICE....2606
Replacing Filter Elements....2606
FUEL SYSTEM....2607
Fuel Specifications....2607
Filling The Fuel Tank....2607
Fuel Filter....2608
Removing Air From The Fuel System....2608
ENGINE LUBRICATION SYSTEM....2609
Checking Engine Oil....2609
Replacing The Oil And Filter....2609
ENGINE COOLING SYSTEM....2610
Cleaning The Cooling System....2610
Checking Coolant Level And Adding Coolant....2610
Replacing The Coolant....2611
ALTERNATOR BELT....2612
Adjusting The Alternator Belt....2612
ELECTRICAL SYSTEM....2612
Description....2612
Cleaning Battery and Terminals....2612
Fuse Location....2613
Using A Booster Battery (Jump Starting)....2614
Removing And Installing The Battery....2615
HYDRAULIC / HYDROSTATIC SYSTEM....2616
Checking And Adding Fluid....2616
Replacing Hydraulic/Hydrostatic Filter....2616
Replacing Hydraulic Fluid and Case Drain Filters....2617
Hydraulic Breather....2618
TIRE MAINTENANCE....2619
Wheel Nuts....2619
Rotating....2619
Mounting....2619
FINAL DRIVE TRANSMISSION (CHAINCASE)....2620
Checking And Adding Oil....2620
Removing Oil From The Chaincase....2620
FAN GEARBOX....2621
Checking And Maintaining....2621
DRIVE BELT....2621
Adjusting The Drive Belt....2621
Replacing The Drive Belt....2621
SPARK ARRESTOR MUFFLER....2622
LUBRICATING THE BOBCAT LOADER....2623
Lubrication Locations....2623
PIVOT PINS....2624
Inspection And Maintenance....2624
BOB-TACH (HAND LEVER)....2625
Inspection And Maintenance....2625
BOB-TACH (POWER) (OPTIONAL)....2626
Inspection And Maintenance....2626
SYSTEM SETUP & ANALYSIS....2627
BICS SYSTEM....2629
Troubleshooting Guide....2629
DIAGNOSTICS SERVICE CODES....2630
Display....2630
Number Codes List....2631
DELUXE INSTRUMENT PANEL SETUP....2635
Deluxe Panel Upgrade....2635
Deluxe Panel Setup....2636
Passwords (Deluxe)....2636
SHUTDOWN FEATURE....2638
SERVICE CLOCK RESET....2638
MACHINE SIGN TRANSLATIONS....2639
SERVICE SCHEDULE (6734534)....2641
WARNING (6728539)....2642
DANGER - ACS (6715944)....2643
WARNING (6732696)....2643
DANGER (6579509)....2644
DANGER (6579639)....2644
DANGER (6717343)....2645
IMPORTANT (6560573)....2645
WARNING (6577754)....2645
WARNING (6579528)....2645
SPECIFICATIONS....2647
LOADER SPECIFICATIONS (S160)....2649
Machine Dimensions....2649
Performance....2650
Controls....2650
Engine....2650
Hydraulic System....2651
Electrical....2651
Drive System....2652
Capacities....2652
Tires....2652
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2653
WARRANTY....2655
6902684 (12-06) - S150 Skid-Steer Loader Operation & Maintenance Manual....2657
OPERATOR SAFETY WARNINGS....2659
CONTENTS....2661
FOREWORD....2663
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....2665
MOTOR OIL....2665
SERIAL NUMBER LOCATIONS....2666
Loader Serial Number....2666
Engine Serial Number....2666
DELIVERY REPORT....2666
MACHINE IDENTIFICATION....2667
FEATURES, ACCESSORIES AND ATTACHMENTS....2668
Standard Items....2668
Options and Accessories....2668
Buckets Available....2669
Attachments....2669
SAFETY....2671
SAFETY INSTRUCTIONS....2673
Before Operation....2673
Safe Operation Is The Operator’s Responsibility....2674
Safe Operation Needs A Qualified Operator....2674
Fire Prevention....2675
MACHINE SIGNS (DECALS)....2676
OPERATING INSTRUCTIONS....2679
INSTRUMENT PANEL IDENTIFICATION....2681
Left Panel....2681
Right Panel (Standard - With Key Switch)....2682
Right Panel (Deluxe - With Keyless Start)....2683
Option And Field Accessory Panels (If Equipped)....2685
Cab Light....2686
LIFT ARM BY-PASS CONTROL....2686
Operation....2686
TRACTION LOCK OVERRIDE....2686
Operation....2686
ENGINE SPEED CONTROL....2687
Operation....2687
INCHING CONTROL....2687
Operation....2687
PARKING BRAKE....2688
Operation....2688
DRIVING AND STEERING THE LOADER....2689
Available Controls Configurations....2689
Operation (Standard and ACS)....2689
Operation (SJC in ‘H’ Control Pattern)....2690
Operation (SJC in ‘ISO’ Control Pattern)....2691
STOPPING THE BOBCAT LOADER....2692
Using The Steering Levers or Joysticks....2692
SEAT BAR RESTRAINT SYSTEM....2692
Operation....2692
HYDRAULIC CONTROLS....2693
Standard Operation (Foot Pedal)....2693
Standard Controls (Also ACS in Foot Pedal Mode)....2693
Advanced Control System (ACS) in HAND Control Mode....2694
Selectable Joystick Control (SJC) - ‘H’ Control Pattern....2695
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern....2695
Quick Couplers....2696
Releasing Hydraulic Pressure (Loader and Attachment)....2696
Auxiliary Hydraulics Button - VARIABLE FLOW....2696
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....2696
Auxiliary Hydraulics Button - DISENGAGE....2696
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....2697
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....2697
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....2697
REAR Auxiliary Hydraulics Operation (If Equipped)....2697
Attachment Control Device (ACD) (If Equipped)....2698
Bucket Position Valve Operation (If Equipped)....2698
DAILY INSPECTION....2699
Daily Inspection and Maintenance....2699
PRE-STARTING PROCEDURES....2700
Before Starting The Engine....2700
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2702
Procedure....2702
STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....2704
Procedure....2704
Cold Temperature Starting....2705
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2706
Procedure....2706
STOPPING THE ENGINE....2706
Procedure....2706
MONITORING THE DISPLAY PANEL....2707
Standard Panel....2707
Deluxe Panel....2707
WARNING and SHUTDOWN....2707
ATTACHMENTS AND BUCKETS....2708
Choosing The Correct Bucket....2708
Pallet Forks....2709
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2709
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2711
Power Bob-Tach - Installing The Bucket Or Attachment....2712
Power Bob-Tach - Removing The Bucket Or Attachment....2713
OPERATING PROCEDURE....2714
Operating With A Full Bucket....2714
Operating With An Empty Bucket....2715
Foot Pedal Machines....2716
Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....2718
Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected....2720
PARKING THE BOBCAT LOADER....2722
Procedure....2722
TRANSPORTING THE BOBCAT LOADER....2723
Loading Onto Transport Vehicle....2723
Fastening To Transport Vehicle....2723
TOWING THE LOADER....2724
Towing Procedure....2724
LIFTING THE LOADER....2724
Single Point Lift....2724
Four Point Lift....2724
PREVENTIVE MAINTENANCE....2725
MAINTENANCE SAFETY....2729
SERVICE SCHEDULE....2731
Chart....2731
LIFT ARM SUPPORT DEVICE....2732
Engaging The Lift Arm Support Device....2732
Disengaging The Lift Arm Support Device....2733
OPERATOR CAB....2734
Raising The Operator Cab....2734
Lowering The Operator Cab....2735
Cab Door Sensor....2735
Emergency Exit....2736
SEAT BELT....2737
Inspection and Maintenance....2737
SEAT BAR RESTRAINT SYSTEM....2738
Inspecting The Seat Bar....2738
Maintaining The Seat Bar....2738
BOCAT INTERLOCK CONTROL SYSTEM (BICS)....2739
Inspecting The BICS Controller (Engine Stopped - Key ON)....2739
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2739
Inspecting The Seat Bar Sensor (Engine RUNNING)....2739
Inspecting The Traction Lock (Engine RUNNING)....2739
Inspecting The Lift Arm By-Pass Control....2739
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....2739
REAR DOOR....2740
Opening And Closing The Rear Door....2740
Adjusting The Rear Door Latch....2740
REAR GRILL....2741
Removing....2741
Installing....2741
HEATING SYSTEM....2741
Cleaning And Maintenance....2741
AIR CLEANER SERVICE....2742
Replacing Filter Elements....2742
FUEL SYSTEM....2743
Fuel Specifications....2743
Filling The Fuel Tank....2743
Fuel Filter....2744
Removing Air From The Fuel System....2744
ENGINE LUBRICATION SYSTEM....2745
Checking Engine Oil....2745
Replacing The Oil And Filter....2745
ENGINE COOLING SYSTEM....2746
Cleaning The Cooling System....2746
Checking Coolant Level And Adding Coolant....2746
Replacing The Coolant....2747
ALTERNATOR BELT....2748
Adjusting The Alternator Belt....2748
ELECTRICAL SYSTEM....2748
Description....2748
Cleaning Battery and Terminals....2748
Fuse Location....2749
Using A Booster Battery (Jump Starting)....2750
Removing And Installing The Battery....2751
HYDRAULIC / HYDROSTATIC SYSTEM....2752
Checking And Adding Fluid....2752
Replacing Hydraulic/Hydrostatic Filter....2752
Replacing Hydraulic Fluid and Case Drain Filters....2753
Hydraulic Breather....2754
TIRE MAINTENANCE....2755
Wheel Nuts....2755
Rotating....2755
Mounting....2755
FINAL DRIVE TRANSMISSION (CHAINCASE)....2756
Checking And Adding Oil....2756
Removing Oil From The Chaincase....2756
FAN GEARBOX....2757
Checking And Maintaining....2757
DRIVE BELT....2757
Adjusting The Drive Belt....2757
Replacing The Drive Belt....2757
SPARK ARRESTOR MUFFLER....2758
LUBRICATING THE BOBCAT LOADER....2759
Lubrication Locations....2759
PIVOT PINS....2760
Inspection And Maintenance....2760
BOB-TACH (HAND LEVER)....2761
Inspection And Maintenance....2761
BOB-TACH (POWER) (OPTIONAL)....2762
Inspection And Maintenance....2762
SYSTEM SETUP & ANALYSIS....2763
BICS SYSTEM....2765
Troubleshooting Guide....2765
DIAGNOSTICS SERVICE CODES....2766
Display....2766
Number Codes List....2767
DELUXE INSTRUMENT PANEL SETUP....2771
Deluxe Panel Upgrade....2771
Deluxe Panel Setup....2772
Passwords (Deluxe)....2772
Viewing Service Codes....2774
SHUTDOWN FEATURE....2775
SERVICE CLOCK RESET....2775
MACHINE SIGN TRANSLATIONS....2777
SERVICE SCHEDULE (6734534)....2779
WARNING (6728539)....2780
WARNING (6727926)....2781
WARNING (6718706)....2782
WARNING (6710358)....2782
DANGER (6702301)....2783
DANGER (6702302)....2783
WARNING (6717343)....2783
WARNING (6577754)....2784
IMPORTANT (6560573)....2784
IMPORTANT (6725370)....2785
WARNING (6579528)....2785
LIFT ARM SUPPORT DEVICE (6706558)....2786
WARNING (6737189)....2787
IMPORTANT (6733996)....2787
SPECIFICATIONS....2789
LOADER SPECIFICATIONS (S150)....2791
Machine Dimensions....2791
Performance....2792
Controls....2792
Engine....2792
Hydraulic System....2793
Electrical....2793
Drive System....2794
Capacities....2794
Tires....2794
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2795
WARRANTY....2797
6902684 (5-12) - S150 Skid-Steer Loader Operation & Maintenance Manual....2799
OPERATOR SAFETY WARNINGS....2801
CONTENTS....2803
FOREWORD....2805
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....2807
MOTOR OIL....2807
SERIAL NUMBER LOCATIONS....2808
Loader Serial Number....2808
Engine Serial Number....2808
DELIVERY REPORT....2808
MACHINE IDENTIFICATION....2809
FEATURES, ACCESSORIES AND ATTACHMENTS....2810
Standard Items....2810
Options and Accessories....2810
Buckets Available....2811
Attachments....2811
SAFETY....2813
SAFETY INSTRUCTIONS....2815
Before Operation....2815
Safe Operation Is The Operator’s Responsibility....2816
Safe Operation Needs A Qualified Operator....2816
Fire Prevention....2817
MACHINE SIGNS (DECALS)....2818
OPERATING INSTRUCTIONS....2821
INSTRUMENT PANEL IDENTIFICATION....2823
Left Panel....2823
Right Panel (Standard - With Key Switch)....2824
Right Panel (Deluxe - With Keyless Start)....2825
Option And Field Accessory Panels (If Equipped)....2827
Cab Light....2828
LIFT ARM BY-PASS CONTROL....2828
Operation....2828
TRACTION LOCK OVERRIDE....2828
Operation....2828
ENGINE SPEED CONTROL....2829
Operation....2829
INCHING CONTROL....2829
Operation....2829
PARKING BRAKE....2830
Operation....2830
DRIVING AND STEERING THE LOADER....2831
Available Controls Configurations....2831
Operation (Standard and ACS)....2831
Operation (SJC in ‘H’ Control Pattern)....2832
Operation (SJC in ‘ISO’ Control Pattern)....2833
STOPPING THE BOBCAT LOADER....2834
Using The Steering Levers or Joysticks....2834
SEAT BAR RESTRAINT SYSTEM....2834
Operation....2834
HYDRAULIC CONTROLS....2835
Standard Operation (Foot Pedal)....2835
Standard Controls (Also ACS in Foot Pedal Mode)....2835
Advanced Control System (ACS) in HAND Control Mode....2836
Selectable Joystick Control (SJC) - ‘H’ Control Pattern....2837
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern....2837
Quick Couplers....2838
Releasing Hydraulic Pressure (Loader and Attachment)....2838
Auxiliary Hydraulics Button - VARIABLE FLOW....2838
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....2838
Auxiliary Hydraulics Button - DISENGAGE....2838
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....2839
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....2839
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....2839
REAR Auxiliary Hydraulics Operation (If Equipped)....2839
Attachment Control Device (ACD) (If Equipped)....2840
Bucket Position Valve Operation (If Equipped)....2840
DAILY INSPECTION....2841
Daily Inspection and Maintenance....2841
PRE-STARTING PROCEDURES....2842
Before Starting The Engine....2842
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2844
Procedure....2844
STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....2846
Procedure....2846
Cold Temperature Starting....2847
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2848
Procedure....2848
STOPPING THE ENGINE....2848
Procedure....2848
MONITORING THE DISPLAY PANEL....2849
Standard Panel....2849
Deluxe Panel....2849
WARNING and SHUTDOWN....2849
ATTACHMENTS AND BUCKETS....2850
Choosing The Correct Bucket....2850
Pallet Forks....2851
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2851
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2853
Power Bob-Tach - Installing The Bucket Or Attachment....2854
Power Bob-Tach - Removing The Bucket Or Attachment....2855
OPERATING PROCEDURE....2856
Operating With A Full Bucket....2856
Operating With An Empty Bucket....2857
Foot Pedal Machines....2858
Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....2860
Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected....2862
PARKING THE BOBCAT LOADER....2864
Procedure....2864
TRANSPORTING THE BOBCAT LOADER....2865
Loading Onto Transport Vehicle....2865
Fastening To Transport Vehicle....2865
TOWING THE LOADER....2866
Towing Procedure....2866
LIFTING THE LOADER....2866
Single Point Lift....2866
Four Point Lift....2866
PREVENTIVE MAINTENANCE....2867
MAINTENANCE SAFETY....2871
SERVICE SCHEDULE....2873
Chart....2873
LIFT ARM SUPPORT DEVICE....2874
Engaging The Lift Arm Support Device....2874
Disengaging The Lift Arm Support Device....2875
OPERATOR CAB....2876
Raising The Operator Cab....2876
Lowering The Operator Cab....2877
Cab Door Sensor....2877
Emergency Exit....2878
SEAT BELT....2879
Inspection and Maintenance....2879
SEAT BAR RESTRAINT SYSTEM....2880
Inspecting The Seat Bar....2880
Maintaining The Seat Bar....2880
BOCAT INTERLOCK CONTROL SYSTEM (BICS)....2881
Inspecting The BICS Controller (Engine Stopped - Key ON)....2881
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2881
Inspecting The Seat Bar Sensor (Engine RUNNING)....2881
Inspecting The Traction Lock (Engine RUNNING)....2881
Inspecting The Lift Arm By-Pass Control....2881
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....2881
REAR DOOR....2882
Opening And Closing The Rear Door....2882
Adjusting The Rear Door Latch....2882
REAR GRILL....2883
Removing....2883
Installing....2883
HEATING SYSTEM....2883
Cleaning And Maintenance....2883
AIR CLEANER SERVICE....2884
Replacing Filter Elements....2884
FUEL SYSTEM....2885
Fuel Specifications....2885
Filling The Fuel Tank....2885
Fuel Filter....2886
Removing Air From The Fuel System....2886
ENGINE LUBRICATION SYSTEM....2887
Checking Engine Oil....2887
Replacing The Oil And Filter....2887
ENGINE COOLING SYSTEM....2888
Cleaning The Cooling System....2888
Checking Coolant Level And Adding Coolant....2888
Replacing The Coolant....2889
ALTERNATOR BELT....2890
Adjusting The Alternator Belt....2890
ELECTRICAL SYSTEM....2890
Description....2890
Cleaning Battery and Terminals....2890
Fuse Location....2891
Using A Booster Battery (Jump Starting)....2892
Removing And Installing The Battery....2893
HYDRAULIC / HYDROSTATIC SYSTEM....2894
Checking And Adding Fluid....2894
Replacing Hydraulic/Hydrostatic Filter....2894
Replacing Hydraulic Fluid and Case Drain Filters....2895
Hydraulic Breather....2896
TIRE MAINTENANCE....2897
Wheel Nuts....2897
Rotating....2897
Mounting....2897
FINAL DRIVE TRANSMISSION (CHAINCASE)....2898
Checking And Adding Oil....2898
Removing Oil From The Chaincase....2898
FAN GEARBOX....2899
Checking And Maintaining....2899
DRIVE BELT....2899
Adjusting The Drive Belt....2899
Replacing The Drive Belt....2899
SPARK ARRESTOR MUFFLER....2900
LUBRICATING THE BOBCAT LOADER....2901
Lubrication Locations....2901
PIVOT PINS....2902
Inspection And Maintenance....2902
BOB-TACH (HAND LEVER)....2903
Inspection And Maintenance....2903
BOB-TACH (POWER) (OPTIONAL)....2904
Inspection And Maintenance....2904
SYSTEM SETUP & ANALYSIS....2905
BICS SYSTEM....2907
Troubleshooting Guide....2907
DIAGNOSTICS SERVICE CODES....2908
Display....2908
Number Codes List....2909
DELUXE INSTRUMENT PANEL SETUP....2913
Deluxe Panel Upgrade....2913
Deluxe Panel Setup....2914
Passwords (Deluxe)....2914
Viewing Service Codes....2916
SHUTDOWN FEATURE....2917
SERVICE CLOCK RESET....2917
MACHINE SIGN TRANSLATIONS....2919
SERVICE SCHEDULE (6734534)....2921
WARNING (6728539)....2922
WARNING (6727926)....2923
WARNING (6718706)....2924
WARNING (6710358)....2924
DANGER (6702301)....2925
DANGER (6702302)....2925
WARNING (6717343)....2925
WARNING (6577754)....2926
IMPORTANT (6560573)....2926
IMPORTANT (6725370)....2927
WARNING (6579528)....2927
LIFT ARM SUPPORT DEVICE (6706558)....2928
WARNING (6737189)....2929
IMPORTANT (6733996)....2929
SPECIFICATIONS....2931
LOADER SPECIFICATIONS (S150)....2933
Machine Dimensions....2933
Performance....2934
Controls....2934
Engine....2934
Hydraulic System....2935
Electrical....2935
Drive System....2936
Capacities....2936
Tires....2936
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2937
WARRANTY....2939
6902686 (12-06) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual....2941
OPERATOR SAFETY WARNINGS....2943
CONTENTS....2945
FOREWORD....2947
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....2949
REGULAR MAINTENANCE ITEMS....2949
MOTOR OIL....2949
SERIAL NUMBER LOCATIONS....2950
Loader Serial Number....2950
Engine Serial Number....2950
DELIVERY REPORT....2950
MACHINE IDENTIFICATION....2951
FEATURES, ACCESSORIES AND ATTACHMENTS....2952
Standard Items....2952
Options and Accessories....2952
Buckets Available....2953
Attachments....2953
SAFETY....2955
SAFETY INSTRUCTIONS....2957
Before Operation....2957
Safe Operation Is The Operator’s Responsibility....2958
Safe Operation Needs A Qualified Operator....2958
Fire Prevention....2959
MACHINE SIGNS (DECALS)....2960
OPERATING INSTRUCTIONS....2963
INSTRUMENT PANEL IDENTIFICATION....2967
Left Panel....2967
Right Panel (Standard - With Key Switch)....2968
Right Panel (Deluxe - With Keyless Start)....2969
Option And Field Accessory Panels (If Equipped)....2971
Cab Light....2972
LIFT ARM BY-PASS CONTROL....2972
Operation....2972
TRACTION LOCK OVERRIDE....2972
Operation....2972
ENGINE SPEED CONTROL....2973
Operation....2973
PARKING BRAKE....2973
Operation....2973
DRIVING AND STEERING THE LOADER....2974
Available Controls Configurations....2974
Operation (Standard and ACS)....2974
Operation (SJC in ‘H’ Control Pattern)....2975
Operation (SJC in ‘ISO’ Control Pattern)....2976
STOPPING THE BOBCAT LOADER....2977
Using The Steering Levers Or Joysticks....2977
SEAT BAR RESTRAINT SYSTEM....2977
Operation....2977
HYDRAULIC CONTROLS....2978
Operation....2978
Standard Controls (Also ACS in Foot Pedal Mode)....2978
Advanced Control System (ACS) in HAND Control Mode....2979
Selectable Joystick Control (SJC) - ‘H’ Control Pattern....2980
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern....2980
Quick Couplers....2981
Releasing Hydraulic Pressure (Loader and Attachment)....2981
Auxiliary Hydraulics Button - VARIABLE FLOW....2981
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....2982
Auxiliary Hydraulics Button - DISENGAGE....2982
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....2982
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....2982
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....2982
REAR Auxiliary Hydraulics Operation (If Equipped)....2983
High-Flow Hydraulics Operation (If Equipped)....2983
Attachment Control Device (ACD) (If Equipped)....2984
Secondary Front Auxiliary Hydraulics (If Equipped)....2984
Bucket Position Valve Operation (If Equipped)....2985
DAILY INSPECTION....2986
Daily Inspection and Maintenance....2986
PRE-STARTING PROCEDURES....2987
Before Starting The Engine....2987
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2989
Procedure....2989
STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....2991
Procedure....2991
Cold Temperature Starting....2992
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2993
Procedure....2993
STOPPING THE ENGINE....2993
Procedure....2993
MONITORING THE DISPLAY PANEL....2994
Standard Panel....2994
Deluxe Panel....2994
WARNING and SHUTDOWN....2994
ATTACHMENTS AND BUCKETS....2995
Choosing The Correct Bucket....2995
Pallet Forks....2996
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2996
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2998
Power Bob-Tach - Installing The Bucket Or Attachment....2999
Power Bob-Tach - Removing The Bucket Or Attachment....3000
OPERATING PROCEDURE....3001
Operating With A Full Bucket....3001
Operating With An Empty Bucket....3002
Foot Pedal Machines....3003
Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....3005
Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected....3007
PARKING THE BOBCAT LOADER....3009
Procedure....3009
TRANSPORTING THE BOBCAT LOADER....3010
Loading Onto Transport Vehicle....3010
Fastening To Transport Vehicle....3010
TOWING THE LOADER....3011
Towing Procedure....3011
LIFTING THE LOADER....3012
Single Point Lift....3012
Four Point Lift....3012
PREVENTIVE MAINTENANCE....3013
MAINTENANCE SAFETY....3017
SERVICE SCHEDULE....3019
Chart....3019
LIFT ARM SUPPORT DEVICE....3020
Engaging The Lift Arm Support Device....3020
Disengaging The Lift Arm Support Device....3021
OPERATOR CAB....3022
Raising The Operator Cab....3022
Lowering The Operator Cab....3023
Cab Door Sensor....3023
Emergency Exit....3024
SEAT BELT....3025
Inspection and Maintenance....3025
SEAT BAR RESTRAINT SYSTEM....3026
Inspecting The Seat Bar....3026
Maintaining The Seat Bar....3026
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3027
Inspecting The BICS Controller (Engine Stopped - Key ON)....3027
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....3027
Inspecting The Seat Bar Sensor (Engine RUNNING)....3027
Inspecting The Traction Lock (Engine RUNNING)....3027
Inspecting The Lift Arm By-Pass Control....3027
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....3027
REAR DOOR....3028
Opening And Closing The Rear Door....3028
Adjusting The Rear Door Latch....3028
REAR GRILL....3029
Removing....3029
Installing....3029
HEATING SYSTEM....3029
Cleaning And Maintenance....3029
AIR CLEANER SERVICE....3030
Replacing Filter Elements....3030
FUEL SYSTEM....3031
Fuel Specifications....3031
Filling The Fuel Tank....3031
Fuel Filter....3032
Removing Air From The Fuel System....3032
ENGINE LUBRICATION SYSTEM....3033
Checking Engine Oil....3033
Replacing The Oil And Filter....3033
ENGINE COOLING SYSTEM....3034
Cleaning The Cooling System....3034
Checking Coolant Level And Adding Coolant....3034
Replacing The Coolant....3035
ALTERNATOR BELT....3036
Adjusting The Alternator Belt....3036
ELECTRICAL SYSTEM....3036
Description....3036
Cleaning Battery and Terminals....3036
Fuse Location....3037
Using A Booster Battery (Jump Starting)....3038
Removing And Installing The Battery....3039
HYDRAULIC / HYDROSTATIC SYSTEM....3040
Checking And Adding Fluid....3040
Replacing Hydraulic/Hydrostatic Filter....3040
Replacing Hydraulic Fluid and Case Drain Filters....3041
Hydraulic Breather....3042
TIRE MAINTENANCE....3043
Wheel Nuts....3043
Rotating....3043
Mounting....3043
FINAL DRIVE TRANSMISSION (CHAINCASE)....3044
Checking And Adding Oil....3044
Removing Oil From The Chaincase....3044
FAN GEARBOX....3045
Checking And Maintaining....3045
DRIVE BELT....3046
Adjusting The Drive Belt....3046
Replacing The Drive Belt....3046
SPARK ARRESTOR MUFFLER....3047
LUBRICATING THE BOBCAT LOADER....3048
Lubrication Locations....3048
PIVOT PINS....3049
Inspection And Maintenance....3049
BOB-TACH (HAND LEVER)....3050
Inspection And Maintenance....3050
BOB-TACH (POWER) (OPTIONAL)....3051
Inspection And Maintenance....3051
SYSTEM SETUP & ANALYSIS....3053
BICS SYSTEM....3055
Troubleshooting Guide....3055
DIAGNOSTICS SERVICE CODES....3056
Display....3056
Number Codes List....3057
DELUXE INSTRUMENT PANEL SETUP....3061
Deluxe Panel Upgrade....3061
Deluxe Panel Setup....3062
Passwords (Deluxe)....3062
Viewing Service Codes....3064
SHUTDOWN FEATURE....3065
SERVICE CLOCK RESET....3065
MACHINE SIGN TRANSLATIONS....3067
SERVICE SCHEDULE (6734534)....3069
WARNING (6728539)....3070
WARNING (6727926)....3071
WARNING (6715944)....3072
WARNING (6710358)....3072
DANGER (6702301)....3073
DANGER (6702302)....3073
WARNING (6717343)....3073
WARNING (6577754)....3074
IMPORTANT (6560573)....3074
WARNING (6725370)....3074
WARNING (6579528)....3075
LIFT ARM SUPPORT DEVICE (6706558)....3075
WARNING (6737189)....3076
WARNING (6733996)....3076
SPECIFICATIONS....3077
LOADER SPECIFICATIONS (S160)....3079
Machine Dimensions....3079
Performance....3080
Controls....3080
Engine....3080
Hydraulic System....3081
Electrical....3081
Drive System....3082
Capacities....3082
Tires....3082
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....3083
WARRANTY....3085
6902686 (5-12) - S160 Turbo, S160 Turbo High Flow Operation & Maintenance Manual....3087
OPERATOR SAFETY WARNINGS....3089
CONTENTS....3091
FOREWORD....3093
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....3095
REGULAR MAINTENANCE ITEMS....3095
MOTOR OIL....3095
SERIAL NUMBER LOCATIONS....3096
Loader Serial Number....3096
Engine Serial Number....3096
DELIVERY REPORT....3096
MACHINE IDENTIFICATION....3097
FEATURES, ACCESSORIES AND ATTACHMENTS....3098
Standard Items....3098
Options and Accessories....3098
Buckets Available....3099
Attachments....3099
SAFETY....3101
SAFETY INSTRUCTIONS....3103
Before Operation....3103
Safe Operation Is The Operator’s Responsibility....3104
Safe Operation Needs A Qualified Operator....3104
Fire Prevention....3105
MACHINE SIGNS (DECALS)....3106
OPERATING INSTRUCTIONS....3109
INSTRUMENT PANEL IDENTIFICATION....3113
Left Panel....3113
Right Panel (Standard - With Key Switch)....3114
Right Panel (Deluxe - With Keyless Start)....3115
Option And Field Accessory Panels (If Equipped)....3117
Cab Light....3118
LIFT ARM BY-PASS CONTROL....3118
Operation....3118
TRACTION LOCK OVERRIDE....3118
Operation....3118
ENGINE SPEED CONTROL....3119
Operation....3119
PARKING BRAKE....3119
Operation....3119
DRIVING AND STEERING THE LOADER....3120
Available Controls Configurations....3120
Operation (Standard and ACS)....3120
Operation (SJC in ‘H’ Control Pattern)....3121
Operation (SJC in ‘ISO’ Control Pattern)....3122
STOPPING THE BOBCAT LOADER....3123
Using The Steering Levers Or Joysticks....3123
SEAT BAR RESTRAINT SYSTEM....3123
Operation....3123
HYDRAULIC CONTROLS....3124
Operation....3124
Standard Controls (Also ACS in Foot Pedal Mode)....3124
Advanced Control System (ACS) in HAND Control Mode....3125
Selectable Joystick Control (SJC) - ‘H’ Control Pattern....3126
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern....3126
Quick Couplers....3127
Releasing Hydraulic Pressure (Loader and Attachment)....3127
Auxiliary Hydraulics Button - VARIABLE FLOW....3127
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....3128
Auxiliary Hydraulics Button - DISENGAGE....3128
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....3128
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....3128
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....3128
REAR Auxiliary Hydraulics Operation (If Equipped)....3129
High-Flow Hydraulics Operation (If Equipped)....3129
Attachment Control Device (ACD) (If Equipped)....3130
Secondary Front Auxiliary Hydraulics (If Equipped)....3130
Bucket Position Valve Operation (If Equipped)....3131
DAILY INSPECTION....3132
Daily Inspection and Maintenance....3132
PRE-STARTING PROCEDURES....3133
Before Starting The Engine....3133
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....3135
Procedure....3135
STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....3137
Procedure....3137
Cold Temperature Starting....3138
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....3139
Procedure....3139
STOPPING THE ENGINE....3139
Procedure....3139
MONITORING THE DISPLAY PANEL....3140
Standard Panel....3140
Deluxe Panel....3140
WARNING and SHUTDOWN....3140
ATTACHMENTS AND BUCKETS....3141
Choosing The Correct Bucket....3141
Pallet Forks....3142
Hand Lever Bob-Tach - Installing The Bucket Or Attachment....3142
Hand Lever Bob-Tach - Removing The Bucket Or Attachment....3144
Power Bob-Tach - Installing The Bucket Or Attachment....3145
Power Bob-Tach - Removing The Bucket Or Attachment....3146
OPERATING PROCEDURE....3147
Operating With A Full Bucket....3147
Operating With An Empty Bucket....3148
Foot Pedal Machines....3149
Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....3151
Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected....3153
PARKING THE BOBCAT LOADER....3155
Procedure....3155
TRANSPORTING THE BOBCAT LOADER....3156
Loading Onto Transport Vehicle....3156
Fastening To Transport Vehicle....3156
TOWING THE LOADER....3157
Towing Procedure....3157
LIFTING THE LOADER....3158
Single Point Lift....3158
Four Point Lift....3158
PREVENTIVE MAINTENANCE....3159
MAINTENANCE SAFETY....3163
SERVICE SCHEDULE....3165
Chart....3165
LIFT ARM SUPPORT DEVICE....3166
Engaging The Lift Arm Support Device....3166
Disengaging The Lift Arm Support Device....3167
OPERATOR CAB....3168
Raising The Operator Cab....3168
Lowering The Operator Cab....3169
Cab Door Sensor....3169
Emergency Exit....3170
SEAT BELT....3171
Inspection and Maintenance....3171
SEAT BAR RESTRAINT SYSTEM....3172
Inspecting The Seat Bar....3172
Maintaining The Seat Bar....3172
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3173
Inspecting The BICS Controller (Engine Stopped - Key ON)....3173
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....3173
Inspecting The Seat Bar Sensor (Engine RUNNING)....3173
Inspecting The Traction Lock (Engine RUNNING)....3173
Inspecting The Lift Arm By-Pass Control....3173
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....3173
REAR DOOR....3174
Opening And Closing The Rear Door....3174
Adjusting The Rear Door Latch....3174
REAR GRILL....3175
Removing....3175
Installing....3175
HEATING SYSTEM....3175
Cleaning And Maintenance....3175
AIR CLEANER SERVICE....3176
Replacing Filter Elements....3176
FUEL SYSTEM....3177
Fuel Specifications....3177
Filling The Fuel Tank....3177
Fuel Filter....3178
Removing Air From The Fuel System....3178
ENGINE LUBRICATION SYSTEM....3179
Checking Engine Oil....3179
Replacing The Oil And Filter....3179
ENGINE COOLING SYSTEM....3180
Cleaning The Cooling System....3180
Checking Coolant Level And Adding Coolant....3180
Replacing The Coolant....3181
ALTERNATOR BELT....3182
Adjusting The Alternator Belt....3182
ELECTRICAL SYSTEM....3182
Description....3182
Cleaning Battery and Terminals....3182
Fuse Location....3183
Using A Booster Battery (Jump Starting)....3184
Removing And Installing The Battery....3185
HYDRAULIC / HYDROSTATIC SYSTEM....3186
Checking And Adding Fluid....3186
Replacing Hydraulic/Hydrostatic Filter....3186
Replacing Hydraulic Fluid and Case Drain Filters....3187
Hydraulic Breather....3188
TIRE MAINTENANCE....3189
Wheel Nuts....3189
Rotating....3189
Mounting....3189
FINAL DRIVE TRANSMISSION (CHAINCASE)....3190
Checking And Adding Oil....3190
Removing Oil From The Chaincase....3190
FAN GEARBOX....3191
Checking And Maintaining....3191
DRIVE BELT....3192
Adjusting The Drive Belt....3192
Replacing The Drive Belt....3192
SPARK ARRESTOR MUFFLER....3193
LUBRICATING THE BOBCAT LOADER....3194
Lubrication Locations....3194
PIVOT PINS....3195
Inspection And Maintenance....3195
BOB-TACH (HAND LEVER)....3196
Inspection And Maintenance....3196
BOB-TACH (POWER) (OPTIONAL)....3197
Inspection And Maintenance....3197
SYSTEM SETUP & ANALYSIS....3199
BICS SYSTEM....3201
Troubleshooting Guide....3201
DIAGNOSTICS SERVICE CODES....3202
Display....3202
Number Codes List....3203
DELUXE INSTRUMENT PANEL SETUP....3207
Deluxe Panel Upgrade....3207
Deluxe Panel Setup....3208
Passwords (Deluxe)....3208
Viewing Service Codes....3210
SHUTDOWN FEATURE....3211
SERVICE CLOCK RESET....3211
MACHINE SIGN TRANSLATIONS....3213
SERVICE SCHEDULE (6734534)....3215
WARNING (6728539)....3216
WARNING (6727926)....3217
WARNING (6715944)....3218
WARNING (6710358)....3218
DANGER (6702301)....3219
DANGER (6702302)....3219
WARNING (6717343)....3219
WARNING (6577754)....3220
IMPORTANT (6560573)....3220
WARNING (6725370)....3220
WARNING (6579528)....3221
LIFT ARM SUPPORT DEVICE (6706558)....3221
WARNING (6737189)....3222
WARNING (6733996)....3222
SPECIFICATIONS....3223
LOADER SPECIFICATIONS (S160)....3225
Machine Dimensions....3225
Performance....3226
Controls....3226
Engine....3226
Hydraulic System....3227
Electrical....3227
Drive System....3228
Capacities....3228
Tires....3228
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....3229
WARRANTY....3231
6902730 (10-12) - S150, S160 Turbo Skid-Steer Loader Service Manual....3233
MAINTENANCE SAFETY....3235
ALPHABETICAL INDEX....3237
CONTENTS....3239
FOREWORD....3240
SAFETY INSTRUCTIONS....3243
FIRE PREVENTION....3245
Maintenance....3245
Operation....3245
Electrical....3245
Hydraulic System....3245
Fueling....3245
Starting....3245
Spark Arrestor Exhaust System....3245
Welding And Grinding....3246
Fire Extinguishers....3246
SERIAL NUMBER LOCATIONS....3247
Loader Serial Number....3247
Engine Serial Number....3247
DELIVERY REPORT....3248
BOBCAT LOADER IDENTIFICATION....3249
SAFETY AND MAINTENANCE....3251
LIFTING AND BLOCKING THE LOADER....3253
Procedure....3253
LIFT ARM SUPPORT DEVICE....3255
Installing Lift Arm Support Device....3255
Removing Lift Arm Support Device....3256
OPERATOR CAB....3257
Description....3257
Raising The Operator Cab....3257
Lowering The Operator Cab....3258
Emergency Exit....3260
TRANSPORTING THE BOBCAT LOADER....3261
Loading Onto Transport Vehicle....3261
Fastening To Transport Vehicle....3261
TOWING THE LOADER....3263
Procedure....3263
REMOTE START TOOL KIT -MEL1563....3265
Remote Start Tool - MEL1563....3265
Service Tool Harness Control - MEL1565....3266
Service Tool Harness Communicator - MEL1566....3267
Remote Start Procedure....3268
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....3271
Description....3271
Remote Start Tool (Service Tool) - 7003030....3272
Loader Service Tool Harness - 6689747....3273
Computer Service Tool Harness - 6689746....3274
Remote Start Procedure....3275
SERVICE SCHEDULE....3279
Chart....3279
AIR CLEANER SERVICE....3281
Testing....3281
Replacing Filter Element(s)....3281
ENGINE COOLING SYSTEM....3283
Cleaning The Cooling System....3283
Checking Coolant Level And Adding Coolant....3283
Checking The Coolant Level....3284
Replacing The Coolant....3284
FUEL SYSTEM....3287
Fuel Specifications....3287
Filling The Fuel Tank....3287
Fuel Filter....3288
Removing Air From The Fuel System....3289
ENGINE LUBRICATION SYSTEM....3291
Checking Engine Oil....3291
Engine Oil Chart....3291
Replacing Oil And Filter....3292
HYDRAULIC / HYDROSTATIC SYSTEM....3293
Checking And Adding Fluid....3293
Hydraulic / Hydrostatic Fluid Chart....3293
Replacing Hydraulic / Hydrostatic Filter....3293
Replacing Hydraulic Fluid....3294
Breather Cap....3295
FINAL DRIVE TRANSMISSION (CHAINCASE)....3297
Checking And Adding Oil....3297
Removing Oil From The Chaincase....3297
FAN GEARBOX....3299
Checking And Maintaining....3299
BOB-TACH....3301
Inspection And Maintenance....3301
POWER BOB-TACH (OPTION)....3303
Inspection And Maintenance....3303
LUBRICATION OF THE BOBCAT LOADER....3305
Procedure....3305
TIRE MAINTENANCE....3307
Wheel Nuts....3307
Rotating....3307
Mounting....3307
SPARK ARRESTER MUFFLER....3309
Cleaning Procedure....3309
SEAT BELT....3311
Inspection And Maintenance....3311
HYDRAULIC SYSTEM....3313
HYDRAULIC / HYDROSTATIC SCHEMATICS....3319
HYDRAULIC SYSTEM INFORMATION....3331
Tighten Procedures....3335
Troubleshooting Chart....3335
CYLINDER (LIFT)....3337
Testing....3337
Removal And Installation....3338
Identification....3339
Disassembly....3340
Assembly....3341
CYLINDER (TILT)....3345
Testing....3345
Removal And Installation....3346
Base End Pivot Pin Replacement....3347
Rod End Pivot Pin Bushing And Seal Replacement....3348
Parts Identification....3349
Disassembly....3350
Assembly....3351
CYLINDER (POWER BOB-TACH)....3355
Testing....3355
Removal And Installation....3356
Identification....3357
Disassembly....3358
Assembly....3359
MAIN RELIEF VALVE....3363
Description....3363
Testing....3363
Adjustment....3364
Removal And Installation....3365
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)....3367
Identification....3367
Removal And Installation....3367
BICS™ Valve Removal And Installation....3371
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....3372
BICS™ Valve, Check Valve Removal And Installation....3374
BICS™ Valve Lock Valve Removal And Installation....3375
BICS™ Valve Solenoid Removal And Installation....3376
BICS™ Valve Solenoid Testing....3377
Identification Chart....3378
Load Check Valve....3379
Main Relief Valve....3380
Port Relief Valve....3381
Anti-Cavitation Valve / Port Relief Valve....3382
Anti-Cavitation Valve....3382
Rubber Boot....3383
Lift And Tilt Lock Block Removal And Installation....3384
Lift Spool And Detent....3384
Tilt Spool Removal And Installation....3393
Auxiliary Spool Removal And Installation....3395
Auxiliary Electric Solenoid....3396
Port-Auxiliary Section....3397
Cleaning And Inspection....3398
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....3399
Identification....3399
Removal And Installation....3399
BICS™ Valve Removal And Installation....3403
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....3405
BICS™ Valve, Check Valve Removal And Installation....3406
BICS™ Valve Lock Valve Removal And Installation....3407
BICS™ Valve Solenoid Removal And Installation....3408
BICS™ Valve Solenoid Testing....3409
Actuator Removal And Installation....3410
Identification Chart (ACS)....3411
Lift Base End Restrictor....3412
Load Check Valve....3412
Main Relief Valve....3413
Port Relief Valve....3414
Anti-Cavitation Valve / Port Relief Valve....3415
Anti-Cavitation Valve....3416
Tilt Spool Removal And Installation....3416
Lift Spool Removal And Installation....3417
Lift and Tilt Spool Disassembly And Assembly....3418
Auxiliary Spool Removal And Installation....3419
Auxiliary Electric Solenoid....3420
Port-Auxiliary Section....3421
Cleaning And Inspection....3421
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)....3423
Identification....3423
Removal And Installation....3423
Identification Chart....3428
Mount Bracket Removal And Installation....3429
BICS™ Valve, Lift Load Check Valve Removal And Installation....3429
Load Check Valve Removal And Installation (Tilt And Auxiliary)....3430
Anti-Cavitation Valve (Lift, Rod End)....3431
Port Relief / Anti-Cavitation Valve (Lift, Base End)....3432
Port Relief / Anti-Cavitation Valve (Tilt, Base End)....3432
Port Relief / Anti-Cavitation Valve (Tilt, Rod End)....3433
Port Relief Valve....3433
Plug Removal....3434
Rubber Boot Removal And Installation....3435
End Cap / Spool Lock Block Removal And Installation....3436
Lift Spool And Detent Removal And Installation....3437
Tilt Spool Removal And Installation....3446
Auxiliary Spool Removal And Installation....3448
Auxiliary Solenoid Disassembly And Assembly....3450
BICS™ Valve Solenoid Disassembly And Assembly....3451
BICS™ Valve, Lock Valve Removal And Installation....3452
BICS™ Valve, Check Valve Removal And Installation....3454
BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly....3455
Main Relief Valve....3455
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....3457
Identification....3457
Removal And Installation....3457
Actuator Removal And Installation (Out Of Loader)....3462
Identification Chart (ACS)....3465
Mount Bracket Removal And Installation....3466
BICS™ Valve, Lift Load Check Valve Removal And Installation....3466
Load Check Valve Removal And Installation (Tilt And Auxiliary)....3467
Anti-Cavitation Valve (Lift, Rod End)....3468
Port Relief / Anti-Cavitation Valve (Lift, Base End)....3469
Port Relief / Anti-Cavitation Valve (Tilt, Base End)....3469
Port Relief / Anti-Cavitation Valve (Tilt, Rod End)....3470
Port Relief Valve....3470
Plug Removal....3471
End Cap Block Removal And Installation....3472
Lift Spool Removal And Installation....3473
Tilt Spool Removal And Installation....3477
Auxiliary Spool Removal And Installation....3479
Auxiliary Solenoid Disassembly And Assembly....3480
BICS™ Valve Solenoid Disassembly And Assembly....3481
BICS™ Valve, Lock Valve Removal And Installation....3482
BICS™ Valve, Check Valve Removal And Installation....3484
BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly....3485
Main Relief Valve....3485
LIFT ARM BYPASS CONTROL VALVE....3487
Inspecting....3487
Removal And Installation....3487
Disassembly And Assembly....3488
HYDRAULIC PUMP....3489
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....3489
Check The Output Of The Hydraulic Pump With Power Bob-Tach.....3491
Removal And Installation....3493
Identification....3495
Disassembly And Assembly....3496
HYDRAULIC PUMP (HIGH FLOW)....3501
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....3501
Check The Output Of The Hydraulic Pump With Power Bob-Tach....3503
Removal And Installation....3505
Identification....3507
Disassembly And Assembly....3508
HYDRAULIC PUMP (SJC)....3517
Test The Output Of The Hydraulic Auxiliary Pump....3517
Test The Output Of The Hydraulic Charge Pump....3518
Removal And Installation....3520
Identification....3522
Disassembly And Assembly....3523
HYDRAULIC PUMP (HIGH FLOW) (SJC)....3531
Test The Output Of The Hydraulic Auxiliary Pump....3531
Test The Output Of The Hydraulic Charge Pump....3532
Test The Output Of The Hydraulic Pump (High Flow)....3534
Removal And Installation....3536
Identification....3538
Disassembly And Assembly....3539
HYDRAULIC / HYDROSTATIC FILTER HOUSING....3551
Removal And Installation....3551
HYDRAULIC FLUID RESERVOIR....3553
Fluid Removal....3553
Removal And Installation....3553
BUCKET POSITION VALVE....3557
Solenoid Removal And Installation....3557
Solenoid Testing....3557
Removal And Installation....3558
Disassembly And Assembly....3560
HIGH FLOW VALVE....3563
Testing The High Flow Relief Valve....3563
High Flow Relief Valve Adjustment Procedure....3565
Removal And Installation....3566
Disassembly And Assembly....3568
Solenoid Testing....3570
REAR AUXILIARY DIVERTER VALVE....3571
Removal And Installation....3571
Disassembly And Assembly....3574
Solenoid Testing....3579
Inspection....3579
POWER BOB-TACH BLOCK....3581
Removal And Installation....3581
Disassembly And Assembly....3583
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....3587
Removal And Installation....3587
Disassembly And Assembly....3587
HYDROSTATIC SYSTEM....3589
HYDROSTATIC SYSTEM INFORMATION....3591
Troubleshooting Chart....3591
Replenishing Valve Function....3592
HYDROSTATIC MOTOR....3593
Description....3593
Removal And Installation....3593
Parts Identification (Wet Bolt)....3595
Disassembly (Wet Bolt)....3596
Assembly (Wet Bolt)....3601
Parts Identification (Dry Bolt)....3607
Disassembly And Assembly (Dry Bolt)....3608
HYDROSTATIC MOTOR CARRIER....3613
Shaft Seal Replacement....3613
Removal And Installation....3615
Parts Identification....3617
Disassembly And Assembly....3618
HYDROSTATIC MOTOR CARRIER (SJC)....3623
Shaft Seal Replacement....3623
Removal And Installation....3625
Parts Identification....3627
Disassembly And Assembly....3628
CHARGE PRESSURE....3633
Sender Removal And Installation (Non SJC Machines)....3633
Testing (Non SJC Machines)....3633
Adjusting (Non SJC Machines)....3634
Sender Removal And Installation (SJC Machines)....3635
Testing (SJC Machines)....3635
Adjusting (SJC Machines)....3636
HYDROSTATIC PUMP....3637
Replenishing / High Pressure Relief Valve....3637
Removal And Installation....3638
Parts Identification (Right Half)....3640
Parts Identification (Left Half)....3642
Hydraulic Pump Removal And Installation....3644
Pump Separation....3644
Disassembly....3645
Assembly....3651
HYDROSTATIC PUMP (SJC)....3659
Description....3659
Hydraulic Controller Removal And Installation....3660
Removal And Installation....3662
Parts Identification....3664
High Pressure Relief And Bypass Valve....3665
Charge Relief Valve....3666
Disassembly And Assembly....3667
Mechanical Neutral Adjustment....3683
Hydraulic Controller Neutral Adjustment....3686
DRIVE BELT....3689
Shield Removal And Installation....3689
Adjusting....3689
Drive Belt Replacement....3691
Tensioner Pulley Removal And Installation....3692
Tensioner Pulley Parts Identification....3693
Tensioner Pulley Disassembly....3694
Tensioner Pulley Assembly....3695
OIL COOLER....3697
Removal And Installation....3697
DRIVE SYSTEM....3699
BRAKE....3701
Disk Removal And Installation....3701
Switch Operated Parking Brake....3702
DRIVE COMPONENTS....3703
Axle Seal Removal And Installation....3703
Axle Sprocket And Bearings Removal And Installation....3705
Chain Removal And Installation....3710
CHAINCASE....3713
Checking And Adding Oil....3713
Removing The Oil....3713
General Information....3714
Front Cover Removal And Installation....3714
Center Cover Removal And Installation....3715
Rear Cover Removal And Installation....3716
MAINFRAME....3717
SEAT BAR....3721
Removal And Installation....3721
Assembling Components....3722
Compression Spring Disassembly And Assembly....3724
OPERATOR CAB....3725
Gas Cylinder Removal And Installation....3725
Gas Cylinder Disassembly....3727
Removal And Installation....3728
OPERATOR SEAT....3731
Removal And Installation....3731
Seat Belt Removal And Installation....3731
OPERATOR SEAT (SUSPENSION)....3733
Removal And Installation....3733
Slide Rail Removal And Installation....3734
Cushion Removal And Installation....3734
Back Removal And Installation....3735
Shock Removal And Installation....3736
3-Point Seat Belt Removal And Installation....3737
BOB-TACH....3739
Removal And Installation....3739
Bob-Tach Lever And Wedge....3740
Pivot Pin Bushing And Seal Removal And Installation....3741
POWER BOB-TACH....3743
Removal And Installation....3743
Power Bob-Tach Lever And Wedge....3744
Pivot Pin Bushing And Seal Removal And Installation....3746
LIFT ARMS....3747
Removal And Installation....3747
REAR GRILLE....3751
Removal And Installation....3751
REAR DOOR....3753
Removal And Installation....3753
Striker Removal And Installation....3754
Striker Disassembly And Assembly....3754
Adjusting The Striker....3754
Latch Removal And Installation....3755
FUEL TANK....3757
Removal And Installation....3757
Fuel Level Sender....3758
Fuel Fill Screen....3758
CONTROL PEDALS....3761
Removal And Installation....3761
Pedal Adjustment....3761
Crossbar Linkage Removal And Installation....3762
Lift Foot Pedal Linkage Removal And Installation....3764
Tilt Foot Pedal Linkage Removal And Installation....3764
CONTROL PEDALS (ACS)....3765
Foot Sensor Removal And Installation....3765
Foot Pedal Removal And Installation....3766
Foot Pedal Linkage Disassembly And Assembly....3767
CONTROL PANEL (NON-ADJUSTABLE PINTLES)....3769
Removal And Installation....3769
Shock Removal And Installation....3772
Shaft Removal And Installation....3772
Shaft Disassembly And Assembly....3772
Linkage Removal And Installation....3773
Linkage Adjustment....3776
Linkage Neutral Adjustment....3780
CONTROL PANEL (ADJUSTABLE PINTLES)....3783
Description....3783
Removal And Installation....3784
Shock Removal And Installation....3787
Shaft Removal And Installation....3787
Shaft Disassembly And Assembly....3788
Linkage Removal And Installation....3789
Pintle Arm Disassembly And Assembly....3793
Linkage Neutral Adjustment....3795
Linkage Travel Adjustment....3799
CONTROL PANEL (SJC)....3803
Removal And Installation....3803
CONTROL HANDLE....3805
Control Lever Removal And Installation....3805
Control Lever Boot....3805
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL....3807
Components Identification....3807
Handle Sensor Removal And Installation....3807
Control Handle Removal And Installation....3810
Control Handle Disassembly And Assembly....3811
Control Lever Removal And Installation....3812
Control Lever Boot....3813
CONTROL HANDLE (SJC)....3815
Joystick Testing (Right And Left)....3815
Joystick Removal (Right And Left)....3816
Lever Assembly Removal (Right And Left)....3817
ELECTRICAL SYSTEM....3819
ELECTRICAL SCHEMATICS....3823
ELECTRICAL SYSTEM INFORMATION....3831
Troubleshooting Chart....3833
Description....3834
Fuse Location....3835
Relay Switch Location....3835
BATTERY....3837
Removal And Installation....3837
Servicing....3838
Using A Booster Battery (Jump Starting)....3839
ALTERNATOR....3841
Adjusting The Alternator Belt....3841
Alternator Identification....3841
Charging System Check....3842
Alternator Voltage Test....3843
Low Voltage Test....3843
High Voltage Test....3844
Removal And Installation....3844
Rectifier Continuity (Diode) Test....3846
Alternator Regulator Test....3847
Disassembly....3847
Stator Continuity Test....3848
Stator Ground Test....3848
Rotor Continuity Test....3848
Rotor Ground Test....3848
Assembly....3849
STARTER....3851
Checking....3851
Removal And Installation....3852
Parts Identification....3853
Disassembly And Assembly....3854
Inspection And Repair....3857
No Load Test....3859
INSTRUMENT PANEL....3861
Left Panel....3861
Right Panel (Standard) (With Key Switch)....3862
Right Panel (Deluxe) (With Keyless Start)....3863
Right Panel Setup Display Options (Deluxe)....3865
Deluxe Panel Setup....3866
Passwords (Deluxe)....3866
Option And Field Accessory Panels (If Equipped)....3868
Standard Panel Removal And Installation (Right Side)....3869
Deluxe Panel Removal And Installation (Right Side)....3870
Standard And Deluxe Panel Removal And Installation (Left Side)....3871
Front Accessory Panel Removal And Installation....3872
LIGHTS....3873
Front Removal And Installation....3873
Rear Removal And Installation....3873
BOBCAT CONTROLLER....3875
Identification Chart....3875
Removal And Installation....3877
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)....3879
Removal And Installation....3879
Identification Chart....3882
DIAGNOSTICS SERVICE CODES....3885
Display....3885
Number Codes List....3886
BICS™ SYSTEM....3893
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....3893
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....3893
Inspecting The Seat Bar Sensor (Engine RUNNING)....3893
Inspecting The Traction Lock (Engine RUNNING)....3893
Inspecting The Lift Arm Bypass Control....3893
Troubleshooting Chart....3894
Troubleshooting Guide....3895
SEAT BAR SENSOR....3897
Description....3897
Troubleshooting....3897
Testing....3898
Removal And Installation....3899
Bobcat Interlock Control System (BICS™) Circuit Test....3902
TRACTION LOCK....3905
Troubleshooting Chart....3905
Description Of The Control System....3906
Inspecting The Control System....3906
Solenoid Removal And Installation....3907
Guide Removal....3909
Guide Installation....3911
ADVANCED CONTROL SYSTEM (ACS)....3913
Components Identification....3913
Troubleshooting Guide....3915
Controller, Connector And Wire Identification....3916
ACS Controller Removal And Installation....3917
Handle Sensor Connector....3918
Switch Handle Removal....3919
Switch Handle Installation....3921
Actuators Disassembly And Assembly....3924
Handle Lock Solenoid Removal And Installation....3926
Handle Lock Solenoid Disassembly And Assembly....3926
Handle Lock Solenoid Connector....3927
Calibration Procedure....3928
Foot Sensor Disassembly And Assembly....3930
Foot Sensor Connector....3930
Foot Lock Solenoid Removal And Installation....3931
Foot Lock Solenoid Connector....3932
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE....3933
Controls Identification Chart....3933
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOY STICK CONTROL) (SJC)....3935
Controls Identification Chart....3935
FLYWHEEL RPM SENSOR....3939
Adjustment....3939
SERVICE PC (LAPTOP COMPUTER)....3941
Connecting The Service PC To Remote Start Tool....3941
CALIBRATION....3943
Description....3943
Actuator Testing....3943
Lift And Tilt Calibration Procedure (SJC)....3946
Hydrostatic Pump Calibration (SJC)....3947
Calibration Procedure (ACS)....3953
SPEED SENSOR....3955
Description....3955
Testing....3955
Removal And Installation....3957
ENGINE SERVICE....3959
TROUBLESHOOTING....3961
Chart....3961
ENGINE SPEED CONTROL....3963
Removal And Installation....3963
Disassembly....3964
MUFFLER....3965
Removal And Installation....3965
AIR CLEANER....3967
Removal And Installation....3967
RADIATOR....3969
Removal And Installation....3969
COOLING FAN....3973
Drive Tension Pulley Removal And Installation....3973
Gearbox / Blower Housing Removal And Installation....3974
Blower Housing Grille Removal And Installation....3976
Blower Disassembly And Assembly....3976
Gearbox Parts Identification....3978
Gearbox Disassembly....3979
Gearbox Assembly....3983
Gearbox Checking Backlash....3988
ENGINE COMPONENTS AND TESTING....3993
Compression Testing....3993
Glow Plugs Testing....3994
Glow Plugs Removal And Installation....3994
Fuel Shut-Off Solenoid, Testing....3995
Fuel Shut-Off Solenoid Removal And Installation....3996
Fuel Injection Pump Removal And Installation (Turbo)....3997
Fuel Injection Pump Removal And Installation (Non- Turbo)....4000
Timing The Injection Pump....4004
Fuel Injector Removal And Installation....4006
Testing Nozzle Injection Pressure....4007
Nozzle Spraying Condition....4008
Valve Seat Tightness....4008
Valve Clearance Adjustment....4009
Valve Timing, Testing....4010
ENGINE....4011
Removal And Installation....4011
Engine Mount Replacement....4019
FLYWHEEL AND HOUSING....4021
Flywheel Removal And Installation....4021
Ring Gear Removal And Installation....4021
Housing Removal And Installation....4022
RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO)....4025
Cylinder Head Removal And Installation....4025
Cylinder Head Disassembly And Assembly....4028
Cylinder Head Servicing....4029
Cylinder Head Top Clearance....4029
Valve Guide Checking....4030
Reconditioning The Valve And Valve Seat....4032
Valve Spring....4033
Rocker Arm And Shaft Checking....4034
Timing Gearcase Cover Removal And Installation....4034
Idler Gear And Camshaft Removal And Installation....4037
Camshaft Servicing....4038
Idler Gear And Shaft Servicing....4039
Timing Gears Checking Backlash....4040
Fuel Camshaft Removal And Installation....4040
Fuel Camshaft Governor....4041
Crankshaft Gear Removal And Installation....4041
Oil Pump Removal And Installation....4042
Oil Pump Service....4042
Checking Engine Oil Pressure....4043
Valve Tappets....4044
Piston And Connecting Rod Removal And Installation....4044
Piston And Connecting Rod Servicing....4046
Connecting Rod Alignment....4049
Crankshaft And Bearings Removal And Installation....4049
Crankshaft And Bearings, Servicing....4051
Cylinder Bore, Checking....4055
Water Pump Removal And Installation....4056
Water Pump Disassembly And Assembly....4056
TURBOCHARGER....4057
Checking....4057
Description....4057
Removal And Installation....4058
HEATING, VENTILATION, AIR CONDITIONING....4061
AIR CONDITIONING SYSTEM FLOW....4064
Principals....4064
Chart....4065
COMPONENTS....4067
Identification....4067
SAFETY....4071
Safety Equipment....4071
REGULAR MAINTENANCE....4073
Filter Elements Removal And Installation....4073
Compressor Drive Belt Inspection....4074
Cleaning The Condenser....4075
BASIC TROUBLESHOOTING....4077
Poor A/C Performance....4077
Cleaning The A/C Evaporator Coil And Heater Coil....4077
Compressor Drive Belt Inspection....4078
Checking The Electrical System....4079
Engine Coolant Bypassing The Heater Valve....4086
Heater Valve Not Opening Or Closing....4087
GENERAL AIR CONDITIONING SERVICE GUIDELINES....4089
Compressor Oil....4089
Compressor Oil Check....4090
Component Replacement And Refrigeration Leaks....4091
SYSTEM TROUBLESHOOTING CHART....4093
Gauge Pressure Related Troubleshooting....4094
TEMPERATURE / PRESSURE....4097
Chart....4097
AIR CONDITIONING SERVICE....4099
Chart....4099
SYSTEM CHARGING AND RECLAMATION....4101
Reclamation Procedure....4101
Charging Procedure With A Manifold Gauge Set....4104
Charging Procedure....4105
COMPRESSOR....4107
Removal And Installation....4107
Compressor Clutch Disassembly....4108
CONDENSER....4113
Removal And Installation....4113
RECEIVER / DRIER....4115
Removal And Installation....4115
PRESSURE RELIEF VALVE....4117
Removal And Installation....4117
PRESSURE SWITCH....4119
Removal And Installation....4119
EVAPORATOR / HEATER UNIT....4121
Removal And Installation....4121
Disassembly And Assembly....4123
THERMOSTAT....4125
Removal And Installation....4125
EXPANSION VALVE....4127
Removal And Installation....4127
EVAPORATOR....4129
Removal And Installation....4129
HEATER COIL....4131
Removal And Installation With A/C....4131
Removal And Installation Without A/C....4132
HEATER / A/C FAN....4133
Removal And Installation....4133
Disassembly And Assembly....4134
Wire Connector Removal And Installation....4136
HEATER VALVE....4139
Removal And Installation....4139
Disassembly And Assembly....4139
SPECIFICATIONS....4141
LOADER SPECIFICATIONS....4143
Machine Dimensions....4143
Performance....4144
Controls....4144
Engine....4144
Hydraulic System....4145
Electrical....4145
Drive System....4146
Capacities....4146
Tires....4146
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI....4147
Fuel Injection Nozzles....4147
Fuel Injection Pump....4147
Cylinder Head....4147
Valves....4147
Valve Springs....4148
Valve Timing....4148
Rocker Arms....4148
Camshaft....4148
Tappet....4148
Cylinders....4149
Piston Rings....4149
Pistons....4149
Connecting Rod....4149
Oil Pump....4149
Crankshaft....4150
Timing Gear....4150
Thermostat....4150
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO)....4151
Fuel Injection Nozzles....4151
Fuel Injection Pump....4151
Cylinder Head....4151
Valves....4151
Valve Springs....4152
Valve Timing....4152
Rocker Arms....4152
Camshaft....4152
Tappet....4152
Cylinder Liner....4153
Piston Rings....4153
Pistons....4153
Connecting Rod....4153
Oil Pump....4153
Crankshaft....4154
Timing Gear....4154
Thermostat....4154
TORQUE SPECIFICATIONS FOR BOLTS....4155
Torque For General SAE Bolts....4155
Torque For General Metric Bolts....4156
HYDRAULIC CONNECTION SPECIFICATIONS....4157
O-ring Face Seal Connection....4157
Straight Thread O-ring Fitting....4158
Tubelines And Hoses....4158
Flare Fitting....4158
O-ring Flare Fitting....4159
Port Seal Fitting....4161
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....4163
Specifications....4163
CONVERSIONS....4165
Decimal And Millimeter Equivalent Chart....4165
U.S. To Metric Conversion Chart....4165
SERVICE MANUAL REVISION....4167
Revision No: S150, S160 - 1....4167
Revision No: S150, S160 - 2....4169
Revision No: S150, S160 - 3....4171
Revision No: S150, S160 - 4....4173
Revision No: S150, S160 - 5....4175
Revision No: S150, S160 - 6....4177
Revision No: S150, S160 - 7....4179
Revision No: S150, S160 - 8....4181
Revision No: S150, S160 - 9....4183
6902730 (5-11) - S150, S160 Turbo Skid-Steer Loader Service Manual....4185
MAINTENANCE SAFETY....4187
ALPHABETICAL INDEX....4189
CONTENTS....4191
FOREWORD....4192
SAFETY INSTRUCTIONS....4195
FIRE PREVENTION....4197
Maintenance....4197
Operation....4197
Electrical....4197
Hydraulic System....4197
Fueling....4197
Starting....4197
Spark Arrestor Exhaust System....4197
Welding And Grinding....4198
Fire Extinguishers....4198
SERIAL NUMBER LOCATIONS....4199
Loader Serial Number....4199
Engine Serial Number....4199
DELIVERY REPORT....4200
BOBCAT LOADER IDENTIFICATION....4201
SAFETY AND MAINTENANCE....4203
LIFTING AND BLOCKING THE LOADER....4205
Procedure....4205
LIFT ARM SUPPORT DEVICE....4207
Installing Lift Arm Support Device....4207
Removing Lift Arm Support Device....4208
OPERATOR CAB....4209
Description....4209
Raising The Operator Cab....4209
Lowering The Operator Cab....4210
Emergency Exit....4212
TRANSPORTING THE BOBCAT LOADER....4213
Loading Onto Transport Vehicle....4213
Fastening To Transport Vehicle....4213
TOWING THE LOADER....4215
Procedure....4215
REMOTE START TOOL KIT -MEL1563....4217
Remote Start Tool - MEL1563....4217
Service Tool Harness Control - MEL1565....4218
Service Tool Harness Communicator - MEL1566....4219
Remote Start Procedure....4220
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....4223
Description....4223
Remote Start Tool (Service Tool) - 7003030....4224
Loader Service Tool Harness - 6689747....4225
Computer Service Tool Harness - 6689746....4226
Remote Start Procedure....4227
SERVICE SCHEDULE....4231
Chart....4231
AIR CLEANER SERVICE....4233
Testing....4233
Replacing Filter Element(s)....4233
ENGINE COOLING SYSTEM....4235
Cleaning The Cooling System....4235
Checking Coolant Level And Adding Coolant....4235
Checking The Coolant Level....4236
Replacing The Coolant....4236
FUEL SYSTEM....4239
Fuel Specifications....4239
Filling The Fuel Tank....4239
Fuel Filter....4240
Removing Air From The Fuel System....4241
ENGINE LUBRICATION SYSTEM....4243
Checking Engine Oil....4243
Engine Oil Chart....4243
Replacing Oil And Filter....4244
HYDRAULIC / HYDROSTATIC SYSTEM....4245
Checking And Adding Fluid....4245
Hydraulic / Hydrostatic Fluid Chart....4245
Replacing Hydraulic / Hydrostatic Filter....4245
Replacing Hydraulic Fluid....4246
Breather Cap....4247
FINAL DRIVE TRANSMISSION (CHAINCASE)....4249
Checking And Adding Oil....4249
Removing Oil From The Chaincase....4249
FAN GEARBOX....4251
Checking And Maintaining....4251
BOB-TACH....4253
Inspection And Maintenance....4253
POWER BOB-TACH (OPTION)....4255
Inspection And Maintenance....4255
LUBRICATION OF THE BOBCAT LOADER....4257
Procedure....4257
TIRE MAINTENANCE....4259
Wheel Nuts....4259
Rotating....4259
Mounting....4259
SPARK ARRESTER MUFFLER....4261
Cleaning Procedure....4261
SEAT BELT....4263
Inspection And Maintenance....4263
HYDRAULIC SYSTEM....4265
HYDRAULIC / HYDROSTATIC SCHEMATICS....4271
HYDRAULIC SYSTEM INFORMATION....4283
Tighten Procedures....4287
Troubleshooting Chart....4287
CYLINDER (LIFT)....4289
Testing....4289
Removal And Installation....4290
Identification....4291
Disassembly....4292
Assembly....4293
CYLINDER (TILT)....4297
Testing....4297
Removal And Installation....4298
Base End Pivot Pin Replacement....4299
Rod End Pivot Pin Bushing And Seal Replacement....4300
Parts Identification....4301
Disassembly....4302
Assembly....4303
CYLINDER (POWER BOB-TACH)....4307
Testing....4307
Removal And Installation....4308
Identification....4309
Disassembly....4310
Assembly....4311
MAIN RELIEF VALVE....4315
Description....4315
Testing....4315
Adjustment....4316
Removal And Installation....4317
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)....4319
Identification....4319
Removal And Installation....4319
BICS™ Valve Removal And Installation....4323
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....4324
BICS™ Valve, Check Valve Removal And Installation....4326
BICS™ Valve Lock Valve Removal And Installation....4327
BICS™ Valve Solenoid Removal And Installation....4328
BICS™ Valve Solenoid Testing....4329
Identification Chart....4330
Load Check Valve....4331
Main Relief Valve....4332
Port Relief Valve....4333
Anti-Cavitation Valve / Port Relief Valve....4334
Anti-Cavitation Valve....4334
Rubber Boot....4335
Lift And Tilt Lock Block Removal And Installation....4336
Lift Spool And Detent....4336
Tilt Spool Removal And Installation....4345
Auxiliary Spool Removal And Installation....4347
Auxiliary Electric Solenoid....4348
Port-Auxiliary Section....4349
Cleaning And Inspection....4350
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....4351
Identification....4351
Removal And Installation....4351
BICS™ Valve Removal And Installation....4355
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation....4357
BICS™ Valve, Check Valve Removal And Installation....4358
BICS™ Valve Lock Valve Removal And Installation....4359
BICS™ Valve Solenoid Removal And Installation....4360
BICS™ Valve Solenoid Testing....4361
Actuator Removal And Installation....4362
Identification Chart (ACS)....4363
Lift Base End Restrictor....4364
Load Check Valve....4364
Main Relief Valve....4365
Port Relief Valve....4366
Anti-Cavitation Valve / Port Relief Valve....4367
Anti-Cavitation Valve....4368
Tilt Spool Removal And Installation....4368
Lift Spool Removal And Installation....4369
Lift and Tilt Spool Disassembly And Assembly....4370
Auxiliary Spool Removal And Installation....4371
Auxiliary Electric Solenoid....4372
Port-Auxiliary Section....4373
Cleaning And Inspection....4373
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)....4375
Identification....4375
Removal And Installation....4375
Identification Chart....4380
Mount Bracket Removal And Installation....4381
BICS™ Valve, Lift Load Check Valve Removal And Installation....4381
Load Check Valve Removal And Installation (Tilt And Auxiliary)....4382
Anti-Cavitation Valve (Lift, Rod End)....4383
Port Relief / Anti-Cavitation Valve (Lift, Base End)....4384
Port Relief / Anti-Cavitation Valve (Tilt, Base End)....4384
Port Relief / Anti-Cavitation Valve (Tilt, Rod End)....4385
Port Relief Valve....4385
Plug Removal....4386
Rubber Boot Removal And Installation....4387
End Cap / Spool Lock Block Removal And Installation....4388
Lift Spool And Detent Removal And Installation....4389
Tilt Spool Removal And Installation....4398
Auxiliary Spool Removal And Installation....4400
Auxiliary Solenoid Disassembly And Assembly....4402
BICS™ Valve Solenoid Disassembly And Assembly....4403
BICS™ Valve, Lock Valve Removal And Installation....4404
BICS™ Valve, Check Valve Removal And Installation....4406
BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly....4407
Main Relief Valve....4407
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....4409
Identification....4409
Removal And Installation....4409
Actuator Removal And Installation (Out Of Loader)....4414
Identification Chart (ACS)....4417
Mount Bracket Removal And Installation....4418
BICS™ Valve, Lift Load Check Valve Removal And Installation....4418
Load Check Valve Removal And Installation (Tilt And Auxiliary)....4419
Anti-Cavitation Valve (Lift, Rod End)....4420
Port Relief / Anti-Cavitation Valve (Lift, Base End)....4421
Port Relief / Anti-Cavitation Valve (Tilt, Base End)....4421
Port Relief / Anti-Cavitation Valve (Tilt, Rod End)....4422
Port Relief Valve....4422
Plug Removal....4423
End Cap Block Removal And Installation....4424
Lift Spool Removal And Installation....4425
Tilt Spool Removal And Installation....4429
Auxiliary Spool Removal And Installation....4431
Auxiliary Solenoid Disassembly And Assembly....4432
BICS™ Valve Solenoid Disassembly And Assembly....4433
BICS™ Valve, Lock Valve Removal And Installation....4434
BICS™ Valve, Check Valve Removal And Installation....4436
BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly....4437
Main Relief Valve....4437
LIFT ARM BYPASS CONTROL VALVE....4439
Inspecting....4439
Removal And Installation....4439
Disassembly And Assembly....4440
HYDRAULIC PUMP....4441
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....4441
Check The Output Of The Hydraulic Pump With Power Bob-Tach.....4443
Removal And Installation....4445
Identification....4447
Disassembly And Assembly....4448
HYDRAULIC PUMP (HIGH FLOW)....4453
Check The Output Of The Hydraulic Pump Without Power Bob-Tach....4453
Check The Output Of The Hydraulic Pump With Power Bob-Tach....4455
Removal And Installation....4457
Identification....4459
Disassembly And Assembly....4460
HYDRAULIC PUMP (SJC)....4469
Test The Output Of The Hydraulic Auxiliary Pump....4469
Test The Output Of The Hydraulic Charge Pump....4470
Removal And Installation....4472
Identification....4474
Disassembly And Assembly....4475
HYDRAULIC PUMP (HIGH FLOW) (SJC)....4483
Test The Output Of The Hydraulic Auxiliary Pump....4483
Test The Output Of The Hydraulic Charge Pump....4484
Test The Output Of The Hydraulic Pump (High Flow)....4486
Removal And Installation....4488
Identification....4490
Disassembly And Assembly....4491
HYDRAULIC / HYDROSTATIC FILTER HOUSING....4503
Removal And Installation....4503
HYDRAULIC FLUID RESERVOIR....4505
Fluid Removal....4505
Removal And Installation....4505
BUCKET POSITION VALVE....4509
Solenoid Removal And Installation....4509
Solenoid Testing....4509
Removal And Installation....4510
Disassembly And Assembly....4512
HIGH FLOW VALVE....4515
Testing The High Flow Relief Valve....4515
High Flow Relief Valve Adjustment Procedure....4517
Removal And Installation....4518
Disassembly And Assembly....4520
Solenoid Testing....4522
REAR AUXILIARY DIVERTER VALVE....4523
Removal And Installation....4523
Disassembly And Assembly....4526
Solenoid Testing....4531
Inspection....4531
POWER BOB-TACH BLOCK....4533
Removal And Installation....4533
Disassembly And Assembly....4535
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....4539
Removal And Installation....4539
Disassembly And Assembly....4539
HYDROSTATIC SYSTEM....4541
HYDROSTATIC SYSTEM INFORMATION....4543
Troubleshooting Chart....4543
Replenishing Valve Function....4544
HYDROSTATIC MOTOR....4545
Description....4545
Removal And Installation....4545
Parts Identification (Wet Bolt)....4547
Disassembly (Wet Bolt)....4548
Assembly (Wet Bolt)....4553
Parts Identification (Dry Bolt)....4559
Disassembly And Assembly (Dry Bolt)....4560
HYDROSTATIC MOTOR CARRIER....4565
Shaft Seal Replacement....4565
Removal And Installation....4567
Parts Identification....4569
Disassembly And Assembly....4570
HYDROSTATIC MOTOR CARRIER (SJC)....4575
Shaft Seal Replacement....4575
Removal And Installation....4577
Parts Identification....4579
Disassembly And Assembly....4580
CHARGE PRESSURE....4585
Sender Removal And Installation (Non SJC Machines)....4585
Testing (Non SJC Machines)....4585
Adjusting (Non SJC Machines)....4586
Sender Removal And Installation (SJC Machines)....4587
Testing (SJC Machines)....4587
Adjusting (SJC Machines)....4588
HYDROSTATIC PUMP....4589
Replenishing / High Pressure Relief Valve....4589
Removal And Installation....4590
Parts Identification (Right Half)....4592
Parts Identification (Left Half)....4594
Hydraulic Pump Removal And Installation....4596
Pump Separation....4596
Disassembly....4597
Assembly....4603
HYDROSTATIC PUMP (SJC)....4611
Description....4611
Hydraulic Controller Removal And Installation....4612
Removal And Installation....4614
Parts Identification....4616
High Pressure Relief And Bypass Valve....4617
Charge Relief Valve....4618
Disassembly And Assembly....4619
Mechanical Neutral Adjustment....4635
Hydraulic Controller Neutral Adjustment....4638
DRIVE BELT....4641
Shield Removal And Installation....4641
Adjusting....4641
Drive Belt Replacement....4643
Tensioner Pulley Removal And Installation....4644
Tensioner Pulley Parts Identification....4645
Tensioner Pulley Disassembly....4646
Tensioner Pulley Assembly....4647
OIL COOLER....4649
Removal And Installation....4649
DRIVE SYSTEM....4651
BRAKE....4653
Disk Removal And Installation....4653
Switch Operated Parking Brake....4654
DRIVE COMPONENTS....4655
Axle Seal Removal And Installation....4655
Axle Sprocket And Bearings Removal And Installation....4657
Chain Removal And Installation....4662
CHAINCASE....4665
Checking And Adding Oil....4665
Removing The Oil....4665
General Information....4666
Front Cover Removal And Installation....4666
Center Cover Removal And Installation....4667
Rear Cover Removal And Installation....4668
MAINFRAME....4669
SEAT BAR....4673
Removal And Installation....4673
Assembling Components....4674
Compression Spring Disassembly And Assembly....4676
OPERATOR CAB....4677
Gas Cylinder Removal And Installation....4677
Gas Cylinder Disassembly....4679
Removal And Installation....4680
OPERATOR SEAT....4683
Removal And Installation....4683
Seat Belt Removal And Installation....4683
OPERATOR SEAT (SUSPENSION)....4685
Removal And Installation....4685
Slide Rail Removal And Installation....4686
Cushion Removal And Installation....4686
Back Removal And Installation....4687
Shock Removal And Installation....4688
3-Point Seat Belt Removal And Installation....4689
BOB-TACH....4691
Removal And Installation....4691
Bob-Tach Lever And Wedge....4692
Pivot Pin Bushing And Seal Removal And Installation....4693
POWER BOB-TACH....4695
Removal And Installation....4695
Power Bob-Tach Lever And Wedge....4696
Pivot Pin Bushing And Seal Removal And Installation....4698
LIFT ARMS....4699
Removal And Installation....4699
REAR GRILLE....4703
Removal And Installation....4703
REAR DOOR....4705
Removal And Installation....4705
Striker Removal And Installation....4706
Striker Disassembly And Assembly....4706
Adjusting The Striker....4706
Latch Removal And Installation....4707
FUEL TANK....4709
Removal And Installation....4709
Fuel Level Sender....4710
Fuel Fill Screen....4710
CONTROL PEDALS....4713
Removal And Installation....4713
Pedal Adjustment....4713
Crossbar Linkage Removal And Installation....4714
Lift Foot Pedal Linkage Removal And Installation....4716
Tilt Foot Pedal Linkage Removal And Installation....4716
CONTROL PEDALS (ACS)....4717
Foot Sensor Removal And Installation....4717
Foot Pedal Removal And Installation....4718
Foot Pedal Linkage Disassembly And Assembly....4719
CONTROL PANEL (NON-ADJUSTABLE PINTLES)....4721
Removal And Installation....4721
Shock Removal And Installation....4724
Shaft Removal And Installation....4724
Shaft Disassembly And Assembly....4724
Linkage Removal And Installation....4725
Linkage Adjustment....4728
Linkage Neutral Adjustment....4732
CONTROL PANEL (ADJUSTABLE PINTLES)....4735
Description....4735
Removal And Installation....4736
Shock Removal And Installation....4739
Shaft Removal And Installation....4739
Shaft Disassembly And Assembly....4740
Linkage Removal And Installation....4741
Pintle Arm Disassembly And Assembly....4745
Linkage Neutral Adjustment....4747
Linkage Travel Adjustment....4751
CONTROL PANEL (SJC)....4755
Removal And Installation....4755
CONTROL HANDLE....4757
Control Lever Removal And Installation....4757
Control Lever Boot....4757
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL....4759
Components Identification....4759
Handle Sensor Removal And Installation....4759
Control Handle Removal And Installation....4762
Control Handle Disassembly And Assembly....4763
Control Lever Removal And Installation....4764
Control Lever Boot....4765
CONTROL HANDLE (SJC)....4767
Joystick Testing (Right And Left)....4767
Joystick Removal (Right And Left)....4768
Lever Assembly Removal (Right And Left)....4769
ELECTRICAL SYSTEM....4771
ELECTRICAL SCHEMATICS....4775
ELECTRICAL SYSTEM INFORMATION....4782
Troubleshooting Chart....4784
Description....4785
Fuse Location....4786
Relay Switch Location....4786
BATTERY....4788
Removal And Installation....4788
Servicing....4789
Using A Booster Battery (Jump Starting)....4790
ALTERNATOR....4792
Adjusting The Alternator Belt....4792
Alternator Identification....4792
Charging System Check....4793
Alternator Voltage Test....4794
Low Voltage Test....4794
High Voltage Test....4795
Removal And Installation....4795
Rectifier Continuity (Diode) Test....4797
Alternator Regulator Test....4798
Disassembly....4798
Stator Continuity Test....4799
Stator Ground Test....4799
Rotor Continuity Test....4799
Rotor Ground Test....4799
Assembly....4800
STARTER....4802
Checking....4802
Removal And Installation....4803
Parts Identification....4804
Disassembly And Assembly....4805
Inspection And Repair....4808
No Load Test....4810
INSTRUMENT PANEL....4812
Left Panel....4812
Right Panel (Standard) (With Key Switch)....4813
Right Panel (Deluxe) (With Keyless Start)....4814
Right Panel Setup Display Options (Deluxe)....4816
Deluxe Panel Setup....4817
Passwords (Deluxe)....4817
Option And Field Accessory Panels (If Equipped)....4819
Standard Panel Removal And Installation (Right Side)....4820
Deluxe Panel Removal And Installation (Right Side)....4821
Standard And Deluxe Panel Removal And Installation (Left Side)....4822
Front Accessory Panel Removal And Installation....4823
LIGHTS....4824
Front Removal And Installation....4824
Rear Removal And Installation....4824
BOBCAT CONTROLLER....4826
Identification Chart....4826
Removal And Installation....4828
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)....4830
Removal And Installation....4830
Identification Chart....4833
DIAGNOSTICS SERVICE CODES....4836
Display....4836
Number Codes List....4837
BICS™ SYSTEM....4844
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....4844
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....4844
Inspecting The Seat Bar Sensor (Engine RUNNING)....4844
Inspecting The Traction Lock (Engine RUNNING)....4844
Inspecting The Lift Arm Bypass Control....4844
Troubleshooting Chart....4845
Troubleshooting Guide....4846
SEAT BAR SENSOR....4848
Description....4848
Troubleshooting....4848
Testing....4849
Removal And Installation....4850
Bobcat Interlock Control System (BICS™) Circuit Test....4853
TRACTION LOCK....4856
Troubleshooting Chart....4856
Description Of The Control System....4857
Inspecting The Control System....4857
Solenoid Removal And Installation....4858
Guide Removal....4860
Guide Installation....4862
ADVANCED CONTROL SYSTEM (ACS)....4864
Components Identification....4864
Troubleshooting Guide....4866
Controller, Connector And Wire Identification....4867
ACS Controller Removal And Installation....4868
Handle Sensor Connector....4869
Switch Handle Removal....4870
Switch Handle Installation....4872
Actuators Disassembly And Assembly....4875
Handle Lock Solenoid Removal And Installation....4877
Handle Lock Solenoid Disassembly And Assembly....4877
Handle Lock Solenoid Connector....4878
Calibration Procedure....4879
Foot Sensor Disassembly And Assembly....4881
Foot Sensor Connector....4881
Foot Lock Solenoid Removal And Installation....4882
Foot Lock Solenoid Connector....4883
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE....4884
Controls Identification Chart....4884
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOY STICK CONTROL) (SJC)....4886
Controls Identification Chart....4886
FLYWHEEL RPM SENSOR....4890
Adjustment....4890
SERVICE PC (LAPTOP COMPUTER)....4892
Connecting The Service PC To Remote Start Tool....4892
CALIBRATION....4894
Description....4894
Actuator Testing....4894
Lift And Tilt Calibration Procedure (SJC)....4897
Hydrostatic Pump Calibration (SJC)....4898
Calibration Procedure (ACS)....4904
SPEED SENSOR....4906
Description....4906
Testing....4906
Removal And Installation....4908
ENGINE SERVICE....4910
TROUBLESHOOTING....4912
Chart....4912
ENGINE SPEED CONTROL....4914
Removal And Installation....4914
Disassembly....4915
MUFFLER....4916
Removal And Installation....4916
AIR CLEANER....4918
Removal And Installation....4918
RADIATOR....4920
Removal And Installation....4920
COOLING FAN....4924
Drive Tension Pulley Removal And Installation....4924
Gearbox / Blower Housing Removal And Installation....4925
Blower Housing Grille Removal And Installation....4927
Blower Disassembly And Assembly....4927
Gearbox Parts Identification....4929
Gearbox Disassembly....4930
Gearbox Assembly....4934
Gearbox Checking Backlash....4939
ENGINE COMPONENTS AND TESTING....4944
Compression Testing....4944
Glow Plugs Testing....4945
Glow Plugs Removal And Installation....4945
Fuel Shut-Off Solenoid, Testing....4946
Fuel Shut-Off Solenoid Removal And Installation....4947
Fuel Injection Pump Removal And Installation (Turbo)....4948
Fuel Injection Pump Removal And Installation (Non- Turbo)....4951
Timing The Injection Pump....4955
Fuel Injector Removal And Installation....4957
Testing Nozzle Injection Pressure....4958
Nozzle Spraying Condition....4959
Valve Seat Tightness....4959
Valve Clearance Adjustment....4960
Valve Timing, Testing....4961
ENGINE....4962
Removal And Installation....4962
Engine Mount Replacement....4970
FLYWHEEL AND HOUSING....4972
Flywheel Removal And Installation....4972
Ring Gear Removal And Installation....4972
Housing Removal And Installation....4973
RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO)....4976
Cylinder Head Removal And Installation....4976
Cylinder Head Disassembly And Assembly....4979
Cylinder Head Servicing....4980
Cylinder Head Top Clearance....4980
Valve Guide Checking....4981
Reconditioning The Valve And Valve Seat....4983
Valve Spring....4984
Rocker Arm And Shaft Checking....4985
Timing Gearcase Cover Removal And Installation....4985
Idler Gear And Camshaft Removal And Installation....4988
Camshaft Servicing....4989
Idler Gear And Shaft Servicing....4990
Timing Gears Checking Backlash....4991
Fuel Camshaft Removal And Installation....4991
Fuel Camshaft Governor....4992
Crankshaft Gear Removal And Installation....4992
Oil Pump Removal And Installation....4993
Oil Pump Service....4993
Checking Engine Oil Pressure....4994
Valve Tappets....4995
Piston And Connecting Rod Removal And Installation....4995
Piston And Connecting Rod Servicing....4997
Connecting Rod Alignment....5000
Crankshaft And Bearings Removal And Installation....5000
Crankshaft And Bearings, Servicing....5002
Cylinder Bore, Checking....5006
Water Pump Removal And Installation....5007
Water Pump Disassembly And Assembly....5007
TURBOCHARGER....5008
Checking....5008
Description....5008
Removal And Installation....5009
HEATING, VENTILATION, AIR CONDITIONING....5012
AIR CONDITIONING SYSTEM FLOW....5015
Principals....5015
Chart....5016
COMPONENTS....5018
Identification....5018
SAFETY....5022
Safety Equipment....5022
REGULAR MAINTENANCE....5024
Filter Elements Removal And Installation....5024
Compressor Drive Belt Inspection....5025
Cleaning The Condenser....5026
BASIC TROUBLESHOOTING....5028
Poor A/C Performance....5028
Cleaning The A/C Evaporator Coil And Heater Coil....5028
Compressor Drive Belt Inspection....5029
Checking The Electrical System....5030
Engine Coolant Bypassing The Heater Valve....5037
Heater Valve Not Opening Or Closing....5038
GENERAL AIR CONDITIONING SERVICE GUIDELINES....5040
Compressor Oil....5040
Compressor Oil Check....5041
Component Replacement And Refrigeration Leaks....5042
SYSTEM TROUBLESHOOTING CHART....5044
Gauge Pressure Related Troubleshooting....5045
TEMPERATURE / PRESSURE....5048
Chart....5048
AIR CONDITIONING SERVICE....5050
Chart....5050
SYSTEM CHARGING AND RECLAMATION....5052
Reclamation Procedure....5052
Charging Procedure With A Manifold Gauge Set....5055
Charging Procedure....5056
COMPRESSOR....5058
Removal And Installation....5058
Compressor Clutch Disassembly....5059
CONDENSER....5064
Removal And Installation....5064
RECEIVER / DRIER....5066
Removal And Installation....5066
PRESSURE RELIEF VALVE....5068
Removal And Installation....5068
PRESSURE SWITCH....5070
Removal And Installation....5070
EVAPORATOR / HEATER UNIT....5072
Removal And Installation....5072
Disassembly And Assembly....5074
THERMOSTAT....5076
Removal And Installation....5076
EXPANSION VALVE....5078
Removal And Installation....5078
EVAPORATOR....5080
Removal And Installation....5080
HEATER COIL....5082
Removal And Installation With A/C....5082
Removal And Installation Without A/C....5083
HEATER / A/C FAN....5084
Removal And Installation....5084
Disassembly And Assembly....5085
Wire Connector Removal And Installation....5087
HEATER VALVE....5090
Removal And Installation....5090
Disassembly And Assembly....5090
SPECIFICATIONS....5092
LOADER SPECIFICATIONS....5094
Machine Dimensions....5094
Performance....5095
Controls....5095
Engine....5095
Hydraulic System....5096
Electrical....5096
Drive System....5097
Capacities....5097
Tires....5097
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI....5098
Fuel Injection Nozzles....5098
Fuel Injection Pump....5098
Cylinder Head....5098
Valves....5098
Valve Springs....5099
Valve Timing....5099
Rocker Arms....5099
Camshaft....5099
Tappet....5099
Cylinders....5100
Piston Rings....5100
Pistons....5100
Connecting Rod....5100
Oil Pump....5100
Crankshaft....5101
Timing Gear....5101
Thermostat....5101
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO)....5102
Fuel Injection Nozzles....5102
Fuel Injection Pump....5102
Cylinder Head....5102
Valves....5102
Valve Springs....5103
Valve Timing....5103
Rocker Arms....5103
Camshaft....5103
Tappet....5103
Cylinder Liner....5104
Piston Rings....5104
Pistons....5104
Connecting Rod....5104
Oil Pump....5104
Crankshaft....5105
Timing Gear....5105
Thermostat....5105
TORQUE SPECIFICATIONS FOR BOLTS....5106
Torque For General SAE Bolts....5106
Torque For General Metric Bolts....5107
HYDRAULIC CONNECTION SPECIFICATIONS....5108
O-ring Face Seal Connection....5108
Straight Thread O-ring Fitting....5109
Tubelines And Hoses....5109
Flare Fitting....5109
O-ring Flare Fitting....5110
Port Seal Fitting....5112
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....5114
Specifications....5114
CONVERSIONS....5116
Decimal And Millimeter Equivalent Chart....5116
U.S. To Metric Conversion Chart....5116
SERVICE MANUAL REVISION....5118
Revision No: S150, S160 - 1....5118
Revision No: S150, S160 - 2....5120
Revision No: S150, S160 - 3....5122
Revision No: S150, S160 - 4....5124
Revision No: S150, S160 - 5....5126
Revision No: S150, S160 - 6....5128
Revision No: S150, S160 - 7....5130
Revision No: S150, S160 - 8....5132
6904124 (4-08) - S150 Skid-Steer Loader Operation & Maintenance Manual....5134
OPERATOR SAFETY WARNINGS....5136
CONTENTS....5138
FOREWORD....5140
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....5142
REGULAR MAINTENANCE ITEMS....5142
SERIAL NUMBER LOCATIONS....5143
Loader Serial Number....5143
Engine Serial Number....5143
DELIVERY REPORT....5143
LOADER IDENTIFICATION....5144
FEATURES, ACCESSORIES AND ATTACHMENTS....5145
Standard Items....5145
Options and Accessories....5145
Buckets Available....5146
Attachments....5146
Special Applications Kit....5147
Special Applications Kit Inspection And Maintenance....5147
SAFETY & TRAINING RESOURCES....5148
SAFETY INSTRUCTIONS....5150
Before Operation....5150
Safe Operation Is The Operator’s Responsibility....5151
Safe Operation Needs A Qualified Operator....5151
Avoid Silica Dust....5152
FIRE PREVENTION....5152
Maintenance....5152
Operation....5152
Electrical....5152
Hydraulic System....5153
Fueling....5153
Starting....5153
Spark Arrestor Exhaust System....5153
Welding And Grinding....5153
Fire Extinguishers....5153
MACHINE SIGNS (DECALS)....5155
PUBLICATIONS AND TRAINING RESOURCES....5157
OPERATING INSTRUCTIONS....5158
INSTRUMENT PANEL IDENTIFICATION....5162
Left Panel....5162
Right Panel (Key Switch)....5163
Right Panel (Keyless)....5164
Cab Light....5165
Side And Front Panels....5166
SEAT BAR RESTRAINT SYSTEM....5167
Operation....5167
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5168
Operation....5168
LIFT ARM BYPASS CONTROL....5169
Operation....5169
PARKING BRAKE....5169
Operation....5169
TRACTION LOCK OVERRIDE....5169
Operation....5169
BACK-UP ALARM SYSTEM....5170
Operation....5170
ENGINE SPEED CONTROL....5170
Operation....5170
DRIVING AND STEERING THE LOADER....5171
Available Controls Configurations....5171
Operation (Standard and ACS)....5171
Operation (SJC) in ‘H’ Control Pattern....5172
Operation (SJC) in ‘ISO’ Control Pattern....5173
STOPPING THE LOADER....5173
Using The Control Levers Or Joysticks....5173
TWO-SPEED CONTROL....5174
Description....5174
Operation....5174
SPEED MANAGEMENT....5175
Operation....5175
STEERING DRIFT COMPENSATION....5176
Description....5176
Selecting And Adjusting....5176
Exiting And Saving....5177
HYDRAULIC CONTROLS....5178
Description....5178
Standard Controls (Also ACS in Foot Pedal Mode)....5178
Advanced Control System (ACS) in HAND Control Mode....5179
Selectable Joystick Control (SJC) In ‘H’ Control Pattern....5179
Selectable Joystick Control (SJC) In ‘ISO’ Control Pattern....5180
Hydraulic Bucket Positioning....5180
FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)....5181
FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)....5181
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....5182
REAR Auxiliary Hydraulics Operation....5182
Quick Couplers....5183
Relieve Hydraulic Pressure (Loader and Attachment)....5183
Secondary Front Auxiliary Hydraulics....5184
ATTACHMENT CONTROL DEVICE (ACD)....5185
Description....5185
DAILY INSPECTION....5186
Daily Inspection And Maintenance....5187
PRE-STARTING PROCEDURES....5188
Entering The Loader....5188
Operation & Maintenance Manual And Operator’s Handbook Locations....5188
Seat Adjustment....5188
Seat Belt Adjustment....5189
Seat Bar....5190
STARTING THE ENGINE....5191
Key Switch....5191
Keyless....5193
Cold Temperature Starting....5194
Warming The Hydraulic / Hydrostatic System....5195
MONITORING THE DISPLAY PANELS....5196
Left Panel....5196
Right Panel (Key Switch)....5196
Right Panel (Keyless)....5196
STOPPING THE ENGINE AND LEAVING THE LOADER....5197
Procedure....5197
Emergency Exit....5198
ATTACHMENTS....5199
Choosing The Correct Bucket....5199
Pallet Fork....5199
Installing And Removing The Attachment (Hand Lever Bob-Tach)....5200
Installing And Removing The Attachment (Power Bob-Tach)....5202
OPERATING PROCEDURE....5205
Inspect The Work Area....5205
Operating With A Full Bucket....5205
Operating With An Empty Bucket....5206
Filling And Emptying The Bucket (Foot Pedals)....5207
Leveling The Ground Using Float (Foot Pedals)....5208
Digging And Filling A Hole (Foot Pedals)....5208
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....5209
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....5210
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....5211
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....5212
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....5213
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....5213
TOWING THE LOADER....5214
Procedure....5214
TRANSPORTING THE LOADER ON A TRAILER....5215
Loading And Unloading....5215
Fastening....5215
LIFTING THE LOADER....5216
Single Point Lift....5216
Four Point Lift....5216
PREVENTIVE MAINTENANCE....5218
MAINTENANCE SAFETY....5222
SERVICE SCHEDULE....5224
Chart....5224
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5225
Inspecting The BICS Controller (Engine Stopped - Key ON)....5225
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5225
Inspecting The Seat Bar Sensor (Engine RUNNING)....5225
Inspecting The Traction Lock (Engine RUNNING)....5225
Inspecting The Lift Arm By-Pass Control....5225
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....5225
SEAT BAR RESTRAINT SYSTEM....5226
Description....5226
Inspecting....5226
Maintaining....5226
SEAT BELT....5227
Inspection and Maintenance....5227
LIFT ARM SUPPORT DEVICE....5228
Installing....5228
Removing....5229
BACK-UP ALARM SYSTEM....5230
Description....5230
Inspecting....5230
Adjusting Switch Position....5230
OPERATOR CAB....5231
Description....5231
Raising....5231
Lowering....5232
Cab Door Sensor....5233
REAR DOOR....5234
Opening And Closing....5234
Adjusting....5234
REAR GRILL....5235
Removing....5235
Installing....5235
HEATING SYSTEM....5236
Cleaning And Maintenance....5236
Filters....5236
Heater Coil....5236
Troubleshooting....5236
AIR CLEANER SERVICE....5237
Replacing Filter Elements....5237
FUEL SYSTEM....5239
Fuel Specifications....5239
Biodiesel Blend Fuel....5239
Filling the Fuel Tank....5240
Fuel Filter....5241
Removing Air From The Fuel System....5241
ENGINE LUBRICATION SYSTEM....5242
Checking And Adding Engine Oil....5242
Engine Oil Chart....5242
Removing And Replacing Oil And Filter....5242
ENGINE COOLING SYSTEM....5243
Cleaning....5243
Checking Level....5243
Removing And Replacing Coolant....5244
ELECTRICAL SYSTEM....5245
Description....5245
Fuse And Relay Location / Identification....5245
Battery Maintenance....5246
Using A Booster Battery (Jump Starting)....5246
Removing And Installing The Battery....5248
HYDRAULIC / HYDROSTATIC SYSTEM....5249
Checking And Adding Fluid....5249
Hydraulic / Hydrostatic Fluid Chart....5249
Removing And Replacing Hydraulic Fluid....5249
Removing And Replacing Hydraulic / Hydrostatic Filter....5250
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....5250
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....5251
Removing And Replacing Hydraulic Charge Filter....5253
Breather Cap....5254
SPARK ARRESTOR MUFFLER....5255
Cleaning Procedure....5255
TIRE MAINTENANCE....5256
Wheel Nuts....5256
Rotating....5256
Mounting....5256
FINAL DRIVE TRANSMISSION (CHAINCASE)....5257
Checking And Adding Oil....5257
Removing And Replacing Oil....5257
ALTERNATOR BELT....5258
Belt Adjustment....5258
Belt Replacement....5258
AIR CONDITIONING BELT....5258
Belt Adjustment....5258
Belt Replacement....5258
DRIVE BELT....5259
Belt Adjustment....5259
Belt Replacement....5259
LUBRICATING THE LOADER....5260
Lubrication Locations....5260
PIVOT PINS....5262
Inspection And Maintenance....5262
BOB-TACH (HAND LEVER)....5263
Inspection And Maintenance....5263
BOB-TACH (POWER)....5264
Inspection And Maintenance....5264
LOADER STORAGE AND RETURN TO SERVICE....5265
Storage....5265
Return to Service....5265
SYSTEM SETUP & ANALYSIS....5266
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5268
Troubleshooting Chart....5268
DIAGNOSTIC SERVICE CODES....5269
Viewing Service Codes (Key Switch)....5269
Viewing Service Codes (Keyless)....5269
Service Codes List....5270
CONTROL PANEL SETUP....5275
Right Panel Setup (Keyless)....5275
Right Panel Setup (Keyless)....5276
Attachment Control Information (Keyless)....5276
PASSWORD SETUP....5277
Password Description....5277
Changing The Owner Password....5277
Changing The User Passwords....5278
Password Lockout Feature....5278
MAINTENANCE CLOCK....5279
Description....5279
Setup....5279
Reset....5279
MACHINE SIGN TRANSLATIONS....5280
SERVICE SCHEDULE (6734534)....5282
WARNING (6718706)....5285
WARNING (6710358)....5285
DANGER (6809511)....5285
DANGER (6702301)....5286
DANGER (6702302)....5286
DANGER (6717343)....5286
WARNING (6577754)....5287
WARNING (6579528)....5287
WARNING (6737248)....5287
WARNING (6728539)....5288
WARNING (6733996)....5289
WARNING (6737189)....5289
IMPORTANT (6560573)....5289
OPERATING INSTRUCTIONS (6727926)....5290
WARNING (7131518)....5291
WARNING (7131519)....5293
LIFT ARM SUPPORT DEVICE (6706558)....5295
SPECIFICATIONS....5296
(S150) LOADER SPECIFICATIONS....5298
Machine Dimensions....5298
Performance....5299
Controls....5299
Engine....5299
Hydraulic System....5300
Electrical....5300
Drive System....5301
Capacities....5301
Tires....5301
WARRANTY....5302
ALPHABETICAL INDEX....5306
6904126 (7-09) - S150, S160 Skid-Steer Loader Service Manual....5308
MAINTENANCE SAFETY....5310
ALPHABETICAL INDEX....5312
CONTENTS....5314
FOREWORD....5315
SAFETY INSTRUCTIONS....5318
FIRE PREVENTION....5320
Maintenance....5320
Operation....5320
Electrical....5320
Hydraulic System....5320
Fueling....5320
Starting....5320
Spark Arrestor Exhaust System....5320
Welding And Grinding....5321
Fire Extinguishers....5321
SERIAL NUMBER LOCATIONS....5322
Loader Serial Number....5322
Engine Serial Number....5322
DELIVERY REPORT....5323
BOBCAT LOADER IDENTIFICATION....5324
SAFETY AND MAINTENANCE....5326
LIFTING AND BLOCKING THE LOADER....5330
Procedure....5330
LIFT ARM SUPPORT DEVICE....5332
Installing....5332
Removing....5333
OPERATOR CAB....5334
Description....5334
Raising....5335
Lowering....5336
Cab Door Sensor....5337
Special Applications Kit....5337
Special Applications Kit Inspection And Maintenance....5337
TRANSPORTING THE LOADER ON A TRAILER....5338
Loading And Unloading....5338
Fastening....5338
TOWING THE LOADER....5340
Procedure....5340
REMOTE START TOOL KIT -MEL1563....5342
Remote Start Tool - MEL1563....5342
Service Tool Harness Control - MEL1565....5343
Service Tool Harness Communicator - MEL1566....5344
Remote Start Procedure....5345
REMOTE START TOOL (SERVICE TOOL) kIT - 6689779....5348
Description....5348
Remote Start Tool (Service Tool) - 6689778....5349
Loader Service Tool Harness - 6689747....5350
Computer Service Tool Harness - 6689746....5351
Remote Start Procedure....5352
SERVICE SCHEDULE....5356
Chart....5356
AIR CLEANER SERVICE....5358
Replacing Filter Elements....5358
ENGINE COOLING SYSTEM....5360
Cleaning....5360
Checking Level....5361
Removing And Replacing Coolant....5362
FUEL SYSTEM....5364
Fuel Specifications....5364
Biodiesel Blend Fuel....5364
Filling The Fuel Tank....5365
Fuel Filter....5366
Removing Air From The Fuel System....5366
ENGINE LUBRICATION SYSTEM....5368
Checking And Adding Engine Oil....5368
Engine Oil Chart....5368
Removing And Replacing Oil And Filter....5369
HYDRAULIC / HYDROSTATIC SYSTEM....5370
Checking And Adding Fluid....5370
Hydraulic / Hydrostatic Fluid Chart....5370
Removing And Replacing Hydraulic Fluid....5371
Removing And Replacing Hydraulic / Hydrostatic Filter....5371
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....5372
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....5373
Removing And Replacing Hydraulic Charge Filter....5375
Breather Cap....5376
FINAL DRIVE TRANSMISSION (CHAINCASE)....5378
Checking And Adding Oil....5378
Removing And Replacing Oil....5378
BOB-TACH (HAND LEVER)....5380
Inspection And Maintenance....5380
BOB-TACH (POWER)....5382
Inspection And Maintenance....5382
LUBRICATING THE LOADER....5384
Lubrication Locations....5384
TIRE MAINTENANCE....5386
Wheel Nuts....5386
Rotating....5386
Mounting....5386
SPARK ARRESTOR MUFFLER....5388
Cleaning Procedure....5388
PIVOT PINS....5390
Inspection And Maintenance....5390
LOADER STORAGE AND RETURN TO SERVICE....5392
Storage....5392
Return to Service....5392
STOPPING THE ENGINE AND LEAVING THE LOADER....5394
Procedure....5394
Emergency Exit....5395
HYDRAULIC SYSTEM....5396
HYDRAULIC / HYDROSTATIC SCHEMATICS....5400
HYDRAULIC SYSTEM INFORMATION....5416
Glossary Of Hydraulic / Hydrostatic Symbols....5416
Troubleshooting....5420
CYLINDER (LIFT)....5422
Testing....5422
Removal And Installation....5423
Parts Identification....5424
Disassembly and Assembly....5425
CYLINDER (TILT)....5428
Testing....5428
Removal And Installation....5429
Base End Pivot Pin Removal and Installation....5430
Rod End Pivot Pin Bushing And Seal Removal And Installation....5431
Parts Identification....5432
Disassembly And Assembly....5433
CYLINDER (BOB-TACH)....5436
Testing....5436
Removal And Installation....5437
Parts Identification....5438
Disassembly and Assembly....5439
MAIN RELIEF VALVE....5442
Description....5442
Testing....5442
Adjusting....5444
Removal and Installation....5445
HYDRAULIC CONTROL VALVE (STANDARD)....5446
Description....5446
Removal And Installation....5446
Identification Chart....5451
Mount Bracket Removal And Installation....5452
Lift Load Check Valve Removal And Installation....5452
Load Check Valve Removal And Installation (Tilt & Auxiliary)....5453
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....5454
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)....5455
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....5455
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....5456
Port Relief Valve Removal And Installation....5456
Plug Removal And Installation....5457
Rubber Boot Removal And Installation....5458
End Cap/Spool Lock Block Removal And Installation....5459
Lift Spool And Detent Removal And Installation....5460
Tilt Spool Removal And Installation....5470
Auxiliary Spool Removal And Installation....5472
Auxiliary Solenoid Removal And Installation....5473
Solenoid Removal And Installation....5474
Lock Valve Removal And Installation....5476
Lift Arm Bypass Orifice Removal And Installation....5478
Main Relief Valve Removal And Installation....5478
Check Valve Removal And Installation....5479
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....5480
Description....5480
Removal And Installation....5480
Actuator Removal And Installation (Out of Loader)....5485
Identification Chart....5488
Mount Bracket Removal And Installation....5489
Lift Load Check Valve Removal And Installation....5489
Load Check Valve Removal And Installation (Tilt & Auxiliary)....5490
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....5491
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)....5492
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....5492
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....5493
Port Relief Valve Removal And Installation....5493
Plug Removal And Installation....5494
End Cap Block Removal And Installation....5495
Lift Spool And Detent Removal And Installation....5496
Tilt Spool Removal And Installation....5501
Auxiliary Spool Removal And Installation....5503
Auxiliary Solenoid Removal And Installation....5504
Solenoid Removal And Installation....5505
Lock Valve Removal And Installation....5507
Lift Arm Bypass Orifice Removal And Installation....5509
Main Relief Valve Removal And Installation....5510
Check Valve Removal And Installation....5511
LIFT ARM BYPASS CONTROL VALVE....5512
Description....5512
Testing....5512
Removal and Installation....5512
Disassembly And Assembly....5513
HYDRAULIC PUMP (STANDARD)....5514
Description....5514
Pump Test at Quick Couplers....5514
Direct Pump Test (Standard Section)....5515
Direct Pump Test (Charge Section)....5517
Removal And Installation....5519
Hydraulic Pump Start Up....5521
Parts Identification....5522
Disassembly And Assembly....5523
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....5532
Description....5532
Pump Test At Quick Couplers....5532
Direct Pump Test (Standard Section)....5533
Direct Pump Test (Charge Section)....5535
Direct Pump Test (High Flow Section)....5537
Removal And Installation....5539
Hydraulic Pump Start Up....5541
Parts Identification....5542
Disassembly And Assembly....5543
HYDRAULIC PUMP (SJC)....5556
Description....5556
Pump Test At Quick Couplers....5556
Direct Pump Test (Standard Section)....5557
Direct Pump Test (Charge Section)....5559
Removal And Installation....5561
Hydraulic Pump Start Up....5563
Parts Identification....5564
Disassembly And Assembly....5565
HYDRAULIC PUMP (SJC) (HIGH FLOW)....5574
Description....5574
Pump Test At Quick Couplers....5574
Direct Pump Test (Standard Section)....5575
Direct Pump Test (Charge Section)....5577
Direct Pump Test (High Flow Section)....5579
Removal And Installation....5581
Hydraulic Pump Start Up....5583
Parts Identification....5584
Disassembly And Assembly....5585
HYDRAULIC/HYDROSTatIC FILTERS....5598
Description....5598
Housing Removal And Installation....5598
Charge Filter Housing Removal And Installation....5600
HYDRAULIC FLUID RESERVOIR....5602
Description....5602
Removal And Installation....5602
Hydraulic Fluid Screen....5605
OIL COOLER....5606
Description....5606
Removal and Installation....5606
BUCKET POSITION VALVE....5608
Description....5608
Solenoid Removal And Installation....5608
Solenoid Testing....5609
Removal And Installation....5610
Disassembly And Assembly....5611
REAR AUXILIARY DIVERTER VALVE....5614
Description....5614
Removal And Installation....5614
Disassembly And Assembly....5617
Solenoid Testing....5623
BOB-TACH (POWER) BLOCK....5624
Description....5624
Removal And Installation....5624
Disassembly And Assembly....5626
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....5630
Description....5630
Removal and Installation....5630
Disassembly And Assembly....5630
HIGH FLOW VALVE....5632
Description....5632
High Flow Relief Valve Testing....5632
High Flow Relief Valve Adjustment....5633
Solenoid Testing....5634
Removal And Installation....5635
Disassembly And Assembly....5636
HYDROSTATIC SYSTEM....5640
HYDROSTATIC SYSTEM INFORMATION....5642
Troubleshooting....5642
Description....5643
HYDROSTATIC MOTOR....5644
Description....5644
Removal And Installation....5644
Parts Identification....5647
Disassembly and Assembly....5648
HYDROSTATIC MOTOR (TWO-SPEED)....5654
Description....5654
Removal And Installation (Left Side)....5655
Removal And Installation (Right Side)....5658
Parts Identification....5661
Disassembly....5662
Assembly....5672
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....5684
Description....5684
Shaft Seal Removal And Installation....5684
Removal And Installation....5686
Parts Identification....5688
Disassembly and Assembly....5689
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....5694
Description....5694
Shaft Seal Removal And Installation....5694
Removal And Installation....5696
Parts Identification....5698
Disassembly and Assembly....5699
CHARGE PRESSURE....5704
Description....5704
Testing....5704
Sender Removal And Installation....5706
Adjusting....5707
HYDROSTATIC PUMP....5710
Description....5710
Replenishing/High Pressure Relief Valve....5710
Removal And Installation....5711
Hydrostatic Pump Start Up....5712
Parts Identification (Left Half)....5713
Parts Identification (Right Half)....5714
Disassembly....5715
Assembly....5721
HYDROSTATIC PUMP (SJC)....5728
Description....5728
Hydraulic Controller Removal And Installation....5729
Removal And Installation....5731
Hydrostatic Pump Start Up....5733
Parts Identification....5734
High Pressure Relief and Bypass Valve....5735
Charge Relief Valve....5736
Disassembly and Assembly....5737
Mechanical Neutral Adjustment....5753
Hydraulic Controller Neutral Adjustment....5756
DRIVE BELT....5760
Description....5760
Shield Removal And Installation....5760
Adjusting....5760
Belt Removal And Installation....5762
Belt Tensioner Removal And Installation....5763
Belt Tensioner Parts Identification....5764
Belt Tensioner Disassembly....5765
Belt Tensioner Assembly....5766
TWO-SPEED VALVE....5768
Description....5768
Valve Removal And Installation....5769
Valve Disassembly And Assembly....5771
CASE DRAIN FILTER....5774
Description....5774
Disassembly And Assembly....5774
DRIVE SYSTEM....5776
BRAKE (SINGLE SPEED)....5778
Description....5778
Disc Removal And Installation....5778
BRAKE (TWO-SPEED)....5780
Description....5780
Disc Removal And Installation....5780
Disc Disassembly and Assembly....5781
DRIVE COMPONENTS....5782
Description....5782
Axle Seal Removal And Installation....5783
Axle Sprocket And Bearings Removal And Installation....5785
Chain Removal And Installation....5790
CHAINCASE....5792
Description....5792
Front Cover Removal And Installation....5792
Center Cover Removal And Installation....5793
Rear Cover Removal And Installation....5794
MAIN FRAME....5796
SEAT BAR....5800
Description....5800
Removal And Installation....5800
Disassembly And Assembly....5801
Compression Spring Disassembly And Assembly....5803
OPERATOR CAB....5804
Gas Cylinder Removal And Installation....5804
Gas Cylinder Bracket Disassembly And Assembly....5806
Removal And Installation....5807
OPERATOR SEAT....5810
Removal And Installation....5810
Seat Belt Removal And Installation....5810
OPERATOR SEAT (SUSPENSION)....5812
Removal And Installation....5812
Slide Rail Removal And Installation....5813
Seat Belt Removal and Installation....5813
Lower Cushion Removal And Installation....5813
Back Cushion Removal And Installation....5815
Shock Removal And Installation....5815
3-Point Seat Belt Removal And Installation....5816
BOB-TACH (HAND LEVER)....5818
Description....5818
Removal And Installation....5818
Lever And Wedge Disassembly And Assembly....5819
Pivot Pin Bushing And Seal Removal And Installation....5821
BOB-TACH (POWER-OPTION)....5822
Description....5822
Removal And Installation....5822
Lever And Wedge Disassembly And Assembly....5824
Pivot Pin Bushing And Seal Removal And Installation....5825
LIFT ARMS....5826
Removal And Installation....5826
REAR GRILL....5830
Removal And Installation....5830
REAR DOOR....5832
Removal And Installation....5832
Striker Removal and Installation....5833
Striker Disassembly and Assembly....5833
Striker (Adjusting)....5833
Latch Removal and Installation....5834
FUEL TANK....5836
Removal And Installation....5836
Fuel Level Sender Removal And Installation....5837
Fuel Fill Screen Removal And Installation....5838
CONTROL PEDALS AND LINKAGES....5840
Description....5840
Pedal Removal And Installation....5840
Linkage Removal And Installation....5841
Pedal (Adjusting)....5843
CONTROL PEDALS (ACS)....5844
Description....5844
Foot Sensor Removal And Installation....5844
Foot Pedal Removal And Installation....5845
Foot Pedal Linkage Disassembly And Assembly....5846
CONTROL PANEL....5848
Description....5848
Removal and Installation....5849
Shock Removal And Installation....5852
Shaft Removal And Installation....5852
Shaft Disassembly And Assembly....5853
Linkage Removal And Installation....5854
Pintle Arm Disassembly and Assembly....5858
Linkage Neutral Adjustment....5860
Linkage Travel Adjustment....5864
CONTROL PANEL (SJC)....5868
Description....5868
Removal And Installation....5868
CONTROL HANDLE/LEVER....5870
Description....5870
Lever Removal And Installation....5870
Boot Removal And Installation....5871
CONTROL HANDLE/LEVER (ACS)....5872
Description....5872
Handle Sensor Removal And Installation....5872
Handle Removal and Installation....5875
Handle Disassembly and Assembly....5876
Lever Removal and Installation....5876
Boot Removal And Installation....5878
CONTROL HANDLE/LEVER (SJC)....5880
Description....5880
Joystick Testing....5880
Joystick Removal And Installation (S/N 529711001 - 529712667, S/N 529811001 - 529811321, S/N 529911001 - 529911971, S/N 530011001 - 530011366)....5881
Joystick Removal And Installation (S/N 529712668 & Above, S/N 529811322 & Above, S/N 529911972 & Above, S/N 530011367 & Above)....5883
Removal And Installation (S/N 529711001 - 529712667, S/N 529811001 - 529811321, S/N 529911001 - 529911971, S/N 530011001 - 530011366)....5884
Removal And Installation (S/N 529712668 & Above, S/ N 529811322 & Above, S/N 529911972 & Above, S/N 530011367 & Above)....5885
ACCESS PANEL (INSIDE)....5886
Removal And Installation (Left)....5886
Removal And Installation (Right)....5886
ACCESS PANEL (INSIDE) (SJC)....5888
Removal And Installation (Left)....5888
Removal And Installation (Right)....5889
WINDOW (REAR)....5892
Removal....5892
Installation....5892
WINDOW (TOP)....5894
Removal And Installation....5894
WINDOW (SIDE)....5896
Removal And Installation....5896
WINDOW (FRONT DOOR)....5898
Removal (Standard Window)....5898
Installation (Standard Window)....5899
Removal And Installation (Special Applications Window)....5901
ELECTRICAL SYSTEM & ANALYSIS....5902
ELECTRICAL SCHEMATICS....5906
ELECTRICAL SYSTEM INFORMATION....5919
Glossary Of Electrical Symbols....5919
Cab Harness Connectors....5922
Mainframe Harness Connectors....5923
Description....5924
Troubleshooting....5925
Fuse And Relay Location / Identification....5926
Solenoid Testing....5927
BATTERY....5929
Removal And Installation....5929
Servicing....5930
Using A Booster Battery (Jump Starting)....5931
ALTERNATOR....5933
Belt Adjustment....5933
Belt Replacement....5933
Charging System Inspection....5934
Alternator Voltage Testing....5935
Low Voltage Testing....5935
High Voltage Testing....5936
Removal And Installation....5937
Parts Identification....5938
STARTER....5939
Testing....5939
Removal And Installation....5940
Parts Identification....5941
INSTRUMENT PANELS....5943
Left Panel....5943
Right Panel (Key Switch)....5944
Right Panel (Keyless)....5945
Side And Front Panels....5947
Removal And Installation (Left And Right)....5948
Bulb Removal And Installation (Left Only)....5951
Key Switch Removal And Installation....5952
Alarm Removal And Installation....5953
Front Accessory Panel Removal And Installation....5953
LIGHTS....5955
Front Removal And Installation....5955
Rear Removal And Installation....5956
Cab Light Removal And Installation....5956
BOBCAT CONTROLLER (MAIN)....5957
Description....5957
Connector Identification....5958
Removal And Installation....5960
BOBCAT CONTROLLER (ACS)....5961
Description....5961
Connector Identification....5963
Removal and Installation....5964
BOBCAT CONTROLLER (SJC) (DRIVE)....5965
Description....5965
Connector Identification....5966
Removal and Installation....5968
WHEEL SPEED SENSORS (SJC)....5971
Description....5971
Testing....5971
Removal and Installation....5973
DIAGNOSTICS SERVICE CODES....5975
Description....5975
Service Codes List....5976
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5981
Description....5981
Inspecting The BICS Controller (Engine Stopped - Key ON)....5982
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5982
Inspecting The Seat Bar Sensor (Engine RUNNING)....5982
Inspecting The Traction Lock (Engine RUNNING)....5982
Inspecting The Lift Arm Bypass Control....5982
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....5982
Troubleshooting....5983
Troubleshooting Chart....5984
SEAT BAR SENSOR....5985
Description....5985
Troubleshooting....5985
Testing....5986
Removal And Installation....5987
Bobcat Interlock Control System (BICS) Circuit Test....5989
TRACTION LOCK....5991
Description....5991
Troubleshooting....5991
Removal And Installation....5992
Inspecting....5996
CONTROL SYSTEM (ACS)....5997
Description....5997
Troubleshooting Chart....5998
Handle Sensor Connector Disassembly And Assembly....5999
Switch Handle Removal....6000
Switch Handle Installation....6002
Actuator Connector Disassembly And Assembly....6005
Handle Lock Solenoid Removal And Installation....6006
Handle Lock Solenoid Disassembly And Assembly....6006
Foot Sensor Disassembly And Assembly....6007
Foot Lock Solenoid Removal And Installation....6008
ELECTRICAL/HYDRAULIC CONTROLS....6009
Identification Chart....6009
ELECTRICAL/HYDRAULIC CONTROLS (SJC)....6011
Identification Chart....6011
SERVICE PC (LAPTOP COMPUTER)....6015
Connecting Remote Start Tool....6015
Connecting Remote Start Tool (Service Tool)....6015
CALIBRATION....6017
Description....6017
Actuator Testing....6017
Lift And Tilt Calibration (ACS)....6019
Lift And Tilt Calibration (SJC)....6021
Hydrostatic Pump Calibration (SJC)....6023
STEERING DRIFT COMPENSATION....6029
Description....6029
Selecting And Adjusting....6029
Exiting And Saving....6030
FLYWHEEL RPM SENSOR....6031
Description....6031
Adjusting....6031
CONTROL PANEL SETUP....6033
Right Panel Setup (Keyless)....6033
Attachment Control Information (Keyless)....6034
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)....6035
Password Description....6035
Changing The Owner And User Passwords....6036
Password Lockout Feature....6037
MAINTENANCE CLOCK....6039
Description....6039
Setup....6040
Reset....6044
BACK-UP ALARM SYSTEM....6045
Description....6045
Inspecting....6045
Adjusting Switch Position....6046
Troubleshooting (Standard and ACS)....6047
Troubleshooting (Joystick)....6048
Alarm Removal And Installation....6049
Switch Removal And Installation....6049
ENGINE SERVICE....6051
ENGINE INFORMATION....6055
Description....6055
Specifications (Kubota V2203-M-DI)....6056
Specifications (Kubota V2003-M-DI-T (Turbo)....6060
Engine Torque Values....6063
Troubleshooting....6063
Removal And Installation....6065
Engine Mount Replacement....6072
Compression - Checking....6073
ENGINE SPEED CONTROL....6075
Removal And Installation....6075
ENGINE SPEED CONTROL (SJC)....6077
Removal And Installation....6077
Disassembly And Assembly....6079
MUFFLER....6081
Removal And Installation....6081
AIR CLEANER....6083
Housing Removal And Installation....6083
ENGINE COOLING SYSTEM....6085
Radiator Removal And Installation....6085
Blower Housing Removal And Installation....6088
Hydraulic Fan Removal And Installation....6090
Hydraulic Fan Description....6091
Hydraulic Fan Disassembly And Assembly....6091
Water Pump Removal And Installation....6092
Water Pump Disassembly And Assembly....6092
Thermostat Housing Removal And Installation....6093
LUBRICATION SYSTEM....6095
Oil Pan Removal And Installation....6095
Oil Pump Removal And Installation....6095
Oil Pump Inspection....6096
Engine Oil Pressure-Testing....6097
FUEL SYSTEM....6099
Fuel Camshaft Removal And Installation....6099
Fuel Camshaft Governor Disassembly And Assembly....6100
Fuel Shutoff Solenoid - Checking....6101
Fuel Shutoff Solenoid Removal And Installation....6101
Fuel Injection Pump Removal And Installation (Turbo)....6102
Fuel Injection Pump Removal And Installation (Non- Turbo)....6105
Injection Pump - Timing....6109
Fuel Injector Removal And Installation....6111
Fuel Injector Nozzle Pressure - Checking....6113
Nozzle Spray Condition....6113
Valve Seat Tightness....6114
CYLINDER HEAD....6115
Glow Plugs - Testing....6115
Glow Plugs Removal And Installation....6115
Valve Clearance Adjustment....6116
Valve Timing, Checking....6117
Cylinder Head Removal And Installation....6118
Cylinder Head Disassembly and Assembly....6121
Cylinder Head - Servicing....6121
Cylinder Head Top Clearance....6122
Valve Guide-Checking....6122
Reconditioning The Valve And Valve Seat....6123
Valve Spring....6125
Valve Tappets....6126
Rocker Arm And Shaft Checking....6126
CRANKSHAFT AND PISTONS....6127
Piston And Connecting Rod Removal And Installation....6127
Piston And Connecting Rod - Servicing....6129
Cylinder Bore- Checking....6131
Connecting Rod Alignment....6132
Crankshaft And Bearings Removal And Installation....6132
Crankshaft And Bearings - Servicing....6134
CAMSHAFT AND TIMING GEARS....6139
Timing Gearcase Cover Removal And Installation....6139
Timing Gears Backlash - Checking....6141
Idler Gear And Shaft Removal And Installation....6142
Camshaft - Servicing....6143
Idler Gear And Shaft Servicing....6144
TURBOCHARGER....6145
Description....6145
Testing....6146
Removal And Installation....6146
FLYWHEEL AND HOUSING....6149
Flywheel Removal And Installation....6149
Ring Gear Removal And Installation....6149
Housing Removal And Installation....6150
HEATING, VENTILATION, AIR CONDITIONING....6153
AIR CONDITIONING SYSTEM FLOW....6156
Description....6156
Chart....6157
Components....6158
Safety Equipment....6161
REGULAR MAINTENANCE....6163
Filter Elements Removal And Installation....6163
Compressor Drive Belt Inspection....6164
Condenser....6165
Air Conditioning Service Chart....6166
Cleaning The A/C Evaporator Coil & Heater Coil....6167
TROUBLESHOOTING....6169
Blower Motor Does Not Operate....6169
Blower Motor Operates Normally, But Air Flow Is Insufficient....6169
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....6169
The Compressor Does Not Operate At All, Or Operates Improperly....6169
Gauge Pressure Related Troubleshooting....6170
Troubleshooting Tree....6172
Temperature/Pressure Chart....6176
Poor A/C Performance....6177
HVAC Repair And Leaks....6178
Electrical System....6179
Engine Coolant Bypassing The Heater Valve....6186
Heater Valve Not Opening Or Closing....6187
SYSTEM CHARGING AND RECLAMATION....6189
Refrigerant Identification....6189
Reclamation And Charging With Recovery / Charging Unit....6190
Charging With A Manifold Gauge Set....6192
COMPRESSOR....6195
Belt Adjustment....6195
Removal And Installation....6196
Oil....6197
Oil Check....6198
Clutch Disassembly And Assembly....6200
CONDENSER....6205
Removal And Installation....6205
RECEIVER/DRIER....6207
Receiver/Drier Removal And Installation....6207
Pressure Relief Valve Removal And Installation....6209
Pressure Switch Removal And Installation....6210
Schraeder Valve Removal And Installation....6210
EVAPORATOR / HEATER UNIT....6211
Removal And Installation....6211
THERMOSTAT....6213
Removal And Installation....6213
EXPANSION VALVE....6215
Removal And Installation....6215
EVAPORATOR....6217
Removal And Installation....6217
HEATER COIL....6219
Removal And Installation With A/C....6219
Removal And Installation Without A/C....6221
BLOWER FAN....6223
Removal And Installation....6223
Disassembly And Assembly....6224
Connector Identification....6226
HEATER VALVE....6227
Removal and Installation....6227
Disassembly And Assembly....6228
SPECIFICATIONS....6229
(S150) LOADER SPECIFICATIONS....6231
Machine Dimensions....6231
Performance....6232
Controls....6232
Engine....6232
Hydraulic System....6233
Electrical....6233
Drive System....6234
Capacities....6234
Tires....6234
(S160) LOADER SPECIFICATIONS....6235
Machine Dimensions....6235
Performance....6236
Controls....6236
Engine....6236
Hydraulic System....6237
Electrical....6237
Drive System....6238
Capacities....6238
Tires....6238
TORQUE SPECIFICATIONS FOR BOLTS....6239
Torque For General SAE Bolts....6239
Torque For General Metric Bolts....6240
HYDRAULIC CONNECTION SPECIFICATIONS....6241
O-ring Face Seal Connection....6241
Straight Thread O-ring Fitting....6242
Tubelines And Hoses....6242
Flare Fitting....6243
Port Seal Fitting....6244
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....6245
Specifications....6245
CONVERSIONS....6247
Decimal And Millimeter Equivalents....6247
U.S. To Metric Conversion Chart....6247
SERVICE MANUAL REVISION....6249
Revision No: S150 / S160 - 1....6249
Revision No: S150 / S160 - 2....6251
Revision No: S150 / S160 - 3....6253
Revision No: S150 / S160 - 4....6255
Revision No: S150 / S160 - 5....6257
Revision No: S150 / S160 - 6....6259
Revision No: S150 / S160 - 7....6261
Revision No: S150 / S160 - 8....6263
Revision No: S150 / S160 - 9....6265
Revision No: S150 / S160 - 10....6267
Revision No: S150 / S160 - 11....6269
Revision No: S150 / S160 - 12....6271
6904128 (4-08) - S160 Skid-Steer Loader Operation & Maintenance Manual....6273
OPERATOR SAFETY WARNINGS....6275
CONTENTS....6277
FOREWORD....6279
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....6281
REGULAR MAINTENANCE ITEMS....6281
SERIAL NUMBER LOCATIONS....6282
Loader Serial Number....6282
Engine Serial Number....6282
DELIVERY REPORT....6282
LOADER IDENTIFICATION....6283
FEATURES, ACCESSORIES AND ATTACHMENTS....6284
Standard Items....6284
Options and Accessories....6284
Buckets Available....6285
Attachments....6285
High-Flow Attachments....6285
Special Applications Kit....6286
Special Applications Kit Inspection And Maintenance....6286
SAFETY & TRAINING RESOURCES....6287
SAFETY INSTRUCTIONS....6289
Before Operation....6289
Safe Operation Is The Operator’s Responsibility....6290
Safe Operation Needs A Qualified Operator....6290
Avoid Silica Dust....6291
FIRE PREVENTION....6291
Maintenance....6291
Operation....6291
Electrical....6291
Hydraulic System....6292
Fueling....6292
Starting....6292
Spark Arrestor Exhaust System....6292
Welding And Grinding....6292
Fire Extinguishers....6292
MACHINE SIGNS (DECALS)....6294
PUBLICATIONS AND TRAINING RESOURCES....6296
OPERATING INSTRUCTIONS....6297
INSTRUMENT PANEL IDENTIFICATION....6301
Left Panel....6301
Right Panel (Key Switch)....6302
Right Panel (Keyless)....6303
Cab Light....6304
Side And Front Panels....6305
SEAT BAR RESTRAINT SYSTEM....6306
Operation....6306
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6307
Operation....6307
LIFT ARM BYPASS CONTROL....6308
Operation....6308
PARKING BRAKE....6308
Operation....6308
TRACTION LOCK OVERRIDE....6308
Operation....6308
BACK-UP ALARM SYSTEM....6309
Operation....6309
ENGINE SPEED CONTROL....6309
Operation....6309
DRIVING AND STEERING THE LOADER....6310
Available Controls Configurations....6310
Operation (Standard and ACS)....6310
Operation (SJC) in ‘H’ Control Pattern....6311
Operation (SJC) in ‘ISO’ Control Pattern....6312
STOPPING THE LOADER....6312
Using The Control Levers Or Joysticks....6312
TWO-SPEED CONTROL....6313
Description....6313
Operation....6313
SPEED MANAGEMENT....6314
Operation....6314
STEERING DRIFT COMPENSATION....6315
Description....6315
Selecting And Adjusting....6315
Exiting And Saving....6316
HYDRAULIC CONTROLS....6317
Description....6317
Standard Controls (Also ACS In FOOT Pedal Mode)....6317
Advanced Control System (ACS) in HAND Control Mode....6318
Selectable Joystick Control (SJC) In ‘H’ Control Pattern....6318
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern....6319
Hydraulic Bucket Positioning....6319
FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)....6320
FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)....6320
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....6321
REAR Auxiliary Hydraulics Operation....6321
Quick Couplers....6322
Relieve Hydraulic Pressure (Loader and Attachment)....6322
High-Flow Hydraulics Operation....6323
Secondary Front Auxiliary Hydraulics....6324
ATTACHMENT CONTROL DEVICE (ACD)....6325
Description....6325
DAILY INSPECTION....6326
Daily Inspection And Maintenance....6327
PRE-STARTING PROCEDURE....6328
Entering The Loader....6328
Operation & Maintenance Manual And Operator’s Handbook Locations....6328
Seat Adjustment....6329
Seat Belt Adjustment....6329
Seat Bar....6330
STARTING THE ENGINE....6331
Key Switch....6331
Keyless....6333
Cold Temperature Starting....6334
Warming The Hydraulic / Hydrostatic System....6335
MONITORING THE DISPLAY PANELS....6336
Left Panel....6336
Right Panel (Key Switch)....6336
Right Panel (Keyless)....6336
Warning and Shutdown....6336
STOPPING THE ENGINE AND LEAVING THE LOADER....6337
Procedure....6337
Emergency Exit....6338
ATTACHMENTS....6339
Choosing The Correct Bucket....6339
Pallet Fork....6339
Installing And Removing The Attachment (Hand Lever Bob-Tach)....6340
Installing And Removing The Attachment (Power Bob-Tach)....6342
OPERATING PROCEDURE....6345
Inspect The Work Area....6345
Operating With A Full Bucket....6345
Operating With An Empty Bucket....6346
Filling And Emptying The Bucket (Foot Pedals)....6347
Leveling The Ground Using Float (Foot Pedals)....6348
Digging And Filling A Hole (Foot Pedals)....6348
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....6349
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....6350
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....6351
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....6352
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....6353
Digging And Filling A Hole (SCJ - ‘ISO’ Pattern)....6353
TOWING THE LOADER....6354
Procedure....6354
TRANSPORTING THE LOADER ON A TRAILER....6355
Loading And Unloading....6355
Fastening....6355
LIFTING THE LOADER....6356
Single Point Lift....6356
Four Point Lift....6356
PREVENTIVE MAINTENANCE....6357
MAINTENANCE SAFETY....6361
SERVICE SCHEDULE....6363
Chart....6363
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6364
Inspecting The BICS Controller (Engine Stopped - Key ON)....6364
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....6364
Inspecting The Seat Bar Sensor (Engine RUNNING)....6364
Inspecting The Traction Lock (Engine RUNNING)....6364
Inspecting The Lift Arm By-Pass Control....6364
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....6364
SEAT BAR RESTRAINT SYSTEM....6365
Description....6365
Inspecting....6365
Maintaining....6365
SEAT BELT....6366
Inspection and Maintenance....6366
LIFT ARM SUPPORT DEVICE....6367
Installing....6367
Removing....6368
BACK-UP ALARM SYSTEM....6369
Description....6369
Inspecting....6369
Adjusting Switch Position....6369
OPERATOR CAB....6370
Description....6370
Raising....6370
Lowering....6371
Cab Door Sensor....6372
REAR DOOR....6372
Opening And Closing....6372
Adjusting....6373
REAR GRILL....6373
Removing....6373
Installing....6373
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....6374
Cleaning And Maintenance....6374
Filters....6374
Evaporator / Heater Coil....6374
Condenser....6374
Air Conditioning Lubrication....6374
Troubleshooting....6374
AIR CLEANER SERVICE....6375
Replacing Filter Elements....6375
FUEL SYSTEM....6377
Fuel Specifications....6377
Biodiesel Blend Fuel....6377
Filling The Fuel Tank....6378
Fuel Filter....6379
Removing Air From The Fuel System....6379
ENGINE LUBRICATION SYSTEM....6380
Checking And Adding Engine Oil....6380
Engine Oil Chart....6380
Removing And Replacing Oil And Filter....6380
ENGINE COOLING SYSTEM....6381
Cleaning....6381
Checking Level....6382
Removing And Replacing Coolant....6383
ELECTRICAL SYSTEM....6384
Description....6384
Fuse And Relay Location / Identification....6384
Battery Maintenance....6385
Using A Booster Battery (Jump Starting)....6385
Removing And Installing The Battery....6387
HYDRAULIC / HYDROSTATIC SYSTEM....6388
Checking And Adding Fluid....6388
Hydraulic / Hydrostatic Fluid Chart....6388
Removing And Replacing Hydraulic Fluid....6388
Removing And Replacing Hydraulic / Hydrostatic Filter....6389
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....6389
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....6390
Removing And Replacing Hydraulic Charge Filter....6392
Breather Cap....6393
SPARK ARRESTOR MUFFLER....6394
Cleaning Procedure....6394
TIRE MAINTENANCE....6395
Wheel Nuts....6395
Rotating....6395
Mounting....6395
FINAL DRIVE TRANSMISSION (CHAINCASE)....6396
Checking And Adding Oil....6396
Removing And Replacing Oil....6396
ALTERNATOR BELT....6397
Belt Adjustment....6397
Belt Replacement....6397
AIR CONDITIONING BELT....6397
Belt Adjustment....6397
Belt Replacement....6397
DRIVE BELT....6398
Belt Adjustment....6398
Belt Replacement....6398
LUBRICATING THE LOADER....6399
Lubrication Locations....6399
PIVOT PINS....6401
Inspection And Maintenance....6401
BOB-TACH (HAND LEVER)....6402
Inspection And Maintenance....6402
BOB-TACH (POWER)....6403
Inspection And Maintenance....6403
LOADER STORAGE AND RETURN TO SERVICE....6404
Storage....6404
Return to Service....6404
SYSTEM SETUP & ANALYSIS....6405
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6407
Troubleshooting Chart....6407
DIAGNOSTIC SERVICE CODES....6408
Viewing Service Codes (Key Switch)....6408
Viewing Service Codes (Keyless)....6408
Service Codes List....6409
CONTROL PANEL SETUP....6414
Right Panel Setup (Keyless)....6414
Right Panel Setup (Keyless)....6415
Attachment Control Information (Keyless)....6415
PASSWORD SETUP....6416
Password Description....6416
Changing The Owner Password....6416
Changing The User Passwords....6417
Password Lockout Feature....6417
MAINTENANCE CLOCK....6418
Description....6418
Setup....6418
Reset....6418
MACHINE SIGN TRANSLATIONS....6419
SERVICE SCHEDULE (6734534)....6421
WARNING (6718706)....6424
WARNING (6710358)....6424
DANGER (6809511)....6424
DANGER (6702301)....6425
DANGER (6702302)....6425
DANGER (6717343)....6425
WARNING (6577754)....6426
WARNING (6579528)....6426
WARNING (6737248)....6426
WARNING (6728539)....6427
WARNING (6733996)....6428
WARNING (6737189)....6428
IMPORTANT (6560573)....6428
OPERATING INSTRUCTIONS (6727926)....6429
WARNING (7131518)....6430
WARNING (7131519)....6432
LIFT ARM SUPPORT DEVICE (6706558)....6434
SPECIFICATIONS....6435
(S160) LOADER SPECIFICATIONS....6437
Machine Dimensions....6437
Performance....6438
Controls....6438
Engine....6438
Hydraulic System....6439
Electrical....6439
Drive System....6440
Capacities....6440
Tires....6440
WARRANTY....6441
ALPHABETICAL INDEX....6445
6986566 (7-09) - S150 Skid-Steer Loader Service Manual....6447
MAINTENANCE SAFETY....6449
ALPHABETICAL INDEX....6451
CONTENTS....6453
FOREWORD....6454
SAFETY INSTRUCTIONS....6457
FIRE PREVENTION....6459
Maintenance....6459
Operation....6459
Electrical....6459
Hydraulic System....6459
Fueling....6459
Starting....6459
Spark Arrestor Exhaust System....6459
Welding And Grinding....6460
Fire Extinguishers....6460
SERIAL NUMBER LOCATIONS....6461
Loader Serial Number....6461
Engine Serial Number....6461
DELIVERY REPORT....6462
BOBCAT LOADER IDENTIFICATION....6463
SAFETY AND MAINTENANCE....6465
LIFTING AND BLOCKING THE LOADER....6469
Procedure....6469
LIFT ARM SUPPORT DEVICE....6471
Installing....6471
Removing....6472
OPERATOR CAB....6473
Description....6473
Raising....6474
Lowering....6475
Cab Door Sensor....6476
Special Applications Kit....6476
Special Applications Kit Inspection And Maintenance....6476
TRANSPORTING THE LOADER ON A TRAILER....6477
Loading And Unloading....6477
Fastening....6477
TOWING THE LOADER....6479
Procedure....6479
REMOTE START TOOL KIT -MEL1563....6481
Remote Start Tool - MEL1563....6481
Service Tool Harness Control - MEL1565....6482
Service Tool Harness Communicator - MEL1566....6483
Remote Start Procedure....6484
REMOTE START TOOL (SERVICE TOOL) kIT - 6689779....6487
Description....6487
Remote Start Tool (Service Tool) - 6689778....6488
Loader Service Tool Harness - 6689747....6489
Computer Service Tool Harness - 6689746....6490
Remote Start Procedure....6491
SERVICE SCHEDULE....6495
Chart....6495
AIR CLEANER SERVICE....6497
Replacing Filter Elements....6497
ENGINE COOLING SYSTEM....6499
Cleaning....6499
Checking Level....6500
Removing And Replacing Coolant....6500
FUEL SYSTEM....6501
Fuel Specifications....6501
Biodiesel Blend Fuel....6501
Filling The Fuel Tank....6502
Fuel Filter....6503
Removing Air From The Fuel System....6503
ENGINE LUBRICATION SYSTEM....6505
Checking And Adding Engine Oil....6505
Engine Oil Chart....6505
Removing And Replacing Oil And Filter....6506
HYDRAULIC / HYDROSTATIC SYSTEM....6507
Checking And Adding Fluid....6507
Hydraulic / Hydrostatic Fluid Chart....6507
Removing And Replacing Hydraulic Fluid....6508
Removing And Replacing Hydraulic / Hydrostatic Filter....6508
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....6509
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....6510
Removing And Replacing Hydraulic Charge Filter....6512
Breather Cap....6513
FINAL DRIVE TRANSMISSION (CHAINCASE)....6515
Checking And Adding Oil....6515
Removing And Replacing Oil....6515
BOB-TACH (HAND LEVER)....6517
Inspection And Maintenance....6517
BOB-TACH (POWER)....6519
Inspection And Maintenance....6519
LUBRICATING THE LOADER....6521
Lubrication Locations....6521
TIRE MAINTENANCE....6523
Wheel Nuts....6523
Rotating....6523
Mounting....6523
SPARK ARRESTOR MUFFLER....6525
Cleaning Procedure....6525
PIVOT PINS....6527
Inspection And Maintenance....6527
LOADER STORAGE AND RETURN TO SERVICE....6529
Storage....6529
Return to Service....6529
STOPPING THE ENGINE AND LEAVING THE LOADER....6531
Procedure....6531
Emergency Exit....6532
HYDRAULIC SYSTEM....6533
HYDRAULIC / HYDROSTATIC SCHEMATICS....6537
HYDRAULIC SYSTEM INFORMATION....6545
Glossary Of Hydraulic / Hydrostatic Symbols....6545
Troubleshooting....6549
CYLINDER (LIFT)....6551
Testing....6551
Removal And Installation....6552
Parts Identification....6553
Disassembly and Assembly....6554
CYLINDER (TILT)....6557
Testing....6557
Removal And Installation....6558
Base End Pivot Pin Removal and Installation....6559
Rod End Pivot Pin Bushing And Seal Removal And Installation....6560
Parts Identification....6561
Disassembly And Assembly....6562
CYLINDER (BOB-TACH)....6565
Testing....6565
Removal And Installation....6566
Parts Identification....6567
Disassembly and Assembly....6568
MAIN RELIEF VALVE....6571
Description....6571
Testing....6571
Adjusting....6573
Removal and Installation....6574
HYDRAULIC CONTROL VALVE (STANDARD)....6575
Description....6575
Removal And Installation....6575
Identification Chart....6580
Mount Bracket Removal And Installation....6581
Lift Load Check Valve Removal And Installation....6581
Load Check Valve Removal And Installation (Tilt & Auxiliary)....6582
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6583
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6584
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6584
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6585
Port Relief Valve Removal And Installation....6585
Plug Removal And Installation....6586
Rubber Boot Removal And Installation....6587
End Cap/Spool Lock Block Removal And Installation....6588
Lift Spool And Detent Removal And Installation....6589
Tilt Spool Removal And Installation....6599
Auxiliary Spool Removal And Installation....6601
Auxiliary Solenoid Removal And Installation....6602
Solenoid Removal And Installation....6603
Lock Valve Removal And Installation....6605
Lift Arm Bypass Orifice Removal And Installation....6607
Main Relief Valve Removal And Installation....6607
Check Valve Removal And Installation....6608
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....6609
Description....6609
Removal And Installation....6609
Actuator Removal And Installation (Out of Loader)....6614
Identification Chart....6617
Mount Bracket Removal And Installation....6618
Lift Load Check Valve Removal And Installation....6618
Load Check Valve Removal And Installation (Tilt & Auxiliary)....6619
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6620
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6621
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6621
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6622
Port Relief Valve Removal And Installation....6622
Plug Removal And Installation....6623
End Cap Block Removal And Installation....6624
Lift Spool And Detent Removal And Installation....6625
Tilt Spool Removal And Installation....6630
Auxiliary Spool Removal And Installation....6632
Auxiliary Solenoid Removal And Installation....6633
Solenoid Removal And Installation....6634
Lock Valve Removal And Installation....6636
Lift Arm Bypass Orifice Removal And Installation....6638
Main Relief Valve Removal And Installation....6639
Check Valve Removal And Installation....6640
LIFT ARM BYPASS CONTROL VALVE....6641
Description....6641
Testing....6641
Removal and Installation....6641
Disassembly And Assembly....6642
HYDRAULIC PUMP (STANDARD)....6643
Description....6643
Pump Test at Quick Couplers....6643
Direct Pump Test (Standard Section)....6644
Direct Pump Test (Charge Section)....6646
Removal And Installation....6648
Hydraulic Pump Start Up....6650
Parts Identification....6651
Disassembly And Assembly....6652
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....6661
Description....6661
Pump Test At Quick Couplers....6661
Direct Pump Test (Standard Section)....6662
Direct Pump Test (Charge Section)....6664
Direct Pump Test (High Flow Section)....6666
Removal And Installation....6668
Hydraulic Pump Start Up....6670
Parts Identification....6671
Disassembly And Assembly....6672
HYDRAULIC PUMP (SJC)....6685
Description....6685
Pump Test At Quick Couplers....6685
Direct Pump Test (Standard Section)....6686
Direct Pump Test (Charge Section)....6688
Removal And Installation....6690
Hydraulic Pump Startup....6692
Parts Identification....6693
Disassembly And Assembly....6694
HYDRAULIC PUMP (SJC) (HIGH FLOW)....6703
Description....6703
Pump Test At Quick Couplers....6703
Direct Pump Test (Standard Section)....6704
Direct Pump Test (Charge Section)....6706
Direct Pump Test (High Flow Section)....6708
Removal And Installation....6710
Hydraulic Pump Startup....6712
Parts Identification....6713
Disassembly And Assembly....6714
HYDRAULIC/HYDROSTatIC FILTERS....6727
Description....6727
Housing Removal And Installation....6727
Charge Filter Housing Removal And Installation....6729
HYDRAULIC FLUID RESERVOIR....6731
Description....6731
Removal And Installation....6731
Hydraulic Fluid Screen....6734
OIL COOLER....6735
Description....6735
Removal and Installation....6735
BUCKET POSITION VALVE....6737
Description....6737
Solenoid Removal And Installation....6737
Solenoid Testing....6738
Removal And Installation....6739
Disassembly And Assembly....6740
REAR AUXILIARY DIVERTER VALVE....6743
Description....6743
Removal And Installation....6743
Disassembly And Assembly....6746
Solenoid Testing....6752
BOB-TACH (POWER) BLOCK....6753
Description....6753
Removal And Installation....6753
Disassembly And Assembly....6755
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....6759
Description....6759
Removal and Installation....6759
Disassembly And Assembly....6759
HIGH FLOW VALVE....6761
Description....6761
High Flow Relief Valve Testing....6761
High Flow Relief Valve Adjustment....6762
Solenoid Testing....6763
Removal And Installation....6764
Disassembly And Assembly....6765
HYDROSTATIC SYSTEM....6769
HYDROSTATIC SYSTEM INFORMATION....6771
Troubleshooting....6771
Description....6772
HYDROSTATIC MOTOR....6773
Description....6773
Removal And Installation....6773
Parts Identification....6776
Disassembly and Assembly....6777
HYDROSTATIC MOTOR (TWO-SPEED)....6783
Description....6783
Removal And Installation (Left Side)....6784
Removal And Installation (Right Side)....6787
Parts Identification....6790
Disassembly....6791
Assembly....6801
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....6813
Description....6813
Shaft Seal Removal And Installation....6813
Removal And Installation....6815
Parts Identification....6817
Disassembly and Assembly....6818
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....6823
Description....6823
Shaft Seal Removal And Installation....6823
Removal And Installation....6825
Parts Identification....6827
Disassembly and Assembly....6828
CHARGE PRESSURE....6833
Description....6833
Testing....6833
Sender Removal And Installation....6835
Adjusting....6836
HYDROSTATIC PUMP....6839
Description....6839
Replenishing/High Pressure Relief Valve....6839
Removal And Installation....6840
Hydrostatic Pump Startup....6841
Parts Identification (Left Half)....6842
Parts Identification (Right Half)....6843
Disassembly....6844
Assembly....6850
HYDROSTATIC PUMP (SJC)....6857
Description....6857
Hydraulic Controller Removal And Installation....6858
Removal And Installation....6860
Hydrostatic Pump Startup....6862
Parts Identification....6863
High Pressure Relief and Bypass Valve....6864
Charge Relief Valve....6865
Disassembly and Assembly....6866
Mechanical Neutral Adjustment....6882
Hydraulic Controller Neutral Adjustment....6885
DRIVE BELT....6889
Description....6889
Shield Removal And Installation....6889
Adjusting....6889
Belt Removal And Installation....6891
Belt Tensioner Removal And Installation....6892
Belt Tensioner Parts Identification....6893
Belt Tensioner Disassembly....6894
Belt Tensioner Assembly....6895
TWO-SPEED VALVE....6897
Description....6897
Valve Removal And Installation....6898
Valve Disassembly And Assembly....6900
CASE DRAIN FILTER....6903
Description....6903
Disassembly And Assembly....6903
DRIVE SYSTEM....6905
BRAKE (SINGLE SPEED)....6907
Description....6907
Disc Removal And Installation....6907
BRAKE (TWO-SPEED)....6909
Description....6909
Disc Removal And Installation....6909
Disc Disassembly and Assembly....6910
DRIVE COMPONENTS....6911
Description....6911
Axle Seal Removal And Installation....6912
Axle Sprocket And Bearings Removal And Installation....6914
Chain Removal And Installation....6919
CHAINCASE....6921
Description....6921
Front Cover Removal And Installation....6921
Center Cover Removal And Installation....6922
Rear Cover Removal And Installation....6923
MAIN FRAME....6925
SEAT BAR....6929
Description....6929
Removal And Installation....6929
Disassembly And Assembly....6930
Compression Spring Disassembly And Assembly....6932
OPERATOR CAB....6933
Gas Cylinder Removal And Installation....6933
Gas Cylinder Bracket Disassembly And Assembly....6935
Removal And Installation....6936
OPERATOR SEAT....6939
Removal And Installation....6939
Seat Belt Removal And Installation....6939
OPERATOR SEAT (SUSPENSION)....6941
Removal And Installation....6941
Slide Rail Removal And Installation....6942
Seat Belt Removal and Installation....6942
Lower Cushion Removal And Installation....6942
Back Cushion Removal And Installation....6944
Shock Removal And Installation....6944
3-Point Seat Belt Removal And Installation....6945
BOB-TACH (HAND LEVER)....6947
Description....6947
Removal And Installation....6947
Lever And Wedge Disassembly And Assembly....6948
Pivot Pin Bushing And Seal Removal And Installation....6950
BOB-TACH (POWER-OPTION)....6951
Description....6951
Removal And Installation....6951
Lever And Wedge Disassembly And Assembly....6953
Pivot Pin Bushing And Seal Removal And Installation....6954
LIFT ARMS....6955
Removal And Installation....6955
REAR GRILL....6959
Removal And Installation....6959
REAR DOOR....6961
Removal And Installation....6961
Striker Removal and Installation....6962
Striker Disassembly and Assembly....6962
Striker (Adjusting)....6962
Latch Removal and Installation....6963
FUEL TANK....6965
Removal And Installation....6965
Fuel Level Sender Removal And Installation....6966
Fuel Fill Screen Removal And Installation....6967
CONTROL PEDALS AND LINKAGES....6969
Description....6969
Pedal Removal And Installation....6969
Linkage Removal And Installation....6970
Pedal (Adjusting)....6972
CONTROL PEDALS (ACS)....6973
Description....6973
Foot Sensor Removal And Installation....6973
Foot Pedal Removal And Installation....6974
Foot Pedal Linkage Disassembly And Assembly....6975
CONTROL PANEL....6977
Description....6977
Removal and Installation....6978
Shock Removal And Installation....6981
Shaft Removal And Installation....6981
Shaft Disassembly And Assembly....6982
Linkage Removal And Installation....6983
Pintle Arm Disassembly and Assembly....6987
Linkage Neutral Adjustment....6989
Linkage Travel Adjustment....6993
CONTROL PANEL (SJC)....6997
Description....6997
Removal And Installation....6997
CONTROL HANDLE/LEVER....6999
Description....6999
Lever Removal And Installation....6999
Boot Removal And Installation....7000
CONTROL HANDLE/LEVER (ACS)....7001
Description....7001
Handle Sensor Removal And Installation....7001
Handle Removal and Installation....7004
Handle Disassembly and Assembly....7005
Lever Removal and Installation....7005
Boot Removal And Installation....7007
CONTROL HANDLE / LEVER (SJC)....7009
Description....7009
Joystick Testing....7009
Joystick Removal And Installation....7010
Joystick Mount Removal And Installation....7011
ACCESS PANEL (INSIDE)....7013
Removal And Installation (Left)....7013
Removal And Installation (Right)....7013
ACCESS PANEL (INSIDE) (SJC)....7015
Removal And Installation (Left)....7015
Removal And Installation (Right)....7016
WINDOW (REAR)....7019
Removal....7019
Installation....7019
WINDOW (TOP)....7021
Removal And Installation....7021
WINDOW (SIDE)....7023
Removal And Installation....7023
WINDOW (FRONT DOOR)....7025
Removal (Standard Window)....7025
Installation (Standard Window)....7026
Removal And Installation (Special Applications Window)....7028
ELECTRICAL SYSTEM & ANALYSIS....7029
ELECTRICAL SCHEMATICS....7033
ELECTRICAL SYSTEM INFORMATION....7040
Glossary Of Electrical Symbols....7040
Cab Harness Connectors....7043
Mainframe Harness Connectors....7044
Description....7045
Troubleshooting....7046
Fuse And Relay Location / Identification....7047
Solenoid Testing....7048
BATTERY....7050
Removal And Installation....7050
Servicing....7051
Using A Booster Battery (Jump Starting)....7051
ALTERNATOR....7054
Belt Adjustment....7054
Belt Replacement....7054
Charging System Inspection....7055
Alternator Voltage Testing....7056
Low Voltage Testing....7056
High Voltage Testing....7057
Removal And Installation....7058
Parts Identification....7059
STARTER....7060
Testing....7060
Removal And Installation....7061
Parts Identification....7062
INSTRUMENT PANELS....7064
Left Panel....7064
Right Panel (Key Switch)....7065
Right Panel (Keyless)....7066
Side And Front Panels....7068
Removal And Installation (Left And Right)....7069
Bulb Removal And Installation (Left Only)....7072
Key Switch Removal And Installation....7073
Alarm Removal And Installation....7074
Front Accessory Panel Removal And Installation....7074
LIGHTS....7076
Front Removal And Installation....7076
Rear Removal And Installation....7077
Cab Light Removal And Installation....7077
BOBCAT CONTROLLER (MAIN)....7078
Description....7078
Connector Identification....7079
Removal And Installation....7081
BOBCAT CONTROLLER (ACS)....7082
Description....7082
Connector Identification....7084
Removal and Installation....7085
BOBCAT CONTROLLER (SJC) (DRIVE)....7086
Description....7086
Connector Identification....7087
Removal and Installation....7089
WHEEL SPEED SENSORS (SJC)....7092
Description....7092
Testing....7092
Removal and Installation....7094
DIAGNOSTICS SERVICE CODES....7096
Viewing Service Codes (Key Switch)....7096
Viewing Service Codes (Keyless)....7096
Service Codes List....7097
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7102
Description....7102
Inspecting The BICS Controller (Engine Stopped - Key ON)....7103
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7103
Inspecting The Seat Bar Sensor (Engine RUNNING)....7103
Inspecting The Traction Lock (Engine RUNNING)....7103
Inspecting The Lift Arm Bypass Control....7103
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....7103
Troubleshooting....7104
Troubleshooting Chart....7105
SEAT BAR SENSOR....7106
Description....7106
Troubleshooting....7106
Testing....7107
Removal And Installation....7108
Bobcat Interlock Control System (BICS) Circuit Test....7110
TRACTION LOCK....7112
Description....7112
Troubleshooting....7112
Removal And Installation....7113
Inspecting....7117
CONTROL SYSTEM (ACS)....7118
Description....7118
Troubleshooting Chart....7119
Handle Sensor Connector Disassembly And Assembly....7120
Switch Handle Removal....7121
Switch Handle Installation....7123
Actuator Connector Disassembly And Assembly....7126
Handle Lock Solenoid Removal And Installation....7127
Handle Lock Solenoid Disassembly And Assembly....7127
Foot Sensor Disassembly And Assembly....7128
Foot Lock Solenoid Removal And Installation....7129
ELECTRICAL/HYDRAULIC CONTROLS....7130
Identification Chart....7130
ELECTRICAL/HYDRAULIC CONTROLS (SJC)....7132
Identification Chart....7132
SERVICE PC (LAPTOP COMPUTER)....7136
Connecting Remote Start Tool....7136
Connecting Remote Start Tool (Service Tool)....7136
CALIBRATION....7138
Description....7138
Actuator Testing....7138
Lift And Tilt Calibration (ACS)....7140
Lift And Tilt Calibration (SJC)....7142
Hydrostatic Pump Calibration (SJC)....7144
STEERING DRIFT COMPENSATION....7150
Description....7150
Selecting And Adjusting....7150
Exiting And Saving....7151
FLYWHEEL RPM SENSOR....7152
Description....7152
Adjusting....7152
CONTROL PANEL SETUP....7154
Right Panel Setup (Keyless)....7154
Attachment Control Information (Keyless)....7155
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)....7156
Password Description....7156
Changing The Owner And User Passwords....7157
Password Lockout Feature....7158
MAINTENANCE CLOCK....7160
Description....7160
Setup....7161
Reset....7165
BACK-UP ALARM SYSTEM....7166
Description....7166
Inspecting....7166
Adjusting Switch Position....7167
Troubleshooting (Standard and ACS)....7168
Troubleshooting (Joystick)....7169
Alarm Removal And Installation....7170
Switch Removal And Installation....7170
ENGINE SERVICE....7172
ENGINE INFORMATION....7174
Description....7174
Specifications....7175
Engine Torque Values....7179
Troubleshooting....7180
Engine Removal And Installation....7182
Engine Mount Replacement....7188
Compression - Checking....7189
ENGINE SPEED CONTROL....7190
Removal And Installation....7190
ENGINE SPEED CONTROL (SJC)....7192
Removal And Installation....7192
Disassembly And Assembly....7194
MUFFLER....7196
Removal And Installation....7196
AIR CLEANER....7198
Housing Removal And Installation....7198
ENGINE COOLING SYSTEM....7200
Radiator Removal And Installation....7200
Hydraulic Fan Description....7202
Hydraulic Fan Disassembly And Assembly....7202
Blower Housing Removal And Installation....7203
Fan Removal And Installation....7205
Hydraulic Fan Motor Removal And Installation....7205
Water Pump Removal And Installation....7206
Water Pump Disassembly And Assembly....7206
Thermostat Housing Removal And Installation....7207
Thermostat - Checking....7208
LUBRICATION SYSTEM....7210
Oil Pan Removal And Installation....7210
Oil Pump Removal And Installation....7210
Oil Pump Inspection....7211
Engine Oil Pressure-Testing....7212
FUEL SYSTEM....7214
Fuel Shutoff Solenoid - Checking....7214
Fuel Shutoff Solenoid - Removal And Installation....7214
Fuel Injection Pump - Checking....7215
Fuel Injection Pump Removal And Installation....7216
Governor Disassembly And Assembly....7220
Fuel Camshaft Removal And Installation....7221
Fuel Injection Pump - Timing....7221
Fuel Injector Removal And Installation....7223
Fuel Injector Nozzle Pressure - Checking....7224
Nozzle Spray Condition....7225
Valve Seat Tightness....7225
CYLINDER HEAD....7226
Glow Plugs - Testing....7226
Glow Plugs Removal And Installation....7226
Valve Clearance Adjustment....7227
Valve Timing - Checking....7228
Cylinder Head Removal And Installation....7229
Cylinder Head Disassembly and Assembly....7232
Cylinder Head - Servicing....7232
Cylinder Head Top Clearance....7233
Valve Guide - Checking....7233
Reconditioning The Valve And Valve Seat....7234
Valve Spring....7236
Valve Tappets....7237
Rocker Arm And Shaft - Checking....7237
CRANKSHAFT AND PISTONS....7238
Piston And Connecting Rod Removal And Installation....7238
Piston And Connecting Rod - Servicing....7239
Cylinder Bore - Checking....7242
Connecting Rod Alignment....7242
Crankshaft Gear Removal And Installation....7243
Crankshaft And Bearings Removal And Installation....7243
Crankshaft And Bearings - Servicing....7245
CAMSHAFT AND TIMING GEARS....7250
Timing Gearcase Cover Removal And Installation....7250
Timing Gears Backlash - Checking....7252
Idler Gear And Camshaft Removal And Installation....7253
Camshaft - Servicing....7254
Idler Gear And Shaft Servicing....7255
FLYWHEEL AND HOUSING....7256
Flywheel Removal And Installation....7256
Ring Gear Removal And Installation....7256
Housing Removal And Installation....7257
HEATER....7260
HEATER SYSTEM....7262
Description....7262
REGULAR MAINTENANCE....7264
Filters....7264
Heater Coil....7264
TROUBLESHOOTING....7266
Blower Motor Does Not Operate....7266
Blower Motor Operators Normally, But Air Flow Is Insufficient....7266
Electrical System....7267
Engine Coolant Bypassing The Heater Valve....7271
Heater Valve Not Opening Or Closing....7272
HEATER UNIT....7274
Removal And Installation....7274
HEATER COIL....7276
Removal And Installation....7276
BLOWER FAN....7278
Removal And Installation....7278
Disassembly And Assembly....7279
Connector Identification....7281
HEATER VALVE....7282
Removal and Installation....7282
Disassembly And Assembly....7283
SPECIFICATIONS....7284
(S150) LOADER SPECIFICATIONS....7286
Machine Dimensions....7286
Performance....7287
Controls....7287
Engine....7287
Hydraulic System....7288
Electrical....7288
Drive System....7289
Capacities....7289
Tires....7289
TORQUE SPECIFICATIONS FOR BOLTS....7290
Torque For General SAE Bolts....7290
Torque For General Metric Bolts....7291
HYDRAULIC CONNECTION SPECIFICATIONS....7292
O-ring Face Seal Connection....7292
Straight Thread O-ring Fitting....7293
Tubelines And Hoses....7293
Flare Fitting....7294
Port Seal Fitting....7295
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....7296
Specifications....7296
CONVERSIONS....7298
Decimal And Millimeter Equivalents....7298
U.S. To Metric Conversion Chart....7298
SERVICE MANUAL REVISION....7300
Revision No: S150 - 1....7300
Revision No: S150 - 2....7302
Revision No: S150 - 3....7304
Revision No: S150 - 4....7306
6986966 (4-08) - S150 Skid-Steer Loader Operation & Maintenance Manual....7308
OPERATOR SAFETY WARNINGS....7310
CONTENTS....7312
FOREWORD....7314
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....7316
REGULAR MAINTENANCE ITEMS....7316
SERIAL NUMBER LOCATIONS....7317
Loader Serial Number....7317
Engine Serial Number....7317
DELIVERY REPORT....7317
LOADER IDENTIFICATION....7318
FEATURES, ACCESSORIES AND ATTACHMENTS....7319
Standard Items....7319
Options and Accessories....7319
Buckets Available....7320
Attachments....7320
Special Applications Kit....7321
Special Applications Kit Inspection And Maintenance....7321
SAFETY & TRAINING RESOURCES....7322
SAFETY INSTRUCTIONS....7324
Before Operation....7324
Safe Operation Is The Operator’s Responsibility....7325
Safe Operation Needs A Qualified Operator....7325
Avoid Silica Dust....7326
FIRE PREVENTION....7326
Maintenance....7326
Operation....7326
Electrical....7326
Hydraulic System....7327
Fueling....7327
Starting....7327
Spark Arrestor Exhaust System....7327
Welding And Grinding....7327
Fire Extinguishers....7327
MACHINE SIGNS (DECALS)....7329
PUBLICATIONS AND TRAINING RESOURCES....7331
OPERATING INSTRUCTIONS....7332
INSTRUMENT PANEL IDENTIFICATION....7336
Left Panel....7336
Right Panel (Key Switch)....7337
Right Panel (Keyless)....7338
Cab Light....7339
Side And Front Panels....7340
SEAT BAR RESTRAINT SYSTEM....7341
Operation....7341
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7342
Operation....7342
LIFT ARM BYPASS CONTROL....7343
Operation....7343
PARKING BRAKE....7343
Operation....7343
TRACTION LOCK OVERRIDE....7343
Operation....7343
BACK-UP ALARM SYSTEM....7344
Operation....7344
ENGINE SPEED CONTROL....7344
Operation....7344
DRIVING AND STEERING THE LOADER....7345
Available Controls Configurations....7345
Operation (Standard and ACS)....7345
Operation (SJC) in ‘H’ Control Pattern....7346
Operation (SJC) in ‘ISO’ Control Pattern....7347
STOPPING THE LOADER....7347
Using The Control Levers Or Joysticks....7347
TWO-SPEED CONTROL....7348
Description....7348
Operation....7348
SPEED MANAGEMENT....7349
Operation....7349
STEERING DRIFT COMPENSATION....7350
Description....7350
Operation....7350
HYDRAULIC CONTROLS....7352
Description....7352
Standard Controls (Also ACS in Foot Pedal Mode)....7352
Advanced Control System (ACS) in HAND Control Mode....7353
Selectable Joystick Control (SJC) In ‘H’ Control Pattern....7353
Selectable Joystick Control (SJC) In ‘ISO’ Control Pattern....7354
Hydraulic Bucket Positioning....7354
FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)....7355
FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)....7355
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....7356
REAR Auxiliary Hydraulics Operation....7356
Quick Couplers....7357
Relieve Hydraulic Pressure (Loader and Attachment)....7357
Secondary Front Auxiliary Hydraulics....7358
ATTACHMENT CONTROL DEVICE (ACD)....7359
Description....7359
DAILY INSPECTION....7360
Daily Inspection And Maintenance....7361
PRE-STARTING PROCEDURES....7362
Entering The Loader....7362
Operation & Maintenance Manual And Operator’s Handbook Locations....7362
Seat Adjustment....7362
Seat Belt Adjustment....7363
Seat Bar....7364
STARTING THE ENGINE....7365
Key Switch....7365
Keyless....7367
Cold Temperature Starting....7368
Warming The Hydraulic / Hydrostatic System....7369
MONITORING THE DISPLAY PANELS....7370
Left Panel....7370
Right Panel (Key Switch)....7370
Right Panel (Keyless)....7370
STOPPING THE ENGINE AND LEAVING THE LOADER....7371
Procedure....7371
Emergency Exit....7372
ATTACHMENTS....7373
Choosing The Correct Bucket....7373
Pallet Fork....7373
Installing And Removing The Attachment (Hand Lever Bob-Tach)....7374
Installing And Removing The Attachment (Power Bob-Tach)....7376
OPERATING PROCEDURE....7379
Inspect The Work Area....7379
Operating With A Full Bucket....7379
Operating With An Empty Bucket....7380
Filling And Emptying The Bucket (Foot Pedals)....7381
Leveling The Ground Using Float (Foot Pedals)....7382
Digging And Filling A Hole (Foot Pedals)....7382
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....7383
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....7384
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....7385
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....7386
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....7387
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....7387
TOWING THE LOADER....7388
Procedure....7388
TRANSPORTING THE LOADER ON A TRAILER....7389
Loading And Unloading....7389
Fastening....7389
LIFTING THE LOADER....7390
Single Point Lift....7390
Four Point Lift....7390
PREVENTIVE MAINTENANCE....7392
MAINTENANCE SAFETY....7396
SERVICE SCHEDULE....7398
Chart....7398
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7399
Inspecting The BICS Controller (Engine Stopped - Key ON)....7399
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7399
Inspecting The Seat Bar Sensor (Engine RUNNING)....7399
Inspecting The Traction Lock (Engine RUNNING)....7399
Inspecting The Lift Arm By-Pass Control....7399
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....7399
SEAT BAR RESTRAINT SYSTEM....7400
Description....7400
Inspecting....7400
Maintaining....7400
SEAT BELT....7401
Inspection and Maintenance....7401
LIFT ARM SUPPORT DEVICE....7402
Installing....7402
Removing....7403
BACK-UP ALARM SYSTEM....7404
Description....7404
Inspecting....7404
Adjusting Switch Position....7404
OPERATOR CAB....7405
Description....7405
Raising....7405
Lowering....7406
Cab Door Sensor....7407
REAR DOOR....7408
Opening And Closing....7408
Adjusting....7408
REAR GRILL....7409
Removing....7409
Installing....7409
HEATING SYSTEM....7410
Cleaning And Maintenance....7410
Filters....7410
Heater Coil....7410
Troubleshooting....7410
AIR CLEANER SERVICE....7411
Replacing Filter Elements....7411
FUEL SYSTEM....7413
Fuel Specifications....7413
Biodiesel Blend Fuel....7413
Filling the Fuel Tank....7414
Fuel Filter....7415
Removing Air From The Fuel System....7415
ENGINE LUBRICATION SYSTEM....7416
Checking And Adding Engine Oil....7416
Engine Oil Chart....7416
Removing And Replacing Oil And Filter....7416
ENGINE COOLING SYSTEM....7417
Cleaning....7417
Checking Level....7418
Removing And Replacing Coolant....7418
ELECTRICAL SYSTEM....7419
Description....7419
Fuse And Relay Location / Identification....7419
Battery Maintenance....7420
Using A Booster Battery (Jump Starting)....7420
Removing And Installing The Battery....7422
HYDRAULIC / HYDROSTATIC SYSTEM....7423
Checking And Adding Fluid....7423
Hydraulic / Hydrostatic Fluid Chart....7423
Removing And Replacing Hydraulic Fluid....7423
Removing And Replacing Hydraulic / Hydrostatic Filter....7424
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....7424
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....7425
Removing And Replacing Hydraulic Charge Filter....7427
Breather Cap....7428
SPARK ARRESTOR MUFFLER....7429
Cleaning Procedure....7429
TIRE MAINTENANCE....7430
Wheel Nuts....7430
Rotating....7430
Mounting....7430
FINAL DRIVE TRANSMISSION (CHAINCASE)....7431
Checking And Adding Oil....7431
Removing And Replacing Oil....7431
ALTERNATOR BELT....7432
Belt Adjustment....7432
Belt Replacement....7432
DRIVE BELT....7433
Belt Adjustment....7433
Belt Replacement....7433
LUBRICATING THE LOADER....7434
Lubrication Locations....7434
PIVOT PINS....7436
Inspection And Maintenance....7436
BOB-TACH (HAND LEVER)....7437
Inspection And Maintenance....7437
BOB-TACH (POWER)....7438
Inspection And Maintenance....7438
LOADER STORAGE AND RETURN TO SERVICE....7439
Storage....7439
Return to Service....7439
SYSTEM SETUP & ANALYSIS....7440
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7442
Troubleshooting Chart....7442
DIAGNOSTIC SERVICE CODES....7443
Viewing Service Codes (Key Switch)....7443
Viewing Service Codes (Keyless)....7443
Service Codes List....7444
CONTROL PANEL SETUP....7449
Right Panel Setup (Keyless)....7449
Right Panel Setup (Keyless)....7450
Attachment Control Information (Keyless)....7450
PASSWORD SETUP....7451
Password Description....7451
Changing The Owner Password....7451
Changing The User Passwords....7452
Password Lockout Feature....7452
MAINTENANCE CLOCK....7453
Description....7453
Setup....7453
Reset....7453
MACHINE SIGN TRANSLATIONS....7454
SERVICE SCHEDULE (6734534)....7456
WARNING (6718706)....7459
WARNING (6710358)....7459
DANGER (6809511)....7459
DANGER (6702301)....7460
DANGER (6702302)....7460
DANGER (6717343)....7460
WARNING (6577754)....7461
WARNING (6579528)....7461
WARNING (6737248)....7461
WARNING (6728539)....7462
WARNING (6733996)....7463
WARNING (6737189)....7463
IMPORTANT (6560573)....7463
OPERATING INSTRUCTIONS (6727926)....7464
WARNING (7131518)....7465
WARNING (7131519)....7467
LIFT ARM SUPPORT DEVICE (6706558)....7469
SPECIFICATIONS....7470
(S150) LOADER SPECIFICATIONS....7472
Machine Dimensions....7472
Performance....7473
Controls....7473
Drive System....7473
Engine....7474
Hydraulic System....7474
Electrical....7475
Capacities....7475
Tires....7475
WARRANTY....7476
ALPHABETICAL INDEX....7480
6986979 (11-10) - S150 Skid-Steer Loader Operation & Maintenance Manual....7482
OPERATOR SAFETY WARNINGS....7484
CONTENTS....7486
FOREWORD....7488
BOBCAT COMPANY IS IS0 9001 CERTIFIED....7490
REGULAR MAINTENANCE ITEMS....7490
SERIAL NUMBER LOCATIONS....7491
Loader Serial Number....7491
Engine Serial Number....7491
DELIVERY REPORT....7491
LOADER IDENTIFICATION....7492
FEATURES, ACCESSORIES AND ATTACHMENTS....7493
Standard Items....7493
Options And Accessories....7493
Buckets Available....7494
Attachments....7494
Special Applications Kit....7495
Special Applications Kit Inspection And Maintenance....7495
SAFETY & TRAINING RESOURCES....7496
SAFETY INSTRUCTIONS....7498
Before Operation....7498
Safe Operation Is The Operator’s Responsibility....7499
Safe Operation Needs A Qualified Operator....7499
Avoid Silica Dust....7500
FIRE PREVENTION....7500
Maintenance....7500
Operation....7500
Electrical....7500
Hydraulic System....7501
Fueling....7501
Starting....7501
Spark Arrestor Exhaust System....7501
Welding And Grinding....7501
Fire Extinguishers....7501
MACHINE SIGNS (DECALS)....7503
PUBLICATIONS AND TRAINING RESOURCES....7505
OPERATING INSTRUCTIONS....7506
INSTRUMENT PANEL IDENTIFICATION....7510
Cab Light....7510
Left Panel....7511
Display Screen....7513
Standard Key Panel....7514
Keyless Start Panel....7514
Deluxe Instrumentation Panel....7515
Side Panel....7516
Front Panel....7516
CONTROL IDENTIFICATION....7517
Standard Controls....7517
Advanced Control System (ACS)....7518
Selectable Joystick Controls (SJC)....7519
SEAT BAR RESTRAINT SYSTEM....7520
Operation....7520
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7521
Operation....7521
LIFT ARM BYPASS CONTROL....7522
Operation....7522
PARKING BRAKE....7522
Operation....7522
TRACTION LOCK OVERRIDE....7522
Operation....7522
EMERGENCY EXIT....7523
Rear Window....7523
Front Door....7523
BACK-UP ALARM SYSTEM....7524
Description....7524
Operation....7524
ENGINE SPEED CONTROL....7525
Operation....7525
DRIVING AND STEERING THE LOADER....7526
Available Control Configurations....7526
Operation (Standard And ACS)....7526
Operation (SJC) In ‘ISO’ Control Pattern....7527
Operation (SJC) In ‘H’ Control Pattern....7528
STOPPING THE LOADER....7528
Using The Control Levers Or Joysticks....7528
TWO-SPEED CONTROL....7529
Description....7529
Operation (Standard And ACS) (If Equipped)....7529
Operation (SJC) (If Equipped)....7529
SPEED MANAGEMENT....7530
Operation....7530
Changing The Factory Default Setting....7531
DRIVE RESPONSE....7532
Description....7532
Operation....7532
STEERING DRIFT COMPENSATION....7534
Description....7534
Operation....7534
HYDRAULIC CONTROLS....7536
Description....7536
Standard Controls (Also ACS In FOOT Pedal Mode)....7536
Advanced Control System (ACS) In HAND Control Mode....7537
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....7537
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....7538
Hydraulic Bucket Positioning....7538
FRONT Auxiliary Hydraulics Operation....7539
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....7540
REAR Auxiliary Hydraulics Operation....7540
Secondary Front Auxiliary Hydraulics Operation....7541
Quick Couplers....7542
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....7543
ATTACHMENT CONTROL DEVICE (ACD)....7544
Description....7544
DAILY INSPECTION....7545
Daily Inspection And Maintenance....7546
PRE-STARTING PROCEDURE....7547
Entering The Loader....7547
Operation & Maintenance Manual And Operator’s Handbook Locations....7547
Seat Adjustment....7548
Seat Belt Adjustment....7549
Seat Bar....7549
STARTING THE ENGINE....7550
Standard Key Panel....7550
Keyless Start Panel....7552
Deluxe Instrumentation Panel....7554
Cold Temperature Starting....7556
Warming The Hydraulic / Hydrostatic System....7557
MONITORING THE DISPLAY PANELS....7558
Left Panel....7558
Warning And Shutdown....7558
STOPPING THE ENGINE AND LEAVING THE LOADER....7559
Procedure....7559
COUNTERWEIGHTS....7560
Description....7560
Effect On The Loader And Loader Operation....7560
When To Consider Using Counterweights....7560
When To Consider Removing Counterweights....7560
Accessories That Affect Machine Weight....7560
ATTACHMENTS....7561
Choosing The Correct Bucket....7561
Pallet Forks....7561
Installing And Removing The Attachment (Hand Lever Bob-Tach)....7562
Installing And Removing The Attachment (Power Bob-Tach)....7564
OPERATING PROCEDURE....7567
Inspect The Work Area....7567
Basic Operating Instructions....7567
Driving On Public Roads....7567
Operating With A Full Bucket....7568
Operating With An Empty Bucket....7568
Filling And Emptying The Bucket (Foot Pedals)....7569
Leveling The Ground Using Float (Foot Pedals)....7570
Digging And Filling A Hole (Foot Pedals)....7570
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....7571
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....7572
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....7573
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....7574
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....7575
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....7575
TOWING THE LOADER....7576
Procedure....7576
LIFTING THE LOADER....7577
Single-Point Lift....7577
Four-Point Lift....7577
TRANSPORTING THE LOADER ON A TRAILER....7578
Loading And Unloading....7578
Fastening....7578
PREVENTIVE MAINTENANCE....7580
MAINTENANCE SAFETY....7584
SERVICE SCHEDULE....7586
Chart....7586
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7587
Inspecting The BICS (Engine STOPPED - Key ON)....7587
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7587
Inspecting The Seat Bar Sensor (Engine RUNNING)....7587
Inspecting The Traction Lock (Engine RUNNING)....7587
Inspecting The Lift Arm Bypass Control....7587
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....7587
SEAT BAR RESTRAINT SYSTEM....7588
Description....7588
Inspecting....7588
Maintaining....7588
SEAT BELT....7589
Inspection And Maintenance....7589
LIFT ARM SUPPORT DEVICE....7590
Installing....7590
Removing....7591
BACK-UP ALARM SYSTEM....7592
Description....7592
Inspecting....7592
Adjusting Switch Position....7592
OPERATOR CAB....7593
Description....7593
Raising....7593
Lowering....7594
Cab Door Sensor....7595
REAR DOOR (TAILGATE)....7596
Opening And Closing....7596
Adjusting....7596
REAR GRILLE....7596
Removing....7596
Installing....7596
HEATING SYSTEM....7597
Cleaning And Maintenance....7597
Filters....7597
Heater Coil....7597
Troubleshooting....7597
AIR CLEANER SERVICE....7598
Replacing Filter Elements....7598
FUEL SYSTEM....7600
Fuel Specifications....7600
Biodiesel Blend Fuel....7600
Filling The Fuel Tank....7601
Fuel Filter....7602
Removing Air From The Fuel System....7602
ENGINE LUBRICATION SYSTEM....7603
Checking And Adding Engine Oil....7603
Engine Oil Chart....7603
Removing And Replacing Oil And Filter....7603
ENGINE COOLING SYSTEM....7604
Cleaning....7604
Removing And Replacing Coolant....7605
Checking Level....7605
ELECTRICAL SYSTEM....7606
Description....7606
Fuse And Relay Location / Identification....7606
Battery Maintenance....7607
Using A Booster Battery (Jump Starting)....7608
Removing And Installing Battery....7609
HYDRAULIC / HYDROSTATIC SYSTEM....7610
Checking And Adding Fluid....7610
Hydraulic / Hydrostatic Fluid Chart....7610
Removing And Replacing Hydraulic Fluid....7611
Removing And Replacing Hydraulic / Hydrostatic Filter....7611
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....7612
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....7613
Removing And Replacing Hydraulic Charge Filter....7615
Breather Cap....7616
SPARK ARRESTER MUFFLER....7617
Cleaning Procedure....7617
TIRE MAINTENANCE....7618
Wheel Nuts....7618
Rotating....7618
Mounting....7618
FINAL DRIVE TRANSMISSION (CHAINCASE)....7619
Checking And Adding Oil....7619
Removing And Replacing Oil....7619
ALTERNATOR BELT....7620
Belt Adjustment....7620
Belt Replacement....7620
DRIVE BELT....7621
Belt Adjustment....7621
Belt Replacement....7621
LUBRICATING THE LOADER....7622
Lubrication Locations....7622
PIVOT PINS....7623
Inspection And Maintenance....7623
BOB-TACH (HAND LEVER)....7624
Inspection And Maintenance....7624
BOB-TACH (POWER)....7625
Inspection And Maintenance....7625
LOADER STORAGE AND RETURN TO SERVICE....7626
Storage....7626
Return To Service....7626
SYSTEM SETUP & ANALYSIS....7628
DIAGNOSTIC SERVICE CODES....7630
Viewing Service Codes....7630
Service Codes List....7631
CONTROL PANEL SETUP....7636
Right Panel Setup (Deluxe Instrumentation Panel)....7636
Attachment Control Information (Deluxe Instrumentation Panel)....7637
PASSWORD SETUP (KEYLESS START PANEL)....7638
Password Description....7638
Changing The Owner Password....7638
Password Lockout Feature....7638
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7639
Password Description....7639
Changing The Owner Password....7639
Changing The User Passwords....7640
Password Lockout Feature....7640
MAINTENANCE CLOCK....7641
Description....7641
Setup....7641
Reset....7641
MACHINE SIGN TRANSLATIONS....7642
SERVICE SCHEDULE (6734534)....7644
DANGER (6702301)....7647
WARNING (6577754)....7647
DANGER (6702302)....7647
DANGER (6717343)....7647
IMPORTANT (6560573)....7648
WARNING (6579528)....7648
WARNING (6728539)....7649
WARNING (6718706)....7650
WARNING (6710358)....7650
DANGER (6809511)....7650
WARNING (6725370)....7651
WARNING (6737189)....7651
WARNING (6737248)....7651
LIFT ARM SUPPORT DEVICE (6706558)....7652
WARNING (7131518)....7653
WARNING (7131519)....7655
WARNING (6726423)....7657
WARNING (6704786)....7657
SPECIFICATIONS....7658
(S150) LOADER SPECIFICATIONS....7660
Machine Dimensions....7660
Performance....7661
Engine....7661
Drive System....7661
Controls....7662
Hydraulic System....7662
Electrical....7663
Capacities....7663
Tires....7663
WARRANTY....7664
WARRANTY....7666
ALPHABETICAL INDEX....7668
6986979 (2-13) - S150 Skid-Steer Loader Operation & Maintenance Manual....7672
OPERATOR SAFETY WARNINGS....7674
CONTENTS....7676
FOREWORD....7678
BOBCAT COMPANY IS IS0 9001 CERTIFIED....7680
REGULAR MAINTENANCE ITEMS....7680
SERIAL NUMBER LOCATIONS....7681
Loader Serial Number....7681
Engine Serial Number....7681
DELIVERY REPORT....7681
LOADER IDENTIFICATION....7682
FEATURES, ACCESSORIES AND ATTACHMENTS....7683
Standard Items....7683
Options And Accessories....7683
Buckets Available....7684
Attachments....7684
Special Applications Kit....7685
Special Applications Kit Inspection And Maintenance....7685
SAFETY & TRAINING RESOURCES....7686
SAFETY INSTRUCTIONS....7688
Before Operation....7688
Safe Operation Is The Operator’s Responsibility....7689
Safe Operation Needs A Qualified Operator....7689
Avoid Silica Dust....7690
FIRE PREVENTION....7690
Maintenance....7690
Operation....7690
Electrical....7690
Hydraulic System....7691
Fueling....7691
Starting....7691
Spark Arrester Exhaust System....7691
Welding And Grinding....7691
Fire Extinguishers....7691
PUBLICATIONS AND TRAINING RESOURCES....7692
MACHINE SIGNS (DECALS)....7693
OPERATING INSTRUCTIONS....7696
INSTRUMENT PANEL IDENTIFICATION....7700
Cab Light....7700
Left Panel....7701
Display Screen....7703
Standard Key Panel....7704
Keyless Start Panel....7704
Deluxe Instrumentation Panel....7705
Side Panel....7706
Front Panel....7706
CONTROL IDENTIFICATION....7707
Standard Controls....7707
Advanced Control System (ACS)....7708
Selectable Joystick Controls (SJC)....7709
SEAT BAR RESTRAINT SYSTEM....7710
Operation....7710
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....7711
Operation....7711
LIFT ARM BYPASS CONTROL....7712
Operation....7712
PARKING BRAKE....7712
Operation....7712
TRACTION LOCK OVERRIDE....7712
Operation....7712
EMERGENCY EXIT....7713
Rear Window....7713
Front Door....7713
BACK-UP ALARM SYSTEM....7714
Description....7714
Operation....7714
ENGINE SPEED CONTROL....7715
Operation....7715
DRIVING AND STEERING THE LOADER....7716
Available Control Configurations....7716
Operation (Standard And ACS)....7716
Operation (SJC) In ‘ISO’ Control Pattern....7717
Operation (SJC) In ‘H’ Control Pattern....7718
STOPPING THE LOADER....7718
Using The Control Levers Or Joysticks....7718
TWO-SPEED CONTROL....7719
Description....7719
Operation (Standard And ACS) (If Equipped)....7719
Operation (SJC) (If Equipped)....7719
SPEED MANAGEMENT....7720
Operation....7720
Changing The Factory Default Setting....7721
DRIVE RESPONSE....7722
Description....7722
Operation....7722
STEERING DRIFT COMPENSATION....7724
Description....7724
Operation....7724
LIFT AND TILT COMPENSATION....7726
Description....7726
Operation....7726
Operation (ACS)....7727
Operation (SJC)....7728
HYDRAULIC CONTROLS....7729
Description....7729
Standard Controls (Also ACS In FOOT Pedal Mode)....7729
Advanced Control System (ACS) In HAND Control Mode....7730
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....7730
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....7731
Hydraulic Bucket Positioning....7731
FRONT Auxiliary Hydraulics Operation....7732
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....7733
REAR Auxiliary Hydraulics Operation....7733
Secondary Front Auxiliary Hydraulics Operation....7734
Quick Couplers....7735
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....7736
ATTACHMENT CONTROL DEVICE (ACD)....7737
Description....7737
DAILY INSPECTION....7738
Daily Inspection And Maintenance....7739
PRE-STARTING PROCEDURE....7740
Entering The Loader....7740
Operation & Maintenance Manual And Operator’s Handbook Locations....7740
Seat Adjustment....7741
Seat Belt Adjustment....7742
Seat Bar....7742
STARTING THE ENGINE....7743
Standard Key Panel....7743
Keyless Start Panel....7745
Deluxe Instrumentation Panel....7747
Cold Temperature Starting....7749
Warming The Hydraulic / Hydrostatic System....7750
MONITORING THE DISPLAY PANELS....7751
Left Panel....7751
Warning And Shutdown....7751
STOPPING THE ENGINE AND LEAVING THE LOADER....7752
Procedure....7752
COUNTERWEIGHTS....7753
Description....7753
Effect On The Loader And Loader Operation....7753
When To Consider Using Counterweights....7753
When To Consider Removing Counterweights....7753
Accessories That Affect Machine Weight....7753
ATTACHMENTS....7754
Choosing The Correct Bucket....7754
Pallet Forks....7754
Installing And Removing The Attachment (Hand Lever Bob-Tach)....7755
Installing And Removing The Attachment (Power Bob-Tach)....7757
OPERATING PROCEDURE....7760
Inspect The Work Area....7760
Basic Operating Instructions....7760
Driving On Public Roads....7760
Operating With A Full Bucket....7761
Operating With An Empty Bucket....7761
Filling And Emptying The Bucket (Foot Pedals)....7762
Leveling The Ground Using Float (Foot Pedals)....7763
Digging And Filling A Hole (Foot Pedals)....7763
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....7764
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....7765
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....7766
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....7767
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....7768
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....7768
TOWING THE LOADER....7769
Procedure....7769
LIFTING THE LOADER....7770
Single-Point Lift....7770
Four-Point Lift....7770
TRANSPORTING THE LOADER ON A TRAILER....7771
Loading And Unloading....7771
Fastening....7771
PREVENTIVE MAINTENANCE....7772
MAINTENANCE SAFETY....7776
SERVICE SCHEDULE....7778
Chart....7778
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....7779
Inspecting The BICS™ (Engine STOPPED - Key ON)....7779
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7779
Inspecting The Seat Bar Sensor (Engine RUNNING)....7779
Inspecting The Traction Lock (Engine RUNNING)....7779
Inspecting The Lift Arm Bypass Control....7779
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....7779
SEAT BAR RESTRAINT SYSTEM....7780
Description....7780
Inspecting....7780
Maintaining....7780
SEAT BELT....7781
Inspection And Maintenance....7781
LIFT ARM SUPPORT DEVICE....7782
Installing....7782
Removing....7783
BACK-UP ALARM SYSTEM....7784
Description....7784
Inspecting....7784
Adjusting Switch Position....7784
OPERATOR CAB....7785
Description....7785
Raising....7785
Lowering....7786
Cab Door Sensor....7787
REAR DOOR (TAILGATE)....7788
Opening And Closing....7788
Adjusting....7788
REAR GRILLE....7788
Removing....7788
Installing....7788
HEATING SYSTEM....7789
Cleaning And Maintenance....7789
Filters....7789
Heater Coil....7789
Troubleshooting....7789
AIR CLEANER SERVICE....7790
Replacing Filter Elements....7790
FUEL SYSTEM....7792
Fuel Specifications....7792
Biodiesel Blend Fuel....7792
Filling The Fuel Tank....7793
Fuel Filter....7794
Removing Air From The Fuel System....7794
ENGINE LUBRICATION SYSTEM....7795
Checking And Adding Engine Oil....7795
Engine Oil Chart....7795
Removing And Replacing Oil And Filter....7795
ENGINE COOLING SYSTEM....7796
Cleaning....7796
Removing And Replacing Coolant....7797
Checking Level....7797
ELECTRICAL SYSTEM....7798
Description....7798
Fuse And Relay Location / Identification....7798
Battery Maintenance....7799
Using A Booster Battery (Jump Starting)....7800
Removing And Installing Battery....7801
HYDRAULIC / HYDROSTATIC SYSTEM....7802
Checking And Adding Fluid....7802
Hydraulic / Hydrostatic Fluid Chart....7802
Removing And Replacing Hydraulic Fluid....7803
Removing And Replacing Hydraulic / Hydrostatic Filter....7803
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....7804
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....7805
Removing And Replacing Hydraulic Charge Filter....7807
Breather Cap....7808
SPARK ARRESTER MUFFLER....7809
Cleaning Procedure....7809
TIRE MAINTENANCE....7810
Wheel Nuts....7810
Rotating....7810
Mounting....7810
FINAL DRIVE TRANSMISSION (CHAINCASE)....7811
Checking And Adding Oil....7811
Removing And Replacing Oil....7811
ALTERNATOR BELT....7812
Belt Adjustment....7812
Belt Replacement....7812
DRIVE BELT....7813
Belt Adjustment....7813
Belt Replacement....7813
LUBRICATING THE LOADER....7814
Lubrication Locations....7814
PIVOT PINS....7815
Inspection And Maintenance....7815
BOB-TACH (HAND LEVER)....7816
Inspection And Maintenance....7816
BOB-TACH (POWER)....7817
Inspection And Maintenance....7817
LOADER STORAGE AND RETURN TO SERVICE....7818
Storage....7818
Return To Service....7818
SYSTEM SETUP & ANALYSIS....7820
DIAGNOSTIC SERVICE CODES....7822
Viewing Service Codes....7822
Service Codes List....7823
CONTROL PANEL SETUP....7828
Right Panel Setup (Deluxe Instrumentation Panel)....7828
Attachment Control Information (Deluxe Instrumentation Panel)....7829
PASSWORD SETUP (KEYLESS START PANEL)....7830
Password Description....7830
Changing The Owner Password....7830
Password Lockout Feature....7830
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7831
Password Description....7831
Changing The Owner Password....7831
Changing The User Passwords....7832
Password Lockout Feature....7832
MAINTENANCE CLOCK....7833
Description....7833
Setup....7833
Reset....7833
MACHINE SIGN TRANSLATIONS....7834
MACHINE SIGN TRANSLATIONS....7836
Service Schedule (6734534)....7836
Danger (6702301)....7839
Warning (6577754)....7839
Danger (6702302)....7839
Danger (6717343)....7839
Important (6560573)....7840
Warning (6579528)....7840
Warning (6728539)....7841
Warning (6718706)....7842
Warning (6710358)....7842
Danger (6809511)....7842
Warning (6725370)....7843
Warning (6737189)....7843
Warning (6737248)....7843
Lift Arm Support Device (6706558)....7844
Warning (7131518)....7845
Warning (7131519)....7847
Warning (7168019)....7849
Warning (7142141)....7850
SPECIFICATIONS....7852
(S150) LOADER SPECIFICATIONS....7854
Machine Dimensions....7854
Performance....7855
Engine....7855
Drive System....7855
Controls....7856
Hydraulic System....7856
Electrical....7857
Capacities....7857
Tires....7857
WARRANTY....7858
WARRANTY....7860
ALPHABETICAL INDEX....7862
6986981 (3-08) - S160 Skid-Steer Loader Operation & Maintenance Manual....7864
OPERATOR SAFETY WARNINGS....7866
CONTENTS....7868
FOREWORD....7870
BOBCAT COMANY IS IS0 9001:2000 CERTIFIED....7872
REGULAR MAINTENANCE ITEMS....7872
SERIAL NUMBER LOCATIONS....7873
Loader Serial Number....7873
Engine Serial Number....7873
DELIVERY REPORT....7873
LOADER IDENTIFICATION....7874
FEATURES, ACCESSORIES AND ATTACHMENTS....7875
Standard Items....7875
Options And Accessories....7875
Buckets Available....7876
Attachments....7876
High-Flow Attachments....7876
Special Applications Kit....7877
Special Applications Kit Inspection And Maintenance....7877
SAFETY & TRAINING RESOURCES....7878
SAFETY INSTRUCTIONS....7880
Before Operation....7880
Safe Operation Is The Operator’s Responsibility....7881
Safe Operation Needs A Qualified Operator....7881
Avoid Silica Dust....7882
FIRE PREVENTION....7882
Maintenance....7882
Operation....7882
Electrical....7882
Hydraulic System....7883
Fueling....7883
Starting....7883
Spark Arrestor Exhaust System....7883
Welding And Grinding....7883
Fire Extinguishers....7883
MACHINE SIGNS (DECALS)....7885
PUBLICATIONS AND TRAINING RESOURCES....7887
OPERATING INSTRUCTIONS....7888
INSTRUMENT PANEL IDENTIFICATION....7892
Cab Light....7892
Left Panel....7893
Display Screen....7895
Standard Key Panel....7895
Deluxe Instrumentation Panel....7896
Side Panel....7897
Front Panel....7897
SEAT BAR RESTRAINT SYSTEM....7898
Operation....7898
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7899
Operation....7899
LIFT ARM BYPASS CONTROL....7900
Operation....7900
PARKING BRAKE....7900
Operation....7900
TRACTION LOCK OVERRIDE....7900
Operation....7900
BACK-UP ALARM SYSTEM....7901
Operation....7901
ENGINE SPEED CONTROL....7901
Operation....7901
DRIVING AND STEERING THE LOADER....7902
Available Control Configurations....7902
Operation (Standard And ACS)....7902
Operation (SJC) in ‘ISO’ Control Pattern....7903
Operation (SJC) in ‘H’ Control Pattern....7904
STOPPING THE LOADER....7904
Using The Control Levers Or Joysticks....7904
TWO-SPEED CONTROL....7905
Description....7905
Operation (Standard And ACS) (If Equipped)....7905
Operation (SJC) (If Equipped)....7905
SPEED MANAGEMENT....7906
Operation....7906
STEERING DRIFT COMPENSATION....7907
Description....7907
Operation....7907
HYDRAULIC CONTROLS....7909
Description....7909
Standard Controls (Also ACS In FOOT Pedal Mode)....7909
Advanced Control System (ACS) In HAND Control Mode....7910
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....7910
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....7911
Hydraulic Bucket Positioning....7911
FRONT Auxiliary Hydraulics Operation....7912
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....7913
REAR Auxiliary Hydraulics Operation....7913
Secondary Front Auxiliary Hydraulics Operation....7914
High-Flow Hydraulics Operation....7915
Quick Couplers....7915
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....7916
ATTACHMENT CONTROL DEVICE (ACD)....7917
Description....7917
DAILY INSPECTION....7918
Daily Inspection And Maintenance....7919
PRE-STARTING PROCEDURE....7920
Entering The Loader....7920
Operation & Maintenance Manual And Operator’s Handbook Locations....7920
Seat Adjustment....7921
Seat Belt Adjustment....7922
Seat Bar....7922
STARTING THE ENGINE....7923
Standard Key Panel....7923
Deluxe Instrumentation Panel....7925
Cold Temperature Starting....7927
Warming The Hydraulic / Hydrostatic System....7928
MONITORING THE DISPLAY PANELS....7929
Left Panel....7929
Warning And Shutdown....7929
STOPPING THE ENGINE AND LEAVING THE LOADER....7930
Procedure....7930
Emergency Exit....7931
ATTACHMENTS....7932
Choosing The Correct Bucket....7932
Pallet Forks....7932
Installing And Removing The Attachment (Hand Lever Bob-Tach)....7933
Installing And Removing The Attachment (Power Bob-Tach)....7935
OPERATING PROCEDURE....7938
Inspect The Work Area....7938
Operating With A Full Bucket....7938
Operating With An Empty Bucket....7939
Filling And Emptying The Bucket (Foot Pedals)....7940
Leveling The Ground Using Float (Foot Pedals)....7941
Digging And Filling A Hole (Foot Pedals)....7941
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....7942
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....7943
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....7944
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....7945
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....7946
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....7946
TOWING THE LOADER....7947
Procedure....7947
LIFTING THE LOADER....7948
Single Point Lift....7948
Four Point Lift....7948
TRANSPORTING THE LOADER ON A TRAILER....7949
Loading And Unloading....7949
Fastening....7949
PREVENTIVE MAINTENANCE....7950
MAINTENANCE SAFETY....7954
SERVICE SCHEDULE....7956
Chart....7956
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7957
Inspecting The BICS (Engine STOPPED - Key ON)....7957
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7957
Inspecting The Seat Bar Sensor (Engine RUNNING)....7957
Inspecting The Traction Lock (Engine RUNNING)....7957
Inspecting The Lift Arm Bypass Control....7957
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....7957
SEAT BAR RESTRAINT SYSTEM....7958
Description....7958
Inspecting....7958
Maintaining....7958
SEAT BELT....7959
Inspection And Maintenance....7959
LIFT ARM SUPPORT DEVICE....7960
Installing....7960
Removing....7961
BACK-UP ALARM SYSTEM....7962
Description....7962
Inspecting....7962
Adjusting Switch Position....7962
OPERATOR CAB....7963
Description....7963
Raising....7963
Lowering....7964
Cab Door Sensor....7965
REAR DOOR....7966
Opening And Closing....7966
Adjusting....7966
REAR GRILL....7966
Removing....7966
Installing....7966
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....7967
Cleaning And Maintenance....7967
Filters....7967
Evaporator / Heater Coil....7967
Condenser....7967
Air Conditioning Lubrication....7967
Troubleshooting....7967
AIR CLEANER SERVICE....7968
Replacing Filter Elements....7968
FUEL SYSTEM....7970
Fuel Specifications....7970
Biodiesel Blend Fuel....7970
Filling The Fuel Tank....7971
Fuel Filter....7972
Removing Air From The Fuel System....7972
ENGINE LUBRICATION SYSTEM....7973
Checking And Adding Engine Oil....7973
Engine Oil Chart....7973
Removing And Replacing Oil And Filter....7973
ENGINE COOLING SYSTEM....7974
Cleaning....7974
Removing And Replacing Coolant....7975
Checking Level....7975
ELECTRICAL SYSTEM....7976
Description....7976
Fuse And Relay Location / Identification....7976
Battery Maintenance....7977
Using A Booster Battery (Jump Starting)....7978
Removing And Installing Battery....7979
HYDRAULIC / HYDROSTATIC SYSTEM....7980
Checking And Adding Fluid....7980
Hydraulic / Hydrostatic Fluid Chart....7980
Removing And Replacing Hydraulic Fluid....7980
Removing And Replacing Hydraulic / Hydrostatic Filter....7981
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....7981
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....7982
Removing And Replacing Hydraulic Charge Filter....7984
Breather Cap....7985
SPARK ARRESTOR MUFFLER....7986
Cleaning Procedure....7986
TIRE MAINTENANCE....7987
Wheel Nuts....7987
Rotating....7987
Mounting....7987
FINAL DRIVE TRANSMISSION (CHAINCASE)....7988
Checking And Adding Oil....7988
Removing And Replacing Oil....7988
ALTERNATOR BELT....7989
Belt Adjustment....7989
Belt Replacement....7989
AIR CONDITIONING BELT....7989
Belt Adjustment....7989
Belt Replacement....7989
DRIVE BELT....7990
Belt Adjustment....7990
Belt Replacement....7990
LUBRICATING THE LOADER....7991
Lubrication Locations....7991
PIVOT PINS....7992
Inspection And Maintenance....7992
BOB-TACH (HAND LEVER)....7993
Inspection And Maintenance....7993
BOB-TACH (POWER)....7994
Inspection And Maintenance....7994
LOADER STORAGE AND RETURN TO SERVICE....7995
Storage....7995
Return To Service....7995
SYSTEM SETUP & ANALYSIS....7996
DIAGNOSTIC SERVICE CODES....7998
Viewing Service Codes (Standard Key Panel)....7998
Viewing Service Codes (Deluxe Instrumentation Panel)....7998
Service Codes List....7999
CONTROL PANEL SETUP....8003
Right Panel Setup (Deluxe Instrumentation Panel)....8003
Attachment Control Information (Deluxe Instrumentation Panel)....8004
PASSWORD SETUP....8005
Password Description....8005
Changing The Owner Password....8005
Changing The User Passwords....8006
Password Lockout Feature....8006
MAINTENANCE CLOCK....8007
Description....8007
Setup....8007
Reset....8007
MACHINE SIGN TRANSLATIONS....8008
SERVICE SCHEDULE (6734534)....8010
DANGER (6702301)....8013
WARNING (6577754)....8013
DANGER (6702302)....8013
DANGER (6717343)....8013
IMPORTANT (6560573)....8014
WARNING (6579528)....8014
WARNING (6728539)....8015
WARNING (6718706)....8016
WARNING (6710358)....8016
DANGER (6809511)....8016
WARNING (6733996)....8017
WARNING (6725370)....8017
WARNING (6737189)....8017
WARNING (6737248)....8017
LIFT ARM SUPPORT DEVICE (6706558)....8018
warning (7131518)....8019
warning (7131519)....8021
WARNING (6726423)....8023
WARNING (6704786)....8023
SPECIFICATIONS....8024
(S160) LOADER SPECIFICATIONS....8026
Machine Dimensions....8026
Performance....8027
Engine....8027
Controls....8027
Drive System....8028
Hydraulic System....8028
Electrical....8029
Capacities....8029
Tires....8029
WARRANTY....8030
ALPHABETICAL INDEX....8034
6987009 (11-10) - S160 Skid-Steer Loader Operation & Maintenance Manual....8036
OPERATOR SAFETY WARNINGS....8038
CONTENTS....8040
FOREWORD....8042
BOBCAT COMPANY IS IS0 9001 CERTIFIED....8044
REGULAR MAINTENANCE ITEMS....8044
SERIAL NUMBER LOCATIONS....8045
Loader Serial Number....8045
Engine Serial Number....8045
DELIVERY REPORT....8045
LOADER IDENTIFICATION....8046
FEATURES, ACCESSORIES AND ATTACHMENTS....8047
Standard Items....8047
Options And Accessories....8047
Buckets Available....8048
Attachments....8048
High-Flow Attachments....8048
Special Applications Kit....8049
Special Applications Kit Inspection And Maintenance....8049
SAFETY & TRAINING RESOURCES....8050
SAFETY INSTRUCTIONS....8052
Before Operation....8052
Safe Operation Is The Operator’s Responsibility....8053
Safe Operation Needs A Qualified Operator....8053
Avoid Silica Dust....8054
FIRE PREVENTION....8054
Maintenance....8054
Operation....8054
Electrical....8054
Hydraulic System....8055
Fueling....8055
Starting....8055
Spark Arrestor Exhaust System....8055
Welding And Grinding....8055
Fire Extinguishers....8055
MACHINE SIGNS (DECALS)....8057
PUBLICATIONS AND TRAINING RESOURCES....8059
OPERATING INSTRUCTIONS....8060
INSTRUMENT PANEL IDENTIFICATION....8064
Cab Light....8064
Left Panel....8065
Display Screen....8067
Standard Key Panel....8068
Keyless Start Panel....8068
Deluxe Instrumentation Panel....8069
Side Panel....8070
Front Panel....8070
CONTROL IDENTIFICATION....8071
Standard Controls....8071
Advanced Control System (ACS)....8072
Selectable Joystick Controls (SJC)....8073
SEAT BAR RESTRAINT SYSTEM....8074
Operation....8074
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....8075
Operation....8075
LIFT ARM BYPASS CONTROL....8076
Operation....8076
PARKING BRAKE....8076
Operation....8076
TRACTION LOCK OVERRIDE....8076
Operation....8076
EMERGENCY EXIT....8077
Rear Window....8077
Front Door....8077
BACK-UP ALARM SYSTEM....8078
Description....8078
Operation....8078
ENGINE SPEED CONTROL....8079
Operation....8079
DRIVING AND STEERING THE LOADER....8080
Available Control Configurations....8080
Operation (Standard And ACS)....8080
Operation (SJC) In ‘ISO’ Control Pattern....8081
Operation (SJC) In ‘H’ Control Pattern....8082
STOPPING THE LOADER....8082
Using The Control Levers Or Joysticks....8082
TWO-SPEED CONTROL....8083
Description....8083
Operation (Standard And ACS) (If Equipped)....8083
Operation (SJC) (If Equipped)....8083
SPEED MANAGEMENT....8084
Operation....8084
Changing The Factory Default Setting....8085
DRIVE RESPONSE....8086
Description....8086
Operation....8086
STEERING DRIFT COMPENSATION....8088
Description....8088
Operation....8088
HYDRAULIC CONTROLS....8090
Description....8090
Standard Controls (Also ACS In FOOT Pedal Mode)....8090
Advanced Control System (ACS) In HAND Control Mode....8091
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....8091
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....8092
Hydraulic Bucket Positioning....8092
FRONT Auxiliary Hydraulics Operation....8093
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....8094
REAR Auxiliary Hydraulics Operation....8094
Secondary Front Auxiliary Hydraulics Operation....8095
High-Flow Hydraulics Operation....8096
Quick Couplers....8096
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....8097
ATTACHMENT CONTROL DEVICE (ACD)....8098
Description....8098
DAILY INSPECTION....8099
Daily Inspection And Maintenance....8100
PRE-STARTING PROCEDURE....8101
Entering The Loader....8101
Operation & Maintenance Manual And Operator’s Handbook Locations....8101
Seat Adjustment....8102
Seat Belt Adjustment....8103
Seat Bar....8103
STARTING THE ENGINE....8104
Standard Key Panel....8104
Keyless Start Panel....8106
Deluxe Instrumentation Panel....8108
Cold Temperature Starting....8110
Warming The Hydraulic / Hydrostatic System....8111
MONITORING THE DISPLAY PANELS....8112
Left Panel....8112
Warning And Shutdown....8112
STOPPING THE ENGINE AND LEAVING THE LOADER....8113
Procedure....8113
COUNTERWEIGHTS....8114
Description....8114
Effect On The Loader And Loader Operation....8114
When To Consider Using Counterweights....8114
When To Consider Removing Counterweights....8114
Accessories That Affect Machine Weight....8114
ATTACHMENTS....8115
Choosing The Correct Bucket....8115
Pallet Forks....8115
Installing And Removing The Attachment (Hand Lever Bob-Tach)....8116
Installing And Removing The Attachment (Power Bob-Tach)....8118
OPERATING PROCEDURE....8121
Inspect The Work Area....8121
Basic Operating Instructions....8121
Driving On Public Roads....8121
Operating With A Full Bucket....8122
Operating With An Empty Bucket....8122
Filling And Emptying The Bucket (Foot Pedals)....8123
Leveling The Ground Using Float (Foot Pedals)....8124
Digging And Filling A Hole (Foot Pedals)....8124
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....8125
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....8126
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....8127
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....8128
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....8129
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....8129
TOWING THE LOADER....8130
Procedure....8130
LIFTING THE LOADER....8131
Single-Point Lift....8131
Four-Point Lift....8131
TRANSPORTING THE LOADER ON A TRAILER....8132
Loading And Unloading....8132
Fastening....8132
PREVENTIVE MAINTENANCE....8134
MAINTENANCE SAFETY....8138
SERVICE SCHEDULE....8140
Chart....8140
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....8141
Inspecting The BICS (Engine STOPPED - Key ON)....8141
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....8141
Inspecting The Seat Bar Sensor (Engine RUNNING)....8141
Inspecting The Traction Lock (Engine RUNNING)....8141
Inspecting The Lift Arm Bypass Control....8141
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....8141
SEAT BAR RESTRAINT SYSTEM....8142
Description....8142
Inspecting....8142
Maintaining....8142
SEAT BELT....8143
Inspection And Maintenance....8143
LIFT ARM SUPPORT DEVICE....8144
Installing....8144
Removing....8145
BACK-UP ALARM SYSTEM....8146
Description....8146
Inspecting....8146
Adjusting Switch Position....8146
OPERATOR CAB....8147
Description....8147
Raising....8147
Lowering....8148
Cab Door Sensor....8149
REAR DOOR (TAILGATE)....8150
Opening And Closing....8150
Adjusting....8150
REAR GRILLE....8150
Removing....8150
Installing....8150
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....8151
Cleaning And Maintenance....8151
Filters....8151
Evaporator / Heater Coil....8151
Condenser....8151
Air Conditioning Lubrication....8151
Troubleshooting....8151
AIR CLEANER SERVICE....8152
Replacing Filter Elements....8152
FUEL SYSTEM....8154
Fuel Specifications....8154
Biodiesel Blend Fuel....8154
Filling The Fuel Tank....8155
Fuel Filter....8156
Removing Air From The Fuel System....8156
ENGINE LUBRICATION SYSTEM....8157
Checking And Adding Engine Oil....8157
Engine Oil Chart....8157
Removing And Replacing Oil And Filter....8157
ENGINE COOLING SYSTEM....8158
Cleaning....8158
Removing And Replacing Coolant....8159
Checking Level....8159
ELECTRICAL SYSTEM....8160
Description....8160
Fuse And Relay Location / Identification....8160
Battery Maintenance....8161
Using A Booster Battery (Jump Starting)....8162
Removing And Installing Battery....8163
HYDRAULIC / HYDROSTATIC SYSTEM....8164
Checking And Adding Fluid....8164
Hydraulic / Hydrostatic Fluid Chart....8164
Removing And Replacing Hydraulic Fluid....8165
Removing And Replacing Hydraulic / Hydrostatic Filter....8165
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....8166
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....8167
Removing And Replacing Hydraulic Charge Filter....8169
Breather Cap....8170
SPARK ARRESTER MUFFLER....8171
Cleaning Procedure....8171
TIRE MAINTENANCE....8172
Wheel Nuts....8172
Rotating....8172
Mounting....8172
FINAL DRIVE TRANSMISSION (CHAINCASE)....8173
Checking And Adding Oil....8173
Removing And Replacing Oil....8173
ALTERNATOR BELT....8174
Belt Adjustment....8174
Belt Replacement....8174
AIR CONDITIONING BELT....8175
Belt Adjustment....8175
Belt Replacement....8175
DRIVE BELT....8176
Belt Adjustment....8176
Belt Replacement....8178
LUBRICATING THE LOADER....8179
Lubrication Locations....8179
PIVOT PINS....8180
Inspection And Maintenance....8180
BOB-TACH (HAND LEVER)....8181
Inspection And Maintenance....8181
BOB-TACH (POWER)....8182
Inspection And Maintenance....8182
LOADER STORAGE AND RETURN TO SERVICE....8183
Storage....8183
Return To Service....8183
SYSTEM SETUP & ANALYSIS....8184
DIAGNOSTIC SERVICE CODES....8186
Viewing Service Codes....8186
Service Codes List....8187
CONTROL PANEL SETUP....8192
Right Panel Setup (Deluxe Instrumentation Panel)....8192
Attachment Control Information (Deluxe Instrumentation Panel)....8193
PASSWORD SETUP (KEYLESS START PANEL)....8194
Password Description....8194
Changing The Owner Password....8194
Password Lockout Feature....8194
PASSWORD SETUP (DELUXE INSTRUMENTATION pANEL)....8195
Password Description....8195
Changing The Owner Password....8195
Changing The User Passwords....8196
Password Lockout Feature....8196
MAINTENANCE CLOCK....8197
Description....8197
Setup....8197
Reset....8197
MACHINE SIGN TRANSLATIONS....8198
SERVICE SCHEDULE (6734534)....8200
DANGER (6702301)....8203
WARNING (6577754)....8203
DANGER (6702302)....8203
DANGER (6717343)....8203
IMPORTANT (6560573)....8204
WARNING (7160879)....8204
WARNING (6728539)....8205
WARNING (6718706)....8206
WARNING (6710358)....8206
DANGER (6809511)....8206
WARNING (6725370)....8207
WARNING (6737189)....8207
WARNING (6737248)....8207
LIFT ARM SUPPORT DEVICE (6706558)....8208
WARNING (7131518)....8209
WARNING (7131519)....8211
WARNING (6726423)....8212
WARNING (6704786)....8213
WARNING (6579528)....8213
SPECIFICATIONS....8214
(S160) LOADER SPECIFICATIONS....8216
Machine Dimensions....8216
Performance....8217
Engine....8217
Drive System....8217
Controls....8218
Hydraulic System....8218
Electrical....8219
Capacities....8219
Tires....8219
WARRANTY....8220
WARRANTY....8222
ALPHABETICAL INDEX....8224
6987009 (2-13) - S160 Skid-Steer Loader Operation & Maintenance Manual....8228
OPERATOR SAFETY WARNINGS....8230
CONTENTS....8232
FOREWORD....8234
BOBCAT COMPANY IS IS0 9001 CERTIFIED....8236
REGULAR MAINTENANCE ITEMS....8236
SERIAL NUMBER LOCATIONS....8237
Loader Serial Number....8237
Engine Serial Number....8237
DELIVERY REPORT....8237
LOADER IDENTIFICATION....8238
FEATURES, ACCESSORIES AND ATTACHMENTS....8239
Standard Items....8239
Options And Accessories....8239
Buckets Available....8240
Attachments....8240
High-Flow Attachments....8240
Special Applications Kit....8241
Special Applications Kit Inspection And Maintenance....8241
SAFETY & TRAINING RESOURCES....8242
SAFETY INSTRUCTIONS....8244
Before Operation....8244
Safe Operation Is The Operator’s Responsibility....8245
Safe Operation Needs A Qualified Operator....8245
Avoid Silica Dust....8246
FIRE PREVENTION....8246
Maintenance....8246
Operation....8246
Electrical....8246
Hydraulic System....8247
Fueling....8247
Starting....8247
Spark Arrester Exhaust System....8247
Welding And Grinding....8247
Fire Extinguishers....8247
PUBLICATIONS AND TRAINING RESOURCES....8248
MACHINE SIGNS (DECALS)....8249
OPERATING INSTRUCTIONS....8252
INSTRUMENT PANEL IDENTIFICATION....8256
Cab Light....8256
Left Panel....8257
Display Screen....8259
Standard Key Panel....8260
Keyless Start Panel....8260
Deluxe Instrumentation Panel....8261
Side Panel....8262
Front Panel....8262
CONTROL IDENTIFICATION....8263
Standard Controls....8263
Advanced Control System (ACS)....8264
Selectable Joystick Controls (SJC)....8265
SEAT BAR RESTRAINT SYSTEM....8266
Operation....8266
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....8267
Operation....8267
LIFT ARM BYPASS CONTROL....8268
Operation....8268
PARKING BRAKE....8268
Operation....8268
TRACTION LOCK OVERRIDE....8268
Operation....8268
EMERGENCY EXIT....8269
Rear Window....8269
Front Door....8269
BACK-UP ALARM SYSTEM....8270
Description....8270
Operation....8270
ENGINE SPEED CONTROL....8271
Operation....8271
DRIVING AND STEERING THE LOADER....8272
Available Control Configurations....8272
Operation (Standard And ACS)....8272
Operation (SJC) In ‘ISO’ Control Pattern....8273
Operation (SJC) In ‘H’ Control Pattern....8274
STOPPING THE LOADER....8274
Using The Control Levers Or Joysticks....8274
TWO-SPEED CONTROL....8275
Description....8275
Operation (Standard And ACS) (If Equipped)....8275
Operation (SJC) (If Equipped)....8275
SPEED MANAGEMENT....8276
Operation....8276
Changing The Factory Default Setting....8277
DRIVE RESPONSE....8278
Description....8278
Operation....8278
STEERING DRIFT COMPENSATION....8280
Description....8280
Operation....8280
LIFT AND TILT COMPENSATION....8282
Description....8282
Operation....8282
Operation (ACS)....8283
Operation (SJC)....8284
HYDRAULIC CONTROLS....8285
Description....8285
Standard Controls (Also ACS In FOOT Pedal Mode)....8285
Advanced Control System (ACS) In HAND Control Mode....8286
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....8286
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....8287
Hydraulic Bucket Positioning....8287
FRONT Auxiliary Hydraulics Operation....8288
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....8289
REAR Auxiliary Hydraulics Operation....8289
Secondary Front Auxiliary Hydraulics Operation....8290
High-Flow Hydraulics Operation....8291
Quick Couplers....8291
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....8292
ATTACHMENT CONTROL DEVICE (ACD)....8293
Description....8293
DAILY INSPECTION....8294
Daily Inspection And Maintenance....8295
PRE-STARTING PROCEDURE....8296
Entering The Loader....8296
Operation & Maintenance Manual And Operator’s Handbook Locations....8296
Seat Adjustment....8297
Seat Belt Adjustment....8298
Seat Bar....8298
STARTING THE ENGINE....8299
Standard Key Panel....8299
Keyless Start Panel....8301
Deluxe Instrumentation Panel....8303
Cold Temperature Starting....8305
Warming The Hydraulic / Hydrostatic System....8306
MONITORING THE DISPLAY PANELS....8307
Left Panel....8307
Warning And Shutdown....8307
STOPPING THE ENGINE AND LEAVING THE LOADER....8308
Procedure....8308
COUNTERWEIGHTS....8309
Description....8309
Effect On The Loader And Loader Operation....8309
When To Consider Using Counterweights....8309
When To Consider Removing Counterweights....8309
Accessories That Affect Machine Weight....8309
ATTACHMENTS....8310
Choosing The Correct Bucket....8310
Pallet Forks....8310
Installing And Removing The Attachment (Hand Lever Bob-Tach)....8311
Installing And Removing The Attachment (Power Bob-Tach)....8313
OPERATING PROCEDURE....8316
Inspect The Work Area....8316
Basic Operating Instructions....8316
Driving On Public Roads....8316
Operating With A Full Bucket....8317
Operating With An Empty Bucket....8317
Filling And Emptying The Bucket (Foot Pedals)....8318
Leveling The Ground Using Float (Foot Pedals)....8319
Digging And Filling A Hole (Foot Pedals)....8319
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....8320
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....8321
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....8322
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....8323
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....8324
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....8324
TOWING THE LOADER....8325
Procedure....8325
LIFTING THE LOADER....8326
Single-Point Lift....8326
Four-Point Lift....8326
TRANSPORTING THE LOADER ON A TRAILER....8327
Loading And Unloading....8327
Fastening....8327
PREVENTIVE MAINTENANCE....8328
MAINTENANCE SAFETY....8332
SERVICE SCHEDULE....8334
Chart....8334
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....8335
Inspecting The BICS™ (Engine STOPPED - Key ON)....8335
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....8335
Inspecting The Seat Bar Sensor (Engine RUNNING)....8335
Inspecting The Traction Lock (Engine RUNNING)....8335
Inspecting The Lift Arm Bypass Control....8335
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....8335
SEAT BAR RESTRAINT SYSTEM....8336
Description....8336
Inspecting....8336
Maintaining....8336
SEAT BELT....8337
Inspection And Maintenance....8337
LIFT ARM SUPPORT DEVICE....8338
Installing....8338
Removing....8339
BACK-UP ALARM SYSTEM....8340
Description....8340
Inspecting....8340
Adjusting Switch Position....8340
OPERATOR CAB....8341
Description....8341
Raising....8341
Lowering....8342
Cab Door Sensor....8343
REAR DOOR (TAILGATE)....8344
Opening And Closing....8344
Adjusting....8344
REAR GRILLE....8344
Removing....8344
Installing....8344
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....8345
Cleaning And Maintenance....8345
Filters....8345
Evaporator / Heater Coil....8345
Condenser....8345
Air Conditioning Lubrication....8345
Troubleshooting....8345
AIR CLEANER SERVICE....8346
Replacing Filter Elements....8346
FUEL SYSTEM....8348
Fuel Specifications....8348
Biodiesel Blend Fuel....8348
Filling The Fuel Tank....8349
Fuel Filter....8350
Removing Air From The Fuel System....8350
ENGINE LUBRICATION SYSTEM....8351
Checking And Adding Engine Oil....8351
Engine Oil Chart....8351
Removing And Replacing Oil And Filter....8351
ENGINE COOLING SYSTEM....8352
Cleaning....8352
Removing And Replacing Coolant....8353
Checking Level....8353
ELECTRICAL SYSTEM....8354
Description....8354
Fuse And Relay Location / Identification....8354
Battery Maintenance....8355
Using A Booster Battery (Jump Starting)....8356
Removing And Installing Battery....8357
HYDRAULIC / HYDROSTATIC SYSTEM....8358
Checking And Adding Fluid....8358
Hydraulic / Hydrostatic Fluid Chart....8358
Removing And Replacing Hydraulic Fluid....8359
Removing And Replacing Hydraulic / Hydrostatic Filter....8359
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....8360
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....8361
Removing And Replacing Hydraulic Charge Filter....8363
Breather Cap....8364
SPARK ARRESTER MUFFLER....8365
Cleaning Procedure....8365
TIRE MAINTENANCE....8366
Wheel Nuts....8366
Rotating....8366
Mounting....8366
FINAL DRIVE TRANSMISSION (CHAINCASE)....8367
Checking And Adding Oil....8367
Removing And Replacing Oil....8367
ALTERNATOR BELT....8368
Belt Adjustment....8368
Belt Replacement....8368
AIR CONDITIONING BELT....8369
Belt Adjustment....8369
Belt Replacement....8369
DRIVE BELT....8370
Belt Adjustment....8370
Belt Replacement....8372
LUBRICATING THE LOADER....8373
Lubrication Locations....8373
PIVOT PINS....8374
Inspection And Maintenance....8374
BOB-TACH (HAND LEVER)....8375
Inspection And Maintenance....8375
BOB-TACH (POWER)....8376
Inspection And Maintenance....8376
LOADER STORAGE AND RETURN TO SERVICE....8377
Storage....8377
Return To Service....8377
SYSTEM SETUP & ANALYSIS....8378
DIAGNOSTIC SERVICE CODES....8380
Viewing Service Codes....8380
Service Codes List....8381
CONTROL PANEL SETUP....8386
Right Panel Setup (Deluxe Instrumentation Panel)....8386
Attachment Control Information (Deluxe Instrumentation Panel)....8387
PASSWORD SETUP (KEYLESS START PANEL)....8388
Password Description....8388
Changing The Owner Password....8388
Password Lockout Feature....8388
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....8389
Password Description....8389
Changing The Owner Password....8389
Changing The User Passwords....8390
Password Lockout Feature....8390
MAINTENANCE CLOCK....8391
Description....8391
Setup....8391
Reset....8391
MACHINE SIGN TRANSLATIONS....8392
MACHINE SIGN TRANSLATIONS....8394
Service Schedule (6734534)....8394
Danger (6702301)....8397
Warning (6577754)....8397
Danger (6702302)....8397
Danger (6717343)....8397
IMPORTANT (6560573)....8398
Warning (7160879)....8398
Warning (6728539)....8399
Warning (6718706)....8400
Warning (6710358)....8400
Danger (6809511)....8400
Warning (6725370)....8401
Warning (6737189)....8401
Warning (6737248)....8401
Lift Arm Support Device (6706558)....8402
Warning (7131518)....8403
Warning (7131519)....8405
Warning (6579528)....8406
Warning (7168019)....8407
Warning (7142141)....8408
SPECIFICATIONS....8410
(S160) LOADER SPECIFICATIONS....8412
Machine Dimensions....8412
Performance....8413
Engine....8413
Drive System....8413
Controls....8414
Hydraulic System....8414
Electrical....8415
Capacities....8415
Tires....8415
WARRANTY....8416
WARRANTY....8418
ALPHABETICAL INDEX....8420
6987033 (11-10) - S150 Skid-Steer Loader Service Manual....8422
MAINTENANCE SAFETY....8424
ALPHABETICAL INDEX....8426
CONTENTS....8428
FOREWORD....8429
SAFETY INSTRUCTIONS....8432
FIRE PREVENTION....8434
Maintenance....8434
Operation....8434
Electrical....8434
Hydraulic System....8434
Fueling....8434
Starting....8434
Spark Arrestor Exhaust System....8434
Welding And Grinding....8435
Fire Extinguishers....8435
SERIAL NUMBER LOCATIONS....8436
Loader Serial Number....8436
Engine Serial Number....8436
DELIVERY REPORT....8437
BOBCAT LOADER IDENTIFICATION....8438
SAFETY & MAINTENANCE....8440
LIFTING AND BLOCKING THE LOADER....8444
Procedure....8444
LIFT ARM SUPPORT DEVICE....8446
Installing....8446
Removing....8447
OPERATOR CAB....8448
Description....8448
Raising....8448
Lowering....8449
Cab Door Sensor....8450
Special Applications Kit....8450
Special Applications Kit Inspection And Maintenance....8450
TRANSPORTING THE LOADER ON A TRAILER....8452
Loading And Unloading....8452
Fastening....8452
TOWING THE LOADER....8454
Procedure....8454
REMOTE START TOOL KIT -MEL1563....8456
Remote Start Tool - MEL1563....8456
Service Tool Harness Control - MEL1565....8457
Service Tool Harness Communicator - MEL1566....8458
Remote Start Procedure....8459
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....8462
Description....8462
Remote Start Tool (Service Tool) - 7003030....8463
Loader Service Tool Harness - 6689747....8464
Computer Service Tool Harness - 6689746....8465
Remote Start Procedure....8466
SERVICE SCHEDULE....8470
Chart....8470
AIR CLEANER SERVICE....8472
Replacing Filter Elements....8472
ENGINE COOLING SYSTEM....8474
Cleaning....8474
Checking Level....8475
Removing And Replacing Coolant....8475
FUEL SYSTEM....8476
Fuel Specifications....8476
Biodiesel Blend Fuel....8476
Filling The Fuel Tank....8477
Fuel Filter....8478
Removing Air From The Fuel System....8478
ENGINE LUBRICATION SYSTEM....8480
Checking And Adding Engine Oil....8480
Engine Oil Chart....8480
Removing And Replacing Oil And Filter....8481
HYDRAULIC / HYDROSTATIC SYSTEM....8482
Checking And Adding Fluid....8482
Hydraulic / Hydrostatic Fluid Chart....8482
Removing And Replacing Hydraulic Fluid....8483
Removing And Replacing Hydraulic / Hydrostatic Filter....8483
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....8484
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....8485
Removing And Replacing Hydraulic Charge Filter....8487
Breather Cap....8488
FINAL DRIVE TRANSMISSION (CHAINCASE)....8490
Checking And Adding Oil....8490
Removing And Replacing Oil....8490
BOB-TACH (HAND LEVER)....8492
Inspection And Maintenance....8492
BOB-TACH (POWER)....8494
Inspection And Maintenance....8494
LUBRICATING THE LOADER....8496
Lubrication Locations....8496
TIRE MAINTENANCE....8498
Wheel Nuts....8498
Rotating....8498
Mounting....8498
SPARK ARRESTOR MUFFLER....8500
Cleaning Procedure....8500
PIVOT PINS....8502
Inspection And Maintenance....8502
LOADER STORAGE AND RETURN TO SERVICE....8504
Storage....8504
Return To Service....8504
STOPPING THE ENGINE AND LEAVING THE LOADER....8506
Procedure....8506
EMERGENCY EXIT....8508
Rear Window....8508
Front Door....8508
SEAT BELT....8510
Inspection And Maintenance....8510
HYDRAULIC SYSTEM....8512
HYDRAULIC / HYDROSTATIC SCHEMATICS....8516
HYDRAULIC SYSTEM INFORMATION....8524
Glossary Of Hydraulic / Hydrostatic Symbols....8524
Troubleshooting....8528
CYLINDER (LIFT)....8530
Testing....8530
Removal And Installation....8531
Parts Identification....8532
Disassembly And Assembly....8533
CYLINDER (TILT)....8536
Testing....8536
Removal And Installation....8537
Rod End Pivot Pin Bushing And Seal Removal And Installation....8539
Base End Pivot Pin Removal And Installation....8539
Parts Identification....8540
Disassembly And Assembly....8541
CYLINDER (BOB-TACH)....8544
Testing....8544
Removal And Installation....8545
Parts Identification....8546
Disassembly And Assembly....8547
MAIN RELIEF VALVE....8550
Description....8550
Testing....8550
Adjusting....8552
Removal And Installation....8553
HYDRAULIC CONTROL VALVE (STANDARD)....8554
Description....8554
Removal And Installation....8555
Identification Chart....8560
Mount Bracket Removal And Installation....8561
Lift Load Check Valve Removal And Installation....8561
Load Check Valve Removal And Installation (Tilt And Auxiliary)....8562
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8563
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8564
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8564
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8565
Port Relief Valve Removal And Installation....8565
Plug Removal And Installation....8566
Rubber Boot Removal And Installation....8567
End Cap / Spool Lock Block Removal And Installation....8568
Lift Spool And Detent Removal And Installation....8569
Tilt Spool Removal And Installation....8579
Auxiliary Spool Removal And Installation....8581
Auxiliary Solenoid Removal And Installation (S/N A3L134999 & Below)....8583
Auxiliary Solenoid Removal And Installation (S/N A3L135001 & Above)....8584
Solenoid Removal And Installation....8585
Lock Valve Removal And Installation....8586
Lift Arm Bypass Orifice Removal And Installation....8588
Main Relief Valve Removal And Installation....8588
Check Valve Removal And Installation....8589
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....8590
Description....8590
Removal And Installation....8591
Actuator Removal And Installation (Out of Loader)....8595
Identification Chart....8598
Mount Bracket Removal And Installation....8599
Lift Load Check Valve Removal And Installation....8599
Load Check Valve Removal And Installation (Tilt And Auxiliary)....8600
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8601
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8602
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8602
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8603
Port Relief Valve Removal And Installation....8603
Plug Removal And Installation....8604
End Cap Block Removal And Installation....8605
Lift Spool And Detent Removal And Installation....8606
Tilt Spool Removal And Installation....8611
Auxiliary Spool Removal And Installation....8613
Auxiliary Solenoid Removal And Installation (S/N A3L134999 & Below)....8615
Auxiliary Solenoid Removal And Installation (S/N A3L135001 & Above)....8616
Solenoid Removal And Installation....8617
Lock Valve Removal And Installation....8618
Lift Arm Bypass Orifice Removal And Installation....8619
Main Relief Valve Removal And Installation....8620
Check Valve Removal And Installation....8621
LIFT ARM BYPASS CONTROL VALVE....8622
Description....8622
Testing....8622
Removal And Installation....8622
Disassembly And Assembly....8623
HYDRAULIC PUMP (STANDARD)....8624
Description....8624
Pump Test at Quick Couplers....8624
Direct Pump Test (Standard Section)....8625
Direct Pump Test (Charge Section)....8627
Removal And Installation....8629
Hydraulic Pump Startup....8631
Parts Identification....8632
Disassembly And Assembly....8633
HYDRAULIC PUMP (SJC)....8642
Description....8642
Pump Test At Quick Couplers....8642
Direct Pump Test (Standard Section)....8643
Direct Pump Test (Charge Section)....8645
Removal And Installation....8647
Hydraulic Pump Startup....8649
Parts Identification....8650
Disassembly And Assembly....8651
HYDRAULIC / HYDROSTATIC FILTERS....8660
Description....8660
Housing Removal And Installation....8660
Charge Filter Housing Removal And Installation....8662
HYDRAULIC FLUID RESERVOIR....8664
Description....8664
Removal And Installation....8664
Hydraulic Fluid Screen....8667
OIL COOLER....8668
Description....8668
Removal And Installation....8668
BUCKET POSITION VALVE....8670
Description....8670
Solenoid Removal And Installation....8670
Solenoid Testing....8671
Removal And Installation....8672
Disassembly And Assembly....8673
REAR AUXILIARY DIVERTER VALVE....8676
Description....8676
Solenoid Testing....8676
Removal And Installation....8677
Disassembly And Assembly....8680
BOB-TACH (POWER) BLOCK....8686
Description....8686
Removal And Installation....8686
Disassembly And Assembly....8688
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....8692
Description....8692
Removal And Installation....8692
Disassembly And Assembly....8692
HYDROSTATIC SYSTEM....8694
HYDROSTATIC SYSTEM INFORMATION....8696
Troubleshooting....8696
Description....8697
HYDROSTATIC DRIVE MOTOR....8698
Description....8698
Removal And Installation....8698
Parts Identification....8701
Disassembly And Assembly....8702
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....8708
Description....8708
Removal And Installation (Left Side)....8709
Removal And Installation (Right Side)....8712
Parts Identification....8715
Disassembly....8716
Assembly....8726
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....8738
Description....8738
Shaft Seal Removal And Installation....8739
Removal And Installation....8741
Parts Identification....8743
Disassembly And Assembly....8744
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....8750
Description....8750
Shaft Seal Removal And Installation....8751
Removal And Installation....8753
Parts Identification....8755
Disassembly And Assembly....8756
CHARGE PRESSURE....8762
Description....8762
Testing (S/N A3L129999 & Below)....8763
Sender Removal And Installation (S/N A3L129999 & Below)....8764
Testing (S/N A3L130001 & Above)....8765
Sender Removal And Installation (S/N A3L130001 & Above)....8766
Adjusting....8767
HYDROSTATIC PUMP....8770
Description....8770
Replenishing / High Pressure Relief Valve Removal And Installation....8770
Removal And Installation....8771
Hydrostatic Pump Startup....8772
Parts Identification (Left Half)....8773
Parts Identification (Right Half)....8774
Disassembly....8775
Assembly....8781
HYDROSTATIC PUMP (SJC)....8788
Description....8788
Hydraulic Controller Removal And Installation....8789
Removal And Installation....8791
Hydrostatic Pump Startup....8793
Parts Identification....8794
High Pressure Relief And Bypass Valve....8795
Charge Relief Valve....8796
Disassembly and Assembly....8797
Mechanical Neutral Adjustment....8813
Hydraulic Controller Neutral Adjustment....8816
DRIVE BELT....8820
Description....8820
Shield Removal And Installation....8820
Adjusting....8821
Belt Removal And Installation....8822
Tensioner Pulley Removal And Installation....8823
Tensioner Pulley Parts Identification....8824
Tensioner Pulley Disassembly....8825
Tensioner Pulley Assembly....8826
TWO-SPEED VALVE....8828
Description....8828
Valve Removal And Installation....8829
Valve Disassembly And Assembly....8831
CASE DRAIN FILTER....8834
Description....8834
Disassembly And Assembly....8834
DRIVE SYSTEM....8836
BRAKE (SINGLE SPEED)....8838
Description....8838
Disc Removal And Installation....8838
BRAKE (TWO-SPEED)....8840
Description....8840
Disc Removal And Installation....8840
Disc Disassembly And Assembly....8841
DRIVE COMPONENTS....8842
Description....8842
Axle Seal Removal And Installation....8843
Axle, Sprocket And Bearings Removal And Installation....8845
Chain Removal And Installation....8850
CHAINCASE....8852
Description....8852
Front Cover Removal And Installation....8852
Center Cover Removal And Installation....8853
Rear Cover Removal And Installation....8854
MAINFRAME....8856
SEAT BAR....8860
Description....8860
Removal And Installation....8860
Disassembly And Assembly....8861
Compression Spring Disassembly And Assembly....8862
OPERATOR CAB....8864
Gas Cylinder Removal And Installation....8864
Gas Cylinder Bracket Disassembly And Assembly....8866
Removal And Installation....8867
OPERATOR SEAT....8870
Removal And Installation....8870
Seat Belt Removal And Installation....8870
OPERATOR SEAT (SUSPENSION)....8872
Removal And Installation....8872
Slide Rail Removal And Installation....8873
Seat Belt Removal And Installation....8873
Lower Cushion Removal And Installation....8873
Back Cushion Removal And Installation....8875
Shock Removal And Installation....8875
3-Point Seat Belt Removal And Installation....8876
BOB-TACH (HAND LEVER)....8878
Description....8878
Removal And Installation....8878
Lever And Wedge Disassembly And Assembly....8879
Pivot Pin Bushing And Seal Removal And Installation....8881
BOB-TACH (POWER)....8882
Description....8882
Removal And Installation....8882
Lever And Wedge Disassembly And Assembly....8884
Pivot Pin Bushing And Seal Removal And Installation....8885
LIFT ARMS....8886
Removal And Installation....8886
REAR GRILLE....8890
Removal And Installation....8890
REAR DOOR (TAILGATE)....8892
Removal And Installation....8892
Striker Removal And Installation....8893
Striker Disassembly And Assembly....8893
Striker (Adjusting)....8894
Latch Removal And Installation....8895
FUEL TANK....8896
Removal And Installation....8896
Fuel Level Sender Removal And Installation....8897
Fuel Fill Screen Removal And Installation....8898
CONTROL PEDALS AND LINKAGES....8900
Description....8900
Pedal Removal And Installation....8900
Linkage Removal And Installation....8901
Pedal (Adjusting)....8903
CONTROL PEDALS (ACS)....8904
Description....8904
Foot Sensor Removal And Installation....8904
Foot Pedal Removal And Installation....8905
Foot Pedal Linkage Disassembly And Assembly....8906
CONTROL PANEL....8908
Description....8908
Removal And Installation....8909
Shock Removal And Installation....8912
Shaft Removal And Installation....8912
Shaft Disassembly And Assembly....8913
Linkage Removal And Installation....8914
Pintle Arm Disassembly And Assembly....8918
Linkage Neutral (Adjusting)....8920
Linkage Travel (Adjusting)....8924
CONTROL PANEL (SJC)....8928
Description....8928
Removal And Installation....8928
CONTROL HANDLE / LEVER....8930
Description....8930
Lever Removal And Installation....8930
Boot Removal And Installation....8931
CONTROL HANDLE / LEVER (ACS)....8932
Description....8932
Handle Sensor Removal And Installation....8932
Handle Removal And Installation....8935
Handle Disassembly And Assembly....8936
Lever Removal And Installation....8936
Boot Removal And Installation....8938
CONTROL HANDLE / LEVER (SJC)....8940
Description....8940
Joystick Testing....8940
Joystick Removal And Installation....8941
Joystick Mount Removal And Installation....8942
ACCESS PANEL (INSIDE)....8944
Removal And Installation (Left)....8944
Removal And Installation (Right)....8944
ACCESS PANEL (INSIDE) (SJC)....8946
Removal And Installation (Left)....8946
Removal And Installation (Right)....8947
WINDOW (REAR)....8950
Removal....8950
Installation (Split Molding)....8950
Installation (Continuous Molding)....8952
WINDOW (TOP)....8954
Removal And Installation....8954
WINDOW (SIDE)....8956
Removal And Installation....8956
WINDOW (CAB DOOR)....8958
Removal (Standard Window)....8958
Installation (Standard Window)....8959
Removal And Installation (Special Applications Window)....8961
CAB DOOR....8962
Description....8962
Removal And Installation....8962
Aligning....8963
Adjusting....8964
Checking Operation....8964
ELECTRICAL SYSTEM & ANALYSIS....8966
ELECTRICAL SCHEMATICS....8972
ELECTRICAL SYSTEM INFORMATION....8978
Glossary Of Electrical Symbols....8978
Standard Cab Harness Connectors....8981
Deluxe Cab Harness Connectors....8982
Mainframe Harness Connectors....8983
Description....8984
Troubleshooting....8985
Fuse And Relay Location / Identification....8986
Solenoid Testing....8987
BATTERY....8988
Removal And Installation....8988
Servicing....8989
Using A Booster Battery (Jump Starting)....8990
ALTERNATOR....8992
Belt Adjustment....8992
Belt Replacement....8992
Charging System Inspection....8993
Alternator Voltage Testing....8994
Low Voltage Testing....8994
High Voltage Testing....8995
Removal And Installation....8996
Parts Identification....8997
STARTER....8998
Testing....8998
Removal And Installation....8999
Parts Identification....9000
INSTRUMENT PANELS....9002
Left Panel....9002
Standard Key Panel....9004
Keyless Start Panel....9004
Deluxe Instrumentation Panel....9005
Side Panel....9006
Front Panel....9006
Front Panel Removal And Installation....9007
Removal And Installation (Left And Right)....9008
Key Switch Removal And Installation....9009
Alarm Removal And Installation....9010
LIGHTS....9012
Front Removal And Installation....9012
Rear Removal And Installation....9013
Cab Light Removal And Installation....9013
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....9014
Description....9014
Connector Identification....9015
Removal And Installation....9021
BOBCAT CONTROLLER (ACS)....9024
Description....9024
Connector And Wire Identification....9025
Removal And Installation....9026
BOBCAT CONTROLLER (SJC) (DRIVE)....9028
Description....9028
Connector Identification....9029
Removal And Installation....9031
SPEED SENSORS (SJC)....9032
Description....9032
Testing....9032
Removal And Installation....9034
DIAGNOSTIC SERVICE CODES....9036
Viewing Service Codes....9036
Service Codes List....9037
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....9042
Description....9042
Inspecting The BICS (Engine STOPPED - Key ON)....9043
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....9043
Inspecting The Seat Bar Sensor (Engine RUNNING)....9043
Inspecting The Traction Lock (Engine RUNNING)....9043
Inspecting The Lift Arm Bypass Control....9043
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....9043
Troubleshooting....9044
SEAT BAR SENSOR....9046
Description....9046
Troubleshooting....9046
Testing....9047
Removal And Installation....9048
Bobcat Interlock Control System (BICS) Circuit Test....9050
TRACTION LOCK....9052
Description....9052
Troubleshooting....9052
Removal And Installation....9053
Inspecting....9057
CONTROL SYSTEM (ACS)....9058
Description....9058
Troubleshooting....9059
Handle Sensor Connector Disassembly And Assembly....9060
Switch Handle Removal....9061
Switch Handle Installation....9063
Actuator Connector Disassembly And Assembly....9066
Handle Lock Solenoid Removal And Installation....9067
Handle Lock Solenoid Disassembly And Assembly....9067
Foot Sensor Disassembly And Assembly....9068
Foot Lock Solenoid Removal And Installation....9069
ELECTRICAL / HYDRAULIC CONTROLS....9070
Identification Chart....9070
Description....9071
Identification Chart ACD Group 0....9072
Identification Chart ACD Group 1....9073
Identification Chart ACD Group 2....9074
Identification Chart ACD Group 3....9075
ELECTRICAL / HYDRAULIC CONTROLS (ACS)....9076
Identification Chart....9076
Description....9077
Identification Chart ACD Group 0....9078
Identification Chart ACD Group 1....9079
Identification Chart ACD Group 2....9080
Identification Chart ACD Group 3....9081
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....9082
Identification Chart....9082
Description....9083
Identification Chart ACD Group 0....9084
Identification Chart ACD Group 1....9085
Identification Chart ACD Group 2....9086
Identification Chart ACD Group 3....9087
SERVICE PC (LAPTOP COMPUTER)....9088
Connecting Remote Start Tool....9088
Connecting Remote Start Tool (Service Tool)....9088
CALIBRATION....9090
Description....9090
Actuator Testing....9090
Lift And Tilt Calibration (SJC)....9093
Hydrostatic Pump Calibration (SJC)....9095
Lift And Tilt Calibration (ACS)....9100
STEERING DRIFT COMPENSATION....9102
Description....9102
Operation....9102
FLYWHEEL RPM SENSOR....9104
Description....9104
Adjusting....9104
CONTROL PANEL SETUP....9106
Right Panel Setup (Deluxe Instrumentation Panel)....9106
Attachment Control Information (Deluxe Instrumentation Panel)....9107
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....9108
Password Description....9108
Changing The Owner Password....9108
Changing The User Passwords....9109
Password Lockout Feature....9109
PASSWORD SETUP (KEYLESS START PANEL)....9110
Password Description....9110
Changing The Owner Password....9110
Password Lockout Feature....9110
MAINTENANCE CLOCK....9112
Description....9112
Setup....9113
Reset....9116
BACK-UP ALARM SYSTEM....9118
Description....9118
Inspecting....9118
Adjusting Switch Position....9119
Troubleshooting (Standard And ACS)....9120
Troubleshooting (Joystick)....9121
Alarm Removal And Installation....9122
Switch Removal And Installation....9122
ENGINE SERVICE....9124
ENGINE INFORMATION....9128
Description....9128
Specifications....9129
Torque Values....9133
Troubleshooting....9134
Engine Removal And Installation....9136
Engine Mount Replacement....9142
Compression - Checking....9143
ENGINE SPEED CONTROL....9144
Removal And Installation....9144
ENGINE SPEED CONTROL (SJC)....9146
Removal And Installation....9146
Disassembly And Assembly....9148
MUFFLER....9150
Removal And Installation....9150
AIR CLEANER....9152
Housing Removal And Installation....9152
ENGINE COOLING SYSTEM....9154
Radiator Removal And Installation....9154
Hydraulic Fan Description (S/N A3L129999 & Below)....9156
Hydraulic Fan Disassembly And Assembly (S/N A3L129999 & Below)....9156
Blower Housing Removal And Installation (S/N A3L129999 & Below)....9157
Fan Removal And Installation (S/N A3L129999 & Below)....9159
Hydraulic Fan Motor Removal And Installation (S/N A3L129999 & Below)....9159
Hydraulic Fan Description (S/N A3L130001 & Above)....9160
Hydraulic Fan Disassembly And Assembly (S/N A3L130001 & Above)....9160
Blower Housing Removal And Installation (S/N A3L130001 & Above)....9162
Fan Removal And Installation (S/N A3L130001 & Above)....9164
Hydraulic Fan Motor Removal And Installation (S/N A3L130001 & Above)....9164
Water Pump Removal And Installation....9165
Water Pump Disassembly And Assembly....9165
Thermostat Housing Removal And Installation....9166
Thermostat - Checking....9167
LUBRICATION SYSTEM....9168
Oil Pan Removal And Installation....9168
Oil Pump Removal And Installation....9168
Oil Pump Inspection....9169
Engine Oil Pressure-Testing....9170
FUEL SYSTEM....9172
Fuel Shutoff Solenoid - Checking....9172
Fuel Shutoff Solenoid Removal And Installation....9172
Fuel Injection Pump - Checking....9173
Fuel Injection Pump Removal And Installation....9174
Governor Disassembly And Assembly....9178
Fuel Camshaft Removal And Installation....9179
Fuel Injection Pump - Timing....9179
Fuel Injector Removal And Installation....9181
Fuel Injector Nozzle Pressure - Checking....9182
Nozzle Spray Condition....9183
Valve Seat Tightness....9183
CYLINDER HEAD....9184
Glow Plugs - Testing....9184
Glow Plugs Removal And Installation....9184
Valve Clearance Adjustment....9185
Valve Timing - Checking....9186
Cylinder Head Removal And Installation....9187
Cylinder Head Disassembly And Assembly....9190
Cylinder Head - Servicing....9190
Cylinder Head Top Clearance....9191
Valve Guide - Checking....9191
Valve Guide Removal And Installation....9192
Reconditioning The Valve And Valve Seat....9192
Valve Spring....9194
Valve Tappets....9195
Rocker Arm And Shaft - Checking....9195
Push Rod Alignment - Checking....9196
CRANKSHAFT AND PISTONS....9198
Piston And Connecting Rod Removal And Installation....9198
Piston And Connecting Rod - Servicing....9199
Cylinder Bore - Checking....9202
Connecting Rod Alignment....9202
Crankshaft Gear Removal And Installation....9203
Crankshaft And Bearings Removal And Installation....9203
Crankshaft And Bearings - Servicing....9205
CAMSHAFT AND TIMING GEARS....9210
Timing Gearcase Cover Removal And Installation....9210
Timing Gears Backlash - Checking....9212
Idler Gear And Camshaft Removal And Installation....9213
Camshaft - Servicing....9214
Idler Gear And Shaft Servicing....9215
FLYWHEEL AND HOUSING....9216
Flywheel Removal And Installation....9216
Ring Gear Removal And Installation....9216
Housing Removal And Installation....9217
HEATER....9220
HEATER SYSTEM....9222
Description....9222
REGULAR MAINTENANCE....9224
Filters....9224
Heater Coil....9224
TROUBLESHOOTING....9226
Blower Motor Does Not Operate....9226
Blower Motor Operators Normally, But Air Flow Is Insufficient....9226
Electrical System....9227
Engine Coolant Bypassing The Heater Valve....9231
Heater Valve Not Opening Or Closing....9232
HEATER UNIT....9234
Removal And Installation....9234
HEATER COIL....9236
Removal And Installation....9236
BLOWER FAN....9238
Removal And Installation....9238
Disassembly And Assembly....9239
Connector Identification....9241
HEATER VALVE....9242
Removal and Installation....9242
Disassembly And Assembly....9243
SPECIFICATIONS....9244
(S150) LOADER SPECIFICATIONS....9246
Dimensions....9246
Performance....9247
Controls....9247
Engine....9247
Hydraulic System....9248
Electrical....9248
Drive System....9249
Capacities....9249
Tires....9249
TORQUE SPECIFICATIONS FOR BOLTS....9250
Torque For General SAE Bolts....9250
Torque For General Metric Bolts....9251
HYDRAULIC CONNECTION SPECIFICATIONS....9252
O-ring Face Seal Connection....9252
Straight Thread O-ring Fitting....9253
Tubelines And Hoses....9253
Flare Fitting....9254
Port Seal Fitting....9255
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....9256
Specifications....9256
CONVERSIONS....9258
Decimal And Millimeter Equivalent Chart....9258
U.S. To Metric Conversion Chart....9258
SERVICE MANUAL REVISION....9260
Revision No: S150 - 1....9260
Revision No: S150 - 2....9262
Revision No: S150 - 3....9264
Revision No: S150 - 4....9266
Revision No: S150 - 5....9268
Revision No: S150 - 6....9270
Revision No: S150 - 7....9272
Revision No: S150 - 8....9274
Revision No: S150 - 9....9276
Revision No: S150 - 10....9278
Revision No: S150 - 11....9280
6987033 (12-12) - S150 Skid-Steer Loader Service Manual....9282
MAINTENANCE SAFETY....9284
CONTENTS....9286
FOREWORD....9288
FOREWORD....9290
SAFETY INSTRUCTIONS....9293
FIRE PREVENTION....9295
Maintenance....9295
Operation....9295
Electrical....9295
Hydraulic System....9295
Fueling....9295
Starting....9295
Spark Arrester Exhaust System....9295
Welding And Grinding....9296
Fire Extinguishers....9296
SERIAL NUMBER LOCATIONS....9297
Loader Serial Number....9297
Engine Serial Number....9297
DELIVERY REPORT....9298
LOADER IDENTIFICATION....9299
SAFETY AND MAINTENANCE....9300
LIFTING AND BLOCKING THE LOADER....9304
Procedure....9304
LIFT ARM SUPPORT DEVICE....9306
Installing....9306
Removing....9307
OPERATOR CAB....9308
Description....9308
Raising....9308
Lowering....9309
Cab Door Sensor....9310
Special Applications Kit....9311
Special Applications Kit Inspection And Maintenance....9311
TRANSPORTING THE LOADER ON A TRAILER....9312
Loading And Unloading....9312
Fastening....9312
TOWING THE LOADER....9314
Procedure....9314
REMOTE START TOOL KIT -MEL1563....9316
Remote Start Tool - MEL1563....9316
Service Tool Harness Control - MEL1565....9317
Service Tool Harness Communicator - MEL1566....9318
Remote Start Procedure....9319
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....9322
Description....9322
Remote Start Tool (Service Tool) - 7022042....9323
Loader Service Tool Harness - 6689747....9324
Computer Service Tool Harness - 6689746....9325
Remote Start Procedure....9326
SERVICE SCHEDULE....9330
Chart....9330
AIR CLEANER SERVICE....9332
Replacing Filter Elements....9332
ENGINE COOLING SYSTEM....9334
Cleaning....9334
Removing And Replacing Coolant....9335
Checking Level....9335
FUEL SYSTEM....9336
Fuel Specifications....9336
Biodiesel Blend Fuel....9336
Filling The Fuel Tank....9337
Fuel Filter....9338
Removing Air From The Fuel System....9338
ENGINE LUBRICATION SYSTEM....9340
Checking And Adding Engine Oil....9340
Engine Oil Chart....9340
Removing And Replacing Oil And Filter....9341
HYDRAULIC / HYDROSTATIC SYSTEM....9342
Checking And Adding Fluid....9342
Hydraulic / Hydrostatic Fluid Chart....9342
Removing And Replacing Hydraulic Fluid....9343
Removing And Replacing Hydraulic / Hydrostatic Filter....9343
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....9344
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....9345
Removing And Replacing Hydraulic Charge Filter....9347
Breather Cap....9348
FINAL DRIVE TRANSMISSION (CHAINCASE)....9350
Checking And Adding Oil....9350
Removing And Replacing Oil....9350
BOB-TACH (HAND LEVER)....9352
Inspection And Maintenance....9352
BOB-TACH (POWER)....9354
Inspection And Maintenance....9354
LUBRICATING THE LOADER....9356
Lubrication Locations....9356
TIRE MAINTENANCE....9358
Wheel Nuts....9358
Rotating....9358
Mounting....9358
SPARK ARRESTER MUFFLER....9360
Cleaning Procedure....9360
PIVOT PINS....9362
Inspection And Maintenance....9362
LOADER STORAGE AND RETURN TO SERVICE....9364
Storage....9364
Return To Service....9364
STOPPING THE ENGINE AND LEAVING THE LOADER....9366
Procedure....9366
EMERGENCY EXIT....9368
Rear Window....9368
Front Door....9368
SEAT BELT....9370
Inspection And Maintenance....9370
HYDRAULIC SYSTEM....9372
HYDRAULIC / HYDROSTATIC SCHEMATICS....9376
HYDRAULIC SYSTEM INFORMATION....9384
Glossary Of Hydraulic / Hydrostatic Symbols....9384
Troubleshooting....9388
CYLINDER (LIFT)....9390
Testing....9390
Removal And Installation....9391
Parts Identification....9392
Disassembly And Assembly....9393
CYLINDER (TILT)....9396
Testing....9396
Removal And Installation....9397
Rod End Pivot Pin Bushing And Seal Removal And Installation....9399
Base End Pivot Pin Removal And Installation....9399
Parts Identification....9400
Disassembly And Assembly....9401
CYLINDER (BOB-TACH)....9404
Testing....9404
Removal And Installation....9405
Parts Identification....9406
Disassembly And Assembly....9407
MAIN RELIEF VALVE....9410
Description....9410
Testing....9410
Adjusting....9412
Removal And Installation....9413
HYDRAULIC CONTROL VALVE (STANDARD)....9414
Description....9414
Removal And Installation....9415
Identification Chart....9420
Mount Bracket Removal And Installation....9421
Lift Load Check Valve Removal And Installation....9421
Load Check Valve Removal And Installation (Tilt And Auxiliary)....9422
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....9423
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....9424
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....9424
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....9425
Port Relief Valve Removal And Installation....9425
Plug Removal And Installation....9426
Rubber Boot Removal And Installation....9427
End Cap / Spool Lock Block Removal And Installation....9428
Lift Spool And Detent Removal And Installation....9429
Tilt Spool Removal And Installation....9439
Auxiliary Spool Removal And Installation....9441
Auxiliary Solenoid Removal And Installation (S/N A3L134999 & Below)....9443
Auxiliary Solenoid Removal And Installation (S/N A3L135001 & Above)....9444
Solenoid Removal And Installation....9445
Lock Valve Removal And Installation....9446
Lift Arm Bypass Orifice Removal And Installation....9448
Main Relief Valve Removal And Installation....9448
Check Valve Removal And Installation....9449
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....9450
Description....9450
Removal And Installation....9451
Actuator Removal And Installation (Out of Loader)....9455
Identification Chart....9458
Mount Bracket Removal And Installation....9459
Lift Load Check Valve Removal And Installation....9459
Load Check Valve Removal And Installation (Tilt And Auxiliary)....9460
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....9461
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....9462
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....9462
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....9463
Port Relief Valve Removal And Installation....9463
Plug Removal And Installation....9464
End Cap Block Removal And Installation....9465
Lift Spool And Detent Removal And Installation....9466
Tilt Spool Removal And Installation....9471
Auxiliary Spool Removal And Installation....9473
Auxiliary Solenoid Removal And Installation (S/N A3L134999 & Below)....9475
Auxiliary Solenoid Removal And Installation (S/N A3L135001 & Above)....9476
Solenoid Removal And Installation....9477
Lock Valve Removal And Installation....9478
Lift Arm Bypass Orifice Removal And Installation....9479
Main Relief Valve Removal And Installation....9480
Check Valve Removal And Installation....9481
LIFT ARM BYPASS CONTROL VALVE....9482
Description....9482
Testing....9482
Removal And Installation....9482
Disassembly And Assembly....9483
HYDRAULIC PUMP (STANDARD)....9484
Description....9484
Pump Test at Quick Couplers....9484
Direct Pump Test (Standard Section)....9485
Direct Pump Test (Charge Section)....9487
Removal And Installation....9489
Hydraulic Pump Startup....9491
Parts Identification....9492
Disassembly And Assembly....9493
HYDRAULIC PUMP (SJC)....9502
Description....9502
Pump Test At Quick Couplers....9502
Direct Pump Test (Standard Section)....9503
Direct Pump Test (Charge Section)....9505
Removal And Installation....9507
Hydraulic Pump Startup....9509
Parts Identification....9510
Disassembly And Assembly....9511
HYDRAULIC / HYDROSTATIC FILTERS....9520
Description....9520
Housing Removal And Installation....9520
Charge Filter Housing Removal And Installation....9522
HYDRAULIC FLUID RESERVOIR....9524
Description....9524
Removal And Installation....9524
Hydraulic Fluid Screen....9527
OIL COOLER....9528
Description....9528
Removal And Installation....9528
BUCKET POSITION VALVE....9530
Description....9530
Solenoid Removal And Installation....9530
Solenoid Testing....9531
Removal And Installation....9532
Disassembly And Assembly....9533
REAR AUXILIARY DIVERTER VALVE....9536
Description....9536
Solenoid Testing....9536
Removal And Installation....9537
Disassembly And Assembly....9540
BOB-TACH (POWER) BLOCK....9546
Description....9546
Removal And Installation....9546
Disassembly And Assembly....9548
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....9552
Description....9552
Removal And Installation....9552
Disassembly And Assembly....9552
HYDROSTATIC SYSTEM....9554
HYDROSTATIC SYSTEM INFORMATION....9556
Troubleshooting....9556
Description....9557
HYDROSTATIC DRIVE MOTOR....9558
Description....9558
Removal And Installation....9558
Parts Identification....9561
Disassembly And Assembly....9562
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....9568
Description....9568
Removal And Installation (Left Side)....9569
Removal And Installation (Right Side)....9572
Parts Identification....9575
Disassembly....9576
Assembly....9586
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....9598
Description....9598
Shaft Seal Removal And Installation....9599
Removal And Installation....9601
Parts Identification....9603
Disassembly And Assembly....9604
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....9610
Description....9610
Shaft Seal Removal And Installation....9611
Removal And Installation....9613
Parts Identification....9615
Disassembly And Assembly....9616
CHARGE PRESSURE....9622
Description....9622
Testing (S/N A3L129999 & Below)....9623
Sender Removal And Installation (S/N A3L129999 & Below)....9624
Testing (S/N A3L130001 & Above)....9625
Sender Removal And Installation (S/N A3L130001 & Above)....9626
Adjusting....9627
HYDROSTATIC PUMP....9630
Description....9630
Replenishing / High Pressure Relief Valve Removal And Installation....9630
Removal And Installation....9631
Hydrostatic Pump Startup....9632
Parts Identification (Left Half)....9633
Parts Identification (Right Half)....9634
Disassembly....9635
Assembly....9641
HYDROSTATIC PUMP (SJC)....9648
Description....9648
Hydraulic Controller Removal And Installation....9649
Removal And Installation....9651
Hydrostatic Pump Startup....9653
Parts Identification....9654
High Pressure Relief And Bypass Valve....9655
Charge Relief Valve....9656
Disassembly And Assembly....9657
Mechanical Neutral Adjustment....9673
Hydraulic Controller Neutral Adjustment....9676
DRIVE BELT....9680
Description....9680
Shield Removal And Installation....9680
Adjusting....9681
Belt Removal And Installation....9682
Tensioner Pulley Removal And Installation....9683
Tensioner Pulley Parts Identification....9684
Tensioner Pulley Disassembly....9685
Tensioner Pulley Assembly....9686
TWO-SPEED VALVE....9688
Description....9688
Valve Removal And Installation....9689
Valve Disassembly And Assembly....9691
CASE DRAIN FILTER....9694
Description....9694
Disassembly And Assembly....9694
DRIVE SYSTEM....9696
BRAKE (SINGLE SPEED)....9698
Description....9698
Disc Removal And Installation....9698
BRAKE (TWO-SPEED)....9700
Description....9700
Disc Removal And Installation....9700
Disc Disassembly And Assembly....9701
DRIVE COMPONENTS....9702
Description....9702
Axle Seal Removal And Installation....9703
Axle, Sprocket And Bearings Removal And Installation....9705
Chain Removal And Installation....9710
CHAINCASE....9712
Description....9712
Front Cover Removal And Installation....9712
Center Cover Removal And Installation....9713
Rear Cover Removal And Installation....9714
MAINFRAME....9716
SEAT BAR....9720
Description....9720
Removal And Installation....9720
Disassembly And Assembly....9721
Compression Spring Disassembly And Assembly....9722
OPERATOR CAB....9724
Gas Cylinder Removal And Installation....9724
Gas Cylinder Bracket Disassembly And Assembly....9726
Removal And Installation....9727
OPERATOR SEAT....9730
Removal And Installation....9730
Seat Belt Removal And Installation....9730
OPERATOR SEAT (SUSPENSION)....9732
Removal And Installation....9732
Slide Rail Removal And Installation....9733
Seat Belt Removal And Installation....9733
Lower Cushion Removal And Installation....9734
Back Cushion Removal And Installation....9735
Shock Removal And Installation....9735
3-Point Seat Belt Removal And Installation....9736
BOB-TACH (HAND LEVER)....9738
Description....9738
Removal And Installation....9738
Lever And Wedge Disassembly And Assembly....9739
Pivot Pin Bushing And Seal Removal And Installation....9741
BOB-TACH (POWER)....9742
Description....9742
Removal And Installation....9742
Lever And Wedge Disassembly And Assembly....9744
Pivot Pin Bushing And Seal Removal And Installation....9745
LIFT ARMS....9746
Removal And Installation....9746
REAR GRILLE....9750
Removal And Installation....9750
REAR DOOR (TAILGATE)....9752
Removal And Installation....9752
Striker Removal And Installation....9753
Striker Disassembly And Assembly....9753
Striker (Adjusting)....9754
Latch Removal And Installation....9755
FUEL TANK....9756
Removal And Installation....9756
Fuel Level Sender Removal And Installation....9757
Fuel Fill Screen Removal And Installation....9758
CONTROL PEDALS AND LINKAGES....9760
Description....9760
Pedal Removal And Installation....9760
Linkage Removal And Installation....9761
Pedal (Adjusting)....9763
CONTROL PEDALS (ACS)....9764
Description....9764
Foot Sensor Removal And Installation....9764
Foot Pedal Removal And Installation....9765
Foot Pedal Linkage Disassembly And Assembly....9766
CONTROL PANEL....9768
Description....9768
Removal And Installation....9769
Shock Removal And Installation....9772
Shaft Removal And Installation....9772
Shaft Disassembly And Assembly....9773
Linkage Removal And Installation....9774
Pintle Arm Disassembly And Assembly....9778
Linkage Neutral (Adjusting)....9780
Linkage Travel (Adjusting)....9784
CONTROL PANEL (SJC)....9788
Description....9788
Removal And Installation....9788
CONTROL HANDLE / LEVER....9790
Description....9790
Lever Removal And Installation....9790
Boot Removal And Installation....9791
CONTROL HANDLE / LEVER (ACS)....9792
Description....9792
Handle Sensor Removal And Installation....9792
Handle Removal And Installation....9795
Handle Disassembly And Assembly....9796
Lever Removal And Installation....9796
Boot Removal And Installation....9798
CONTROL HANDLE / LEVER (SJC)....9800
Description....9800
Joystick Testing....9800
Joystick Removal And Installation....9801
Joystick Mount Removal And Installation....9802
ACCESS PANEL (INSIDE)....9804
Removal And Installation (Left)....9804
Removal And Installation (Right)....9804
ACCESS PANEL (INSIDE) (SJC)....9806
Removal And Installation (Left)....9806
Removal And Installation (Right)....9807
WINDOW (REAR)....9810
Removal....9810
Installation (Split Molding)....9810
Installation (Continuous Molding)....9812
WINDOW (TOP)....9814
Removal And Installation....9814
WINDOW (SIDE)....9816
Removal And Installation....9816
WINDOW (CAB DOOR)....9818
Removal (Standard Window)....9818
Installation (Standard Window)....9819
Removal And Installation (Special Applications Window)....9821
CAB DOOR....9822
Description....9822
Removal And Installation....9822
Aligning....9823
Adjusting....9824
Checking Operation....9824
ELECTRICAL SYSTEM AND ANALYSIS....9826
ELECTRICAL SCHEMATICS....9830
ELECTRICAL SYSTEM INFORMATION....9836
Glossary Of Electrical Symbols....9836
Standard Cab Harness Connectors....9839
Deluxe Cab Harness Connectors....9840
Mainframe Harness Connectors....9841
Description....9842
Troubleshooting....9843
Fuse And Relay Location / Identification....9844
Solenoid Testing....9845
BATTERY....9846
Removal And Installation....9846
Servicing....9847
Using A Booster Battery (Jump Starting)....9848
ALTERNATOR....9850
Belt Adjustment....9850
Belt Replacement....9850
Charging System Inspection....9851
Alternator Voltage Testing....9852
Low Voltage Testing....9852
High Voltage Testing....9853
Removal And Installation....9854
Parts Identification....9855
STARTER....9856
Testing....9856
Removal And Installation....9857
Parts Identification....9858
INSTRUMENT PANELS....9860
Left Panel....9860
Standard Key Panel....9862
Keyless Start Panel....9862
Deluxe Instrumentation Panel....9863
Side Panel....9864
Front Panel....9864
Front Panel Removal And Installation....9865
Removal And Installation (Left And Right)....9866
Key Switch Removal And Installation....9867
Alarm Removal And Installation....9868
LIGHTS....9870
Front Removal And Installation....9870
Rear Removal And Installation....9871
Cab Light Removal And Installation....9871
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....9872
Description....9872
Connector Identification....9873
Removal And Installation....9879
BOBCAT CONTROLLER (ACS)....9882
Description....9882
Connector And Wire Identification....9883
Removal And Installation....9884
BOBCAT CONTROLLER (SJC) (DRIVE)....9886
Description....9886
Connector Identification....9887
Removal And Installation....9889
SPEED SENSORS (SJC)....9890
Description....9890
Testing....9890
Removal And Installation....9892
DIAGNOSTIC SERVICE CODES....9894
Viewing Service Codes....9894
Service Codes List....9895
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....9900
Description....9900
Inspecting The BICS™ (Engine STOPPED - Key ON)....9901
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....9901
Inspecting The Seat Bar Sensor (Engine RUNNING)....9901
Inspecting The Traction Lock (Engine RUNNING)....9901
Inspecting The Lift Arm Bypass Control....9901
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....9901
Troubleshooting....9902
SEAT BAR SENSOR....9904
Description....9904
Troubleshooting....9904
Testing....9905
Removal And Installation....9906
Bobcat Interlock Control System (BICS™) Circuit Test....9909
TRACTION LOCK....9912
Description....9912
Troubleshooting....9912
Removal And Installation....9913
Inspecting....9917
CONTROL SYSTEM (ACS)....9918
Description....9918
Troubleshooting....9919
Handle Sensor Connector Disassembly And Assembly....9920
Switch Handle Removal....9921
Switch Handle Installation....9923
Actuator Connector Disassembly And Assembly....9926
Handle Lock Solenoid Removal And Installation....9927
Handle Lock Solenoid Disassembly And Assembly....9927
Foot Sensor Disassembly And Assembly....9928
Foot Lock Solenoid Removal And Installation....9929
ELECTRICAL / HYDRAULIC CONTROLS....9930
Identification Chart....9930
Description....9931
Identification Chart ACD Group 0....9932
Identification Chart ACD Group 1....9933
Identification Chart ACD Group 2....9934
Identification Chart ACD Group 3....9935
ELECTRICAL / HYDRAULIC CONTROLS (ACS)....9936
Identification Chart....9936
Description....9937
Identification Chart ACD Group 0....9938
Identification Chart ACD Group 1....9939
Identification Chart ACD Group 2....9940
Identification Chart ACD Group 3....9941
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....9942
Identification Chart....9942
Description....9943
Identification Chart ACD Group 0....9944
Identification Chart ACD Group 1....9945
Identification Chart ACD Group 2....9946
Identification Chart ACD Group 3....9947
SERVICE PC (LAPTOP COMPUTER)....9948
Connecting Remote Start Tool....9948
Connecting Remote Start Tool (Service Tool)....9948
CALIBRATION....9950
Description....9950
Actuator Testing....9950
Lift And Tilt Calibration (SJC)....9953
Hydrostatic Pump Calibration (SJC)....9955
Lift And Tilt Calibration (ACS)....9960
STEERING DRIFT COMPENSATION....9962
Description....9962
Operation....9962
FLYWHEEL RPM SENSOR....9964
Description....9964
Adjusting....9964
CONTROL PANEL SETUP....9966
Right Panel Setup (Deluxe Instrumentation Panel)....9966
Attachment Control Information (Deluxe Instrumentation Panel)....9967
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....9968
Password Description....9968
Changing The Owner Password....9968
Changing The User Passwords....9969
Password Lockout Feature....9969
PASSWORD SETUP (KEYLESS START PANEL)....9970
Password Description....9970
Changing The Owner Password....9970
Password Lockout Feature....9970
MAINTENANCE CLOCK....9972
Description....9972
Setup....9973
Reset....9976
BACK-UP ALARM SYSTEM....9978
Description....9978
Inspecting....9978
Adjusting Switch Position....9979
Troubleshooting (Standard And ACS)....9980
Troubleshooting (Joystick)....9981
Alarm Removal And Installation....9982
Switch Removal And Installation....9982
ENGINE SERVICE....9984
ENGINE INFORMATION....9986
Description....9986
Specifications....9987
Torque Values....9991
Troubleshooting....9992
Engine Removal And Installation....9994
Engine Mount Replacement....10000
Compression - Checking....10001
ENGINE SPEED CONTROL....10002
Removal And Installation....10002
ENGINE SPEED CONTROL (SJC)....10004
Removal And Installation....10004
Disassembly And Assembly....10006
MUFFLER....10008
Removal And Installation....10008
AIR CLEANER....10010
Housing Removal And Installation....10010
ENGINE COOLING SYSTEM....10012
Radiator Removal And Installation....10012
Hydraulic Fan Description (S/N A3L129999 & Below)....10014
Hydraulic Fan Disassembly And Assembly (S/N A3L129999 & Below)....10014
Blower Housing Removal And Installation (S/N A3L129999 & Below)....10015
Fan Removal And Installation (S/N A3L129999 & Below)....10017
Hydraulic Fan Motor Removal And Installation (S/N A3L129999 & Below)....10017
Hydraulic Fan Description (S/N A3L130001 & Above)....10018
Hydraulic Fan Disassembly And Assembly (S/N A3L130001 & Above)....10018
Blower Housing Removal And Installation (S/N A3L130001 & Above)....10020
Fan Removal And Installation (S/N A3L130001 & Above)....10022
Hydraulic Fan Motor Removal And Installation (S/N A3L130001 & Above)....10022
Water Pump Removal And Installation....10023
Water Pump Disassembly And Assembly....10023
Thermostat Housing Removal And Installation....10024
Thermostat - Checking....10025
LUBRICATION SYSTEM....10026
Oil Pan Removal And Installation....10026
Oil Pump Removal And Installation....10026
Oil Pump Inspection....10027
Engine Oil Pressure-Testing....10028
FUEL SYSTEM....10030
Fuel Shutoff Solenoid - Checking....10030
Fuel Shutoff Solenoid Removal And Installation....10030
Fuel Injection Pump - Checking....10031
Fuel Injection Pump Removal And Installation....10032
Governor Disassembly And Assembly....10036
Fuel Camshaft Removal And Installation....10037
Fuel Injection Pump - Timing....10037
Fuel Injector Removal And Installation....10039
Fuel Injector Nozzle Pressure - Checking....10040
Nozzle Spray Condition....10041
Valve Seat Tightness....10041
CYLINDER HEAD....10042
Glow Plugs - Testing....10042
Glow Plugs Removal And Installation....10042
Valve Clearance Adjustment....10043
Valve Timing - Checking....10044
Cylinder Head Removal And Installation....10045
Cylinder Head Disassembly And Assembly....10048
Cylinder Head - Servicing....10048
Cylinder Head Top Clearance....10049
Valve Guide - Checking....10049
Valve Guide Removal And Installation....10050
Reconditioning The Valve And Valve Seat....10050
Valve Spring....10052
Valve Tappets....10053
Rocker Arm And Shaft - Checking....10053
Push Rod Alignment - Checking....10054
CRANKSHAFT AND PISTONS....10056
Piston And Connecting Rod Removal And Installation....10056
Piston And Connecting Rod - Servicing....10057
Cylinder Bore - Checking....10060
Connecting Rod Alignment....10060
Crankshaft Gear Removal And Installation....10061
Crankshaft And Bearings Removal And Installation....10061
Crankshaft And Bearings - Servicing....10063
CAMSHAFT AND TIMING GEARS....10068
Timing Gearcase Cover Removal And Installation....10068
Timing Gears Backlash - Checking....10070
Idler Gear And Camshaft Removal And Installation....10071
Camshaft - Servicing....10072
Idler Gear And Shaft Servicing....10073
FLYWHEEL AND HOUSING....10074
Flywheel Removal And Installation....10074
Ring Gear Removal And Installation....10074
Housing Removal And Installation....10075
HEATER....10078
HEATER SYSTEM....10080
Description....10080
REGULAR MAINTENANCE....10082
Filters....10082
Heater Coil....10082
TROUBLESHOOTING....10084
Blower Motor Does Not Operate....10084
Blower Motor Operators Normally, But Air Flow Is Insufficient....10084
Electrical System....10085
Engine Coolant Bypassing The Heater Valve....10089
Heater Valve Not Opening Or Closing....10090
HEATER UNIT....10092
Removal And Installation....10092
HEATER COIL....10094
Removal And Installation....10094
BLOWER FAN....10096
Removal And Installation....10096
Disassembly And Assembly....10097
Connector Identification....10099
HEATER VALVE....10100
Removal And Installation....10100
Disassembly And Assembly....10101
SPECIFICATIONS....10102
(S150) LOADER SPECIFICATIONS....10104
Machine Dimensions....10104
Performance....10105
Engine....10105
Drive System....10105
Controls....10106
Hydraulic System....10106
Electrical....10107
Capacities....10107
Tires....10107
TORQUE SPECIFICATIONS FOR BOLTS....10108
Torque For General SAE Bolts....10108
Torque For General Metric Bolts....10109
HYDRAULIC CONNECTION SPECIFICATIONS....10110
O-ring Face Seal Connection....10110
Straight Thread O-ring Fitting....10111
Tubelines And Hoses....10111
Flare Fitting....10112
Port Seal Fitting....10113
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....10114
Specifications....10114
CONVERSIONS....10116
Decimal And Millimeter Equivalent Chart....10116
U.S. To Metric Conversion Chart....10116
ALPHABETICAL INDEX....10118
SERVICE MANUAL REVISION....10120
Revision No: S150 - 1....10120
Revision No: S150 - 2....10122
Revision No: S150 - 3....10124
Revision No: S150 - 4....10126
Revision No: S150 - 5....10128
Revision No: S150 - 6....10130
Revision No: S150 - 7....10132
Revision No: S150 - 8....10134
Revision No: S150 - 9....10136
Revision No: S150 - 10....10138
Revision No: S150 - 11....10140
Revision No: S150 - 12....10142
Revision No: S150 - 13....10144
6987034 (9-09) - S160 Skid-Steer Loader Service Manual....10146
MAINTENANCE SAFETY....10148
ALPHABETICAL INDEX....10150
CONTENTS....10152
FOREWORD....10153
SAFETY INSTRUCTIONS....10156
FIRE PREVENTION....10158
Maintenance....10158
Operation....10158
Electrical....10158
Hydraulic System....10158
Fueling....10158
Starting....10158
Spark Arrestor Exhaust System....10158
Welding And Grinding....10159
Fire Extinguishers....10159
SERIAL NUMBER LOCATIONS....10160
Loader Serial Number....10160
Engine Serial Number....10160
DELIVERY REPORT....10161
BOBCAT LOADER IDENTIFICATION....10162
SAFETY & MAINTENANCE....10164
LIFTING AND BLOCKING THE LOADER....10168
Procedure....10168
LIFT ARM SUPPORT DEVICE....10170
Installing....10170
Removing....10171
OPERATOR CAB....10172
Description....10172
Raising....10173
Lowering....10174
Cab Door Sensor....10175
Special Applications Kit....10175
Special Applications Kit Inspection And Maintenance....10175
TRANSPORTING THE LOADER ON A TRAILER....10176
Loading And Unloading....10176
Fastening....10176
TOWING THE LOADER....10178
Procedure....10178
REMOTE START TOOL KIT -MEL1563....10180
Remote Start Tool - MEL1563....10180
Service Tool Harness Control - MEL1565....10181
Service Tool Harness Communicator - MEL1566....10182
Remote Start Procedure....10183
REMOTE START TOOL (SERVICE TOOL) kIT - 6689779....10186
Description....10186
Remote Start Tool (Service Tool) - 6689778....10187
Loader Service Tool Harness - 6689747....10188
Computer Service Tool Harness - 6689746....10189
Remote Start Procedure....10190
SERVICE SCHEDULE....10194
Chart....10194
AIR CLEANER SERVICE....10196
Replacing Filter Elements....10196
ENGINE COOLING SYSTEM....10198
Cleaning....10198
Checking Level....10199
Removing And Replacing Coolant....10200
FUEL SYSTEM....10202
Fuel Specifications....10202
Biodiesel Blend Fuel....10202
Filling The Fuel Tank....10203
Fuel Filter....10204
Removing Air From The Fuel System....10204
ENGINE LUBRICATION SYSTEM....10206
Checking And Adding Engine Oil....10206
Engine Oil Chart....10206
Removing And Replacing Oil And Filter....10207
HYDRAULIC / HYDROSTATIC SYSTEM....10208
Checking And Adding Fluid....10208
Hydraulic / Hydrostatic Fluid Chart....10208
Removing And Replacing Hydraulic Fluid....10209
Removing And Replacing Hydraulic / Hydrostatic Filter....10209
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....10210
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....10211
Removing And Replacing Hydraulic Charge Filter....10213
Breather Cap....10214
FINAL DRIVE TRANSMISSION (CHAINCASE)....10216
Checking And Adding Oil....10216
Removing And Replacing Oil....10216
BOB-TACH (HAND LEVER)....10218
Inspection And Maintenance....10218
BOB-TACH (POWER)....10220
Inspection And Maintenance....10220
LUBRICATING THE LOADER....10222
Lubrication Locations....10222
TIRE MAINTENANCE....10224
Wheel Nuts....10224
Rotating....10224
Mounting....10224
SPARK ARRESTOR MUFFLER....10226
Cleaning Procedure....10226
PIVOT PINS....10228
Inspection And Maintenance....10228
LOADER STORAGE AND RETURN TO SERVICE....10230
Storage....10230
Return to Service....10230
STOPPING THE ENGINE AND LEAVING THE LOADER....10232
Procedure....10232
EMERGENCY EXIT....10234
Rear Window....10234
Front Door....10234
HYDRAULIC SYSTEM....10236
HYDRAULIC / HYDROSTATIC SCHEMATICS....10242
HYDRAULIC SYSTEM INFORMATION....10258
Glossary Of Hydraulic / Hydrostatic Symbols....10258
Troubleshooting....10262
CYLINDER (LIFT)....10264
Testing....10264
Removal And Installation....10265
Parts Identification....10266
Disassembly and Assembly....10267
CYLINDER (TILT)....10270
Testing....10270
Removal And Installation....10271
Base End Pivot Pin Removal and Installation....10272
Rod End Pivot Pin Bushing And Seal Removal And Installation....10273
Parts Identification....10274
Disassembly And Assembly....10275
CYLINDER (BOB-TACH)....10278
Testing....10278
Removal And Installation....10279
Parts Identification....10280
Disassembly and Assembly....10281
MAIN RELIEF VALVE....10284
Description....10284
Testing....10285
Adjusting....10286
Removal and Installation....10287
HYDRAULIC CONTROL VALVE (STANDARD)....10288
Description....10288
Removal And Installation....10288
Identification Chart....10293
Mount Bracket Removal And Installation....10294
Lift Load Check Valve Removal And Installation....10294
Load Check Valve Removal And Installation (Tilt & Auxiliary)....10295
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....10296
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....10297
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....10297
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....10298
Port Relief Valve Removal And Installation....10298
Plug Removal And Installation....10299
Rubber Boot Removal And Installation....10300
End Cap / Spool Lock Block Removal And Installation....10301
Lift Spool And Detent Removal And Installation....10302
Tilt Spool Removal And Installation....10312
Auxiliary Spool Removal And Installation....10314
Auxiliary Solenoid Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10316
Auxiliary Solenoid Removal And Installation (S/N AHWA11001 & Above)....10317
Solenoid Removal And Installation....10317
Lock Valve Removal And Installation....10319
Lift Arm Bypass Orifice Removal And Installation....10321
Main Relief Valve Removal And Installation....10321
Check Valve Removal And Installation....10322
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....10324
Description....10324
Removal And Installation....10324
Actuator Removal And Installation (Out of Loader)....10329
Identification Chart....10332
Mount Bracket Removal And Installation....10333
Lift Load Check Valve Removal And Installation....10333
Load Check Valve Removal And Installation (Tilt & Auxiliary)....10334
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....10335
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....10336
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....10336
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....10337
Port Relief Removal And Installation....10337
Plug Removal And Installation....10338
End Cap Block Removal And Installation....10339
Lift Spool And Detent Removal And Installation....10340
Tilt Spool Removal And Installation....10345
Auxiliary Spool Removal And Installation....10347
Auxiliary Solenoid Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10349
Auxiliary Solenoid Removal And Installation (S/N AHWA11001 & Above)....10350
Solenoid Removal And Installation....10350
Lock Valve Removal And Installation....10352
Lift Arm Bypass Orifice Removal And Installation....10353
Main Relief Valve Removal And Installation....10354
Check Valve Removal And Installation....10355
LIFT ARM BYPASS CONTROL VALVE....10356
Description....10356
Testing....10356
Removal and Installation....10356
Disassembly And Assembly....10357
HYDRAULIC PUMP (STANDARD)....10358
Description....10358
Pump Test at Quick Couplers....10358
Direct Pump Test (Standard Section)....10359
Direct Pump Test (Charge Section)....10361
Removal And Installation....10363
Hydraulic Pump Startup....10365
Parts Identification....10366
Disassembly And Assembly....10367
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....10376
Description....10376
Pump Test At Quick Couplers....10376
Direct Pump Test (Standard Section)....10377
Direct Pump Test (Charge Section)....10379
Direct Pump Test (High Flow Section)....10381
Removal And Installation....10383
Hydraulic Pump Startup....10385
Parts Identification....10386
Disassembly And Assembly....10387
HYDRAULIC PUMP (SJC)....10400
Description....10400
Pump Test At Quick Couplers....10400
Direct Pump Test (Standard Section)....10401
Direct Pump Test (Charge Section)....10403
Removal And Installation....10405
Hydraulic Pump Startup....10407
Parts Identification....10408
Disassembly And Assembly....10409
HYDRAULIC PUMP (SJC) (HIGH FLOW)....10418
Description....10418
Pump Test At Quick Couplers....10418
Direct Pump Test (Standard Section)....10419
Direct Pump Test (Charge Section)....10421
Direct Pump Test (High Flow Section)....10423
Removal And Installation....10425
Hydraulic Pump Startup....10427
Parts Identification....10428
Disassembly And Assembly....10429
HYDRAULIC / HYDROSTATIC FILTERS....10442
Description....10442
Housing Removal And Installation....10442
Charge Filter Housing Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10444
HYDRAULIC FLUID RESERVOIR....10446
Description....10446
Removal And Installation....10446
Hydraulic Fluid Screen....10449
OIL COOLER....10450
Description....10450
Removal and Installation....10450
BUCKET POSITION VALVE....10452
Description....10452
Solenoid Removal And Installation....10452
Solenoid Testing....10453
Removal And Installation....10454
Disassembly And Assembly....10455
REAR AUXILIARY DIVERTER VALVE....10458
Description....10458
Solenoid Testing....10458
Removal And Installation....10459
Disassembly And Assembly....10462
BOB-TACH (POWER) BLOCK....10468
Description....10468
Removal And Installation....10468
Disassembly And Assembly....10470
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....10474
Description....10474
Removal and Installation....10474
Disassembly And Assembly....10474
HIGH FLOW VALVE....10476
Description....10476
High Flow Relief Valve Testing....10476
High Flow Relief Valve Adjustment....10477
Solenoid Testing....10478
Removal And Installation....10479
Disassembly And Assembly....10480
HYDROSTATIC SYSTEM....10484
HYDROSTATIC SYSTEM INFORMATION....10486
Troubleshooting....10486
Description....10487
HYDROSTATIC MOTOR....10488
Description....10488
Removal And Installation....10488
Parts Identification....10491
Disassembly and Assembly....10492
HYDROSTATIC MOTOR (TWO-SPEED)....10498
Description....10498
Removal And Installation (Left Side)....10499
Removal And Installation (Right Side)....10502
Parts Identification....10505
Disassembly....10506
Assembly....10516
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....10528
Description....10528
Shaft Seal Removal And Installation....10528
Removal And Installation....10530
Parts Identification....10532
Disassembly and Assembly....10533
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....10538
Description....10538
Shaft Seal Removal And Installation....10538
Removal And Installation....10540
Parts Identification....10542
Disassembly and Assembly....10543
CHARGE PRESSURE....10548
Description....10548
Testing (S/N 529960001 & Above, 530060002 & Above And AC3260001 & Above)....10548
Sender Removal And Installation....10550
Testing (S/N AHWA11001 & Above)....10551
Sender Removal And Installation (S/N AHWA11001 & Above)....10552
Adjusting....10553
HYDROSTATIC PUMP....10556
Description....10556
Replenishing / High Pressure Relief Valve Removal And Installation....10556
Removal And Installation....10557
Hydrostatic Pump Startup....10558
Parts Identification (Left Half)....10559
Parts Identification (Right Half)....10560
Disassembly....10561
Assembly....10567
HYDROSTATIC PUMP (SJC)....10574
Description....10574
Hydraulic Controller Removal And Installation....10575
Removal And Installation....10577
Hydrostatic Pump Startup....10579
Parts Identification....10580
High Pressure Relief and Bypass Valve....10581
Charge Relief Valve....10582
Disassembly and Assembly....10583
Mechanical Neutral Adjustment....10599
Hydraulic Controller Neutral Adjustment....10602
DRIVE BELT....10606
Description....10606
Shield Removal And Installation....10606
Adjusting....10607
Belt Removal And Installation....10608
Tensioner Pulley Removal And Installation....10609
Tensioner Pulley Parts Identification....10610
Tensioner Pulley Disassembly....10611
Tensioner Pulley Assembly....10612
TWO-SPEED VALVE....10614
Description....10614
Valve Removal And Installation....10615
Valve Disassembly And Assembly....10617
CASE DRAIN FILTER....10620
Description....10620
Disassembly And Assembly....10620
DRIVE SYSTEM....10622
BRAKE (SINGLE SPEED)....10624
Description....10624
Disc Removal And Installation....10624
BRAKE (TWO-SPEED)....10626
Description....10626
Disc Removal And Installation....10626
Disc Disassembly and Assembly....10627
DRIVE COMPONENTS....10628
Description....10628
Axle Seal Removal And Installation....10629
Axle Sprocket And Bearings Removal And Installation....10631
Chain Removal And Installation....10636
CHAINCASE....10638
Description....10638
Front Cover Removal And Installation....10638
Center Cover Removal And Installation....10639
Rear Cover Removal And Installation....10640
MAIN FRAME....10642
SEAT BAR....10646
Description....10646
Removal And Installation....10646
Disassembly And Assembly....10647
Compression Spring Disassembly And Assembly....10649
OPERATOR CAB....10650
Gas Cylinder Removal And Installation....10650
Gas Cylinder Bracket Disassembly And Assembly....10652
Removal And Installation....10653
OPERATOR SEAT....10656
Removal And Installation....10656
Seat Belt Removal And Installation....10656
OPERATOR SEAT (SUSPENSION)....10658
Removal And Installation....10658
Slide Rail Removal And Installation....10659
Seat Belt Removal and Installation....10659
Lower Cushion Removal And Installation....10659
Back Cushion Removal And Installation....10661
Shock Removal And Installation....10661
3-Point Seat Belt Removal And Installation....10662
BOB-TACH (HAND LEVER)....10664
Description....10664
Removal And Installation....10664
Lever And Wedge Disassembly And Assembly....10665
Pivot Pin Bushing And Seal Removal And Installation....10667
BOB-TACH (POWER)....10668
Description....10668
Removal And Installation....10668
Lever And Wedge Disassembly And Assembly....10670
Pivot Pin Bushing And Seal Removal And Installation....10671
LIFT ARMS....10672
Removal And Installation....10672
REAR GRILL....10676
Removal And Installation....10676
REAR DOOR....10678
Removal And Installation....10678
Striker Removal and Installation....10679
Striker Disassembly and Assembly....10679
Striker (Adjusting)....10679
Latch Removal and Installation....10680
FUEL TANK....10682
Removal And Installation....10682
Fuel Level Sender Removal And Installation....10683
Fuel Fill Screen Removal And Installation....10684
CONTROL PEDALS AND LINKAGES....10686
Description....10686
Pedal Removal And Installation....10686
Linkage Removal And Installation....10687
Pedal (Adjusting)....10689
CONTROL PEDALS (ACS)....10690
Description....10690
Foot Sensor Removal And Installation....10690
Foot Pedal Removal And Installation....10691
Foot Pedal Linkage Disassembly And Assembly....10692
CONTROL PANEL....10694
Description....10694
Removal and Installation....10695
Shock Removal And Installation....10698
Shaft Removal And Installation....10698
Shaft Disassembly And Assembly....10699
Linkage Removal And Installation....10700
Pintle Arm Disassembly and Assembly....10704
Linkage Neutral (Adjusting)....10706
Linkage Travel (Adjusting)....10710
CONTROL PANEL (SJC)....10714
Description....10714
Removal And Installation....10714
CONTROL HANDLE / LEVER....10716
Description....10716
Lever Removal And Installation....10716
Boot Removal And Installation....10717
CONTROL HANDLE / LEVER (ACS)....10718
Description....10718
Handle Sensor Removal And Installation....10718
Handle Removal and Installation....10721
Handle Disassembly and Assembly....10722
Lever Removal and Installation....10722
Boot Removal And Installation....10724
CONTROL HANDLE / LEVER (SJC)....10726
Description....10726
Joystick Testing....10726
Joystick Removal And Installation....10727
Joystick Mount Removal And Installation....10728
ACCESS PANEL (INSIDE)....10730
Removal And Installation (Left)....10730
Removal And Installation (Right)....10730
ACCESS PANEL (INSIDE) (SJC)....10732
Removal And Installation (Left)....10732
Removal And Installation (Right)....10733
WINDOW (REAR)....10736
Removal....10736
Installation (Split Molding)....10736
Installation (Continuous Molding)....10738
WINDOWS (TOP)....10740
Removal And Installation....10740
WINDOWS (SIDE)....10742
Removal And Installation....10742
WINDOWS (CAB DOOR)....10744
Removal (Standard Window)....10744
Installation (Standard Window)....10745
Removal And Installation (Special Applications Window)....10747
CAB DOOR....10748
Description....10748
Removal And Installation....10748
Aligning....10749
Adjusting....10750
Checking Operation....10750
ELECTRICAL SYSTEM & ANALYSIS....10752
ELECTRICAL SCHEMATICS....10756
ELECTRICAL SYSTEM INFORMATION....10762
Glossary Of Electrical Symbols....10762
Standard Cab Harness Connectors....10765
Deluxe Cab Harness Connectors....10766
Mainframe Harness Connectors....10767
Description....10768
Troubleshooting....10769
Fuse And Relay Location / Identification....10770
Solenoid Testing....10771
BATTERY....10772
Removal And Installation....10772
Servicing....10773
Using A Booster Battery (Jump Starting)....10774
ALTERNATOR....10776
Belt Adjustment....10776
Belt Replacement....10776
Charging System Inspection....10777
Alternator Voltage Testing....10778
Low Voltage Testing....10778
High Voltage Testing....10779
Removal And Installation....10780
Parts Identification....10781
STARTER....10782
Testing....10782
Removal And Installation....10783
Parts Identification....10784
INSTRUMENT PANELS....10786
Left Panel....10786
Standard Key Panel....10788
Deluxe Instrumentation Panel....10789
Side Panel....10790
Front Panel....10790
Front Panel Removal And Installation....10791
Removal And Installation (Left And Right)....10791
Key Switch Removal And Installation....10793
Alarm Removal And Installation....10794
LIGHTS....10796
Front Removal And Installation....10796
Rear Removal And Installation....10797
Cab Light Removal And Installation....10797
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....10798
Description....10798
Connector Identification....10799
Removal and Installation....10805
BOBCAT CONTROLLER (ACS)....10808
Description....10808
Connector Identification....10809
Removal and Installation....10810
BOBCAT CONTROLLER (SJC) (DRIVE)....10812
Description....10812
Connector Identification....10813
Removal and Installation....10815
SPEED SENSORS (SJC)....10816
Description....10816
Testing....10816
Removal and Installation....10818
DIAGNOSTIC SERVICE CODES....10820
Viewing Service Codes (Standard Key Panel)....10820
Viewing Service Codes (Deluxe Instrumentation Panel)....10820
Service Codes List....10821
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....10826
Description....10826
Inspecting The BICS Controller (Engine STOPPED - Key ON)....10827
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....10827
Inspecting The Seat Bar Sensor (Engine RUNNING)....10827
Inspecting The Traction Lock (Engine RUNNING)....10827
Inspecting The Lift Arm Bypass Control....10827
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....10827
Troubleshooting....10828
SEAT BAR SENSOR....10830
Description....10830
Troubleshooting....10830
Testing....10831
Removal And Installation....10832
Bobcat Interlock Control System (BICS) Circuit Test....10834
TRACTION LOCK....10836
Description....10836
Troubleshooting....10836
Removal And Installation....10837
Inspecting....10841
CONTROL SYSTEM (ACS)....10842
Description....10842
Troubleshooting....10843
Handle Sensor Connector Disassembly And Assembly....10844
Switch Handle Removal....10845
Switch Handle Installation....10847
Actuator Connector Disassembly And Assembly....10850
Handle Lock Solenoid Removal And Installation....10851
Handle Lock Solenoid Disassembly And Assembly....10851
Foot Sensor Disassembly And Assembly....10852
Foot Lock Solenoid Removal And Installation....10853
ELECTRICAL / HYDRAULIC CONTROLS....10854
Identification Chart....10854
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....10856
Identification Chart....10856
SERVICE PC (LAPTOP COMPUTER)....10860
Connecting Remote Start Tool....10860
Connecting Remote Start Tool (Service Tool)....10860
CALIBRATION....10862
Description....10862
Actuator Testing....10862
Lift And Tilt Calibration (ACS)....10864
Lift And Tilt Calibration (SJC)....10866
Hydrostatic Pump Calibration (SJC)....10868
STEERING DRIFT COMPENSATION....10874
Description....10874
Operation....10874
FLYWHEEL RPM SENSOR....10876
Description....10876
Adjusting....10876
CONTROL PANEL SETUP....10878
Right Panel Setup (Deluxe Instrumentation Panel)....10878
Attachment Control Information (Deluxe Instrumentation Panel)....10879
PASSWORD SETUP....10880
Password Description....10880
Changing The Owner Password....10880
Changing The User Passwords....10881
Password Lockout Feature....10881
MAINTENANCE CLOCK....10882
Description....10882
Setup....10883
Reset....10886
BACK-UP ALARM SYSTEM....10888
Description....10888
Inspecting....10888
Adjusting Switch Position....10889
Troubleshooting (Standard and ACS)....10890
Troubleshooting (Joystick)....10891
Alarm Removal And Installation....10892
Switch Removal And Installation....10892
ENGINE SERVICE....10894
ENGINE INFORMATION....10898
Description....10898
Specifications....10899
Torque Values....10902
Troubleshooting....10902
Engine Removal And Installation....10904
Engine Mount Replacement....10911
Compression - Checking....10912
ENGINE SPEED CONTROL....10914
Removal And Installation....10914
ENGINE SPEED CONTROL (SJC)....10916
Removal And Installation....10916
Disassembly And Assembly....10918
MUFFLER....10920
Removal And Installation....10920
AIR CLEANER....10922
Housing Removal And Installation....10922
ENGINE COOLING SYSTEM....10924
Radiator Removal And Installation....10924
Hydraulic Fan Description (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10927
Hydraulic Fan Disassembly And Assembly (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10927
Blower Housing Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10928
Fan Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10930
Hydraulic Fan Motor Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above)....10930
Hydraulic Fan Description (S/N AHWA11001 & Above)....10931
Hydraulic Fan Disassembly And Assembly (S/N AHWA11001 & Above)....10931
Blower Housing Removal And Installation (S/N AHWA11001 & Above)....10933
Fan Removal And Installation (S/N AHWA11001 & Above)....10935
Hydraulic Fan Motor Removal And Installation (S/N AHWA11001 & Above)....10935
Water Pump Removal And Installation....10936
Water Pump Disassembly And Assembly....10936
Thermostat Housing Removal And Installation....10937
Thermostat - Checking....10938
LUBRICATION SYSTEM....10940
Oil Pan Removal And Installation....10940
Oil Pump Removal And Installation....10940
Oil Pump Inspection....10941
Engine Oil Pressure-Testing....10942
FUEL SYSTEM....10944
Fuel Shutoff Solenoid - Checking....10944
Fuel Shutoff Solenoid Removal And Installation....10944
Fuel Injection Pump - Checking....10945
Fuel Injection Pump Removal And Installation....10946
Governor Disassembly And Assembly....10950
Fuel Camshaft Removal And Installation....10951
Injection Pump - Timing....10952
Fuel Injector Removal And Installation....10954
Fuel Injector Nozzle Pressure - Checking....10955
Nozzle Spray Condition....10956
Valve Seat Tightness....10956
CYLINDER HEAD....10958
Glow Plugs - Testing....10958
Glow Plugs Removal And Installation....10958
Valve Clearance Adjustment....10959
Valve Timing, Checking....10960
Cylinder Head Removal And Installation....10961
Cylinder Head Disassembly and Assembly....10964
Cylinder Head - Servicing....10964
Cylinder Head Top Clearance....10965
Valve Guide-Checking....10965
Reconditioning The Valve And Valve Seat....10966
Valve Spring....10968
Valve Tappets....10969
Rocker Arm And Shaft - Checking....10969
Push Rod Alignment - Checking....10970
CRANKSHAFT AND PISTONS....10972
Piston And Connecting Rod Removal And Installation....10972
Piston And Connecting Rod - Servicing....10974
Cylinder Bore - Checking....10976
Connecting Rod Alignment....10976
Crankshaft Gear Removal And Installation....10977
Crankshaft And Bearings Removal And Installation....10977
Crankshaft And Bearings - Servicing....10979
CAMSHAFT AND TIMING GEARS....10984
Timing Gearcase Cover Removal And Installation....10984
Timing Gears Backlash - Checking....10986
Idler Gear And Camshaft Removal And Installation....10987
Camshaft - Servicing....10988
Idler Gear And Shaft Servicing....10989
TURBOCHARGER....10990
Description....10990
Testing....10991
Removal And Installation....10991
FLYWHEEL AND HOUSING....10994
Flywheel Removal And Installation....10994
Ring Gear Removal And Installation....10994
Housing Removal And Installation....10995
HEATING, VENTILATION, AIR CONDITIONING....10998
AIR CONDITIONING SYSTEM FLOW....11001
Description....11001
Chart....11002
Components....11003
Safety Equipment....11006
REGULAR MAINTENANCE....11008
Filters....11008
Compressor Drive Belt Adjustment....11008
Compressor Drive Belt Replacement....11008
Condenser....11009
Air Conditioning Lubrication....11009
Air Conditioning Service Chart....11010
Evaporator / Heater Coil....11011
TROUBLESHOOTING....11012
Blower Motor Does Not Operate....11012
Blower Motor Operates Normally, But Air Flow Is Insufficient....11012
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....11012
The Compressor Does Not Operate At All, Or Operates Improperly....11012
Gauge Pressure Related Troubleshooting....11013
Troubleshooting Tree....11015
Temperature/Pressure Chart....11019
Poor A/C Performance....11020
HVAC Repair And Leaks....11021
Electrical System....11022
Engine Coolant Bypassing The Heater Valve....11029
Heater Valve Not Opening Or Closing....11030
SYSTEM CHARGING AND RECLAMATION....11032
Refrigerant Identification....11032
Reclamation And Charging With Recovery / Charging Unit....11033
Charging With A Manifold Gauge Set....11035
COMPRESSOR....11038
Removal And Installation....11038
Oil....11039
Oil Check....11040
Clutch Disassembly And Assembly....11042
CONDENSER....11046
Removal And Installation....11046
RECEIVER / DRIER....11048
Receiver / Drier Removal And Installation....11048
Pressure Relief Valve Removal And Installation....11050
Pressure Switch Removal And Installation....11051
Schraeder Valve Removal And Installation....11051
EVAPORATOR / HEATER UNIT....11052
Removal And Installation....11052
THERMOSTAT....11054
Removal And Installation....11054
EXPANSION VALVE....11056
Removal And Installation....11056
EVAPORATOR COIL....11058
Removal And Installation....11058
HEATER COIL....11060
Removal And Installation With A/C....11060
Removal And Installation Without A/C....11062
BLOWER FAN....11064
Removal And Installation....11064
Disassembly And Assembly....11065
Connector Identification....11067
HEATER VALVE....11068
Removal and Installation....11068
Disassembly And Assembly....11069
SPECIFICATIONS....11070
(S160) LOADER SPECIFICATIONS....11072
Machine Dimensions....11072
Performance....11073
Engine....11073
Drive System....11073
Controls....11074
Hydraulic System....11074
Electrical....11075
Capacities....11075
Tires....11075
TORQUE SPECIFICATIONS FOR BOLTS....11076
Torque For General SAE Bolts....11076
Torque For General Metric Bolts....11077
HYDRAULIC CONNECTION SPECIFICATIONS....11078
O-ring Face Seal Connection....11078
Straight Thread O-ring Fitting....11079
Tubelines And Hoses....11079
Flare Fitting....11080
Port Seal Fitting....11081
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....11082
Specifications....11082
CONVERSIONS....11084
Decimal And Millimeter Equivalents....11084
U.S. To Metric Conversion Chart....11084
SERVICE MANUAL REVISION....11086
Revision No: S160 - 1....11086
Revision No: S160 - 2....11088
Revision No: S160 - 3....11090
Revision No: S160 - 4....11092
Revision No: S160 - 5....11094
6987048 (1-13) - S160 Skid-Steer Loader Service Manual....11096
MAINTENANCE SAFETY....11098
CONTENTS....11100
FOREWORD....11102
FOREWORD....11104
SAFETY INSTRUCTIONS....11106
FIRE PREVENTION....11108
Maintenance....11108
Operation....11108
Electrical....11108
Hydraulic System....11108
Fueling....11108
Starting....11108
Spark Arrester Exhaust System....11108
Welding And Grinding....11109
Fire Extinguishers....11109
SERIAL NUMBER LOCATIONS....11110
Loader Serial Number....11110
Engine Serial Number....11110
DELIVERY REPORT....11111
LOADER IDENTIFICATION....11112
SAFETY AND MAINTENANCE....11114
LIFTING AND BLOCKING THE LOADER....11118
Procedure....11118
LIFT ARM SUPPORT DEVICE....11120
Installing....11120
Removing....11121
OPERATOR CAB....11122
Description....11122
Raising....11122
Lowering....11123
Cab Door Sensor....11124
Special Applications Kit....11125
Special Applications Kit Inspection And Maintenance....11125
TRANSPORTING THE LOADER ON A TRAILER....11126
Loading And Unloading....11126
Fastening....11126
TOWING THE LOADER....11128
Procedure....11128
REMOTE START TOOL KIT -MEL1563....11130
Remote Start Tool - MEL1563....11130
Service Tool Harness Communicator - MEL1566....11132
Remote Start Procedure....11133
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....11138
Description....11138
Remote Start Tool (Service Tool) - 7022042....11139
Loader Service Tool Harness - 6689747....11140
Computer Service Tool Harness - 6689746....11141
Remote Start Procedure....11142
SERVICE SCHEDULE....11146
Chart....11146
AIR CLEANER SERVICE....11148
Replacing Filter Elements....11148
ENGINE COOLING SYSTEM....11150
Cleaning....11150
Checking Level....11151
Removing And Replacing Coolant....11152
FUEL SYSTEM....11154
Fuel Specifications....11154
Biodiesel Blend Fuel....11154
Filling The Fuel Tank....11155
Fuel Filter....11156
Removing Air From The Fuel System....11156
ENGINE LUBRICATION SYSTEM....11158
Checking And Adding Engine Oil....11158
Engine Oil Chart....11158
Removing And Replacing Oil And Filter....11159
HYDRAULIC / HYDROSTATIC SYSTEM....11160
Checking And Adding Fluid....11160
Hydraulic / Hydrostatic Fluid Chart....11160
Removing And Replacing Hydraulic Fluid....11161
Removing And Replacing Hydraulic / Hydrostatic Filter....11162
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....11163
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....11164
Removing And Replacing Hydraulic Charge Filter....11166
Breather Cap....11167
FINAL DRIVE TRANSMISSION (CHAINCASE)....11168
Checking And Adding Oil....11168
Removing And Replacing Oil....11168
BOB-TACH (HAND LEVER)....11170
Inspection And Maintenance....11170
BOB-TACH (POWER)....11172
Inspection And Maintenance....11172
LUBRICATING THE LOADER....11174
Lubrication Locations....11174
TIRE MAINTENANCE....11176
Wheel Nuts....11176
Rotating....11176
Mounting....11176
SPARK ARRESTER MUFFLER....11178
Cleaning Procedure....11178
PIVOT PINS....11180
Inspection And Maintenance....11180
LOADER STORAGE AND RETURN TO SERVICE....11182
Storage....11182
Return To Service....11182
STOPPING THE ENGINE AND LEAVING THE LOADER....11184
Procedure....11184
EMERGENCY EXIT....11186
Rear Window....11186
Front Door....11186
SEAT BELT....11188
Inspection And Maintenance....11188
HYDRAULIC SYSTEM....11190
HYDRAULIC / HYDROSTATIC SCHEMATICS....11196
HYDRAULIC SYSTEM INFORMATION....11212
Glossary Of Hydraulic / Hydrostatic Symbols....11212
Troubleshooting....11216
CYLINDER (LIFT)....11218
Testing....11218
Removal And Installation....11219
Parts Identification....11220
Disassembly And Assembly....11221
CYLINDER (TILT)....11224
Testing....11224
Removal And Installation....11225
Base End Pivot Pin Removal And Installation....11226
Rod End Pivot Pin Bushing And Seal Removal And Installation....11227
Parts Identification....11228
Disassembly And Assembly....11229
CYLINDER (BOB-TACH)....11232
Testing....11232
Removal And Installation....11233
Parts Identification....11234
Disassembly And Assembly....11235
MAIN RELIEF VALVE....11238
Description....11238
Testing....11239
Adjusting....11240
Removal And Installation....11241
HYDRAULIC CONTROL VALVE (STANDARD)....11242
Description....11242
Removal And Installation....11243
Identification Chart....11248
Mount Bracket Removal And Installation....11249
Lift Load Check Valve Removal And Installation....11249
Load Check Valve Removal And Installation (Tilt And Auxiliary)....11250
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....11251
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....11252
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....11252
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....11253
Port Relief Valve Removal And Installation....11253
Plug Removal And Installation....11254
Rubber Boot Removal And Installation....11255
End Cap / Spool Lock Block Removal And Installation....11256
Lift Spool And Detent Removal And Installation....11257
Tilt Spool Removal And Installation....11267
Auxiliary Spool Removal And Installation....11269
Auxiliary Solenoid Removal And Installation (S/N A3L334999 & Below And A3L434999 & Below)....11271
Auxiliary Solenoid Removal And Installation (S/N A3L335001 & Above And A3L435001 & Above)....11272
Solenoid Removal And Installation....11273
Lock Valve Removal And Installation....11274
Lift Arm Bypass Orifice Removal And Installation....11276
Main Relief Valve Removal And Installation....11276
Check Valve Removal And Installation....11277
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....11278
Description....11278
Removal And Installation....11279
Actuator Removal And Installation (Out of Loader)....11283
Identification Chart....11286
Mount Bracket Removal And Installation....11287
Lift Load Check Valve Removal And Installation....11287
Load Check Valve Removal And Installation (Tilt And Auxiliary)....11288
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....11289
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....11290
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....11290
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....11291
Port Relief Valve Removal And Installation....11291
Plug Removal And Installation....11292
End Cap Block Removal And Installation....11293
Lift Spool And Detent Removal And Installation....11294
Tilt Spool Removal And Installation....11299
Auxiliary Spool Removal And Installation....11301
Auxiliary Solenoid Removal And Installation (S/N A3L334999 & Below And A3L434999 & Below)....11303
Auxiliary Solenoid Removal And Installation (S/N A3L335001 & Above And A3L435001 & Above)....11304
Solenoid Removal And Installation....11305
Lock Valve Removal And Installation....11306
Lift Arm Bypass Orifice Removal And Installation....11308
Main Relief Valve Removal And Installation....11308
Check Valve Removal And Installation....11309
LIFT ARM BYPASS CONTROL VALVE....11310
Description....11310
Testing....11310
Removal And Installation....11310
Disassembly And Assembly....11311
HYDRAULIC PUMP (STANDARD)....11312
Description....11312
Pump Test At Quick Couplers....11312
Direct Pump Test (Standard Section)....11313
Direct Pump Test (Charge Section)....11315
Removal And Installation....11317
Hydraulic Pump Startup....11319
Parts Identification....11320
Disassembly And Assembly....11321
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....11330
Description....11330
Pump Test At Quick Couplers....11330
Direct Pump Test (Standard Section)....11331
Direct Pump Test (Charge Section)....11333
Direct Pump Test (High Flow Section)....11335
Removal And Installation....11337
Hydraulic Pump Startup....11339
Parts Identification....11340
Disassembly And Assembly....11341
HYDRAULIC PUMP (SJC)....11354
Description....11354
Pump Test At Quick Couplers....11354
Direct Pump Test (Standard Section)....11355
Direct Pump Test (Charge Section)....11357
Removal And Installation....11359
Hydraulic Pump Startup....11361
Parts Identification....11362
Disassembly And Assembly....11363
HYDRAULIC PUMP (SJC) (HIGH FLOW)....11372
Description....11372
Pump Test At Quick Couplers....11372
Direct Pump Test (Standard Section)....11373
Direct Pump Test (Charge Section)....11375
Direct Pump Test (High Flow Section)....11377
Removal And Installation....11379
Hydraulic Pump Startup....11381
Parts Identification....11382
Disassembly And Assembly....11383
HYDRAULIC / HYDROSTATIC FILTERS....11396
Description....11396
Housing Removal And Installation....11396
Charge Filter Housing Removal And Installation....11398
HYDRAULIC FLUID RESERVOIR....11400
Description....11400
Removal And Installation....11400
Hydraulic Fluid Screen....11403
OIL COOLER....11404
Description....11404
Removal And Installation....11404
BUCKET POSITION VALVE....11406
Description....11406
Solenoid Removal And Installation....11406
Solenoid Testing....11407
Removal And Installation....11408
Disassembly And Assembly....11409
REAR AUXILIARY DIVERTER VALVE....11412
Description....11412
Solenoid Testing....11412
Removal And Installation....11413
Disassembly And Assembly....11416
BOB-TACH (POWER) BLOCK....11422
Description....11422
Removal And Installation....11422
Disassembly And Assembly....11424
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....11428
Description....11428
Removal And Installation....11428
Disassembly And Assembly....11428
HIGH FLOW VALVE....11430
Description....11430
High Flow Relief Valve Testing....11430
High Flow Relief Valve Adjustment....11431
Solenoid Testing....11432
Removal And Installation....11433
Disassembly And Assembly....11434
HYDROSTATIC SYSTEM....11438
HYDROSTATIC SYSTEM INFORMATION....11440
Troubleshooting....11440
Description....11441
HYDROSTATIC DRIVE MOTOR....11442
Description....11442
Removal And Installation....11442
Parts Identification....11445
Disassembly And Assembly....11446
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....11452
Description....11452
Removal And Installation (Left Side)....11453
Removal And Installation (Right Side)....11456
Parts Identification....11459
Disassembly....11460
Assembly....11470
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....11482
Description....11482
Shaft Seal Removal And Installation....11483
Removal And Installation....11485
Parts Identification....11487
Disassembly And Assembly....11488
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....11494
Description....11494
Shaft Seal Removal And Installation....11495
Removal And Installation....11497
Parts Identification....11499
Disassembly And Assembly....11500
CHARGE PRESSURE....11506
Description....11506
Testing (S/N A3L329999 & Below And A3L429999 & Below)....11507
Sender Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....11508
Testing (S/N A3L330001 & Above And A3L430001 & Above)....11509
Sender Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....11510
Adjusting....11511
HYDROSTATIC PUMP....11514
Description....11514
Replenishing / High Pressure Relief Valve Removal And Installation....11514
Removal And Installation....11515
Hydrostatic Pump Startup....11516
Parts Identification (Left Half)....11517
Parts Identification (Right Half)....11518
Disassembly....11519
Assembly....11525
HYDROSTATIC PUMP (SJC)....11532
Description....11532
Hydraulic Controller Removal And Installation....11533
Removal And Installation....11535
Hydrostatic Pump Startup....11537
Parts Identification....11538
High Pressure Relief And Bypass Valve....11539
Charge Relief Valve....11540
Disassembly And Assembly....11541
Mechanical Neutral Adjustment....11557
Hydraulic Controller Neutral Adjustment....11560
DRIVE BELT....11564
Description....11564
Shield Removal And Installation....11564
Adjusting....11565
Belt Removal And Installation....11566
Tensioner Pulley Removal And Installation....11567
Tensioner Pulley Parts Identification....11568
Tensioner Pulley Disassembly....11569
Tensioner Pulley Assembly....11570
TWO-SPEED VALVE....11572
Description....11572
Valve Removal And Installation....11573
Valve Disassembly And Assembly....11575
CASE DRAIN FILTER....11578
Description....11578
Disassembly And Assembly....11578
DRIVE SYSTEM....11580
BRAKE (SINGLE SPEED)....11582
Description....11582
Disc Removal And Installation....11582
BRAKE (TWO-SPEED)....11584
Description....11584
Disc Removal And Installation....11584
Disc Disassembly And Assembly....11585
DRIVE COMPONENTS....11586
Description....11586
Axle Seal Removal And Installation....11587
Axle Sprocket And Bearings Removal And Installation....11589
Chain Removal And Installation....11594
CHAINCASE....11596
Description....11596
Front Cover Removal And Installation....11596
Center Cover Removal And Installation....11597
Rear Cover Removal And Installation....11598
MAINFRAME....11600
SEAT BAR....11604
Description....11604
Removal And Installation....11604
Disassembly And Assembly....11605
Compression Spring Disassembly And Assembly....11606
OPERATOR CAB....11608
Gas Cylinder Removal And Installation....11608
Gas Cylinder Bracket Disassembly And Assembly....11610
Removal And Installation....11611
OPERATOR SEAT....11614
Removal And Installation....11614
Seat Belt Removal And Installation....11614
OPERATOR SEAT (SUSPENSION)....11616
Removal And Installation....11616
Slide Rail Removal And Installation....11617
Seat Belt Removal And Installation....11617
Lower Cushion Removal And Installation....11617
Back Cushion Removal And Installation....11619
Shock Removal And Installation....11619
3-Point Seat Belt Removal And Installation....11620
BOB-TACH (HAND LEVER)....11622
Description....11622
Removal And Installation....11622
Lever And Wedge Disassembly And Assembly....11623
Pivot Pin Bushing And Seal Removal And Installation....11625
BOB-TACH (POWER)....11626
Description....11626
Removal And Installation....11626
Lever And Wedge Disassembly And Assembly....11628
Pivot Pin Bushing And Seal Removal And Installation....11629
LIFT ARMS....11630
Removal And Installation....11630
REAR GRILLE....11634
Removal And Installation....11634
REAR DOOR (TAILGATE)....11636
Removal And Installation....11636
Striker Removal And Installation....11637
Striker Disassembly And Assembly....11637
Striker (Adjusting)....11638
Latch Removal And Installation....11639
FUEL TANK....11640
Removal And Installation....11640
Fuel Level Sender Removal And Installation....11641
Fuel Fill Screen Removal And Installation....11642
CONTROL PEDALS AND LINKAGES....11644
Description....11644
Pedal Removal And Installation....11644
Linkage Removal And Installation....11645
Pedal (Adjusting)....11647
CONTROL PEDALS (ACS)....11648
Description....11648
Foot Sensor Removal And Installation....11648
Foot Pedal Removal And Installation....11649
Foot Pedal Linkage Disassembly And Assembly....11650
CONTROL PANEL....11652
Description....11652
Removal And Installation....11653
Shock Removal And Installation....11656
Shaft Removal And Installation....11656
Shaft Disassembly And Assembly....11657
Linkage Removal And Installation....11658
Pintle Arm Disassembly And Assembly....11662
Linkage Neutral (Adjusting)....11664
Linkage Travel (Adjusting)....11668
CONTROL PANEL (SJC)....11672
Description....11672
Removal And Installation....11672
CONTROL HANDLE / LEVER....11674
Description....11674
Lever Removal And Installation....11674
Boot Removal And Installation....11675
CONTROL HANDLE / LEVER (ACS)....11676
Description....11676
Handle Sensor Removal And Installation....11676
Handle Removal And Installation....11679
Handle Disassembly And Assembly....11680
Lever Removal And Installation....11680
Boot Removal And Installation....11682
CONTROL HANDLE / LEVER (SJC)....11684
Description....11684
Joystick Testing....11684
Joystick Removal And Installation....11685
Joystick Mount Removal And Installation....11686
ACCESS PANEL (INSIDE)....11688
Removal And Installation (Left)....11688
Removal And Installation (Right)....11688
ACCESS PANEL (INSIDE) (SJC)....11690
Removal And Installation (Left)....11690
Removal And Installation (Right)....11691
WINDOW (REAR)....11694
Removal....11694
Installation (Split Molding)....11694
Installation (Continuous Molding)....11696
WINDOW (TOP)....11698
Removal And Installation....11698
WINDOW (SIDE)....11700
Removal And Installation....11700
WINDOW (CAB DOOR)....11702
Removal (Standard Window)....11702
Installation (Standard Window)....11703
Removal And Installation (Special Applications Window)....11705
CAB DOOR....11706
Description....11706
Removal And Installation....11706
Aligning....11707
Adjusting....11708
Checking Operation....11708
ELECTRICAL SYSTEM AND ANALYSIS....11710
ELECTRICAL SCHEMATICS....11714
ELECTRICAL SYSTEM INFORMATION....11720
Glossary Of Electrical Symbols....11720
Standard Cab Harness Connectors....11723
Deluxe Cab Harness Connectors....11724
Mainframe Harness Connectors....11725
Description....11726
Troubleshooting....11727
Fuse And Relay Location / Identification....11728
Solenoid Testing....11729
BATTERY....11730
Removal And Installation....11730
Servicing....11731
Using A Booster Battery (Jump Starting)....11732
ALTERNATOR....11734
Belt Adjustment....11734
Belt Replacement....11734
Charging System Inspection....11735
Alternator Voltage Testing....11736
Low Voltage Testing....11736
High Voltage Testing....11737
Removal And Installation....11738
Parts Identification....11739
STARTER....11740
Testing....11740
Removal And Installation....11741
Parts Identification....11742
INSTRUMENT PANELS....11744
Left Panel....11744
Standard Key Panel....11746
Keyless Start Panel....11746
Deluxe Instrumentation Panel....11747
Side Panel....11748
Front Panel....11748
Front Panel Removal And Installation....11749
Removal And Installation (Left And Right)....11749
Key Switch Removal And Installation....11751
Alarm Removal And Installation....11752
LIGHTS....11754
Front Removal And Installation....11754
Rear Removal And Installation....11755
Cab Light Removal And Installation....11755
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....11756
Description....11756
Connector Identification....11757
Removal And Installation....11763
BOBCAT CONTROLLER (ACS)....11766
Description....11766
Connector And Wire Identification....11767
Removal And Installation....11768
BOBCAT CONTROLLER (SJC) (DRIVE)....11770
Description....11770
Connector Identification....11771
Removal And Installation....11773
SPEED SENSORS (SJC)....11774
Description....11774
Testing....11774
Removal And Installation....11776
DIAGNOSTIC SERVICE CODES....11778
Viewing Service Codes....11778
Service Codes List....11779
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....11784
Description....11784
Inspecting The BICS™ (Engine STOPPED - Key ON)....11785
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....11785
Inspecting The Seat Bar Sensor (Engine RUNNING)....11785
Inspecting The Traction Lock (Engine RUNNING)....11785
Inspecting The Lift Arm Bypass Control....11785
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....11785
Troubleshooting....11786
SEAT BAR SENSOR....11788
Description....11788
Troubleshooting....11788
Testing....11789
Removal And Installation....11790
Bobcat Interlock Control System (BICS™) Circuit Test....11793
TRACTION LOCK....11796
Description....11796
Troubleshooting....11796
Removal And Installation....11797
Inspecting....11801
CONTROL SYSTEM (ACS)....11802
Description....11802
Troubleshooting....11803
Handle Sensor Connector Disassembly And Assembly....11804
Switch Handle Removal....11805
Switch Handle Installation....11807
Actuator Connector Disassembly And Assembly....11810
Handle Lock Solenoid Removal And Installation....11811
Handle Lock Solenoid Disassembly And Assembly....11811
Foot Sensor Disassembly And Assembly....11812
Foot Lock Solenoid Removal And Installation....11813
ELECTRICAL / HYDRAULIC CONTROLS....11814
Identification Chart....11814
Description....11815
Identification Chart ACD Group 0....11816
Identification Chart ACD Group 1....11817
Identification Chart ACD Group 2....11818
Identification Chart ACD Group 3....11819
ELECTRICAL / HYDRAULIC CONTROLS (ACS)....11820
Identification Chart....11820
Description....11821
Identification Chart ACD Group 0....11822
Identification Chart ACD Group 1....11823
Identification Chart ACD Group 2....11824
Identification Chart ACD Group 3....11825
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....11826
Identification Chart....11826
Description....11827
Identification Chart ACD Group 0....11828
Identification Chart ACD Group 1....11829
Identification Chart ACD Group 2....11830
Identification Chart ACD Group 3....11831
SERVICE PC (LAPTOP COMPUTER)....11832
Connecting Remote Start Tool....11832
Connecting Remote Start Tool (Service Tool)....11832
CALIBRATION....11834
Description....11834
Actuator Testing....11834
Lift And Tilt Calibration (SJC)....11837
Hydrostatic Pump Calibration (SJC)....11839
Lift And Tilt Calibration (ACS)....11844
STEERING DRIFT COMPENSATION....11846
Description....11846
Operation....11846
FLYWHEEL RPM SENSOR....11848
Description....11848
Adjusting....11848
CONTROL PANEL SETUP....11850
Right Panel Setup (Deluxe Instrumentation Panel)....11850
Attachment Control Information (Deluxe Instrumentation Panel)....11851
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....11852
Password Description....11852
Changing The Owner Password....11852
Changing The User Passwords....11853
Password Lockout Feature....11853
PASSWORD SETUP (KEYLESS START PANEL)....11854
Password Description....11854
Changing The Owner Password....11854
Password Lockout Feature....11854
MAINTENANCE CLOCK....11856
Description....11856
Setup....11857
Reset....11860
BACK-UP ALARM SYSTEM....11862
Description....11862
Inspecting....11862
Adjusting Switch Position....11863
Troubleshooting (Standard And ACS)....11864
Troubleshooting (Joystick)....11865
Alarm Removal And Installation....11866
Switch Removal And Installation....11866
ENGINE SERVICE....11868
ENGINE INFORMATION....11872
Description....11872
Specifications....11873
Torque Values....11877
Troubleshooting....11877
Engine Removal And Installation....11879
Engine Mount Replacement....11886
Compression - Checking....11887
ENGINE SPEED CONTROL....11888
Removal And Installation....11888
ENGINE SPEED CONTROL (SJC)....11890
Removal And Installation....11890
Disassembly And Assembly....11892
MUFFLER....11894
Removal And Installation....11894
AIR CLEANER....11896
Housing Removal And Installation....11896
ENGINE COOLING SYSTEM....11898
Radiator Removal And Installation....11898
Hydraulic Fan Description (S/N A3L329999 & Below And A3L429999 & Below)....11901
Hydraulic Fan Disassembly And Assembly (S/N A3L329999 & Below And A3L429999 & Below)....11901
Blower Housing Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....11902
Fan Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....11904
Hydraulic Fan Motor Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....11904
Hydraulic Fan Description (S/N A3L330001 & Above And A3L430001 & Above)....11905
Hydraulic Fan Disassembly And Assembly (S/N A3L330001 & Above And A3L430001 & Above)....11905
Blower Housing Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....11907
Fan Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....11909
Hydraulic Fan Motor Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....11909
Water Pump Removal And Installation....11910
Water Pump Disassembly And Assembly....11910
Thermostat Housing Removal And Installation....11911
Thermostat - Checking....11912
LUBRICATION SYSTEM....11914
Oil Pan Removal And Installation....11914
Relief Valve - Testing....11915
Oil Pump Inspection....11915
Oil Filter Cooler Removal And Installation....11916
Engine Oil Pressure - Testing....11917
FUEL SYSTEM....11918
Fuel Shutoff Solenoid - Checking....11918
Fuel Shutoff Solenoid Removal And Installation....11918
Fuel Injection Pump - Checking....11919
Fuel Injection Pump Assembly Removal And Installation....11920
Governor Housing Disassembly And Assembly....11923
Governor Disassembly And Assembly....11925
Fuel Camshaft Removal And Installation....11927
Fuel Injection Pump Removal And Installation....11930
Fuel Injection Pump - Timing....11932
Fuel Injector Removal And Installation....11934
Fuel Injector Nozzle Pressure - Checking....11936
Nozzle Spray Condition....11936
Valve Seat Tightness....11937
CYLINDER HEAD....11938
Glow Plugs - Testing....11938
Glow Plugs Removal And Installation....11938
Valve Clearance Adjustment....11939
Valve Timing - Checking....11940
Cylinder Head Removal And Installation....11941
Cylinder Head Disassembly And Assembly....11944
Cylinder Head - Servicing....11944
Cylinder Head Top Clearance....11945
Valve Guide - Checking....11945
Valve Guide Removal And Installation....11946
Reconditioning The Valve And Valve Seat....11946
Valve Spring....11948
Valve Tappets....11949
Rocker Arm And Shaft - Checking....11950
Bridge Arm And Bridge Arm Shaft - Checking....11950
Bridge Arm Shaft Removal And Installation....11951
Push Rod Alignment - Checking....11952
CRANKSHAFT AND PISTONS....11954
Piston And Connecting Rod Removal And Installation....11954
Piston And Connecting Rod - Servicing....11955
Cylinder Bore - Checking....11959
Connecting Rod Alignment....11960
Crankshaft Gear Removal And Installation....11960
Crankshaft And Bearings Removal And Installation....11961
Crankshaft And Bearings - Servicing....11964
CAMSHAFT AND TIMING GEARS....11968
Timing Gearcase Cover Removal....11968
Timing Gearcase Cover Installation....11969
Timing Gears Backlash - Checking....11972
Idler Gear And Camshaft Removal And Installation....11972
Camshaft - Servicing....11973
Idler Gear And Shaft - Servicing....11974
TURBOCHARGER....11976
Description....11976
Testing....11976
Removal And Installation....11977
FLYWHEEL AND HOUSING....11978
Flywheel Removal And Installation....11978
Ring Gear Removal And Installation....11979
Housing Removal And Installation....11980
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....11982
Description....11982
Testing....11983
Removal And Installation....11986
Disassembly And Assembly....11987
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....11988
AIR CONDITIONING SYSTEM FLOW....11990
Description....11990
Chart....11991
Components....11992
Safety Equipment....11995
REGULAR MAINTENANCE....11996
Filters....11996
Compressor Drive Belt Adjustment....11996
Compressor Drive Belt Replacement....11997
Condenser....11997
Air Conditioning Lubrication....11997
Air Conditioning Service Chart....11998
Evaporator / Heater Coil....11999
TROUBLESHOOTING....12000
Blower Motor Does Not Operate....12000
Blower Motor Operates Normally, But Air Flow Is Insufficient....12000
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....12000
The Compressor Does Not Operate At All, Or Operates Improperly....12000
Gauge Pressure Related Troubleshooting....12001
Troubleshooting Tree....12003
Temperature / Pressure Chart....12007
Poor A/C Performance....12008
HVAC Repair And Leaks....12009
Electrical System....12010
Engine Coolant Bypassing The Heater Valve....12017
Heater Valve Not Opening Or Closing....12018
SYSTEM CHARGING AND RECLAMATION....12020
Refrigerant Identification....12020
Reclamation And Charging With Recovery / Charging Unit....12021
Charging With A Manifold Gauge Set....12023
COMPRESSOR....12026
Removal And Installation....12026
Oil....12028
Oil Check....12028
Clutch Disassembly And Assembly....12030
CONDENSER....12034
Removal And Installation....12034
RECEIVER / DRIER....12036
Receiver / Drier Removal And Installation....12036
Pressure Relief Valve Removal And Installation....12038
Pressure Switch Removal And Installation....12039
Schraeder® Valve Removal And Installation....12039
EVAPORATOR / HEATER UNIT....12040
Removal And Installation....12040
THERMOSTAT....12042
Description....12042
Removal And Installation....12043
EXPANSION VALVE....12044
Removal And Installation....12044
EVAPORATOR COIL....12046
Removal And Installation....12046
HEATER COIL....12048
Removal And Installation With A/C....12048
Removal And Installation Without A/C....12050
BLOWER FAN....12052
Removal And Installation....12052
Disassembly And Assembly....12053
Connector Identification....12055
HEATER VALVE....12056
Removal And Installation....12056
Disassembly And Assembly....12057
SPECIFICATIONS....12058
(S160) LOADER SPECIFICATIONS....12060
Machine Dimensions....12060
Performance....12061
Engine....12061
Drive System....12061
Controls....12062
Hydraulic System....12062
Electrical....12063
Capacities....12063
Tires....12063
TORQUE SPECIFICATIONS FOR BOLTS....12064
Torque For General SAE Bolts....12064
Torque For General Metric Bolts....12065
HYDRAULIC CONNECTION SPECIFICATIONS....12066
O-ring Face Seal Connection....12066
Straight Thread O-ring Fitting....12067
Tubelines And Hoses....12067
Flare Fitting....12068
Port Seal Fitting....12069
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....12070
Specifications....12070
CONVERSIONS....12072
Decimal And Millimeter Equivalent Chart....12072
U.S. To Metric Conversion Chart....12072
ALPHABETICAL INDEX....12074
SERVICE MANUAL REVISION....12078
Revision No: S160 - 1....12078
Revision No: S160 - 2....12080
Revision No: S160 - 3....12082
Revision No: S160 - 4....12084
Revision No: S160 - 5....12086
Revision No: S160 - 6....12088
Revision No: S160 - 7....12090
Revision No: S160 - 8....12092
Revision No: S160 - 9....12094
Revision No: S160 - 10....12096
Revision No: S160 - 11....12098
Revision No: S160 - 12....12100
Revision No: S160 - 13....12102
Revision No: S160 - 14....12104
Revision No: S160 - 15....12106
Revision No: S160 - 16....12108
6987048 (11-10) - S160 Skid-Steer Loader Service Manual....12110
MAINTENANCE SAFETY....12112
ALPHABETICAL INDEX....12114
CONTENTS....12116
FOREWORD....12117
SAFETY INSTRUCTIONS....12120
FIRE PREVENTION....12122
Maintenance....12122
Operation....12122
Electrical....12122
Hydraulic System....12122
Fueling....12122
Starting....12122
Spark Arrestor Exhaust System....12122
Welding And Grinding....12123
Fire Extinguishers....12123
SERIAL NUMBER LOCATIONS....12124
Loader Serial Number....12124
Engine Serial Number....12124
DELIVERY REPORT....12125
BOBCAT LOADER IDENTIFICATION....12126
SAFETY & MAINTENANCE....12128
LIFTING AND BLOCKING THE LOADER....12132
Procedure....12132
LIFT ARM SUPPORT DEVICE....12134
Installing....12134
Removing....12135
OPERATOR CAB....12136
Description....12136
Raising....12136
Lowering....12137
Cab Door Sensor....12138
Special Applications Kit....12138
Special Applications Kit Inspection And Maintenance....12138
TRANSPORTING THE LOADER ON A TRAILER....12140
Loading And Unloading....12140
Fastening....12140
TOWING THE LOADER....12142
Procedure....12142
REMOTE START TOOL KIT -MEL1563....12144
Remote Start Tool - MEL1563....12144
Service Tool Harness Control - MEL1565....12145
Service Tool Harness Communicator - MEL1566....12146
Remote Start Procedure....12147
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....12150
Description....12150
Remote Start Tool (Service Tool) - 7003030....12151
Loader Service Tool Harness - 6689747....12152
Computer Service Tool Harness - 6689746....12153
Remote Start Procedure....12154
SERVICE SCHEDULE....12158
Chart....12158
AIR CLEANER SERVICE....12160
Replacing Filter Elements....12160
ENGINE COOLING SYSTEM....12162
Cleaning....12162
Checking Level....12163
Removing And Replacing Coolant....12164
FUEL SYSTEM....12166
Fuel Specifications....12166
Biodiesel Blend Fuel....12166
Filling The Fuel Tank....12167
Fuel Filter....12168
Removing Air From The Fuel System....12168
ENGINE LUBRICATION SYSTEM....12170
Checking And Adding Engine Oil....12170
Engine Oil Chart....12170
Removing And Replacing Oil And Filter....12171
HYDRAULIC / HYDROSTATIC SYSTEM....12172
Checking And Adding Fluid....12172
Hydraulic / Hydrostatic Fluid Chart....12172
Removing And Replacing Hydraulic Fluid....12173
Removing And Replacing Hydraulic / Hydrostatic Filter....12174
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....12175
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....12176
Removing And Replacing Hydraulic Charge Filter....12178
Removing And Replacing Hydraulic Charge Filter....12179
Breather Cap....12179
FINAL DRIVE TRANSMISSION (CHAINCASE)....12180
Checking And Adding Oil....12180
Removing And Replacing Oil....12180
BOB-TACH (HAND LEVER)....12182
Inspection And Maintenance....12182
BOB-TACH (POWER)....12184
Inspection And Maintenance....12184
LUBRICATING THE LOADER....12186
Lubrication Locations....12186
TIRE MAINTENANCE....12188
Wheel Nuts....12188
Rotating....12188
Mounting....12188
SPARK ARRESTOR MUFFLER....12190
Cleaning Procedure....12190
PIVOT PINS....12192
Inspection And Maintenance....12192
LOADER STORAGE AND RETURN TO SERVICE....12194
Storage....12194
Return to Service....12194
STOPPING THE ENGINE AND LEAVING THE LOADER....12196
Procedure....12196
EMERGENCY EXIT....12198
Rear Window....12198
Front Door....12198
SEAT BELT....12200
Inspection And Maintenance....12200
HYDRAULIC SYSTEM....12202
HYDRAULIC / HYDROSTATIC SCHEMATICS....12208
HYDRAULIC SYSTEM INFORMATION....12224
Glossary Of Hydraulic / Hydrostatic Symbols....12224
Troubleshooting....12228
CYLINDER (LIFT)....12230
Testing....12230
Removal And Installation....12231
Parts Identification....12232
Disassembly and Assembly....12233
CYLINDER (TILT)....12236
Testing....12236
Removal And Installation....12237
Base End Pivot Pin Removal and Installation....12238
Rod End Pivot Pin Bushing And Seal Removal And Installation....12239
Parts Identification....12240
Disassembly And Assembly....12241
CYLINDER (BOB-TACH)....12244
Testing....12244
Removal And Installation....12245
Parts Identification....12246
Disassembly And Assembly....12247
MAIN RELIEF VALVE....12250
Description....12250
Testing....12251
Adjusting....12252
Removal And Installation....12253
HYDRAULIC CONTROL VALVE (STANDARD)....12254
Description....12254
Removal And Installation....12255
Identification Chart....12260
Mount Bracket Removal And Installation....12261
Lift Load Check Valve Removal And Installation....12261
Load Check Valve Removal And Installation (Tilt And Auxiliary)....12262
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....12263
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....12264
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....12264
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....12265
Port Relief Valve Removal And Installation....12265
Plug Removal And Installation....12266
Rubber Boot Removal And Installation....12267
End Cap / Spool Lock Block Removal And Installation....12268
Lift Spool And Detent Removal And Installation....12269
Tilt Spool Removal And Installation....12279
Auxiliary Spool Removal And Installation....12281
Auxiliary Solenoid Removal And Installation (S/N A3L334999 & Below And A3L434999 & Below)....12283
Auxiliary Solenoid Removal And Installation (S/N A3L335001 & Above And A3L435001 & Above)....12284
Solenoid Removal And Installation....12285
Lock Valve Removal And Installation....12286
Lift Arm Bypass Orifice Removal And Installation....12288
Main Relief Valve Removal And Installation....12288
Check Valve Removal And Installation....12289
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....12290
Description....12290
Removal And Installation....12291
Actuator Removal And Installation (Out of Loader)....12295
Identification Chart....12298
Mount Bracket Removal And Installation....12299
Lift Load Check Valve Removal And Installation....12299
Load Check Valve Removal And Installation (Tilt And Auxiliary)....12300
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....12301
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....12302
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....12302
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....12303
Port Relief Valve Removal And Installation....12303
Plug Removal And Installation....12304
End Cap Block Removal And Installation....12305
Lift Spool And Detent Removal And Installation....12306
Tilt Spool Removal And Installation....12311
Auxiliary Spool Removal And Installation....12313
Auxiliary Solenoid Removal And Installation (S/N A3L334999 & Below And A3L434999 & Below)....12315
Auxiliary Solenoid Removal And Installation (S/N A3L335001 & Above And A3L435001 & Above)....12316
Solenoid Removal And Installation....12317
Lock Valve Removal And Installation....12318
Lift Arm Bypass Orifice Removal And Installation....12320
Main Relief Valve Removal And Installation....12320
Check Valve Removal And Installation....12321
LIFT ARM BYPASS CONTROL VALVE....12322
Description....12322
Testing....12322
Removal And Installation....12322
Disassembly And Assembly....12323
HYDRAULIC PUMP (STANDARD)....12324
Description....12324
Pump Test at Quick Couplers....12324
Direct Pump Test (Standard Section)....12325
Direct Pump Test (Charge Section)....12327
Removal And Installation....12329
Hydraulic Pump Startup....12331
Parts Identification....12332
Disassembly And Assembly....12333
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....12342
Description....12342
Pump Test At Quick Couplers....12342
Direct Pump Test (Standard Section)....12343
Direct Pump Test (Charge Section)....12345
Direct Pump Test (High Flow Section)....12347
Removal And Installation....12349
Hydraulic Pump Startup....12351
Parts Identification....12352
Disassembly And Assembly....12353
HYDRAULIC PUMP (SJC)....12366
Description....12366
Pump Test At Quick Couplers....12366
Direct Pump Test (Standard Section)....12367
Direct Pump Test (Charge Section)....12369
Removal And Installation....12371
Hydraulic Pump Startup....12373
Parts Identification....12374
Disassembly And Assembly....12375
HYDRAULIC PUMP (SJC) (HIGH FLOW)....12384
Description....12384
Pump Test At Quick Couplers....12384
Direct Pump Test (Standard Section)....12385
Direct Pump Test (Charge Section)....12387
Direct Pump Test (High Flow Section)....12389
Removal And Installation....12391
Hydraulic Pump Startup....12393
Parts Identification....12394
Disassembly And Assembly....12395
HYDRAULIC / HYDROSTATIC FILTERS....12408
Description....12408
Housing Removal And Installation....12408
Charge Filter Housing Removal And Installation....12410
HYDRAULIC FLUID RESERVOIR....12412
Description....12412
Removal And Installation....12412
Hydraulic Fluid Screen....12415
OIL COOLER....12416
Description....12416
Removal and Installation....12416
BUCKET POSITION VALVE....12418
Description....12418
Solenoid Removal And Installation....12418
Solenoid Testing....12419
Removal And Installation....12420
Disassembly And Assembly....12421
REAR AUXILIARY DIVERTER VALVE....12424
Description....12424
Solenoid Testing....12424
Removal And Installation....12425
Disassembly And Assembly....12428
BOB-TACH (POWER) BLOCK....12434
Description....12434
Removal And Installation....12434
Disassembly And Assembly....12436
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....12440
Description....12440
Removal And Installation....12440
Disassembly And Assembly....12440
HIGH FLOW VALVE....12442
Description....12442
High Flow Relief Valve Testing....12442
High Flow Relief Valve Adjustment....12443
Solenoid Testing....12444
Removal And Installation....12445
Disassembly And Assembly....12446
HYDROSTATIC SYSTEM....12450
HYDROSTATIC SYSTEM INFORMATION....12452
Troubleshooting....12452
Description....12453
HYDROSTATIC DRIVE MOTOR....12454
Description....12454
Removal And Installation....12454
Parts Identification....12457
Disassembly And Assembly....12458
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....12464
Description....12464
Removal And Installation (Left Side)....12465
Removal And Installation (Right Side)....12468
Parts Identification....12471
Disassembly....12472
Assembly....12482
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)....12494
Description....12494
Shaft Seal Removal And Installation....12495
Removal And Installation....12497
Parts Identification....12499
Disassembly And Assembly....12500
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)....12506
Description....12506
Shaft Seal Removal And Installation....12507
Removal And Installation....12509
Parts Identification....12511
Disassembly And Assembly....12512
CHARGE PRESSURE....12518
Description....12518
Testing (S/N A3L329999 & Below And A3L429999 & Below)....12519
Sender Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....12520
Testing (S/N A3L330001 & Above And A3L430001 & Above)....12521
Sender Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....12522
Adjusting....12523
HYDROSTATIC PUMP....12526
Description....12526
Replenishing / High Pressure Relief Valve Removal And Installation....12526
Removal And Installation....12527
Hydrostatic Pump Startup....12528
Parts Identification (Left Half)....12529
Parts Identification (Right Half)....12530
Disassembly....12531
Assembly....12537
HYDROSTATIC PUMP (SJC)....12544
Description....12544
Hydraulic Controller Removal And Installation....12545
Removal And Installation....12547
Hydrostatic Pump Startup....12549
Parts Identification....12550
High Pressure Relief And Bypass Valve....12551
Charge Relief Valve....12552
Disassembly And Assembly....12553
Mechanical Neutral Adjustment....12569
Hydraulic Controller Neutral Adjustment....12572
DRIVE BELT....12576
Description....12576
Shield Removal And Installation....12576
Adjusting....12577
Belt Removal And Installation....12578
Tensioner Pulley Removal And Installation....12579
Tensioner Pulley Parts Identification....12580
Tensioner Pulley Disassembly....12581
Tensioner Pulley Assembly....12582
TWO-SPEED VALVE....12584
Description....12584
Valve Removal And Installation....12585
Valve Disassembly And Assembly....12587
CASE DRAIN FILTER....12590
Description....12590
Disassembly And Assembly....12590
DRIVE SYSTEM....12592
BRAKE (SINGLE SPEED)....12594
Description....12594
Disc Removal And Installation....12594
BRAKE (TWO-SPEED)....12596
Description....12596
Disc Removal And Installation....12596
Disc Disassembly And Assembly....12597
DRIVE COMPONENTS....12598
Description....12598
Axle Seal Removal And Installation....12599
Axle Sprocket And Bearings Removal And Installation....12601
Chain Removal And Installation....12606
CHAINCASE....12608
Description....12608
Front Cover Removal And Installation....12608
Center Cover Removal And Installation....12609
Rear Cover Removal And Installation....12610
MAINFRAME....12612
SEAT BAR....12616
Description....12616
Removal And Installation....12616
Disassembly And Assembly....12617
Compression Spring Disassembly And Assembly....12618
OPERATOR CAB....12620
Gas Cylinder Removal And Installation....12620
Gas Cylinder Bracket Disassembly And Assembly....12622
Removal And Installation....12623
OPERATOR SEAT....12626
Removal And Installation....12626
Seat Belt Removal And Installation....12626
OPERATOR SEAT (SUSPENSION)....12628
Removal And Installation....12628
Slide Rail Removal And Installation....12629
Seat Belt Removal and Installation....12629
Lower Cushion Removal And Installation....12629
Back Cushion Removal And Installation....12631
Shock Removal And Installation....12631
3-Point Seat Belt Removal And Installation....12632
BOB-TACH (HAND LEVER)....12634
Description....12634
Removal And Installation....12634
Lever And Wedge Disassembly And Assembly....12635
Pivot Pin Bushing And Seal Removal And Installation....12637
BOB-TACH (POWER)....12638
Description....12638
Removal And Installation....12638
Lever And Wedge Disassembly And Assembly....12640
Pivot Pin Bushing And Seal Removal And Installation....12641
LIFT ARMS....12642
Removal And Installation....12642
REAR GRILLE....12646
Removal And Installation....12646
REAR DOOR (TAILGATE)....12648
Removal And Installation....12648
Striker Removal And Installation....12649
Striker Disassembly And Assembly....12649
Striker (Adjusting)....12650
Latch Removal And Installation....12651
FUEL TANK....12652
Removal And Installation....12652
Fuel Level Sender Removal And Installation....12653
Fuel Fill Screen Removal And Installation....12654
CONTROL PEDALS AND LINKAGES....12656
Description....12656
Pedal Removal And Installation....12656
Linkage Removal And Installation....12657
Pedal (Adjusting)....12659
CONTROL PEDALS (ACS)....12660
Description....12660
Foot Sensor Removal And Installation....12660
Foot Pedal Removal And Installation....12661
Foot Pedal Linkage Disassembly And Assembly....12662
CONTROL PANEL....12664
Description....12664
Removal And Installation....12665
Shock Removal And Installation....12668
Shaft Removal And Installation....12668
Shaft Disassembly And Assembly....12669
Linkage Removal And Installation....12670
Pintle Arm Disassembly And Assembly....12674
Linkage Neutral (Adjusting)....12676
Linkage Travel (Adjusting)....12680
CONTROL PANEL (SJC)....12684
Description....12684
Removal And Installation....12684
CONTROL HANDLE / LEVER....12686
Description....12686
Lever Removal And Installation....12686
Boot Removal And Installation....12687
CONTROL HANDLE / LEVER (ACS)....12688
Description....12688
Handle Sensor Removal And Installation....12688
Handle Removal And Installation....12691
Handle Disassembly And Assembly....12692
Lever Removal And Installation....12692
Boot Removal And Installation....12694
CONTROL HANDLE / LEVER (SJC)....12696
Description....12696
Joystick Testing....12696
Joystick Removal And Installation....12697
Joystick Mount Removal And Installation....12698
ACCESS PANEL (INSIDE)....12700
Removal And Installation (Left)....12700
Removal And Installation (Right)....12700
ACCESS PANEL (INSIDE) (SJC)....12702
Removal And Installation (Left)....12702
Removal And Installation (Right)....12703
WINDOW (REAR)....12706
Removal....12706
Installation (Split Molding)....12706
Installation (Continuous Molding)....12708
WINDOW (TOP)....12710
Removal And Installation....12710
WINDOW (SIDE)....12712
Removal And Installation....12712
WINDOW (CAB DOOR)....12714
Removal (Standard Window)....12714
Installation (Standard Window)....12715
Removal And Installation (Special Applications Window)....12717
CAB DOOR....12718
Description....12718
Removal And Installation....12718
Aligning....12719
Adjusting....12720
Checking Operation....12720
ELECTRICAL SYSTEM & ANALYSIS....12722
ELECTRICAL SCHEMATICS....12728
ELECTRICAL SYSTEM INFORMATION....12734
Glossary Of Electrical Symbols....12734
Standard Cab Harness Connectors....12737
Deluxe Cab Harness Connectors....12738
Mainframe Harness Connectors....12739
Description....12740
Troubleshooting....12741
Fuse And Relay Location / Identification....12742
Solenoid Testing....12743
BATTERY....12744
Removal And Installation....12744
Servicing....12745
Using A Booster Battery (Jump Starting)....12746
ALTERNATOR....12748
Belt Adjustment....12748
Belt Replacement....12748
Charging System Inspection....12749
Alternator Voltage Testing....12750
Low Voltage Testing....12750
High Voltage Testing....12751
Removal And Installation....12752
Parts Identification....12753
STARTER....12754
Testing....12754
Removal And Installation....12755
Parts Identification....12756
INSTRUMENT PANELS....12758
Left Panel....12758
Standard Key Panel....12760
Keyless Start Panel....12760
Deluxe Instrumentation Panel....12761
Side Panel....12762
Front Panel....12762
Front Panel Removal And Installation....12763
Removal And Installation (Left And Right)....12763
Key Switch Removal And Installation....12765
Alarm Removal And Installation....12766
LIGHTS....12768
Front Removal And Installation....12768
Rear Removal And Installation....12769
Cab Light Removal And Installation....12769
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....12770
Description....12770
Connector Identification....12771
Removal And Installation....12777
BOBCAT CONTROLLER (ACS)....12780
Description....12780
Connector And Wire Identification....12781
Removal And Installation....12782
BOBCAT CONTROLLER (SJC) (DRIVE)....12784
Description....12784
Connector Identification....12785
Removal And Installation....12787
SPEED SENSORS (SJC)....12788
Description....12788
Testing....12788
Removal And Installation....12790
DIAGNOSTIC SERVICE CODES....12792
Viewing Service Codes....12792
Service Codes List....12793
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....12798
Description....12798
Inspecting The BICS (Engine STOPPED - Key ON)....12799
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....12799
Inspecting The Seat Bar Sensor (Engine RUNNING)....12799
Inspecting The Traction Lock (Engine RUNNING)....12799
Inspecting The Lift Arm Bypass Control....12799
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....12799
Troubleshooting....12800
SEAT BAR SENSOR....12802
Description....12802
Troubleshooting....12802
Testing....12803
Removal And Installation....12804
Bobcat Interlock Control System (BICS) Circuit Test....12806
TRACTION LOCK....12808
Description....12808
Troubleshooting....12808
Removal And Installation....12809
Inspecting....12813
CONTROL SYSTEM (ACS)....12814
Description....12814
Troubleshooting....12815
Handle Sensor Connector Disassembly And Assembly....12816
Switch Handle Removal....12817
Switch Handle Installation....12819
Actuator Connector Disassembly And Assembly....12822
Handle Lock Solenoid Removal And Installation....12823
Handle Lock Solenoid Disassembly And Assembly....12823
Foot Sensor Disassembly And Assembly....12824
Foot Lock Solenoid Removal And Installation....12825
ELECTRICAL / HYDRAULIC CONTROLS....12826
Identification Chart....12826
Description....12827
Identification Chart ACD Group 0....12828
Identification Chart ACD Group 1....12829
Identification Chart ACD Group 2....12830
Identification Chart ACD Group 3....12831
ELECTRICAL / HYDRAULIC CONTROLS (ACS)....12832
Identification Chart....12832
Description....12833
Identification Chart ACD Group 0....12834
Identification Chart ACD Group 1....12835
Identification Chart ACD Group 2....12836
Identification Chart ACD Group 3....12837
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....12838
Identification Chart....12838
Description....12839
Identification Chart ACD Group 0....12840
Identification Chart ACD Group 1....12841
Identification Chart ACD Group 2....12842
Identification Chart ACD Group 3....12843
SERVICE PC (LAPTOP COMPUTER)....12844
Connecting Remote Start Tool....12844
Connecting Remote Start Tool (Service Tool)....12844
CALIBRATION....12846
Description....12846
Actuator Testing....12846
Lift And Tilt Calibration (SJC)....12849
Hydrostatic Pump Calibration (SJC)....12851
Lift And Tilt Calibration (ACS)....12856
STEERING DRIFT COMPENSATION....12858
Description....12858
Operation....12858
FLYWHEEL RPM SENSOR....12860
Description....12860
Adjusting....12860
CONTROL PANEL SETUP....12862
Right Panel Setup (Deluxe Instrumentation Panel)....12862
Attachment Control Information (Deluxe Instrumentation Panel)....12863
PASSWORD SETUP (DELUXE INSTRUMENTATION pANEL)....12864
Password Description....12864
Changing The Owner Password....12864
Changing The User Passwords....12865
Password Lockout Feature....12865
PASSWORD SETUP (KEYLESS START PANEL)....12866
Password Description....12866
Changing The Owner Password....12866
Password Lockout Feature....12866
MAINTENANCE CLOCK....12868
Description....12868
Setup....12869
Reset....12872
BACK-UP ALARM SYSTEM....12874
Description....12874
Inspecting....12874
Adjusting Switch Position....12875
Troubleshooting (Standard and ACS)....12876
Troubleshooting (Joystick)....12877
Alarm Removal And Installation....12878
Switch Removal And Installation....12878
ENGINE SERVICE....12880
ENGINE INFORMATION....12884
Description....12884
Specifications....12885
Torque Values....12889
Troubleshooting....12889
Engine Removal And Installation....12891
Engine Mount Replacement....12898
Compression - Checking....12899
ENGINE SPEED CONTROL....12900
Removal And Installation....12900
ENGINE SPEED CONTROL (SJC)....12902
Removal And Installation....12902
Disassembly And Assembly....12904
MUFFLER....12906
Removal And Installation....12906
AIR CLEANER....12908
Housing Removal And Installation....12908
ENGINE COOLING SYSTEM....12910
Radiator Removal And Installation....12910
Hydraulic Fan Description (S/N A3L329999 & Below And A3L429999 & Below)....12913
Hydraulic Fan Disassembly And Assembly (S/N A3L329999 & Below And A3L429999 & Below)....12913
Blower Housing Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....12914
Fan Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....12916
Hydraulic Fan Motor Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below)....12916
Hydraulic Fan Description (S/N A3L330001 & Above And A3L430001 & Above)....12917
Hydraulic Fan Disassembly And Assembly (S/N A3L330001 & Above And A3L430001 & Above)....12917
Blower Housing Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....12919
Fan Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....12921
Hydraulic Fan Motor Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above)....12921
Water Pump Removal And Installation....12922
Water Pump Disassembly And Assembly....12922
Thermostat Housing Removal And Installation....12923
Thermostat - Checking....12924
LUBRICATION SYSTEM....12926
Oil Pan Removal And Installation....12926
Oil Pump Removal And Installation....12926
Relief Valve - Testing....12927
Oil Pump Inspection....12927
Oil Filter Cooler Removal And Installation....12928
Engine Oil Pressure - Testing....12929
FUEL SYSTEM....12930
Fuel Shutoff Solenoid - Checking....12930
Fuel Shutoff Solenoid Removal And Installation....12930
Fuel Injection Pump - Checking....12931
Fuel Injection Pump Assembly Removal And Installation....12932
Governor Housing Disassembly And Assembly....12935
Governor Disassembly And Assembly....12937
Fuel Camshaft Removal And Installation....12939
Fuel Injection Pump Removal And Installation....12941
Fuel Injection Pump - Timing....12943
Fuel Injector Removal And Installation....12945
Fuel Injector Nozzle Pressure - Checking....12947
Nozzle Spray Condition....12947
Valve Seat Tightness....12948
CYLINDER HEAD....12950
Glow Plugs - Testing....12950
Glow Plugs Removal And Installation....12950
Valve Clearance Adjustment....12951
Valve Timing - Checking....12952
Cylinder Head Removal And Installation....12953
Cylinder Head Disassembly And Assembly....12956
Cylinder Head - Servicing....12956
Cylinder Head Top Clearance....12957
Valve Guide - Checking....12957
Valve Guide Removal And Installation....12958
Reconditioning The Valve And Valve Seat....12958
Valve Spring....12960
Valve Tappets....12961
Rocker Arm And Shaft - Checking....12962
Bridge Arm And Bridge Arm Shaft - Checking....12962
Bridge Arm Shaft Removal And Installation....12963
Push Rod Alignment - Checking....12964
CRANKSHAFT AND PISTONS....12966
Piston And Connecting Rod Removal And Installation....12966
Piston And Connecting Rod - Servicing....12967
Cylinder Bore - Checking....12971
Connecting Rod Alignment....12972
Crankshaft Gear Removal And Installation....12972
Crankshaft And Bearings Removal And Installation....12973
Crankshaft And Bearings - Servicing....12976
CAMSHAFT AND TIMING GEARS....12980
Timing Gearcase Cover Removal....12980
Timing Gearcase Cover Installation....12981
Timing Gears Backlash - Checking....12984
Idler Gear And Camshaft Removal And Installation....12984
Camshaft - Servicing....12985
Idler Gear And Shaft - Servicing....12986
TURBOCHARGER....12988
Description....12988
Testing....12988
Removal And Installation....12989
FLYWHEEL AND HOUSING....12990
Flywheel Removal And Installation....12990
Ring Gear Removal And Installation....12991
Housing Removal And Installation....12992
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....12994
Description....12994
Testing....12995
Removal And Installation....12998
Disassembly And Assembly....12999
HEATING, VENTILATION, AIR CONDITIONING....13000
AIR CONDITIONING SYSTEM FLOW....13003
Description....13003
Chart....13004
Components....13005
Safety Equipment....13008
REGULAR MAINTENANCE....13010
Filters....13010
Compressor Drive Belt Adjustment....13010
Compressor Drive Belt Replacement....13011
Condenser....13011
Air Conditioning Lubrication....13011
Air Conditioning Service Chart....13012
Evaporator / Heater Coil....13013
TROUBLESHOOTING....13014
Blower Motor Does Not Operate....13014
Blower Motor Operates Normally, But Air Flow Is Insufficient....13014
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....13014
The Compressor Does Not Operate At All, Or Operates Improperly....13014
Gauge Pressure Related Troubleshooting....13015
Troubleshooting Tree....13017
Temperature / Pressure Chart....13021
Poor A/C Performance....13022
HVAC Repair And Leaks....13023
Electrical System....13024
Engine Coolant Bypassing The Heater Valve....13031
Heater Valve Not Opening Or Closing....13032
SYSTEM CHARGING AND RECLAMATION....13034
Refrigerant Identification....13034
Reclamation And Charging With Recovery / Charging Unit....13035
Charging With A Manifold Gauge Set....13037
COMPRESSOR....13040
Removal And Installation....13040
Oil....13042
Oil Check....13042
Clutch Disassembly And Assembly....13044
CONDENSER....13048
Removal And Installation....13048
RECEIVER / DRIER....13050
Receiver / Drier Removal And Installation....13050
Pressure Relief Valve Removal And Installation....13052
Pressure Switch Removal And Installation....13053
Schraeder Valve Removal And Installation....13053
EVAPORATOR / HEATER UNIT....13054
Removal And Installation....13054
THERMOSTAT....13056
Description....13056
Removal And Installation....13057
EXPANSION VALVE....13058
Removal And Installation....13058
EVAPORATOR COIL....13060
Removal And Installation....13060
HEATER COIL....13062
Removal And Installation With A/C....13062
Removal And Installation Without A/C....13064
BLOWER FAN....13066
Removal And Installation....13066
Disassembly And Assembly....13067
Connector Identification....13069
HEATER VALVE....13070
Removal And Installation....13070
Disassembly And Assembly....13071
SPECIFICATIONS....13072
(S160) LOADER SPECIFICATIONS....13074
Machine Dimensions....13074
Performance....13075
Engine....13075
Drive System....13075
Controls....13076
Hydraulic System....13076
Electrical....13077
Capacities....13077
Tires....13077
TORQUE SPECIFICATIONS FOR BOLTS....13078
Torque For General SAE Bolts....13078
Torque For General Metric Bolts....13079
HYDRAULIC CONNECTION SPECIFICATIONS....13080
O-ring Face Seal Connection....13080
Straight Thread O-ring Fitting....13081
Tubelines And Hoses....13081
Flare Fitting....13082
Port Seal Fitting....13083
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....13084
Specifications....13084
CONVERSIONS....13086
Decimal And Millimeter Equivalent Chart....13086
U.S. To Metric Conversion Chart....13086
SERVICE MANUAL REVISION....13088
Revision No: S160 - 1....13088
Revision No: S160 - 2....13090
Revision No: S160 - 3....13092
Revision No: S160 - 4....13094
Revision No: S160 - 5....13096
Revision No: S160 - 6....13098
Revision No: S160 - 7....13100
Revision No: S160 - 8....13102
Revision No: S160 - 9....13104
Revision No: S160 - 10....13106
Revision No: S160 - 11....13108
Revision No: S160 - 12....13110
Revision No: S160 - 13....13112
Revision No: S160 - 14....13114
6987054 (10-08) - S150 Skid-Steer Loader Service Manual....13116
MAINTENANCE SAFETY....13118
ALPHABETICAL INDEX....13120
CONTENTS....13122
FOREWORD....13123
SAFETY INSTRUCTIONS....13126
FIRE PREVENTION....13128
Maintenance....13128
Operation....13128
Electrical....13128
Hydraulic System....13128
Fueling....13128
Starting....13128
Welding And Grinding....13129
Fire Extinguishers....13129
SERIAL NUMBER LOCATIONS....13130
Loader Serial Number....13130
Engine Serial Number....13130
DELIVERY REPORT....13131
BOBCAT LOADER IDENTIFICATION....13132
SAFETY AND MAINTENANCE....13134
LIFTING AND BLOCKING THE LOADER....13138
Procedure....13138
LIFT ARM SUPPORT DEVICE....13140
Installing....13140
Removing....13141
OPERATOR CAB....13142
Description....13142
Raising....13143
Lowering....13144
Cab Door Sensor....13145
Special Applications Kit....13145
Special Applications Kit Inspection And Maintenance....13145
TRANSPORTING THE LOADER ON A TRAILER....13146
Loading And Unloading....13146
Fastening....13146
TOWING THE LOADER....13148
Procedure....13148
REMOTE START TOOL KIT -MEL1563....13150
Remote Start Tool - MEL1563....13150
Service Tool Harness Control - MEL1565....13151
Service Tool Harness Communicator - MEL1566....13152
Remote Start Procedure....13153
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....13156
Description....13156
Remote Start Tool (Service Tool) - 6689778....13157
Loader Service Tool Harness - 6689747....13158
Computer Service Tool Harness - 6689746....13159
Remote Start Procedure....13160
SERVICE SCHEDULE....13164
Chart....13164
AIR CLEANER SERVICE....13166
Replacing Filter Elements....13166
ENGINE COOLING SYSTEM....13168
Cleaning....13168
Checking Level....13168
Removing And Replacing Coolant....13169
FUEL SYSTEM....13170
Fuel Specifications....13170
Biodiesel Blend Fuel....13170
Filling The Fuel Tank....13171
Fuel Filter....13172
Removing Air From The Fuel System....13172
ENGINE LUBRICATION SYSTEM....13174
Checking And Adding Engine Oil....13174
Engine Oil Chart....13174
Removing And Replacing Oil And Filter....13175
HYDRAULIC / HYDROSTATIC SYSTEM....13176
Checking And Adding Fluid....13176
Hydraulic / Hydrostatic Fluid Chart....13176
Removing And Replacing Hydraulic Fluid....13177
Removing And Replacing Hydraulic / Hydrostatic Filter....13177
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....13178
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....13178
Removing And Replacing Hydraulic Charge Filter....13180
Breather Cap....13181
FINAL DRIVE TRANSMISSION (CHAINCASE)....13182
Checking And Adding Oil....13182
Removing And Replacing Oil....13182
BOB-TACH (HAND LEVER)....13184
Inspection And Maintenance....13184
BOB-TACH (POWER)....13186
Inspection And Maintenance....13186
LUBRICATING THE LOADER....13188
Lubrication Locations....13188
TIRE MAINTENANCE....13190
Wheel Nuts....13190
Rotating....13190
Mounting....13190
SPARK ARRESTOR MUFFLER....13192
Cleaning Procedure....13192
PIVOT PINS....13194
Inspection And Maintenance....13194
LOADER STORAGE AND RETURN TO SERVICE....13196
Storage....13196
Return to Service....13196
STOPPING THE ENGINE AND LEAVING THE LOADER....13198
Procedure....13198
Emergency Exit....13199
HYDRAULIC SYSTEM....13200
HYDRAULIC SYSTEM INFORMATION....13212
Glossary Of Hydraulic / Hydrostatic Symbols....13212
Troubleshooting....13216
CYLINDER (LIFT)....13218
Testing....13218
Removal And Installation....13219
Parts Identification....13220
Disassembly and Assembly....13221
CYLINDER (TILT)....13224
Testing....13224
Removal And Installation....13225
Base End Pivot Pin Removal and Installation....13226
Rod End Pivot Pin Bushing And Seal Removal And Installation....13227
Parts Identification....13228
Disassembly And Assembly....13229
CYLINDER (BOB-TACH)....13232
Testing....13232
Removal And Installation....13233
Parts Identification....13234
Disassembly and Assembly....13235
MAIN RELIEF VALVE....13238
Description....13238
Testing....13238
Adjusting....13239
Removal and Installation....13240
HYDRAULIC CONTROL VALVE (STANDARD)....13242
Description....13242
Removal And Installation....13242
Identification Chart....13247
Mount Bracket Removal And Installation....13248
Lift Load Check Valve Removal And Installation....13248
Load Check Valve Removal And Installation (Tilt & Auxiliary)....13249
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....13250
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)....13251
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....13251
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....13252
Port Relief Valve Removal And Installation....13252
Plug Removal And Installation....13253
Rubber Boot Removal And Installation....13254
End Cap/Spool Lock Block Removal And Installation....13255
Lift Spool And Detent Removal And Installation....13256
Tilt Spool Removal And Installation....13266
Auxiliary Spool Removal And Installation....13268
Auxiliary Solenoid Removal And Installation....13270
Solenoid Removal And Installation....13271
Lock Valve Removal And Installation....13272
Lift Arm Bypass Orifice Removal And Installation....13274
Main Relief Valve Removal And Installation....13274
Check Valve Removal And Installation....13275
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....13276
Description....13276
Removal And Installation....13276
Actuator Removal And Installation (Out of Loader)....13281
Identification Chart....13284
Mount Bracket Removal And Installation....13285
Lift Load Check Valve Removal And Installation....13285
Load Check Valve Removal And Installation (Tilt & Auxiliary)....13286
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....13287
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)....13288
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....13288
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....13289
Port Relief Valve Removal And Installation....13289
Plug Removal And Installation....13290
End Cap Block Removal And Installation....13291
Lift Spool And Detent Removal And Installation....13292
Tilt Spool Removal And Installation....13297
Auxiliary Spool Removal And Installation....13299
Auxiliary Solenoid Removal And Installation....13300
Solenoid Removal And Installation....13301
Lock Valve Removal And Installation....13303
Lift Arm Bypass Orifice Removal And Installation....13304
Main Relief Valve Removal And Installation....13305
Check Valve Removal And Installation....13306
LIFT ARM BYPASS CONTROL VALVE....13308
Description....13308
Testing....13308
Removal and Installation....13308
Disassembly And Assembly....13309
HYDRAULIC PUMP (STANDARD)....13310
Description....13310
Pump Test at Quick Couplers....13310
Direct Pump Test (Standard Section)....13311
Direct Pump Test (Charge Section)....13313
Removal And Installation....13315
Hydraulic Pump Start Up....13317
Parts Identification....13318
Disassembly And Assembly....13319
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....13328
Description....13328
Pump Test At Quick Couplers....13328
Direct Pump Test (Standard Section)....13329
Direct Pump Test (Charge Section)....13331
Direct Pump Test (High Flow Section)....13333
Removal And Installation....13335
Hydraulic Pump Start Up....13337
Parts Identification....13338
Disassembly And Assembly....13339
HYDRAULIC PUMP (SJC)....13352
Description....13352
Pump Test At Quick Couplers....13352
Direct Pump Test (Standard Section)....13353
Direct Pump Test (Charge Section)....13355
Removal And Installation....13357
Hydraulic Pump Start Up....13359
Parts Identification....13360
Disassembly And Assembly....13361
HYDRAULIC PUMP (SJC) (HIGH FLOW)....13370
Description....13370
Pump Test At Quick Couplers....13370
Direct Pump Test (Standard Section)....13371
Direct Pump Test (Charge Section)....13373
Direct Pump Test (High Flow Section)....13375
Removal And Installation....13377
Hydraulic Pump Start Up....13379
Parts Identification....13380
Disassembly And Assembly....13381
HYDRAULIC/HYDROSTatIC FILTERS....13394
Description....13394
Housing Removal And Installation....13394
Charge Filter Housing Removal And Installation....13396
HYDRAULIC FLUID RESERVOIR....13398
Description....13398
Removal And Installation....13398
Hydraulic Fluid Screen....13401
OIL COOLER....13402
Description....13402
Removal and Installation....13402
BUCKET POSITION VALVE....13404
Description....13404
Solenoid Removal And Installation....13404
Solenoid Testing....13405
Removal And Installation....13406
Disassembly And Assembly....13407
REAR AUXILIARY DIVERTER VALVE....13410
Description....13410
Removal And Installation....13410
Disassembly And Assembly....13413
Solenoid Testing....13419
BOB-TACH (POWER) BLOCK....13420
Description....13420
Removal And Installation....13420
Disassembly And Assembly....13422
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....13426
Description....13426
Removal and Installation....13426
Disassembly And Assembly....13426
HIGH FLOW VALVE....13428
Description....13428
High Flow Relief Valve Testing....13428
High Flow Relief Valve Adjustment....13429
Solenoid Testing....13430
Removal And Installation....13431
Disassembly And Assembly....13432
HYDROSTATIC SYSTEM....13436
HYDROSTATIC SYSTEM INFORMATION....13438
Troubleshooting....13438
Description....13439
HYDROSTATIC MOTOR....13440
Description....13440
Removal And Installation....13440
Parts Identification....13443
Disassembly and Assembly....13444
HYDROSTATIC MOTOR (TWO-SPEED)....13450
Description....13450
Removal And Installation (Left Side)....13451
Removal And Installation (Right Side)....13454
Parts Identification....13457
Disassembly....13458
Assembly....13468
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO- SPEED WITH MANUAL CONTROLS)....13480
Description....13480
Shaft Seal Removal And Installation....13480
Removal And Installation....13482
Parts Identification....13484
Disassembly and Assembly....13485
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO- SPEED WITH SJC CONTROLS)....13490
Description....13490
Shaft Seal Removal And Installation....13490
Removal And Installation....13492
Parts Identification....13494
Disassembly and Assembly....13495
CHARGE PRESSURE....13500
Description....13500
Testing....13500
Sender Removal And Installation....13501
Adjusting....13502
HYDROSTATIC PUMP....13504
Description....13504
Replenishing/High Pressure Relief Valve....13504
Removal And Installation....13505
Hydrostatic Pump Start Up....13506
Parts Identification (Left Half)....13507
Parts Identification (Right Half)....13508
Disassembly....13509
Assembly....13515
HYDROSTATIC PUMP (SJC)....13522
Description....13522
Hydraulic Controller Removal And Installation....13523
Removal And Installation....13525
Hydrostatic Pump Start Up....13527
Parts Identification....13528
High Pressure Relief and Bypass Valve....13529
Charge Relief Valve....13530
Disassembly and Assembly....13531
Mechanical Neutral Adjustment....13547
Hydraulic Controller Neutral Adjustment....13550
DRIVE BELT....13554
Description....13554
Shield Removal And Installation....13554
Adjusting....13554
Belt Removal And Installation....13556
Belt Tensioner Removal And Installation....13557
Belt Tensioner Parts Identification....13558
Belt Tensioner Disassembly....13559
Belt Tensioner Assembly....13560
TWO-SPEED VALVE....13562
Description....13562
Valve Removal And Installation....13563
Valve Disassembly And Assembly....13565
CASE DRAIN FILTER....13568
Description....13568
Disassembly And Assembly....13568
DRIVE SYSTEM....13570
BRAKE (SINGLE SPEED)....13572
Description....13572
Disc Removal And Installation....13572
BRAKE (TWO-SPEED)....13574
Description....13574
Disc Removal And Installation....13574
Disc Disassembly and Assembly....13575
DRIVE COMPONENTS....13576
Description....13576
Axle Seal Removal And Installation....13577
Axle Sprocket And Bearings Removal And Installation....13579
Chain Removal And Installation....13584
CHAINCASE....13586
Description....13586
Front Cover Removal And Installation....13586
Center Cover Removal And Installation....13587
Rear Cover Removal And Installation....13588
MAIN FRAME....13590
SEAT BAR....13594
Description....13594
Removal And Installation....13594
Disassembly And Assembly....13596
Compression Spring Disassembly And Assembly....13597
OPERATOR CAB....13598
Gas Cylinder Removal And Installation....13598
Gas Cylinder Bracket Disassembly And Assembly....13600
Removal And Installation....13601
OPERATOR SEAT....13604
Removal And Installation....13604
Seat Belt Removal And Installation....13604
OPERATOR SEAT (SUSPENSION)....13606
Removal And Installation....13606
Slide Rail Removal And Installation....13607
Seat Belt Removal and Installation....13607
Lower Cushion Removal And Installation....13608
Back Cushion Removal And Installation....13609
Shock Removal And Installation....13609
3-Point Seat Belt Removal And Installation....13610
BOB-TACH (HAND LEVER)....13612
Description....13612
Removal And Installation....13612
Lever And Wedge Disassembly And Assembly....13613
Pivot Pin Bushing And Seal Removal And Installation....13615
BOB-TACH (POWER-OPTION)....13616
Description....13616
Removal And Installation....13616
Lever And Wedge Disassembly And Assembly....13618
Pivot Pin Bushing And Seal Removal And Installation....13619
LIFT ARMS....13620
Removal And Installation....13620
REAR GRILL....13624
Removal And Installation....13624
REAR DOOR....13626
Removal And Installation....13626
Striker Removal and Installation....13627
Striker Disassembly and Assembly....13627
Striker (Adjusting)....13628
Latch Removal and Installation....13629
FUEL TANK....13630
Removal And Installation....13630
Fuel Level Sender Removal And Installation....13631
Fuel Fill Screen Removal And Installation....13631
CONTROL PEDALS AND LINKAGES....13632
Description....13632
Pedal Removal And Installation....13632
Linkage Removal And Installation....13633
Pedal (Adjusting)....13635
CONTROL PEDALS (ACS)....13636
Description....13636
Foot Sensor Removal And Installation....13636
Foot Pedal Removal And Installation....13637
Foot Pedal Linkage Disassembly And Assembly....13637
CONTROL PANEL....13638
Description....13638
Removal and Installation....13639
Shock Removal And Installation....13642
Shaft Removal And Installation....13642
Shaft Disassembly And Assembly....13643
Linkage Removal And Installation....13644
Pintle Arm Disassembly and Assembly....13648
Linkage Neutral Adjustment....13650
Linkage Travel Adjustment....13654
CONTROL PANEL (SJC)....13658
Description....13658
Removal And Installation....13658
CONTROL HANDLE/LEVER....13660
Description....13660
Lever Removal And Installation....13660
Boot Removal And Installation....13661
CONTROL HANDLE/LEVER (ACS)....13662
Description....13662
Handle Sensor Removal And Installation....13662
Handle Removal and Installation....13665
Handle Disassembly and Assembly....13666
Lever Removal and Installation....13667
Boot Removal And Installation....13668
CONTROL HANDLE/LEVER (SJC)....13670
Description....13670
Joystick Testing....13670
Joystick Removal And Installation....13672
Removal And Installation....13673
ACCESS PANEL (INSIDE)....13674
Removal And Installation (Left)....13674
Removal And Installation (Right)....13674
ACCESS PANEL (INSIDE) (SJC)....13676
Removal And Installation (Left)....13676
Removal And Installation (Right)....13677
WINDOW (REAR)....13680
Removal....13680
Installation....13680
WINDOW (TOP)....13682
Removal And Installation....13682
WINDOW (SIDE)....13684
Removal And Installation....13684
WINDOW (FRONT DOOR)....13686
Removal (Standard Window)....13686
Installation (Standard Window)....13687
Removal And Installation (Special Applications Window)....13689
ELECTRICAL SYSTEM & ANALYSIS....13690
ELECTRICAL SYSTEM INFORMATION....13700
Glossary Of Electrical Symbols....13700
Standard Cab Harness Connectors....13703
Deluxe Cab Harness Connectors....13704
Mainframe Harness Connectors....13705
Description....13706
Troubleshooting....13707
Fuse And Relay Location / Identification....13708
Solenoid Testing....13709
BATTERY....13710
Removal And Installation....13710
Servicing....13711
Using A Booster Battery (Jump Starting)....13712
ALTERNATOR....13714
Belt Adjustment....13714
Belt Replacement....13714
Charging System Inspection....13715
Alternator Voltage Testing....13716
Low Voltage Testing....13716
High Voltage Testing....13717
Removal And Installation....13718
Parts Identification....13719
STARTER....13720
Testing....13720
Removal And Installation....13720
Parts Identification....13721
INSTRUMENT PANELS....13722
Left Panel....13722
Standard Key Panel....13724
Deluxe Instrumentation Panel....13725
Side Panel....13726
Front Panel....13726
Front Panel Removal And Installation....13727
Removal And Installation (Left And Right)....13727
Key Switch Removal And Installation....13729
Alarm Removal And Installation....13729
LIGHTS....13730
Front Removal And Installation....13730
Rear Removal And Installation....13731
Cab Light Removal And Installation....13731
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....13732
Description....13732
Connector Identification....13733
Removal And Installation....13739
BOBCAT CONTROLLER (ACS)....13740
Description....13740
Connector And Wire Identification....13741
Removal and Installation....13742
BOBCAT CONTROLLER (SJC) (DRIVE)....13744
Description....13744
Connector Identification....13745
Removal and Installation....13747
SPEED SENSORS (SJC)....13750
Description....13750
Testing....13750
Removal and Installation....13752
DIAGNOSTICS SERVICE CODES....13754
Viewing Service Codes (Standard Key Panel)....13754
Viewing Service Codes (Deluxe Instrumentation Panel)....13754
Service Codes List....13755
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....13760
Description....13760
Inspecting The BICS Controller (Engine Stopped - Key ON)....13761
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....13761
Inspecting The Seat Bar Sensor (Engine RUNNING)....13761
Inspecting The Traction Lock (Engine RUNNING)....13761
Inspecting The Lift Arm Bypass Control....13761
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....13761
Troubleshooting....13762
SEAT BAR SENSOR....13764
Description....13764
Troubleshooting....13764
Testing....13765
Removal And Installation....13766
Bobcat Interlock Control System (BICS) Circuit Test....13768
TRACTION LOCK....13770
Description....13770
Troubleshooting....13770
Removal And Installation....13771
Inspecting....13775
CONTROL SYSTEM (ACS)....13776
Description....13776
Troubleshooting....13777
Handle Sensor Connector Disassembly And Assembly....13778
Switch Handle Removal....13779
Switch Handle Installation....13781
Actuator Connector Disassembly And Assembly....13784
Handle Lock Solenoid Removal And Installation....13785
Handle Lock Solenoid Disassembly And Assembly....13785
Foot Sensor Disassembly And Assembly....13786
Foot Lock Solenoid Removal And Installation....13787
ELECTRICAL/HYDRAULIC CONTROLS....13788
Identification Chart....13788
ELECTRICAL/HYDRAULIC CONTROLS (SJC)....13790
Identification Chart....13790
SERVICE PC (LAPTOP COMPUTER)....13794
Connecting Remote Start Tool....13794
Connecting Remote Start Tool (Service Tool)....13794
CALIBRATION....13796
Description....13796
Actuator Testing....13796
Lift And Tilt Calibration (ACS)....13798
Lift And Tilt Calibration (SJC)....13800
Hydrostatic Pump Calibration (SJC)....13802
STEERING DRIFT COMPENSATION....13808
Description....13808
Operation....13808
FLYWHEEL RPM SENSOR....13810
Description....13810
Adjusting....13810
CONTROL PANEL SETUP....13812
Right Panel Setup (Deluxe Instrumentation Panel)....13812
Attachment Control Information (Deluxe Instrumentation Panel)....13813
PASSWORD SETUP....13814
Password Description....13814
Changing The Owner Password....13814
Changing The User Passwords....13815
Password Lockout Feature....13815
MAINTENANCE CLOCK....13816
Description....13816
Setup....13817
Reset....13820
BACK-UP ALARM SYSTEM....13822
Description....13822
Inspecting....13822
Adjusting Switch Position....13823
Troubleshooting (Standard and ACS)....13824
Troubleshooting (Joystick)....13825
Alarm Removal And Installation....13826
Switch Removal And Installation....13826
ENGINE SERVICE....13828
ENGINE INFORMATION....13830
Description....13830
Specifications....13831
Engine Torque Values....13835
Troubleshooting....13835
Removal And Installation....13837
Engine Mount Replacement....13844
Compression - Checking....13845
ENGINE SPEED CONTROL....13846
Removal And Installation....13846
ENGINE SPEED CONTROL (SJC)....13848
Removal And Installation....13848
Disassembly And Assembly....13850
MUFFLER....13852
Removal And Installation....13852
AIR CLEANER....13854
Housing Removal And Installation....13854
ENGINE COOLING SYSTEM....13856
Radiator Removal And Installation....13856
Blower Housing Removal And Installation....13859
Hydraulic Fan Removal And Installation....13861
Hydraulic Fan Description....13862
Hydraulic Fan Disassembly And Assembly....13862
Water Pump Removal And Installation....13863
Water Pump Disassembly And Assembly....13863
Thermostat Housing Removal And Installation....13864
LUBRICATION SYSTEM....13866
Oil Pan Removal And Installation....13866
Oil Pump Removal And Installation....13866
Oil Pump Inspection....13867
Engine Oil Pressure-Testing....13868
FUEL SYSTEM....13870
Fuel Camshaft Removal And Installation....13870
Fuel Camshaft Governor Disassembly And Assembly....13871
Fuel Shutoff Solenoid - Checking....13872
Fuel Shutoff Solenoid Removal And Installation....13872
Fuel Injection Pump Removal And Installation....13873
Injection Pump - Timing....13876
Fuel Injector Removal And Installation....13878
Fuel Injector Nozzle Pressure - Checking....13879
Nozzle Spray Condition....13880
Valve Seat Tightness....13880
CYLINDER HEAD....13882
Glow Plugs - Testing....13882
Glow Plugs Removal And Installation....13882
Valve Clearance Adjustment....13883
Valve Timing, Checking....13884
Cylinder Head Removal And Installation....13885
Cylinder Head Disassembly and Assembly....13888
Cylinder Head - Servicing....13888
Cylinder Head Top Clearance....13889
Valve Guide-Checking....13889
Reconditioning The Valve And Valve Seat....13890
Valve Spring....13892
Valve Tappets....13893
Rocker Arm And Shaft Checking....13893
CRANKSHAFT AND PISTONS....13894
Piston And Connecting Rod Removal And Installation....13894
Piston And Connecting Rod - Servicing....13896
Cylinder Bore- Checking....13898
Connecting Rod Alignment....13899
Crankshaft And Bearings Removal And Installation....13899
Crankshaft And Bearings - Servicing....13901
CAMSHAFT AND TIMING GEARS....13906
Timing Gearcase Cover Removal And Installation....13906
Timing Gears Backlash - Checking....13908
Idler Gear And Shaft Removal And Installation....13909
Camshaft - Servicing....13910
Idler Gear And Shaft Servicing....13911
FLYWHEEL AND HOUSING....13912
Flywheel Removal And Installation....13912
Ring Gear Removal And Installation....13912
Housing Removal And Installation....13913
HEATER....13916
HEATER SYSTEM....13918
Description....13918
REGULAR MAINTENANCE....13920
Filter Elements Removal And Installation....13920
Cleaning The Heater Coil....13921
TROUBLESHOOTING....13922
Blower Motor Does Not Operate....13922
Blower Motor Operators Normally, But Air Flow Is Insufficient....13922
Electrical System....13923
Engine Coolant Bypassing The Heater Valve....13927
Heater Valve Not Opening Or Closing....13928
HEATER UNIT....13930
Removal And Installation....13930
HEATER COIL....13932
Removal And Installation....13932
HEATER FAN....13934
Blower Removal And Installation....13934
Disassembly And Assembly....13935
Connector Identification....13937
HEATER VALVE....13938
Removal and Installation....13938
Disassembly And Assembly....13939
SPECIFICATIONS....13940
LOADER SPECIFICATIONS....13942
Machine Dimensions....13942
Performance....13943
Controls....13943
Engine....13943
Hydraulic System....13944
Electrical....13944
Drive System....13945
Capacities....13945
Tires....13945
TORQUE SPECIFICATIONS FOR BOLTS....13946
Torque For General SAE Bolts....13946
Torque For General Metric Bolts....13947
HYDRAULIC CONNECTION SPECIFICATIONS....13948
O-ring Face Seal Connection....13948
Straight Thread O-ring Fitting....13949
Tubelines And Hoses....13949
Flare Fitting....13950
Port Seal Fitting....13951
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....13952
Specifications....13952
CONVERSIONS....13954
Decimal And Millimeter Equivalents....13954
U.S. To Metric Conversion Chart....13954
6989453 (11-10) - S160 Skid-Steer Loader Operation & Maintenance Manual....13956
OPERATOR SAFETY WARNINGS....13958
CONTENTS....13960
FOREWORD....13962
BOBCAT COMPANY IS IS0 9001 CERTIFIED....13964
REGULAR MAINTENANCE ITEMS....13964
SERIAL NUMBER LOCATIONS....13965
Loader Serial Number....13965
Engine Serial Number....13965
DELIVERY REPORT....13965
LOADER IDENTIFICATION....13966
FEATURES, ACCESSORIES AND ATTACHMENTS....13967
Standard Items....13967
Options And Accessories....13967
Buckets Available....13968
Attachments....13968
High-Flow Attachments....13968
Special Applications Kit....13969
Special Applications Kit Inspection And Maintenance....13969
SAFETY & TRAINING RESOURCES....13970
SAFETY INSTRUCTIONS....13972
Before Operation....13972
Safe Operation Is The Operator’s Responsibility....13973
Safe Operation Needs A Qualified Operator....13973
Avoid Silica Dust....13974
FIRE PREVENTION....13974
Maintenance....13974
Operation....13974
Electrical....13974
Hydraulic System....13975
Fueling....13975
Starting....13975
Spark Arrestor Exhaust System....13975
Welding And Grinding....13975
Fire Extinguishers....13975
MACHINE SIGNS (DECALS)....13977
PUBLICATIONS AND TRAINING RESOURCES....13979
OPERATING INSTRUCTIONS....13980
INSTRUMENT PANEL IDENTIFICATION....13984
Cab Light....13984
Left Panel....13985
Display Screen....13987
Standard Key Panel....13988
Keyless Start Panel....13988
Deluxe Instrumentation Panel....13989
Side Panel....13990
Front Panel....13990
CONTROL IDENTIFICATION....13991
Standard Controls....13991
Advanced Control System (ACS)....13992
Selectable Joystick Controls (SJC)....13993
SEAT BAR RESTRAINT SYSTEM....13994
Operation....13994
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....13995
Operation....13995
LIFT ARM BYPASS CONTROL....13996
Operation....13996
PARKING BRAKE....13996
Operation....13996
TRACTION LOCK OVERRIDE....13996
Operation....13996
EMERGENCY EXIT....13997
Rear Window....13997
Front Door....13997
BACK-UP ALARM SYSTEM....13998
Description....13998
Operation....13998
ENGINE SPEED CONTROL....13999
Operation....13999
DRIVING AND STEERING THE LOADER....14000
Available Control Configurations....14000
Operation (Standard And ACS)....14000
Operation (SJC) In ‘ISO’ Control Pattern....14001
Operation (SJC) In ‘H’ Control Pattern....14002
STOPPING THE LOADER....14002
Using The Control Levers Or Joysticks....14002
TWO-SPEED CONTROL....14003
Description....14003
Operation (Standard And ACS) (If Equipped)....14003
Operation (SJC) (If Equipped)....14003
SPEED MANAGEMENT....14004
Operation....14004
Changing The Factory Default Setting....14005
DRIVE RESPONSE....14006
Description....14006
Operation....14006
STEERING DRIFT COMPENSATION....14008
Description....14008
Operation....14008
HYDRAULIC CONTROLS....14010
Description....14010
Standard Controls (Also ACS In FOOT Pedal Mode)....14010
Advanced Control System (ACS) In HAND Control Mode....14011
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....14011
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....14012
Hydraulic Bucket Positioning....14012
FRONT Auxiliary Hydraulics Operation....14013
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....14014
REAR Auxiliary Hydraulics Operation....14014
Secondary Front Auxiliary Hydraulics Operation....14015
High-Flow Hydraulics Operation....14016
Quick Couplers....14016
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....14017
ATTACHMENT CONTROL DEVICE (ACD)....14018
Description....14018
DAILY INSPECTION....14019
Daily Inspection And Maintenance....14020
PRE-STARTING PROCEDURE....14021
Entering The Loader....14021
Operation & Maintenance Manual And Operator’s Handbook Locations....14021
Seat Adjustment....14022
Seat Belt Adjustment....14023
Seat Bar....14023
STARTING THE ENGINE....14024
Standard Key Panel....14024
Keyless Start Panel....14026
Deluxe Instrumentation Panel....14028
Cold Temperature Starting....14030
Warming The Hydraulic / Hydrostatic System....14031
MONITORING THE DISPLAY PANELS....14032
Left Panel....14032
Warning And Shutdown....14032
STOPPING THE ENGINE AND LEAVING THE LOADER....14033
Procedure....14033
COUNTERWEIGHTS....14034
Description....14034
Effect On The Loader And Loader Operation....14034
When To Consider Using Counterweights....14034
When To Consider Removing Counterweights....14034
Accessories That Affect Machine Weight....14034
ATTACHMENTS....14035
Choosing The Correct Bucket....14035
Pallet Forks....14035
Installing And Removing The Attachment (Hand Lever Bob-Tach)....14036
Installing And Removing The Attachment (Power Bob-Tach)....14038
OPERATING PROCEDURE....14041
Inspect The Work Area....14041
Basic Operating Instructions....14041
Driving On Public Roads....14041
Operating With A Full Bucket....14042
Operating With An Empty Bucket....14042
Filling And Emptying The Bucket (Foot Pedals)....14043
Leveling The Ground Using Float (Foot Pedals)....14044
Digging And Filling A Hole (Foot Pedals)....14044
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....14045
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....14046
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....14047
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....14048
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....14049
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....14049
TOWING THE LOADER....14050
Procedure....14050
LIFTING THE LOADER....14051
Single-Point Lift....14051
Four-Point Lift....14051
TRANSPORTING THE LOADER ON A TRAILER....14052
Loading And Unloading....14052
Fastening....14052
PREVENTIVE MAINTENANCE....14054
MAINTENANCE SAFETY....14058
SERVICE SCHEDULE....14060
Chart....14060
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....14061
Inspecting The BICS (Engine STOPPED - Key ON)....14061
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....14061
Inspecting The Seat Bar Sensor (Engine RUNNING)....14061
Inspecting The Traction Lock (Engine RUNNING)....14061
Inspecting The Lift Arm Bypass Control....14061
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....14061
SEAT BAR RESTRAINT SYSTEM....14062
Description....14062
Inspecting....14062
Maintaining....14062
SEAT BELT....14063
Inspection And Maintenance....14063
LIFT ARM SUPPORT DEVICE....14064
Installing....14064
Removing....14065
BACK-UP ALARM SYSTEM....14066
Description....14066
Inspecting....14066
Adjusting Switch Position....14066
OPERATOR CAB....14067
Description....14067
Raising....14067
Lowering....14068
Cab Door Sensor....14069
REAR DOOR (TAILGATE)....14070
Opening And Closing....14070
Adjusting....14070
REAR GRILLE....14070
Removing....14070
Installing....14070
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....14071
Cleaning And Maintenance....14071
Filters....14071
Evaporator / Heater Coil....14071
Condenser....14071
Air Conditioning Lubrication....14071
Troubleshooting....14071
AIR CLEANER SERVICE....14072
Replacing Filter Elements....14072
FUEL SYSTEM....14074
Fuel Specifications....14074
Biodiesel Blend Fuel....14074
Filling The Fuel Tank....14075
Fuel Filter....14076
Removing Air From The Fuel System....14076
ENGINE LUBRICATION SYSTEM....14077
Checking And Adding Engine Oil....14077
Engine Oil Chart....14077
Removing And Replacing Oil And Filter....14077
ENGINE COOLING SYSTEM....14078
Cleaning....14078
Removing And Replacing Coolant....14079
Checking Level....14079
ELECTRICAL SYSTEM....14080
Description....14080
Fuse And Relay Location / Identification....14080
Battery Maintenance....14081
Using A Booster Battery (Jump Starting)....14082
Removing And Installing Battery....14083
HYDRAULIC / HYDROSTATIC SYSTEM....14084
Checking And Adding Fluid....14084
Hydraulic / Hydrostatic Fluid Chart....14084
Removing And Replacing Hydraulic Fluid....14085
Removing And Replacing Hydraulic / Hydrostatic Filter....14085
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....14086
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....14087
Removing And Replacing Hydraulic Charge Filter....14089
Breather Cap....14090
SPARK ARRESTER MUFFLER....14091
Cleaning Procedure....14091
TIRE MAINTENANCE....14092
Wheel Nuts....14092
Rotating....14092
Mounting....14092
FINAL DRIVE TRANSMISSION (CHAINCASE)....14093
Checking And Adding Oil....14093
Removing And Replacing Oil....14093
ALTERNATOR BELT....14094
Belt Adjustment....14094
Belt Replacement....14094
AIR CONDITIONING BELT....14094
Belt Adjustment....14094
Belt Replacement....14094
DRIVE BELT....14095
Belt Adjustment....14095
Belt Replacement....14095
LUBRICATING THE LOADER....14096
Lubrication Locations....14096
PIVOT PINS....14097
Inspection And Maintenance....14097
BOB-TACH (HAND LEVER)....14098
Inspection And Maintenance....14098
BOB-TACH (POWER)....14099
Inspection And Maintenance....14099
LOADER STORAGE AND RETURN TO SERVICE....14100
Storage....14100
Return To Service....14100
SYSTEM SETUP & ANALYSIS....14102
DIAGNOSTIC SERVICE CODES....14104
Viewing Service Codes....14104
Service Codes List....14105
CONTROL PANEL SETUP....14110
Right Panel Setup (Deluxe Instrumentation Panel)....14110
Attachment Control Information (Deluxe Instrumentation Panel)....14111
PASSWORD SETUP (KEYLESS START PANEL)....14112
Password Description....14112
Changing The Owner Password....14112
Password Lockout Feature....14112
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....14113
Password Description....14113
Changing The Owner Password....14113
Changing The User Passwords....14114
Password Lockout Feature....14114
MAINTENANCE CLOCK....14115
Description....14115
Setup....14115
Reset....14115
SPECIFICATIONS....14116
(S160) LOADER SPECIFICATIONS....14118
Machine Dimensions....14118
Performance....14119
Engine....14119
Drive System....14119
Controls....14120
Hydraulic System....14120
Electrical....14121
Capacities....14121
Tires....14121
WARRANTY....14122
WARRANTY....14124
ALPHABETICAL INDEX....14126
6989453 (2-13) - S160 Skid-Steer Loader Operation & Maintenance Manual....14130
OPERATOR SAFETY WARNINGS....14132
CONTENTS....14134
FOREWORD....14136
BOBCAT COMPANY IS IS0 9001 CERTIFIED....14138
REGULAR MAINTENANCE ITEMS....14138
SERIAL NUMBER LOCATIONS....14139
Loader Serial Number....14139
Engine Serial Number....14139
DELIVERY REPORT....14139
LOADER IDENTIFICATION....14140
FEATURES, ACCESSORIES AND ATTACHMENTS....14141
Standard Items....14141
Options And Accessories....14141
Buckets Available....14142
Attachments....14142
High-Flow Attachments....14142
Special Applications Kit....14143
Special Applications Kit Inspection And Maintenance....14143
SAFETY & TRAINING RESOURCES....14144
SAFETY INSTRUCTIONS....14146
Before Operation....14146
Safe Operation Is The Operator’s Responsibility....14147
Safe Operation Needs A Qualified Operator....14147
Avoid Silica Dust....14148
FIRE PREVENTION....14148
Maintenance....14148
Operation....14148
Electrical....14148
Hydraulic System....14149
Fueling....14149
Starting....14149
Spark Arrester Exhaust System....14149
Welding And Grinding....14149
Fire Extinguishers....14149
PUBLICATIONS AND TRAINING RESOURCES....14150
MACHINE SIGNS (DECALS)....14151
OPERATING INSTRUCTIONS....14154
INSTRUMENT PANEL IDENTIFICATION....14158
Cab Light....14158
Left Panel....14159
Display Screen....14161
Standard Key Panel....14162
Keyless Start Panel....14162
Deluxe Instrumentation Panel....14163
Side Panel....14164
Front Panel....14164
CONTROL IDENTIFICATION....14165
Standard Controls....14165
Advanced Control System (ACS)....14166
Selectable Joystick Controls (SJC)....14167
SEAT BAR RESTRAINT SYSTEM....14168
Operation....14168
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....14169
Operation....14169
LIFT ARM BYPASS CONTROL....14170
Operation....14170
PARKING BRAKE....14170
Operation....14170
TRACTION LOCK OVERRIDE....14170
Operation....14170
EMERGENCY EXIT....14171
Rear Window....14171
Front Door....14171
BACK-UP ALARM SYSTEM....14172
Description....14172
Operation....14172
ENGINE SPEED CONTROL....14173
Operation....14173
DRIVING AND STEERING THE LOADER....14174
Available Control Configurations....14174
Operation (Standard And ACS)....14174
Operation (SJC) In ‘ISO’ Control Pattern....14175
Operation (SJC) In ‘H’ Control Pattern....14176
STOPPING THE LOADER....14176
Using The Control Levers Or Joysticks....14176
TWO-SPEED CONTROL....14177
Description....14177
Operation (Standard And ACS) (If Equipped)....14177
Operation (SJC) (If Equipped)....14177
SPEED MANAGEMENT....14178
Operation....14178
Changing The Factory Default Setting....14179
DRIVE RESPONSE....14180
Description....14180
Operation....14180
STEERING DRIFT COMPENSATION....14182
Description....14182
Operation....14182
LIFT AND TILT COMPENSATION....14184
Description....14184
Operation....14184
Operation (ACS)....14185
Operation (SJC)....14186
HYDRAULIC CONTROLS....14187
Description....14187
Standard Controls (Also ACS In FOOT Pedal Mode)....14187
Advanced Control System (ACS) In HAND Control Mode....14188
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern....14188
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern....14189
Hydraulic Bucket Positioning....14189
FRONT Auxiliary Hydraulics Operation....14190
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....14191
REAR Auxiliary Hydraulics Operation....14191
Secondary Front Auxiliary Hydraulics Operation....14192
High-Flow Hydraulics Operation....14193
Quick Couplers....14193
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....14194
ATTACHMENT CONTROL DEVICE (ACD)....14195
Description....14195
DAILY INSPECTION....14196
Daily Inspection And Maintenance....14197
PRE-STARTING PROCEDURE....14198
Entering The Loader....14198
Operation & Maintenance Manual And Operator’s Handbook Locations....14198
Seat Adjustment....14199
Seat Belt Adjustment....14200
Seat Bar....14200
STARTING THE ENGINE....14201
Standard Key Panel....14201
Keyless Start Panel....14203
Deluxe Instrumentation Panel....14205
Cold Temperature Starting....14207
Warming The Hydraulic / Hydrostatic System....14208
MONITORING THE DISPLAY PANELS....14209
Left Panel....14209
Warning And Shutdown....14209
STOPPING THE ENGINE AND LEAVING THE LOADER....14210
Procedure....14210
COUNTERWEIGHTS....14211
Description....14211
Effect On The Loader And Loader Operation....14211
When To Consider Using Counterweights....14211
When To Consider Removing Counterweights....14211
Accessories That Affect Machine Weight....14211
ATTACHMENTS....14212
Choosing The Correct Bucket....14212
Pallet Forks....14212
Installing And Removing The Attachment (Hand Lever Bob-Tach)....14213
Installing And Removing The Attachment (Power Bob-Tach)....14215
OPERATING PROCEDURE....14218
Inspect The Work Area....14218
Basic Operating Instructions....14218
Driving On Public Roads....14218
Operating With A Full Bucket....14219
Operating With An Empty Bucket....14219
Filling And Emptying The Bucket (Foot Pedals)....14220
Leveling The Ground Using Float (Foot Pedals)....14221
Digging And Filling A Hole (Foot Pedals)....14221
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)....14222
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)....14223
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)....14224
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)....14225
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)....14226
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)....14226
TOWING THE LOADER....14227
Procedure....14227
LIFTING THE LOADER....14228
Single-Point Lift....14228
Four-Point Lift....14228
TRANSPORTING THE LOADER ON A TRAILER....14229
Loading And Unloading....14229
Fastening....14229
PREVENTIVE MAINTENANCE....14230
MAINTENANCE SAFETY....14234
SERVICE SCHEDULE....14236
Chart....14236
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....14237
Inspecting The BICS™ (Engine STOPPED - Key ON)....14237
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....14237
Inspecting The Seat Bar Sensor (Engine RUNNING)....14237
Inspecting The Traction Lock (Engine RUNNING)....14237
Inspecting The Lift Arm Bypass Control....14237
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....14237
SEAT BAR RESTRAINT SYSTEM....14238
Description....14238
Inspecting....14238
Maintaining....14238
SEAT BELT....14239
Inspection And Maintenance....14239
LIFT ARM SUPPORT DEVICE....14240
Installing....14240
Removing....14241
BACK-UP ALARM SYSTEM....14242
Description....14242
Inspecting....14242
Adjusting Switch Position....14242
OPERATOR CAB....14243
Description....14243
Raising....14243
Lowering....14244
Cab Door Sensor....14245
REAR DOOR (TAILGATE)....14246
Opening And Closing....14246
Adjusting....14246
REAR GRILLE....14246
Removing....14246
Installing....14246
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....14247
Cleaning And Maintenance....14247
Filters....14247
Evaporator / Heater Coil....14247
Condenser....14247
Air Conditioning Lubrication....14247
Troubleshooting....14247
AIR CLEANER SERVICE....14248
Replacing Filter Elements....14248
FUEL SYSTEM....14250
Fuel Specifications....14250
Biodiesel Blend Fuel....14250
Filling The Fuel Tank....14251
Fuel Filter....14252
Removing Air From The Fuel System....14252
ENGINE LUBRICATION SYSTEM....14253
Checking And Adding Engine Oil....14253
Engine Oil Chart....14253
Removing And Replacing Oil And Filter....14253
ENGINE COOLING SYSTEM....14254
Cleaning....14254
Removing And Replacing Coolant....14255
Checking Level....14255
ELECTRICAL SYSTEM....14256
Description....14256
Fuse And Relay Location / Identification....14256
Battery Maintenance....14257
Using A Booster Battery (Jump Starting)....14258
Removing And Installing Battery....14259
HYDRAULIC / HYDROSTATIC SYSTEM....14260
Checking And Adding Fluid....14260
Hydraulic / Hydrostatic Fluid Chart....14260
Removing And Replacing Hydraulic Fluid....14261
Removing And Replacing Hydraulic / Hydrostatic Filter....14261
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)....14262
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)....14263
Removing And Replacing Hydraulic Charge Filter....14265
Breather Cap....14266
SPARK ARRESTER MUFFLER....14267
Cleaning Procedure....14267
TIRE MAINTENANCE....14268
Wheel Nuts....14268
Rotating....14268
Mounting....14268
FINAL DRIVE TRANSMISSION (CHAINCASE)....14269
Checking And Adding Oil....14269
Removing And Replacing Oil....14269
ALTERNATOR BELT....14270
Belt Adjustment....14270
Belt Replacement....14270
AIR CONDITIONING BELT....14270
Belt Adjustment....14270
Belt Replacement....14270
DRIVE BELT....14271
Belt Adjustment....14271
Belt Replacement....14271
LUBRICATING THE LOADER....14272
Lubrication Locations....14272
PIVOT PINS....14273
Inspection And Maintenance....14273
BOB-TACH (HAND LEVER)....14274
Inspection And Maintenance....14274
BOB-TACH (POWER)....14275
Inspection And Maintenance....14275
LOADER STORAGE AND RETURN TO SERVICE....14276
Storage....14276
Return To Service....14276
SYSTEM SETUP & ANALYSIS....14278
DIAGNOSTIC SERVICE CODES....14280
Viewing Service Codes....14280
Service Codes List....14281
CONTROL PANEL SETUP....14286
Right Panel Setup (Deluxe Instrumentation Panel)....14286
Attachment Control Information (Deluxe Instrumentation Panel)....14287
PASSWORD SETUP (KEYLESS START PANEL)....14288
Password Description....14288
Changing The Owner Password....14288
Password Lockout Feature....14288
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....14289
Password Description....14289
Changing The Owner Password....14289
Changing The User Passwords....14290
Password Lockout Feature....14290
MAINTENANCE CLOCK....14291
Description....14291
Setup....14291
Reset....14291
SPECIFICATIONS....14292
(S160) LOADER SPECIFICATIONS....14294
Machine Dimensions....14294
Performance....14295
Engine....14295
Drive System....14295
Controls....14296
Hydraulic System....14296
Electrical....14297
Capacities....14297
Tires....14297
WARRANTY....14298
WARRANTY....14300
ALPHABETICAL INDEX....14302
