Bobcat S150, S160 Skid-Steer Loader Repair Service Manual - 6902498

(S/N: 523811001 & Above - S/N: 523911001 & Above - S/N: 524011001 & Above - S/N: 524111001 & Above) 
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This workshop repair service manual PDF download for the S150, S160 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader S150, S160
S/N: 523811001 & Above
S/N: 523911001 & Above
S/N: 524011001 & Above
S/N: 524111001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION 
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE 
HEATER 
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902498 (4-11)
Total Pages : 716


This Bobcat Skid-Steer Loader Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Loader Serial Number
        Engine Serial Number
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    
SAFETY AND MAINTENANCE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    LIFT ARM SUPPORT DEVICE
        Installing Lift Arm Support Device
        Removing Lift Arm Support Device
    OPERATOR CAB
        Description
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    TRANSPORTING THE BOBCAT LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    REMOTE START TOOL KIT - MEL1563
        Remote Start Tool - MEL1563
        Service Tool Harness Control - MEL1565
        Service Tool Harness Communicator - MEL1566
        Remote Start Procedure
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031
        Description
        Remote Start Tool (Service Tool) - 7003030
        Loader Service Tool Harness - 6689747
        Computer Service Tool Harness - 6689746
        Remote Start Procedure
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Testing
        Replacing Filter Element(s)
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
        Checking Coolant Level And Adding Coolant
        Checking The Coolant Level
        Replacing the Coolant
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Engine Oil Chart
        Replacing Oil And Filter
    HYDRAULIC / HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic / Hydrostatic Fluid Chart
        Replacing Hydraulic / Hydrostatic Filter
        Replacing Hydraulic Fluid
        Breather Cap
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
        Removing Oil From The Chaincase
    FAN GEARBOX
        Checking And Maintaining
    BOB-TACH (HAND LEVER)
        Inspection And Maintenance
    BOB-TACH (POWER)
        Inspection And Maintenance
    LUBRICATION OF THE BOBCAT LOADER
        Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Rotating
        Mounting
    SPARK ARRESTER MUFFLER
        Cleaning Procedure
    SEAT BELT
        Inspection And Maintenance
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Tighten Procedures
        Troubleshooting Chart
    CYLINDER (LIFT)
        Testing
        Removal And Installation
        Identification
        Disassembly
        Assembly
    CYLINDER (TILT)
        Testing
        Removal And Installation
        Rod End Pivot Pin Bushing And Seal Replacement
        Base End Pivot Pin Replacement
        Identification
        Disassembly
        Assembly
    CYLINDER (POWER BOB-TACH)
        Testing
        Removal And Installation
        Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE
        Description
        Testing
        Adjustment
        Removal And Installation
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)
        Removal And Installation
        BICS™ Valve Removal And Installation
        BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation
        BICS™ Valve, Check Valve Removal And Installation
        BICS™ Valve Lock Valve Removal And Installation
        BICS™ Valve Solenoid Removal And Installation
        BICS™ Valve Solenoid Testing
        Identification Chart
        Load Check Valve
        Main Relief Valve
        Port Relief Valve
        Anti-Cavitation Valve / Port Relief Valve
        Anti-Cavitation Valve
        Rubber Boot
        Lift And Tilt Lock Block Removal And Installation
        Lift Spool And Detent
        Tilt Spool Removal And Installation
        Auxiliary Spool Removal And Installation
        Auxiliary Electric Solenoid
        Port-Auxiliary Section
        Cleaning And Inspection
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
        Description
        Removal And Installation
        BICS™ Valve Removal And Installation
        BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation
        BICS™ Valve, Check Valve Removal And Installation
        BICS™ Valve Lock Valve Removal And Installation
        BICS™ Valve Solenoid Removal And Installation
        BICS™ Valve Solenoid Testing
        Actuator Removal And Installation
        Identification Chart (ACS)
        Lift Base End Restrictor
        Load Check Valve
        Main Relief Valve
        Port Relief Valve
        Anti-Cavitation Valve / Port Relief Valve
        Anti-Cavitation Valve
        Lift Spool Removal And Installation
        Tilt Spool Removal And Installation
        Lift And Tilt Spool Disassembly And Assembly
        Auxiliary Spool Removal And Installation
        Auxiliary Electric Solenoid
        Port-Auxiliary Section
        Cleaning And Inspection
    LIFT ARM BYPASS CONTROL VALVE
        Inspecting
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Check The Output Of The Hydraulic Pump Without Power Bob-Tach
        Check The Output Of The Hydraulic Pump With Power Bob-Tach.
        Removal And Installation
        Identification
        Disassembly And Assembly
    HYDRAULIC PUMP (HI FLOW)
        Check The Output Of The Hydraulic Pump Without Power Bob-Tach
        Check The Output Of The Hydraulic Pump With Power Bob-Tach
        Removal And Installation
        Identification
        Disassembly And Assembly
    HYDRAULIC FILTER HOUSING
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Fluid Removal
        Removal And Installation
    BUCKET POSITION VALVE
        Solenoid Removal And Installation
        Solenoid Testing
        Removal And Installation
        Disassembly And Assembly
    HIGH FLOW VALVE
        Checking The High Flow Relief Valve
        High Flow Relief Valve Adjustment Procedure
        Removal And Installation
        Disassembly And Assembly
        Solenoid Testing
    REAR AUXILIARY DIVERTER VALVE
        Removal And Installation
        Disassembly And Assembly
        Solenoid Testing
        Inspection
    POWER BOB-TACH BLOCK
        Removal And Installation
        Disassembly And Assembly
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
        Removal And Installation
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
        Replenishing Valve Function
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
        Carrier Shaft Seal Replacement
        Carrier Removal And Installation
        Carrier Parts Identification
        Carrier Disassembly
        Carrier Assembly
    CHARGE PRESSURE
        Sender Removal And Installation
        Testing Charge Pressure
        Adjusting
    HYDROSTATIC PUMP
        Replenishing / High Pressure Relief Valve
        Removal And Installation
        Parts Identification (Right Half)
        Parts Identification (Left Half)
        Hydraulic Pump Removal And Installation
        Pump Separation
        Disassembly
        Assembly
    DRIVE BELT
        Shield Removal And Installation
        Adjusting
        Drive Belt Replacement
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Parts Identification
        Tensioner Pulley Disassembly
        Tensioner Pulley Assembly
    OIL COOLER
        Removal And Installation
        
DRIVE SYSTEM
    BRAKE
        Disk Removal And Installation
        Switch Operated Parking Brake
    DRIVE COMPONENTS
        Axle Seal Removal And Installation
        Axle Sprocket And Bearings Removal And Installation
        Chain Removal And Installation
    CHAINCASE
        Checking And Adding Oil
        Removing The Oil
        Front Cover Removal And Installation
        Center Cover Removal And Installation
        Rear Cover Removal And Installation
        
MAINFRAME
    SEAT BAR
        Removal And Installation
        Assembling Components
        Compression Spring Disassembly And Assembly
    OPERATOR CAB
        Gas Cylinder Removal And Installation
        Gas Cylinder Disassembly
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
        Seat Belt Removal And Installation
    OPERATOR SEAT (SUSPENSION)
        Removal And Installation
        Slide Rail Removal And Installation
        Cushion Removal And Installation
        Back Removal And Installation
        Shock Removal And Installation
        3-Point Seat Belt Removal And Installation
    BOB-TACH
        Removal And Installation
        Bob-Tach Lever And Wedge
        Pivot Pin Bushing And Seal Removal And Installation
    POWER BOB-TACH
        Removal And Installation
        Power Bob-Tach Lever And Wedge
        Pivot Pin Bushing And Seal Removal And Installation
    LIFT ARMS
        Removal And Installation
    REAR GRILLE
        Removal And Installation
    REAR DOOR
        Removal And Installation
        Striker Removal And Installation
        Striker Disassembly And Assembly
        Adjusting The Striker
        Latch Removal And Installation
    FUEL TANK
        Removal And Installation
        Fuel Level Sender
        Fuel Fill Screen
    CONTROL PEDALS
        Removal And Installation
        Pedal Adjustment
        Crossbar Linkage Removal And Installation
        Lift Foot Pedal Linkage Removal And Installation
        Tilt Foot Pedal Linkage Removal And Installation
    CONTROL PEDALS (ACS)
        Foot Sensor Removal And Installation
        Foot Pedal Removal And Installation
        Foot Pedal Linkage Disassembly And Assembly
    CONTROL PANEL
        Removal And Installation
        Shock Removal And Installation
        Shaft Removal And Installation
        Shaft Disassembly And Assembly
        Linkage Removal And Installation
        Linkage Adjustment
        Linkage Neutral Adjustment
    CONTROL HANDLE
        Control Lever Removal And Installation
        Control Lever Boot
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL
        Components Identification
        Handle Sensor Removal And Installation
        Control Handle Removal And Installation
        Control Handle Disassembly And Assembly
        Control Lever Removal And Installation
        Control Lever Boot
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuse Location
        Relay Switch Location
    BATTERY
        Removal And Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    ALTERNATOR (90 AMP)
        Adjusting The Alternator Belt
        Alternator Identification
        Charging System Check
        Alternator Voltage Test
        Low Voltage Test
        High Voltage Test
        Removal And Installation
        Rectifier Continuity (Diode) Test
        Alternator Regulator Test
        Disassembly
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Assembly
    STARTER
        Checking
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inspection And Repair
        No Load Test
    INSTRUMENT PANEL
        Left Panel
        Right Panel (Standard) (With Key Switch)
        Right Panel - (Deluxe) (With Keyless Start)
        Option And Field Accessory Panels
        Removal And Installation
        Front Accessory Panel Removal And Installation
    LIGHTS
        Front Removal And Installation
        Rear Removal And Installation
    BOBCAT CONTROLLER
        Identification Chart
        Removal And Installation
    DIAGNOSTIC SERVICE CODES
        Display
        Number Codes List
    BICS™ SYSTEM
        Inspecting The BICS™ Controller (Engine STOPPED - Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
        Inspecting The Seat Bar Sensor (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm Bypass Control
        Troubleshooting Chart
        Troubleshooting Guide
    SEAT BAR SENSOR
        Description
        Troubleshooting
        Testing
        Removal And Installation
        Bobcat Interlock Control System (BICS™) Circuit Test
    TRACTION LOCK
        Troubleshooting Chart
        Inspecting
        Solenoid Removal And Installation
        Guide Removal
        Guide Installation
    ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL
        Components Identification
        Troubleshooting Guide
        Controller, Connector And Wire Identification
        ACS Controller Removal And Installation
        Handle Sensor Connector
        Switch Handle Removal
        Switch Handle Installation
        Actuators Disassembly And Assembly
        Handle Lock Solenoid Removal And Installation
        Handle Lock Solenoid Disassembly And Assembly
        Handle Lock Solenoid Connector
        Calibration Of The ACS System
        Switchable Hand / Foot Controls Calibration Procedure
        Hand Controls Only Calibration Procedure
        Foot Sensor Disassembly And Assembly
        Foot Sensor Connector
        Foot Lock Solenoid Removal And Installation
        Foot Lock Solenoid Connector
    ELECTRICAL / HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    ENGINE SPEED CONTROL
        Removal And Installation
        Disassembly
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Removal And Installation
    RADIATOR
        Removal And Installation
    COOLING FAN
        Drive Tension Pulley Removal And Installation
        Gearbox / Blower Housing Removal And Installation
        Blower Housing Grille Removal And Installation
        Blower Disassembly And Assembly
        Gearbox Parts Identification
        Gearbox Disassembly
        Gearbox Assembly
        Gearbox Checking Backlash
    ENGINE COMPONENTS AND TESTING
        Compression Checking
        Glow Plugs Checking
        Glow Plugs Removal And Installation
        Fuel Shut-Off Solenoid - Checking
        Fuel Shut-Off Solenoid - Adjusting
        Fuel Shut-Off Solenoid Removal And Installation
        Checking
        Fuel Injection Pump Removal And Installation
        Timing The Injection Pump
        Fuel Injector Removal And Installation
        Fuel Injector - Checking
        Fuel Injector Disassembly
        Fuel Injector Assembly
        Valve Clearance Adjustment
        Rocker Arm And Shaft - Checking
        Valve Timing - Checking
    ENGINE
        Removal And Installation
        Engine Mount Replacement
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
        Ring Gear Removal And Installation
        Housing Removal And Installation
    RPM SENSOR
        Adjustment
    RECONDITIONING THE ENGINE-KUBOTA V2203-EB AND V2003T-EB (TURBO)
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head Servicing
        Cylinder Head Top Clearance
        Checking The Valve Guide
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Rocker Arm And Shaft Checking
        Timing Gearcase Cover Removal And Installation
        Idler Gear And Camshaft Removal And Installation
        Servicing The Camshaft
        Servicing The Idle Gear And Shaft
        Timing Gears Checking Backlash
        Fuel Camshaft Removal And Installation
        Fuel Camshaft Governor
        Crankshaft Gear Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Service
        Checking Engine Oil Pressure
        Relief Valve
        Piston And Connecting Rod Removal And Installation
        Servicing The Piston And Connecting Rod
        Connecting Rod Alignment
        Crankshaft And Bearings Removal And Installation
        Servicing The Crankshaft And Bearings
        Checking The Cylinder Bore
        Water Pump Disassembly And Assembly
    TURBOCHARGER
        Troubleshooting
        Description
        Removal And Installation
        
HEATING, VENTILATION, AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Principals
        Chart
    COMPONENTS
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Elements Removal And Installation
        Compressor Drive Belt Inspection
        Cleaning The Condenser
    BASIC TROUBLESHOOTING
        Poor A/C Performance
        Cleaning The A/C Evaporator Coil & Heater Coil
        Compressor Drive Belt Inspection
        Checking The Electrical System
        Engine Coolant Bypassing The Heater Valve
        Heater Valve Not Opening Or Closing
    GENERAL AIR CONDITIONING SERVICE GUIDELINES
        Compressor Oil
        Compressor Oil Check
        Component Replacement And Refrigeration Leaks
    SYSTEM TROUBLESHOOTING CHART
        Gauge Pressure Related Troubleshooting
    TEMPERATURE / PRESSURE
        Chart
    AIR CONDITIONING SERVICE
        Chart
    SYSTEM CHARGING AND RECLAMATION
        Reclamation Procedure
        Charging Procedure With A Manifold Gauge Set
        Charging Procedure
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly
    CONDENSER
        Removal And Installation
    RECEIVER / DRIER
        Removal And Installation
    PRESSURE RELIEF VALVE
        Removal And Installation
    PRESSURE SWITCH
        Removal And Installation
    EVAPORATOR / HEATER UNIT
        Removal And Installation
        Disassembly And Assembly
    THERMOSTAT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    EVAPORATOR
        Removal And Installation
    HEATER COIL
        Removal And Installation With A/C
        Removal And Installation Without A/C
    HEATER / A/C FAN
        Removal And Installation
        Disassembly And Assembly
        Wire Connector Removal And Installation
    HEATER VALVE
        Removal And Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        Machine Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS - KUBOTA V2203-EB
        Fuel Injection Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Valve Timing
        Rocker Arms
        Camshaft
        Tappet
        Cylinders
        Piston Rings
        Pistons
        Connecting Rod
        Oil Pump
        Crankshaft
        Timing Gear
        Thermostat
        Crankshaft Re-Grind Data
    ENGINE SPECIFICATIONS - KUBOTA V2003T-EB (TURBO)
        Fuel Injection Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Valve Timing
        Rocker Arms
        Camshaft
        Tappet
        Cylinder Liner
        Piston Rings
        Pistons
        Connecting Rod
        Oil Pump
        Crankshaft
        Timing Gear
        Thermostat
        Crankshaft Re-Grind Data
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O-ring Face Seal Connection
        Straight Thread O-ring Fitting
        Tubelines And Hoses
        Flare Fitting
        O-ring Flare Fitting
        Port Seal Fitting
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalent Chart
        U.S. To Metric Conversion Chart
        
SERVICE MANUAL REVISION
    Revision No: S150, S160-1
    Revision No: S150, S160-2
    Revision No: S150, S160-3
    
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