19
MAINTENANCE SAFETY
Never service the Bobcat Skid-Steer Loader without instructions.
Have good ventilation whenwelding or grinding paintedparts.Wear dust mask when grindingpainted parts. Toxic dust and gascan be produced.Avoid exhaust fume leaks whichcan kill without warning. Exhaustsystem must be tightly sealed.
Stop, cool and clean engine offlammable materials beforechecking fluids.Never service or adjust loaderwith the engine running unlessinstructed to do so in themanual.Avoid contact with leakinghydraulic fluid or diesel fuelunder pressure. It can penetratethe skin or eyes.Never fill fuel tank with enginerunning, while smoking or whennear open flame.
Disconnecting or loosening anyhydraulic tubeline, hose, fitting,component or a part failure cancause lift arms to drop. Do not gounder lift arms when raisedunless supported by anapproved lift arm support device.Replace it if damaged.
Keep body, jewelry and clothingaway from moving parts,electrical contact, hot parts andexhaust.Wear eye protection to guardfrom battery acid, compressedsprings, fluids under pressureand flying debris when enginesare running or tools are used.Use eye protection approved fortype of welding.Keep rear door closed except forservice. Close and latch doorbefore operating the loader.
Never work on loader with liftarms up unless lift arms are heldby an approved lift arm supportdevice. Replace if damaged.Never modify equipment or addattachments not approved byBobcat Company.
Lead-acid batteries produceflammable and explosive gases.Keep arcs, sparks, flames andlighted tobacco away frombatteries.Batteries contain acid whichburns eyes or skin on contact.Wear protective clothing. If acidcontacts body, flush well withwater. For eye contact flush welland get immediate medicalattention.
Use the correct procedure to lift orlower operator cab.
Cleaning and maintenance arerequired daily.
MSW08-0409
WRONG
B-6589
P-90216
CORRECT
B-15590
CORRECT
B-15591
CORRECT
B-15599
WRONGWRONG
B-15593
WRONG
B-15592
B-15600
WRONG WRONG
B-15601
WARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual, Operator’s Handbook andsigns (decals) on machine. Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2003-0807
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in the Operation & MaintenanceManual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcatreplacement parts. The Service Safety Training Course is available from your Bobcat dealer.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
S150, S160 Service Manual
ALPHABETICAL INDEX
ACCESS PANEL (INSIDE) ..................................... 50-01ACCESS PANEL (INSIDE) (SJC) ........................... 50-01AIR CLEANER ........................................................70-01AIR CLEANER SERVICE .......................................10-01AIR CONDITIONING SYSTEM FLOW ................... 80-01ALTERNATOR ........................................................ 60-01
BACK-UP ALARM SYSTEM................................... 60-01BATTERY................................................................ 60-01BLOWER FAN ........................................................ 80-01BOBCAT CONTROLLER (ACS) ............................. 60-01BOBCAT CONTROLLER (MAIN)............................ 60-01BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ................................................... 60-01BOB-TACH (HAND LEVER) ........................ 10-01, 50-01BOB-TACH (POWER)............................................. 10-01BOB-TACH ([POWER-OPTION)............................. 50-01BOB-TACH (POWER) BLOCK................................ 20-01BRAKE (SINGLE SPEED) ...................................... 40-01BRAKE (TWO-SPEED)........................................... 40-01BUCKET POSITION VALVE ................................... 20-01
CALIBRATION ........................................................ 60-01CAMSHAFT AND TIMING GEARS......................... 70-01CASE DRAIN FILTER............................................. 30-01CHAINCASE ........................................................... 40-01CHARGE PRESSURE ........................................... 30-01COMPRESSOR ...................................................... 80-01CONDENSER ......................................................... 80-01CONTROL HANDLE/LEVER .................................. 50-01CONTROL HANDLE/LEVER (ACS) ....................... 50-01CONTROL HANDLE/LEVER (SJC) ........................ 50-01CONTROL PANEL.................................................. 50-01CONTROL PANEL (SJC)........................................ 50-01CONTROL PANEL SETUP ..................................... 60-01CONTROL PEDALS AND LINKAGE ...................... 50-01CONTROL PEDALS (ACS) .................................... 50-01CONTROL SYSTEM (ACS).................................... 60-01CONVERSIONS ................................................SPEC-01CRANKSHAFT AND PISTONS ............................. 70-01CYLINDER (BOB-TACH) ........................................ 20-01CYLINDER (LIFT) ................................................... 20-01CYLINDER (TILT) ................................................... 20-01CYLINDER HEAD................................................... 70-01
DIAGNOSTICS SERVICE CODES......................... 60-01DRIVE BELT ........................................................... 30-01DRIVE COMPONENTS .......................................... 40-01
ELECTRICAL/HYD. CONTROLS ........................... 60-01ELECTRICAL/HYD. CONTROLS REFERENCE (SJC).............................................. 60-01ELECTRICAL SYSTEM INFORMATION ................ 60-01ENGINE COOLING SYSTEM................................. 10-01ENGINE LUBRICATION SYSTEM ......................... 10-01
ENGINE COOLING SYSTEM .................................70-01ENGINE INFORMATION.........................................70-01ENGINE SPEED CONTROL ...................................70-01ENGINE SPEED CONTROL (SJC).........................70-01EVAPORATOR ........................................................80-01EVAPORATOR/HEATER UNIT................................80-01EXPANSION VALVE................................................80-01
FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01FLYWHEEL AND HOUSING ...................................70-01FLYWHEEL RPM SENSOR ....................................60-01FRONT AUXILIARY HYDRAULIC COUPLER BLOCK ...............................................20-01FUEL SYSTEM.............................................10-01, 70-01FUEL TANK .............................................................50-01
HEATER COIL.........................................................80-01HEATER VALVE ......................................................80-01HIGH FLOW VALVE ................................................20-01HYDRAULIC CONNECTION SPECS ............... SPEC-01HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..20-01HYDRAULIC CONTROL VALVE (STANDARD) ......20-01HYDRAULIC/HYDROSTATIC FILTERS ..................20-01HYDRAULIC FLUID RESERVOIR ..........................20-01HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS................................ SPEC-01HYDRAULIC/HYDROSTATIC SYSTEM..................10-01HYDRAULIC PUMP (STANDARD)..........................20-01HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01HYDRAULIC PUMP (SJC) ......................................20-01HYDRAULIC PUMP (SJC) (HIGH FLOW)...............20-01HYDRAULIC SYSTEM INFORMATION ..................20-01HYDROSTATIC MOTOR .........................................30-01HYDROSTATIC MOTOR (TWO SPEED) ................30-01HYDROSTATIC MOTOR CARRIER (SINGLE ANDTWO-SPEED WITH MANUAL CONTROLS) .........................................................30-01HYDROSTATIC MOTOR CARRIER (SINGLE ANDTWO-SPEED WITH SJC CONTROLS) .........................................................30-01HYDROSTATIC PUMP ............................................30-01HYDROSTATIC PUMP (SJC)..................................30-01HYDROSTATIC SYSTEM INFORMATION..............30-01
INSTRUMENT PANELS .........................................60-01
S150, S160 Service Manual
ALPHABETICAL INDEX (CONT’D)
LIFT ARMS ..............................................................50-01LIFT ARM BYPASS CONTROL VALVE...................20-01LIFT ARM SUPPORT DEVICE................................10-01LIFTING AND BLOCKING THE LOADER...............10-01LIGHTS....................................................................60-01S150 LOADER SPECIFICATIONS....................SPEC-01S160 LOADER SPECIFICATIONS....................SPEC-01LOADER STORAGE AND RETURN TO SERVICE 10-01LUBRICATING THE LOADER.................................10-01LUBRICATION SYSTEM .........................................70-01
MAIN RELIEF VALVE ..............................................20-01MAINTENANCE CLOCK .........................................60-01MUFFLER................................................................70-01OIL COOLER...........................................................20-01OPERATOR CAB..........................................10-01, 50-01OPERATOR SEAT...................................................50-01OPERATOR SEAT (SUSPENSION)........................50-01
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).................................................60-01PIVOT PINS.............................................................10-01
REAR AUXILIARY DIVERTER VALVE....................20-01REAR DOOR ..........................................................50-01REAR GRILL ..........................................................50-01RECEIVER/DRIER ..................................................80-01REGULAR MAINTENANCE ....................................80-01REMOTE START TOOL KIT-MEL1563 ...................10-01REMOTE START TOOL (SERVICE TOOL) ‘ KIT - 6689779 ........................................................10-01
SEAT BAR ...............................................................50-01SEAT BAR SENSOR ...............................................60-01SERVICE PC (LAPTOP COMPUTER) ....................60-01SERVICE SCHEDULE.............................................10-01SPARK ARRESTOR MUFFLER..............................10-01STARTER ................................................................60-01STEERING DRIFT COMPENSATION.....................60-01STOPPING THE ENGINE AND LEAVING THE LOADER .......................................10-01SYSTEM CHARGING AND RECLAMATION ..........80-01
THERMOSTAT.........................................................80-01TORQUE SPECIFICATIONS FOR BOLTS........SPEC-01TOWING THE LOADER ..........................................10-01TRACK CARRIAGE COMPONENTS ......................40-01TRACTION LOCK....................................................60-01TRANSPORTING THE LOADER ON A TRAILER ..10-01TROUBLESHOOTING.............................................80-01TURBOCHARGER ..................................................70-01TWO-SPEED VALVE...............................................30-01
WHEEL SPEED SENSOR (SJC) ............................ 60-01WINDOW (FRONT DOOR) ..................................... 50-01WINDOW (REAR) ................................................... 50-01WINDOW (SIDE)..................................................... 50-01WINDOW (TOP)...................................................... 50-01
I S150, S160 Service Manual
CONTENTS
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . .XI
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
SAFETY &
HYDROSTATIC
MAIN FRAME
SYSTEM
SYSTEMDRIVE
ELECTRICAL
MAINTENANCE
SYSTEM &
ENGINESERVICEENGINE
SPECIFICATIONS
HVAC
SPECIFICATIONS
HYDRAULICSYSTEM
ANALYSIS
II S150, S160 Service Manual
FOREWORDThis manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustmentprocedures for the Bobcat loader and its component parts and systems. Refer to the Operation &Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
FW SSL-1008 SM
1. Check that the ROPS/FOPS(Including side screens) is ingood condition and is notmodified.
9. The parking brake mustfunction correctly.
2. Check that ROPS mountinghardware is tightened and isBobcat approved.
10. Enclosure door latches mustopen and close freely.
3. The seat belt must becorrectly installed, functionaland in good condition.
11. Bob-Tach wedges andlinkages must functioncorrectly and be in goodcondition.
4. The seat bar must becorrectly adjusted, clean andlubricated.
12. Safety treads must be in goodcondition.
5. Check lift arm support device,replace if damaged.
13. Check for correct function ofindicator lamps.
6. Machine signs (decals) mustbe legible and in the correctlocation.
14. Check hydraulic fluid level,engine oil level and fuelsupply.
7. Steering levers, hand controlsand foot pedals must return toneutral (as applicable).
15. Inspect for fuel, oil orhydraulic fluid leaks.
8. Check for correct function ofthe work lights.
16. Lubricate the loader.
III S150, S160 Service Manual
FW SSL-1008 SM
17. Check the condition of thebattery and cables.
23. Operate the machine andcheck all functions.
18. Inspect the air cleaner fordamage or leaks. Check thecondition of the element.
24. Check for correct function ofthe Bobcat Interlock ControlSystem (BICS™) before themachine is returned to thecustomer.
19. Check the electrical chargingsystem.
25. Check for proper function offront horn and back-up alarm(if equipped).
20. Check tires for wear andpressure. Check tracks forwear and tension. Use onlyapproved tires or tracks.
26. Check function or condition of all equipped options and accessories (examples: fire extinguisher, rotating beacon, lift kits, etc.).
21. Inspect for loose or brokenparts or connections.
27. Recommend to the ownerthat all necessary correctionsbe made before the machineis returned to service.
22. Check for any fieldmodification not completed.
CALIFORNIAPROPOSITION 65 WARNING
Diesel engine exhaust and some of itsconstituents are known to the state of California
to cause cancer, birth defects and otherreproductive harm.
IV S150, S160 Service Manual
FW SSL-1008 SM
V S150, S160 Service Manual
SAFETY INSTRUCTIONS
WARNINGInstructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, Operator’sHandbook and signs (decals) on machine. Followwarnings and instructions in the manuals whenmaking repairs, adjustments or servicing. Check forcorrect function after adjustments, repairs or service.Untrained operators and failure to follow instructionscan cause injury or death.
W-2003-0903
IMPORTANTThis notice identifies procedures which must befollowed to avoid damage to the machine.
I-2019-0284
DANGERThe signal word DANGER on the machine and in themanuals indicates a hazardous situation which, if notavoided, will result in death or serious injury.
D-1002-1107
WARNINGThe signal word WARNING on the machine and in themanuals indicates a potentially hazardous situationwhich, if not avoided, could result in death or seriousinjury.
W-2044-1107
The following publications provide information on thesafe use and maintenance of the Bobcat machine andattachments:
• The Delivery Report is used to assure that completeinstructions have been given to the new owner andthat the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered withthe machine or attachment contains operatinginformation as well as routine maintenance andservice procedures. It is a part of the machine and canbe stored in a container provided on the machine.Replacement Operation & Maintenance Manuals canbe ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operationand care of your Bobcat machine or attachment. Thesigns and their locations are shown in the Operation& Maintenance Manual. Replacement signs areavailable from your Bobcat dealer.
• An Operator’s Handbook fastened to the operatorcab. It’s brief instructions are convenient to theoperator. The handbook is available from your dealerin an English edition or one of many other languages.See your Bobcat dealer for more information ontranslated versions.
• The AEM Safety Manual delivered with the machinegives general safety information.
• The Service Manual and Parts Manual are availablefrom your dealer for use by mechanics to do shop-type service and repair work.
• The Skid-Steer Loader Operator Training Course isavailable through your local dealer or atwww.training.bobcat.com or www.bobcat.com.This course is intended to provide rules and practicesof correct operation of the Skid-Steer Loader. Thecourse is available in English and Spanish versions.
• Service Safety Training Courses are available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com. They provide information forsafe and correct service procedures.
• The Skid-Steer Loader Safety Video is available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com.
SI SSL-1008 SM
This symbol with a warning statement means:“Warning, be alert! Your safety is involved!”Carefully read the message that follows.
Safety Alert Symbol
VI S150, S160 Service Manual
SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review therecommended uses of the product when delivered. If theowner / operator will be using the machine for a differentapplication(s) he or she must ask the dealer forrecommendations on the new use.
Call Before You DigDial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in yourstate / province, or city for information about buried lines(telephone, cable TV, water, sewer, gas, etc.).
Cutting or drilling concrete containing sand or rockcontaining quartz may result in exposure to silica dust.Do not exceed Permissible Exposure Limits (PEL) tosilica dust as determined by OSHA or other job site Rulesand Regulations. Use a respirator, water spray or othermeans to control dust. Silica dust can cause lung diseaseand is known to the state of California to cause cancer.
SI SSL-1008 SM
VII S150, S160 Service Manual
FIRE PREVENTION
Maintenance
The machine and some attachments have componentsthat are at high temperatures under normal operatingconditions. The primary source of high temperatures isthe engine and exhaust system. The electrical system, ifdamaged or incorrectly maintained, can be a source ofarcs or sparks.
Flammable debris (leaves, straw, etc.) must be removedregularly. If flammable debris is allowed to accumulate, itcan cause a fire hazard. Clean often to avoid thisaccumulation. Flammable debris in the enginecompartment is a potential fire hazard.
The operator’s area, engine compartment and enginecooling system must be inspected every day and cleanedif necessary to prevent fire hazards and overheating.
All fuels, most lubricants and some coolants mixtures areflammable. Flammable fluids that are leaking or spilledonto hot surfaces or onto electrical components cancause a fire.
Operation
Do not use the machine where exhaust, arcs, sparks orhot components can contact flammable material,explosive dust or gases.
Electrical
Check all electrical wiring and connections for damage.Keep the battery terminals clean and tight. Repair orreplace any damaged part or wires that are loose orfrayed.
Battery gas can explode and cause serious injury. Usethe procedure in the Operation & Maintenance Manualfor connecting the battery and for jump starting. Do notjump start or charge a frozen or damaged battery. Keepany open flames or sparks away from batteries. Do notsmoke in battery charging area.
Hydraulic System
Check hydraulic tubes, hoses and fittings for damageand leakage. Never use open flame or bare skin to checkfor leaks. Hydraulic tubes and hoses must be properlyrouted and have adequate support and secure clamps.Tighten or replace any parts that show leakage.
Always clean fluid spills. Do not use gasoline or dieselfuel for cleaning parts. Use commercial nonflammablesolvents.
Fueling
Stop the engine and let it cool before adding fuel. Nosmoking! Do not refuel a machine near open flames orsparks. Fill the fuel tank outdoors.
Starting
Do not use ether or starting fluids on any engine that hasglow plugs or air intake heater. These starting aids cancause explosion and injure you or bystanders.
Use the procedure in the Operation & MaintenanceManual for connecting the battery and for jump starting.
Spark Arrestor Exhaust System
The spark arrestor exhaust system is designed to controlthe emission of hot particles from the engine and exhaustsystem, but the muffler and the exhaust gases are stillhot.
Check the spark arrestor exhaust system regularly tomake sure it is maintained and working properly. Use theprocedure in the Operation & Maintenance Manual forcleaning the spark arrestor muffler (if equipped).
SI SSL-1008 SM
VIII S150, S160 Service Manual
FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnectthe battery, and disconnect the wiring from the Bobcatcontrollers before welding. Cover rubber hoses, batteryand all other flammable parts. Keep a fire extinguishernear the machine when welding.
Have good ventilation when grinding or welding paintedparts. Wear dust mask when grinding painted parts.Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such ashoods, fenders or covers can be flammable or explosive.Repair such components in a well ventilated area awayfrom open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits arelocated and how to use them. Inspect the fireextinguisher and service the fire extinguisher regularly.Obey the recommendations on the instructions plate.
SI SSL-1008 SM
IX S150, S160 Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the loader whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto use a different procedure in doing a specific serviceoperation.
Figure 1
Loader Serial Number
The loader serial number plate is located on the outsideof the loader frame [Figure 1].
Explanation of loader Serial Number:
Engine Serial Number
Figure 2
The engine serial number is located on the side of theengine [Figure 2].
1
P-45263
XXXX XXXXX
Module 2. - ProductionSequence (Series)
Module 1. - Model / EngineCombination
1. The four digit Model/Engine Combination Modulenumber identifies the model number and enginecombination.
2. The five digit Production Sequence Number identifiesthe order which the loader is produced.
P-48387
X S150, S160 Service Manual
DELIVERY REPORT
Figure 3
The delivery report must be filled out by the dealer andsigned by the owner or operator when the Bobcat loaderis delivered. An explanation of the form must be given tothe owner. Make sure it is filled out completely [Figure3].
B-16315
XI S150, S160 Service Manual
BOBCAT LOADER IDENTIFICATION
FRONTLIGHTS
GRABHANDLES
OPERATOR SEATwith SEAT BELT
& SEAT BAR
† BUCKET
◆ REAR AUXILIARY QUICK COUPLERS
FRONT AUXILIARYQUICK COUPLERS
STEPSBUCKETSTEPS
REARGRILL LIFT
CYLINDER
LIFT ARMSUPPORT DEVICE
TAILLIGHT
REARLIGHT
✽ TIRES
REARDOOR
LIFT ARM
◆ Optional or Field Accessory (Not Standard Equipment)✽ TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.† Bucket - Several different buckets and other attachments are available for this machine.● ROPS, FOPS - Roll Over Protective Structure, per SAE / ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I. Level I I is available.
● OPERATOR CAB(ROPS / FOPS)
B-19877A
B-19876A
TILTCYLINDERS
XII S150, S160 Service Manual
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