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Service Manual S150, S160 Turbo Skid-Steer Loader
Dealer Copy -- Not for Resale
S/N 526611001 & Above S/N 526711001 & Above S/N 526811001 & Above S/N 526911001 & Above
EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 6902730 (5-11)
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Printed in U.S.A.
© Bobcat Company 2011
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Dealer Copy -- Not for Resale
MAINTENANCE SAFETY WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0807 instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
CORRECT
P-90216
B-15590
Never service the Bobcat SkidSteer Loader without instructions.
Use the correct procedure to lift or lower operator cab.
CORRECT
B-15591
Cleaning and maintenance are required daily.
WRONG
WRONG
WRONG
B-15592
B-15593
B-15599
Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.
Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.
WRONG
WRONG
B-15600
B-15601
Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.
Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader.
Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.
WRONG
B-6589
Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.
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 & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW08-0409
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Dealer Copy -- Not for Resale
CORRECT
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Dealer Copy -- Not for Resale
ALPHABETICAL INDEX
BATTERY................................................................ 60-01 BASIC TROUBLESHOOTING ................................80-01 BICS™ SYSTEM .................................................... 60-01 BOBCAT CONTROLLER .....................................60-01 BOB-TACH ............................................... 10-01, 50-01 BRAKE .................................................................... 40-01 BUCKET POSITION VALVE ................................ 20-01 CALIBRATION ........................................................ 60-01 CHAINCASE ........................................................... 40-01 CHARGE PRESSURE ............................................ 30-01 COMPONENTS ...................................................... 80-01 COMPRESSOR ...................................................... 80-01 CONDENSER ......................................................... 80-01 CONTROL HANDLE ............................................... 50-01 CONTROL HANDLE (SJC)..................................... 50-01 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL.... 50-01 CONTROL PANEL .................................................. 50-01 CONTROL PANEL (SJC)........................................ 50-01 CONTROL PEDALS ............................................... 50-01 CONTROL PEDALS (ACS) .................................... 50-01 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) ....................................................................... 50-01 CONVERSIONS ............................................SPEC-01 COOLING FAN ....................................................... 70-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (POWER BOB-TACH).......................... 20-01 CYLINDER (TILT) ................................................ 20-01 DIAGNOSTICS SERVICE CODES ..................... 60-01 DRIVE BELT ........................................................... 30-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ELECTRICAL / HYRAULIC CONTROLS REF. ....... 60-01 ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) ....... 60-01 ENGINE ................................................................. 70-01 ENGINE COMPONENTS AND TESTING .............. 70-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPECIFICATIONS ...........................SPEC-01 ENGINE SPEED CONTROL .................................. 70-01 EVAPORATOR........................................................ 80-01 EVAPORATOR / HEATER UNIT ............................. 80-01 EXPANSION VALVE ............................................... 80-01
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FAN GEARBOX .......................................................10-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01 FLYWHEEL AND HOUSING ................................ 70-01 FLYWHEEL RPM SENSOR ....................................60-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01 FUEL SYSTEM........................................................10-01 FUEL TANK .............................................................50-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES ...........................................................80-01 HEATER COIL .........................................................80-01 HEATER / A/C FAN .................................................80-01 HEATER VALVE ......................................................80-01 HIGH FLOW VALVE ................................................20-01 HYDRAULIC CONNECTION SPECS. .............. SPEC-01 HYDRAULIC CONTROL VALVE .............................20-01 HYDRAULIC FILTER HOUSING .............................20-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01 HYDRAULIC FLUID RESERVOIR ..........................20-01 HYDRAULIC / HYDROSTATIC SYSTEM ................10-01 HYDRAULIC PUMP ................................................20-01 HYDRAULIC PUMP (HIGH FLOW).........................20-01 HYDRAULIC PUMP (HIGH FLOW) (SJC)...............20-01 HYDARULIC PUMP (SJC) ......................................20-01 HYDRAULIC SYSTEM INFORMATION ..................20-01 HYDROSTATIC MOTOR ..................................... 30-01 HYDROSTATIC MOTOR CARRIER ........................30-01 HYDROSTATIC MOTOR CARRIER (SJC)..............30-01 HYDROSTATIC PUMP ........................................ 30-01 HYDROSTATIC SYSTEM INFORMATION ..........30-01 INSTRUMENT PANEL.............................................60-01 LIFT ARMS ..............................................................50-01 LIFT ARM BYPASS CONTROL VALVE .............. 20-01 LIFT ARM SUPPORT DEVICE ........................... 10-01 LIFTING AND BLOCKING THE LOADER...............10-01 LIGHTS ................................................................60-01 LOADER SPECIFICATIONS ............................. SPEC-01 LUBRICATING THE LOADER.................................10-01 MAIN RELIEF VALVE ..............................................20-01 MUFFLER................................................................70-01 OIL COOLER...........................................................30-01 OPERATOR CAB .........................................10-01, 50-01 OPERATOR SEAT...................................................50-01 OPERATOR SEAT (SUSPENSION)........................50-01 POWER BOB-TACH .................................10-01, 50-01 POWER BOB-TACH BLOCK...................................20-01 PRESSURE RELIEF VALVE ...................................80-01 PRESSURE SWITCH..............................................80-01
Dealer Copy -- Not for Resale
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL .............. 60-01 AIR CLEANER .................................................... 70-01 AIR CLEANER SERVICE ....................................... 10-01 AIR CONDITIONING SERVICE.............................. 80-01 AIR CONDITIONING SYSTEM FLOW ................... 80-01 ALTERNATOR ........................................................ 60-01
ALPHABETICAL INDEX (CONT’D)
SAFETY...................................................................80-01 SEAT BELT ..............................................................10-01 SEAT BAR .............................................................. 50-01 SEAT BAR SENSOR ...............................................60-01 SERVICE PC (LAPTOP COMPUTER) ....................60-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTER MUFFLER ............................. 10-01 SPEED SENSOR ................................................... 60-01 STARTER ................................................................60-01 SYSTEM CHARGING AND RECLAMATION ......... 80-01 SYSTEM TROUBLESHOOTING CHART ...............80-01 TEMPERATURE / PRESSURE .............................. 80-01 THERMOSTAT........................................................ 80-01 TIRE MAINTENANCE .............................................10-01 TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01 TOWING THE LOADER ..........................................10-01 TRACTION LOCK....................................................60-01 TRANSPORTING THE BOBCAT LOADER.............10-01 TROUBLESHOOTING.............................................70-01 TURBOCHARGER ..................................................70-01
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RADIATOR.............................................................. 70-01 REAR AUXILIARY DIVERTER VALVE ....................20-01 REAR DOOR ...................................................... 50-01 REAR GRILLE .........................................................50-01 RECEIVER / DRIER ................................................80-01 RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO) ......................................... 70-01 REGULAR MAINTENANCE ................................... 80-01 REMOTE START ................................................ 10-01 RPM SENSOR ....................................................70-01
SAFETY & MAINTENANCE
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
HYDRAULIC SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
HYDROSTATIC SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
DRIVE SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 MAINFRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAINFRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 70-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
Dealer Copy -- Not for Resale
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS
SPECIFICATIONS
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S150, S160 Bobcat Loader Service Manual
FOREWORD This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures 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: 9. The parking brake function correctly.
must
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
10. Enclosure door latches must open and close freely.
3. The seat belt must be correctly installed, functional and in good condition.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
12. Safety treads must be in good condition.
5. Check lift arm support device, replace if damaged.
13. Check for correct function of indicator lamps.
6. Machine signs (decals) must be legible and in the correct location.
14. Check hydraulic fluid level, engine oil level and fuel supply.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
15. Inspect for fuel, hydraulic fluid leaks.
8. Check for correct function of the work lights.
16. Lubricate the loader.
oil
Dealer Copy -- Not for Resale
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
or
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S150, S160 Bobcat Loader Service Manual
23. Operate the machine and check all functions.
18. Inspect the air cleaner for damage or leaks. Check the condition of the element.
24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.
19. Check the electrical charging system.
25. Check for proper function of front horn and back-up alarm (if equipped).
20. Check tires for wear and pressure. Check tracks for wear and tension. Use only approved 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 broken parts or connections.
27. Recommend to the owner that all necessary corrections be made before the machine is returned to service.
Dealer Copy -- Not for Resale
17. Check the condition of the battery and cables.
22. Check for any field modification not completed.
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale FW SSL-1008 SM
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S150, S160 Bobcat Loader Service Manual
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
•
The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
•
The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
•
Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
•
An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
•
The AEM Safety Manual delivered with the machine gives general safety information.
•
The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
•
The Skid-Steer Loader Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Skid-Steer Loader. The course is available in English and Spanish versions.
•
Service Safety Training Courses are available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com. They provide information for safe and correct service procedures.
•
The Skid-Steer Loader Safety Video is available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com.
WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903
IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine. I-2019-0284
DANGER The signal word DANGER on the machine and in the manuals indicates a hazardous situation which, if not avoided, will result in death or serious injury. D-1002-1107
WARNING The signal word WARNING on the machine and in the manuals indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. W-2044-1107
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS (CONT’D) The dealer and owner / operator review the recommended uses of the product when delivered. If the owner / operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.
Cutting or drilling concrete containing sand or rock containing quartz may result in exposure to silica dust. Do not exceed Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other job site Rules and Regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer.
Call Before You Dig Dealer Copy -- Not for Resale
Dial 811 (USA Only) 1-888-258-0808 (USA & Canada) When you call, you will be directed to a location in your state / province, or city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1008 SM
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Hydraulic System
FIRE PREVENTION
Check hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Hydraulic tubes and hoses must be properly routed and have adequate support and secure clamps. Tighten or replace any parts that show leakage. Maintenance
Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.
The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.
Fueling
Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard. The operator’s area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.
Starting Do not use ether or starting fluids on any engine that has glow plugs or air intake heater. These starting aids can cause explosion and injure you or bystanders.
All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.
Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.
Operation Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.
Spark Arrestor Exhaust System The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.
Electrical
Check the spark arrestor exhaust system regularly to make sure it is maintained and working properly. Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped). Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed. Battery gas can explode and cause serious injury. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting. Do not jump start or charge a frozen or damaged battery. Keep any open flames or sparks away from batteries. Do not smoke in battery charging area. SI SSL-1008 SM
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Dealer Copy -- Not for Resale
Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a machine near open flames or sparks. Fill the fuel tank outdoors.
FIRE PREVENTION (CONT’D) Welding And Grinding Always clean the machine and attachment, disconnect the battery, and disconnect the wiring from the Bobcat controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced. Dust generated from repairing nonmetallic parts such as hoods, fenders or covers can be flammable or explosive. Repair such components in a well ventilated area away from open flames or sparks.
Dealer Copy -- Not for Resale
Fire Extinguishers
Know where fire extinguishers and first aid kits are located and how to use them. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instructions plate.
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S150, S160 Bobcat Loader Service Manual
SERIAL NUMBER LOCATIONS
Engine Serial Number
Always use the serial number of the loader when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.
Figure 2
Figure 1
1
P-21821
Dealer Copy -- Not for Resale
The engine serial number is located on the side of the engine [Figure 2].
P-45263
Loader Serial Number The loader serial number plate is located on the outside of the loader frame [Figure 1]. Explanation of loader Serial Number: XXXX
XXXXX Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination
1. The four digit Model / Engine Combination Module number identifies the model number and engine combination. 2. The five digit Production Sequence Number identifies the order which the loader is produced.
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DELIVERY REPORT Figure 3
B-16315
Dealer Copy -- Not for Resale
The delivery report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 3].
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BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS
OPERATOR SEAT with SEAT BELT & SEAT BAR
GRAB HANDLES
TILT CYLINDERS
BUCKET STEPS
STEPS B-19880
■ BUCKET
● OPERATOR CAB
(ROPS / FOPS) LIFT ARM SUPPORT DEVICE
◆ REAR AUXILIARY
QUICK COUPLERS
LIFT ARM REAR GRILLE
LIFT CYLINDER
REAR DOOR REAR LIGHT TAIL LIGHT
❏ TIRES
B-19881
◆ 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 J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available.
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Dealer Copy -- Not for Resale
FRONT AUXILIARY QUICK COUPLERS
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SAFETY & MAINTENANCE
SAFETY AND MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY MAINTENANCE
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . Checking Coolant Level And Adding Coolant . . . . . . . . . . Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SYSTEM
10-110-1 10-110-1 10-110-1 10-110-2
FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 Removing Oil From The Chaincase. . . . . . . . . . . . . . . . . 10-130-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System . . . . . . . . . . . . . . .
10-100-1 10-100-1 10-100-2 10-100-1 10-100-3
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . .
10-120-1 10-120-3 10-120-1 10-120-1 10-120-2 10-120-1
ELECTRICAL SYSTEM ANALYSIS ENGINE SERVICE
SPECIFICATIONS
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1 Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . 10-20-2 LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LUBRICATION OF THE BOBCAT LOADER. . . . . . . . . . . . . 10-160-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 Continued On Next Page
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Dealer Copy -- Not for Resale
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
10-90-1 10-90-2 10-90-1 10-90-1 10-90-2
S150, S160 Service Manual
SAFETY AND MAINTENANCE (CONT’D) OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . .
10-30-1 10-30-1 10-30-4 10-30-2 10-30-1
REMOTE START TOOL KIT -MEL1563 . . . . . . . . . . . . . . . . . Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . Service Tool Harness Communicator - MEL1566 . . . . . . . Service Tool Harness Control - MEL1565 . . . . . . . . . . . . .
10-60-1 10-60-4 10-60-1 10-60-3 10-60-2
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . Computer Service Tool Harness - 6689746 . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Start Tool (Service Tool) - 7003030 . . . . . . . . . . .
10-60-1 10-60-4 10-60-1 10-60-3 10-60-5 10-60-2
Dealer Copy -- Not for Resale
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . 10-151-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-190-1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-170-1 10-170-1 10-170-1 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1 Fastening To Transport Vehicle . . . . . . . . . . . . . . . . . . . . . 10-40-1 Loading Onto Transport Vehicle. . . . . . . . . . . . . . . . . . . . . 10-40-1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
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LIFTING AND BLOCKING THE LOADER
Figure 10-10-2
Procedure Figure 10-10-1
P-45481
Put a floor jack under the rear of the loader. B-7023A
Lift the rear of the loader and install jackstands [Figure 10-10-2].
Dealer Copy -- Not for Resale
Figure 10-10-3
WARNING AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0807
P-45482
Always park the loader on a level surface. Put the floor jack under the front of the loader.
WARNING
Lift the front of the loader and put jackstands under the axle tubes [Figure 10-10-3].
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
NOTE: Make sure the jackstands do not touch the tires. Make sure tires clear the floor and any obstacles.
W-2017-0286
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LIFT ARM SUPPORT DEVICE
Figure 10-20-1
Installing Lift Arm Support Device
WARNING
P-45481
2
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
W-2572-0407
P-45251
Put jackstands under the rear corners of the loader frame (Inset) [Figure 10-20-1]. Disconnect the spring from the lift arm support device retaining pin (Item 1). Support the lift arm support device (Item 2) [Figure 10-20-1] with your hand and remove the retaining pin.
DANGER
Figure 10-20-2
1 P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
P-45252
D-1009-0409
Lower the lift arm support device on top of the lift cylinder. Hook the free end of the spring (Item 1) [Figure 10-202] to the lift arm support device so there will be no interference with the support device engagement. The operator must be in the operator's seat, with the seat belt fastened and seat bar lowered. Start the engine, and raise the lift arms all the way up.
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Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.
1
LIFT ARM SUPPORT DEVICE (CONT’D)
Removing Lift Arm Support Device
Installing Lift Arm Support Device (Cont’d)
Figure 10-20-4
Figure 10-20-3 1 1
P-45485
P-45486
Remove the pin from the lift arm support device.
Raise the lift arms until the lift arm support device drops onto the lift cylinder rod [Figure 10-20-3]. Lower the lift arms slowly until the lift arm support device is held between the lift arms and lift cylinder [Figure 1020-3]. Stop the engine. Raise the seat bar, and move both the pedals until both pedals lock.
Connect the spring (Item 1) [Figure 10-20-4] from the lift arm support device to the bracket below the lift arms. The operator must be in the operator's seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is removed and the lift arms are lowered all the way. Start the engine, raise the lift arms all the way up. The spring will lift the support device off the lift cylinder rod.
Install pin (Item 1) (Inset) [Figure 10-20-3].
Lower the lift arms all the way and stop the engine.
Note:
Raise the seat bar and move the pedals until both pedals lock.
The lift arm support device must be tight against the cylinder rod. The tabs of the lift arm support device must be under the cylinder as shown (Inset) [Figure 10-20-3].
Disconnect the spring from the bracket. Figure 10-20-5
1 2
P-45251
Return the lift arm support device to storage position and insert pin (Item 1) through lift arm support device (Item 2) [Figure 10-20-5] and welded tab on boom. Connect spring to pin. Remove the jackstands.
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P-45484
OPERATOR CAB
Raising The Operator Cab
Description
Always stop the engine before raising or lowering the cab.
Figure 10-30-1 Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Install jackstands under the rear of the loader frame [Figure 10-30-1]. Figure 10-30-2
The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection. ROPS / FOPS - Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available.
P10564
P10563
Remove the nuts and plates [Figure 10-30-2] (both sides).
Level I - Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services. Level II - Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.
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P-45481
OPERATOR CAB (CONT'D)
Lowering The Operator Cab
Raising The Operator Cab (Cont’d)
Always stop the engine before raising or lowering the cab.
Figure 10-30-3 NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab. Figure 10-30-4
WARNING
N-20120
Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death. W-2069-0200
Lift on the grab handle and bottom of the operator cab slowly until the cab is all the way up and the latching mechanism engages [Figure 10-30-3].
P-45262
Pull down on the bottom of the operator cab until it stops at the latching mechanism [Figure 10-30-4]. NOTE: The weight of the cab increases when equipped with options and accessories such cab door, heater, air conditioning, etc. In these cases, the cab may need to be raised slightly from the latch to be able to release the latch. Support the cab and release the latching mechanism (Inset) [Figure 10-30-4]. Remove your hand from latching mechanism when the cab is past the latch stop. Use both hands to lower the cab all the way.
WARNING WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT MOVEMENT CAUSED BY CAB CONTACT WITH CONTROLS CAN CAUSE SERIOUS INJURY OR DEATH •
PINCH POINT CAN CAUSE INJURY Remove your hand from the latching mechanism when the cab is past the latch stop.
STOP ENGINE before raising or lowering cab. W-2758-0908
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P-45261
OPERATOR CAB (CONT’D) Lowering The Operator Cab (Cont’d) Figure 10-30-5
P-31288
P-31289
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Install the plates and nuts (both sides) [Figure 10-30-5]. Tighten the nuts to 40 - 50 ft.-lb. (54 - 68 N•m) torque.
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Figure 10-30-8
OPERATOR CAB (CONT’D) Emergency Exit Figure 10-30-6
N-20171
Front Door (If Equipped) P0660
NOTE: If the loader has a Special Application Door Kit installed, the window of the front door is NOT an emergency exit.
Rear Window (If Equipped) Pull on the tag on the top of the rear window to remove the rubber cord [Figure 10-30-6].
Pull the plastic loop at the top of the window in the front door to remove the rubber cord [Figure 10-30-8].
Figure 10-30-7 Figure 10-30-9
x P-45260 P-24472
Push the rear window out of the rear of the operator cab. Exit through the rear of the operator cab [Figure 10-307].
Push the window out with your foot [Figure 10-30-9] at any corner of the window. Exit through the front door.
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The front opening on the operator cab and rear window provide exits.
NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [Figure 10-30-8].
TRANSPORTING THE BOBCAT LOADER
Fastening To Transport Vehicle
Loading Onto Transport Vehicle
Figure 10-40-2
WARNING AVOID SERIOUS INJURY OR DEATH Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.
P-31228
W-2058-0807
P-31230
Be sure the transport and towing vehicles are of adequate size and capacity. For weight of loader (See Capacities on Page SPEC 10-4.)
Alternate Front Tie-Down
P-45989
P-45218A
Use the following procedure to fasten the Bobcat Loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [Figure 10-40-2]. • • • • • •
Lower the bucket or attachment to the floor. Stop the engine. Engage the parking brake. Install chains at the front and rear loader tie down positions [Figure 10-40-2] Fasten each end of the chain to the transport vehicle. Use chain binders to tighten the chains.
10-40-1
S150, S160 Bobcat Loader Service Manual
1 P-43631
P-45215A
A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure 1040-1]. The rear of the trailer must be blocked or supported (Item 1) [Figure 10-40-1] when loading or unloading the loader to prevent the front end of the trailer from raising up.
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Figure 10-40-1
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TOWING THE LOADER Procedure Because of the design of the loader, there is not a recommended towing procedure. •
The loader can be lifted onto a transport vehicle.
•
The loader can be skidded a short distance to move for service (EXAMPLE: Move onto a transport vehicle.) without damage to the hydrostatic system. (The tires / tracks will not turn.) There might be slight wear to the tires / tracks when the loader is skidded.
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The towing chain (or cable) must be rated at 1.5 times the weight of the loader (See LOADER SPECIFICATIONS on Page SPEC-10-1.)
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Figure 10-60-2
REMOTE START TOOL KIT -MEL1563 Remote Start Tool - MEL1563 Tools that will be needed to complete the following steps are:
2 MEL1563 - Remote Start Tool MEL1565 - Service Tool Harness Control MEL1566 - Service Tool Harness Communicator (Computer Interface)
3
1
Figure 10-60-1
P16117
1
P16114
The remote start tool (Item 1) [Figure 10-60-1] is required when the service technician is checking the hydraulic / hydrostatic system or adjusting the steering linkage.
The maximum flow / variable flow switch (Item 2) [Figure 10-60-2] is used to activate the auxiliary hydraulics. Pressing the switch once will activate maximum flow. Pressing the switch again will activate variable flow. The switch will illuminate to indicate which flow rate is active. Pressing the switch a third time will turn the flow OFF. The switch is used when checking pressures and flow rate. The auxiliary pressure release (Item 3) [Figure 10-60-2] is used to release hydraulic pressure to the front and / or rear auxiliary couplers. To release pressure; push and hold the switch for a few seconds. NOTE: With the engine running; pushing and holding the pressure release switch will cause the engine to stop. To relieve the pressure; press the switch until the engine stops.
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The traction lock switch (Item 1) [Figure 10-60-2] is used to turn traction lock ON or OFF. Push the switch to the override position. The switch will illuminate to indicate traction lock OVERRIDE, in this position the wheels are able to turn.
REMOTE START TOOL-MEL1563 (CONT'D)
Service Tool Harness Control - MEL1565
Remote Start Tool - MEL1563 (Cont’d)
Figure 10-60-5
Figure 10-60-3
2
1
1
P16114 P16116
Figure 10-60-4
Dealer Copy -- Not for Resale
The service tool harness control (Item 1) [Figure 10-605] is used to connect the remote start tool (Item 2) [Figure 10-60-5] to the electrical system on the loader. Figure 10-60-6
1
1
P16120
The 10-pin rectangular connector (Item 1) [Figure 10-603] is used to update software in the Deluxe Instrumentation Panel (Item 1) [Figure 10-60-4]. NOTE: The Service PC must be connected to the remote start tool to update the deluxe panel software.
N-19561
Remove the plug (Item 1) [Figure 10-60-6] from the loader harness connector. Connect the service tool harness control to the loader harness connector.
The panel must be removed from inside the operator cab and plugged into this connector [Figure 10-60-3].
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REMOTE START TOOL-MEL1563 (CONT'D)
Service Tool Harness Communicator - MEL1566
Service Tool Harness Control - MEL1565 (Cont’d)
Figure 10-60-8
Figure 10-60-7
2
2 1
1 P16119 N-19631
Dealer Copy -- Not for Resale
Loaders equipped with an attachment harness (Item 1) [Figure 10-60-7] must disconnect the attachment harness from the loader harness (Item 2) [Figure 10-607].
The service tool harness communicator (Item 1) [Figure 10-60-8] is required to connect remote start tool to the Service PC (Item 2) [Figure 10-60-8].
Connect the service tool harness to the ACD connector and the loader harness connector. NOTE: To monitor, diagnose or load new software the Service PC must be connected to the Remote Start Tool Switch.
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Figure 10-60-11
REMOTE START TOOL KIT-MEL1563 (CONT’D) Remote Start Procedure The tool listed will be needed to do the following procedure: MEL1563: Remote Start Tool Kit
1
Figure 10-60-9
1 N-19150
Remove the plug (Item 1) [Figure 10-60-10] or disconnect the attachment control harness (Item 1) [Figure 10-60-11] if connected.
P16115
The remote start tool (Item 1) [Figure 10-60-9] is required when the operator cab is in the raised position for service and the service technician needs to turn the key switch on or start the engine. Example: adjusting the steering linkage. Lift and block the loader. Raise the lift arms (if required by the procedure) and install an approved lift arm support device. P13861
Raise the operator cab (if required by the procedure). Connect the remote start tool to the engine harness connector [Figure 10-60-12].
Open the rear door of the loader. Figure 10-60-10
NOTE: The key switch on the right-hand side operator panel must be in the off position or the Remote Start Kit will not operate.
1
N-19151
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Figure 10-60-12
Figure 10-60-14
REMOTE START TOOL KIT-MEL1563 (CONT'D) Remote Start Procedure (Cont'd)
WARNING
2 3
UNAUTHORIZED AND UNEXPECTED ENGINE STARTUP CAN CAUSE SERIOUS INJURY OR DEATH
1
With the 7-pin connector plugged into the machine and Remote Start Tool Key Switch in the OFF position, the engine can be started from the operator panel inside the cab. •
•
Place the key switch of the Remote Start Tool in the RUN position to disconnect the operator panel from the start circuit. Remove the operator panel key (key switch), lock the keypad with a unique password (keyless) or otherwise disable the starter before working in the engine area.
P16118
The traction lock switch (Item 1) [Figure 10-60-14] is used to turn traction lock on or off. Push the switch to the override position. The switch will illuminate to indicate traction lock OVERRIDE, in this position the wheels are able to turn. The maximum flow / variable flow switch (Item 2) [Figure 10-60-14] is used to activate the auxiliary hydraulics. Pressing the switch once will activate variable flow. Pressing the switch again will activate maximum flow. The switch will illuminate to indicate which flow rate is active. Pressing the switch a third time will turn the flow OFF. The switch is used when checking pressures and flow rate.
Figure 10-60-13
The auxiliary pressure release (Item 3) [Figure 10-60-14] is used to release hydraulic pressure to the front and / or rear auxiliary couplers. To release pressure; push and hold the switch for three seconds.
1
NOTE: With the engine running; pushing and holding the pressure release switch will cause the engine to stop in three seconds. To relieve the pressure; continue to press the switch after the engine has stopped.
P16116
The remote start tool (Item 1) [Figure 10-60-13] has three rocker switches.
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W-2457-1110
REMOTE START TOOL KIT-MEL1563 (CONT'D) Remote Start Procedure (Cont'd)
WARNING • • • • •
AVOID INJURY OR DEATH Use traction lock override switch for service work with seat bar raised. Traction lock is engaged when light is OFF. Lift and block the loader. Check that wheels are clear. Traction lock is disengaged when light is ON. See Service Manual for more instruction. W-2785-0209
Dealer Copy -- Not for Resale
NOTE: With the engine running; pushing and holding the pressure release switch will cause the engine to stop in three seconds. To relieve the pressure at the rear or right hand auxiliary, (If so equipped.) continue to hold the switch for three seconds after the engine has stopped. Figure 10-60-15
P-34661
Push the couplers on the front auxiliary block toward the block and hold for five seconds to release the front auxiliary pressure [Figure 10-60-15].
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REMOTE START TOOL (SERVICE TOOL) KIT 7003031 Description The Remote Start Tool (Service Tool) Kit is a replacement tool for MEL 1563 Remote Start Tool and MEL 1400B BOSS® Diagnostic Tool. The Remote Start Tool (Service Tool) Kit, P/N 7003031, can be used to service older loaders with the BOSS® system using the supplied BOSS® Service Tool Harness P/N 6689745. The Remote Start Tool (Service Tool) Kit, P/N 7003031, can be used to service newer loaders using the supplied harness P/N 6689747.
Dealer Copy -- Not for Resale
A computer can be connected to the Remote Start Tool (Service Tool) for diagnostics and software updates using the computer harness P/N 6689746 in conjunction with the loader harness.
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Figure 10-61-2
REMOTE START TOOL (SERVICE TOOL) KIT 7003031 (CONT'D)
2
Remote Start Tool (Service Tool) - 7003030 Tools that will be needed to complete the following steps are:
5
3
Order from Bobcat Parts P/N: 7003031 - Remote Start Tool (Service Tool) Kit
6
4
Kit Includes:
1
7003030 - Remote Start Tool (Service Tool) 6689747 - Loader Service Tool Harness 6689746 - Computer Service Tool Harness 6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-61-1
The STOP button (Item 2) [Figure 10-61-2] is used to stop the Remote Start Tool (Service Tool) from communicating and stop the loader engine. The RUN button (Item 3) [Figure 10-61-2] is used to turn the Remote Start Tool (Service Tool) on and activates the loader ignition power. The button will illuminate to indicate the service tool is active.
1
The START button (Item 4) [Figure 10-61-2] is used to start the loader engine. P-76678
The remote start tool (Item 1) [Figure 10-61-1] is required when the service technician is checking the hydraulic / hydrostatic system or adjusting the steering linkage.
The traction lock button (Item 5) [Figure 10-61-2] is used to turn traction lock ON or OFF. Push the button and the button will illuminate indicating the traction lock is disabled in which the wheels or tracks are able to turn. The auxiliary button (Item 6) [Figure 10-61-2] is used to activate the auxiliary hydraulics. The button will illuminate to indicate the auxiliary hydraulics are active. Pressing the button a second time will turn the flow OFF. The button is used when checking pressures and flow rate.
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The Remote Start Tool (Service Tool) (Item 1) [Figure 1061-2] has five buttons.
Figure 10-61-5
REMOTE START TOOL (SERVICE TOOL) KIT 7003031 (CONT'D) Loader Service Tool Harness - 6689747
2
Figure 10-61-3
1 1
P-76452
2
P-76678
The loader service tool harness (Item 1) [Figure 10-61-3] is used to connect the remote start tool (service tool) (Item 2) [Figure 10-61-3] to the electrical system on the loader.
When the remote start procedure is completed, replace the loader connector cap (Item 1) [Figure 10-61-4] or reconnect the attachment control harness to the loader harness [Figure 10-61-5].
Figure 10-61-4
1
P-76451
Loaders without an attachment control harness, remove the loader harness cap (Item 1) [Figure 10-61-4] and connect the Loader Service Tool Harness from the Remote Start Tool (Service Tool).
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Loaders with an attachment control harness (7 pin or 14 pin), the attachment harness (Item 1) must be disconnected from the loader harness (Item 2) [Figure 10-61-5].
NOTE: The right instrument panel (Standard Key Panel or Deluxe Instrumentation Panel) must be in the off position or the Remote Start Tool (Service Tool) will not operate.
REMOTE START TOOL (SERVICE TOOL) KIT 7003031 (CONT'D) Loader Service Tool Harness - 6689747 (Cont’d) Figure 10-61-6 2
WARNING 1 • • •
•
3 1
AVOID INJURY OR DEATH Lift and block the machine. Check that wheels or tracks are clear. Cab ignition must be in the “STOP” position to start the engine with the Service Tool (if applicable). See machine Service Manual for more instructions. W-2792-0409
P-76453
Computer Service Tool Harness - 6689746 Figure 10-61-7
Dealer Copy -- Not for Resale
NOTE: The Remote Start Tool (Service Tool) connection harness has two connectors (Item 1) and (Item 3). The main connector (Item 1) [Figure 10-61-6] is always used for connection to the loader harness.
1 The second connector (Item 3) [Figure 10-616] is used for attachment ACD upgrades or attachment operational diagnostics only. This connector has a cap attached to it to prevent damage or corrosion when not in use. Connect the Remote Start Tool (Service Tool) connector (Item 1) to the loader harness connector (Item 2) and the other Remote Start Tool (Service Tool) connector to the ACD harness connector (Item 3) [Figure 10-61-6].
2 P-76450
The computer service tool harness (Item 1) [Figure 1061-7] is required to connect remote start tool (service tool) to the Service PC (Item 2) [Figure 10-61-7].
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Figure 10-61-9
REMOTE START TOOL (SERVICE TOOL) KIT 7003031 (CONT'D) Remote Start Procedure
1
WARNING UNAUTHORIZED AND UNEXPECTED ENGINE STARTUP CAN CAUSE SERIOUS INJURY OR DEATH With the 7-pin connector plugged into the machine and Remote Start Tool RUN button not illuminated, the engine can be started from the operator panel inside the cab.
•
Press the RUN button of the Remote Start Tool to disconnect the operator panel from the start circuit. Remove the operator panel key (key switch), lock the keypad with a unique password (keyless) or otherwise disable the starter before working in the engine area. W-2661-1110
P-76451
Loaders without an attachment control harness, remove the loader harness cap (Item 1) [Figure 10-61-9] and connect the Loader Service Tool Harness from the Remote Start Tool (Service Tool). Figure 10-61-10
The tool listed will be needed to do the following procedure:
Dealer Copy -- Not for Resale
•
2
7003031: Remote Start Tool (Service Tool) Kit Figure 10-61-8
1
1
P-76452
Loaders with an attachment control harness (7 pin or 14 pin), the attachment harness (Item 1) must be disconnected from the loader harness (Item 2) [Figure 10-61-10].
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure 1061-8] is required when the operator cab is in the raised position for service and the service technician needs to turn on the loader or start the engine. Example: adjusting the steering linkage.
When the remote start procedure is completed, replace the loader connector cap (Item 1) [Figure 10-61-10] or reconnect the attachment control harness to the loader harness [Figure 10-61-10].
Lift and block the loader. Raise the lift arms (if required by the procedure) and install an approved lift arm support device. Raise the operator cab (if required by the procedure). Open the rear door of the loader.
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REMOTE START TOOL (SERVICE TOOL) KIT 7003031 (CONT'D)
Figure 10-61-12 2
Remote Start Procedure (Cont'd) Figure 10-61-11
5
3
6
4
2 1 1
P-76439
3 1
The Remote Start Tool (Service Tool) (Item 1) [Figure 1061-12] has five buttons.
NOTE: The Remote Start Tool (Service Tool) connection harness has two connectors (Item 1) and (Item 3). The main connector (Item 1) [Figure 10-61-11] is always used for connection to the loader harness. The second connector (Item 3) [Figure 10-6111] is used for attachment ACD upgrades or attachment operational diagnostics only. This connector has a cap attached to it to prevent damage or corrosion when not in use. Connect the Remote Start Tool (Service Tool) connector (Item 1) to the loader harness connector (Item 2) and the other Remote Start Tool (Service Tool) connector to the ACD harness connector (Item 3) [Figure 10-61-11]. NOTE: The right instrument panel (Standard Key Panel or Deluxe Instrumentation Panel) must be in the off position or the Remote Start Tool (Service Tool) will not operate.
The STOP button (Item 2) [Figure 10-61-12] is used to stop the Remote Start Tool (Service Tool) from communicating and stop the loader engine. The RUN button (Item 3) [Figure 10-61-12] is used to turn the Remote Start Tool (Service Tool) on and activates the loader ignition power. The button will illuminate to indicate the service tool is active. The START button (Item 4) [Figure 10-61-12] is used to start the loader engine. The traction lock button (Item 5) [Figure 10-61-12] is used to turn traction lock ON or OFF. Push the button and the button will illuminate indicating the traction lock is disabled in which the wheels or tracks are able to turn. The auxiliary button (Item 6) [Figure 10-61-12] is used to activate the auxiliary hydraulics. The button will illuminate to indicate the auxiliary hydraulics are active. Pressing the button a second time will turn the flow OFF. The button is used when checking pressures and flow rate.
WARNING • • •
•
AVOID INJURY OR DEATH Lift and block the machine. Check that wheels or tracks are clear. Cab ignition must be in the “STOP” position to start the engine with the Service Tool (if applicable). See machine Service Manual for more instructions. W-2792-0409
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P-76453
Figure 10-61-14
REMOTE START TOOL (SERVICE TOOL) KIT 7003031 (CONT'D) Remote Start Procedure (Cont'd) Figure 10-61-13
1
2 P-34661
Push the couplers on the front auxiliary block toward the block and hold for five seconds to release the front auxiliary pressure [Figure 10-61-14].
P-76441
Dealer Copy -- Not for Resale
The gear icon with the left facing arrows (Item 1) [Figure 10-61-13] will illuminate and blink when the RUN key is pressed and the loader is communicating with the service tool. The computer icon with the right facing arrows (Item 2) [Figure 10-61-13] will illuminate and blink when the Remote Start Tool (Service Tool) is transmitting data to and from the computer. NOTE: To relieve the pressure at the rear or secondary front auxiliary, (if equipped) press the RUN button on the remote start tool. Then press the auxiliary (AUX) hydraulics button on the remote start tool and move the AUXILIARY Hydraulic Switch on the to the right and left several times.
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SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.
SERVICE SCHEDULE
ITEM
SERVICE REQUIRED
Engine Oil Engine Air Filter and Air System
Check the oil level and add as needed. Do not overfill. Check display panel. Service only when required. Check for leaks and damaged components. Clean debris from oil cooler, radiator and grille. Check coolant level COLD and add premixed coolant as needed. Remove the trapped water. Lubricate with multi-purpose lithium based grease.
Engine Cooling System Fuel Filter Lift Arms, Cylinders, Bob-Tach Pivot Pins and Wedges Tires
HOURS ■ ■ ■ 8-10 50 100 250 500 1000
Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the tire. Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris from moving parts. Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat (BICS™) bar raised. See details in this Manual. Front Horn / Back-up Alarm Check for proper function. Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn. Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab. Indicators and Lights Check for correct operation of all indicators and lights. Heater and A/C Filters Clean or replace filters as needed. (If Equipped) Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or Tubelines replace as needed. Final Drive Trans. (Chaincase), Check fluid level and add as needed. Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed. Hand Controls and Steering Levers or Joysticks Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE ❏ MAINTENANCE in this manual.) Spark Arrester Muffler Clean the spark chamber. Battery Check cables, connections and electrolyte level. Add distilled water as needed. Steering Lever Pivots Grease fittings. Fuel Filter Replace filter element. Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲ Drive Belts (Alternator, air Check condition and tension. Adjust or replace as needed. conditioning, water pump) Bobcat Interlock Control System Check the function of the lift arm bypass control. (BICS™) Engine Oil and Filter Replace oil and filter. ▲ ✶ Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ● Charge Filter, Reservoir Breather breather. Final Drive Trans. (Chaincase) Replace the fluid. Hydraulic Reservoir Replace the fluid. Case Drain Filters Replace the filters. ▲ Engine Valves Adjust the engine valves. Coolant Replace the coolant Every 2 years ■ ▲ ❏ ● ✶ ❍
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WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903
❍
Or every 12 months. Perform at first 50 hours, then as scheduled. Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals. Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when service code [M0217] is displayed or as scheduled. Change oil and filter every 100 hours when operating under severe conditions. Perform at first 500 hours, then as scheduled.
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AIR CLEANER SERVICE
Replacing Filter Element(s)
Testing
Outer Filter
Figure 10-80-1
Figure 10-80-3
1 1
P-21769A
It is important to change the air filter element only when the Air Cleaner icon in the right panel is ON (Item 1) [Figure 10-80-1] and you hear three beeps from the alarm.
Remove the wing nut (Item 1) [Figure 10-80-3] and remove the dust cover. Figure 10-80-4
Replace the inner filter every third time the outer filter is replaced or as indicated. (See Removal And Installation on Page 70-40-1.) Figure 10-80-2
1
2
P-43239
1 Remove the wing nut (Item 1) [Figure 10-80-4] from the outer filter element. Remove the outer filter element.
N-18409
Press and hold the LIGHT Button (Item 1) [Figure 10-802] for two seconds. If the filter element needs replacement, the CODE [0117] (Air Filter Plugged) will show in the HOURMETER / CODE DISPLAY (Item 2) [Figure 10-80-2].
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P-31836
Figure 10-80-6
AIR CLEANER SERVICE (CONT’D) Replacing Filter Element(s) (Cont’d) Figure 10-80-5
1
P-43241
Remove the inner filter wing nut (Item 1) [Figure 10-806].
P-31837
Figure 10-80-7
Install the new filter push all the way in until it contacts the base of the housing. Install wing nut [Figure 10-80-4 on Page 10-80-1]. Install the dust cover and tighten the wing nut. Check the air intake hose and the air cleaner housing for damage. Make sure all connections are tight. 1
Inner Filter Only replace the inner filter element under the following conditions: •
Replace the inner filter element every third time the outer filter is replaced.
•
After the outer element has been replaced, start the engine and run at full rpm. If the HOURMETER / CODE DISPLAY shows [01-17] (Air Filter Plugged), replace the inner filter element.
P-31838
Remove the inner filter (Item 1) [Figure 10-80-7]. Install a new filter and tighten the wing nut. Install the outer element and install the dust cover and the wing nut. NOTE: Make sure all sealing surfaces are free of dirt and debris Do Not use compressed air.
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NOTE: Make sure all sealing surfaces are free of dirt and debris Do Not use compressed air.
ENGINE COOLING SYSTEM
Checking Coolant Level And Adding Coolant
Cleaning The Cooling System
Open the rear door and remove the rear grille. NOTE: The machine uses a pressurized coolant recovery system.
WARNING
Figure 10-90-2
AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.
1 2 P-45246
W-2019-0907
Check the cooling system every day to prevent overheating, loss of performance or engine damage. Open the rear door and remove the rear grille. (See Removal And Installation on Page 80-120-1.)
Check the coolant level on the side of the recovery tank (Item 1) [Figure 10-90-2]. The level must be between the MIN and MAX marks.
Figure 10-90-1
Remove the cover (Item 2) [Figure 10-90-2] from the coolant recovery tank. Add premixed coolant to the recovery tank and install the cover. 1
Install the rear grille and close the rear door.
2
IMPORTANT
P-45101
Use low air pressure or water pressure to clean the top of the oil cooler (Item 1) [Figure 10-90-1]. NOTE: Be careful when raising and lowering the oil cooler so that the oil cooler does not fall on the radiator and damage the fins. Raise the oil cooler and use low air pressure or water pressure to clean the top of the radiator (Item 2) [Figure 10-90-1]. Lower the oil cooler.
AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage. I-2124-0497
Check the cooling system for leaks. Install the rear grille and close the rear door.
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P-45245
Replacing The Coolant
ENGINE COOLING SYSTEM (CONT’D) Checking The Coolant Level
WARNING
Figure 10-90-3
AVOID BURNS Do not remove radiator cap when the engine is hot. You can be seriously burned. W-2070-1203 P-45106
Figure 10-90-4
1 P-45102
Look at the side of the coolant recovery tank [Figure 1090-3]. Check the coolant level. The level markers are on the side of the tank. Coolant must be at the bottom marker when the engine is cold; top marker when hot. Install the rear grille and close the rear door before operating the loader.
P-45102
Open the rear door and remove the rear grille. Remove the radiator cap (Item 1) [Figure 10-90-4].
IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage. I-2124-0497
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Open the rear door and remove the rear grille.
Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.
ENGINE COOLING SYSTEM (CONT’D) Replacing The Coolant (Cont’d)
Mix the coolant in a separate container. (See Capacities on Page SPEC-10-4.)
KUBOTA V2203-M-DI Figure 10-90-5
The correct mixture of coolant to provide a -37°C (-34°F) freeze protection is 5 L propylene glycol mixed with 4,4 L of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt of water. Use a refractometer to check the condition of propylene glycol in your cooling system. 1
Fill the radiator with the premixed coolant. Install the radiator cap. Remove the cover from the coolant recovery tank. Fill the tank until it is at the lower marker.(side of tank). Run the engine until it is at operating temperature. P-48512
Connect a hose to the engine block drain valve (Item 1) [Figure 10-90-5]. Open the drain valve and drain the coolant into a container.
Check the coolant level in the recovery tank when cool.
KUBOTA V2003T-M-DIT (TURBO)
Install the rear grille and close the rear door.
Add coolant as needed.
Figure 10-90-6
1
P-45490
Connect a hose to the engine block drain valve (Item 1) [Figure 10-90-6]. Open the drain valve and drain the coolant into a container. Recycle or dispose of used coolant in an environmentally safe manner. Close the drain valve and remove the hose. NOTE: The loader is factory filled with propylene glycol coolant (purple color). DO NOT mix propylene glycol with ethylene glycol.
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Stop the engine.
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FUEL SYSTEM
Figure 10-100-1
Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is one suggested blending guideline which should prevent fuel gelling during cold temperatures: TEMPERATURE
NO. 2
NO. 1
-9°C (+15°F)
100%
0%
Down to -29°C (-20°F)
50%
50%
Below -29°C (-20°F)
0%
100%
1 P-48074
Contact your fuel supplier for local recommendations. Open the rear door.
Filling The Fuel Tank
Remove the fuel fill cap (Item 1) [Figure 10-100-1]
WARNING
WRONG
AVOID INJURY OR DEATH Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W-2063-0807
WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. W-2103-0508
B-19895
Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [Figure 10-100-2]. Install and tighten the fuel fill cap (Item 1) [Figure 10100-1].
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Figure 10-100-2
FUEL SYSTEM (CONT’D) Fuel Filter Figure 10-100-3
2
1 P-45960
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(See SERVICE SCHEDULE on Page 10-70-1), for the service interval for removing water from, or replacing the fuel filter. Removing Water Loosen the drain (Item 1) [Figure 10-100-3] at the bottom of the filter element to remove water from the filter. Replacing Element Remove the filter element (Item 2) [Figure 10-100-3]. Clean the area around the filter housing. Put clean oil on the seal of the new filter element. Install the fuel filter, and hand tighten.
WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. W-2103-0508
Remove the air from the fuel system. (See Below.)
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It may be necessary to open the vent plug (Item 3) [Figure 10-100-4] briefly while the engine is running. Close the vent when the engine runs smoothly.
FUEL SYSTEM (CONT’D) Removing Air From The Fuel System After replacing the filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.
WARNING AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. W-2072-0807
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Figure 10-100-4
3
2
1
P-48076
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter housing. Squeeze the hand pump (priming bulb) (Item 2) [Figure 10-100-4] until fuel flows from the vent with no air bubbles. Close the vent (Item 1) [Figure 10-100-4] on the fuel filter housing. Open the vent (Item 3) [Figure 10-100-4] on the fuel injection pump. Squeeze the hand pump (priming bulb) (Item 2) [Figure 10-100-4] until the pump feels solid. Tighten the vent plug (Item 3) [Figure 10-100-4]. Start the engine.
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ENGINE LUBRICATION SYSTEM
Engine Oil Chart
Checking Engine Oil
Figure 10-110-2
Check the engine oil level every day before starting the engine for the work shift.
ENGINE OIL RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
Figure 10-110-1
1
Park the loader on level ground. Open the rear door and remove the dipstick (Item 1) [Figure 10-110-1]. Keep the oil level between the marks on the dipstick. DO NOT OVERFILL. Use a good quality motor oil that meets API Service Classification of CD or better.
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CI-4 OR BETTER) [1]Synthetic Oil - Use recommendation from Synthetic Oil Manufacturer. Use a good quality motor oil that meets API Service Classification of CI-4 or better See Oil Chart [Figure 10110-2].
Install the dipstick and close the rear door.
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P-48079
ENGINE LUBRICATION SYSTEM (CONT’D)
Figure 10-110-4
Replacing Oil And Filter (See SERVICE SCHEDULE on Page 10-70-1), for the service interval for replacing the engine oil and filter.
1
Run the engine until it is at operating temperature. Park the loader on level ground and stop the engine. Open the rear door. Figure 10-110-3
P-1575
3 Put oil in the engine. (See Capacities on Page SPEC-104.) [Figure 10-110-4] (See Engine Oil Chart on Page 10110-1.)
2
Stop the engine and check for leaks at the oil filter. Remove the dipstick and check the oil level.
1 P-48078
Add oil until it reaches the top mark (Item 1) [Figure 10110-4] on the dipstick. DO NOT OVERFILL. Remove the drain plug (Item 1) [Figure 10-110-3]. Install the dipstick and the fill plug. Drain the oil into a container and dispose of used oil in an environmentally safe manner.
Close the rear door.
Remove the oil filter (Item 2) [Figure 10-110-3]. Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten. Install and tighten the drain plug. Remove the fill cap (Item 3) [Figure 10-110-3].
WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. W-2103-0508
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Start the engine and let it run for several minutes.
HYDRAULIC / HYDROSTATIC SYSTEM
Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid
Figure 10-120-3
Figure 10-120-1
N-18445
Use only recommended fluid in the hydraulic system. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.) Park the loader on a level surface. Lower the lift arms and tilt the Bob-Tach fully back. Stop the engine.
TEMPERATURE RANGE ANTICIPATED DURING MACHINE USE [1] VG 100; Minimum VI 130 [2] VG 46; Minimum VI 150 [3] BOBCAT All-Season Fluid [4] BOBCAT Synthetic Fluid [5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid (Unlike biodegradable fluids that are vegetable based, Bobcat biodegradable fluid is formulated to prevent oxidation and thermal breakdown at operating temperatures.) Use only recommended fluid in the hydraulic system [Figure 10-120-3]. (See Hydraulic System on Page SPEC-10-3.
Check fluid level in the sight gauge [Figure 10-120-1]. Open the rear door and remove the rear grille.
Replacing Hydraulic / Hydrostatic Filter
Figure 10-120-2 (See SERVICE SCHEDULE on Page 10-70-1), for the correct service intervals. Open the rear door. Remove the filter element (Item 2) [Figure 10-120-2]. Clean the surface of the filter housing where the seal contacts the housing. Put clean oil on the seal of the new filter element.
2
Install and hand tighten the filter element.
1
Close the rear door before operating the loader. P-45243
P-48866
Remove the fill cap (Item 1) [Figure 10-120-2]. Add the fluid as needed to bring the level to the center of the sight gauge [Figure 10-120-1]. Install the fill cap. Replace the rear grille and close the rear door.
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HYDRAULIC / HYDROSTATIC FLUID RECOMMENDED ISO VISCOSITY GRADE (VG) AND VISCOSITY INDEX (VI)
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
WARNING
Replacing Hydraulic Fluid (See SERVICE SCHEDULE on Page 10-70-1), for the service interval. The fluid must be replaced if it becomes contaminated or after major repairs. If the fluid is replaced, the hydrostatic filter and both case drain filters must be replaced. Use only recommended fluid in the hydraulic system. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.)
AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. W-2103-0508
Figure 10-120-5
Park the loader on a level surface. Lower the lift arms and tilt the Bob-Tach fully back. Stop the engine. 2 Check fluid level in the sight gauge [Figure 10-120-1]. Open the rear door and remove the rear grille.
1
P-45499
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1)
P-45243
1
Drain the hydraulic fluid reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2) Disconnect the hoses (Item 1) [Figure 10-120-5] from the case drain filter located on the reservoir. Use a plug and cap on the filter hose and case drain hose to prevent leakage.
P-45245
Remove the reservoir fill cap (Item 1) [Figure 10-120-4].
WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290
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Figure 10-120-4
On SJC equipped loaders, the hydrostatic charge pressure filter (Item 1) [Figure 10-120-7] is located on a bracket mounted to the transmission.
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Replacing Hydraulic Fluid (Cont’d) Figure 10-120-6
Remove and replace the hydrostatic charge pressure filter. Add the correct fluid to the reservoir until the fluid level is at the center of the sight gauge (Do not overfill). Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2)
1
Start the engine and operate the loader hydraulic controls. Stop the engine and check for leaks.
2
Check the fluid level in the reservoir and add as needed. P-45493
Breather Cap Figure 10-120-8
Dealer Copy -- Not for Resale
Disconnect the hose (Item 1) [Figure 10-120-6] from the case drain filter located on the right drive motor. Use a plug and cap on the filter and case drain hose to prevent leakage. Remove the case drain filters (Item 2) [Figure 10-120-5] and [Figure 10-120-6] and drain the fluid into a container. Replace the hydraulic / hydrostatic filter element. (See Replacing Hydraulic / Hydrostatic Filter on Page 10-1201.)
1
Replace both hydrostatic motor case drain filters (Item 2) [Figure 10-120-5] and [Figure 10-120-6]. P-34227
Connect the hoses to the case drain filters. Figure 10-120-7
(See SERVICE SCHEDULE on Page 10-70-1), for the correct replacement interval. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1) Remove the breather cap (Item 1) [Figure 10-120-8] and discard.
1
Install new cap. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2)
P-64317
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FINAL DRIVE TRANSMISSION (CHAINCASE)
Removing Oil From The Chaincase
Checking And Adding Oil
Figure 10-130-2
Figure 10-130-1
1 1
P-64141 P-45496
The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic / hydrostatic system. (See LOADER SPECIFICATIONS on Page SPEC-10-1.)
Use a vacuum pump to extract the fluid from the chain case.
To check the chaincase oil level, use the following procedure: Stop the loader on a level surface. Stop the engine. Remove the plug (Item 1) [Figure 10-130-1] from the front of the chaincase housing. If oil can be reached with the tip of your finger through the hole, the oil level is correct. If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.
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Remove the chaincase cover (Item 1) [Figure 10-130-2] (See CHAINCASE on Page 40-30-1.)
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FAN GEARBOX Checking And Maintaining Figure 10-140-1
1
N-18460
Dealer Copy -- Not for Resale
(See SERVICE SCHEDULE on Page 10-70-1), for the correct service interval. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the plug (Item 1) [Figure 10-140-1]. Lubricant level must be at the bottom edge of the plug hole. If the level is low, add SAE 90W gear lubricant through the check plug hole until lubricant flows from the hole. Install and tighten the plug. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
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Figure 10-150-3
BOB-TACH Inspection And Maintenance
Bob-Tach Wedge
WARNING Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death. W-2102-0497
Wedge Must Contact Lower Edge Of Hole In The Attachment
Figure 10-150-1
B-15177
The spring-loaded wedge (Item 1) [Figure 10-150-1] must contact the lower edge of the hole in the attachment (Item 1) [Figure 10-150-2] and [Figure 10-150-3]. If the wedges do not contact the lower edge of the holes [Figure 10-150-2] and [Figure 10-150-3], the attachment will be loose and can come off the Bob-Tach. Figure 10-150-4
N-17027
Move the Bob-Tach levers to engage the wedges [Figure 10-150-1]. The levers and wedges must move freely. Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 10-150-4]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.
1
Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. N-16044A
The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-150-1].
Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1) and (See LUBRICATION OF THE BOBCAT LOADER on Page 10-160-1.)
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1
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Figure 10-151-3
POWER BOB-TACH (OPTION) Inspection And Maintenance Figure 10-151-1 FRONT ACCESSORY PANEL
1 B-15177
Wedge Must Contact Lower Edge Of Hole In The Attachment
N-17022A
If the wedges do not contact the lower edge of the holes [Figure 10-151-3], the attachment will be loose and can come off the Bob-Tach.
Push and hold the BOB-TACH “WEDGES UP” switch until wedges are fully raised. Push and hold the BOBTACH “WEDGES DOWN” switch [Figure 10-151-1] until the wedges are fully down. The wedges must move freely.
Figure 10-151-4
Dealer Copy -- Not for Resale
B-15891
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 10-151-4]. Replace any parts including decals and lever that are damaged, bent, or missing. Keep all fasteners tight. Inspect the hoses and fittings for leaks.
1 N-16043A
The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-151-2] and must contact the lower edge of the hole in the attachment [Figure 10-151-2] and (Item 1) [Figure 10151-3].
Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1) and (See LUBRICATION OF THE BOBCAT LOADER on Page 10-160-1.)
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Figure 10-160-2
LUBRICATION OF THE BOBCAT LOADER Procedure Figure 10-160-1
1
2 P-45256 P-45255
Lubricate the loader as specified in the (SERVICE SCHEDULE Page 10-01), for the best performance of the loader. Record the operating hours each time you lubricate the Bobcat loader. Always use a good quality lithium based multi-purpose grease when you lubricate the loader. Apply lubricant until extra grease shows.
P-45973
2. Lift Cylinder Base [Figure 10-160-2].
End
(Both
Sides)
Figure 10-160-3
Lubricate the following locations on the loader: 3
1. Lift Cylinder Rod End (Both Sides) [Figure 10-160-1]
N-18510
3. Tilt Cylinder Base [Figure 10-160-3].
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End
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Sides)
S150, S160 Bobcat Loader Service Manual
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Access Hole
Figure 10-160-6
LUBRICATION OF THE BOBCAT LOADER (CONT’D) Procedure (Cont’d) Figure 10-160-4
8
4
5 P-45253
8. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-6]. P-45975
Figure 10-160-7
5. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-4]. Figure 10-160-5
6 9 P-45976 P-45497
9. 250 Hours: Steering Lever Shaft [Figure 10-160-7].
7 P16045
6. Bob-Tach Wedge (Both Sides) [Figure 10-160-5]. 7. Power Bob-Tach Cylinder (If Equipped) (Both Sides) [Figure 10-160-5].
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4. Tilt Cylinder Rod End. [Figure 10-160-4].
It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.
TIRE MAINTENANCE Wheel Nuts Figure 10-170-1
Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader. Mounting Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage. The rim flange must be cleaned and free of rust. N-18514
When installing wheel nuts, tighten to 160 ft.-lb. (217 N•m) torque.
Avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.
When checking wheel nut torque, set the torque wrench to 140 ft.-lb. (190 N•m) torque to prevent over-tightening.
IMPORTANT
Rotating Figure 10-170-2
Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same machine. I-2057-1010
WARNING AVOID INJURY OR DEATH Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death. W-2078-1007
B-9976
Check the tires regularly for wear, damage and pressure. (See Tires on Page SPEC-10-4.), for the correct tire pressure. Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [Figure 10-170-2]. 10-170-1 75 of 949
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(See SERVICE SCHEDULE on Page 10-70-1), for the service interval to check the wheel nuts [Figure 10-1701].
The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire.
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SPARK ARRESTER MUFFLER Cleaning Procedure
WARNING
IMPORTANT
Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.
This machine is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor exhaust system.
On some models, the turbocharger functions as the spark arrestor and must operate correctly for proper spark arrestor function. If this machine is operated on flammable forest, brush, or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442. PRC. Refer to local laws and regulations for spark arrestor requirements.
WARNING Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death. W-2068-1285
Figure 10-180-1
I-2284-0409
1
WARNING When the engine is running during service, the driving and steering controls must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W-2006-1209
P-45498
(See SERVICE SCHEDULE on Page 10-70-1), for service interval for cleaning the spark arrester muffler. Do not operate the loader with a defective exhaust system. Stop the engine. Open the rear door and remove the rear grille.
WARNING AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning. W-2050-0807
Remove the plug (Item 1) [Figure 10-180-1] from the bottom of the muffler. Start the engine and run for about ten seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler. This will force contaminants out through the cleanout hole. Stop the engine. Install and tighten the plug. Install the rear grille and close the rear door.
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The spark arrestor muffler, if equipped, must be cleaned to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.
W-2011-1285
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Figure 10-190-1
SEAT BELT Inspection And Maintenance
1
WARNING
3
Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death. W-2466-0703
2
Check the seat belt daily for correct function.
4
Any seat belt system that shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet UV exposure, dusty / dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), hardware or any other obvious problem should be replaced immediately.
B-22283
The items below are referenced in [Figure 10-190-1]. 1. Check the webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. Look for cuts, wear, fraying, dirt and stiffness. 2. Check the buckle and latch for correct operation. Make sure latch plate is not excessively worn, deformed or buckle is not damaged or casing broken. 3. Check the retractor web storage device (if equipped) by extending webbing to determine if it looks correct and that it spools out and retracts webbing correctly. 4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have deteriorated. See your Bobcat dealer for seat belt system replacement parts for your machine.
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Inspect the seat belt system thoroughly at least once each year or more often if the machine is exposed to severe environmental conditions or applications.
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HYDRAULIC SYSTEM 20-90-1 20-90-4 20-90-2 20-90-1 20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-20-1 20-20-5 20-20-1 20-20-4 20-20-3 20-20-2
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-22-1 20-22-5 20-22-1 20-22-4 20-22-3 20-22-2
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base End Pivot Pin Replacement . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Rod End Pivot Pin Bushing And Seal Replacement . . . . .
20-21-1 20-21-7 20-21-3 20-21-1 20-21-6 20-21-5 20-21-2 20-21-4
HYDRAULIC SAFETY SYSTEM
DRIVE SYSTEM
ELECTRICAL SYSTEM ANALYSIS ENGINE SERVICE
Dealer Copy -- Not for Resale
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . 20-130-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-130-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing The High Flow Relief Valve . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . High Flow Relief Valve Adjustment Procedure . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-100-1 20-100-1 20-100-6 20-100-3 20-100-4 20-100-8
Continued On Next Page
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . . . . . 20-43-6 Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12 Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 20-43-24 Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-23 BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . 20-43-28 BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly . . . . . 20-43-29 BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . 20-43-10 BICS™ Valve, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . 20-43-26 BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . .20-43-25 End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-16 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-43-1 Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-9 Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17 Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . .20-43-11 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-29 Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-43-10 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-14 Port Relief / Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . 20-43-13 Port Relief / Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . 20-43-13 Port Relief / Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . 20-43-14 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1 Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-15 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-21 Continued On Next Page
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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1 Actuator Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12 Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18 Anti-Cavitation Valve / Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17 Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22 Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21 BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . 20-41-8 BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation . . . . . . . . 20-41-7 BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-41-9 BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5 BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . 20-41-10 BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11 Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13 Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-41-20 Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14 Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19 Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15 Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL). . . . 20-40-1 Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16 Anti-Cavitation Valve / Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16 Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30 Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29 BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . 20-40-8 BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation . . . . . . . . 20-40-6 BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-40-9 BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . 20-40-10 BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-11 Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12 Lift And Tilt Lock Block Removal And Installation . . . . . . . . . . . . . . . . . . . 20-40-18 Lift Spool And Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18 Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14 Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27 Continued On Next Page
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Dealer Copy -- Not for Resale
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL). . . . 20-42-1 Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-9 Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . .20-42-28 Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-26 BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . .20-42-32 BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly . . . . . .20-42-33 BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . . .20-42-7 End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . .20-42-14 BICS™ Valve, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . .20-42-30 BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . .20-42-29 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-6 Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . .20-42-15 Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . .20-42-8 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-33 Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-7 Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-12 Port Relief / Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . .20-42-10 Port Relief / Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . .20-42-10 Port Relief / Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . . 20-42-11 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-11 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-1 Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-13 Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-42-24 HYDRAULIC / HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . .20-70-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1 HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1 Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1 Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . . . . .20-60-3 Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . .20-60-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-8 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-5 HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-1 Check The Output Of The Hydraulic Pump With Power Bob-Tach . . . . . . . .20-61-3 Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . .20-61-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-8 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-5 Continued On Next Page
20-04 84 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC SYSTEM (CONT’D) HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Test The Output Of The Hydraulic Auxiliary Pump . . . . . . Test The Output Of The Hydraulic Charge Pump . . . . . . . Test The Output Of The Hydraulic Pump (High Flow) . . . .
20-63-1 20-63-9 20-63-8 20-63-6 20-63-1 20-63-2 20-63-4
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Test The Output Of The Hydraulic Auxiliary Pump . . . . . . Test The Output Of The Hydraulic Charge Pump . . . . . . .
20-62-1 20-62-7 20-62-6 20-62-4 20-62-1 20-62-2
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-50-1 20-50-2 20-50-1 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30-1 20-30-2 20-30-1 20-30-1 20-30-3
Dealer Copy -- Not for Resale
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1 Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-120-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-110-1 20-110-4 20-110-9 20-110-1 20-110-9
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
20-05 85 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale 20-06 86 of 949
S150, S160 Bobcat Loader Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC S150 (S/N 526811001 - 526814999) (S/N 526911001 - 526914999) S160 (S/N 526611001 - 526614999) (S/N 526711001 - 526714999) (PRINTED APRIL 2005) V-0400legend
Printable Version Click Here
LEGEND 1
RESERVOIR: Capacity . . . . . . . 19.2 Qts. (18,2 L)
14 LOAD CHECK VALVE
27
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
2
SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 Bar)
28
RESTRICTOR - 0.140 inch (3,6 mm)
3
DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 Bar) Normally Closed
15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP
4 5 6
7
8 9
10
DRIVE MOTOR SHUTTLE VALVE RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5000 PSI (345 Bar) RELIEF VALVE - CHARGE INLET: 220-270 PSI (15,1-18,6 Bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle RELIEF VALVE - MAIN: 3250 - 3350 PSI (224-231 Bar) at Front Quick Couplers RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)
16
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 19
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY
13
RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)
41
30
RELIEF VALVE:
3300 PSI (228 Bar)
42 RELIEF VALVE - PORT: 3500 PSI (241,3 Bar)
31 FILTER - HYDRAULIC (CANISTER)
43 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END) 3500 PSI (241,3 Bar)
32 FILTER - CASE DRAIN (SINTERED BRONZE)
44
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH
45
RESTRICTION - 0.089 inch (2,26 mm)
46
RESTRICTION - 0.025 inch (0,6 mm)
47
RELIEF VALVE - 2000 PSI (137 Bar)
48
RELIEF VALVE - 1200 PSI (83 Bar)
49
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
50
CHECK VALVE - With 300 PSI (20,7 Bar) Spring And With 0.016 inch (0,40 mm) Orifice
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT - BICS CONTROL VALVE Dealer Copy --33NotFILTER for Resale ARM BY-PASS (SCREEN)
34 CHECK VALVE - BUCKET POSITION VALVE
21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL
35
RESTRICTION
36
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP
22
CHECK VALVE - BICS CONTROL VALVE
29 RESTRICTOR - 0.031 inch (0,8 mm)
20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
FLOW DIVIDER ADJUSTMENT VALVE 37
SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 Bar)
23
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
24
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD
38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR
25
LOAD SHUTTLE VALVE - BLEED OFF
26
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL
39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
11 ANTICAVITATION VALVE 12
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
NOTE: Unless otherwise specified springs have NO significant pressure value. Printed in U.S.A. 87 of 949
V-0400legend (4-11-05)
(REAR QUICK COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC S150 (S/N 526811001 - 526814999) (S/N 526911001 - 526914999) S160 (S/N 526611001 - 526614999) (S/N 526711001 - 526714999)
BASE
(PRINTED APRIL 2005) Printable Version Click Here V-0400
MALE
ROD
REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK COUPLER BLOCK
24
23
MALE
25
26
28
7
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE 7
DRIVE MOTOR 29
30
1
FEMALE
27
4
37 P-OUT
P-IN
T
32
BUCKET POSITION VALVE (OPTIONAL)
38
D 34
HYDRAULIC FILTER 31 OIL COOLER
2 B
HYDROSTATIC PUMPS
A
36
5
22
5
A
6
40
3
C 21
HYDRAULIC CONTROL VAVLE
20
Dealer Copy -- Not for Resale 12
12
13
CHARGE INLET
B B
BOB-TACH CYLINDER (OPTIONAL)
A
AUXILIARY SPOOL HYDRAULIC POWERED BOB-TACH (OPTIONAL)
36
5
D
C
14 TILT CYLINDERS
43
BICS CONTROL VALVE
5 39 DR
8 INLET
OUTLET 50 48
46 49
B
47
17
A TILT CYLINDER SPOOL
42
45 PP
11
DRIVE MOTOR
14 LIFT CYLINDERS
10
38
P2
P1
18 44 B
A LIFT CYLINDER SPOOL
35
15 14 4
37 9
16 33
41
33
WORKING CIRCUITS PILOT CIRCUITS DRAIN CIRCUITS COMPONENTS LIFT ARM BY PASS VALVE
32 19
Printed in U.S.A.
88 of 949
V-0400 (4-11-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S160 (S/N 526611001 - 526614999) (S/N 526711001 - 526714999) Printable Version Click Here
(PRINTED APRIL 2005) V-0401legend
LEGEND 1
RESERVOIR: Capacity . . . . . . . 19.2 Qts. (18,2 L)
14 LOAD CHECK VALVE
27
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
2
SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 Bar)
28
RESTRICTOR - 0.140 inch (3,6 mm)
3
DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 Bar) Normally Closed
15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP
4
DRIVE MOTOR SHUTTLE VALVE
5
RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5000 PSI (345 Bar)
6
7
8
9
10
RELIEF VALVE - CHARGE INLET: 220-270 PSI (15,1-18,6 Bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 Bar) at Front Quick Couplers RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)
16
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 19
13
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY RELIEF VALVE - PORT: . . . . . (Optional) 3500 PSI (241,3 Bar)
30
RELIEF VALVE:
3300 PSI (228 Bar)
32 FILTER - CASE DRAIN (SINTERED BRONZE)
CHECK VALVE - BICS CONTROL VALVE
42 RELIEF VALVE - PORT: 3500 PSI (241,3 Bar) 43 RELIEF/ANTICAVITATION VALVE PORT (TILT BASE END) 3500 PSI (241,3 Bar) 44
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH
45
RESTRICTION - 0.089 inch (2,26 mm)
46
RESTRICTION - 0.025 inch (0,6 mm)
47
RELIEF VALVE - 2000 PSI (137 Bar) RELIEF VALVE - 1200 PSI (83 Bar)
31 FILTER - HYDRAULIC (CANISTER)
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT - BICS CONTROL VALVE Dealer Copy --33NotFILTER for Resale ARM BY-PASS (SCREEN)
20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
34 CHECK VALVE - BUCKET POSITION VALVE
48
21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL
35
RESTRICTION
49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
36
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP
37
SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 Bar)
22 23
FLOW DIVIDER ADJUSTMENT VALVE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD
38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR
25
LOAD SHUTTLE VALVE - BLEED OFF
39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
26
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL
40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
24
11 ANTICAVITATION VALVE 12
29 RESTRICTOR - 0.031 inch (0,8 mm)
41
50
RELIEF VALVE - 3300 PSI (228 Bar)
51
DUMP VALVE - (ON/OFF)
52
CHECK VALVE
53
AUXILIARY HYDRAULIC PUMP 9.5 GPM (36 L/min) at High Engine Idle CHECK VALVE - With 300 PSI (20,7 Bar) Spring And With 0.016 inch (0,40 mm) Orifice
54
NOTE: Unless otherwise specified springs have NO significant pressure value. Printed in U.S.A. 89 of 949
V-0401legend (4-11-05)
(REAR QUICK COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S160 (S/N 526611001 - 526614999) (S/N 526711001 - 526714999)
BASE
MALE
ROD
REAR AUX VALVE (OPTIONAL)
Printable Version Click Here
INTEGRATED QUICK COUPLER BLOCK
24
23
(PRINTED APRIL 2005) V-0401
MALE
25
26
28
7
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE 7
DRIVE MOTOR 29
30
1
FEMALE
27
4
37 P-OUT
P-IN
T
32
BUCKET POSITION VALVE (OPTIONAL)
38
D 34
HYDRAULIC FILTER 31 OIL COOLER
2 B
HYDROSTATIC PUMPS
A
36
5
22
5
A
6
40
3
C 21
HYDRAULIC CONTROL VAVLE
20
Dealer Copy -- Not for Resale 12
12
13
CHARGE INLET
B B
A
AUXILIARY SPOOL 14
36
TILT CYLINDERS
43 5
HIGH FLOW VALVE
5 D
BICS CONTROL VALVE
C 51
8 50
52 OUTLET
INLET
B
17
A TILT CYLINDER SPOOL
42
53 BOB-TACH CYLINDER (OPTIONAL) DRIVE MOTOR 38
11
HYDRAULIC POWERED BOB-TACH (OPTIONAL)
14 LIFT CYLINDERS
10 18
39 B
DR
A LIFT CYLINDER SPOOL
54 46
48
4
49
37
35
15
47 14
45 PP 9
16 33
41
33
P2
P1
WORKING CIRCUITS PILOT CIRCUITS DRAIN CIRCUITS COMPONENTS
44 LIFT ARM BY PASS VALVE 32 19
Printed in U.S.A.
90 of 949
V-0401 (4-11-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED JULY 2005) V-0573legend
Printable Version Click Here
LEGEND 1
RESERVOIR: Capacity . . . . . . . 19.2 Qts. (18,2 L)
14 LOAD CHECK VALVE
27
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
2
SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 Bar)
28
RESTRICTOR - 0.140 inch (3,6 mm)
3
DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 Bar) Normally Closed
15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP
4 5 6
7
8
9
DRIVE MOTOR SHUTTLE VALVE RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5000 PSI (345 Bar) RELIEF VALVE - CHARGE INLET: 220-270 PSI (15,1-18,6 Bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle RELIEF VALVE - MAIN: 3250 - 3350 PSI (224-231 Bar) at Front Quick Couplers
10 PORT RELIEF/ANTICAVITATION VALVE: 3500 PSI (241,3 Bar)
16
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 19
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY
13
PORT RELIEF/ANTICAVITATION VALVE: (OPTIONAL) 3500 PSI (241,3 Bar)
30
RELIEF VALVE:
CHECK VALVE - BICS CONTROL VALVE
42
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
43
CHECK VALVE - With 300 PSI (20,7 Bar) Spring And With 0.016 inch (0,40 mm) Orifice
44
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH
45
RESTRICTION - 0.089 inch (2,26 mm)
46
RESTRICTION - 0.025 inch (0,6 mm)
47
RELIEF VALVE - 2000 PSI (137 Bar)
48
RELIEF VALVE - 1200 PSI (83 Bar)
49
FILTER - BOB-TACH VALVE (S/N 526815146 & Above) (S/N 526917054 & Above) (S/N 526615185 & Above) (S/N 526716179 & Above)
3300 PSI (228 Bar)
31 FILTER - HYDRAULIC (CANISTER) 32 FILTER - CASE DRAIN (SINTERED BRONZE)
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT - BICS CONTROL VALVE Dealer Copy --33NotFILTER for Resale ARM BY-PASS (SCREEN)
34 CHECK VALVE - BUCKET POSITION VALVE
21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL
35
RESTRICTION
36
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP
22
41 29 RESTRICTOR - 0.031 inch (0,8 mm)
20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
FLOW DIVIDER ADJUSTMENT VALVE 37
SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 Bar)
23
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
24
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD
38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR
25
LOAD SHUTTLE VALVE - BLEED OFF
26
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL
39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
11 ANTICAVITATION VALVE 12
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
NOTE: Unless otherwise specified springs have NO significant pressure value. Printed in U.S.A. 91 of 949
V-0573legend (7-11-05)
(REAR QUICK COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE)
BASE
(PRINTED JULY 2005) Printable Version Click Here V-0573
MALE
ROD
REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK COUPLER BLOCK
24
23
MALE
25
26
28
7
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE 7
DRIVE MOTOR 29
30
1
FEMALE
27
4
37 P-OUT
P-IN
T
32
BUCKET POSITION VALVE (OPTIONAL)
38
D 34
HYDRAULIC FILTER 31 OIL COOLER
2 B
HYDROSTATIC PUMPS
A
36
5
22
5
HYDRAULIC CONTROL VAVLE
6
A 40
3
C 21
13 20
Dealer Copy -- Not for Resale 12
12 B
CHARGE INLET
B
BOB-TACH CYLINDER (OPTIONAL)
A
AUXILIARY SPOOL HYDRAULIC POWERED BOB-TACH (OPTIONAL)
36
5
D
C
14 TILT CYLINDERS
10
BICS CONTROL VALVE
5 39 DR 10
INLET
OUTLET 43 48 8
46 42
B
47
TILT CYLINDER SPOOL
45 PP
DRIVE MOTOR
17
A
11 14
49
LIFT CYLINDERS
10
38
P2
P1
18
44 B
A LIFT CYLINDER SPOOL
35
15 4
37 14 9 33
41
16 33
WORKING CIRCUITS PILOT CIRCUITS DRAIN CIRCUITS COMPONENTS LIFT ARM BY PASS VALVE
32 19
Printed in U.S.A.
92 of 949
V-0573 (7-11-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) Printable Version Click Here
(PRINTED JULY 2005) V-0574legend
LEGEND 1
RESERVOIR: Capacity . . . . . . . 19.2 Qts. (18,2 L)
14 LOAD CHECK VALVE
27
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
2
SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 Bar)
28
RESTRICTOR - 0.140 inch (3,6 mm)
3
DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 Bar) Normally Closed
15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP
4 5 6
7 8
9
10
DRIVE MOTOR SHUTTLE VALVE RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5000 PSI (345 Bar) RELIEF VALVE - CHARGE INLET: 220-270 PSI (15,1-18,6 Bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM (64 L/min.) at High Engine Idle RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 Bar) at Front Quick Couplers PORT RELIEF/ANTICAVITATION VALVE: 3500 PSI (241,3 Bar)
16
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 19
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY
13
PORT RELIEF/ANTICAVITATION VALVE: (OPTIONAL) 3500 PSI (241,3 Bar)
30
RELIEF VALVE:
32 FILTER - CASE DRAIN (SINTERED BRONZE)
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT - BICS CONTROL VALVE Dealer Copy --33NotFILTER for Resale ARM BY-PASS (SCREEN)
21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL
RESTRICTION
36
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP
FLOW DIVIDER ADJUSTMENT VALVE 37 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
24
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD
25
LOAD SHUTTLE VALVE - BLEED OFF
26
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL
42
AUXILIARY HYDRAULIC PUMP 9.5 GPM (36 L/min) at High Engine Idle
43
CHECK VALVE - With 300 PSI (20,7 Bar) Spring And With 0.016 inch (0,40 mm) Orifice
44
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH
45
RESTRICTION - 0.089 inch (2,26 mm)
46
RESTRICTION - 0.025 inch (0,6 mm)
31 FILTER - HYDRAULIC (CANISTER)
35
23
CHECK VALVE - BICS CONTROL VALVE
3300 PSI (228 Bar)
34 CHECK VALVE - BUCKET POSITION VALVE
22
41 29 RESTRICTOR - 0.031 inch (0,8 mm)
20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
11 ANTICAVITATION VALVE 12
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
47 RELIEF VALVE - 2000 PSI (137 Bar) 48 RELIEF VALVE - 1200 PSI (83 Bar)
SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 Bar)
38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL) 50
RELIEF VALVE - 3300 PSI (228 Bar)
51
DUMP VALVE - (ON/OFF)
52
CHECK VALVE
53
FILTER - BOB-TACH VALVE (S/N 526615185 & Above) (S/N 526716179 & Above)
NOTE: Unless otherwise specified springs have NO significant pressure value. Printed in U.S.A. 93 of 949
V-0574legend (7-11-05)
(REAR QUICK COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE)
BASE
MALE
ROD
REAR AUX VALVE (OPTIONAL)
Printable Version Click Here
(PRINTED JULY 2005) V-0574
INTEGRATED QUICK COUPLER BLOCK
24
23
MALE
25
26
28
7 7
DRIVE MOTOR 29
30
1
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE
FEMALE
27 4
37 P-OUT
P-IN
T
32
BUCKET POSITION VALVE (OPTIONAL)
38
D
34
HYDRAULIC FILTER 31 OIL COOLER
2 B
HYDROSTATIC PUMPS 36
5
22
A 5
A
HYDRAULIC CONTROL VAVLE 6
40
3
C 21
13 20 12
Dealer Copy -- Not for Resale
CHARGE INLET
B
12 B
A
AUXILIARY SPOOL 14
36
TILT CYLINDERS
10 5
HIGH FLOW VALVE
5 D
BICS CONTROL VALVE
C 51
8
50
10 52
OUTLET
INLET
B
17
A
TILT CYLINDER SPOOL
42 BOB-TACH CYLINDER (OPTIONAL) DRIVE MOTOR 38
11
HYDRAULIC POWERED BOB-TACH (OPTIONAL)
14 LIFT CYLINDERS
10 18
39 B
DR
A LIFT CYLINDER SPOOL
43 46
48
4
49
37
47
45 PP
14 9
53
P1
35
15
33
41
16 33
P2
WORKING CIRCUITS PILOT CIRCUITS DRAIN CIRCUITS COMPONENTS
44 LIFT ARM BY PASS VALVE 32 19
Printed in U.S.A.
94 of 949
V-0574 (7-11-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC With SJC Option S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED JULY 2005) V-0710legend
Printable Version Click Here
LEGEND 1
RESERVOIR: Capacity . . . . . . . 19.2 qt. (18,2 L)
2
SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 bar)
3
DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 bar) Normally Closed
4
DRIVE MOTOR SHUTTLE VALVE
5
RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5250 PSI (362 bar)
15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP 16
7 8
9
10
RELIEF VALVE - CHARGE INLET: 360 PSI (24,8 bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE HYDRAULIC PUMP . . . . . . . Gear Type 16.3 GPM (61,7 L/min.) at High Engine Idle
30
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
RELIEF VALVE:
3300 PSI (228 bar) 44
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH
45
RESTRICTION - 0.089 inch (2,26 mm)
46
RESTRICTION - 0.025 inch (0,6 mm)
47
RELIEF VALVE - 2000 PSI (137 bar)
34 CHECK VALVE - BUCKET POSITION VALVE
48
RELIEF VALVE - 1200 PSI (83 bar)
35
RESTRICTION
49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
36
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC PUMP
50
CHECK VALVE - With 300 PSI (20,7 bar) Spring with 0.016 inch (0,40 mm) orifice
37
SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 bar)
51
CHARGE PRESSURE SENSOR
52
POSITION SENSOR - Swash Plate
53
SERVO PISTON - Swash Plate
54
SOLENOID ACTIVATED CONTROL VALVE - FORWARD/REVERSE
55
CHARGE PUMP . . . . . . . Gear Type 12.8 GPM (48,5 L/min.) at High Engine Idle
32 FILTER - CASE DRAIN (SINTERED BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY-PASS
33 FILTER - BICS CONTROL VALVE (SCREEN)
Dealer Copy -- Not for Resale
20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL 21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 22
FLOW DIVIDER ADJUSTMENT VALVE
RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 bar) at Front Quick Couplers
23
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
FILTER - Bob-Tach Valve
38 FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDROSTATIC MOTOR
24
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD
39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
11 ANTICAVITATION VALVE
43 PORT RELIEF/ANTICAVITATION VALVE 3500 PSI (241,3 bar)
31 FILTER - HYDRAULIC (CANISTER)
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL
19 6
29 RESTRICTOR - 0.031 inch (0,8 mm)
25
LOAD SHUTTLE VALVE - BLEED OFF
12
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY
26
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL
13
PORT RELIEF/ANTICAVITATION VALVE: . . . . . (Optional) 3500 PSI (241,3 bar)
27
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
28
40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF) 41
CHECK VALVE - BICS CONTROL VALVE
42
RESTRICTION - 0.343 inch (8,7 mm)
RESTRICTOR - 0.140 inch (3,6 mm)
14 LOAD CHECK VALVE NOTE: Unless otherwise specified, springs have NO significant pressure value. Printed in U.S.A. 95 of 949
V-0710legend (7-11-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH SJC OPTION S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED JULY 2005) (V-0710)
(REAR QUICK COUPLERS)
FEMALE
BASE
Printable Version Click Here
MALE
ROD
REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK COUPLER BLOCK
24
23
MALE
25
26
28
7
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE 7
DRIVE MOTOR
29
30
1
FEMALE
27
4
37 P-OUT
P-IN
T
32
BUCKET POSITION VALVE (OPTIONAL) D
38
34
HYDRAULIC FILTER 31
B
HYDROSTATIC PUMPS
A 2
54
OIL COOLER
22
53
A
HYDRAULIC CONTROL VALVE 5
52
40
3
5
C 21
6
13
36
20 12
Dealer Copy -- Not for Resale 12
CHARGE INLET
B
AUXILIARY SPOOL A
B
42 51
2
52
31
14
36
TILT CYLINDERS
43
53
5
BICS CONTROL VALVE
5
54 3 B
TILT SPOOL
A
17
C
D 8
43
11 14
INLET
LIFT CYLINDERS 55
43 HYDRAULIC POWERED BOB-TACH (OPTIONAL)
OUTLET
38 39
18 B
A
LIFT SPOOL 35
47 15
DR 14 50 48 46 49 4
9
33
41
33
16
45 PP
37
10
32
LIFT ARM BY PASS VALVE
P2
P1 44
19
Printed in U.S.A. DRIVE MOTOR V-0710 (7-11-05)
96 of 949
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH SJC AND HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) Printable Version Click Here
(PRINTED JULY 2005) V-0711legend
LEGEND 1
RESERVOIR: Capacity . . . . . . . 19.2 qt. (18,2 L)
2
SPRING LOADED FILTER BY-PASS VALVE: 45-55 PSI (3,1-3,8 bar)
3
16
32 FILTER - CASE DRAIN (SINTERED BRONZE)
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL
33 FILTER - BICS CONTROL VALVE (SCREEN)
DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (2,5-3,0 bar) Normally Closed
18 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL
34
4
DRIVE MOTOR SHUTTLE VALVE
19
5
RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 5250 PSI (362 bar)
6
7
RELIEF VALVE - CHARGE INLET: 360 PSI (24,8 bar) at High Engine Idle With 140 degrees F. (60 degrees C.) Fluid FRONT AUXILIARY MANUAL PRESSURE BLEED-OFF VALVE
8
9
10
RELIEF VALVE - MAIN: 3250-3350 PSI (224-231 bar) at Front Quick Couplers CHARGE PRESSURE SENSOR
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - AUXILIARY
13
PORT RELIEF/ANTICAVITATION VALVE: . . . . . (Optional) 3500 PSI (241,3 bar)
RELIEF VALVE - 2000 PSI (137 bar)
48
RELIEF VALVE - 1200 PSI (83 bar)
49 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL)
CHECK VALVE - BUCKET POSITION VALVE
50
RELIEF VALVE - 3300 PSI (228 bar)
35
RESTRICTION
51
DUMP VALVE - (ON/OFF)
36
VARIABLE CAPACITY DISPLACEMENT BI-DIRECTIONAL HYDROSTATIC PUMP
52
CHECK VALVE
53
37
SHUTTLE RELIEF VALVE (Not Adjustable - Factory Set) 65 PSI (4,5 bar)
21 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL Dealer Copy 38 -- Not for Resale FIXED CAPACITY DISPLACEMENT BI-DIRECTIONAL HYDROSTATIC FLOW DIVIDER ADJUSTMENT VALVE 22 MOTOR
54
56
23
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BASE
39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
57
POSITION SENSOR -Swash Plate
24
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - ROD
40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
58
FILTER - Bob-Tach Valve
59
25
LOAD SHUTTLE VALVE - BLEED OFF
CHARGE PUMP 12.8 GPM (48,5 L/min) at High Engine Idle
41
CHECK VALVE - BICS CONTROL VALVE
26
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL
42
RESTRICTION - 0.343 inch (8,7 mm)
27
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
28
RESTRICTOR - 0.140 inch (3,6 mm)
RELIEF VALVE:
3300 PSI (228 bar)
30
15 LIFT CYLINDER SPOOL - MADE TO RESTRICT FLOW DURING BOOM DOWN BUT NOT DURING BOOM UP
31 FILTER - HYDRAULIC (CANISTER)
55
43 PORT RELIEF/ANTICAVITATION VALVE 3500 PSI (241,3 bar) 44
PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC POWERED BOB-TACH
45
RESTRICTION - 0.089 inch (2,26 mm)
46
RESTRICTION - 0.025 inch (0,6 mm)
29 RESTRICTOR - 0.031 inch (0,8 mm)
14 LOAD CHECK VALVE
Printed in U.S.A.
47
AUXILIARY HYDRAULIC PUMP 9.5 GPM (36 L/min) at High Engine Idle CHECK VALVE - With 300 PSI (20,7 bar) Spring with 0.016 inch (0,40 mm) orifice SOLENOID ACTIVATED CONTROL VALVE - FORWARD/REVERSE SERVO PISTON -Swash Plate
11 ANTICAVITATION VALVE 12
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE LIFT ARM BY-PASS
20 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
CHARGE PRESSURE SENSOR
97 of 949
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
NOTE: Unless otherwise specified, springs have NO significant pressure value. V-0711legend (7-11-05)
RELIEF VALVE - PORT: . . . . . (Optional) 3100 PSI (213,8 bar)
(REAR QUICK COUPLERS)
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC WITH SJC AND HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE)
BASE
MALE
ROD
REAR AUX VALVE (OPTIONAL)
Printable Version Click Here
(PRINTED JULY 2005) (V-0711)
INTEGRATED QUICK COUPLER BLOCK
24
23
MALE
25
26
28
7
(FRONT AUXILIARY LEFT SIDE LIFT ARM)
MALE 7
DRIVE MOTOR
29
30
1
FEMALE
27
4
37 P-OUT
P-IN
T
32
BUCKET POSITION VALVE (OPTIONAL) D
38
34
HYDRAULIC FILTER 31
B
HYDROSTATIC PUMPS
A
OIL COOLER
2
55
22
56
A
HYDRAULIC CONTROL VALVE 5
57
40
3
5
C 21
6
13
36
20 12
Dealer Copy -- Not for Resale 12
CHARGE INLET
B
AUXILIARY SPOOL A
B
42 10
2
57
31
14
36
TILT CYLINDERS
43
BICS CONTROL VALVE
HIGH FLOW VALVE 56
5
5 51
55 50
52
3
B
TILT SPOOL
A
17
C
D 8
11
43
14
INLET
LIFT CYLINDERS 59
43 HYDRAULIC POWERED BOB-TACH (OPTIONAL)
OUTLET
53 38
39
18 B
A
LIFT SPOOL 35
47 15
DR 14 54 48
33
46 49 4
9
41
33
16
45 PP
37
58
32
LIFT ARM BY PASS VALVE
P2
P1 44
19
Printed in U.S.A. DRIVE MOTOR V-0711 (7-11-05)
98 of 949
Dealer Copy -- Not for Resale
HYDRAULIC SYSTEM INFORMATION
20-10-1 99 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
HYDRAULIC SYSTEM INFORMATION (CONT’D)
20-10-2 100 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
HYDRAULIC SYSTEM INFORMATION (CONT’D)
20-10-3 101 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale 20-10-4 102 of 949
S150, S160 Bobcat Loader Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Troubleshooting Chart
Tighten Procedures
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
WARNING Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W-2004-1285
For tightening torques for hydraulic fittings, tubelines etc., (See HYDRAULIC CONNECTION SPECIFICATIONS on Page SPEC-40-1.) CAUSE
The hydraulic system will not operate. The transmission warning light comes ON when hydraulics are operating. Slow hydraulic system action. Hydraulic action is not smooth. Lift arms go up slowly at full engine rpm. The lift arms or Bob-Tach will move when the pedal is in neutral position. Lift arm bypass control valve stuck. Lift arm bypass control valve stem bent or broken.
1, 2, 3, 5, 8 1, 3, 1, 3, 4, 6, 8 1, 4, 5, 6, 7 1, 3, 4, 5, 6, 7, 8, 9 4 10 11
KEY TO CORRECT THE CAUSE 1. The fluid level is not correct. 2. The pedal linkage is disconnected. 3. The hydraulic pump has damage. 4. The pedal linkage is not adjusted correctly. 5. Relief valve is not at the correct pressure. 6. Suction leak on the inlet side of the hydraulic pump. 7. Fluid is cold. Wrong viscosity fluid. (See LOADER SPECIFICATIONS on Page SPEC10-1.) 8. Exceeding the loaders rated operating capacity. 9. Internal leak in the lift cylinder(s). 10. Rotate shaft. 11. Replace lift arm bypass control valve assembly.
20-10-5 103 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
PROBLEM
Dealer Copy -- Not for Resale 20-10-6 104 of 949
S150, S160 Bobcat Loader Service Manual
Figure 20-20-2
CYLINDER (LIFT) Testing
WARNING
2 1
AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.
P-45266
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and tighten.
Figure 20-20-1
Engage the parking brake. Lower the seat bar. Start the engine. Press the PRESS TO OPERATE BUTTON. Push the top (toe) of the lift pedal. 1
If there is any leakage from the base end cylinder port (Item 2) [Figure 20-20-2], remove the cylinder for repair. Repeat the procedure to check the other cylinder.
WARNING
P-45265
Lower the lift arms. Stop the engine. Pull up on the lift arm bypass control and move the lift pedal to release the hydraulic pressure. Raise the seat bar. Check only one cylinder at a time. Open the rear door.
AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. W-2103-0508
Disconnect the negative ground cable to the battery. Disconnect the hose (Item 1) [Figure 20-20-1] from the cylinder base end port.
20-20-1 105 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Connect the negative ground cable to the battery.
Figure 20-20-4
CYLINDER (LIFT) (CONT’D) Removal And Installation Figure 20-20-3
1
2
1
P-45267
Remove the retainer bolt (Item 1) [Figure 20-20-4] and nut from the lift arm pin (both sides).
Stop the engine. Pull up on the lift arm bypass control to release the hydraulic pressure.
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Open the rear door.
Use a drift pin and hammer, remove the cylinder pivot pin (Item 2) [Figure 20-20-4] (both sides).
Disconnect the negative ground cable to the battery.
Figure 20-20-5
Disconnect the hoses (Item 1) [Figure 20-20-3] from the lift cylinder. 1
Install a plug in the hoses and tighten.
2
P-45258
Remove the retainer bolt (Item 1) [Figure 20-20-5] and nut from the cylinder rod end pivot pin (both sides). Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Use a drift pin and hammer, remove the cylinder pivot pin (Item 2) [Figure 20-20-5] (both sides). Remove the cylinder. (both sides)
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P-45265
CYLINDER (LIFT) (CONT’D) Identification
1. Plug 2. O-ring 3. Cylinder 4. O-ring 5. Nut 6. Piston 7. Seal 8. O-ring
9. Spacer 10. Seal 11. O-ring 12. Head 13. Rod Seal 14. Wiper Seal 15. Rod
9
7
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8
6
1
15
2 5 4
14 1 2
13 12
3 11
10
B-13593
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Figure 20-20-8
CYLINDER (LIFT) (CONT’D) Disassembly
2
Use the following tools to disassemble the cylinder: MEL1074 - O-ring Seal Hook Spanner Wrench
1
Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Put the base end of the cylinder in a vise.
3
Figure 20-20-6
P-48038
NOTE: If the fiber surface (Item 3) [Figure 20-20-8] on the piston head, becomes damaged, the complete piston head must be replaced. Figure 20-20-9 1 P-48033
Use a spanner wrench to loosen the head (Item 1) [Figure 20-20-6] from the cylinder case.
2
Figure 20-20-7 4 3
P-48039
2 1
Remove the two O-rings (Item 1) and the back-up washer (Item 2) [Figure 20-20-9] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3) and head (Item 4) [Figure 20-20-7].
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Remove the seal (Item 1) and O-ring (Item 2) [Figure 2020-8] from the piston.
1
CYLINDER (LIFT) (CONT'D)
Assembly
Disassembly (Cont'd)
Use the following tools to assemble the cylinder:
Figure 20-20-10
MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Figure 20-20-12
1
P-48040
P7424
Figure 20-20-11
Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. 1
Lubricate all O-rings and seals with hydraulic oil during installation. Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-20-12]. Allow the seal to stretch for 30 seconds before installing it on the piston.
P-48042
Remove the rod seal (Item 1) [Figure 20-20-11] from the cylinder head.
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Remove the wiper seal (Item 1) [Figure 20-20-10] from the cylinder head.
Figure 20-20-15
CYLINDER (LIFT) (CONT'D) Assembly (Cont'd) Figure 20-20-13
1 2
P7425
Install the rod seal in the head [Figure 20-20-15]. P-48038
Figure 20-20-16
2
Figure 20-20-14 1
1
P-48041
P-48043
P-48042
Install the wiper seal, with the wiper side of the seal (Item 1) toward the outside of the head (Item 2) [Figure 20-2016].
P7427
Install the rod seal on the rod seal tool [Figure 20-20-14]. NOTE: During installation, the spring side of the seal (Item 1) [Figure 20-20-14] must be installed toward the inside of the cylinder. Rotate the handles to collapse the rod seal [Figure 2020-14].
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Install the O-ring (Item 1) and seal (Item 2) [Figure 2020-13] on the cylinder piston.
CYLINDER (LIFT) (CONT'D) Assembly (Cont'd) Figure 20-20-17
1
2
3 4
P-48036
Dealer Copy -- Not for Resale
NOTE: Clean and dry the threads before installing the nut. Install the new nut from the kit. Install the head (Item 1), spacer (Item 2) piston (Item 3), and nut (Item 4) [Figure 20-20-17]. Tighten the nut (Item 4) [Figure 20-20-17] to 850 ft.-lb. (1152 N•m) torque. Figure 20-20-18
1
P-48035
Put the base end of the hydraulic cylinder in a vise. Using a spanner wrench, tighten the head (Item 1) [Figure 20-20-18] until the head is flush with the end of the cylinder tube assembly.
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Remove the attachment. Roll the Bob-Tach fully back. Stop the engine. Raise the seat bar.
CYLINDER (TILT) Testing
Disconnect the hose (Item 1) [Figure 20-21-1] which goes to the base end of the cylinder.
WARNING
Install a cap (Item 1) [Figure 20-21-2] on the fitting and tighten.
Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290
Engage the parking brake. Lower the seat bar. Start the engine and push the Press to Operate button. Push the bottom (heel) of the tilt pedal. If there is leakage from the open port, remove the cylinder for repair.
Dealer Copy -- Not for Resale
Figure 20-21-1
1
N-18801
Figure 20-21-2
1
N-18802
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CYLINDER (TILT) (CONT'D)
Figure 20-21-4
Removal And Installation
WARNING
1
AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire. W-2103-0508 N-18545
Figure 20-21-3 Use a drift pin and hammer, remove the rod end pivot pin (Item 1) [Figure 20-21-4]. Figure 20-21-5
1
3
N-18544
2
Remove the attachment. Roll the Bob-Tach forward. Stop the engine. Raise the seat bar. Remove the retainer bolt (Item 1) [Figure 20-21-3] and nut from the rod end pin. Installation: Tighten the bolt and nut to 34 - 38 N•m (25 28 ft-lb) torque.
P-34137
Remove the retainer bolt (Item 1) [Figure 20-21-5] from the cylinder base end pivot pin. Installation: Tighten the bolt and nut to 125 - 140 ft.-lb. (170 - 190 N•m) torque. Remove the step (Item 2) [Figure 20-21-5]. Disconnect the hose (Item 3) [Figure 20-21-5] from the cylinders.
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1
CYLINDER (TILT) (CONT'D)
Base End Pivot Pin Replacement
Removal And Installation (Cont’d)
Figure 20-21-7
Figure 20-21-6
1 1
2 P-24709 P-34228
Disconnect the hose (Item 1) [Figure 20-21-6] from the cylinder. Remove the cylinder (Item 2) [Figure 20-21-6] from the rod end pivot pin.
Loosen the retainer bolt (Item 1) [Figure 20-21-7] from the cylinder base end pin. Installation: Tighten the retainer bolt to 175 - 190 ft.-lb. (240 - 260 N•m) torque.
Remove the cylinder from the loader. Strike the head of the bolt (Item 1) [Figure 20-21-7] to push the pivot pin out. Reverse the removal procedure to install the pivot pin.
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Remove the cylinder from the Bob-Tach. (See Removal And Installation, Page 20-21-2.)
Figure 20-21-10
CYLINDER (TILT) (CONT'D) Rod End Pivot Pin Bushing And Seal Replacement Figure 20-21-8
1
1
N-18554
Reverse the removal procedure to install the pivot pin bushing and seal [Figure 20-21-10].
N-18556
Dealer Copy -- Not for Resale
Remove the rod end of the cylinder from the Bob-Tach. (See Removal And Installation, Page 20-21-2.) Use a seal pick to remove the seals (Item 1) [Figure 2021-8] on both sides of the pivot bushing. Figure 20-21-9
N-18555
Remove and replace bushing with a driver tool and hammer [Figure 20-21-9].
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CYLINDER (TILT) (CONT'D) Parts Identification
1. Case 2. Plug 3. O-ring 4. Nut 5. Piston 6. Seal 7. O-ring 8. O-ring
9. Washer 10. O-ring 11. Head 12. Seal 13. Seal 14. Rod 15. Seal 16. Bushing
MC-1688B
3 MC-01688A
2
1
Dealer Copy -- Not for Resale
8
9
4 10
7
12
6
13
11
5
MC-01688D
MC-01688C
14 15
16 15
PE-1056A
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Figure 20-21-13
CYLINDER (TILT) (CONT'D) Disassembly
2
Use the following tools to disassemble the cylinder: MEL1074 - O-ring Seal Hook Spanner Wrench
1
Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Put the base end of the cylinder in a vise. Figure 20-21-11
P-48073
Remove the seal (Item 1), and O-ring (Item 2) [Figure 20-21-13] from the piston.
1
1
2 P-48034
Use a spanner wrench to loosen the head (Item 1) [Figure 20-21-11] from the cylinder case. Figure 20-21-12
P-48039
3
Remove the two O-rings (Item 1) and the back-up washer (Item 2) [Figure 20-21-14] from the cylinder head.
2 1
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item 3) [Figure 20-21-12].
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Figure 20-21-14
CYLINDER (TILT) (CONT'D)
Assembly
Disassembly (Cont'd)
Use the following tools to assemble the cylinder:
Figure 20-21-15
MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Figure 20-21-17
1
P-48040
P7424
Figure 20-21-16
Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. 1
Lubricate all O-rings and seals with hydraulic oil during installation. Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-21-17]. Allow the seal to stretch for 30 seconds before installing it on the piston.
P-48042
Remove the rod seal (Item 1) [Figure 20-21-16] from the cylinder head.
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Remove the wiper seal (Item 1) [Figure 20-21-15] from the cylinder head.
Figure 20-21-20
CYLINDER (TILT) (CONT'D) Assembly (Cont'd) Figure 20-21-18
1 2
P7425
Install the rod seal in the head [Figure 20-21-20]. P-48073
Figure 20-21-21
2
Figure 20-21-19 1
1
P-48041
P-48043
P-48042
Install the wiper seal, with the wiper side of the seal (Item 1) toward the outside of the head (Item 2) [Figure 20-2121].
P7427
Install the rod seal on the rod seal tool [Figure 20-21-19]. NOTE: During installation the spring side of the seal (Item 1) [Figure 20-21-19] must be installed toward the inside of the cylinder. Rotate the handles to collapse the rod seal [Figure 2021-19].
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Install the O-ring (Item 1) and seal (Item 2) [Figure 2021-18] on the cylinder piston.
Figure 20-21-24
CYLINDER (TILT) (CONT'D) Assembly (Cont'd) Figure 20-21-22
1
1 2 3
P-48070
Put the base end of the hydraulic cylinder in a vise. P-48071
Tighten the head (Item 1) [Figure 20-21-24] using a spanner wrench.
Dealer Copy -- Not for Resale
NOTE: Clean and dry the threads before installing the nut. Install the new nut from the kit. Install the head (Item 1), piston (Item 2) and nut (Item 3) [Figure 20-21-22]. Tighten the nut (Item 3) [Figure 20-21-22] to 100 ft.-lb. (136 N•m) torque. Figure 20-21-23
P-48088
P-48089
Mark the end of the shaft and nut. Tighten the nut an additional 135 degrees or 2-1/4 flats [Figure 20-21-23].
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Figure 20-22-2
CYLINDER (POWER BOB-TACH) Testing
WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.
1
W-2103-0508 P-48131
WARNING
Disconnect the hose (Item 1) [Figure 20-22-2] from the power Bob-Tach cylinder base end port. Figure 20-22-3
2
W-2072-0807
Figure 20-22-1
1
P16332
Install a plug in the hose (Item 1) [Figure 20-22-3] and tighten. Engage the parking brake. Lower the seat bar. Start the engine. Push and hold the BOB-TACH “WEDGES UP” Switch (Front Accessory Panel). P-48131
Tilt the Bob-Tach forward, so it is parallel to the floor [Figure 20-22-1].
If there is any leakage from the base end cylinder port (Item 2) [Figure 20-22-3], remove the Power Bob-Tach cylinder for repair.
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AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.
CYLINDER (POWER BOB-TACH) (CONT’D) Removal And Installation Figure 20-22-4
1
2
P-48131
Dealer Copy -- Not for Resale
Disconnect the hoses (Item 1 and 2) [Figure 20-22-4] from the cylinder fittings. Install plugs and cap on fittings. NOTE: Connect the hose with the 45° end (Item 1) [Figure 20-22-4] to the base end fitting on the cylinder. Figure 20-22-5
1 1 N-21400A
Remove the bolts (Item 1) [Figure 20-22-5]. Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the washers and cylinder from the lever pivots.
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CYLINDER (POWER BOB-TACH) (CONT’D) Identification 1. Cylinder 2. Plug 3. O-ring 4. Nut 5. Piston 6. O-ring 7. Ring 8. Spacer 9. O-ring 10. Ring 11. O-ring 12. Head 13. Seal 14. Seal 15. Rod
14
2 13
12
11
10
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1
3
9
8
7 6
5
4
15
PE1064A
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Figure 20-22-8
CYLINDER (POWER BOB-TACH) (CONT’D) Disassembly
3 2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook Spanner Wrench Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Figure 20-22-6 P16295
Piston: Remove the O-ring (Item 1), and seal (Item 2) from the piston (Item 3) [Figure 20-22-8].
3
5
4 P-43212
2 1
Put the base end of the cylinder in a vise. Use a spanner wrench to loosen the head [Figure 20-226]. Figure 20-22-7
N-20611
4
3
2
Remove the wiper seal (Item 1), and rod seal (Item 2), the back up washer (Item 3) the thin O-ring (Item 4) and the thick O-ring (Item 5) [Figure 20-22-9] from the head.
1
P16294
Remove the head and rod assembly from the cylinder [Figure 20-22-7]. Put the rod end in a vise. Remove the nut (Item 1), piston (Item 2), spacer (Item 3) and head (Item 4) [Figure 20-22-7] from the rod.
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Figure 20-22-9
Figure 20-22-11
CYLINDER (POWER BOB-TACH) (CONT’D) Assembly
3
2
Use the following tools to assembly the cylinder: MEL1396 - Seal Installation Tool MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench
1
4
Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts.
Lubricate all O-rings and seals with hydraulic oil during installation.
Piston: Install the O-ring (Item 1) and seal (Item 2) on the piston (Item 3) [Figure 20-22-11].
Figure 20-22-10
NOTE: The piston center hole (Item 4) [Figure 20-2211] has a bevel on one end. The bevel goes toward the rod. Figure 20-22-12
P7424
Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-22-10]. Allow the seal to stretch for 30 seconds before installing it on the piston.
N-20612
Install the rod seal on the rod seal tool [Figure 20-22-12]. NOTE: During installation the O-ring side of the seal must be toward the inside of the cylinder.
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P16295
Always install new O-rings and seals during assembly.
Figure 20-22-15
CYLINDER (POWER BOB-TACH) (CONT’D) Assembly (Cont’d) Figure 20-22-13
1 2 3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15]. N-20613
Rotate the handles to collapse the rod seal [Figure 2022-13].
NOTE: Clean and dry the threads before installing the nut. Install the new nut from the seal kit.
Figure 20-22-14 Figure 20-22-16
1
2
3 4
P7425 P16294
Install the rod seal in the head [Figure 20-22-14]. Install the wiper seal with the wiper toward the outside of the head.
Install the head (Item 1), and spacer (Item 2) [Figure 2022-16]. Install the piston (Item 3) [Figure 20-22-16]. Grease the piston where the nut contacts the piston. do not get grease on the threads. Install the new nut (Item 4) [Figure 20-22-16]. Tighten the nut to 90 ft.-lb. (122 N•m) torque.
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Install the back-up washer (Item 2) and thick O-ring (Item 3) [Figure 20-22-15] into the groove on the head.
CYLINDER (POWER BOB-TACH) (CONT’D) Assembly (Cont’d) Figure 20-22-17
P-43212
Dealer Copy -- Not for Resale
Put the base end of the hydraulic cylinder in a vise. Tighten the head using a spanner wrench [Figure 20-2217].
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Figure 20-30-1
MAIN RELIEF VALVE Description The main relief valve limits the hydraulic system pressure by opening at a certain pressure and allowing the hydraulic oil to flow back to the hydraulic reservoir. (See Hydraulic System on Page SPEC-10-3.)
2
The main relief valve is adjustable and is located on the hydraulic control valve near the bottom, facing the front of the loader.
1
Testing P-34480
The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
WARNING
Connect the IN port (Item 1) [Figure 20-30-1] of the hydraulic tester to the bottom (female) quick coupler on the loader. Connect the OUT port (Item 2) [Figure 20-30-1] of the hydraulic tester to the top (male) quick coupler on the loader. Figure 20-30-2
When the engine is running during service, the driving and steering controls must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W-2006-1209
1
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
N-18409
•
Press the AUXILIARY HYDRAULICS Button (Item 1) [Figure 20-30-2] Maximum Flow.
The tools listed will be needed to do the following procedure: MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Turn the key switch to the OFF position. To release the hydraulic pressure at the front auxiliary quick couplers push the couplers into the coupler block and hold for three seconds. Lift and block the loader. (See Procedure on Page 10-101.)
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IMPORTANT
MAIN RELIEF VALVE (CONT’D)
Adjustment
Testing (Cont’d)
Figure 20-30-4
Figure 20-30-3 Right Steering Lever Control
O-ring
1 Back-up
B-6764
1 P-31833
•
•
Push the front switch (Item 1) [Figure 20-30-3] to give the front quick couplers a constant flow of fluid. To release from continuous operation, press the front switch (Item 1) [Figure 20-30-3] a second time.
Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full rpm.
Turn the adjusting screw in or out until the pressure is correct. NOTE: If the correct pressure can not be reached, replace the main relief valve. Check the pressure setting of the new relief valve.
For both flow and pressure specifications of the hydraulic system. (See SPECIFICATIONS on Page SPEC-01.) Check the free flow specification. Turn the restrictor control, on the tester, until the main relief valve opens. Check the relief pressure. If the relief pressure is not correct, stop the engine and adjust the main relief valve.
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If the pressure is not correct, adjust the main relief valve. Remove the end cap (Item 1) [Figure 20-30-4].
Installation: Tighten the main relief valve to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
MAIN RELIEF VALVE (CONT’D) Removal And Installation Figure 20-30-5
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
1
I-2003-0888
1
P-48872
Dealer Copy -- Not for Resale
Remove the four motor cover mounting bolts (Item 1) [Figure 20-30-5]. Installation: Tighten the mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque. Figure 20-30-6
1
P-48874
Clean the area around the control valve. Loosen and remove the main relief valve (Item 1) [Figure 20-30-6]. Remove the O-rings and back-up washers [Figure 2030-4]. Clean the main relief valve in clean solvent. Use air pressure to dry the valve. Install new O-rings and back-up washers. Install the main relief valve (Item 1) [Figure 20-30-6] and tighten. Check the pressure again. (See Testing on Page 20-30-1.)
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)
WARNING
Identification
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 20-40-1
W-2059-0598
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
1 N-18695
The BICS™ section and main control valve are in two separate castings. For identification of the hydraulic control valve (1 piece casting) (foot control), (See Identification on Page 20-421.). Removal And Installation
Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Clean the area around the control valve. Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.)
DANGER
Remove the control panel. (See Removal And Installation on Page 50-100-1.) Remove the control pedal crossbar linkage and tilt linkage. (See CONTROL PEDALS on Page 50-90-1.)
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
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I-2003-0888
The hydraulic control valve (2 piece casting) (foot control) has a removable BICS™ section (Item 1) [Figure 20-401].
Figure 20-40-4
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal And Installation (Cont’d) Figure 20-40-2
1
1
P-31999
Remove the tie - strap (Item 1) [Figure 20-40-4] from the fixed end main valve hose. P-34004
Figure 20-40-5
Locate and remove the access covers (Item 1) [Figure 20-40-2] on the right side of the machine. 3
Figure 20-40-3 1
1
2 P-34387
Disconnect the tubeline (Item 1) [Figure 20-40-5] from the lift arm by pass valve. Remove the drain tubeline (Item 2) [Figure 20-40-5] from the lift arm bypass valve and the control valve.
P-31998
Remove the bolts (Item 3) [Figure 20-40-5] from the lift arm bypass control valve.
Mark all tubelines and hoses for correct installation. The fixed end main valve hose assembly (Item 1) [Figure 20-40-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.
Installation: Tighten the bolts to 180 - 200 in.-lb. (21 - 23 N•m) torque.
NOTE: Remember the hose routing for ease of control valve installation.
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Remove the right rear tire.
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
Figure 20-40-8
Removal And Installation (Cont’d) Figure 20-40-6 1 2 1 3 4
2
P-34390
1 Disconnect the tilt tubeline (Item 1) [Figure 20-40-8]. Disconnect the tilt tubeline (Item 2) [Figure 20-40-8].
P-34388
Disconnect the outlet tubeline (Item 2) [Figure 20-40-6] from the control valve.
Disconnect the lift tubeline (Item 4) [Figure 20-40-8]. Figure 20-40-9
Figure 20-40-7
1
5
3
4
1
2 P-31997
Disconnect the BICS™ valve electrical connector (Item 1) [Figure 20-40-9].
P-34389
Disconnect the drive motor case drain hose (Item 1) [Figure 20-40-7]. Disconnect the Power Bob-Tach drain hose (Item 2) [Figure 20-40-7] if so equipped. Disconnect the drain to reservoir hose (Item 3) [Figure 20-40-7]. Disconnect the auxiliary tubeline (Item 4) and (Item 5) [Figure 20-40-7].
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Disconnect the drain hose (Item 3) [Figure 20-40-8]. Label and disconnect the four electrical connectors (Item 1) [Figure 20-40-6].
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
DANGER
Removal And Installation (Cont’d) Figure 20-40-10
1
P-90328
•
• P-34005
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Figure 20-40-12
Dealer Copy -- Not for Resale
Disconnect the inlet hose (Item 1) [Figure 20-40-10] from the bottom of the control valve. Figure 20-40-11
1
1
P-34006
P-34391
Connect a hoist (Item 1) [Figure 20-40-11] to the control valve.
Locate and remove the two control valve mounting bolts (Item 1) [Figure 20-40-12] through the right side access panels. Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Figure 20-40-15
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal And Installation (Cont’d) Figure 20-40-13
N-18695
Remove the BICS™ valve assembly from the top of the control valve [Figure 20-40-15]. P-34391
Figure 20-40-16 valve
from
the
loader
BICS™ Valve Removal And Installation Figure 20-40-14
1
1
2
1
1
1
N-18697
1 1
Remove the four large O-rings (Item 1) and the small Oring (Item 2) [Figure 20-40-16] from the top of the control valve.
1
N-18679
Remove the control valve. (See Removal And Installation on Page 20-40-1.)
Installation: Install the four large O-rings (Item 1) and the small O-ring (Item 2) [Figure 20-40-16] on the top of the control valve.
To remove the BICS™ from the control valve loosen and remove the six mounting bolts (Item 1) [Figure 20-4014].
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Remove the control [Figure 20-40-13].
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation
BICS™ Valve Removal And Installation (Cont’d)
Figure 20-40-18
Figure 20-40-17
6
3 1
2
1
5 4
N-18686
Remove the fitting (Item 1) [Figure 20-40-18] from the valve.
N-18679
Dealer Copy -- Not for Resale
Install the six mounting bolts [Figure 20-40-17]. The chart below lists the correct torque specifications and tightening sequence when reinstalling the BICS™ valve assembly to the control valve. Thoroughly clean and dry bolts and threads in valve. Use liquid adhesive Loctite® #242 or equivalent. STEP
TORQUE
1
110 - 130 in.-lb. (12,5 - 23,7N•m)
2
190 - 210 in.-lb. (21,5 - 23,7N•m)
3
190 - 210 in.-lb. (21,5 - 23,7 N•m)
SEQUENCE
1,2,3,4,5 & 6
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for every bolt or repeat step 3.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation (Cont’d) Figure 20-40-19
1
N-18687
Dealer Copy -- Not for Resale
Figure 20-40-20
1
N-18685
Using a flat blade screw driver, remove the lift arm bypass orifice (Item 1) [Figure 20-40-19] and [Figure 20-40-20]. Orifice size is 2 mm (0.078 in). Reverse the removal procedure to install the lift arm bypass orifice.
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Figure 20-40-23
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve, Check Valve Removal And Installation Figure 20-40-21
1
P-8956
1 Clean and inspect the screen (Item 1) [Figure 20-40-23] on the end of the valve. N-18683
Remove the check valve (Item 1) [Figure 20-40-21].
Dealer Copy -- Not for Resale
Reverse the removal procedure to install the BICS™ check valve.
Installation: Tighten the valve to 20 ft.-lb. (27 N•m) torque. Figure 20-40-22
3
2 1
N-18684
Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-22]. Install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-22] on the check valve. Check valve (Item 3) [Figure 20-40-22] has a rating of 5 - 10 PSI.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve Lock Valve Removal And Installation
Remove the lock valves (Item 1) [Figure 20-40-24], [Figure 20-40-25] and [Figure 20-40-26] from the BICS™ valve. Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m) torque.
Figure 20-40-24
Figure 20-40-27
1 1 1
1
2
N-18682
Figure 20-40-25
2 N-18690
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-27] from both the tilt and lift lock valves. Install new O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-27] on the tilt and lift lock valves. Reverse the removal procedure to install the lock valve. 1
N-18688
Figure 20-40-26
1
N-18689
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2
Figure 20-40-30
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) BICS™ Valve Solenoid Removal And Installation
1 Figure 20-40-28
1
2
N-18692
Remove the solenoid cartridge (Item 1) [Figure 20-4030]. N-18691
Dealer Copy -- Not for Resale
Remove the mounting nut (Item 1) [Figure 20-40-28] from the solenoid cartridge.
Installation: Tighten the cartridge to 20 ft-lb (27 N•m) torque.
Installation: Tighten the mounting nut to 53 in-lb (6 N•m) torque. Remove the solenoid (Item 2) [Figure 20-40-28]. Figure 20-40-29
1 1
N-18693
Remove the O-rings (Item 1) [Figure 20-40-29] from both ends of the solenoid.
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BICS™ Valve Solenoid Testing
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
Figure 20-40-32
BICS™ Valve Solenoid Removal And Installation (Cont’d) Figure 20-40-31
3 2
P9175
1
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-40-31] from the cartridge. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear and replace any showing excessive wear.
[Figure
Coil wires do not have polarity. Correct resistance for the BICS™ is 9.7 ± 1 ohm @ 20°C. Correct resistance for the tilt and lift lock coils is 7.7 ± 1 ohm @ 20°C.
NOTE: The screen (Item 3) [Figure 20-40-31] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-40-29] and [Figure 20-40-31] and new back-up rings (Item 2) [Figure 20-40-31] on the solenoid cartridge.
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Use an ohmmeter to measure coil resistance 20-40-32].
N-18694
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
ITEM
S150, S160 LOADER
A1
Lift Cylinder Base End / Restrictor
A2
Tilt Cylinder Base End
A3
Auxiliary Hydraulics
B1
Lift Cylinder Rod End
B2
Tilt Cylinder Rod End
B3
Auxiliary Hydraulics
C1
Load Check Valve / Lift Function
C2
Load Check Valve / Tilt Function
C3
Orificed Load Check Valve Auxiliary Function
C4
Outlet Fluid Flow
D1
Lift Spool Centering Spring / Detent
D2
Tilt Spool Centering Spring
D3
Auxiliary Spool / Centering Springs
E1
Port Relief Valve - 3500 psi
E2
Anti-Cavitation / Port Relief Valve - 3500 psi
F1
Anti-Cavitation Valve
F2
Port Relief Valve - 3500 psi
G1
Lift Spool End
G2
Tilt Spool End
G3
Auxiliary Spool / Centering Springs
H1
Auxiliary Electric Solenoid
H2
Plug / Port Relief (Optional) - 3100 psi
H3
Auxiliary Electric Solenoid
MR
Main Relief Valve - 3300 psi
Dealer Copy -- Not for Resale
Identification Chart
Figure 20-40-33 H1
H2
H3
C4 A3
B3 G3
D3
C3 B2
G2 F2 G1
A2
E2
A1
E1
D2
C2 B1
F1 MR
D1
C1
TS-1918
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Figure 20-40-35
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Load Check Valve
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-18698
Figure 20-40-34 Mark each valve section, spool and related parts so that they will be returned to its original valve section during assembly.
1
Use bolts to fasten the control valve to a work bench for easier disassembly and assembly procedures. 1
1
Loosen the load [Figure 20-40-35].
2
check
valve
plugs
(Item
1)
Installation: Always use new O-ring. tighten the plug to 35 - 40 ft.-lb. (47 - 54 N•m) torque. Figure 20-40-36 N-18697
Remove the BICS™ valve assembly from the control valve. (See BICS™ Valve Removal And Installation on Page 20-40-5.) Remove the four large O-rings (Item 1) and small O-ring (Item 2) [Figure 20-40-34]. Always replace these O-rings before installing the BICS™ valve assembly.
1
3 2
N-18699
Remove the load check plugs (Item 1) [Figure 20-40-36]. Remove the spring (Item 2) and poppet (Item 3) [Figure 20-40-36].
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1
Figure 20-40-39
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Load Check Valve (Cont’d) Figure 20-40-37 1
1 N-19031
Remove the main relief valve (Item 1) [Figure 20-40-39]. 2 2 l
The auxiliary section (Item 1) uses an orifice load check poppet (Item 2) [Figure 20-40-37].
l 1
NOTE: For correct port locations and valve component values (See Identification Chart on Page 20-40-12.)
3 4 l l
5 l
B-06764
1. Relief Valve 2. O-ring 3. Sleeve 4. Glide Ring 5. O-ring
Main Relief Valve Figure 20-40-38
CD-15092
Remove the O-rings, sleeve, and glide ring from the main relief valve [Figure 20-40-40]. Installation: Always use new O-rings. sleeve, and glide ring. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque. 1
N-18923
Loosen the main relief valve (Item 1) [Figure 20-40-38].
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Figure 20-40-40
N-18700
Figure 20-40-43
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Port Relief Valve Figure 20-40-41
1
1 N-18977
Remove the port relief valve (Item 1) [Figure 20-40-43].
Figure 20-40-42
4 3 2 1
1
1. O-ring 2. Back-up Washer 3. O-ring 4. Relief Valve N-18844
Remove the O-rings and back-up washer from the port relief valve [Figure 20-40-44].
N-18923
Loosen the port relief valve (Item 1) [Figure 20-40-41] and [Figure 20-40-42] (Port E1 or F2). Installation: Always use new O-rings and back-up washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
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Figure 20-40-44
N-18976
Figure 20-40-47
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Anti-Cavitation Valve / Port Relief Valve Figure 20-40-45
1
1 N-18843
Remove the O-rings (Item 1) [Figure 20-40-47] from the anti-cavitation / port relief valve. N-18976
Anti-Cavitation Valve Figure 20-40-48
Installation: Always use new O-rings and back-up washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Dealer Copy -- Not for Resale
Loosen the anti-cavitation valve (Item 1) [Figure 20-4045].
2
Figure 20-40-46
1 1 N-18923
Remove the lift lock solenoid (Item 1) [Figure 20-40-48] and [Figure 20-40-49]. Installation: Always use new O-rings and back-up washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
N-18978
Remove the anti-cavitation / port relief valve (Item 1) [Figure 20-40-46] from the control valve for the tilt section.
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Rubber Boot
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
Figure 20-40-51
Anti-Cavitation Valve (Cont’d) Figure 20-40-49
2 1
1
N-18923
Remove the anti-cavitation valve (Item 2) [Figure 20-4048] and [Figure 20-40-49] from the control valve for the lift section.
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. Figure 20-40-52
Figure 20-40-50 1
2
3
2
4 1
E-01509
1. Anti-Cavitation Valve 2. O-ring 3. Back-up Washer 4. O-ring
1
2
N-18924 N-18839
Remove the O-rings and back-up washer from the anti-cavitation valve [Figure 20-40-50].
Remove the rubber boot (Item 1) and retainer (Item 2) [Figure 20-40-52].
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Remove the two screws (Item 1) [Figure 20-40-51] on the rubber boot retainer.
N-19032
Figure 20-40-55
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift And Tilt Lock Block Removal And Installation Figure 20-40-53
1
N-18926
2 1
Remove the block [Figure 20-40-55].
Figure 20-40-54
Lift Spool And Detent The tool listed will be needed to do the following procedure:
1
MEL1278 - Detent Tool MEL1285 - Detent Spring Tool Figure 20-40-56 2
2
1 N-18925
1 Remove the lock solenoids (Item 1) [Figure 20-40-53] and [Figure 20-40-54] from the lock block. 2
Remove the rubber boot (Item 2) [Figure 20-40-53] and [Figure 20-40-54]. (See Identification Chart on Page 2040-12.)
1
N-18923
Remove the lift and tilt lock solenoids (Item 1) [Figure 20-40-56]. Remove the lift and tilt lock block [Figure 20-40-56] from the control valve.
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2)
S150, S160 Bobcat Loader Service Manual
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NOTE: The lock block must be clean and oil free. (Oil can cause the solenoids not to function properly.)
N-18923
Figure 20-40-59
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-57
1
1
2
2 N-18971
Use safety glasses and a screwdriver to remove the snap ring (Item 1) [Figure 20-40-59]. N-18927
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-57] from the lift spool.
Figure 20-40-60
Figure 20-40-58
1
2 1 1 N-18972
N-18976
Remove the end cap (Item 1) [Figure 20-40-58].
Remove the screws (Item 1) [Figure 20-40-60] from the detent bonnet. Remove the detent bonnet (Item 2) [Figure 20-40-60].
IMPORTANT The detent assembly has small springs and balls. Do not lose these parts during disassembly and assembly. I-2012-0284
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Remove the washer (Item 2) [Figure 20-40-59].
Figure 20-40-63
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-61
1
N-18975
Remove the spool assembly and seal (Item 1) [Figure 20-40-63] from the control valve.
1 N-18973
Put a rag around the detent assembly (Item 1) [Figure 20-40-61]. This will prevent the detent balls and spring from being lost when the detent sleeve is removed. Figure 20-40-62
1
2 3
N-18930
1
Remove the spool seal (Item 1) [Figure 20-40-64] from the linkage end of the valve.
2 N-18974
Remove the detent sleeve (Item 1), detent balls (Item 2) and spring (Item 3) [Figure 20-40-62].
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Figure 20-40-64
Figure 20-40-67
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-65
1 2 N-18916
Put a rag around the detent assembly [Figure 20-40-67]. This will prevent the detent balls and spring from being lost when the detent adapter is removed.
Clamp the linkage end of the spool in a vise [Figure 20-40-65]. Figure 20-40-66
Remove the detent adapter with an allen wrench. Remove the back-up washer (Item 1) and spool seal (Item 2) [Figure 20-40-67]. Figure 20-40-68
2
1 1
N-18915 N-19004
Install the spring tool (Item 1) [Figure 20-40-66] over the centering spring. NOTE: Be careful when removing the detent adapter (Item 2) [Figure 20-40-66] from the centering spring, as it is under spring pressure.
Remove the detent adapter (Item 1) [Figure 20-40-68] from the spring assembly.
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P-8988
Figure 20-40-71
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-69
1
N-18918
Remove the stud [Figure 20-40-71].
from
the
end
of
the
spool
N-19009
Remove spring tool (Item 1) [Figure 20-40-69] from the spring assembly. Figure 20-40-70
2
1 1
3 4
N-18920
Removal of the plastic plug: Make a center point in the plug using a 1/16 inch drill.
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-40-70].
Drill a hole all the way through the plug using a 7/64 inch tap drill. Turn a 6-32 tap (Item 1) [Figure 20-40-72] into the plug. Pull the tap and plug out of the spool. Be careful, do not break the tap. Clean all the debris from inside the spool bore. NOTE: DO NOT USE Loctite® ON THE STUD THREADS.
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Figure 20-40-72
Figure 20-40-75
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
O-ring
Lift Spool And Detent (Cont’d) Figure 20-40-73
2
Plastic Plug
1
0.60 in. (15,2 mm) B-14712
Install the stud and tighten until the other end of the stud is out about 0.60 in. (15,2 mm) from the spool [Figure 20-40-75].
Install the O-ring (Item 1) over the nipple on the plastic plug (Item 2) [Figure 20-40-73].
Figure 20-40-76
Dealer Copy -- Not for Resale
N-18961
Figure 20-40-74 1
N-18967
Clamp the collar (Item 1) [Figure 20-40-76] in a vice. N-18963
Install the plastic plug and O-ring in the spool [Figure 20-40-74].
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Figure 20-40-79
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-77
1 2
1
N-19004
3 2
Install the spring tool (Item 1) [Figure 20-40-79] over the washer, spring, collar and detent adapter. N-18958
Apply grease on all the detent component surfaces before assembly [Figure 20-40-77]. Install the spring (Item 1) and detent balls (Item 2) into the adapter (Item 3) [Figure 20-40-77] and compress with the detent pliers [Figure 20-40-78].
2
Figure 20-40-78
1
N-18917
Install the spool seal (Item 1) and back-up washer (Item 2) [Figure 20-40-80].
N-18968
Install the detent adapter to the collar [Figure 20-40-78]. NOTE: The collar and the detent adapter are held together by spring pressure when assembled to the lift spool not the detent balls. Hold the detent adapter and collar together to prevent the detent balls and spring from falling out.
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Figure 20-40-80
Figure 20-40-83
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-81
1
N-19007
Hold the detent balls in place with the detent pliers [Figure 20-40-83]. N-19005
Install the spring assembly to the lift spool hand tight [Figure 20-40-81]. Remove the spring tool. Check the alignment of the detent adapter and the washer. 1 Tighten the adapter to 90 - 100 in.-lb. (10,2 - 11,3 N•m). NOTE: The adapter must fit in the center of the washer (Item 1) [Figure 20-40-81]. Figure 20-40-82
N-19008
Install the detent sleeve (Item 1) [Figure 20-40-84] to the detent adapter.
CD-15051
Install the detent balls and spring [Figure 20-40-82].
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Figure 20-40-84
Figure 20-40-87
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Lift Spool And Detent (Cont’d) Figure 20-40-85
1
2 N-18976
1 Install the end cap (Item 1) [Figure 20-40-87]. 2
Install the lift spool assembly in the spool bore [Figure 20-40-85]. Install the detent bonnet (Item 1) [Figure 20-40-85]. Install the mounting screws (Item 2) [Figure 20-40-85]. Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 11,3 N•m) torque.
1
Figure 20-40-86 N-18930
Install the spool seal (Item 1) [Figure 20-40-88] on the linkage end of the valve. 2
1 N-18971
Install the washer (Item 1) and snap ring (Item 2) [Figure 20-40-86].
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Figure 20-40-88
N-18972
Tilt Spool Removal And Installation
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
Figure 20-40-91
Lift Spool And Detent (Cont’d) Figure 20-40-89
1
2 1
N-18927
Install the spacer (Item 1) and O-ring (Item 2) [Figure 2040-89] on the linkage end of the lift spool.
Remove the lift and tilt lock block (Item 1) [Figure 20-40-91] from the control valve. (See Lift And Tilt Lock Block Removal And Installation on Page 20-4018.) Figure 20-40-92
Figure 20-40-90
1
2
1
N-18928 N-18923
Install the lift and tilt lock block (Item 1) [Figure 20-4090]. (See Lift And Tilt Lock Block Removal And Installation on Page 20-40-18.)
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-40-92] from the tilt spool.
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N-18923
Figure 20-40-95
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Tilt Spool Removal And Installation (Cont’d)
1 Figure 20-40-93
1
N-18942 N-18942
Put the linkage end of the spool in the vice [Figure 20-40-95]. N-18686
Dealer Copy -- Not for Resale
Remove the screws (Item 1) [Figure 20-40-93] from the end cap.
Install the spool tool (Item 1) [Figure 20-40-95] over the centering spring. Figure 20-40-96
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. 1
Figure 20-40-94
N-19014
Remove the bolt (Item 1) [Figure 20-40-96] holding the centering spring to the spool. N-18816
Remove the spool, centering spring, back-up washer and spool seal [Figure 20-40-94].
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal.
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Auxiliary Spool Removal And Installation
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
Figure 20-40-99
Tilt Spool Removal And Installation (Cont’d) Figure 20-40-97
2
1
3 4 1
N-18976
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-40-97].
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque.
Figure 20-40-98
Figure 20-40-100 2 1
1
N-18930
N-18943
N-18990
Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-40-98].
Remove the end cap, O-ring, springs and washer (both sides).
Assembly: Always use a new spool seal.
Assembly: Put grease on all the centering spring component parts.
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Dealer Copy -- Not for Resale
Remove the screws (Item 1) [Figure 20-40-99] from the end cap (both sides).
N-18944A
Figure 20-40-103
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Auxiliary Spool Removal And Installation (Cont’d) Figure 20-40-101
1
2 1
N-18823
Remove the end plate (Item 1) and housing (Item 2) [Figure 20-40-103]. N-18989
Figure 20-40-104
Assembly: Always use a new spool seal. Auxiliary Electric Solenoid Figure 20-40-102
3
2 1
N-18992
1
Remove the coil (Item 1) and end plate (Item 2) [Figure 20-40-104].
1
Remove the solenoid valve (Item 3) [Figure 20-40-104]. Installation: Tighten valve to 96 - 144 in.-lb. (11 - 16 N•m) torque.
N-18822
Remove the nut (Item 1) [Figure 20-40-102] from both solenoids. Installation: Tighten the nut to 96 - 144 in.-lb. (11 - 16 N•m) torque.
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Dealer Copy -- Not for Resale
Remove the spool (Item 1) [Figure 20-40-101].
Figure 20-40-107
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D)
Plug
Auxiliary Electric Solenoid (Cont’d) Figure 20-40-105 2
1 1 1 N-18800
Figure 20-40-108
Remove the O-rings (Item 1) [Figure 20-40-105] from the solenoid valves. 1
Port-Auxiliary Section
2
Figure 20-40-106 1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-107] and [Figure 20-40-108] and back-up ring (Item 2) [Figure 20-40-107] and [Figure 20-40-108] from the plug or port relief.
1
N-18993
Remove the plug (Item 1) [Figure 20-40-106] or optional port relief valve from the control valve.
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Dealer Copy -- Not for Resale
Port Relief (Optional)
N-18795
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) (CONT’D) Cleaning And Inspection Clean all components with clean solvent and dry with compressed air. Check the spools for wear or scratches. Check that the spools are not loose in their bore. Check that the centering springs are not broken. Check that the load check valve seats are not worn. Check the load check poppets for damage. Check the rubber boots and retainers. Replace the parts as needed.
Dealer Copy -- Not for Resale
Use new O-rings and back-up rings. Apply oil to all new O-rings and back-up rings before installation.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)
WARNING
Identification
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 20-41-1
W-2059-0598
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
1 N-18695
The BICS™ section and main control valve are in two separate castings.
Lift and block the loader. (See Procedure Page 10-10-1.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device Page 10-20-1.)
For identification of the hydraulic control valve (1 piece casting) (Advanced Control System) (ACS), (See Identification Page 20-43-1.)
Raise the operator cab. (See Raising The Operator Cab Page 10-30-1.)
Removal And Installation
Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid Page 10-120-2.)
Clean the area around the control valve.
Remove the control panel. (See Removal And Installation Page 50-100-1.)
DANGER
Figure 20-41-2
1
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
P-48872
Remove the right rear tire. Locate and remove the access covers (Item 1) [Figure 20-41-2] on the right side of the machine.
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I-2003-0888
The hydraulic control valve (2 piece casting) (Advance Control System) (ACS) has a removable BICS™ section (Item 1) [Figure 20-41-1].
Figure 20-41-5
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal And Installation (Cont’d) Figure 20-41-3
1
1
P-48881
Remove the tubeline clamp (Item 1) [Figure 20-41-5]. This will allow room to move the auxiliary tubelines away from the control valve.
P-31998
The fixed end main valve hose assembly (Item 1) [Figure 20-41-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.
Dealer Copy -- Not for Resale
Figure 20-41-6
Mark all tubelines and hoses for correct installation.
4
1
NOTE: Remember the hose routing for ease of control valve installation.
2 3
Figure 20-41-4
P-48878
Disconnect the tubeline (Item 1) [Figure 20-41-6] from the lift arm bypass valve. Disconnect the drain hose (Item 2) [Figure 20-41-6] from the control valve.
1
Disconnect the motor case drain hose (Item 3) [Figure 20-41-6] from the lift arm bypass valve.
P-31999
Remove the tie - strap (Item 1) [Figure 20-41-4] from the fixed end main valve hose.
Remove the bolts (Item 4) [Figure 20-41-6] from the lift arm bypass control valve. After removing the lift arm bypass valve mounting bolts move the wire harness and bypass valve towards the engine to give more room for control valve removal.
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Figure 20-41-9
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal And Installation (Cont’d)
1
2
Figure 20-41-7 1
1
3 2
P-48884
Remove the drain tubeline (Item 1) [Figure 20-41-9] from the control valve and BICS™ valve. P-48879
Disconnect the outlet tubeline (Item 2) [Figure 20-41-7] from the control valve.
Disconnect the drain hose (Item 3) [Figure 20-41-9] from the control valve. Figure 20-41-10
Figure 20-41-8 3
2 5
2 1
4
1 P-48883 P-48880
Label and disconnect the actuator electrical connectors (Item 1) [Figure 20-41-8]. Remove the bolt (Item 2) [Figure 20-41-8] from the wire harness clamp. Installation: Tighten the bolt to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the tilt tubeline (Item 1) [Figure 20-41-10] from the bucket positioning valve (if so equipped) and the control valve. Disconnect the lift tubeline (Item 2) [Figure 20-41-10]. Disconnect the tilt tubeline (Item 3) [Figure 20-41-10]. Remove the tilt tubeline (Item 4) [Figure 20-41-10] from the bucket positioning valve and the control valve (if so equipped). Disconnect the tilt tubeline (Item 5) [Figure 20-41-10].
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Label and disconnect the electrical connectors (Item 1) [Figure 20-41-7].
Disconnect the auxiliary tubelines (Item 2) [Figure 20-419].
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
DANGER
Removal And Installation (Cont’d) Figure 20-41-11
1
P-90328
2 •
• P-48876
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Figure 20-41-13
Dealer Copy -- Not for Resale
Disconnect the BICS™ valve electrical connector (Item 1) [Figure 20-41-11]. Disconnect the inlet hose (Item 2) [Figure 20-41-11] from the bottom of the control valve. Figure 20-41-12
1
1
P-48873
Locate and remove the two control valve mounting bolts (Item 1) [Figure 20-41-13] through the right side access panels. P-48884
Connect a hoist (Item 1) [Figure 20-41-12] to the control valve.
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the control valve from the loader.
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Figure 20-41-16
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve Removal And Installation Figure 20-41-14
1
1
1 1 2 1
1
N-18697
1 1 N-18679
Remove the control valve. (See Removal And Installation Page 20-41-1.)
Install the four large O-rings (Item 1) and the small O-ring (Item 2) [Figure 20-41-16] on the top of the control valve.
To remove the BICS™ from the control valve loosen and remove the six mounting bolts (Item 1) [Figure 20-4114]. Figure 20-41-15
N-18695
Remove the BICS™ valve assembly from the top of the control valve [Figure 20-41-15].
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Dealer Copy -- Not for Resale
Remove the four large O-rings (Item 1) and the small Oring (Item 2) [Figure 20-41-16] from the top of the control valve.
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve Removal And Installation (Cont’d) Figure 20-41-17
6
3
2
1 5
4
N-18679
Dealer Copy -- Not for Resale
Install the six mounting bolts [Figure 20-41-17]. The chart below lists the correct torque specifications and tightening sequence when reinstalling the BICS™ valve assembly to the control valve. Thoroughly clean and dry bolts and threads in valve. Use liquid adhesive Loctite® #242 or equivalent. STEP
TORQUE
1
110 - 130 in.-lb. (12,4 - 14,7 N•m)
2
190 - 210 in.-lb. (21,5 - 23,7 N•m)
3
190 - 210 in.-lb. (21,5 - 23,7 N•m)
SEQUENCE
1,2,3,4,5 & 6
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for every bolt or repeat step 3.
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Figure 20-41-19
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation Figure 20-41-18
1
N-18687
1
Figure 20-41-20
Remove the fitting (Item 1) [Figure 20-41-18] from the valve.
1
N-18685
Using a flat blade screw driver, remove the lift arm bypass orifice (Item 1) [Figure 20-41-19] and [Figure 20-41-20]. Orifice size is 2 mm (0.078 in). Reverse the removal procedure to install the lift arm bypass orifice.
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N-18686
Figure 20-41-23
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Check Valve Removal And Installation Figure 20-41-21
1
1
P-8956
Clean and inspect the screen (Item 1) [Figure 20-41-23] on the end of the valve. N-18683
Remove the check valve (Item 1) [Figure 20-41-21].
Dealer Copy -- Not for Resale
Reverse the removal procedure to install the BICS™ check valve.
Installation: Tighten the valve to 20 ft.-lb. (27 N•m) torque. Figure 20-41-22
3
2 1
N-18684
Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-41-22]. Install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-41-22] on the check valve. Check valve (Item 3) [Figure 20-41-22] has a rating of 5 10 psi.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-26
BICS™ Valve Lock Valve Removal And Installation Figure 20-41-24
1 1 1
N-18689
Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m) torque.
Figure 20-41-25
1
N-18688
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N-18682
Remove the lock valves (Item 1) [Figure 20-41-24], [Figure 20-41-25] and [Figure 20-41-26] from the BICS™ valve.
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-29
BICS™ Valve Lock Valve Removal And Installation (Cont’d)
1 1
Figure 20-41-27
1
1 N-18693
2
Remove the O-rings (Item 1) [Figure 20-41-29] from both ends of the solenoid.
2 2
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-27] from both the tilt and lift lock valves.
1
Install new O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-27] on the tilt and lift lock valves. Reverse the removal procedure to install the lock valve. BICS™ Valve Solenoid Removal And Installation Figure 20-41-28
N-18692
1
Remove the solenoid cartridge (Item 1) [Figure 20-4130]. 2
Installation: Tighten the cartridge to 20 ft.-lb. (27 N•m) torque.
N-18691
Remove the mounting nut (Item 1) [Figure 20-41-28] from the solenoid cartridge. Installation: Tighten the mounting nut to 53 in.-lb. (6 N•m) torque. Remove the solenoid (Item 2) [Figure 20-41-28].
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Figure 20-41-30
N-18690
BICS™ Valve Solenoid Testing
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-32
BICS™ Valve Solenoid Removal And Installation (Cont’d) Figure 20-41-31
3 2
P9175
1
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-41-31] from the cartridge. Clean all parts in solvent and dry with compressed air. Inspect all parts for wear and replace any showing excessive wear.
Coil wires do not have polarity. Correct resistance for the BICS™ is 9.7 ± 1 ohm at 20°C. Correct resistance for the tilt and lift lock coils is 7.7 ± 1 ohm at 20°C.
NOTE: The screen (Item 3) [Figure 20-41-31] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-41-29] and [Figure 20-41-31] and new back-up rings (Item 2) [Figure 20-41-31] on the solenoid cartridge.
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Use an ohmmeter to measure coil resistance [Figure 2041-32].
N-18694
Figure 20-41-35
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation NOTE: Actuators can be removed with the control valve in the loader. Remove the lift arm bypass valve to allow room for actuator removal in the loader.
4
Figure 20-41-33
3 2
1
1
N-19114
Remove the actuator (Item 1) [Figure 20-41-35]. Remove the O-ring (Item 2) [Figure 20-41-35].
1 2
Dealer Copy -- Not for Resale
Remove the spacer block (Item 3) [Figure 20-41-35]. Remove the O-ring (Item 4) [Figure 20-41-35]. N-19112
Figure 20-41-36 Remove the two screws (Item 1) [Figure 20-41-33] on the actuator retainer. Installation: Tighten the bolt and nut to 90 - 100 in.-lb. (10,2 - 11,3 N•m) torque. Pull the actuator (Item 2) [Figure 20-41-33] away from the control valve. Figure 20-41-34
N-18940
Repeat removal for the other actuator [Figure 20-41-36]. NOTE: The calibration procedure must be followed when replacing handle sensor, actuator or ACS controller. (See Calibration Procedure Page 60-120-16.)
1
N-19113
Use a drift pin and hammer to remove the actuator pin (Item 1) [Figure 20-41-34] from the actuator and the lift or tilt spool.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-37 H1 H3
Identification Chart (ACS) S150, S160 ACS LOADER
A1
Lift Cylinder Base End / Restrictor
A2
Tilt Cylinder Base End
A3
Auxiliary Hydraulics
B1
Lift Cylinder Rod End
B2
Tilt Cylinder Rod End
B3
Auxiliary Hydraulics
C1
Load Check Valve / Lift Function
C2
Load Check Valve / Tilt Function
C3
Orificed Load Check Valve / Auxiliary Function
C4
Outlet Fluid Flow
D1
Lift Spool Centering Spring
D2
Tilt Spool Centering Spring
D3
Auxiliary Spool / Centering Springs
E1
Port Relief Valve - 3500 psi
E2
Anti-Cavitation / Port Relief Valve - 3500 psi
F1
Anti-Cavitation Valve
F2
Port Relief Valve - 3500 psi
G1
Lift Spool End
G2
Tilt Spool End
G3
Auxiliary Spool / Centering Springs
H1
Auxiliary Electric Solenoid
H2
Plug / Port Relief (Optional) - 3100 psi
H3
Auxiliary Electric Solenoid
MR
Main Relief Valve - 3300 psi
C4 G3
A3
D3
C3 G2
B2
A2
E2
A1
E1
D2
C2
F2
G1 F1
B1
D1
C1 MR
PE1339
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B3
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ITEM
H2
S150, S160 Bobcat Loader Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
IMPORTANT
Lift Base End Restrictor Figure 20-41-38
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
1 Figure 20-41-40
N-21159
Remove the BICS™ valve assembly from the control valve. (See BICS™ Valve Removal And Installation Page 20-41-5.) Remove the restrictor (Item 1) [Figure 20-41-38] from the lift section base end port. Load Check Valve
N-19100
Mark each valve section, spool and related parts so that they will be returned to their original valve section during assembly.
Figure 20-41-39
Use bolts to fasten the control valve to a work bench for easier disassembly and assembly procedures. 1
1
1
Loosen the load check valve plugs (Item 1) [Figure 2041-40].
1
Installation: Always use new O-ring. tighten the plug to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
2 N-19099
Remove the BICS™ valve assembly from the control valve. (See BICS™ Valve Removal And Installation Page 20-41-5.) Remove the four large O-rings (Item 1) and small O-ring (Item 2) [Figure 20-41-39]. Always replace these O-rings before installing the BICS™ valve assembly
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1
Main Relief Valve
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-43
Load Check Valve (Cont’d) Figure 20-41-41
1
1
N-19034
3 Loosen the main relief valve (Item 1) [Figure 20-41-43].
N-19101
Remove the load check plugs (Item 1) [Figure 20-41-41].
Figure 20-41-44
Dealer Copy -- Not for Resale
2
Remove the spring (Item 2) and poppet (Item 3) [Figure 20-41-41]. Figure 20-41-42 1 1
N-19035
Remove the main relief valve (Item 1) [Figure 20-41-44]. 2
N-19102
The auxiliary section (Item 1) uses an orifice load check poppet (Item 2) [Figure 20-41-42].
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Figure 20-41-47
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Main Relief Valve (Cont’d) Figure 20-41-45
1 2
3
4
5
1 B-06764
1. Relief Valve 2. O-ring 3. Sleeve 4. Glide Ring 5. O-ring
N-19034
CD-15092
Remove the O-rings, sleeve, and glide ring from the main relief valve [Figure 20-41-45]. Installation: Always use new O-rings, sleeve, and glide ring. TIghten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Installation: Always use new O-rings and back-up washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque. Figure 20-41-48
Port Relief Valve Figure 20-41-46
1
1
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-48].
N-19000
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Loosen the port relief valve (Item 1) [Figure 20-41-46] and [Figure 20-41-47] (Port E1 or F2). (See Identification Chart (ACS) Page 20-41-13.)
Figure 20-41-51
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Port Relief Valve (Cont’d) Figure 20-41-49 4
1
3 2 1 1. O-ring 2. Back-up Washer 3. O-ring 4. Relief Valve
N-18980
Remove the anti-cavitation / port relief valve (Item 1) from the control valve for the tilt section [Figure 20-41-51].
N-18844
Dealer Copy -- Not for Resale
Remove the O-rings and back-up washer from the port relief valve [Figure 20-41-49].
Installation: Always use new O-rings and back-up washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque. Figure 20-41-52
Anti-Cavitation Valve / Port Relief Valve Figure 20-41-50 1
1
N-18843
Remove the O-rings (Item 1) [Figure 20-41-52] from the anti-cavitation / port relief valve.
N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-4150].
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-55 1
Anti-Cavitation Valve
2
3
4
Figure 20-41-53 E-1509A
1 1. Anti-Cavitation Valve 2. O-ring 3. Back-up Washer 4. O-ring N-18839
Remove the O-rings and back-up washer from the anticavitation valve [Figure 20-41-55]. N-19034
Tilt Spool Removal And Installation Figure 20-41-54
Dealer Copy -- Not for Resale
Figure 20-41-56
1
1 N-19036
N-19112
Remove the anti-cavitation valve (Item 1) [Figure 20-4153] and [Figure 20-41-54] from the control valve.
Remove the actuator (Item 1) [Figure 20-41-56] from the control valve. (See Actuator Removal And Installation Page 20-41-12.)
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Lift Spool Removal And Installation
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-59
Tilt Spool Removal And Installation (Cont’d) Figure 20-41-57
1
1
1 N-19112
Remove the screws (Item 1) [Figure 20-41-57] from the cap.
Remove the actuator (Item 1) [Figure 20-41-59] from the control valve. (See Actuator Removal And Installation Page 20-41-12.) Figure 20-41-60
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. Figure 20-41-58 1 1
1
N-19003
Remove the screws (Item 1) [Figure 20-41-60] from the end cap. N-18983
Remove the spool assembly (Item 1) [Figure 20-41-58] and seal from the control valve.
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque.
Assembly: Always use a new spool seal.
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N-19003
Figure 20-41-63
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal And Installation (Cont’d) Figure 20-41-61
1
1
N-19014
Remove the bolt (Item 1) [Figure 20-41-63] holding the centering spring to the spool. N-18985
Assembly: Always use a new spool seal.
Dealer Copy -- Not for Resale
Remove the spool assembly (Item 1) [Figure 20-41-61] and seal from the control valve.
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. Remove spring tool from the spring assembly. Figure 20-41-64
Lift and Tilt Spool Disassembly And Assembly Figure 20-41-62
3
2
1
4 1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3), and washer (Item 4) [Figure 20-41-64].
N-18942
Put the linkage end of the spool in the vice [Figure 2041-62]. Install the spool tool (Item 1) [Figure 20-41-62] over the centering spring.
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Figure 20-41-67
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift and Tilt Spool Disassembly And Assembly (Cont’d)
4 3
Figure 20-41-65
2
1
2 1
N-18987
1 Remove the end cap (Item 1), O-ring (Item 2) springs (Item 3) and washer (Item 4) [Figure 20-41-67] (both sides). N-18930
N-18943
Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-41-65].
Dealer Copy -- Not for Resale
Assembly: Always use a new spool seal. Figure 20-41-68
Assembly: Always use a new spool seal. Auxiliary Spool Removal And Installation
1
Figure 20-41-66
N-18988
1 Remove the spool (Item 1) [Figure 20-41-68].
Assembly: Put grease on all the centering spring component parts. N-19003
Remove the screws (Item 1) [Figure 20-41-66] from the end cap (both sides). Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque.
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Figure 20-41-71
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Auxiliary Electric Solenoid Figure 20-41-69
3
2 1
N-18992
1
Remove the coil (Item 1) and end plate (Item 2) [Figure 20-41-71].
1 N-18996
Remove the nut (Item 1) [Figure 20-41-69] from both solenoids.
Installation: Tighten valve to 96 - 144 in.-lb. (11 - 16 N•m) torque.
Installation: Tighten the nut to 96 - 144 in.-lb. (11 - 16 N•m) torque.
Figure 20-41-72
Figure 20-41-70
2 1 1
N-18795
Remove the O-rings (Item 1) [Figure 20-41-72] from the solenoid valves.
N-18823
Remove the end plate (Item 1) and housing (Item 2) [Figure 20-41-70].
Installation: Always use new O-rings and apply oil to the O-rings prior to installation.
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Remove the solenoid valve (Item 3) [Figure 20-41-71].
Figure 20-41-75
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Port-Auxiliary Section Figure 20-41-73
2
1
1
N-18843
1
Remove the O-rings (Item 1) [Figure 20-41-74] and [Figure 20-41-75] and back-up ring (Item 2) [Figure 2041-74] and [Figure 20-41-75] from the plug.
Remove the plug (Item 1) [Figure 20-41-73] or optional port relief valve from the control valve. Figure 20-41-74
Cleaning And Inspection Clean all components with clean solvent and dry with compressed air. Check the spools for wear or scratches.
Plug
Check that the spools are not loose in their bore. Check that the centering springs are not broken.
2
Check that the load check valve seats are not worn. Check the load check poppets for damage. Check the rubber boots and retainers.
1
Replace the parts as needed.
1 N-18800
Use new O-rings and back-up rings. Apply oil to all new O-rings and back-up rings before installation.
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N-18996
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)
WARNING
Identification
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 20-42-1
W-2059-0598
1
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
P-51436
The BICS™ section and main control valve are in one casting. For identification of the hydraulic control valve (2 piece casting) (foot control), (See Identification on Page 20-401.)
Lift and block the loader. ((See Procedure on Page 1010-1.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Clean the area around the control valve.
Removal And Installation
Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Remove the control panel. (See Removal And Installation on Page 50-100-1.)
DANGER
Figure 20-42-2
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
1
P-34004
Remove the right rear tire. Locate and remove the access covers (Item 1) [Figure 20-42-2] on the right side of the machine.
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I-2003-0888
The hydraulic control valve (1 piece casting) (foot control) (Item 1) [Figure 20-42-1] does not have a removable BICS™ section.
Figure 20-42-5
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT’D)
4
Removal And Installation (Cont’d) 2
Figure 20-42-3
1
3
1
1
P-51714
Mark and disconnect the four electric solenoid connectors for correct installation (Item 1) [Figure 20-425].
P-51710
Mark all tubelines and hoses for correct installation. The fixed end main valve hose (Item 1) [Figure 20-42-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.
Disconnect and cap the supply hose (Item 3) and the supply hose clamp (Item 4) [Figure 20-42-5]. Figure 20-42-6 1
NOTE: Remember the hose routing for ease of control valve installation. Figure 20-42-4 2
P-51715
1 Disconnect and cap the tubeline (Item 1) [Figure 20-426] from the lift arm bypass valve to the control valve. Disconnect and cap the hose (Item 2) [Figure 20-42-6] from the lift arm bypass valve to the drive motor case drain.
P-31999
Remove the tie-strap (Item 1) [Figure 20-42-4] from the fixed end main valve hose.
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Remove the outlet tubeline (Item 2) [Figure 20-42-5] from the control valve to the hydraulic oil cooler.
Figure 20-42-9
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal And Installation (Cont'd) Figure 20-42-7
1
1
1
P-48287
Remove the connector pins (Item 1) [Figure 20-42-9].
Remove the tie-strap (Item 1) [Figure 20-42-7] from the main valve mounting bracket. 1
Figure 20-42-8
2
P-51723
1 Remove the wire harness clamp bolt (Item 1) [Figure 2042-10]. Remove the control pedal crossbar linkage and tilt linkage. (See CONTROL PEDALS on Page 50-90-1.)
P-51724
Disconnect the wire harness tie-strap mounts (Item 1) [Figure 20-42-8] from the lift arm bypass bracket. Remove the lift arm bypass tubeline (Item 2) [Figure 2042-8] from the control valve drain.
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Figure 20-42-10
P-51719
Figure 20-42-13
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT’D) Removal And Installation (Cont'd) Figure 20-42-11
2
1
1
1
P-51714
Remove and cap both tubelines (Item 1) [Figure 20-4213] from the auxiliary section of the control valve. P-51721
Dealer Copy -- Not for Resale
Remove the two lift arm bypass valve mounting bolts (Item 1) [Figure 20-42-11].
Disconnect and cap the drain hose (Item 2) [Figure 2042-13] from the control valve. Figure 20-42-14
Remove the lift arm bypass valve and mounting bracket. Figure 20-42-12 1 1 2 3
P-51729
Disconnect and cap the tubelines (Item 1) and (Item 2) [Figure 20-42-14] from the tilt section of the control valve.
P-51727
Remove tubeline clamp bolt (Item 1) [Figure 20-42-12] from the auxiliary tubelines in the left rear upright.
Disconnect and cap the tubeline (Item 3) [Figure 20-4214] from the lift section of the control valve.
Installation: Tighten bolt to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
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Figure 20-42-17
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Removal And Installation (Cont'd) Figure 20-42-15
1
1
P-51726
1 Connect a hoist to the lifting brackets (Item 1) [Figure 2042-17] on the control valve. P-51728
Remove the fixed-end main valve hose (Item 1) [Figure 20-42-15] from the main control valve fitting. Figure 20-42-16
1
1
P-34004PP-51713 51713
Remove the two mounting bolts (Item 1) [Figure 20-4218] fastening the control valve and bracket to the side of the loader.
P-51722
Mark and disconnect the BICS™ electric solenoid connector (Item 1) [Figure 20-42-16].
Remove the control valve from the loader. Reverse procedure for installation.
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Figure 20-42-18
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Identification Chart Figure 20-42-19
C2 D5
J2
C3
J4
B3
E3 G1
G2
F2
A3
B2
D4
E3
D3 E2
F4 A2
D1
D2 F1
F3
H2
B1 MR
C1 H1
E1 H3
J3
J1
MS1926
ITEM
S150 / S160 LOADER
ITEM
S150 / S160 LOADER
A1 A2 A3 B1 B2 B3 C1
Lift Cylinder Base End Tilt Cylinder Base End Auxiliary Hydraulic Rod End Lift Cylinder Rod End Tilt Cylinder Rod End Auxiliary Hydraulics Base End Load Check / BICS™ Valve Lift Load Check Valve Tilt Function Load Check Valve Auxiliary Function Anti-Cavitation Valve Lift (Rod End) Port Relief / Anti-Cavitation Valve – 3500 PSI Lift (Base End) Port Relief / Anti-Cavitation Valve – 3500 PSI Tilt (Base End) Port Relief / Anti-Cavitation Valve – 3500 PSI Tilt (Rod End) Port Relief / Anti-Cavitation Valve (Auxiliary) 3500 PSI (Optional)
E1 E2 E3 F1 F2 F3 F4 G1 G2 H1
Lift Spool Detent Tilt Spool Centering Spring Auxiliary Spool / Centering Springs LIft Spool Tilt Spool Lift Spool Lock Solenoid Tilt Spool Lock Solenoid Auxiliary Solenoid Stem Auxiliary Solenoid Stem
H2
BICS™ Lock Valve (Tilt)
H3
BICS™ Lock Valve (Lift)
J1 J2 J3 J4 MR
Inlet Fluid Flow (From Pump) Outlet Fluid Flow (Return to Tank) Lift Arm Bypass Orifice Drain (Case) Main Relief Valve – 3300 PSI
C2 C3 D1 D2 D3 D4 D5
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A1
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
BICS™ Valve, Lift Load Check Valve Removal And Installation
Mount Bracket Removal And Installation
Figure 20-42-22
Figure 20-42-20
1
P-51438
1 P-51690
Figure 20-42-21
Installation: Lubricate the O-ring and tighten the valve to 55 - 65 ft.-lb. (75 - 88 N•m) torque. Figure 20-42-23
1
2 1 2
2 P-51435
P-51439
Disconnect the tubeline (Item 1) [Figure 20-42-21] from the inlet fitting on the control valve. Remove the two mount bolts (Item 2) [Figure 20-42-21] from the control valve mount plate. Remove the mount plate and tubeline.
Remove and install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-42-23].
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Remove the control valve and mount bracket (Item 1) [Figure 20-42-20] from the loader.
Remove the lift load check valve (Item 1) [Figure 20-4222].
Figure 20-42-26
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve, Lift Load Check Valve Removal And Installation (Cont’d)
4
Figure 20-42-24 1
1 3
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure 20-42-26].
Check for free movement of the load check valve (Item 1) [Figure 20-42-24]. Load Check Valve Removal And Installation (Tilt And Auxiliary)
Installation: Install a new O-ring (Item 4) on the plug and lightly lubricate with oil before installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
Figure 20-42-25
2
1
P-51691
At the front side of the control valve locate the tilt section load check valve (Item 1) [Figure 20-42-25]. At the front side of the control valve locate the auxiliary section load check valve (Item 2) [Figure 20-42-25]. NOTE: The tilt and auxiliary load check valves are interchangeable.
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Check the orifice (Item 3) [Figure 20-42-26] in the poppet to be sure it is not plugged.
P-51440
Figure 20-42-29
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Anti-Cavitation Valve (Lift, Rod End)
4
Figure 20-42-27
1 3
1
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure 20-42-29]. P-51692
At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-42-27].
IMPORTANT
Installation: Install a new O-ring (Item 4) [Figure 20-4229] on the plug and lightly lubricate with oil before installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Figure 20-42-28
1 P-51693
Installation: Always use new O-ring (Item 1) [Figure 2042-28] on the anti-cavitation valve plug. Tighten the plug to 35 - 40 ft.-lb. (47 - 54 N•m) torque. 20-42-9 199 of 949
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Check the orifice (Item 3) [Figure 20-42-29] in the poppet to be sure it is not plugged.
Port Relief / Anti-Cavitation Valve (Tilt, Base End)
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-32
Port Relief / Anti-Cavitation Valve (Lift, Base End) Figure 20-42-30
1
1 P-51692
Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-42-32] from the base end of the tilt section.
Loosen the lift circuit port relief / anti-cavitation valve (Item 1) [Figure 20-42-30].
Figure 20-42-33
Dealer Copy -- Not for Resale
P-51692
Figure 20-42-31
1
P-51454
1
Replace the O-ring (Item 1) [Figure 20-42-33] before installation.
P-51451
Replace the O-ring (Item 1) [Figure 20-42-31] before installation.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
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Port Relief Valve
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-36
Port Relief / Anti-Cavitation Valve (Tilt, Rod End) Figure 20-42-34
1
1
P-51692
Remove the port relief plug (Item 1) [Figure 20-42-36] from the auxiliary circuit of the control valve.
Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-42-34] from the rod end of the tilt section.
Figure 20-42-37
Dealer Copy -- Not for Resale
P-51692
Figure 20-42-35
1 1
P-51695
Installation: Always use new O-rings (Item 1) [Figure 20-42-37]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
P-51694
Replace the O-ring (Item 1) [Figure 20-42-35] before installation. Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
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Plug Removal
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-40
Port Relief Valve (Cont’d) Figure 20-42-38
1
1
P-51459
At the top side of the control valve, remove the plug (Item 1) [Figure 20-42-40].
The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-42-38].
Figure 20-42-41
Dealer Copy -- Not for Resale
P-51696
Remove the auxiliary port relief valve. Figure 20-42-39
1
1 P-51460
Installation: Always use new O-rings (Item 1) [Figure 20-42-41]. Tighten to 40 ft.-lb. (54 N•m) torque. P-51640
Installation: Always use new O-rings (Item 1) [Figure 20-42-39]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
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Rubber Boot Removal And Installation
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-44
Plug Removal (Cont’d)
1
Figure 20-42-42
1
1
P-51506
1
At the bottom side of the control valve remove the plug (Item 1) [Figure 20-42-42].
Installation: Tighten the screws to 90 - 100 in.-lb. (10 11,3 N•m) torque.
Figure 20-42-43
Figure 20-42-45
1
2
1 1
P-51462
P-51701
Installation: Always use new O-rings (Item 1) [Figure 20-42-43]. Tighten to 40 ft.-lb. (54 N•m) torque.
Remove the rubber boots (Item 1) from the retainer plate (Item 2) [Figure 20-42-45].
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Remove the three screws (Item 1) [Figure 20-42-44] on the rubber boot retainer plate.
P-51461
Figure 20-42-48
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) End Cap / Spool Lock Block Removal And Installation Figure 20-42-46
1
1
2 1 P-51699
1 Remove the four end cap / spool lock block mount screws (Item 1) [Figure 20-42-48].
Remove the lift spool lock solenoid (Item 1) and the tilt spool lock solenoid (Item 2) [Figure 20-42-46] from the end cap / spool lock block.
Remove the rubber boots and retainer plate from the lift and tilt spools. Figure 20-42-49
Figure 20-42-47
1
1 P-51700 P-51698
Disconnect the tube line (Item 1) [Figure 20-42-47] from the end cap / spool lock block.
Remove the end cap / spool lock block (Item 1) [Figure 20-42-49] from the control valve.
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Installation: Tighten the screws to 90 - 100 in.-lb. (10 11,3 N•m) torque.
P-51697
Figure 20-42-52
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation The tool listed will be needed to do the following procedure: MEL1278 - Detent Tool MEL1285 - Detent Spring Tool
1
Remove the end cap / spool lock block from the control valve. Figure 20-42-50 P-51513
Remove the end cap (Item 1) [Figure 20-42-52]. Figure 20-42-53
P-51511
1 2
Remove the O-ring (Item 1) [Figure 20-42-50]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the end cap / spool lock block. Figure 20-42-51
P-51514
Use a screwdriver to remove the snap ring (Item 1) [Figure 20-42-53]. Remove the washer (Item 2) [Figure 20-42-53].
2 1
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-51] from the lift spool.
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1
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-56
Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-42-54
2
1
3
1 2
Remove the detent sleeve (Item 1), detent balls (Item 2) and spring (Item 3) [Figure 20-42-56].
2 P-51515
Figure 20-42-57
Remove the screws (Item 1) [Figure 20-42-54] from the detent bonnet. Remove the detent bonnet (Item 2) [Figure 20-42-54]. Installation: Lubricate the screws and tighten to 90 - 100 in.-lb. (10 - 11,3 N•m) torque.
IMPORTANT The detent assembly has small springs and balls. Do not lose these parts during disassembly and assembly.
1 P-51518
I-2012-0284
Remove the lift spool assembly and seal (Item 1) [Figure 20-42-57] from the control valve.
Figure 20-42-55
P-51516
Put a rag around the detent assembly [Figure 20-42-55]. This will prevent the detent balls and spring from being lost when the detent sleeve is removed. 20-42-16 206 of 949
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1
P-51517
Figure 20-42-60
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
2 Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-42-58
1 3
N-18915
1
P-51519
Remove the lift spool seal (Item 1) [Figure 20-42-58] from the linkage end of the valve. Figure 20-42-59
NOTE: Be careful when removing the detent adapter (Item 2) [Figure 20-42-60] from the centering spring, as it is under spring pressure. NOTE: The centering spring (Item 3) [Figure 20-42-60] is white on all 700 series loaders. Figure 20-42-61
1 P-8988
2 N-18916
Clamp the linkage end of the spool in a vise [Figure 2042-59]. NOTE: Protect spool before clamping in vise.
Put a rag around the detent assembly [Figure 20-42-61]. This will prevent the detent balls and spring from being lost when the detent adapter is removed. Remove the detent adapter with an Alan wrench. Remove the back-up washer (Item 1) and spool seal (Item 2) [Figure 20-42-61].
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Install the spring tool (Item 1) [Figure 20-42-60] over the centering spring.
Figure 20-42-64
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd)
2
1
3 Figure 20-42-62 4
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-42-64].
Remove the detent adapter (Item 1) [Figure 20-42-62] from the spring assembly. Figure 20-42-63 1
N-18918
Remove the stud from the end of the spool [Figure 2042-65]. N-19009
Remove spring tool (Item 1) [Figure 20-42-63] from the spring assembly.
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Figure 20-42-65
N-19004
Figure 20-42-68
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-42-66
N-18963
1 Install the plastic plug and O-ring in the spool [Figure 2042-68].
Removal of the plastic plug:
O-ring
Make a center point in the plug using a 1/16 inch drill. Drill a hole all the way through the plug using a 7/64 inch tap drill Turn a 6-32 tap (Item 1) [Figure 20-42-66] into the plug. Pull the tap and plug out of the spool. Be careful, do not break the tap.
Plastic Plug
Clean all the debris from inside the spool bore. NOTE: DO NOT USE Loctite® ON THE STUD THREADS. Figure 20-42-67
0.60 in. (15,2 mm) B-14712
Install the stud and tighten until the other end of the stud is out about 0.600 in. (15,2 mm) from the spool [Figure 20-42-69]. 2 1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic plug (Item 2) [Figure 20-42-67].
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Figure 20-42-69
N-18920
Figure 20-42-72
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-42-70
1 1
N-18968
Clamp the collar (Item 1) [Figure 20-42-70] in a vice.
NOTE: The collar and the detent adapter are held together by spring pressure when assembled to the lift spool not the detent balls. Hold the detent adapter and collar together to prevent the detent balls and spring from falling out.
Figure 20-42-71
Figure 20-42-73
N-18967
2 1
1
3 2 N-18958
N-19004
Apply grease on all the detent component surfaces before assembly [Figure 20-42-71].
Install the spring tool (Item 1) [Figure 20-42-73] over the washer, spring, collar and detent adapter.
Install the spring (Item 1) and detent balls (Item 2) into the adapter (Item 3) [Figure 20-42-71] and compress with the detent pliers (Item 1) [Figure 20-42-72].
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Install the detent adapter to the collar [Figure 20-42-72].
Figure 20-42-76
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-42-74
2
CD-15051
1 Install the detent balls and spring [Figure 20-42-76]. Figure 20-42-77
Install the spool seal (Item 1) and back-up washer (Item 2) [Figure 20-42-74]. Figure 20-42-75
1 N-19007
Hold the detent balls in place with the detent pliers [Figure 20-42-77].
N-19005
Install the spring assembly to the lift spool hand tight [Figure 20-42-75]. Remove the spring tool. Check the alignment of the detent adapter and the washer. Tighten the adapter to 90 - 100 in.-lb. (10,2 - 11,3 N•m). NOTE: The adapter must fit in the center of the washer (Item 1) [Figure 20-42-75].
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N-18917
Figure 20-42-80
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd) Figure 20-42-78
2 1 1 P-51514
Install the washer (Item 1) and snap ring (Item 2) [Figure 20-42-80].
Install the detent sleeve (Item 1) [Figure 20-42-78] to the detent adapter. Figure 20-42-79 1
2 P-51513
1 Install the end cap (Item 1) [Figure 20-42-81]. 2 P-51515
Install the lift spool assembly in the spool bore [Figure 20-42-79]. Install the detent bonnet (Item 1) [Figure 20-42-79]. Install the mounting screws (Item 2) [Figure 20-42-79]. Installation: Lubricate the screws and tighten to 90 - 100 in.-lb. (10 - 11,3 N•m) torque.
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Figure 20-42-81
N-19008
Figure 20-42-84
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd)
1
Figure 20-42-82
1
P-51511
Install the O-ring (Item 1) [Figure 20-42-84] on the control valve.
Install the spool seal (Item 1) [Figure 20-42-82] on the linkage end of the valve.
2
Figure 20-42-83 1
3
4
1
Install the end cap / spool lock block (Item 1) and the mount bolt (Item 2) [Figure 20-42-85].
2
P-51512
Install the O-ring (Item 1) and bushing (Item 2) [Figure 20-42-83] on the lift spool.
Install the lift and tilt spool rubber boots and mount plate (Item 3) and install the three mounting screws (Item 4) [Figure 20-42-85]. Installation: Tighten the screws to 90 - 100 in.-lb. (10 11,3 N•m) torque.
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P-51701
S150/S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Figure 20-42-85
P-51520
Tilt Spool Removal And Installation
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Lift Spool And Detent Removal And Installation (Cont'd)
Remove the lift and tilt end cap / spool lock block. (See End Cap / Spool Lock Block Removal And Installation on Page 20-40-14.)
Figure 20-42-86
Figure 20-42-88
1 1
2
P-51698
Connect the tubeline (Item 1) [Figure 20-42-86].
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-88] from the tilt spool.
Figure 20-42-87
Figure 20-42-89
2 1 1
1
P-51697
P-51522
Use an ohmmeter to measure the lock solenoid coils resistance. The correct resistance for the coil is 5.5 ± 0.28 ohm. Installation: Install the lift spool (Item 1) and tilt spool (Item 2) [Figure 20-42-87] lock solenoids and tighten to 35 - 45 ft.-lb. (52 - 61 N•m) torque.
Remove the three screws (Item 1) [Figure 20-42-89] from the spool centering block. Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3 N•m) torque.
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P-51521
Figure 20-42-92
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Tilt Spool Removal And Installation (Cont'd)
1
Figure 20-42-90
2
N-18942
Put the linkage end of the spool in the vice [Figure 2042-92].
1 P-51543
Dealer Copy -- Not for Resale
Remove the spool centering block (Item 1) [Figure 2042-90] from the control valve.
Install the spool tool (Item 1) [Figure 20-42-92] over the centering spring. Figure 20-42-93
Check and replace the O-ring (Item 2) [Figure 20-42-90] before replacing the spool centering block. 1
Figure 20-42-91
N-19014
Remove the bolt (Item 1) [Figure 20-42-93] holding the centering spring to the spool. P-51544
Remove the tilt spool, centering spring, back-up washer and spool seal [Figure 20-42-91].
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. Remove spring tool from the spring assembly.
Assembly: Always use a new spool seal.
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Auxiliary Spool Removal And Installation
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-96
Tilt Spool Removal And Installation (Cont'd) Figure 20-42-94
2 2
1 1
3 4 1
P-51522
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-42-94].
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3 N•m) torque.
Figure 20-42-95
Remove the spool centering block (Item 2) [Figure 2042-96] from the control valve. 2 Figure 20-42-97
1
1
2 1
P-51545
N-18943
Remove the spool seal(s) (Item 1) [Figure 20-42-95] and the back-up washer (Item 2) [Figure 20-42-95]. Assembly: Always use a new spool seal.
P-51546
Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-42-97] from the auxiliary spool. Note:
20-42-26 216 of 949
If the centering spring retainer (Item 2) [Figure 20-42-97] must be replaced, replace the retainer on the opposite end also.
S150/S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Remove the three screws (Item 1) [Figure 20-42-96] from the spool centering block.
N-18944A
Figure 20-42-100
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Auxiliary Spool Removal And Installation (Cont’d) Figure 20-42-98
1
2
1 P-51550
2
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-100] from the auxiliary spool. P-51547
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-42-98] from the auxiliary spool. Figure 20-42-99 1
2
1 P-51551
Remove the spool (Item 1) [Figure 20-42-101]. P-51549
Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-42-99] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-42-99] must be replaced, replace the retainer on the opposite end also.
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Figure 20-42-101
Figure 20-42-104
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) Auxiliary Solenoid Disassembly And Assembly Figure 20-42-102
1
1 1
P-51703
Remove the solenoid stem (Item 1) [Figure 20-42-104]. Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19 N•m) torque.
Remove the nut (Item 1) [Figure 20-42-102] from both solenoids.
Figure 20-42-105
Dealer Copy -- Not for Resale
P-51702
Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m) torque. Figure 20-42-103 1
1 2 2 P-51555
Remove the O-rings (Item 1) [Figure 20-42-105] from the solenoid stem. Check and clean the screen (Item 2) [Figure 20-42-105].
P-51553
Remove the nut (Item 1) and solenoid coil (Item 2) [Figure 20-42-103]. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 4.9 ± 0.25 ohm.
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Figure 20-42-108
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve Solenoid Disassembly And Assembly Figure 20-42-106
1 1
2 P-51445
Remove the solenoid stem (Item 1) [Figure 20-42-108]. Installation: Lubricate the O-rings and tighten the stem to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Remove the nut (Item 1) [Figure 20-42-106] from the solenoid stem.
Figure 20-42-109
Dealer Copy -- Not for Resale
P-51444
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque. Remove the solenoid coil (Item 2) [Figure 20-42-106].
3 2
Figure 20-42-107
1 1 1 N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-109] from the cartridge. Clean all parts in solvent and dry with compressed air. N-18693A
Inspect all parts for wear and replace any showing excessive wear. Remove the O-rings (Item 1) [Figure 20-42-107] from both ends of the solenoid coil. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 9.79 ± 0.29 ohm.
NOTE: The screen (Item 3) [Figure 20-42-109] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-42-107] and [Figure 20-42-109] and new back-up rings (Item 2) [Figure 20-42-109] on the solenoid stem.
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Figure 20-42-112
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve, Lock Valve Removal And Installation Figure 20-42-110
1 1 1 2
1
1 2 2 2 P-51564
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-112] from the lift lock valve, and replace with new.
P-51704
Dealer Copy -- Not for Resale
Locate the two BICS™ lock valves, (Item 1) is for the tilt circuit and (Item 2) [Figure 20-42-110] is for the lift circuit. Figure 20-42-111
1
P-51443
Remove the lift lock valve (Item 1) [Figure 20-42-111] from the back of the control valve. Installation: Lightly lubricate the lock valve O-rings and tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
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Figure 20-42-115
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D) BICS™ Valve, Lock Valve Removal And Installation (Cont’d) Figure 20-42-113
1 1 P-51706
Remove the tilt lock valve (Item 1) [Figure 20-42-115] from the front of the control valve.
Locate the tilt circuit lock valve (Item 1) [Figure 20-42113].
Dealer Copy -- Not for Resale
Installation: Lightly lubricate the lock valve O-rings and tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
P-51705
Figure 20-42-116
Figure 20-42-114 1 1 1
2
1 2 1
2 2 P-51564
P-51697P51504
Remove the lift spool lock solenoid (Item 1) [Figure 2042-114].
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-42-116] from the tilt lock valve, and replace with new.
Remove the tilt spool lock solenoid (Item 2) [Figure 2042-114]. Installation: Lubricate the O-rings and tighten the spool lock solenoids to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
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Figure 20-42-119
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
1
BICS™ Valve, Check Valve Removal And Installation Figure 20-42-117
2 3
1
4 P-51447
Check that there is no blockage in the orifice (Item 1) [Figure 20-42-119]. P-51438
Remove the BICS™ valve (Item 1) [Figure 20-42-117]. Installation: Lubricate the O-ring and tighten the valve to 55 - 65 ft.-lb. (75 - 88 N•m) torque.
Replace the O-ring (Item 4) [Figure 20-42-119] on the plug before installation.
Figure 20-42-118
1
P-51446
Remove the plug (Item 1) [Figure 20-42-118] from the top of the BICS™ valve.
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Inspect the check valve (Item 2) and spring (Item 3) [Figure 20-42-119].
Main Relief Valve
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Figure 20-42-122
BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly Figure 20-42-120
1
P-51707
1
Remove the main relief valve (Item 1) [Figure 20-42122].
Remove the fitting (Item 1) [Figure 20-42-120] from the valve.
Figure 20-42-123
Dealer Copy -- Not for Resale
P-51436
Figure 20-42-121
1 1 P-51463
Remove the O-rings from the main relief valve (Item 1) [Figure 20-42-123].
P-51437
Check the lift arm bypass orifice (Item 1) [Figure 20-42121].
Installation: Always use new O-rings. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
NOTE: This orifice is not removable from the valve casting.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)
WARNING
Identification
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 20-43-1
W-2059-0598
1
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
P-51730
The BICS™ section and main control valve are in one casting. For identification of the hydraulic control valve (2 piece casting) (ACS), (See Identification on Page 20-41-1.)
Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Clean the area around the control valve.
Removal And Installation
Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.)
DANGER
Remove the control panel. (See Removal And Installation on Page 50-100-1.) Figure 20-43-2
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
1
P-34004
Remove the right rear tire. Locate and remove the access covers (Item 1) [Figure 20-43-2] on the right side of the machine.
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I-2003-0888
The hydraulic control valve (1 piece casting) (ACS) (Item 1) [Figure 20-43-1] does not have a removable BICS™ section.
Figure 20-43-5
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
4
Removal And Installation (Cont’d) Figure 20-43-3
1
1
2 3
1
P-51975
P-51710
Remove the outlet tubeline (Item 2) [Figure 20-43-5] from the control valve to the hydraulic oil cooler.
Mark all tubelines and hoses for correct installation. The fixed end main valve hose (Item 1) [Figure 20-43-3] is connected to a fixed end fitting on the control valve. The hose is routed to the back upright where the hose is connected to a tee fitting that feeds the base end of both lift cylinders. The hose must be removed at the back tee fitting, located in the right side upright.
Disconnect and cap the supply hose (Item 3) and the supply hose clamp (Item 4) [Figure 20-43-5]. Figure 20-43-6 1
NOTE: Remember the hose routing for ease of control valve installation. Figure 20-43-4 3 2
P-51976
1 Disconnect and cap the tubeline (Item 1) [Figure 20-436] from the lift arm bypass valve to the control valve. Disconnect and cap the hose (Item 2) [Figure 20-43-6] from the lift arm bypass valve to the drive motor case drain.
P-31999
Remove the tie-strap (Item 1) [Figure 20-43-4] from the fixed end main valve hose.
Remove the lift arm bypass tubeline (Item 3) [Figure 2043-6] from the control valve drain.
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Mark and disconnect the two auxiliary electric solenoid connectors (Item 1) [Figure 20-43-5] for correct installation.
Figure 20-43-9
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal And Installation (Cont'd) Figure 20-43-7
1 1
P-51983
Disconnect the connectors (Item 1) [Figure 20-43-9] from the lift and tilt actuators. P-51719
Dealer Copy -- Not for Resale
Remove the tie-strap (Item 1) [Figure 20-43-7] from the main valve mounting bracket. Figure 20-43-8
1
P-51977
Disconnect the wire harness tie-strap mounts (Item 1) [Figure 20-43-8] from the lift arm bypass bracket.
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Figure 20-43-12
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal And Installation (Cont'd) Figure 20-43-10
1
1
2
1
P-51980
Remove and cap both tubelines (Item 1) [Figure 20-4312] from the auxiliary section of the control valve. P-51721
Dealer Copy -- Not for Resale
Remove the two lift arm bypass valve mounting bolts (Item 1) [Figure 20-43-10].
Disconnect and cap the drain hose (Item 2) [Figure 2043-12] from the control valve. Figure 20-43-13
Remove the lift arm bypass valve and mounting bracket. Figure 20-43-11 2 1 1
3
P-51982
Disconnect and cap the tubelines (Item 1) and (Item 2) [Figure 20-43-13] from the tilt section of the control valve.
P-51727
Remove tubeline clamp bolt (Item 1) [Figure 20-43-11] from the auxiliary tubelines in the left rear upright.
Disconnect and cap the tubeline (Item 3) [Figure 20-4313] from the lift section of the control valve.
Installation: Tighten bolt to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
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Figure 20-43-16
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Removal And Installation (Cont'd) Figure 20-43-14
1
1
P-51726
1 Connect a hoist to the lifting brackets (Item 1) [Figure 2043-16] on the control valve. P-51728
Remove the fixed-end main valve hose (Item 1) [Figure 20-43-14] from the main control valve fitting. Figure 20-43-15 1
1
P-31999 P-34004P51713
Remove the two mounting bolts (Item 1) [Figure 20-4317] fastening the control valve and bracket to the side of the loader.
P-51722
Mark and disconnect the BICS™ electric solenoid connector (Item 1) [Figure 20-43-15].
Remove the control valve from the loader. Reverse procedure for installation.
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Figure 20-43-17
Figure 20-43-20
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation (Out Of Loader) Remove the control valve from the loader. Figure 20-43-18
1 1
P-51734
1 Using a drift pin and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-43-20] from the actuator and the tilt spool.
Remove the two mount bolts (Item 1) [Figure 20-43-18] from the tilt actuator.
Dealer Copy -- Not for Resale
Remove the actuator and linkage pin from the valve.
P-51732
Figure 20-43-21
Installation: Tighten the mounting bolts to 90 - 100 in.-lb. (10,2 - 11,3 N•m) torque. 1
Figure 20-43-19
2 1
P-51736
Inspect the O-ring (Item 1) [Figure 20-43-21] on the face of the actuator, and replace as needed. Check the linkage pin (Item 2) [Figure 20-43-21] and replace as needed.
P-51733
Slide the actuator mount bracket (Item 1) [Figure 20-4319] away from the control valve. Pull the actuator away from the control valve [Figure 2043-19].
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Figure 20-43-24
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation (Out Of Loader) (Cont’d) Figure 20-43-22
1 1 P-51800
Using a drift pin and a hammer, remove the actuator linkage pin (Item 1) [Figure 20-43-24] from the actuator and the tilt spool.
1 P-51737
Remove the two mount bolts (Item 1) [Figure 20-43-22] from the lift actuator.
Dealer Copy -- Not for Resale
Remove the actuator and linkage pin from the valve. Figure 20-43-25
Installation: Tighten the mounting bolts to 90 - 100 in.-lb. (10,2 - 11,3 N•m) torque. Figure 20-43-23
1
1 2 P-51736
Inspect the O-ring (Item 1) [Figure 20-43-25] on the face of the actuator, and replace as needed. Check the linkage pin (Item 2) [Figure 20-43-25] and replace as needed.
P-51799
Slide the actuator mount bracket (Item 1) [Figure 20-4323] away from the control valve. Pull the actuator away from the control valve [Figure 2043-23].
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Actuator Removal And Installation (Out of Loader) (Cont’d) Figure 20-43-26 1 4
1
2 3 P-51738
Dealer Copy -- Not for Resale
NOTE: The two longer bolts (Item 1) are used to mount the lift actuator and end cap (Item 2) [Figure 20-43-26] to the control valve. The two shorter mount bolts (Item 3) are used to mount the tilt actuator to the end cap (Item 4) [Figure 20-43-26]. Installation: Tighten the mounting bolts to 90 - 100 in.-lb. (10,2 - 11,3 N•m) torque (Item 1) [Figure 20-43-26]
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Identification Chart (ACS) Figure 20-43-27 C2 D5
J2
C3
J4
B3
E3 G1
G2
F2
A3
B2
D4
E3
D3 E2
A2 D1
D2 A1 B1
H2
H3
MR
C1 H1
E1
J3
J1 MS1929
ITEM
S150 / S160 LOADER
ITEM
S150 / S160 LOADER
A1 A2 A3
Lift Cylinder Base End Tilt Cylinder Base End
E1 E2 E3 F1 F2 G1 G2 H1
Lift Spool Centering Spring Tilt Spool Centering Spring Auxiliary Spool / Centering Springs LIft Spool Tilt Spool Auxiliary Solenoid Stem Auxiliary Solenoid Stem
H2
BICS™ Lock Valve (Tilt)
H3
BICS™ Lock Valve (Lift)
J1 J2 J3 J4
Inlet Fluid Flow (From Pump) Outlet Fluid Flow (Return to Tank) Lift Arm Bypass Orifice Drain (Case) Main Relief Valve – 3300 PSI
B1 B2 B3 C1 C2 C3 D1 D2 D3 D4 D5
Auxiliary Hydraulic Rod End Lift Cylinder Rod End Tilt Cylinder Rod End Auxiliary Hydraulics Base End Load Check / BICS™ Valve Lift Load Check Valve Tilt Function Load Check Valve Auxiliary Function Anti-Cavitation Valve Lift (Rod End) Port Relief / Anti-Cavitation Valve – 3500 PSI Lift (Base End) Port Relief / Anti-Cavitation Valve – 3500 PSI Tilt (Base End) Port Relief / Anti-Cavitation Valve – 3500 PSI Tilt (Rod End) Port Relief / Anti-Cavitation Valve (Auxiliary) 3500 PSI (Optional)
MR
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BICS™ Valve Solenoid
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
F1
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
BICS™ Valve, Lift Load Check Valve Removal And Installation
Mount Bracket Removal And Installation
Figure 20-43-30
Figure 20-43-28
1
P-51740
1 P-51730
Figure 20-43-29
Installation: Lubricate the O-ring and tighten the valve to 55 - 65 ft.-lb. (75 - 88 N•m) torque. Figure 20-43-31
1 1
2 2 P-51731 P-51439
Disconnect the tubeline (Item 1) [Figure 20-43-29] from the inlet fitting on the control valve. Remove the two mount bolts (Item 2) [Figure 20-43-29] from the control valve mount plate. Remove the mount plate and tubeline.
Remove and install new O-rings (Item 1) and back-up ring (Item 2) [Figure 20-43-31].
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S150, S160 Bobcat Loader Service Manual
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Remove the control valve and mount bracket (Item 1) [Figure 20-43-28] from the loader.
Remove the lift load check valve (Item 1) [Figure 20-4330].
Figure 20-43-34
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Lift Load Check Valve Removal And Installation (Cont’d)
4
Figure 20-43-32 1
1 3
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure 20-43-34].
Check for free movement of the load check valve (Item 1) [Figure 20-43-32]. Load Check Valve Removal And Installation (Tilt And Auxiliary)
Installation: Install a new O-ring (Item 4) [Figure 20-4334] on the plug and lightly lubricate with oil before installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
Figure 20-43-33
2 1
P-51741
At the front side of the control valve locate the tilt section load check valve (Item 1) [Figure 20-43-33]. At the front side of the control valve locate the auxiliary section load check valve (Item 2) [Figure 20-43-33]. NOTE: The tilt and auxiliary load check valves are interchangeable.
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Check the orifice (Item 3) [Figure 20-43-34] in the poppet to be sure it is not plugged.
P-51440
Figure 20-43-37
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Anti-Cavitation Valve (Lift, Rod End)
4
Figure 20-43-35
1 3
2
P-51453
1 Remove the spring (Item 1) and poppet (Item 2) [Figure 20-43-37]. P-51742
IMPORTANT
Installation: Install a new O-ring (Item 4) [Figure 20-4337] on the plug and lightly lubricate with oil before installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Figure 20-43-36
1 P-51452
Always use new O-ring (Item 1) [Figure 20-43-36] on the anti-cavitation valve plug.
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At the back side of the control valve, remove the lift section anti-cavitation valve (Item 1) [Figure 20-43-35].
Check the orifice (Item 3) [Figure 20-43-37] in the poppet to be sure it is not plugged.
Port Relief / Anti-Cavitation Valve (Tilt, Base End)
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-40
Port Relief / Anti-Cavitation Valve (Lift, Base End) Figure 20-43-38
1
1 P-51742
Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-43-40] from the base end of the tilt section.
Loosen the lift circuit port relief / anti-cavitation valve (Item 1) [Figure 20-43-38].
Figure 20-43-41
Dealer Copy -- Not for Resale
P-51742
Figure 20-43-39
1
1
P-51454
Replace the O-ring (Item 1) [Figure 20-43-41] before installation.
P-51451
Replace the O-ring (Item 1) [Figure 20-43-39] before installation.
Installation: Lightly lubricate with oil and tighten to 38 45 ft.-lb. (52 - 61 N•m) torque.
Installation: Lightly lubricate with oil and tighten to 38 45 ft.-lb. (52 - 61 N•m) torque.
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Port Relief Valve
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-44
Port Relief / Anti-Cavitation Valve (Tilt, Rod End) Figure 20-43-42
1
1
P-51742
Remove the port relief plug (Item 1) [Figure 20-43-44] from the auxiliary circuit of the control valve.
Remove the tilt port relief / anti-cavitation valve (Item 1) [Figure 20-43-42] from the rod end of the tilt section.
Figure 20-43-45
Dealer Copy -- Not for Resale
P-51742
Figure 20-43-43
1 1
P-51801
P-51455
Replace the O-ring (Item 1) [Figure 20-43-43] before installation.
Installation: Always use new O-rings (Item 1) [Figure 20-43-45]. Lightly lubricate with oil and tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
Installation: Lightly lubricate with oil and tighten to 38 45 ft.-lb. (52 - 61 N•m) torque.
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Plug Removal
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-48
Port Relief Valve (Cont’d) Figure 20-43-46
1
1
P-51459
At the top side of the control valve, remove the plug (Item 1) [Figure 20-43-48].
The control valve may be equipped with an optional auxiliary port relief valve (Item 1) [Figure 20-43-46].
Figure 20-43-49
Dealer Copy -- Not for Resale
P-51743
Remove the auxiliary port relief valve. Figure 20-43-47
1
1 P-51460
Installation: Always use new O-rings (Item 1) [Figure 20-43-49]. Tighten to 40 ft.-lb. (54 N•m) torque. P-51640
Installation: Always use new O-rings (Item 1) [Figure 20-43-47]. Lightly lubricate with oil and tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
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End Cap Block Removal And Installation
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Remove the lift and tilt actuators from the control valve. (See Actuator Removal And Installation (Out Of Loader) on Page 20-43-6.)
Plug Removal (Cont’d) Figure 20-43-50
Figure 20-43-52
1 1 2
P-51461
At the bottom side of the control valve remove the plug (Item 1) [Figure 20-43-50]. Figure 20-43-51
Disconnect the tube line (Item 1) [Figure 20-43-52] from the end cap block. Remove the two end cap block mount screws (Item 2) [Figure 20-43-52]. Installation: Tighten the screws to 90 - 100 in.-lb. (10 11,3 N•m) torque. Figure 20-43-53
1
P-51462
1
Installation: Always use new O-rings (Item 1) [Figure 20-43-51]. Tighten to 40 ft.-lb. (54 N•m) torque.
P-51745
Remove the end cap block (Item 1) [Figure 20-43-53] from the control valve.
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P-51744
Figure 20-43-56
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal And Installation
1
The tool listed will be needed to do the following procedure: MEL1285 - Spring Tool Remove the end cap block from the control valve. Figure 20-43-54
1 P-51748
Remove the two screws (Item 1) [Figure 20-43-56] from the lift spool end cap. 1
Dealer Copy -- Not for Resale
Installation: Lubricate the screws and tighten to 90 - 100 in.-lb. (10 - 11,3 N•m) torque. Figure 20-43-57
P-51746
Remove the O-ring (Item 1) [Figure 20-43-54]. Installation: Replace the O-ring, and lubricate lightly with oil before installation of the end cap block. 1
Figure 20-43-55
P-51749
Remove the lift spool end cap (Item 1) [Figure 20-43-57] from the control valve.
2 1
P-51747
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-55] from the lift spool.
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Figure 20-43-60
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal And Installation (Cont'd) Figure 20-43-58
P-51772
Clamp the linkage end of the spool in a vise [Figure 2043-60].
1 P-51770
Remove the lift spool assembly and seal (Item 1) [Figure 20-43-58] from the control valve.
Figure 20-43-61
Figure 20-43-59
1
1
P-51773
Install the spring tool (Item 1) [Figure 20-43-61] over the centering spring.
P-51771
Remove the lift spool seal (Item 1) [Figure 20-43-59] from the linkage end of the valve.
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NOTE: Protect spool before clamping in vise.
Figure 20-43-64
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal And Installation (Cont'd)
1
Figure 20-43-62
2
1
1
P-51771
P-51775
Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-43-64]. N-190146
Assembly: Always use a new spool seal. Figure 20-43-65
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque.
Dealer Copy -- Not for Resale
Remove the bolt (Item 1) [Figure 20-43-62] holding the centering spring to the spool.
1
Remove spring tool from the spring assembly. Figure 20-43-63 3
3
2 3
2 4
1
P-51749
Install the lift spool assembly (Item 1) [Figure 20-43-65] in the spool bore. Install the end cap (Item 2) [Figure 20-43-65]. Install the mounting screws (Item 3) [Figure 20-43-65].
P-51776
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-43-63].
Installation: Lubricate the screws and tighten to 90 - 100 in.-lb. (10 - 11,3 N•m) torque.
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Figure 20-43-68
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Lift Spool Removal And Installation (Cont'd) Figure 20-43-66
1
1
P-51746
Install the O-ring (Item 1) [Figure 20-43-68] on the control valve. P-51777
Install the spool seal (Item 1) [Figure 20-43-66] on the linkage end of the valve. Figure 20-43-67
3 2 1
2
1 P-51744
2
Install the end cap block (Item 1) and the two mount bolts (Item 2) [Figure 20-43-69]. P-51747
Install the O-ring (Item 1) and bushing (Item 2) [Figure 20-43-67] on the lift spool.
Installation: Tighten the screws to 90 - 100 in.-lb. (10 11,3 N•m) torque. Connect the tube line (Item 3) [Figure 20-43-69] to the end cap block. Install the lift and tilt actuators to the control valve.
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Figure 20-43-69
Figure 20-43-72
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Tilt Spool Removal And Installation Remove the end cap block. (See End Cap Block Removal And Installation on Page 20-43-16.) Figure 20-43-70
2
1 P-51780
Remove the spool centering block (Item 1) [Figure 2043-72] from the control valve.
2
1
Check and replace the O-ring (Item 2) [Figure 20-43-72] before replacing the spool centering block.
Dealer Copy -- Not for Resale
P-51778
Figure 20-43-73 Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-70] from the tilt spool. Figure 20-43-71
1
1 2 P-51781
Remove the tilt spool, centering spring, back-up washer and spool seal (Item 1) [Figure 20-43-73].
2 P-51779
Assembly: Always use a new spool seal. Disconnect the tubeline (Item 1) [Figure 20-43-71]. Remove the three screws (Item 2) [Figure 20-43-71] from the spool centering block. Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3 N•m) torque.
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Figure 20-43-76
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Tilt Spool Removal And Installation (Cont'd)
2 Figure 20-43-74
1
3
4 1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item 3) and washer (Item 4) [Figure 20-43-76]. N-18942
Put the linkage end of the spool in the vice [Figure 2043-74].
2 1
Install the spring tool (Item 1) [Figure 20-43-74] over the centering spring. Figure 20-43-75
1 1
P-51545
N-18943
Remove the spool seal(s) (Item 1) and the back-up washer (Item 2) [Figure 20-43-77]. Assembly: Always use a new spool seal. N-19014
Remove the bolt (Item 1) [Figure 20-43-75] holding the centering spring to the spool. Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 11,3 N•m) torque. Remove spring tool from the spring assembly.
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Figure 20-43-77
Figure 20-43-80
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Auxiliary Spool Removal And Installation Figure 20-43-78
2
1
1 2
P-51783
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-80] from the auxiliary spool.
2
P-51779
Disconnect the tubeline (Item 1) [Figure 20-43-78] from the spool centering block. Remove the three screws (Item 2) [Figure 20-43-78] from the spool centering block. Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3 N•m) torque. 1 Remove the spool centering block from the control valve. 2
Figure 20-43-79
P-51784
Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-43-81] from the auxiliary spool. NOTE: If the centering spring retainer (Item 2) [Figure 20-43-81] must be replaced, replace the retainer on the opposite end also. 2 1 P-51782
Remove the spring (Item 1) and center spring retainer (Item 2) [Figure 20-43-79] from the auxiliary spool. Note:
If the centering spring retainer (Item 2) [Figure 20-43-79] must be replaced, replace the retainer on the opposite end also.
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Figure 20-43-81
Auxiliary Solenoid Disassembly And Assembly
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-84
Auxiliary Spool Removal And Installation (Cont’d) Figure 20-43-82
1
1
1 2 P-51552
Remove the spacer (Item 1) and O-ring (Item 2) [Figure 20-43-82] from the auxiliary spool.
Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m) torque.
Figure 20-43-83
Figure 20-43-85
1
2
1
P-51786
Remove the auxiliary spool (Item 1) [Figure 20-43-83].
P-51553
Remove the nut (Item 1) and solenoid coil (Item 2) [Figure 20-43-85]. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 4.9 ± 0.25 ohm.
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Remove the nut (Item 1) [Figure 20-43-84] from both solenoids.
P-51785
BICS™ Valve Solenoid Disassembly And Assembly
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-88
Auxiliary Solenoid Disassembly and Assembly (Cont’d) Figure 20-43-86
1
1 2
P-51788
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.
Remove the solenoid stem (Item 1) [Figure 20-43-86]. Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19 N•m) torque.
Remove the solenoid coil (Item 2) [Figure 20-43-88]. Figure 20-43-89
Figure 20-43-87 1 1
1
2 N-18693A P-51555
Remove the O-rings (Item 1) [Figure 20-43-87] from the solenoid stem. Check and clean the screen (Item 2) [Figure 20-43-87].
Remove the O-rings (Item 1) [Figure 20-43-89] from both ends of the solenoid coil. Use an ohmmeter to measure the solenoid coil resistance. The correct resistance for the coil is 9.79 ± 0.29 ohm.
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Remove the nut (Item 1) [Figure 20-43-88] from the solenoid stem.
P-51787
Figure 20-43-91
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve Solenoid Disassembly And Assembly (Cont’d)
3
Figure 20-43-90
2
1 1 N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-91] from the stem.
Remove the solenoid stem (Item 1) [Figure 20-43-90].
Inspect all parts for wear and replace any showing excessive wear.
Installation: Lubricate the O-rings and tighten the stem to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
NOTE: The screen (Item 3) [Figure 20-43-91] may be cleaned with solvent. If it is torn or worn it needs to be replaced. Use only new O-rings and apply oil to all O-rings and back-up rings before installation. Install new O-rings (Item 1) [Figure 20-43-89] and [Figure 20-43-91] and new back-up rings (Item 2) [Figure 20-43-91] on the solenoid stem. BICS™ Valve, Lock Valve Removal And Installation Figure 20-43-92
1
2
P-51790
Locate the two BICS™ lock valves, (Item 1) is for the tilt circuit and (Item 2) [Figure 20-43-92] is for the lift circuit.
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Clean all parts in solvent and dry with compressed air.
P-51789
Figure 20-43-95
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) BICS™ Valve, Lock Valve Removal And Installation (Cont’d) Figure 20-43-93
1
P-51792
1 Remove the tilt lock valve (Item 1) [Figure 20-43-95] from the back of the control valve.
Remove the lift lock valve (Item 1) [Figure 20-43-93] from the back of the control valve.
Dealer Copy -- Not for Resale
Installation: Lightly lubricate the lock valve O-rings and tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
P-51791
Figure 20-43-96
Installation: Lightly lubricate the lock valve O-rings and tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque. 1 Figure 20-43-94
1 1 1
1 2
1 1
2 2 P-51564
1 2
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-96] from the tilt lock valve, and replace with new.
2 2 P-51564
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-43-94] from the lift lock valve, and replace with new.
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Figure 20-43-99
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
1
BICS™ Valve, Check Valve Removal And Installation Figure 20-43-97
2 3
4 P-51447
1
Check that there is no blockage in the orifice (Item 1) [Figure 20-43-99]. P-51788
Remove the BICS™ valve (Item 1) [Figure 20-43-97]. Installation: Lubricate the O-ring and tighten the valve to 55 - 65 ft.-lb. (75 - 88 N•m) torque.
Replace the O-ring (Item 4) [Figure 20-43-99] on the plug before installation.
Figure 20-43-98
1
P-51446
Remove the plug (Item 1) [Figure 20-43-98] from the top of the BICS™ valve.
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Inspect the check valve (Item 2) and spring (Item 3) [Figure 20-43-99].
Main Relief Valve
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-102
BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly Figure 20-43-100
1
1
P-51794
Remove the main relief valve (Item 1) [Figure 20-43102].
Remove the fitting (Item 1) [Figure 20-43-100] from the valve.
Figure 20-43-103
Dealer Copy -- Not for Resale
P-51793
Figure 20-43-101
1 1 P-51463
Remove the O-rings from the main relief valve (Item 1) [Figure 20-43-103].
P-51437
Check the lift arm bypass orifice (Item 1) [Figure 20-43101].
Installation: Always use new O-rings. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
NOTE: This orifice is not removable from the valve casting.
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S150, S160 Bobcat Loader Service Manual
LIFT ARM BYPASS CONTROL VALVE
Figure 20-50-1
Inspecting Raise the lift arms 6 feet (2 m) off the ground. Stop the engine. Turn the Lift Arm Bypass Control Knob clockwise 1/4 turn. Then pull the Lift Arm Bypass Control Knob until the lift arms slowly lower.
2
4
3 Removal And Installation Install jack stands under the rear corners of the loader. Start the engine. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
1 P-31990
The Lift Arm Bypass valve (Item 1) [Figure 20-50-1] is located under the right side of the control panel.
DANGER
Remove the Lift Arm Bypass Control knob (Item 2) and the jam nut (Item 3) [Figure 20-50-1] from the Lift Arm Bypass valve shaft. Remove the rubber washer (Item 4) [Figure 20-50-1]. P-90328
•
•
Figure 20-50-2
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
1
3
D-1009-0409
WARNING
2
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-34045
Disconnect the base end lift tubeline (Item [Figure 20-50-2] from the Lift Arm Bypass valve.
1)
Disconnect the drain tubeline (Item 2) [Figure 20-50-2] from the Lift Arm Bypass valve. Remove the two mounting bolt / nuts (Item 3) [Figure 20-50-2]. Installation: Tighten the mounting bolts to 180 - 200 in. lb. (21 - 23 N•m) torque. Remove the lift arm bypass control valve.
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Hold the Lift Arm Bypass Control knob (Item 2) and loosen the jam nut (Item 3) [Figure 20-50-1] on the Lift Arm Bypass valve shaft.
LIFT ARM BYPASS CONTROL VALVE (CONT’D) Disassembly And Assembly Figure 20-50-3
1
P-07939
Dealer Copy -- Not for Resale
Remove the Lift Arm Bypass Control valve (Item 1) [Figure 20-50-3] from the valve block. Inspect the bypass valve for damage and replace if necessary. Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50 N•m) torque. Inspect the hydraulic fittings on the valve block for the damage and replace if necessary.
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Figure 20-60-1
HYDRAULIC PUMP Check The Output Of The Hydraulic Pump Without Power Bob-Tach
2
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
1 P-26071
WARNING
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1] from the pump. Figure 20-60-2
W-2059-0598
The tools listed will be needed to do the following procedure:
2
1
MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-24594
Connect the INLET hose (Item 1) [Figure 20-60-2] from the tester to the OUTLET fitting (Item 2) [Figure 20-60-1] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-60-2] from the tester to the hose (Item 1) [Figure 2060-1] which was disconnected from the pump.
Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump Without Power Bob-Tach (Cont'd) Figure 20-60-3
Reservoir
EXAMPLE: TESTER CONNECTION
Hydraulic Pump Out In Hydraulic Control Valve 1 B-16277
Dealer Copy -- Not for Resale
Sample tester connection shown [Figure 20-60-3]. Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-60-3] on the tester to about 1000 PSI (6895 kPa). DO NOT EXCEED SYSTEM RELIEF PRESSURE. Open the restrictor control and record the free flow (GPM) at full rpm. Push the maximum / variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump. *For system relief pressure and full rpm specifications. (See SPECIFICATIONS on Page SPEC-01.)
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S150, S160 Bobcat Loader Service Manual
Figure 20-60-4
HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach.
1
2
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286 P-26682
WARNING
Disconnect the OUTLET hose (Item 1) [Figure 20-60-4] from the top of the Power Bob-Tach block. Figure 20-60-5
W-2059-0598
The tools listed will be needed to do the following procedure:
1
2
MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-24594
Connect the INLET hose (Item 1) [Figure 20-60-5] from the tester to the OUTLET fitting (Item 2) [Figure 20-60-4] on the top of the Power Bob-Tach block. Connect the OUTLET hose (Item 2) [Figure 20-60-5] from the tester to the hose (Item 1) [Figure 20-60-4] which was disconnected from the Power Bob-Tach block.
Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
20-60-3 259 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach. (Cont'd) Figure 20-60-6
Reservoir
EXAMPLE: TESTER CONNECTION
Hydraulic Pump Out In Hydraulic Control Valve 1 B-16277
Dealer Copy -- Not for Resale
Sample tester connection shown [Figure 20-60-6]. Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-60-6] on the tester to about 1000 PSI (6895 kPa). DO NOT EXCEED SYSTEM RELIEF PRESSURE. Open the restrictor control and record the free flow (GPM) at full rpm. Push the maximum / variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump. *For system relief pressure and full rpm specifications. (See SPECIFICATIONS on Page SPEC-01.)
20-60-4 260 of 949
S150, S160 Bobcat Loader Service Manual
HYDRAULIC PUMP (CONT'D)
Stop the engine. Raise the seat bar.
Removal And Installation
Lift and block the rear of the loader. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
DANGER
Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Open the rear door of the loader. Remove the Power Bob-Tach block if equipped. (See Removal And Installation on Page 20-120-1.) Disconnect and cap the outlet hose (Item 1) [Figure 20-60-7] from the back of the hydraulic pump. P-90328
•
D-1009-0409
WARNING 1 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
P-26068
Disconnect and cap the inlet hose (Item 1) [Figure 20-60-8] from the front of the hydraulic pump. Figure 20-60-9
W-2059-0598
Figure 20-60-7 1
2
P-26069
1 Remove the two mounting bolts [Figure 20-60-9] from the hydraulic pump.
P-26071
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
1)
Installation: Tighten the mounting bolts to 27 - 37 in.-lb. (37 - 50 N•m) torque. Remove the hydraulic pump (Item 2) [Figure 20-60-9] from the hydrostatic pump.
20-60-5 261 of 949
(Item
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
•
Figure 20-60-8
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
HYDRAULIC PUMP (CONT'D) Removal And Installation (Cont’d) Figure 20-60-10
P-26347
1
2
P-26347
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 20-60-10]. Remove the coupler (Item 2) [Figure 20-60-10] from the hydraulic pump shaft. Reverse the removal procedure to install the hydraulic pump. Installation: Use a new O-ring (Item 1) [Figure 20-60-10] when installing the hydraulic pump. (See Disassembly And Assembly on Page 20-60-8.)
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HYDRAULIC PUMP (CONT'D) Identification
15
8 7 6 14 13 12
7 1
3
4
5
9
10
2
B-16050A
REF.
DESCRIPTION
REF.
1
RETAINING RING
2
PUMP END SECTION
10
PUMP CENTER SECTION
3
PRE-LOAD SEAL
11
WEAR PLATE
4
LOAD SEAL
12
SECTION SEAL
5
SECTION SEAL
13
PUMP END SECTION
6
WEAR PLATE
14
BOLTS (4)
7
PINS
15
BOLTS (4)
8
DRIVE GEAR
9
20-60-7 263 of 949
DESCRIPTION IDLER GEAR
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
11
HYDRAULIC PUMP (CONT'D)
Figure 20-60-12
Disassembly And Assembly
1
Figure 20-60-11
1 P-26352
2
2
P-26353
1 Remove the pump [Figure 20-60-12].
P-26351
end
section
(Item
1)
Dealer Copy -- Not for Resale
Mark the pump sections for correct assembly [Figure 2060-11]. Remove the four smaller pump housing bolts (Item 1) [Figure 20-60-11]. Remove the four larger pump housing bolts (Item 2) [Figure 20-60-11]. Installation: Tighten the four smaller bolts (Item 1) to 30 ft.-lb. (40,7 N•m) torque. Tighten the four larger bolts (Item 2) [Figure 20-60-11] to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
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S150, S160 Bobcat Loader Service Manual
Figure 20-60-15
HYDRAULIC PUMP (CONT'D) Disassembly And Assembly (Cont'd)
1
Figure 20-60-13
1
P-26358
2
Figure 20-60-16 P-26354
4 3
1
P-26359
2
Remove the pump center section (Item 1) [Figure 20-60-15] and [Figure 20-60-16] from the pump end section.
P-26355
Remove the wear plate (Item 1) [Figure 20-60-13] and [Figure 20-60-14] and section seal (Item 2) [Figure 20-60-13] and [Figure 20-60-14] from the pump end section.
NOTE: Inspect the pump center section (Item 1) [Figure 20-60-16]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-60-14] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the pump end section (Item 3) and bushings (Item 4) [Figure 20-60-14]. If excessive wear or damage is visible, the pump must be replaced.
20-60-9 265 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
1
Figure 20-60-14
Figure 20-60-19
HYDRAULIC PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-60-17
1
1 P-26391
Figure 20-60-20 P-26389
2 P-26362
1
1 P-26362
To remove the drive gear (Item 1) [Figure 20-60-19] from the pump end section, locate and remove the retaining ring (Item 2) (Inset) [Figure 20-60-20] from the spline end of the drive gear.
P-26390
Remove the idler gear (Item 1) [Figure 20-60-17] and [Figure 20-60-18]. NOTE: Inspect the idler gear (Item 1) [Figure 20-6018]. If excessive wear or damage is visible, the pump must be replaced.
20-60-10 266 of 949
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Dealer Copy -- Not for Resale
Figure 20-60-18
Figure 20-60-23
HYDRAULIC PUMP (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-60-21
1 2 1
P-26394
NOTE: Position wear plate (Item 1) [Figure 20-60-23] inlets and traps as shown with bronze side toward gears.
Remove the drive gear (Item 1) [Figure 20-60-21] from the pump end section.
Figure 20-60-24 1
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-21]. If excessive wear or damage is visible, the pump must be replaced.
P-26396
Figure 20-60-22
1
P-26395
1 Remove the load seal (Item 1) [Figure 20-60-24]. 2
P-26393
Remove the wear plate (Item 1) [Figure 20-60-22] and [Figure 20-60-23] and section seal (Item 2) [Figure 20-60-22] and [Figure 20-60-23] from the pump end section.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
P-26392
HYDRAULIC PUMP (CONT'D)
Figure 20-60-26
Disassembly And Assembly (Cont'd) 1 Figure 20-60-25
1 2 P-26398
1 P-26374
P-26397
NOTE: Inspect the pump end section (Item 1) and bushings (Item 2) [Figure 20-60-26]. If excessive wear or damage is visible, the pump must be replaced.
Dealer Copy -- Not for Resale
Remove the pre-load seal (Item 1) [Figure 20-60-25].
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S150, S160 Bobcat Loader Service Manual
Figure 20-61-1
HYDRAULIC PUMP (HIGH FLOW) Check The Output Of The Hydraulic Pump Without Power Bob-Tach
2
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
1 P-26753
WARNING
Disconnect the OUTLET hose (Item 1) [Figure 20-61-1] from the pump. Figure 20-61-2
W-2059-0598
The tools listed will be needed to do the following procedure:
1
2
MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-24594
Connect the INLET hose (Item 1) [Figure 20-61-2] from the tester to the OUTLET fitting (Item 2) [Figure 20-61-1] of the pump. Connect the OUTLET hose (Item 2) [Figure 20-61-2] from the tester to the hose (Item 1) [Figure 2061-1] which was disconnected from the pump.
Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
20-61-1 269 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
HYDRAULIC PUMP (HI FLOW) (CONT'D) Check The Output Of The Hydraulic Pump Without Power Bob-Tach (Cont'd) Figure 20-61-3
Reservoir
EXAMPLE: TESTER CONNECTION
Hydraulic Pump Out In Hydraulic Control Valve 1 B-16277
Dealer Copy -- Not for Resale
Sample tester connection shown [Figure 20-61-3]. Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-61-3] on the tester to about 1000 PSI (6895 kPa). DO NOT EXCEED SYSTEM RELIEF PRESSURE. Open the restrictor control and record the free flow (GPM) at full rpm. Push the maximum / variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics, the light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump. *For system relief pressure and full rpm specifications. (See SPECIFICATIONS on Page SPEC-01.)
20-61-2 270 of 949
S150, S160 Bobcat Loader Service Manual
Figure 20-61-4
HYDRAULIC PUMP (HI FLOW) (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach
1 2
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286 P-26754
WARNING
Disconnect the OUTLET hose (Item 1) [Figure 20-61-4] from the top of the Power Bob-Tach block. Figure 20-61-5
W-2059-0598
2
The tools listed will be needed to do the following procedure:
1
MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-24594
Connect the INLET hose (Item 1) [Figure 20-61-5] from the tester to the OUTLET fitting (Item 2) [Figure 20-61-4] on the top of the Power Bob-Tach block. Connect the OUTLET hose (Item 2) [Figure 20-61-5] from the tester to the hose (Item 1) [Figure 20-61-4] which was disconnected from the Power Bob-Tach block.
Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
20-61-3 271 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
HYDRAULIC PUMP (HI FLOW) (CONT'D) Check The Output Of The Hydraulic Pump With Power Bob-Tach (Cont'd) Figure 20-61-6
Reservoir
EXAMPLE: TESTER CONNECTION
Hydraulic Pump Out In Hydraulic Control Valve 1 B-16277
Dealer Copy -- Not for Resale
Sample tester connection shown [Figure 20-61-6]. Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-61-6] on the tester to about 1000 PSI (6895 kPa). DO NOT EXCEED SYSTEM RELIEF PRESSURE. Open the restrictor control and record the free flow (GPM) at full rpm. Push the maximum / variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics, the light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump. *For system relief pressure and full rpm specifications. (See SPECIFICATIONS on Page SPEC-01.)
20-61-4 272 of 949
S150, S160 Bobcat Loader Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT'D)
Stop the engine. Raise the seat bar.
Removal And Installation
Lift and block the rear of the loader. (See Procedure on Page 10-10-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
DANGER
Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Open the rear door of the loader. Remove the Power Bob-Tach block if equipped. (See Removal And Installation on Page 20-120-1.) Disconnect and cap the outlet hoses (Item 1) [Figure 20-61-7] from the back of the hydraulic pump. P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
WARNING
1 1
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
P-26739
Disconnect and cap the inlet hoses (Item 1) [Figure 20-61-8] from the front of the hydraulic pump. Figure 20-61-9
W-2059-0598
Figure 20-61-7
1 2
P-26740
1
Remove the two mounting bolts [Figure 20-61-9] from the hydraulic pump.
(Item
1)
P-26741
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Installation: Tighten the mounting bolts to 27 - 37 ft.-lb. (37 - 50 N•m) torque. Remove the hydraulic pump (Item 2) [Figure 20-61-9] from the hydrostatic pump.
20-61-5 273 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
•
Figure 20-61-8
HYDRAULIC PUMP (HI FLOW) (CONT'D) Removal And Installation (Cont’d) Figure 20-61-10
P-26684
1
2
P-26684
Dealer Copy -- Not for Resale
Remove the O-ring (Item 1) [Figure 20-61-10]. Remove the coupler (Item 2) [Figure 20-61-10] from the hydraulic pump shaft. Reverse the removal procedure to install the hydraulic pump. Installation: Use a new O-ring (Item 1) [Figure 20-61-10] when installing the hydraulic pump. (See Disassembly And Assembly on Page 20-61-8.)
20-61-6 274 of 949
S150, S160 Bobcat Loader Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT'D) Identification
26
22 23 19
27
23 20 17 18 15 16
25
24
21 7 8
2
13
11
1
3 4
5
6
7
9
12
10
B-16051a
REF.
DESCRIPTION
REF.
DESCRIPTION
1
RETAINING RING
14
PUMP CENTER SECTION
2
PUMP END SECTION
15
PRE-LOAD SEAL
3
PRE-LOAD SEAL
16
LOAD SEAL
4
LOAD SEAL
17
SECTION SEAL
5
SECTION SEAL
18
WEAR PLATE
6
WEAR PLATE
19
DRIVE GEAR
7
PINS
20
IDLER GEAR
8
DRIVE GEAR
21
PUMP SECTION
9
IDLER GEAR
22
WEAR PLATE
10
PUMP SECTION
23
PINS
11
WEAR PLATE
24
SECTION SEAL
12
SECTION SEAL
25
PUMP END SECTION
13
SPLINE SHAFT
26
BOLT (4)
27
BOLT (4)
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
14
HYDRAULIC PUMP (HI FLOW) (CONT'D)
Figure 20-61-12
Disassembly And Assembly 1 Figure 20-61-11
1 P-26622
2 P-26624
2
Mark the pump [Figure 20-61-11].
Remove the pump [Figure 20-61-12].
P-26622
sections
for
correct
end
section
(Item
1)
assembly
Dealer Copy -- Not for Resale
1
Remove the four smaller pump housing bolts (Item 1) [Figure 20-61-11]. Remove the four larger pump housing bolts (Item 2) [Figure 20-61-11]. Installation: Tighten the four smaller bolts (Item 1) to 30 ft.-lb. (40,7 N•m) torque. Tighten the four larger bolts (Item 2) [Figure 20-61-11] to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
20-61-8 276 of 949
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Figure 20-61-15
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-13
1
1
P-26627
2
Figure 20-61-16 P-26625
4 1 3 1
P-26628
Remove the pump section (Item 1) [Figure 20-61-15] and [Figure 20-61-16] from the pump center section.
2 P-26626
Remove the wear plate (Item 1) [Figure 20-61-13] and [Figure 20-61-14] and section seal (Item 2) [Figure 20-61-13] and [Figure 20-61-14] from the pump end section.
NOTE: Inspect the pumps center section (Item 1) [Figure 20-61-16]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-61-14] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the pump end section (Item 3) and bushings (Item 4) [Figure 20-61-14]. If excessive wear or damage is visible, the pump must be replaced.
20-61-9 277 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Figure 20-61-14
Figure 20-61-19
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-17
1 1
P-26631
Figure 20-61-20 P-26629
Figure 20-61-18 1
P-26632
1 Remove the drive gear (Item 1) [Figure 20-61-19] and [Figure 20-61-20]. NOTE: Inspect the drive gear (Item 1) [Figure 20-6120]. If excessive wear or damage is visible, the pump must be replaced.
P-26630
NOTE: Inspect the idler gear (Item 1) [Figure 20-61-18]. If excessive wear or damage is visible, the pump must be replaced.
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Dealer Copy -- Not for Resale
Remove the idler gear (Item 1) [Figure 20-61-17] and [Figure 20-61-18].
Figure 20-61-23
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd)
1 Figure 20-61-21
P-26636A
1 1
P-26635
2 Remove the load seal (Item 1) [Figure 20-61-23]. P-26633
Figure 20-61-24 Figure 20-61-22
P-26638A
1 2 1
P-26637 P-26634
Remove the pre-load seal (Item 1) [Figure 20-61-24]. Remove the wear plate (Item 1) [Figure 20-61-21] and [Figure 20-61-22] and section seal (Item 2) [Figure 20-61-21] and [Figure 20-61-22] from the pump center section. NOTE: Position wear plate (Item 1) [Figure 20-61-22] inlets and traps as shown with bronze side toward gears.
20-61-11 279 of 949
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Dealer Copy -- Not for Resale
1
Figure 20-61-27
HYDRAULIC PUMP (HI FLOW) (CONT'D)
3
Disassembly And Assembly (Cont'd) Figure 20-61-25
4
1 1 2 P-26657
Remove the pump center section [Figure 20-61-25] from the pump sections.
(Item
1)
Figure 20-61-26
NOTE: Inspect the pump center section (Item 3) and bushings (Item 4) [Figure 20-61-27]. If excessive wear or damage is visible, the pump must be replaced. Figure 20-61-28
1
1 2 P-26655
Remove the wear plate (Item 1) [Figure 20-61-26] and [Figure 20-61-27] and section seal (Item 2) [Figure 20-61-26] and [Figure 20-61-27] from the pump section.
P-26659
Remove the pump section (Item 1) [Figure 20-61-28] from the pump end section.
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Dealer Copy -- Not for Resale
NOTE: Position wear plate (Item 1) [Figure 20-61-27] inlets and traps as shown with bronze side toward gears.
P-26654
Figure 20-61-31
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-29 1
1
P-26662
NOTE: Inspect the idler gear (Item 1) [Figure 20-61-31]. If excessive wear or damage is visible, the pump must be replaced.
P-26660
Dealer Copy -- Not for Resale
NOTE: Inspect the pump section (Item 1) [Figure 20-61-29]. If excessive wear or damage is visible, the pump must be replaced. Figure 20-61-30
1
P-26661
Remove the idler gear (Item 1) [Figure 20-61-30] and [Figure 20-61-31].
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Figure 20-61-34
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-32
1
1
P-26666
NOTE: Inspect the drive gear (Item 1) [Figure 20-61-34]. If excessive wear or damage is visible, the pump must be replaced.
Figure 20-61-33
Figure 20-61-35 1 P-26665
1 1 P-26664
To remove the drive gear (Item 1) [Figure 20-61-32] from the pump end section, locate and remove the retaining ring (Item 1) [Figure 20-61-33] from the spline end of the drive gear.
P-26674
Remove the spline shaft (Item 1) [Figure 20-61-35] from the end of the drive gear. NOTE: Inspect the spline shaft (Item 1) [Figure 20-61-35]. If excessive wear or damage is visible, the pump must be replaced.
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Remove the drive gear (Item 1) [Figure 20-61-34] from the pump end section.
P-26663
Figure 20-61-38
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd)
1
Figure 20-61-36
P-26670A
1
1 P-26669
2
Remove the load seal (Item 1) [Figure 20-61-38]. P-26667
Figure 20-61-39
1
P-26672A
1
1 2
P-26671 P-26668
Remove the pre-load seal (Item 1) [Figure 20-61-39]. Remove the wear plate (Item 1) [Figure 20-61-36] and [Figure 20-61-37] and section seal (Item 2) [Figure 20-61-36] and [Figure 20-61-37] from the pump end section. NOTE: Position wear plate (Item 1) [Figure 20-61-37] inlets and traps as shown with bronze side toward gears.
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Figure 20-61-37
HYDRAULIC PUMP (HI FLOW) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-61-40 1
2
P-26673
20-61-16 284 of 949
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NOTE: Inspect the pump end section (Item 1) and bushings (Item 2) [Figure 20-61-40]. If excessive wear or damage is visible, the pump must be replaced.
S150, S160 Bobcat Loader Service Manual
Figure 20-62-2
HYDRAULIC PUMP (SJC) Test The Output Of The Hydraulic Auxiliary Pump
WARNING 1
2 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Figure 20-62-1
Connect the INLET hose (Item 1) [Figure 20-62-2] from the tester, to the OUTLET hose (Item 1) [Figure 20-62-1] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-62-2] from the tester, to the INLET tubeline (Item 2) [Figure 20-62-1] leading to the control valve.
1
2
IMPORTANT P-64570
The hydraulic tester must be in the fully open position before you start the engine.
The tools listed will be needed to do the following procedure:
I-2024-0284
MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.) Disconnect the OUTLET hose (Item 1) [Figure 20-62-1].
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P-48256
Test The Output Of The Hydraulic Charge Pump
HYDRAULIC PUMP (SJC) (CONT'D) Test The Output Of The Hydraulic Auxiliary Pump (Cont'd)
WARNING
Figure 20-62-3
Reservoir
EXAMPLE: TESTER CONNECTION
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Figure 20-62-4 Hydraulic Pump Out In Hydraulic Control Valve 1
1 B-16277
Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-62-3] on the tester to about 1000 PSI (6895 kPa). DO NOT exceed system relief pressure. Open the restrictor control and record the free flow (GPM) at full rpm. Push the maximum / variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
2 P-64315
The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
X100
Open the rear door of the loader.
A low percentage may indicate a failed pump. *For system relief pressure and full rpm specifications. (See SPECIFICATIONS on Page SPEC-01.)
Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.) Disconnect the charge pump OUTLET hose (Item 1) from the INLET fitting (Item 2) [Figure 20-62-4] at the charge filter housing.
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Sample tester connection shown [Figure 20-62-3].
HYDRAULIC PUMP (SJC) (CONT'D)
Turn the restrictor down to 2000 PSI. DO NOT EXCEED 2000 PSI. The high pressure flow must be at least 80% of free flow.
Test The Output Of The Hydraulic Charge Pump (Cont’d)
%=
Figure 20-62-5
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics for pump flow and full rpm. 2
1
P-48256
Dealer Copy -- Not for Resale
Connect the INLET hose (Item 1) [Figure 20-62-5] from the tester, to the charge pump OUTLET hose (Item 1) [Figure 20-62-4] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-62-5] from the tester, to the INLET fitting (Item 2) [Figure 20-62-4] at the charge filter housing.
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-62-3] on the tester to about 1000 PSI (6895 kPa). DO NOT exceed 2000 PSI. Open the restrictor control and record the free flow (GPM) at full rpm.
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HYDRAULIC PUMP (SJC) (CONT'D)
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Removal And Installation
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
DANGER
Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Open the rear door of the loader. Disconnect and cap the outlet hose (Item 1) [Figure 2062-6] from the back of the hydraulic pump. Remove the Power Bob-Tach block (Item 2) [Figure 2062-6] if equipped. (See Removal And Installation on Page 20-120-1.) P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Figure 20-62-7
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
1
I-2003-0888
Figure 20-62-6 1
P-64547
Disconnect and cap the inlet hoses (Item 1) [Figure 2062-7] from the front of the hydraulic pump.
1 2
P-64546
Lift and block the rear of the loader. (See Procedure on Page 10-10-1.) 20-62-4 288 of 949
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•
Remove the hydraulic pump (Item 3) [Figure 20-62-9] from the hydrostatic pump.
HYDRAULIC PUMP (SJC) (CONT'D) Removal And Installation (Cont’d)
Figure 20-62-10 Figure 20-62-8
1
1
P-64446 P-64549
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb. (75 - 85 N•m) torque.
Replace the O-ring (Item 1) [Figure 20-62-10] in the hydrostatic pump. Reverse the removal procedure to install the hydraulic pump.
Figure 20-62-9
3 1
2
P-64343
Remove the bracket mounting bolt (Item 1) from the pump mounting bracket (Item 2) [Figure 20-62-9]. NOTE: The mounting bolt is a special purpose bolt. Only replace with original Bobcat Parts. Installation: Apply a medium strength threadlocker to mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136 N•m) torque. Remove the mounting bracket (Item 2) [Figure 20-62-9].
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Remove the two mounting bolts (Item 1) [Figure 20-628] from the hydraulic pump.
HYDRAULIC PUMP (SJC) (CONT'D) Identification
15 14 7 5 13 8 5 3
4
7 9 7
8
11
5 6 10 9
3
4
5
7 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
1 2
Shaft Seal Pump Flange Section Pre-Load Seal Load Seal O-ring Wear Plate Pins Drive Gear Idler Gear Auxiliary Pump Section Spline Shaft Pump Center Section Charge Pump Section Pump End Section Bolt (8) B-21259A
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12
6
HYDRAULIC PUMP (SJC) (CONT'D)
Figure 20-62-12
Disassembly And Assembly
1
Figure 20-62-11 2 P-26352 P-64507
1
1
P-64509
1 Remove the pump end section (Item 1) [Figure 20-6212].
P-64508
Dealer Copy -- Not for Resale
Mark the pump sections for correct assembly [Figure 2062-11]. Remove the eight pump housing bolts (Item 1) [Figure 20-62-11]. Installation: Tighten the bolts (Item 2) [Figure 20-62-11] to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
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Figure 20-62-15
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-13
1
1
P-64511
2
Figure 20-62-16 P-64509
3 4
1
P-64512
2
Remove the charge pump section (Item 1) [Figure 2062-15] and [Figure 20-62-16] from the pump center section.
P-64510
Remove the wear plate (Item 1) and section seal (Item 2) [Figure 20-62-13] and [Figure 20-62-14] from the pump end section.
NOTE: Inspect the pump section (Item 1) [Figure 2062-16]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-62-14] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the pump end section (Item 3) [Figure 20-62-14] and bushings (Item 4) [Figure 20-6214]. If excessive wear or damage is visible, the pump must be replaced.
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1
Figure 20-62-14
Figure 20-62-19
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-17
1 1
P-64515
Figure 20-62-20 P-64513
1
1
P-64516
Remove the idler gear (Item 1) [Figure 20-62-19] and [Figure 20-62-20] from the pump center section.
P-64514
Remove the drive gear (Item 1) [Figure 20-62-17] and [Figure 20-62-18].
NOTE: Inspect the idler gear (Item 1) [Figure 20-6220]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Inspect the drive gear (Item 1) [Figure 20-6218]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-62-18
Figure 20-62-23
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-21
1
P-64519
1 Figure 20-62-24
2 P-64517
2
1 2
1 P-64520
Remove the load seal (Item 1) [Figure 20-62-23] and [Figure 20-62-24]. Inspect for damage and replace as needed.
P-64518
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-62-21] and [Figure 20-62-22] from the pump center section. Inspect for damage and replace as needed.
Remove the pre-load seal (Item 2) [Figure 20-62-24].
NOTE: Position wear plate (Item 1) [Figure 20-62-22] inlets and traps as shown with bronze side toward gears.
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Figure 20-62-22
Figure 20-62-27
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-25
2
2
3 1 1 P-64526
Figure 20-62-28 P-64521
Inspect the pre-load seal (Item 1) [Figure 20-62-25] for damage and replace as needed.
4
NOTE: Inspect the pump center section (Item 2) and bushings (Item 3) [Figure 20-62-25]. If excessive wear or damage is visible, the pump must be replaced.
1
Figure 20-62-26 2
1
P-64527
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-62-27] and [Figure 20-62-28] from the pump center section. Inspect for damage and replace as needed. NOTE: Position wear plate (Item 1) [Figure 20-62-28] inlets and traps as shown with bronze side toward gears. P-64525
Remove the pump center section (Item 1) [Figure 20-6226].
NOTE: Inspect the pump center section (Item 3) and bushings (Item 4) [Figure 20-62-28]. If excessive wear or damage is visible, the pump must be replaced.
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3
Figure 20-62-31
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-29
1
P-64530
1 Remove the drive gear (Item 1) [Figure 20-62-31] from the pump flange section.
P-64528
Figure 20-62-32
1
1
P-64531 P-64529
Remove the auxiliary pump section (Item 1) [Figure 2062-29] and [Figure 20-62-30] from the pump flange section.
NOTE: Inspect the drive gear (Item 1) [Figure 20-6232]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Inspect the pump section (Item 1) [Figure 2062-30]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-62-30
Figure 20-62-35
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-33
1 2 1
2
P-64535
Figure 20-62-36 P-64532
Remove the idler gear (Item 2) [Figure 20-62-33]. Figure 20-62-34 1
2 P-64536
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-62-35] and [Figure 20-62-36] from the pump flange section. Inspect for damage and replace as needed.
1
NOTE: Position wear plate (Item 1) [Figure 20-62-36] inlets and traps as shown with bronze side toward gears.
P-64534
NOTE: Inspect the idler gear (Item 1) [Figure 20-6234]. If excessive wear or damage is visible, the pump must be replaced.
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Remove the spline shaft (Item 1) [Figure 20-62-33] from the end of the drive gear.
Figure 20-62-39
HYDRAULIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-62-37
3
2 1
1 P-64540
NOTE: Inspect the pump flange section (Item 2) and bushings (Item 3) [Figure 20-62-39]. If excessive wear or damage is visible, the pump must be replaced.
Figure 20-62-38
Figure 20-62-40
1 2 2
1
P-30188A
P-64538
Remove the load seal (Item 1) [Figure 20-62-37] and [Figure 20-62-38]. Inspect for damage and replace as needed. Remove the pre-load seal (Item 2) [Figure 20-62-38].
P-64541
Remove the shaft seal (Item 1) [Figure 20-62-40] from the pump flange section. Installation: The shaft seal flush surface (Item 2) [Figure 20-62-40] must be facing out away from the pump.
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Inspect the pre-load seal (Item 1) [Figure 20-62-39] for damage and replace as needed.
P-64537
Figure 20-63-2
HYDRAULIC PUMP (HIGH FLOW) (SJC) Test The Output Of The Hydraulic Auxiliary Pump
WARNING 1
2 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Figure 20-63-1
Connect the INLET hose (Item 1) [Figure 20-63-2] from the tester, to the OUTLET hose (Item 1) [Figure 20-63-1] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-63-2] from the tester, to the INLET tubeline (Item 2) [Figure 20-63-1] leading to the hydraulic control valve.
1
2
IMPORTANT P-64570
The hydraulic tester must be in the fully open position before you start the engine.
The tools listed will be needed to do the following procedure:
I-2024-0284
MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.) Disconnect the OUTLET hose (Item 1) [Figure 20-63-1].
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P-48256
Test The Output Of The Hydraulic Charge Pump
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Auxiliary Pump (Cont'd)
WARNING
Figure 20-63-3
Reservoir
EXAMPLE: TESTER CONNECTION
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Figure 20-63-4 Hydraulic Pump Out In Hydraulic Control Valve 1
1 B-16277
Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-63-3] on the tester to about 1000 PSI (6895 kPa). DO NOT exceed system relief pressure. Open the restrictor control and record the free flow (GPM) at full rpm. Push the maximum / variable flow switch (on the remote start tool) to engage the front auxiliary hydraulics. The light will come ON. Push the button (on the right control lever) for fluid flow to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow. %=
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
2 P-64315
The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
X100
Open the rear door of the loader.
A low percentage may indicate a failed pump. *For system relief pressure and full rpm specifications. (See SPECIFICATIONS on Page SPEC-01.)
Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.) Disconnect the charge pump OUTLET hose (Item 1) from the INLET fitting (Item 2) [Figure 20-63-4] at the charge filter housing.
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Sample tester connection shown [Figure 20-63-3].
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)
Turn the restrictor down to 2000 PSI. DO NOT EXCEED 2000 PSI. The high pressure flow must be at least 80% of free flow.
Test The Output Of The Hydraulic Charge Pump (Cont’d)
%=
Figure 20-63-5
HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
X100
A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics for pump flow and full rpm. 2
1
P-48256
Dealer Copy -- Not for Resale
Connect the INLET hose (Item 1) [Figure 20-63-5] from the tester, to the charge pump OUTLET hose (Item 1) [Figure 20-63-4] coming from the gear pump. Connect the OUTLET hose (Item 2) [Figure 20-63-5] from the tester, to the INLET fitting (Item 2) [Figure 20-63-4] at the charge filter housing.
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
Start the engine and run at low idle rpm. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*. Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-63-3] on the tester to about 1000 PSI (6895 kPa). DO NOT exceed 2000 PSI. Open the restrictor control and record the free flow (GPM) at full rpm.
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Figure 20-63-6
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Pump (High Flow)
1
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
P-48463
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Install a jumper hose (Item 1) [Figure 20-63-6] onto the front auxiliary quick couplers. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
W-2059-0598
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
The tools listed will be needed to do the following procedure: MEL1563 - Remote Start Tool MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit Lift and block the loader. (See Procedure on Page 10-101.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Open the rear door of the loader. Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
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WARNING
Figure 20-63-9
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Pump (High Flow) (Cont'd)
Reservoir
EXAMPLE: TESTER CONNECTION
Figure 20-63-7
Hydraulic Pump Out In High Flow Valve 1 1
B-16277
P-48235
Disconnect the high flow pump OUTLET hose (Item 1) from the high flow valve INLET fitting (Item 2) [Figure 2063-7].
Start the engine and run at low idle rpm. Press the front auxiliary button. Press the High Flow button. Push the button (on the right control lever) for fluid flow to the quick coupler. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full rpm*.
Figure 20-63-8 Warm the fluid to 140°F (60°C) by turning the restrictor control (Item 1) [Figure 20-63-9] on the tester to about 1000 PSI (6895 kPa). NOTE: DO NOT EXCEED 3300 PSI. 2
Open the restrictor control and record the free flow (GPM) at full rpm. Turn the restrictor control on the tester to 3300 PSI and the flow should go to zero GPM.
1
If pressure readings are not obtained go to the High Flow Valve, relief valve adjustment procedure. (See High Flow Relief Valve Adjustment Procedure on Page 20-100-3.) P-48256
Record the highest pressure (psi) and flow (GPM). The high pressure flow must be at least 80% of free flow.
Connect the INLET hose (Item 1) [Figure 20-63-8] from the tester, to the high flow pump OUTLET hose (Item 1) [Figure 20-63-7]. Connect the OUTLET hose (Item 2) [Figure 20-63-8] from the tester, to the high flow valve INLET fitting (Item 2) [Figure 20-63-7] on the High Flow valve. Lower the cab.
%=
X100
A low percentage may indicate a failed pump. *Refer to Hydraulic Schematics Legend for system relief pressure and full rpm.
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HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Sample tester connection shown [Figure 20-63-9].
2
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)
Figure 20-63-10
Removal And Installation
DANGER
1 P-64545
P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
Figure 20-63-11
D-1009-0409
1 Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
2
Lift and block the rear of the loader. (See Procedure on Page 10-10-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the hydraulic fluid from the reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Open the rear door of the loader.
P-64546
Disconnect and cap the outlet hoses (Item 1) [Figure 2063-10] and [Figure 20-63-11] from the back of the hydraulic pump. Remove the Power Bob-Tach block (Item 2) [Figure 2063-11] if equipped. (See Removal And Installation on Page 20-120-1.)
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
20-63-6 304 of 949
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•
Figure 20-63-14
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Removal And Installation (Cont’d) Figure 20-63-12
3 1
1 2
P-64343
1
Remove the bracket mounting bolt (Item 1) from the pump mounting bracket (Item 2) [Figure 20-63-14].
Disconnect and cap the inlet hoses (Item 1) [Figure 2063-12] from the front of the hydraulic pump.
NOTE: The mounting bolt is a special purpose bolt. Only replace with original Bobcat Parts. Installation: Apply a medium strength threadlocker to mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136 N•m) torque.
Figure 20-63-13
Remove the mounting bracket (Item 2) [Figure 20-6314]. Remove the hydraulic pump (Item 3) [Figure 20-63-14] from the hydrostatic pump.
1
Figure 20-62-15
1 P-64549
Remove the two mounting bolts (Item 1) [Figure 20-6313] from the hydraulic pump. Installation: Tighten the mounting bolts to 55 - 60 ft.-lb. (75 - 85 N•m) torque. P-64446
Replace the O-ring (Item 1) [Figure 20-62-15] in the hydrostatic pump. Reverse the removal procedure to install the hydraulic pump.
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P-64544
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Identification
17 16 8
12
2
15
4
7 3
14 7
6
13
5
9
6 7
12
7
8 7
9 3
6
3 4
1
5
6
5
4
5
6
11
9 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
2
Shaft Seal Pump Flange Section Pre-Load Seal Load Seal O-ring Valve Plate Pin Drive Gear Idler Gear Auxiliary Pump Section Auxiliary Center Section Splined Shaft Charge Pump Section Charge Center Section High Flow Pump Section High Flow End Section Bolt
B-18248
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8
4 5
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)
Figure 20-63-17
Disassembly And Assembly
1
Figure 20-63-16
1 P-64553
P-64554
1 1
Remove the high flow end section (Item 1) [Figure 2063-17].
P-64552
Dealer Copy -- Not for Resale
Mark the pump sections for correct assembly [Figure 2063-16]. Remove the eight pump housing bolts (Item 1) [Figure 20-63-16]. Installation: Tighten the bolts (Item 2) [Figure 20-63-16] to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
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Figure 20-63-20
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd)
1
Figure 20-63-18
1
P-64556
2
Figure 20-63-21 P-64554
1
3
4
1 P-64557
2
Remove the high flow pump section (Item 1) [Figure 2063-20] and [Figure 20-63-21] from the charge center section.
P-64555
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-18] and [Figure 20-63-19] from the high flow end section.
NOTE: Inspect the high flow pump section (Item 1) [Figure 20-63-21]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-63-19] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the high flow end section (Item 3) and bushings (Item 4) [Figure 20-63-19]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-63-19
Figure 20-63-24
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-22
1 1
P-64560
Figure 20-63-25 P-64558
1 1
P-64561
Remove the idler gear (Item 1) [Figure 20-63-24] and [Figure 20-63-25] from the charge center section.
P-64559
Remove the drive gear (Item 1) [Figure 20-63-22] and [Figure 20-63-23].
NOTE: Inspect the idler gear (Item 1) [Figure 20-6325]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Inspect the drive gear (Item 1) [Figure 20-6323]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-63-23
Figure 20-63-28
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-26
1
1
P-64564
2 Figure 20-63-29 P-64562
2
1 2 1 P-64565
Remove the load seal (Item 1) [Figure 20-63-28] and [Figure 20-63-29]. Inspect for damage and replace as needed.
P-64563
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-26] and [Figure 20-63-27] from the charge center section. Inspect for damage and replace as needed.
Remove the pre-load seal (Item 2) [Figure 20-63-29].
NOTE: Position wear plate (Item 1) [Figure 20-63-27] inlets and traps as shown with bronze side toward gears.
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Figure 20-63-27
Figure 20-63-32
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-30
2
2
3 1 1 P-64569
Figure 20-63-33 P-64567
Inspect the pre-load seal (Item 1) [Figure 20-63-30] for damage and replace as needed.
4
NOTE: Inspect the charge center section (Item 2) and bushings (Item 3) [Figure 20-63-30]. If excessive wear or damage is visible, the pump must be replaced.
1
Figure 20-63-31 2 1
P-64571
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-32] and [Figure 20-63-33] from the charge center section. Inspect for damage and replace as needed. NOTE: Position wear plate (Item 1) [Figure 20-63-33] inlets and traps as shown with bronze side toward gears. P-64568
Remove the charge center section (Item 1) [Figure 2063-31].
NOTE: Inspect the charge center section (Item 3) and bushings (Item 4) [Figure 20-63-33]. If excessive wear or damage is visible, the pump must be replaced.
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3
Figure 20-63-36
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-34 1
1
P-64574
Remove the drive gear (Item 1) [Figure 20-63-36] from the auxiliary center section.
P-64572
Figure 20-63-37
1
1
P-64575 P-64573
Remove the charge pump section (Item 1) [Figure 2063-34] and [Figure 20-63-35] from the auxiliary pump center section.
NOTE: Inspect the drive gear (Item 1) [Figure 20-6337]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Inspect the charge pump section (Item 1) [Figure 20-63-35]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-63-35
Figure 20-63-40
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-38
1
1
2
2
P-64578
Figure 20-63-41
Remove the spline shaft (Item 1) [Figure 20-63-38] from the end of the drive gear. Inspect for damage and replace as needed. Remove the idler gear (Item 2) [Figure 20-63-38].
1 2
Figure 20-63-39
P-64579
1
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-40] and [Figure 20-63-41] from the auxiliary center section. Inspect for damage and replace as needed. NOTE: Position wear plate (Item 1) [Figure 20-63-41] inlets and traps as shown with bronze side toward gears.
P-64577
NOTE: Inspect the idler gear (Item 1) [Figure 20-6339]. If excessive wear or damage is visible, the pump must be replaced.
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P-64576
Figure 20-63-44
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd)
2
Figure 20-63-42 3 1 1
P-64521
NOTE: Inspect the auxiliary center section (Item 2) and bushings (Item 3) [Figure 20-63-44]. If excessive wear or damage is visible, the pump must be replaced.
Figure 20-63-43
2
Figure 20-63-45 1
1 P-64520
Remove the load seal (Item 1) [Figure 20-63-42] and [Figure 20-63-43]. Inspect for damage and replace as needed. Remove the pre-load seal (Item 2) [Figure 20-63-43].
P-64525
Remove the auxiliary center section (Item 1) [Figure 2063-45].
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Inspect the pre-load seal (Item 1) [Figure 20-63-44] for damage and replace as needed.
P-64519
Figure 20-63-48
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-46
2
1 P-64528
1 Figure 20-63-49 P-64526
3
4 1
1 P-64529
2
Remove the auxiliary pump section (Item 1) [Figure 2063-48] and [Figure 20-63-49] from the pump flange section.
P-64527
Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-63-46] and [Figure 20-63-47] from the auxiliary center section. Inspect for damage and replace as needed.
NOTE: Inspect the auxiliary pump section (Item 1) [Figure 20-63-49]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-63-47] inlets and traps as shown with bronze side toward gears. NOTE: Inspect the auxiliary center section (Item 3) and bushings (Item 4) [Figure 20-63-47]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-63-47
Figure 20-63-52
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-50
1 1 2
P-64532
Remove the spline shaft (Item 1) [Figure 20-63-52] from the end of the drive gear.
P-64530
Remove the idler gear (Item 2) [Figure 20-63-52]. Figure 20-63-53
Dealer Copy -- Not for Resale
Remove the drive gear (Item 1) [Figure 20-63-50] from the pump flange section. Figure 20-63-51
1
1
P-64534 P-64531
Remove the idler gear (Item 1) [Figure 20-63-53] from the pump flange section. NOTE: Inspect the drive gear (Item 1) [Figure 20-6351]. If excessive wear or damage is visible, the pump must be replaced.
NOTE: Inspect the idler gear (Item 1) [Figure 20-6353]. If excessive wear or damage is visible, the pump must be replaced.
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Figure 20-63-56
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-54
1
1 2 P-64537
Figure 20-63-57 P-64535
2 1
1
P-64538
Remove the load seal (Item 1) [Figure 20-63-56] and [Figure 20-63-57]. Inspect for damage and replace as needed.
2 P-64536
Remove the wear plate (Item 1) and section seal (Item 2) [Figure 20-63-54] and [Figure 20-63-55] from the pump flange section. Inspect for damage and replace as needed.
Remove the pre-load seal (Item 2) [Figure 20-63-57].
NOTE: Position wear plate (Item 1) [Figure 20-63-55] inlets and traps as shown with bronze side toward gears.
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Figure 20-63-55
Figure 20-63-59
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-63-58
1 2
P-30188A
3
2
P-64541
P-64540
Inspect the pre-load seal (Item 1) [Figure 20-63-58] for damage and replace as needed.
Installation: The shaft seal flush surface (Item 2) [Figure 20-63-59] must be facing out away from the pump.
NOTE: Inspect the pump flange section (Item 2) and bushings (Item 3) [Figure 20-63-58]. If excessive wear or damage is visible, the pump must be replaced.
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Remove the shaft seal (Item 1) [Figure 20-63-59] from the pump flange section.
1
Figure 20-70-2
HYDRAULIC / HYDROSTATIC FILTER HOUSING Removal And Installation
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
2
3
I-2003-0888
P-48260
Implement Filter Housing Disconnect the wires from the charge pressure sender (Item 1) [Figure 20-70-2] from the filter housing.
Figure 20-70-1
Disconnect the wire connector (Item 3) [Figure 20-70-2] from the differential pressure switch on the filter housing.
1
Figure 20-70-3 3 2 P-48259
1 Stop the engine and open the rear door. Drain the hydraulic fluid. (See Replacing Hydraulic Fluid on Page 10-120-2.) Remove the two mounting bolts (Item 1) and remove the hydraulic filter drip pan (Item 2) [Figure 20-70-1]. Disconnect the tubeline (Item 3) [Figure 20-70-1] from the filter housing.
P-48257
Using MEL 1558 tool disconnect the oil cooler tubeline (Item 1) [Figure 20-70-3] from the filter housing.
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Disconnect the temperature sender connector (Item 2) [Figure 20-70-2] from the filter housing.
Charge Filter Housing
HYDRAULIC / HYDROSTATIC FILTER HOUSING (CONT’D)
Stop the engine and open the rear door.
Removal And Installation (Cont’d)
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-70-4
Figure 20-70-5 1 1 1
P-48258
Installation: Tighten the mounting screws to 15 - 20 ft.lb. (20 - 27 N•m) torque.
Disconnect the hoses (Item 1) [Figure 20-70-5] from the filter housing.
Remove the hydraulic filter housing and filter.
Disconnect the hose (Item 2) [Figure 20-70-5] from the filter housing.
Reverse the removal procedure to install the filter housing and filter.
Figure 20-70-6
2
1 2 P-64317
Disconnect the wire connector (Item 1) [Figure 20-70-6] from the differential pressure switch on the filter housing. Remove the four mounting bolts (Item 2) [Figure 20-706] from the filter housing. Remove the hydraulic filter housing and filter. Reverse the removal procedure to install the filter housing and filter. 20-70-2 320 of 949
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P-64317
Remove the two mounting screws (Item 1) [Figure 2070-4] from the filter housing mounting bracket.
HYDRAULIC FLUID RESERVOIR
WARNING
Fluid Removal Figure 20-80-1
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
1
W-2059-0598
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
Remove the plug (Item 1) [Figure 20-80-1] from the hydraulic reservoir.
I-2003-0888
Stop the engine.
Remove the fluid from the tank with pump.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Removal And Installation Lift and block the loader. (See Procedure on Page 10-101.) Start the engine. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Remove the fluid from the hydraulic reservoir. Remove the control panel.(See Removal And Installation on Page 50-100-1.) Remove Bucket position valve if so equipped. (See Removal And Installation on Page 20-90-2.) Remove the crossbar linkage. (See Crossbar Linkage Removal And Installation on Page 50-90-2.)
DANGER
Figure 20-80-2
2
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
1 P-34113
Remove the left [Figure 20-80-2]. Remove the two [Figure 20-80-2].
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rear
tire
access
assembly panels
(Item (Item
1) 2)
S150, S160 Bobcat Loader Service Manual
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P-34037
Figure 20-80-5
HYDRAULIC FLUID RESERVOIR (CONT’D) Removal And Installation (Cont’d) Figure 20-80-3
1
1 2 3
2
P-34040
Remove the drive motor drain [Figure 20-80-5] at the drain filter
Remove the two mounting bolts (Item 1) and remove the plate (Item 2) [Figure 20-80-3] from the loader.
(Item
1)
Remove the auxiliary pressure relief drain hose (Item 2) [Figure 20-80-5] at the drain filter. Remove the drive [Figure 20-80-5].
Figure 20-80-4
hose
motor
supply
hose
(Item
3)
Figure 20-80-6
2
1 3
2
1 P-34038N19059 P-34039
Remove the tie-straps (Item 1) [Figure 20-80-4] from the breather hose. Remove the hose clamp (Item 2) [Figure 20-80-4].
Remove the two control valve drain hoses (Item 1) [Figure 20-80-6].
Remove the hydraulic fill hose (Item 3) [Figure 20-80-4] from the hydraulic reservoir.
Remove the fitting (Item 2) [Figure 20-80-6] from the reservoir.
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P-34037
Figure 20-80-9
HYDRAULIC FLUID RESERVOIR (CONT’D) Removal And Installation (Cont’d) Figure 20-80-7
2
1 1
2 P-34044
Remove the hose clamp (Item 1) [Figure 20-80-9] from the fitting.
Remove the hose clamp (Item 1) [Figure 20-80-7] from the tank outlet.
Remove the breather hose (Item 2) [Figure 20-80-9] from the hydraulic reservoir.
Dealer Copy -- Not for Resale
P-34042
Figure 20-80-10 Remove the hydrostatic supply hose (Item [Figure 20-80-7] from the bottom of the reservoir.
2)
Figure 20-80-8 1
1 2
P-34053
If the loader is equipped with rear auxiliaries remove the auxiliary tubeline (Item 1) [Figure 20-80-10] to allow the hydraulic reservoir to roll out from under the fender.
P-34043
Remove the bolt and nut (Item 1) [Figure 20-80-8]. Loosen the bolt and nut (Item 2) [Figure 20-80-8] to allow the hydraulic reservoir mount to drop down.
NOTE: Standard loaders without rear auxiliaries and all high flow loaders will have a one-piece auxiliary tubeline from the control valve to the rear upright hoses. Disconnect the tubeline (Item 1) [Figure 20-80-10] from the control valve and loosen the fitting in the left rear upright to allow movement of the tubeline for the hydraulic reservoir removal.
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HYDRAULIC FLUID RESERVOIR (CONT’D) Removal And Installation (Cont’d) Figure 20-80-11
1
P-34052
Dealer Copy -- Not for Resale
Remove the hydraulic reservoir (Item 1) [Figure 20-8011] from the loader.
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Figure 20-90-3
BUCKET POSITION VALVE Solenoid Removal And Installation Figure 20-90-1
1
1
2 2 N-18191
Inspect the solenoid stem and replace the O-rings (Item 1) and the back-up washer (Item 2) [Figure 20-90-3].
Disconnect the wire harness connector (Item 1) [Figure 20-90-1].
Solenoid Testing
Dealer Copy -- Not for Resale
P-34024
Figure 20-90-4 Remove the solenoid nut (Item 2) [Figure 20-90-1] Installation: Tighten the solenoid nut to 60 in.-lb. (6,78 N•m) torque. Figure 20-90-2
1
P-9175
Use a test meter to measure coil resistance [Figure 20-90-4]. Coil wires do not have polarity. Correct resistance for the coil is 9.7 ohm ± 1 ohm @ 78° F. P-34025
Replace the test meter with 12 volt power. You can see and hear the spool shift. Remove the solenoid stem (Item 1) [Figure 20-90-2] from the bucket positioning valve. Installation: Put oil on the O-rings and back-up washers and tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6 N•m) torque.
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BUCKET POSITION VALVE (CONT’D)
Figure 20-90-5
Removal And Installation Start the engine. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) 2
2
DANGER 1
1
P-34166
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Remove the four steering linkage mounting bolts (Item 2) [Figure 20-90-5]. Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 25 28 ft.-lb. (34 - 38 N•m) torque. Figure 20-90-6
WARNING
1
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
2
W-2059-0598
P-34024
IMPORTANT
Disconnect the wire harness connector (Item 1) [Figure 20-90-6].
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
Remove the solenoid nut (Item 2) [Figure 20-90-6]. Installation: Tighten the solenoid nut to 60 in.-lb. (6,78 N•m) torque.
I-2003-0888
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P-90328
Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 20-90-5] which are connected to the steering shaft on the control panel.
Figure 20-90-9
BUCKET POSITION VALVE (CONT’D) Removal And Installation (Cont’d) Figure 20-90-7
1 2
1
3 P-34027
Remove the lift tubeline (Item 1) [Figure 20-90-9] from the A port.
P-34026
Figure 20-90-10
Remove the lift tubeline (Item 2) [Figure 20-90-7] from the B port.
1
Remove the tilt tubeline (Item 3) [Figure 20-90-7] from the D port. Figure 20-90-8
P-34029
Remove the mounting bolts (Item 1) [Figure 20-90-10]. 1 Remove the bucket position valve from the loader.
P-34028
Remove the lift tubeline (Item 1) [Figure 20-90-8] from the A port of the bucket positioning valve.
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Remove the tilt tubeline (Item 1) [Figure 20-90-7] from the C port.
Figure 20-90-13
BUCKET POSITION VALVE (CONT’D) Disassembly And Assembly Figure 20-90-11
1 1 N-19072
NOTE: Always install new O-rings before any parts are installed into the valve. Check the parts for wear or damage and replace as needed.
Remove the solenoid nut (Item 1) [Figure 20-90-11]. Installation: Tighten the nut to 60 in.-lb. (6,78 N•m) torque.
Figure 20-90-14
Figure 20-90-12
2
1 1
N-19041 N-19070
Remove the plug (Item 1) [Figure 20-90-14]. Remove the solenoid (Item 1) and the solenoid stem (Item 2) [Figure 20-90-12]. Installation: Tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6 N•m) torque.
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Remove the flow adjustment valve and O-ring (Item 1) [Figure 20-90-13].
N-19069
Figure 20-90-17
BUCKET POSITION VALVE (CONT’D) Disassembly And Assembly (Cont’d) Figure 20-90-15
2
1 N-19045
Remove the plug [Figure 20-90-17]. N-18339
Figure 20-90-18
Inspect the flow control spool for wear, inspect the O-ring on the plug and replace as needed. 3
Figure 20-90-16
2 1 N-19046
1 Remove the plug (Item 1), spring (Item 2) and unloading spool (Item 3) [Figure 20-90-18].
2
Inspect all parts and replace as needed. Install a new Oring on the plug before installing.
3 N-19042
Remove the tilt cylinder check valve (item 1) spring (Item 2) and plug (Item 3) [Figure 20-90-16]. Inspect for wear, inspect the O-ring and replace as needed.
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Dealer Copy -- Not for Resale
Remove the plug (Item 1), and flow control spool (Item 2) [Figure 20-90-15].
Dealer Copy -- Not for Resale 20-90-6 330 of 949
S150, S160 Bobcat Loader Service Manual
HIGH FLOW VALVE
WARNING
Testing The High Flow Relief Valve Figure 20-100-1
2
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
1
W-2017-0286
Figure 20-100-2
3
1
P-34480
2
MEL10003 - Hydraulic Tester MEL10006 - Hydraulic Test Kit
N-18409
Lift and block the loader. (See Procedure on Page 10-101.) NOTE: Test the Main Relief Valve (See Testing on Page 20-30-1) for proper flow and pressure before checking the High Flow Relief Valve. Connect the IN port of the hydraulic tester to the female quick coupler (Item 1) [Figure 20-100-1] on the loader.
Start the engine and run at low idle rpm. Push the flow switch (Item 1) once (on the instrument panel) to engage the front auxiliary hydraulics variable flow, the light (Item 2) will come ON [Figure 20-100-2]. Push the high flow switch (Item 3) [Figure 20-100-2] and the High Flow light will come ON.
Connect the OUT port of the hydraulic tester to the male quick coupler (Item 2) [Figure 20-100-1] on the loader.
IMPORTANT The hydraulic tester must be in the fully open position before you start the engine. I-2024-0284
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
The tools listed will be needed to do the following procedure:
HIGH FLOW VALVE (CONT'D) Testing The High Flow Relief Valve (Cont’d) Figure 20-100-3 Right Steering Lever Control
1
•
Push the front switch (Item 1) [Figure 20-100-3] to give the front quick couplers a constant flow of fluid.
•
To release from continuous operation, press the front switch (Item 1) [Figure 20-100-3] a second time.
Dealer Copy -- Not for Resale
P-31833
Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full rpm. Warm the fluid to 140°F (60°C) by turning the restrictor control on the tester to about 1000 PSI (6895 kPa). DO NOT exceed system relief pressure. NOTE: DO NOT EXCEED 3300 PSI. Turn the restrictor control on the tester counter clockwise, to obtain free flow, the flow should be at 27 GPM. Start turning the restrictor clockwise, causing more restriction on the flow. The GPM should drop off slightly until the pressure reaches approximately 3100 PSI. At approximately 3100 PSI the flow should start decreasing rapidly until the pressure reaches 3250 - 3350 PSI. At 3250 - 3350 PSI the flow should be at 0 GPM. Turn the restrictor control counter clockwise to free flow. Shut the front auxiliary hydraulics off. If the specs from above are reached, the high flow relief valve is OK. If the high flow relief pressure is not correct, stop the engine and adjust the high flow relief valve. (See High Flow Relief Valve Adjustment Procedure on Page 20100-3.)
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Figure 20-100-5
HIGH FLOW VALVE (CONT'D) High Flow Relief Valve Adjustment Procedure NOTE: The high flow relief valve is located between the control valve and the hydraulic reservoir. Figure 20-100-4
1
1
P-45469
To increase the high flow relief valve PSI turn the screw (Item 1) [Figure 20-100-5] clockwise a 1/4 turn and recheck the high flow relief valve. (1/4 turn equals approximately 200 PSI.)
If the relief pressure is not correct, stop the engine and raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the high flow relief valve adjustment plug (Item 1) [Figure 20-100-4].
To decrease the high flow relief valve PSI turn the screw (Item 1) [Figure 20-100-5] counterclockwise a 1/4 turn and recheck the high flow relief valve. (1/4 turn equals approximately 200 PSI.) NOTE: If the relief screw (Item 1) [Figure 20-100-5] has been turned in 1/4 turn and the pressure remains the same, remove and inspect the high flow relief valve, replace as needed. Install the plug into the high flow relief valve.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
P-48231
HIGH FLOW VALVE (CONT'D)
Figure 20-100-7
Removal And Installation Figure 20-100-6
2
2
1
1
P-48236
1 Disconnect the electrical connector (Item 1) [Figure 20100-7] from the solenoid.
P-48235
Remove the four steering linkage mounting bolts (Item 2) [Figure 20-100-6].
2
Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 25 28 ft.-lb. (34 - 38 N•m) torque. The high flow valve is located between the control valve and the hydraulic reservoir.
1
P-48238
IMPORTANT
Mark all tubelines and hoses for correct installation.
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
Disconnect and cap the hose (Item 1) [Figure 20-100-8] from the pump outlet to the high flow valve. Disconnect and cap the hose (Item 2) [Figure 20-100-8] from the high flow valve to the pump inlet.
I-2003-0888
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Figure 20-100-8 Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 20-100-6] which are connected to the steering shaft on the control panel.
HIGH FLOW VALVE (CONT'D) Removal And Installation (Cont’d) Figure 20-100-9
1 1 2
P-48232
Dealer Copy -- Not for Resale
Disconnect and cap the tubelines (Item 1) [Figure 20100-9] to the tilt cylinders. Remove the two mounting bolts (Item 2) [Figure 20-1009]. Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Figure 20-100-12
HIGH FLOW VALVE (CONT'D) Disassembly And Assembly Figure 20-100-10
2
1 2
1 P-48110
Inspect O-rings (Item 1) and back-up washer (Item 2) on the solenoid stem [Figure 20-100-12].
Remove the solenoid nut (Item 1) and solenoid (Item 2) from the solenoid valve [Figure 20-100-10].
Installation: Put oil on O-rings and back-up washer. Install and tighten to 25 ft.-lb. (39,9 N•m) torque.
Dealer Copy -- Not for Resale
P-48108
Figure 20-100-13 Installation: Tighten to 4 - 6 ft.-lb. (5 - 8 N•m) torque. Figure 20-100-11
1
1
P-48111
Remove the relief valve (Item 1) [Figure 20-100-13].
P-48109
Remove the solenoid valve (Item 1) [Figure 20-100-11] from the valve.
Installation: Apply to oil to the O-rings and back-up washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
Installation: Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
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Figure 20-100-16
HIGH FLOW VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-100-14
1
1 P-48113
2 Remove the check valve (Item 1) [Figure 20-100-16] from the high flow valve.
P-48112
Figure 20-100-17
Figure 20-100-15 1 2
1
P-48114
Inspect the check valve and replace the two O-rings (Item 1) and back-up washer (Item 2) [Figure 20-10017].
P-45469
Inspect the O-ring (Item 1) [Figure 20-100-15] on the relief valve adjustment plug for damage and replace as needed.
Installation: Apply oil to the O-rings and back-up washer. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
Installation: Tighten to 20 ft.-lb. (27,1 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Inspect the relief valve and replace the two O-rings (Item 1) and back-up washer (Item 2) [Figure 20-100-14].
HIGH FLOW VALVE (CONT'D) Solenoid Testing Figure 20-100-18
P9175
Dealer Copy -- Not for Resale
Use a test meter to measure coil resistance [Figure 20100-18]. Coil terminals do not have polarity. Correct resistance for the pressure relief coil is 7.5 ohm. Replace the test meter with 12 volt power. You can see and hear the spool shift.
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Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
REAR AUXILIARY DIVERTER VALVE Removal And Installation
Disconnect the negative battery cable. (See Removal And Installation on Page 60-20-1.)
DANGER
Remove the speed control lever. (See Joystick Removal (Right And Left) on Page 50-112-2.) Remove the control panel. (See Removal And Installation on Page 50-100-1.) Remove the right rear tire. (See TIRE MAINTENANCE on Page 10-170-1.) Figure 20-110-1
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
1
D-1009-0409
WARNING P-48301
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
The rear auxiliary valve (Item 1) [Figure 20-110-1] is located between the control valve and the gear pump on the right side of the loader.
W-2059-0598
IMPORTANT
WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
W-2103-0508
Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
P-90328
Figure 20-110-4
REAR AUXILIARY DIVERTER VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-110-2
1 1
P-48300
Disconnect the four solenoid connectors (Item 1) [Figure 20-110-4] from the rear auxiliary valve.
2 P-48302
Figure 20-110-5
Remove the fittings (Item 2) [Figure 20-110-2] from the valve. 1
Figure 20-110-3
1 P-48304
Disconnect the drain tubeline (Item 1) [Figure 20-110-5] from the lift arm by pass valve. Figure 20-110-6
P-48872
Remove the three access covers (Item 1) [Figure 20110-3] on the right side of the machine.
1
P-48303
Disconnect and remove the drain tubeline (Item 1) [Figure 20-110-6] from the rear auxiliary valve. 20-110-2 340 of 949
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Dealer Copy -- Not for Resale
Disconnect the base and rod end tubelines (Item 1) [Figure 20-110-2].
Figure 20-110-9
REAR AUXILIARY DIVERTER VALVE (CONT'D) Removal And Installation (Cont'd) Figure 20-110-7
1
2 P-48870
1
Disconnect the pump outlet hose (Item 1) [Figure 20110-7] from the rear auxiliary valve.
The valve needs to be tilted as shown in [Figure 20-1109] for it to be removed through the hole.
Disconnect the tubeline (Item 2) [Figure 20-110-7] from the bottom of the control valve and the rear auxiliary valve. Figure 20-110-8
1
1
P-48869
Loosen and remove the two bolts and nuts (Item 1) [Figure 20-110-8] that hold the rear auxiliary valve.
20-110-3 341 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Remove the rear auxiliary valve (Item 1) [Figure 20-1109] by moving the valve to the rear access hole which allows enough room for the valve to be removed from the loader.
P-48305
REAR AUXILIARY DIVERTER VALVE (CONT'D)
IMPORTANT
Disassembly And Assembly Figure 20-110-10
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Figure 20-110-12
1 1 1 P-48751
P-48755
1
Remove the shuttle valve (Item 1) [Figure 20-110-12]. Figure 20-110-13
P-48752
1
1
1
Clean the diverter valve to remove dirt before disassembly. Valve ports are labeled for correct assembly. Several plugs (Item 1) [Figure 20-110-10] and [Figure 20-110-11] are located all over the diverter valve and can be removed for cleanout purposes.
2 P-48756
Installation: Put oil on O-rings and back-up washers.Tighten to 10 ft.-lb. (13,6 N•m) torque.
Inspect the O-rings (Item 1) and back-up washers (Item 2) [Figure 20-110-13] for damage. Installation: Put oil on the O-rings and back-up washers. Tighten to 10 - 12 ft.-lb. (14 - 16 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Figure 20-110-11
Figure 20-110-16
REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-110-14
1
P-48753
1
Remove the relief valve (Item 1) [Figure 20-110-16]. P-48755
Figure 20-110-17
1 Figure 20-110-15
2 2
P-48754
Inspect the O-rings (Item 1) and back-up washer (Item 2) [Figure 20-110-17] for damages.
1 P-48757
Installation: Put oil on O-rings and back-up washer. Tighten to 20 - 25 ft.-lb. (27 - 34 N•m) torque. Inspect the O-rings (Item 1) and back-up washers (Item 2) [Figure 20-110-15] for damages. Installation: Put oil on O-rings and back-up washers. Tighten to 50 - 55 ft.-lb. (68 - 75 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Remove the differential sensing valve (Item 1) [Figure 20-110-14].
Figure 20-110-20
REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-110-18
1
1
P-48761
NOTE: Before removing the solenoid coils mark the coils for proper alignment.
P-48759
Installation: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m) torque.
3
1 2
P-48760
NOTE: Before removing the solenoid coils mark the coils for proper alignment. Remove the nut (Item 1) [Figure 20-110-18] and [Figure 20-110-19] from the solenoid valve stem. Installation: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m) torque. Remove the spacer (Item 2) and solenoid valve coils (Item 3) [Figure 20-110-19].
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Remove the nuts (Item 1) [Figure 20-110-20] from the solenoid valve stems.
Figure 20-110-19
Figure 20-110-23
REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd)
1
Figure 20-110-21
1
P-48763A
Figure 20-110-24 P-48762
1
2 1
2
2 1
P-48764
Remove the solenoid valve stem (Item 1) [Figure 20110-23] and [Figure 20-110-24] and inspect the O-rings and back-up washers (Item 2) [Figure 20-110-24] for damage.
P-48763
Remove the solenoid valve stems (Item 1) [Figure 20110-21] and [Figure 20-110-22] and inspect the O-rings and back-up washers (Item 2) [Figure 20-110-22] for damage.
Installation: Put oil on O-rings and back-up washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
Installation: Put oil on O-rings and back-up washers. Tighten to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
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Dealer Copy -- Not for Resale
Figure 20-110-22
Figure 20-110-27
REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-110-25
1
1
P-48765
Remove the plug (Item 1) [Figure 20-110-27]. P-48765
Installation: Tighten the plug to 10 ft.-lb. (13,6 N•m) torque. Remove the plug (Item 1) [Figure 20-110-25].
Dealer Copy -- Not for Resale
Figure 20-110-28 Installation: Tighten the plug to 38 ft.-lb. (51,5 N•m) torque. Figure 20-110-26
1
P-48786
Remove the orifice (Item 1) [Figure 20-110-28].
1 P-48766
Installation: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m) torque. Remove and inspect the orifice (Item 1) [Figure 20-11026] for dirt and debris. Installation: Tighten the orifice to 22 ft.-lb. (29,8 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT'D)
Solenoid Testing
Disassembly And Assembly (Cont'd)
Figure 20-110-30
Figure 20-110-29
1
P9137
Remove the plugs (Item 1) [Figure 20-110-29].
Use a test meter to measure coil resistance [Figure 20110-30]. Coil wires do not have polarity. Correct resistance is 8.6 - 9.5 ohm @ 68° F.
Installation: Tighten the plug to 14 ft.-lb. (19 N•m) torque.
Replace the test meter with 12 volt power. You can see and hear the spool shift. Inspection Inspect cartridges, check valves, solenoid valves and sealing washers for contamination or damage. Wash all parts in clean solvent. Use air pressure for drying them. Install new O-rings and back-up washers. Inspect diverter valve cavities for contamination. Wash valve in clean solvent. Use air pressure to dry.
20-110-9 347 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
P-48758
Dealer Copy -- Not for Resale 20-110-10 348 of 949
S150, S160 Bobcat Loader Service Manual
POWER BOB-TACH BLOCK
Figure 20-120-1
Removal And Installation
3
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
1 2
W-2059-0598
3 P-48229
DANGER
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Open the rear door. Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Remove the nut from the speed control linkage (Item 1) and unplug the rear lights electrical connector (Item 2) [Figure 20-120-1]. Remove the fuel fill bracket mounting bolts (Item 3) [Figure 20-120-1].
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
20-120-1 349 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Lift and block the loader. (See Procedure on Page 10-101.)
Figure 20-120-4
POWER BOB-TACH BLOCK (CONT'D) Removal And Installation (Cont'd) Figure 20-120-2
1
1 1
P-48227
Remove the four mounting bolts (Item 1) [Figure 20-1204].
Installation: The harness connectors are marked with Red or Black tie straps. Be sure the connectors with the same color are connected. Disconnect the power Bob-Tach harness from the solenoid connectors (Item 1) [Figure 20-120-2] by the hydraulic pump.
Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the power Bob-Tach block. NOTE: There is an O-ring in-between the power BobTach block and the hydraulic pump. Inspect and replace as needed.
Figure 20-120-3
4 1
2 3 P-48226
Disconnect the hose (Item 1) [Figure 20-120-3] from the “DR” port fitting on the block. Disconnect the hose (Item 2) [Figure 20-120-3] from the power Bob-Tach cylinder rod end fitting on the block. Disconnect the hose (Item 3) [Figure 20-120-3] from the power Bob-Tach cylinder base end fitting on the block. Disconnect the outlet hose (Item 4) [Figure 20-120-3] from the fitting on top of the block. 20-120-2 350 of 949
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Dealer Copy -- Not for Resale
P-48230
POWER BOB-TACH BLOCK (CONT'D)
Figure 20-120-6
Disassembly And Assembly Figure 20-120-5
3
1 4
2 2 1 P-48120
Remove the spring guide (Item 1), spring (Item 2) and the spool (Item 3) [Figure 20-120-6].
Clean the block (Item 1) [Figure 20-120-5] to remove dirt before disassembly. Block ports are labeled for correct assembly.
Inspect the O-ring (Item 4) [Figure 20-120-6] on the plug and replace as needed.
Dealer Copy -- Not for Resale
P-48115
Figure 20-120-7
Remove the plug (Item 2) [Figure 20-120-5]. Installation: Tighten the plug to 25 - 30 ft.-lb. (34 - 40,6 N•m) torque.
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
P-48116
I-2003-0888
NOTE: This plug is a zero leak plug and should not be removed. If removed damage may occur and the plug and O-ring must be replaced. Do not remove the plug (Item 1) [Figure 20-120-7]. Installation: Tighten the plug to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Figure 20-120-10
POWER BOB-TACH BLOCK (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-120-8
1 1 P-48122
Do not remove the plugs (Item 1) [Figure 20-120-10]. P-48382
Remove the check valve (Item 1) [Figure 20-120-8]. Installation: Oil the check valve and O-rings and tighten the check valve to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.
Dealer Copy -- Not for Resale
NOTE: Do not remove plugs. If the plugs are removed the internal pressure relieving spring setting will be altered. Figure 20-120-11
Figure 20-120-9
1 2 1 P-48384
3 Remove the plug (Item 1) [Figure 20-120-11], inspect the O-ring and replace as needed.
P-48119
Inspect the check valve (Item 1) and piston assembly (Item 2) [Figure 20-120-9].
Installation: Tighten the plug (Item 1) [Figure 20-12011] to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
Inspect the O-rings and back up washers (Item 3) [Figure 20-120-9] on the check valve and piston assembly and replace as needed.
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S150, S160 Bobcat Loader Service Manual
Figure 20-120-14
POWER BOB-TACH BLOCK (CONT'D) Disassembly And Assembly (Cont'd)
3
Figure 20-120-12 2 1
2 1 P-48106
Remove the orifice screw (Item 2) located behind the plug (Item 1) [Figure 20-120-12].
NOTE: Remember the solenoid coil orientation for ease of installation.
Installation: Tighten the orifice screw (Item 2) [Figure 20-120-12] to 6 - 8 ft.-lb. (8,1 - 10,8 N•m) torque.
Figure 20-120-15
Figure 20-120-13
1
1 2
P-48386
Remove the solenoid stem (Item 1) [Figure 20-120-15].
P-48127
NOTE: This plug is a zero leak plug and should not be removed. If removed damage may occur and the plug and O-ring must be replaced.
Installation: Tighten the solenoid stem to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.
Do not remove the plug (Item 1) [Figure 20-120-13]. Remove the solenoid nut (Item 2) [Figure 20-120-13]. Installation: Tighten the solenoid valve stem nut to 15 45 in.-lb. (1,7 - 5,1 N•m) torque.
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Dealer Copy -- Not for Resale
Remove the first solenoid coil (Item 1), spacer (Item 2) and the second solenoid coil (Item 3) [Figure 20-12014].
P-48664
Figure 20-120-18
POWER BOB-TACH BLOCK (CONT'D) Disassembly And Assembly (Cont'd) Figure 20-120-16
1
P-48174
1 Remove the screened orifice plug (Item 1) [Figure 20120-18].
Remove the armature rod assembly (Item 1) [Figure 20120-16].
Installation: Tighten the screened orifice plug to 11 - 12 ft.-lb. (14,9 - 16,3 N•m) torque.
Dealer Copy -- Not for Resale
P-48175
Figure 20-120-19 Figure 20-120-17
3 2
2 1
1 P-48138 P-48173
Inspect the solenoid stem (Item 1), armature assembly (Item 2) and the spool (Item 3) for damage [Figure 20120-17]. NOTE: If the solenoid stem is damaged (Item 1) inspect the armature assembly (Item 2) for damage.
Inspect the screened orifice plug (Item 1) [Figure 20120-19] for damage replace as needed. If the screened orifice plug is blocked replace with a new plug. Inspect the O-ring (Item 2) [Figure 20-120-19] and replace as needed.
The armature assembly (Item 2) and spool (Item 3) are non-serviceable parts. If they are damaged, order a new power Bob-Tach block assembly from Bobcat parts [Figure 20-12017].
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FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Disassembly And Assembly
Removal And Installation
Figure 20-130-2
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
2 4 3
I-2003-0888
Figure 20-130-1 P-34661
Figure 20-130-3
1 1 3 6
2
4 5
3
P-34360
Disconnect the auxiliary tubelines (Item 1) and drain tubeline (Item 2) [Figure 20-130-1] from the coupler block. Remove the two mounting bolts (Item 3) [Figure 20-1301].
P-34760
Remove the male coupler (Item 1) [Figure 20-130-2] and [Figure 20-130-3]. Installation: Tighten the male coupler (Item 1) [Figure 20-130-2] and [Figure 20-130-3] to 59 ft.-lb. (80 N•m) Remove the drain coupler (Item 2) [Figure 20-130-2] and [Figure 20-130-3]. Installation: Tighten the drain coupler (Item 2) [Figure 20-130-2] and [Figure 20-130-3] to 37 ft.-lb. (50 N•m) Remove the female coupler (Item 3) [Figure 20-130-2] and [Figure 20-130-3]. Installation: Tighten the female coupler (Item 3) [Figure 20-130-2] and [Figure 20-130-3] to 59 ft.-lb. (80 N•m) Remove the fittings (Item 4) [Figure 20-130-2] and [Figure 20-130-3] inspect the O-rings (Item 5) [Figure 20-130-3] and replace as needed. Remove the springs (Item 6) [Figure 20-130-3].
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2
Figure 20-130-6
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (CONT’D) Disassembly And Assembly (Cont’d)
1
Figure 20-130-4
1 2 P-34665
Inspect the O-rings (Item 1) back-up O-rings (Item 2) [Figure 20-130-6] for damage and replace as needed. P-34663
Inspect the O-ring (Item 1) [Figure 20-130-4] for damage and replace as needed.
1
Figure 20-130-5
1
2 P-34664
Inspect the O-rings (Item 1) back-up O-rings (Item 2) [Figure 20-130-7] for damage and replace as needed. P-34701
Press center of male couplers down and inspect the Oring (Item 1) [Figure 20-130-5] for damage and replace as needed. .
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Figure 20-130-7
HYDROSTATIC SYSTEM 30-30-1 30-30-2 30-30-4 30-30-1 30-30-3 30-30-1 30-30-3
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Disassembly . . . . . . . . . . . . . . . . . . . . . . Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . Tensioner Pulley Removal And Installation . . . . . . . . . . . .
30-50-1 30-50-1 30-50-3 30-50-1 30-50-7 30-50-6 30-50-5 30-50-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 Assembly (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 Disassembly And Assembly (Dry Bolt) . . . . . . . . . . . . . . 30-20-16 Disassembly (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 Parts Identification (Dry Bolt) . . . . . . . . . . . . . . . . . . . . . . 30-20-15 Parts Identification (Wet Bolt) . . . . . . . . . . . . . . . . . . . . . . 30-20-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
30-21-1 30-21-6 30-21-5 30-21-3 30-21-1
HYDROSTATIC MOTOR CARRIER (SJC) . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
30-22-1 30-22-6 30-22-5 30-22-3 30-22-1
SAFETY MAINTENANCE
HYDROSTATIC SYSTEM
DRIVE SYSTEM
ELECTRICAL SYSTEM ANALYSIS ENGINE SERVICE
SPECIFICATIONS
Continued On Next Page
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CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . Adjusting (SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . Sender Removal And Installation (Non SJC Machines) . . Sender Removal And Installation (SJC Machines) . . . . . . Testing (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . Testing (SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . .
S150, S160 Bobcat Loader Service Manual
HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1 Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-8 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6 High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-7 Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 30-41-28 Hydraulic Controller Removal And Installation. . . . . . . . . . . . . . . . . . . . . 30-41-2 Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-25 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-4 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
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HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9 Hydraulic Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8 Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6 Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4 Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2 Replenishing / High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
HYDROSTATIC SYSTEM INFORMATION
WARNING
Troubleshooting Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W-2004-1285
PROBLEM
CAUSE
No drive on one side, in one direction. No drive on one side in both directions. The loader does not move in a straight line. The hydrostatic system is overheating. Hydraulic Service codes appear. (Warnings, low charge pressure.)
1, 2 2, 3, 4, 5 2, 3, 5, 6, 7 8, 9, 10, 11 8, 11, 12, 13
KEY TO CORRECT THE CAUSE 1. The hydrostatic pump replenishing valves not seating.
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2. The steering linkage needs adjustment. 3. The hydrostatic pump has damage. 4. The final drive chains are broken. 5. The hydrostatic motor has damage. 6. The tires do not have the correct tire pressure. 7. The tires are not the same size. 8. The hydrostatic fluid is not at the correct level. 9. The oil cooler has a restriction. 10. The temperature sending switch is not operating correctly. 11. The loader is not being operated at the correct rpm. 12. The hydraulic charge pressure sender is defective. 13. Pump is defective or worn hydrostatics.
S150, S160 Bobcat Loader Service Manual
HYDROSTATIC SYSTEM INFORMATION
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Replenishing Valve Function Figure 30-10-8
FUNCTION 1
FUNCTION 2
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CHARGE OIL
Valve Moves for Charge Oil Replacement
Valve Stays on Seat to Hold High Pressure for Drive B-2804
The functions of the replenishing valves are: 1. To give replacement fluid to the low pressure side of the hydrostatic circuit. Replacement fluid is needed because of normal internal leakage and the controlled flow to the oil cooler for cooling; Function 1 [Figure 30-10-8]. 2. To keep high pressure fluid out of the low pressure side of the hydrostatic circuitry; Function 2 [Figure 30-10-8].
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Removal And Installation
HYDROSTATIC MOTOR Description
DANGER
Two types of hydrostatic drive motors have been used on this model loader. Both designs remove and install the same. Figure 30-20-1
P-90328
•
•
1
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
The early design is identified by the tie bolts (Item 1) [Figure 30-20-1] mounting from the inside of the hydrostatic drive motor with the heads of the tie bolts immersed in the hydraulic oil. The tie bolts are not visible when the hydrostatic drive motor is installed on the loader. This type is called the “wet bolt” design. Figure 30-20-2
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.
1
W-2103-0508 P-39894
The later design has the tie bolts (Item 1) [Figure 30-203] mounting from the outside of the hydrostatic drive motor. The tie bolt heads are not immersed in hydraulic oil and are visible when the hydrostatic drive motor is installed on the loader. This type is called the “dry bolt” design.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the front and rear wheel / tire assemblies. (See TIRE MAINTENANCE on Page 10-170-1.) Remove the control panel. (See Removal And Installation on Page 50-100-1.)
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D-1009-0409
N-00621
Figure 30-20-5
HYDROSTATIC MOTOR (CONT’D) Removal And Installation (Cont’d) Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.)
1
1
Figure 30-20-3
1
N-19240
Remove the four drive motor mounting bolts (Item 1) [Figure 30-20-5].
1
Dealer Copy -- Not for Resale
Installation: Tighten the drive motor mounting bolts to 90 - 100 ft.-lb. (122 - 136 N•m) torque. Figure 30-20-6 P-34004
Remove the four motor cover mounting bolts (Item 1) [Figure 30-20-3].
2
Figure 30-20-4 1
P-4141
1 Remove the drive motor from the access hole in the loader frame [Figure 30-20-6].
2
Inspect drive motor O-ring (Item 1) and carrier shaft seal (Item 2) [Figure 30-20-6]. N-19238
Reverse the removal HYDROSTATIC MOTOR.
procedure
to
install
the
Mark the two hoses (Item 1) [Figure 30-20-4] before disconnecting them from the HYDROSTATIC MOTOR for correct installation. Remove the two hoses (Item 1) [Figure 30-20-4] from the drive motor. Remove the drain hose (Item 2) [Figure 30-20-4] from the drive motor. 30-20-2 362 of 949
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HYDROSTATIC MOTOR (CONT’D) Parts Identification (Wet Bolt) 3 10
11
9 8 13
4 16
3 5 11
15 21
14
Dealer Copy -- Not for Resale
6
3 7
6 22 20
17
19 18
19 17 20
1
3
12
24 23
26 25
2 D-3431B
Ref.
Description
Ref.
Description
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
HOUSING O-RING SEAL, square VALVE, plate GEROTER BALL PLATE, balance RING, back-up SEAL RING, back-up O-RING PLUG FLANGE, mounting SEAL, face
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
SHAFT, drive BOLT SPRING PISTON POPPET SLEEVE PLUG O-RING O-RING SPRING SHIM POPPET
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Remove the nine bolts (Item 1) [Figure 30-20-8] from the motor.
HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt)
Figure 30-20-9
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Figure 30-20-7 N-00623
NOTE: Do not scratch or damage the surfaces of the motor sections. Always put them on a soft surface. Figure 30-20-10
1
N-00621
2
Seal all open ports and clean the motor with solvent. Drain the oil from the motor. Put a mark across the sections of the motor for correct assembly [Figure 30-20-7]. Figure 30-20-8
1
N-00624
Turn the mounting flange over and remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 30-20-10].
N-00622
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Lift and remove the mounting flange (Item 1) [Figure 3020-9] from the motor.
Figure 30-20-13
HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt) (Cont’d)
1
Figure 30-20-11
1
N-00627
Remove the main drive (Item 1) [Figure 30-20-13] from the geroter assembly.
N-00625
Figure 30-20-14
Figure 30-20-12 1 1 1
N-00628
Remove the two check balls (Item 1) [Figure 30-20-14] from the geroter.
N-00626
Remove the balance plate (Item 1) [Figure 30-20-12] from the geroter assembly.
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Turn the mounting flange back over and remove the seal (Item 1) [Figure 30-20-11] from the mounting flange.
Figure 30-20-17
HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt) (Cont’d) Figure 30-20-15
1
N-00631
1
Carefully turn the geroter assembly over and remove the square cut seal (Item 1) [Figure 30-20-17].
N-00629
1
Figure 30-20-16
1
N-00632
Remove the valve plate (Item 1) [Figure 30-20-18] from the end cap.
N-00630
Remove the geroter assembly (Item 1) [Figure 30-2016]. NOTE: Care should be taken to keep the gerolor assembly together. NOTE: If rollers are removed, put them back in their original bore.
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Figure 30-20-18 Remove the square cut seal (Item 1) [Figure 30-20-15] from the geroter.
Figure 30-20-21
HYDROSTATIC MOTOR (Wet Bolt) (CONT’D) Disassembly (Wet Bolt) (Cont’d)
1
Figure 30-20-19 1 2
N-00635
Remove the poppet and shuttle valve (Item 1) [Figure 30-20-21].
N-00633
Figure 30-20-22
Figure 30-20-20
1 2
N-00636
Turn the end cover over and remove the shuttle valve plug from the end cover [Figure 30-20-22].
N-00634
Remove the spring seat (Item 1) and spring (Item 2) [Figure 30-20-20].
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Remove the square cut seal (Item 1) and small O-ring (Item 2) [Figure 30-20-19] from the end cap.
Figure 30-20-25
HYDROSTATIC MOTOR (CONT’D) Disassembly (Wet Bolt) (Cont’d)
3
Figure 30-20-23 2 1
1 2 3
N-00640
Remove the spring seat (Item 1), spring (Item 2) and poppet (Item 3) [Figure 30-20-23]. Figure 30-20-24
NOTE: The relief pressure is factory set and must not be changed. Shims may or may not have been used at the factory for setting the pressure. If shims are present, make sure they are reinstalled during assembly. Figure 30-20-26
3 2
1
N-00639
N-00641
Remove the low pressure relief valve plug from the side of the end cover [Figure 30-20-24].
The low pressure relief valve is made up of the poppet (Item 1), the spring (Item 2) and the plug assembly (Item 3) [Figure 30-20-26].
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Remove the spring (Item 1) and poppet (Item 2) from the end cover (Item 3) [Figure 30-20-25].
N-00637
Figure 30-20-28
HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt)
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-00643
Prior to assembly: Install the new O-ring on the plug and tighten to 300 in.lb. (34 N•m) torque [Figure 30-20-28].
Clean all parts with solvent and dry with compressed air. Put grease on O-rings.
Figure 30-20-29
Figure 30-20-27
3
2
2 1 1
N-00644
Install the poppet (Item 1), the spring (Item 2) and the spring seat (Item 3) [Figure 30-20-29] in the end cover.
N-00642
Install the poppet (Item 1) and spring (Item 2) [Figure 3020-27] in the low pressure relief port in the end cover.
NOTE: The tapered end of the poppet must face towards the shuttle valve.
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Lubricate parts with oil.
Figure 30-20-32
HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d) Figure 30-20-30
1
2
N-00648
Install the square cut seal (Item 1) and small O-ring (Item 2) [Figure 30-20-32] in the end cover.
N-00646
Figure 30-20-33
NOTE: Always use new O-rings and seals when assembling the motor. Put a small amount of grease on all the O-rings and seals for easier installation. Figure 30-20-31 4 2
3
1
N-00649
Mark the case drain port location on the outside of the end cover for ease of assembly [Figure 30-20-33].
N-00647
Install the shuttle valve (Item 1), poppet (Item 2), spring (Item 3) and spring seat (Item 4) [Figure 30-20-31] in the port hole in the end cap. NOTE: The tapered end of the poppet must face towards the shuttle valve.
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Install a new O-ring on the plug [Figure 30-20-30] and tighten to 260 in.-lb. (41 N•m) torque.
Figure 30-20-36
HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d) Figure 30-20-34
N-00652
Mark the case drain port location on the outside edge of the valve plate as shown [Figure 30-20-36].
N-00650
1
Figure 30-20-35 1
N-00653
Install the Geroler® assembly (Item 1) [Figure 30-20-37] by aligning the case drain hole with the case drain hole in the valve plate.
N-00651
Install the large square cut seal (Item 1) [Figure 30-2035] in Geroler® assembly.
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Figure 30-20-37 Align the case drain ports in the valve plate with the case drain port in the end cover [Figure 30-20-34].
Figure 30-20-40
HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d)
1
Figure 30-20-38
1
N-00656
Install the square cut seal (Item 1) [Figure 30-20-38] in the geroter outer ring.
NOTE: Whenever the main drive is not symmetrical, the smallest end of the main drive must be installed into the gerolors.
Figure 30-20-39
Figure 30-20-41
1
N-00655
N-00657
Install the two check balls (Item 1) [Figure 30-20-39] in their bores in the geroter.
Mark the case drain hole on the outer ring of the Geroler® (as shown) [Figure 30-20-41].
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Install the main drive (Item 1) [Figure 30-20-40] in the Geroler® (as shown).
N-00654
Figure 30-20-44
HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d)
1
Figure 30-20-42
2
3 4 5
N-00660
Install the square cut seal (Item 1), seal (Item 2), back-up seal (Item 3), seal (Item 4) and back-up ring (Item 5) [Figure 30-20-44] in the mounting flange.
1 N-00658
Figure 30-20-45
Dealer Copy -- Not for Resale
Align the case drain holes and install the balance plate (Item 1) [Figure 30-20-42] on the geroter assembly. Figure 30-20-43
1
N-00661
N-00659
Mark the case drain holes on the side of the balance plate [Figure 30-20-45].
Install the seal (Item 1) [Figure 30-20-43] (as shown).
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Figure 30-20-48
HYDROSTATIC MOTOR (CONT’D) Assembly (Wet Bolt) (Cont’d) Figure 30-20-46
1
N-00664
Install the nine bolts into the motor. Make sure all the parts are in correct alignment [Figure 30-20-48].
N-00662
Figure 30-20-47
1
MC-2230
1. Tighten the bolts to 45 - 55 ft.-lb. (61 - 75 N•m) torque as shown in figure [Figure 30-20-49]. N-00663
2. Tighten the bolts to 55 - 65 ft.-lb. (75 - 88 N•m) torque as shown in figure [Figure 30-20-49]. Align the two case drain port (Item 1) [Figure 30-20-47] and install the mounting flange on the balance plate.
NOTE: To prevent damage to the balance plate, never lift or support the motor by the center shaft.
Be careful not to displace the seals and back-up rings.
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Figure 30-20-49 Align the case drain port (Item 1) [Figure 30-20-46] in the mounting flange with the case drain port in the balance plate (as shown).
HYDROSTATIC MOTOR (CONT’D) Parts Identification (Dry Bolt)
16
14
3 15
20 14 16
3
19
14 18
18
13
19 17
5
3
12 5 11
10
Dealer Copy -- Not for Resale
5
9
8 10
7 6
3 3 5 4 3 2 1
PE2620T
Ref.
Description
Ref.
Description
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SHAFT, drive SEAL, face O-RING FLANGE, mounting SEAL, square cut RING, back-up SPRING, belleville PLATE, outer balance PLATE, inner balance BALL
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
GEROTER PLATE, valve END CAP POPPET SPRING PLUG BOLT SLEEVE SPRING VALVE, shuttle
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S150, S160 Bobcat Loader Service Manual
Figure 30-20-51
HYDROSTATIC MOTOR (CONT’D) Disassembly And Assembly (Dry Bolt)
1
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 P-39894
Figure 30-20-50 Remove the nine tie bolts (Item 1) [Figure 30-20-51] from the motor.
1
9 6
4
3
7
P-64267
Seal all open ports and clean the motor with solvent.
8
Drain the oil from the motor.
2 5 P-39894
Put a mark across the sections of the motor for correct assembly [Figure 30-20-50]. Assembly: 1. Tighten the bolts to 45 - 55 ft.-lb. (61 - 75 N•m) torque in the order shown in figure [Figure 30-20-52]. 2. Tighten the bolts to 55 - 65 ft.-lb. (75 - 88 N•m) torque in the order shown in figure [Figure 30-20-52]. NOTE: To prevent damage to the balance plate, never lift or support the motor by the drive shaft.
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Figure 30-20-52
Figure 30-20-55
HYDROSTATIC MOTOR (CONT’D) Disassembly And Assembly (Dry Bolt) (Cont’d) Figure 30-20-53
3 1
2
1 P-63785
Once the tie bolts have been removed and the motor begins to separate, the drive shaft can be removed. (Item 1) [Figure 30-20-53].
Installation: Lubricate relief valve assembly with hydraulic oil and tighten plug to 260 in.-lb. (41 N•m) torque.
Assembly: Install drive shaft before tightening tie bolts. Figure 30-20-56 Figure 30-20-54
1
2 1
P-39896 P-39895
Lift and remove the end cap (Item 1) [Figure 30-20-54] from the motor.
Remove the plug (Item 1) and shuttle valve assembly (Item 2) [Figure 30-20-56]. Inspect for scoring on shuttle valve. Ensure it can operate freely in the bore.
NOTE: Do not scratch or damage the surfaces of the motor sections. Always put them on a soft surface.
Installation: Lubricate shuttle valve assembly with hydraulic oil and tighten plug to 260 in.-lb. (41 N•m) torque.
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Remove the plug (Item 1) spring (Item 2) and poppet (Item 3) [Figure 30-20-55] that make up the relief valve assembly. Inspect for scoring on poppet. Ensure it can operate freely in the bore. Inspect O-ring on plug.
P-64267
Figure 30-20-59
HYDROSTATIC MOTOR (CONT’D) Disassembly And Assembly (Dry Bolt) (Cont’d)
3
Figure 30-20-57 2
1
1
P-64274
Remove and inspect / replace seal (Item 1) [Figure 3020-59].
Remove the remaining pieces to the shuttle valve assembly (Item 1) [Figure 30-20-57] from the inside of the end cap. Inspect for broken or damaged parts. Parts should move freely in bore. Assembly: Apply grease to shuttle valve parts to help hold in place during assembly.
Remove the geroter section as an assembly (Item 2) [Figure 30-20-59]. NOTE: There are two check balls on the backside of the geroter section. Be careful not to lose these check balls. See [Figure 30-20-60]. Note location of case drain hole (Item 3) [Figure 3020-59]. Align hole with other sections on drive motor.
Figure 30-20-58
2
3 1
1
P-39898
Remove and inspect / replace seals (Item 1) [Figure 3020-58]. Remove the valve plate (Item 2) [Figure 30-20-58]. Assembly: Apply grease to seals. Note location of case drain hole (Item 3) [Figure 30-20-58]. Align hole with other sections on drive motor.
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P-39897
Figure 30-20-61
HYDROSTATIC MOTOR (CONT’D) Disassembly And Assembly (Dry Bolt) (Cont’d)
1 4
Figure 30-20-60
2 3 1
1
P-64268
Remove the center piece of the balance plate (Item 1) [Figure 30-20-61].
Remove the two check balls (Item 1) [Figure 30-20-60] from the geroter.
Remove and inspect / replace the seal (Item 2) [Figure 30-20-61]. Remove the balance plate (Item 3) [Figure 30-20-61].
Assembly: Inspect for scoring and wear on the geroter assembly. Apply grease to check balls to keep them from falling out of there seats when assembling.
Assembly: Apply grease to seals. Note location of case drain hole (Item 4) [Figure 30-20-61]. Align hole with other sections on drive motor.
NOTE: Care should be taken to keep the geroter assembly together. NOTE: If rollers are removed, put them back in their original bore.
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S150, S160 Bobcat Loader Service Manual
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P-39901
Figure 30-20-64
HYDROSTATIC MOTOR (CONT’D) Disassembly And Assembly (Dry Bolt) (Cont’d)
1 Figure 30-20-62
1
P-64272
Remove the belleville spring. (Item 1) [Figure 30-20-64]. P-64270
Assembly: If the belleville spring is no longer cone shaped, replace with new. Remove the back up ring (Item 1) [Figure 30-20-62].
Dealer Copy -- Not for Resale
Figure 30-20-65 Assembly: Apply grease to back up ring. One side of the back up ring is grooved to fit against the O-ring underneath. Figure 30-20-63
1 1 P-64273
1 Carefully turn the mounting flange over and remove the seal (Item 1) [Figure 30-20-65].
1 P-64271
Assembly: Replace the seal. Remove and inspect / replace the seals (Item 1) [Figure 30-20-63] from the Geroler®. Assembly: Apply grease to seals.
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Figure 30-21-2
HYDROSTATIC MOTOR CARRIER Shaft Seal Replacement The tool listed is necessary for the following procedure: MEL1420 - Carrier Seal Tool Remove the hydrostatic motor. (See Removal And Installation on Page 30-20-1.)
WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.
P-4456
Drill a 0.125 in. (3 mm) hole in the motor carrier seal [Figure 30-21-2]. Figure 30-21-3
Figure 30-21-1
1 P-4455
Use a slide hammer to remove the seal from the motor carrier shaft [Figure 30-21-3].
P-4153
The motor carrier seal (Item 1) [Figure 30-21-1] is located on the outside of the motor carrier shaft.
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W-2019-0907
Figure 30-21-6
HYDROSTATIC MOTOR CARRIER (CONT’D) Shaft Seal Replacement (Cont’d) Figure 30-21-4
1
P-4149
Installation: Install a new seal over the motor carrier shaft [Figure 30-21-4]. Figure 30-21-5
NOTE: Before reinstalling the hydrostatic motor, check the plug (Item 1) [Figure 30-21-6] located in the center of the carrier shaft for tightness. If the plug becomes loosened, case drain lubrication oil from the hydrostatic motor can leak into the chaincase.
P-4150
Installation: Install MEL1420 Carrier Seal Tool over the carrier seal [Figure 30-21-5]. Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-21-5].
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Photo [Figure 30-21-6] shows the motor carrier seal correctly installed.
P-4454
Figure 30-21-7
HYDROSTATIC MOTOR CARRIER (CONT’D) Removal And Installation
2
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
1
W-2059-0598
Lift and block the loader. (See Procedure on Page 10-101.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.)
P-4152
Remove the parking brake disc (Item 1) [Figure 30-217]. (See Disk Removal And Installation on Page 40-101.) Remove the six motor carrier mounting bolts (Item 2) [Figure 30-21-7] from the inside of the chaincase. Installation: Tighten the motor carrier mounting bolts to 125 - 140 ft.-lb. (170 - 190 N•m) torque. Figure 30-21-8
Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel. (See Removal And Installation on Page 50-100-1.)
1
Remove the lift arm bypass control valve. (See Removal And Installation on Page 20-50-1.) 2
Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.)
P-4167
Remove the front chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.) Remove the front axle and sprocket. (See Axle Sprocket And Bearings Removal And Installation on Page 40-203.) Remove the hydrostatic motor. (See Removal And Installation on Page 30-20-1.)
For ease of removal, fasten the front drive chain (previously removed) to the chaincase as shown (Item 1) [Figure 30-21-8]. Tip the end of the sprocket toward the rear of the loader and remove the rear drive chain (Item 2) [Figure 30-218] from the sprocket.
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Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
HYDROSTATIC MOTOR CARRIER (CONT’D) Removal And Installation (Cont’d) Figure 30-21-9
1
P-4165
Dealer Copy -- Not for Resale
Slide the motor carrier out of the chaincase [Figure 3021-9]. Installation: Check the motor carrier gasket (Item 1) [Figure 30-21-9] for wear or damage and replace if necessary. Figure 30-21-10
1
P-4168
Use one of the motor carrier mounting bolts (Item 1) [Figure 30-21-10] and install partially into one mounting hole on the carrier. Fasten a chain hoist to the bolt on the motor carrier and remove the carrier from the loader. Reverse the removal procedure to install the motor carrier.
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HYDROSTATIC MOTOR CARRIER (CONT’D) Parts Identification
1 8
2
3
4
4 3
7
6
MC-1937A
Ref.
Description
Ref.
Description
1.
MOUNT ASSY.
5.
HOUSING
2.
SHAFT
6.
SNAP RING
3.
BEARING
7.
SEAL
4.
RACE
8.
PLUG
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5
Figure 30-21-13
HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly And Assembly Figure 30-21-11 3.000’’ O.D. Diameter (76,2 mm) 2.530’’ I.D. Diameter (64,26 mm) 7.000’’ Length (177,8 mm)
P-4176
Put the motor carrier in the hydraulic press as shown [Figure 30-21-13].
It is necessary to locate or fabricate a press tool for this procedure. Refer to photo [Figure 30-21-11] for the correct dimensions of the tool needed.
Use 2-1/4 inch driver tool and press the sprocket shaft out of the motor carrier housing [Figure 30-21-13]. NOTE: The outer bearing will now be free from the sprocket shaft.
Figure 30-21-12 Figure 30-21-14
2 1
1 P-4372 P-4365
A hydraulic press, slide hammer with puller end and snap ring pliers are also recommended for this procedure. Remove the motor carrier shaft seal. (See Shaft Seal Replacement on Page 30-21-1.) Remove the snap ring (Item 1) [Figure 30-21-12] from the motor carrier shaft using the snap ring pliers.
Remove the housing from the press and install a bearing puller (Item 1) [Figure 30-21-14] on the sprocket shaft. Put the assembly in the hydraulic press. Use the same tool driver and remove the bearing (Item 2) [Figure 3021-14] from the shaft.
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MC-2102
Figure 30-21-17
HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-21-15
2
1
P-4369
Fasten the carrier motor housing to the work surface securely with the inner bearing race (Item 1) [Figure 3021-15] facing up. Install the slide hammer with puller end (Item 2) [Figure 30-21-15] on the bottom side of the bearing race.
Use 4-5/16 inch driver tool and press the new inner bearing race into the motor carrier housing [Figure 3021-17]. Press the bearing race in until it is fully seated in the carrier housing. Figure 30-21-18
Remove the bearing race from the carrier housing [Figure 30-21-15]. Figure 30-21-16
P-4368
Turn the motor carrier housing over as shown [Figure 30-21-18].
P-4370
Put the motor carrier housing in the hydraulic press as shown [Figure 30-21-16].
Use 4-5/16 inch driver tool and press the new outer bearing race into the motor carrier housing [Figure 3021-18].
Use a 3-7/8 inch driver tool and press the outer bearing race from the housing.
Press the bearing race in until it is fully seated in the carrier housing.
Inspect all parts for wear and damage. Replace the bearing race when new bearings are to be installed.
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Put the motor carrier housing in the press as shown [Figure 30-21-17].
P-4373
Figure 30-21-20
HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-21-19
1 1
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-21-20] over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 inch driver tool, install the new inner bearing (Item 2) [Figure 30-2119] on the sprocket shaft as shown. Remove the press and drive tools from the sprocket shaft.
Put the outer bearing over the end of the sprocket shaft and press the bearing on with the press tool and driver tool [Figure 30-21-20]. Remove the press and driver tools from the sprocket shaft.
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2
Figure 30-21-23
HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-21-21
1 1
P-4374
Put the snap ring (Item 1) [Figure 30-21-21] over the end of the sprocket shaft. NOTE: Use the snap ring pliers to spread the snap ring so it will fit over the sprocket shaft.
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-2123] and install the shaft seal.
Using the press and driver tools, press the snap ring (Item 1) [Figure 30-21-21] over the sprocket.
Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-21-23].
Press the snap ring on until it snaps into the groove on the shaft.
Figure 30-21-24
Figure 30-21-22
1
N-15088
Inspect the end play of the motor carrier as follows:
P-4376
Put a new shaft seal (Item 1) [Figure 30-21-22] on the sprocket shaft.
Use a rubber mallet [Figure 30-21-24], tap down on the cluster shaft.
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P-4375
HYDROSTATIC MOTOR CARRIER (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-21-25
Dealer Copy -- Not for Resale
1
N-15087
Install a dial indicator as shown in Photo [Figure 30-2125]. Use a pry bar (Item 1) [Figure 30-21-25] to lift the carrier shaft and read the end play on the dial indicator. The carrier shaft must turn freely with end play not to exceed 0.007 in. (0,17 mm).
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S150, S160 Bobcat Loader Service Manual
Figure 30-22-2
HYDROSTATIC MOTOR CARRIER (SJC) Shaft Seal Replacement The tool listed is necessary for the following procedure: MEL1420 - Carrier Seal Tool Remove the hydrostatic motor. (See Removal And Installation on Page 30-20-1.)
WARNING AVOID INJURY OR DEATH Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used.
P-39783
Drill a 0.125 in. (3 mm) hole in the motor carrier seal [Figure 30-22-2]. Figure 30-22-3
Figure 30-22-1
1 P-39784
Use a slide hammer to remove the seal from the motor carrier shaft [Figure 30-22-3].
P-39780
The motor carrier seal (Item 1) [Figure 30-22-1] is located on the outside of the motor carrier shaft.
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W-2019-0907
Figure 30-22-6
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Shaft Seal Replacement (Cont’d) Figure 30-22-4
1
P-39780
Installation: Install a new seal over the motor carrier shaft [Figure 30-22-4]. Figure 30-22-5
NOTE: Before reinstalling the hydrostatic motor, check the plug (Item 1) [Figure 30-22-6] located in the center of the carrier shaft for tightness. If the plug becomes loosened, case drain lubrication oil from the hydrostatic motor can leak into the chaincase.
P-39786
Installation: Install MEL1420 Carrier Seal Tool over the carrier seal [Figure 30-22-5]. Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-22-5].
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Photo [Figure 30-22-6] shows the motor carrier seal correctly installed.
P-4454A
Figure 30-22-7
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Removal And Installation
WARNING 2
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
1
W-2059-0598
Lift and block the loader. (See Procedure on Page 10-101.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.)
P-39781
Remove the parking brake disc (Item 1) [Figure 30-227]. (See Disk Removal And Installation on Page 40-101.) Remove the six motor carrier mounting bolts (Item 2) [Figure 30-22-7] from the inside of the chaincase. Installation: Tighten the motor carrier mounting bolts to 125 - 140 ft.-lb. (170 - 190 N•m) torque. Figure 30-22-8
Remove the engine speed control. (See Removal And Installation on Page 70-20-1.)
1
Remove the control panel. (See Removal And Installation on Page 50-100-1.) Remove the lift arm bypass control valve. (See Removal And Installation on Page 20-50-1.) 2
Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.)
P-4167A
Remove the front chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.) Remove the front axle and sprocket. (See Axle Sprocket And Bearings Removal And Installation on Page 40-203.) Remove the hydrostatic motor. (See Removal And Installation on Page 30-20-1.)
For ease of removal, fasten the front drive chain (previously removed) to the chaincase as shown (Item 1) [Figure 30-22-8]. Tip the end of the sprocket toward the rear of the loader and remove the rear drive chain (Item 2) [Figure 30-228] from the sprocket.
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Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Removal And Installation (Cont’d) Figure 30-22-9
1
P-39812
Dealer Copy -- Not for Resale
Slide the motor carrier out of the chaincase [Figure 3022-9]. Installation: Check the motor carrier gasket (Item 1) [Figure 30-22-9] for wear or damage and replace if necessary. Figure 30-22-10
1
P-39813
Use one of the motor carrier mounting bolts (Item 1) [Figure 30-22-10] and install partially into one mounting hole on the carrier. Fasten a chain hoist to the bolt on the motor carrier and remove the carrier from the loader. Reverse the removal procedure to install the motor carrier.
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HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Parts Identification
1
2 3
5 4 3 6 7 P-64693
Ref.
Description
Ref.
Description
1.
SHAFT
5.
HOUSING
2.
SENSOR DISC
6.
SNAP RING
3.
BEARING
7.
SEAL
4.
RACE
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4
Figure 30-22-13
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly And Assembly Figure 30-22-11 3.000’’ O.D. Diameter (76,2 mm) 2.530’’ I.D. Diameter (64,26 mm) 7.000’’ Length (177,8 mm)
P-39816
Put the motor carrier in the hydraulic press as shown [Figure 30-22-13].
It is necessary to locate or fabricate a press tool for this procedure. Refer to photo [Figure 30-22-11] for the correct dimensions of the tool needed.
Use 2-1/4 inch driver tool and press the sprocket shaft out of the motor carrier housing [Figure 30-22-13]. NOTE: The outer bearing will now be free from the sprocket shaft.
Figure 30-22-12 Figure 30-22-14
2 1
1 P-39815 P-4365
A hydraulic press, slide hammer with puller end and snap ring pliers are also recommended for this procedure. Remove the motor carrier shaft seal. (See Shaft Seal Replacement on Page 30-22-1.) Remove the snap ring (Item 1) [Figure 30-22-12] from the motor carrier shaft using the snap ring pliers.
Remove the housing from the press and install a bearing puller (Item 1) [Figure 30-22-14] on the sprocket shaft. Put the assembly in the hydraulic press. Use the same tool driver and remove the bearing (Item 2) [Figure 3022-14] from the shaft.
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MC-2102
Figure 30-22-17
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-22-15
2
1
P-39820
Fasten the carrier motor housing to the work surface securely with the inner bearing race (Item 1) [Figure 3022-15] facing up. Install the slide hammer with puller end (Item 2) [Figure 30-22-15] on the bottom side of the bearing race.
Use a 4-5/16 inch driver tool and press the new inner bearing race into the motor carrier housing [Figure 3022-17]. Press the bearing race in until it is fully seated in the carrier housing. Figure 30-22-18
Remove the bearing race from the carrier housing [Figure 30-22-15]. Figure 30-22-16
P-39819
Turn the motor carrier housing over as shown [Figure 30-22-18].
P-39818
Put the motor carrier housing in the hydraulic press as shown [Figure 30-22-16].
Use 4-5/16 inch driver tool and press the new outer bearing race into the motor carrier housing [Figure 3022-18].
Use a 3-7/8 inch driver tool and press the outer bearing race from the housing.
Press the bearing race in until it is fully seated in the carrier housing.
Check all parts for wear and damage. Replace the bearing race when new bearings are to be installed.
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Put the motor carrier housing in the press as shown [Figure 30-22-17].
P-39817
Figure 30-22-20
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-22-19
1 1
P-4371
P-4366
Put the motor carrier housing (Item 1) [Figure 30-22-20] over the sprocket shaft as shown.
Use the fabricated press tool (Item 1) and 3.0 inch driver tool, install the new inner bearing (Item 2) [Figure 30-2219] on the sprocket shaft as shown. Remove the press and drive tools from the sprocket shaft.
Put the outer bearing over the end of the sprocket shaft and press the bearing on with the press tool and driver tool [Figure 30-22-20]. Remove the press and driver tools from the sprocket shaft.
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2
Figure 30-22-23
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-22-21
1 1
P-39814
Put the snap ring (Item 1) [Figure 30-22-21] over the end of the sprocket shaft. NOTE: Use the snap ring pliers to spread the snap ring so it will fit over the sprocket shaft.
Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-2223] and install the shaft seal.
Using the press and driver tools, press the snap ring (Item 1) [Figure 30-22-21] over the sprocket.
Hit the tool with a hammer until the seal is fully seated on the carrier shaft [Figure 30-22-23].
Press the snap ring on until it snaps into the groove on the shaft.
Figure 30-22-24
Figure 30-22-22
1
P-39821
Inspect the end play of the motor carrier as follows:
P-4376
Put a new shaft seal (Item 1) [Figure 30-22-22] on the sprocket shaft.
Use a rubber mallet [Figure 30-22-24], tap down on the cluster shaft.
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P-4375
HYDROSTATIC MOTOR CARRIER (SJC) (CONT’D) Disassembly And Assembly (Cont’d) Figure 30-22-25
Dealer Copy -- Not for Resale
1
N-15087
Install a dial indicator as shown in Photo [Figure 30-2225]. Use a pry bar (Item 1) [Figure 30-22-25] to lift the carrier shaft and read the end play on the dial indicator. The carrier shaft must turn freely with end play not to exceed 0.007 in. (0,17 mm).
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Figure 30-30-2
CHARGE PRESSURE Sender Removal And Installation (Non SJC Machines)
2
WARNING 1 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286 P-28590
Figure 30-30-1
Disconnect the wires (Item 1) [Figure 30-30-2] from the charge pressure sender.
1
Installation: Tighten the sender to 7.4 - 8.1 ft.-lb. (10 - 11 N•m) torque. 2
Testing (Non SJC Machines) Lift and block the loader. (See Procedure on Page 10-101.) P-48580
Remove the two mounting bolts (Item 1) to remove the oil filter drip shield (Item 2) [Figure 30-30-1].
Open the rear door. Remove the two mounting bolts (Item 1) to remove the oil filter drip shield (Item 2) [Figure 30-30-1]. Installation: Tighten the mounting bolts and nuts to 15 ft.-lb. (20 N•m) torque.
Disconnect the wires (Item 1) [Figure 30-30-2] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-2] from the fitting. Installation: Tighten the sender to 7.4 - 8.1 ft.-lb. (10 - 11 N•m) torque. Install a tee fitting into the charge pressure sender fitting. Install a hose with a pressure gauge of at least 500 PSI on one end of the tee fitting and the charge pressure sender into the other end. Reconnect the wires to the charge pressure sender. Start the engine. The gauge must read as follows: 220 - 270 PSI (15,1 - 18,6 bar) with approximately 140° F (60° C) fluid @ High Idle.
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Remove the charge pressure sender (Item 2) [Figure 3030-2] from the fitting.
Figure 30-30-4
CHARGE PRESSURE (CONT'D) Adjusting (Non SJC Machines)
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-17231
Figure 30-30-3 Remove the plug, spring and poppet [Figure 30-30-4]. Inspect the poppet and spring for wear or damage. 1
Dealer Copy -- Not for Resale
Figure 30-30-5
N-19567
1
If the charge pressure is not correct loosen the charge relief valve plug (Item 1) [Figure 30-30-3]. Assemble: Always use a new O-ring. Tighten the plug to 30 - 50 ft.-lb. (41 - 68 N•m) torque.
N-19568
There are several different thickness of the shims (Item 1) [Figure 30-30-5] and are used to adjust the charge pressure. NOTE: 0.010 in. (0,254 mm) is 55.16 kPa (0.55 bar) (8 psi) increase in pressure. The charge pressure should be set at 1516 - 1861 kPa (15,1 - 18,6 bar) (220 - 270 psi).
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CHARGE PRESSURE (CONT'D)
Testing (SJC Machines)
Sender Removal And Installation (SJC Machines)
Lift and block the loader. (See Procedure on Page 10-101.) Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.)
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Figure 30-30-6
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the wires (Item 1) [Figure 30-30-6] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-6] from the fitting. Installation: Tighten the sender to 7.4 - 8.1 ft.-lb. (10 - 11 N•m) torque.
1
Install a hose with a pressure gauge of at least 500 PSI on one end of the tee fitting and the charge pressure sender into the other end. Reconnect the wires to the charge pressure sender. Start the engine. P-64580
The gauge must read as follows: Raise the lift arms and install an approved lift arm support device (See Installing Lift Arm Support Device on Page 10-20-1.)
2482 kPa (24,8 bar) (360 psi) with approximately 140° F (60° C) fluid @ High Idle.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the wires (Item 1) [Figure 30-30-6] from the charge pressure sender. Remove the charge pressure sender (Item 2) [Figure 3030-6] from the fitting. Installation: Tighten the sender to 7.4 - 8.1 ft.-lb. (10 - 11 N•m) torque.
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Dealer Copy -- Not for Resale
Install a tee fitting into the charge pressure sender fitting.
2
Figure 30-30-8
CHARGE PRESSURE (CONT'D) Adjusting (SJC Machines)
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
1
I-2003-0888 P-64435
Figure 30-30-7 Inspect the poppet and spring for wear or damage.
NOTE: 1.0 mm shim (Item 1) [Figure 30-30-8] = 43.5 PSI (3 bar) in pressure change. Adding shims increases charge pressure. Removing shims decreases charge pressure.
1
The charge pressure should be set at 2482 kPa (24,8 bar) (360 psi). P-64431
If the charge pressure is not correct remove the charge relief valve (Item 1) [Figure 30-30-7]. NOTE: The pump has been removed for photo clarity. The charge pressure relief valve is located on the engine side of the hydrostatic pump when installed in the loader. Assemble: Always use a new O-ring. Tighten the plug to 30 - 50 ft.-lb. (41 - 68 N•m) torque.
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Dealer Copy -- Not for Resale
There are several different thickness of shims (Item 1) [Figure 30-30-8] used to adjust the charge pressure.
Figure 30-40-2
HYDROSTATIC PUMP Replenishing / High Pressure Relief Valve
1 Figure 30-40-1 2 1
3
N-19566
Remove the high pressure relief valve (Item 1) [Figure 30-40-2] from the pump.
There are four replenishing / high pressure relief valves (Item 1) [Figure 30-40-1] in the hydrostatic pump assembly. Two are located at the top of the pumps and two at the bottom of the pumps.
Assemble: Tighten the plug to 30 - 50 ft.-lb. (41 - 68 N•m) torque. Inspect for damage and replace as needed.
(See Replenishing Valve Function on Page 30-10-2.)
Inspect the O-rings (Item 2 and 3) [Figure 30-40-2] for damage and replace as needed.
NOTE: The two top valves are for the reverse drive loop and the two bottom valves are for the forward drive loop.
If the high pressure relief valve must be replaced, it must be replaced as a complete unit. The pressure setting for a new high pressure relief valve is 34475 kPa (344,75 bar) (5000 psi).
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N-19565
Figure 30-40-4
HYDROSTATIC PUMP (CONT’D) Removal And Installation
1
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
2
I-2003-0888 P-34567
Loosen the drive belt tensioner (Item 1) [Figure 30-40-4] and remove the drive belt.
Remove the control handle linkage from the hydrostatic pump. (See Linkage Removal And Installation on Page 50-101-7.)
Remove the hydrostatic pump drive pulley mounting nut (Item 2) [Figure 30-40-4] and washer.
Remove the hydraulic pump from the hydrostatic pump. (See Removal And Installation on Page 20-60-5.)
Installation: Tighten the pump pulley mounting nut to 175 - 200 ft.-lb. (237 - 271 N•m) torque.
Figure 30-40-3
Figure 30-40-5
1 P-4235
P-34568
Remove the hydrostatic pump mounting bolt (Item 1) [Figure 30-40-3] and washer(s).
Install a puller on the hydrostatic pump drive pulley and remove the pulley from the pump shaft [Figure 30-40-5].
Installation: Tighten the mounting bolt to 65 - 70 ft.-lb. (88 - 95 N•m) torque.
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Remove the engine / hydrostatic pump assembly from the loader. (See Removal And Installation on Page 7080-1.)
HYDROSTATIC PUMP (CONT’D)
WARNING
Removal And Installation (Cont’d) Figure 30-40-6
AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.
1
W-2103-0508
Reverse the removal procedure to install the hydrostatic pump assembly. 2
P-4238
Dealer Copy -- Not for Resale
Installation: Install the key in the hydrostatic pump shaft (Item 1) [Figure 30-40-6] before installing the pump drive pulley. Figure 30-40-7
1
P-28850
Hold the nut (Item 1) [Figure 30-40-7] on the two hydrostatic pump mounting bolts (Item 2) [Figure 30-406]. Remove the two hydrostatic pump mounting bolts from the pump and drive belt housing. Installation: Tighten the pump mounting bolts to 65 - 70 ft.-lb. (88 - 95 N•m) torque.
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HYDROSTATIC PUMP (CONT’D) Parts Identification (Right Half) 5 8
7
4 3
6 2
9
1 13 14
10
11
15
12
17 19 21
16
Dealer Copy -- Not for Resale
18
23 20
25 27 22 24
29 26
28 38 30
33
36 34
32 31
37
35
46 47
48
40 42
45 39
44 49
41 43
D-2427
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HYDROSTATIC PUMP (CONT’D) Parts Identification (Right Half) (Cont'd)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Ref. Description
BOLT END CAP PLUG O-RING PLUG O-RING O-RING RELIEF VALVE BOLT GASKET BEARING PLUG O-RING O-RING RELIEF VALVE PIN VALVE PLATE RETAINER WASHER SPRING WASHER BLOCK RETAINER PIN WASHER
26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.
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RETAINER RETAINER PISTON ASSEMBLY PLATE SWACHPLATE PIN HOUSING PLUG BEARING SEAL O-RING COVER BOLT SHAFT SNAP RING BEARING SNAP RING SNAP RING PLUG O-RING BEARING O-RING PLATE BOLT
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Ref. Description
HYDROSTATIC PUMP (CONT’D) Parts Identification (Left Half) 4 6
17 16
8 11 14
13
10
2
3
12
1
5 7 9
15
22
18
23
21 19 20
24
Dealer Copy -- Not for Resale
28 30 32
26
27
34 38
25
36
29
31 33 35
47
37
46
39 44 48 49
45 43
42
50
40 51 52
41
58
53 53 52 55 54
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60
57 59
56
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S150, S160 Bobcat Loader Service Manual
HYDROSTATIC PUMP (CONT’D) Parts Identification (Left Half) (Cont'd)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Ref. Description
SNAP RING WASHER SEAL SNAP RING SNAP RING BEARING SNAP RING KEY SHAFT HOUSING PLUG O-RING BEARING SEAL O-RING COVER BOLT PIN O-RING PLUG BEARING O-RING PLATE BOLT SWASH PLATE WEAR PLATE PISTON ASSEMBLY PISTON RETAINER RETAINER WASHER
31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60.
30-40-7 411 of 949
PIN RETAINER BLOCK WASHER SPRING WASHER WASHER VALVE PLATE PIN GASKET BEARING PLUG POPPET SPRING SHIM O-RING PLUG RELIEF VALVE O-RING O-RING PLUG PIN O-RING COUPLER O-RING BOLT O-RING O-RING RELIEF VALVE END CAP
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Ref. Description
HYDROSTATIC PUMP (CONT’D)
Pump Separation
Hydraulic Pump Removal And Installation
Figure 30-40-10
Figure 30-40-8 1
1
2
1
1
1
N-21967 N-21967
Remove the four mounting bolts (Item 1) [Figure 30-4010]. Figure 30-40-11
Dealer Copy -- Not for Resale
Remove the pump mounting bolts (Item 1) [Figure 3040-8] (both sides). Installation: Tighten the mounting bolts to 27 - 37 ft.-lb. (37 - 50 N•m) torque. Remove the hydraulic pump (Item 2) [Figure 30-40-8] from the hydrostatic pumps. Figure 30-40-9
2
N-19570
1 Separate the two hydrostatic pumps [Figure 30-40-11].
N-21969
Remove the O-ring (Item 1) and coupler (Item 2) [Figure 30-40-9] with the hydraulic pump.
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Figure 30-40-14
HYDROSTATIC PUMP (CONT’D) Pump Separation (Cont’d) Figure 30-40-12
3
1
2 1 N-19551
2
3 Remove the pump housing end cap (Item 1) [Figure 3040-14].
N-19571
Remove the gasket (Item 2) [Figure 30-40-14]. Remove the pump coupler (Item 1) [Figure 30-40-12].
Dealer Copy -- Not for Resale
Figure 30-40-15 Remove the large O-ring (Item 2) [Figure 30-40-12]. 1
Remove the two small O-rings (Item 3) [Figure 30-4012]. Disassembly Figure 30-40-13
1
1
N-17193
Remove the valve plate (Item 1) [Figure 30-40-15]. Inspect the valve plate for wear. (Both Sides.)
N-19550
Remove the four bolts (Item 1) [Figure 30-40-13] from the pump housing end cap.
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Figure 30-40-18
HYDROSTATIC PUMP (CONT’D) Disassembly (Cont’d)
1 Figure 30-40-16 2
1
2
N-17198
Remove the slipper guide and pistons (Item 1) [Figure 30-40-18] from the cylinder block.
Inspect the valve plate locating pin (Item 1) [Figure 3040-16] for wear and replace if needed.
Inspect all the pistons (Item 2) [Figure 30-40-18] for wear and replace the rotating group as needed.
Dealer Copy -- Not for Resale
N-17194
Figure 30-40-19 Inspect the needle bearing (Item 2) [Figure 30-40-16] for wear and replace if needed. 1
Figure 30-40-17
1
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-4019] from the cylinder block.
N-17197
Remove the rotating group (Item 1) [Figure 30-40-17] from the pump.
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Figure 30-40-22
HYDROSTATIC PUMP (CONT’D) Disassembly (Cont’d) Figure 30-40-20 4
4
3
1 4
4
2
1
2
3 N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2) and the support washer (Item 3) [Figure 30-40-22] from the drive shaft end of the pump.
Inspect the ball guide retainer (Item 1) and washer (Item 2) [Figure 30-40-20] for wear and replace as needed.
Figure 30-40-23
Dealer Copy -- Not for Resale
N-17200
Remove the pin retainer (Item 3) [Figure 30-40-20]. 1
Remove the four pins (Item 4) [Figure 30-40-20] from the cylinder block. Inspect the cylinder block for wear and replace as needed. Inspect pins (Item 4) [Figure 30-40-20] to see if they are all the same length. Figure 30-40-21
N-17239
Use a seal puller and remove the seal (Item 1) [Figure 30-40-23] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-21] from the pump housing.
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Figure 30-40-26
HYDROSTATIC PUMP (CONT’D) Disassembly (Cont’d) Figure 30-40-24
1
1 N-17242
Inspect the pump shaft (Item 1) [Figure 30-40-26] for wear and replace if needed.
N-17240
Figure 30-40-25
1
1
N-17243
1 Remove the four mount bolts (Item 1) [Figure 30-40-27] from the lower trunnion cover. Remove the cover. N-17241
Remove the snap ring (Item 1) [Figure 30-40-25] from the driveshaft and remove the bearing. Inspect the bearing for wear and replace if worn.
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Figure 30-40-27 Remove the snap ring (Item 1) [Figure 30-40-24] from the pump housing and remove the driveshaft and bearing from the housing.
Figure 30-40-30
HYDROSTATIC PUMP (CONT’D) Disassembly (Cont’d) Figure 30-40-28
2
2 1
1 1
N-17246
Remove the four mount bolts (Item 1) from the pump housing and remove the linkage bracket (Item 2) [Figure 30-40-30].
Remove the O-ring (Item 1) and bearing race (Item 2) [Figure 30-40-28] from the pump housing.
Figure 30-40-31
Dealer Copy -- Not for Resale
N-17244
Figure 30-40-29
1 1 2 N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-4031].
N-17245
Inspect the bearing race (Item 1) and O-ring (Item 2) [Figure 30-40-29] for wear and replace as needed.
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Figure 30-40-34
HYDROSTATIC PUMP (CONT’D) Disassembly (Cont’d) Figure 30-40-32
1
2 1
N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2) [Figure 30-40-34] and replace as needed.
N-17250
Figure 30-40-35
Figure 30-40-33
1
1
2
N-17251
Slide the swash plate from side to side and remove the tapered roller bearing (Item 1) [Figure 30-40-35] from the swash plate shaft.
N-17248
Remove the O-ring (Item 1) and bearing race (Item 2) [Figure 30-40-33] from the pump housing.
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Inspect the seal (Item 1) [Figure 30-40-32] in the upper trunnion cover and replace if needed.
HYDROSTATIC PUMP (CONT’D)
Assembly
Disassembly (Cont’d)
Figure 30-40-37
Figure 30-40-36
1 1
N-17253 N-17252
Install the lower bearing (Item 1) [Figure 30-40-37] on the swash plate. Figure 30-40-38
Dealer Copy -- Not for Resale
Tilt the swash plate (Item 1) [Figure 30-40-36] and remove the swash plate and lower bearing from the pump housing.
N-17252
Install the swash plate and bearing into the pump housing [Figure 30-40-38].
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Figure 30-40-41
HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d) Figure 30-40-39
1
1 2
N-17247
3 Install the upper trunnion seal (Item 1) [Figure 30-40-41] and cover.
N-17249
Figure 30-40-42
Figure 30-40-40
1
N-17246
Install the linkage bracket (Item 1) [Figure 30-40-42] and the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 30 N•m) torque.
N-17248
Install the bearing race (Item 2) [Figure 30-40-39] and Oring (Item 3) [Figure 30-40-39] as shown in [Figure 3040-40].
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Install the tapered bearing (Item 1) [Figure 30-40-39] on the swash plate shaft.
Figure 30-40-45
HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d) Figure 30-40-43
1
2 N-17243
Align the marks on the lower trunnion cover and pump housing as shown in [Figure 30-40-45].
N-17245
Dealer Copy -- Not for Resale
Install the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 - 30 N•m) torque.
Figure 30-40-44
Figure 30-40-46
1
N-17244
Install the bearing race (Item 1) [Figure 30-40-43] and Oring (Item 2) [Figure 30-40-43] at the lower trunnion as shown in [Figure 30-40-44].
N-17242
Install the snap ring (Item 1) [Figure 30-40-46] on the pump shaft.
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Figure 30-40-49
HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d)
1
2
1
Figure 30-40-47
1 1
3
4
1 N-17200
Install the bearing and snap ring (Item 1) [Figure 30-4047] on the pump shaft.
Apply a small amount of grease to the washer (Item 3) and install into the ball guide retainer (Item 4) [Figure 3040-49].
Figure 30-40-48 Figure 30-40-50 1
1
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 3040-48].
Install the ball guide retainer and washer (Item 1) [Figure 30-40-50] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-48].
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Install the four slipper pins (Item 1) into the cylinder block. Use the retaining ring (Item 2) [Figure 30-40-49] to hold the pins in place.
N-17241
Figure 30-40-53
HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d)
1
2
Figure 30-40-51
N-17194
Replace the needle bearing (Item 1) and valve plate locating pin (Item 2) [Figure 30-40-53] in the charge pump.
Assemble the piston assemblies into the slipper guide. Lubricate the pistons and cylinder block bores and insert the piston assemblies into the cylinder bores [Figure 3040-51].
Figure 30-40-54
Lay the pump housing on its side and install the cylinder block, piston assembly into the housing.
2
Dealer Copy -- Not for Resale
N-17198
1
Figure 30-40-52
N-17196
The bearing cage (Item 1) [Figure 30-40-54] will protrude from 0.08 - 0.10 in. (2,0 - 2,5 mm) from the surface of the charge pump. The valve plate locating spring pin (Item 2) [Figure 3040-54] will protrude from 0.165 - 0.185 in. (4,19 - 4,70 mm) from the surface of the charge pump.
N-17197
Place the pump on a work surface with the end cap opening up [Figure 30-40-52].
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Figure 30-40-57
HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d)
1
1
Figure 30-40-55
1
N-19550
Install the valve plate and end cap on the pump housing. Tighten the bolts (Item 1) [Figure 30-40-57] to 35 - 45 ft.lb. (47 - 61 N•m) torque.
Coat the backside of the valve plate with petroleum jelly to hold it in position and install the valve plate onto the charge pump, bronze face up [Figure 30-40-55].
Figure 30-40-58
Dealer Copy -- Not for Resale
N-17193
The notch (Item 1) [Figure 30-40-55] on the valve plate must engage the locating pin. Figure 30-40-56
1 3
2 1 N-19571
1 Install the two small O-rings (Item 1) [Figure 30-40-58]. Install the large new O-ring (Item 2) [Figure 30-40-58]. Install the pump coupler (Item 3) [Figure 30-40-58].
N-19551
Coat a new end cap gasket (Item 1) [Figure 30-40-56] with petroleum jelly and install onto the end cap.
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HYDROSTATIC PUMP (CONT’D) Assembly (Cont’d) Figure 30-40-59
N-19570
Dealer Copy -- Not for Resale
Install the two pumps together [Figure 30-40-59]. Figure 30-40-60
1
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-40-60] to 35 45 ft.-lb. (47 - 61 N•m) torque.
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Dealer Copy -- Not for Resale 30-40-22 426 of 949
S150, S160 Bobcat Loader Service Manual
HYDROSTATIC PUMP (SJC) Description The SJC hydrostatic pump is a fully proportional dual piston pump in one pump casing. The endcaps are removable to gain access to the rotating assemblies. The hydraulic controllers are fed charge pressure from an external charge pump. 12 volt electrical solenoids shift a spool in the hydraulic controller that directs flow to a servo piston.
The servo piston strokes the swash plate in the rotating group. The rotating group generates flow to the A or B ports on the hydrostatic pump. The flow from the A and B ports is sent to the hydrostatic drive motors where forward or reverse drive motor rotation is obtained. There are swash plate angle sensors on the bottom of the pump that monitor swash plate movement. Ports are labeled on the hydrostatic pump casting.
Dealer Copy -- Not for Resale
Figure 30-41-1
P-64943
A,B
Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1
Case Drain Port
MA
Operating Pressure of “A” Port
MB
Operating Pressure of “B” Port
R
Air Bleed Port
X1,X2 Control Pressure Gauge Port G
Charge Pressure Inlet Port
MG
Gauge Port For Charge Pressure
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Figure 30-41-3
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Removal And Installation The loader’s right hand side hydraulic controller can be removed with the hydrostatic pump still in the loader. The loader’s left hand side hydraulic controller can only be removed when the hydrostatic pump is separated from the engine / hydrostatic pump cast mount.
1
Controller solenoids can be bled of trapped air in the controller. This should be performed when hydraulic controllers are replaced, removed or uncommanded oscillations in the controls are present. Raise the lift arms and install and approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Place the loader on jack stands. (See Procedure on Page 10-10-1.)
P-64460
Disconnect all of the electrical harness connectors (Item 1) [Figure 30-41-3] from the loader harness.
WARNING
IMPORTANT
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Figure 30-41-4 Figure 30-41-2 1
1
P-64426 P-64425
Locate the two hydraulic controllers (Item 1) [Figure 3041-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-41-4] from the hydraulic controller.
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Removal:
Figure 30-41-7
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Removal And Installation (Cont'd)
1
Figure 30-41-5
1
2 1
P-64427
2 3
P-64427
Remove the controller (Item 1) [Figure 30-41-5] from the pump. Remove the controller gaskets (Item 2) [Figure 30-41-5] from the pump.
NOTE: When a hydraulic controller is replaced, the hydrostatic pumps must be calibrated. (See Hydraulic Controller Neutral Adjustment on Page 30-41-28.) Figure 30-41-8
Installation: Figure 30-41-6 1
1
P-64978
P-64444
Be sure the feedback lever (Item 3) [Figure 30-41-5] is in the center of the servo piston groove (Item 1) [Figure 3041-6].
With the engine running and the loader on jack stands: Bleed the trapped air in the controller by loosening the small set screw (Item 1) [Figure 30-41-8] a maximum of 2 turns. Leave the screw loose until oil comes dripping out of the set screw. Tighten set screw to 18 in.-lb. (2 N•m) torque. Repeat the bleeding procedure for all of the solenoids.
Use a small amount of grease on a new gasket and install the gasket on the hydraulic controller (Item 1) [Figure 30-41-5]. Be sure the pump surface is clean.
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Alternately tighten bolts (Item 1) [Figure 30-41-7] to 7.7 ft.-lb. (10,4 N•m) torque. Ensure bolts are tight to specifications.
Figure 30-41-10
HYDROSTATIC PUMP (SJC) (CONT'D) Removal And Installation Remove the hydrostatic pump / engine assembly from the loader. (See Removal And Installation on Page 7080-1.)
IMPORTANT
1
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
P-64345
Loosen the washer and nut (Item 1) [Figure 30-41-10] on the hydrostatic pump drive shaft.
Figure 30-41-9
Dealer Copy -- Not for Resale
Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271 N•m) torque Figure 30-41-11
1
2
1
P-64344
Loosen the tensioner mount bolt (Item 1) [Figure 30-419].
P-64346
Remove the drive belt (Item 2) [Figure 30-41-9]. Installation: (See Drive Belt Replacement on Page 3050-3.)
Use a puller (Item 1) [Figure 30-41-11] to loosen the pulley from the pump drive shaft. NOTE: DO NOT strike puller or pump shaft with a hammer. Internal pump damage may result. Remove the nut and washer from the pump drive shaft. Remove the pump pulley from the pump drive shaft.
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Figure 30-41-14
HYDROSTATIC PUMP (SJC) (CONT'D) Removal And Installation (Cont’d) Figure 30-41-12
2
1
1
1
P-64343
Remove the mounting bolt (Item 1) [Figure 30-41-14] at the hydraulic pump mounting bracket.
P-64348
NOTE: The mounting bolt is a special purpose bolt. Only replace with original Bobcat Parts. Figure 30-41-15
1
1
P-64337
1
P-64338
Remove the two mounting bolts (Item 1) [Figure 30-4112] and nuts (Item 1) [Figure 30-41-13]. P-64458
Installation: Tighten the mounting bolts and nuts to 65 70 ft.-lb. (88 - 95 N•m) torque.
Remove the air bleed plugs (Item 1) [Figure 30-41-15]. Make sure the key (Item 2) [Figure 30-41-12] is installed. BEFORE START UP: Fill one of the air bleed ports with new hydraulic oil until the hydraulic oil flows out of the other air bleed port. This will remove trapped air in the hydrostatic pumps before start up. Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
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Remove the hydrostatic pump from the mounting bracket and drive belt housing.
Figure 30-41-13
HYDROSTATIC PUMP (SJC) (CONT'D) Parts Identification
3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
4
5
O-ring Bolt End Housing O-ring Right Rotating Assembly Timing Pin Bearing Spacer / Coupler Pin Positioning Pin O-ring Snap Ring Position Sensor Washer Bolt
7 8
1
6
10 11 12
9
2
13 14 15 16
25
20
21 23 22
26
17
19
18
26
18
27 32
29
19 31
6
2
7 30 4
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
28 Steel Cover Bolt Hydraulic Controller High Pressure Relief Case Housing Bolt Plug Screen Plug Orifice Dowel Pin Charge Pressure Relief Left Servo Right Servo Left Rotating Assembly Key End Housing B25010
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24
Figure 30-41-18
HYDROSTATIC PUMP (SJC) (CONT'D) High Pressure Relief And Bypass Valve Figure 30-41-16
1 2 1 1
P-64437
Check the valve seat surface (Item 1) [Figure 30-41-18] for scratches and replace as needed.
There are four system check relief valves (Item 1) [Figure 30-41-16] in the back of the hydrostatic pump.
Inspect the spring (Item 2) [Figure 30-41-18] for breakage. Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-16]. Assembly: Tighten cap to 111 - 125 ft.-lb. (150 - 170 N•m) torque.
Do not disassemble the relief valve assembly. If replacement is required, replace as an assembly. Factory setting on the relief valve is 5250 PSI (362 bar).
Figure 30-41-17
4
2
3
1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring (Item 2) [Figure 30-41-17], replace as needed. Remove relief valve assembly (Item 3) [Figure 30-41-17] from the valve cap. Check the conical spring (Item 4) [Figure 30-41-17] to ensure it is not broken or flattened.
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P-64431
Figure 30-41-21
HYDROSTATIC PUMP (SJC) (CONT'D) Charge Relief Valve
3
Figure 30-41-19
1
2
5
4
P-64435
1
The charge relief valve (Item 1) [Figure 30-41-19] is located on the back of the hydrostatic pump.
Inspect the sealing ring (Item 3) [Figure 30-41-21] and the mating seat in the pump housing for damage or foreign material.
Remove the charge relief valve. Assembly: Tighten charge relief valve to 52 ft.-lb. (70 N•m) torque.
Inspect the spring (Item 4) and the charge relief valve shims (Item 5) [Figure 30-41-21]. NOTE: 1,0 mm shim (Item 5) [Figure 30-41-21] = 43.5 PSI (3 bar) in pressure change. Adding shims increases charge pressure. Removing shims decreases charge pressure.
Figure 30-41-20
1
P-64435
Check and replace the O-ring (Item 1) [Figure 30-41-20].
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Inspect the poppet (Item 1) and the mating seat (Item 2) [Figure 30-41-21] for damage or foreign material. Ensure the poppet moves freely in it’s bore.
P-64431
Figure 30-41-24
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly Remove the hydrostatic pump / engine assembly from the loader. (See Removal And Installation on Page 7080-1.)
2
Figure 30-41-22
1
1 1
P-64439
Remove the bolts (Item 1) mounting the steel covers (Item 2) [Figure 30-41-24]. Assembly: Tighten bolts to 38 ft.-lb. (51 N•m) torque.
Remove the hydraulic controllers (Item 1) [Figure 30-4122]. (See Hydraulic Controller Removal And Installation on Page 30-41-2.)
Dealer Copy -- Not for Resale
Figure 30-41-25
P-64458
1
Figure 30-41-23
2
2 1
1
1
P-64440
Remove the mounting bolts and washers for the swash plate angle sensor (Item 1) [Figure 30-41-25]. Assembly: Tighten bolts to 27.4 in.-lb. (3,1 N•m) torque. P-64438
Swash plate angle sensors (Item 1) are mounted on the bottom of the hydrostatic pump. They are protected by steel covers (Item 2) [Figure 30-41-23]. Note the connectors facing each other. Note the steel covers facing direction.
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Figure 30-41-28
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-26 1
2
P-64442
Both swash plate angle sensors and associated hardware removed from the hydrostatic pump. [Figure 30-41-28]
P-64441
Dealer Copy -- Not for Resale
Assembly: Note the slotted portion (Item 1) of the positioning pin tightly fits the machined section on the swash plate angle sensor shaft (Item 2) [Figure 30-4126] Note the machined section of the swash plate angle sensor shaft faces the center of the hydrostatic pump. Figure 30-41-27
1
P-64453
NOTE: Improperly installing the swash plate angle sensor, with the shaft facing toward the outside of the hydrostatic pump, will make it hard to install the sensor mounting bolts and also destroy the seal (Item 1) [Figure 30-4127].
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Figure 30-41-31
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Right End Housing Figure 30-41-29 3
1
2 P-64464
Pull the end housings from the case housing [Figure 3041-31].
1
Dealer Copy -- Not for Resale
P-64445
Left End Housing Figure 30-41-30 3
1
2
1 P-64447
Remove the four mount bolts (Item 1) securing the end housing (Item 2) to the main case housing (Item 3) [Figure 30-41-29] and [Figure 30-41-30]. Assembly: Alternately, tighten mount bolts to 96 ft.-lb. (130 N•m) torque.
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Figure 30-41-34
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-32
1 1
2
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole in case housing (Item 2) [Figure 30-41-34] before tightening screws.
P-64465
Dealer Copy -- Not for Resale
Replace O-ring (Item 1) [Figure 30-41-32]. Figure 30-41-33
1
P-64466
Ensure servo follower (Item 2) [Figure 30-41-32] is swung out for proper engagement with the notch in the servo piston (Item 1) [Figure 30-41-33].
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HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-35 RIGHT SIDE
1
2 P-64454
Dealer Copy -- Not for Resale
Figure 30-41-36 LEFT SIDE
1
2
P-64501
Remove valve plate (Item 1) [Figure 30-41-35] and [Figure 30-41-36] from the case housing. Inspect valve plate for scratches or scoring. Replace a valve plate if the scratches are deep enough to catch with a fingernail. NOTE: Pay attention to the notches (Item 2) [Figure 30-41-35] and [Figure 30-41-36] in the valve plate for assembly reasons. There are different valve plates for the left and right side. The valve plates are NOT interchangeable.
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HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-41-39
Disassembly And Assembly (Cont'd)
RIGHT SIDE
Figure 30-41-37
1 2
RIGHT SIDE
1
P-64456
2 Figure 30-41-40 P-64455
LEFT SIDE Figure 30-41-38 LEFT SIDE
P-64503
1 2 P-64502
Assembly: Align the timing pin (Item 1) [Figure 30-4137] and [Figure 30-41-38] in the case housing with the notch (Item 1) [Figure 30-41-39] and [Figure 30-41-40] that does not go through the valve plate. Align the shoulder of the roller bearing (Item 2) [Figure 30-41-37] and [Figure 30-41-38] with the beveled edge on the valve plate (Item 2) [Figure 30-41-39] and [Figure 30-41-40]. NOTE: Valve plate should sit FLUSH with the case housing when properly installed.
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1 2
Figure 30-41-43
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-43]. B25012
Figure 30-41-44
Figure 30-41-42
1
P-64475
B25011
Remove the pistons (Item 1) [Figure 30-41-44] from the rotating block.
Left Side Rotating Group [Figure 30-41-42].
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Right Side Rotating Group [Figure 30-41-41].
Figure 30-41-47
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd)
1 Figure 30-41-45
1
P-64471
Remove the spherical washer (Item 1) [Figure 30-4147].
P-64476
1
Figure 30-41-46
1
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-48]. They should be all the same length. Do not remove. P-64477
Inspect the mating surface of the spherical washer for scoring or scratches (Item 1) [Figure 30-41-46].
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Figure 30-41-48 Inspect the pistons, look for scoring and scratches. Ensure the holes (Item 1) [Figure 30-41-45] in the slippers, are not plugged.
Figure 30-41-51
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd)
3 Figure 30-41-49 1 1
2
P-64479
Inspect mating surface for the slippers on the swash plate (Item 1) [Figure 30-41-51].
Inspect the spherical washer for scoring and wear (Item 1) [Figure 30-41-49].
Remove the swash plate from the endcap housing (Item 2) [Figure 30-41-51]. Remove the slide ring (Item 3) [Figure 30-41-51], ensure it pivots freely.
Figure 30-41-50
Figure 30-41-52 1 2 1
3
2
P-64478
Inspect the back surface of the rotating block (Item 1) [Figure 30-41-50] where the valve plate seals. Ensure there is no scratches or scoring.
P-64480
Assembly: Carefully align bearing pin eyelets (Item 1) into holes in endcap housing (Item 2) [Figure 30-41-52].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure 30-41-50] are not bent or damaged.
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P-64474
Figure 30-41-55
HYDROSTATIC PUMP (SJC) (CONT'D)
2
Disassembly And Assembly (Cont'd)
1
Figure 30-41-53
1
2
1
P-64483
Assembly: Ensure bearing pins are in the holes of the swash plate (Item 1) [Figure 30-41-53].
Assembly: Note shell bearing races have an edge (Item 2) [Figure 30-41-55] on them. The edges face towards the outside of the endcap housing
Figure 30-41-54
Inspect bearing surfaces for scratches or scoring.
2
1
P-64482
Remove the shell bearing (Item 1) [Figure 30-41-54]. Inspect individual roller bearings and machined surfaces (Item 2) [Figure 30-41-54] on swash plate.
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Remove the shell bearing races (Item 1) [Figure 30-4155].
P-64481
Figure 30-41-58
HYDROSTATIC PUMP (SJC) (CONT'D)
LEFT SIDE
Disassembly And Assembly (Cont'd) Figure 30-41-56 1 2
1
P-64486
Figure 30-41-59 P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin (Item 2) [Figure 30-41-56]. Figure 30-41-57
2
1 P-64523
Remove the snap ring (Item 1) [Figure 30-41-58] and [Figure 30-41-59] from the end housing. Figure 30-41-60 P-64485
Pull the positioning pin from the end housing. Replace O-ring (Item 1) [Figure 30-41-57]. Inspect wear surfaces (Item 2) [Figure 30-41-57] for scratches or scoring. Ensure positioning pin can rotate smoothly in the end housing without excessive play. 1
P-64524
The pump seal (Item 1) [Figure 30-41-60] is removed by inserting a screw into the seal and prying out. 30-41-19 445 of 949
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1
Figure 30-41-62
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-61
2 1
P-64488
The drive shaft can be tapped out of the end housing with a rubber mallet.
Inspect bearing (Item 1); if bearing needs replacement, remove snap ring (Item 2) [Figure 30-41-61] and remove bearing.
Dealer Copy -- Not for Resale
Inspect wear surfaces for scratches, and inspect splines for excessive wear.
B25013
Servo Piston Assembly [Figure 30-41-62]. Figure 30-41-63
The Servo Piston Assembly [Figure 30-41-62] cannot be removed unless the hydraulic controller and rotating group is removed first. 1
1
P-64489
Remove servo piston mounting bolts (Item 1) [Figure 3041-63]. Installation: Tighten bolts to 7.7 ft.-lb. (10,4 N•m) torque.
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Figure 30-41-66
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-64
P-64492
Slide the servo piston assembly out of the bore. [Figure 30-41-66].
P-64490
Dealer Copy -- Not for Resale
Measure and record servo piston depth at the adjustment screw [Figure 30-41-64]. Figure 30-41-65
1
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1) [Figure 30-41-65].
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Figure 30-41-69
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-67
1 2 1 2
P-64493
Remove the bushings (Item 1), seals and O-rings (Item 2) [Figure 30-41-69] from the pump housing.
P-64467
Figure 30-41-70
1 1 2
3 P-64494 P-64466
Assembly: Align the servo piston so the guide slot (Item 1) [Figure 30-41-68] is parallel to the driveshaft centerline. Measure with a straight-edge [Figure 30-4167].
Each servo has a pair of bushings (Item 1), O-rings (Item 2) and square-cut seals (Item 3) [Figure 30-41-70].
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Figure 30-41-68
Figure 30-41-73
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-71
1 P-64497
1 Remove snap ring (Item 1) [Figure 30-41-73] from the servo piston.
P-64495
1 2
Assembly: Tighten lock nut to 22 ft.-lb. (30 N•m) torque. Figure 30-41-72
1
P-64498
Remove the piston stop adjustment mechanism (Item 1) [Figure 30-41-74] from the servo piston. Inspect mechanism for broken parts.
P-64496
Replace O-ring (Item 2) [Figure 30-41-74] Remove the servo cover (Item 1) [Figure 30-41-72] from the servo piston.
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Figure 30-41-74 Remove the lock nut (Item 1) [Figure 30-41-71] from the servo piston.
Figure 30-41-77
HYDROSTATIC PUMP (SJC) (CONT'D) Disassembly And Assembly (Cont'd) Figure 30-41-75
1 2
1
1
3 P-64499
Remove the four control pressure plugs (Item 1) [Figure 30-41-77] at the top of the case housing to gain access to the four orifices (Item 1) [Figure 30-41-78].
Remove the plug (Item 1) from the top center of the case housing. Replace O-ring (Item 2) [Figure 30-41-75].
Replace O-rings on plugs. Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
Assembly: Tighten plug to 45 ft.-lb. (10 N•m) torque. Figure 30-41-78 Remove internal screen (Item 3) [Figure 30-41-75]. Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m) torque.
1
Figure 30-41-76
P-64500
Ensure the four orifices (Item 1) [Figure 30-41-78] in case housing are clean and not plugged. P-64462
Ensure screen is clean [Figure 30-41-76].
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P-64461
HYDROSTATIC PUMP (SJC) (CONT'D)
Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd)
The pump mechanical neutral adjustment sets the position of the servo piston and pump swash plate relative to the hydraulic controller. This procedure should be followed if the hydrostatic pump has been disassembled for servicing the servo piston and the setting has been disrupted.
Figure 30-41-79
Place the loader on jackstands. (See Procedure on Page 10-10-1.) 2 1
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
P-64502
Inspect center coupler (Item 2) [Figure 30-41-79].
Raise the lift arms, and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.) Disconnect the swash plate angle sensors in the electrical harness. This prevents unwanted swash plate movement error codes from occurring during adjustments. Disconnecting the sensors does not have to be done directly at the sensor, follow the harness back to find an accessible connector to disconnect. Disconnect the speed sensors located on the top of the motor carriers. This prevents uncommanded wheel movement error codes from occurring during adjustments.
WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290
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W-2017-0286
Bearings (Item 1) [Figure 30-41-79] in case housing are replaced by using a press and bearing driver.
Figure 30-41-82
HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment (Cont’d) Figure 30-41-80 1 1
1
P-64438
Remove the plugs (Item 1) [Figure 30-41-82] from the MA ports on the bottom of the pump, and install 7500 PSI pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-41-80] between port X1 and port X2 on each side of the hydrostatic pump, to equalize the pressures on both ends of the servo pistons.
Figure 30-41-83
Dealer Copy -- Not for Resale
P-64973
Figure 30-41-81
1 1
1
1 P-64977
P-64425
Remove the plugs (Item 1) [Figure 30-41-81] from the MB ports on the front side of the pump, and install 7500 PSI (241 bar) pressure gauges.
Remove drive hoses from the A and B ports (Item 1) [Figure 30-41-83]. Plug the ports with metal caps. The caps must be able to handle at least 7500 PSI. Plugging the A and B ports eliminates leakage at the drive motors from causing errors in the pump mechanical neutral setting.
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Figure 30-41-86
HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment (Cont’d) Figure 30-41-84
1
1 P-64457
Turn the adjustment screw (Item 1) [Figure 30-41-86] counterclockwise, until the other gauge registers an increase in system pressure. Mark the position of the adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1) [Figure 30-41-84].
Figure 30-41-87
Dealer Copy -- Not for Resale
P-64457
Start the loader using the remote start tool and run at an idle.
WARNING Stay clear of the loader wheels. They will turn whenever the pump is not centered. W-2276-1297
1 Figure 30-41-85 P-64457
Turn the adjustment screw (Item 1) [Figure 30-41-87] clockwise, to a position halfway between the recorded positions. The pressure gauges should read equal pressures.
1 P-64457
Turn the adjustment screw (Item 1) [Figure 30-41-85] clockwise, until one of the gauges registers an increase in system pressure. Mark the position of the adjustment screw. 30-41-27 453 of 949
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HYDROSTATIC PUMP (SJC) (CONT'D)
Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d)
The hydraulic controller neutral adjustment, aligns the pump swash plate and the control spool so that a zero angle control setting provides a zero degree swash plate setting. This adjustment should be performed whenever any part of the control or swash plate mechanisms are adjusted or removed or after the pump mechanical neutral setting is adjusted. Ensure the pump mechanical neutral setting is correct before performing hydraulic controller neutral adjustments.
Figure 30-41-88
NOTE: Procedure is shown for the left side hydraulic controller. Procedure is the same for the right side hydraulic controller, except you disconnect the electrical connectors for the right side hydraulic controller and connect pressure gauges in the X1 and X2 ports on the right side of the pump.
2
1 P-64457
WARNING
Shut loader OFF. Remove the hydraulic hose from the X1 and X2 ports on the pump. Install the plugs and tighten to 18 ft.-lb. (25 N•m) torque. Remove the pressure gauges from the MA and MB ports on the pump. Install the plugs and tighten to 18 ft.-lb. (25 N•m) torque. NOTE: The Hydraulic Controller Neutral Adjustment must be performed whenever the Mechanical Neutral Adjustment is done. (See Hydraulic Controller Neutral Adjustment on Page 30-4128.)
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Raise the lift arms, and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. W-2145-0290
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While holding the adjustment screw (Item 1) in position, tighten the lock nut (Item 2) [Figure 30-41-88] to 22 ft.-lb. (30 N•m) torque.
Place the loader on jack stands. (See Procedure on Page 10-10-1.)
Figure 30-41-91
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment (Cont’d) Figure 30-41-89
2 1
P-64975
1
Install 500 PSI pressure gauges in the X1 and X2 ports pertaining to the side of the hydrostatic pump you are adjusting.
Disconnect the hydraulic controller connectors (Item 1) [Figure 30-41-89] from the loader wiring harness for the hydraulic controller you are adjusting.
Figure 30-41-92
Dealer Copy -- Not for Resale
P-64460
Figure 30-41-90
1
1
2 P-64459
Loosen the locking screw (Item 1) [Figure 30-41-92]. P-64458
Start the loader using the remote start tool and run at an idle. Remove the X1 plug (Item 1) and X2 plug (Item 2) [Figure 30-41-90] pertaining to the side of the hydrostatic pump you are adjusting.
WARNING Stay clear of the loader wheels. They will turn whenever the pump is not centered. W-2276-1297
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Figure 30-41-95
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment (Cont’d) Figure 30-41-93
1
1 P-64459
Turn the adjustment screw (Item 1) [Figure 30-41-95] clockwise, to a position halfway between the recorded positions. The pressure gauges should read equal pressures.
Turn the adjustment screw (Item 1) [Figure 30-41-93] clockwise, until one of the gauges registers an increase in system pressure. Mark the position of the adjustment screw.
Figure 30-41-96
Dealer Copy -- Not for Resale
P-64459
2 Figure 30-41-94
1
1
P-64459
While holding the adjustment screw (Item 1) in position, tighten the locking screw (Item 2) [Figure 30-41-96] to 4.5 ft.-lb. (6,1 N•m) torque.
P-64459
Turn the adjustment screw (Item 1) [Figure 30-41-94] counterclockwise, until the other gauge registers an increase in system pressure. Mark the position of the adjustment screw.
Shut loader OFF. Remove the pressure gauges from the X1 and X2 ports on the pump. Install the plugs and tighten to 18 ft.-lb. (25 N•m) torque. Connect the hydraulic controller wire connectors to the loader wiring harness. Perform a controller calibration procedure. Calibration Procedure (ACS) on Page 60-160-11.)
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(See
S150, S160 Bobcat Loader Service Manual
DRIVE BELT
Adjusting
Shield Removal And Installation
To adjust the drive belt between the flywheel and the hydrostatic pump pulley, use the following procedure:
Figure 30-50-1 Stop the engine. Open the rear door. Disconnect the negative (-) battery cable. Remove the belt shield. (See Shield Removal And Installation.) The pulley tensioner is located between the flywheel and pump pulley.
1
Figure 30-50-3
P-48001
1
2 Figure 30-50-2
1
P-8760
Loosen the bolt (Item 1) [Figure 30-50-3] on the spring loaded drive idler. NOTE: The pointer (Item 2) [Figure 30-50-3] will be at the 1 o'clock position when the idler is not under spring tension. P-48000
Remove the belt shield (Item 1) [Figure 30-50-2].
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Remove the three drive belt shield mounting clips (Item 1) [Figure 30-50-1].
NOTE: Do not set the idler against the travel stop in the 3 o'clock position.
DRIVE BELT (CONT’D) Adjusting (Cont’d)
Run the engine for a few minutes. Figure 30-50-4 Stop the engine and recheck the pointer position. Readjust if necessary. After the idler has been in service, readjust when the pointer reaches the 1 o'clock position. 1
Install the belt shield using the fasteners. Reconnect the negative (-) battery cable. Close the rear door.
P-48479
Note:
Dealer Copy -- Not for Resale
Using the Belt Tensioner Bar (MEL1405) or a pry bar push the idler assembly against the belt, the pointer (Item 1) [Figure 30-50-4] will be at the 3 o'clock position when the idler stop is bottomed out. Do not pry directly on the pulley, pry on the tensioner bracket the pulley is mounted on. If the pointer does not move when prying on the tensioner mounting bracket, manually move the arrow towards the 3’oclock position with a screwdriver while putting tension on the bracket to help get it started.
Figure 30-50-5
1
P-48480
Raise the idler assembly slightly so that the pulley is operating on spring tension and not against the stop. Tighten the mounting bolt (Item 1) [Figure 30-50-5] to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Figure 30-50-8
DRIVE BELT (CONT’D) Drive Belt Replacement Figure 30-50-6
P-48481
Stop the engine. Open the rear door.
Install the new drive belt. Install the belt tensioner assembly.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Install the fan drive belt. Adjust the drive belt. (See Adjusting on Page 30-50-1.)
Remove the negative (-) cable from the battery. The battery may be removed for additional working clearance. (See Removal And Installation on Page 60-20-1.)
Reinstall belt shield and connect the negative (-) cable to the battery.
Remove the belt shield [Figure 30-50-6]. (See Shield Removal And Installation.) Figure 30-50-7 1
2
P-48478
Remove the fan drive belt (Item 1) [Figure 30-50-7]. The belt tensioner is located between the flywheel and pump pulley. Loosen and remove the bolt (Item 2) [Figure 30-50-7] from the belt tensioner. Remove the belt tensioner assembly. 30-50-3 459 of 949
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Remove the drive belt from the pump pulley and flywheel. Remove the drive belt from the loader [Figure 30-50-8].
P-48000
Figure 30-50-10
DRIVE BELT (CONT’D) Tensioner Pulley Removal And Installation
1
Figure 30-50-9
P-48478
Loosen and remove the tensioner pulley mounting bolt (Item 1) [Figure 30-50-10].
P-43217
Remove the negative (-) cable from the battery. the battery may be removed for additional working clearance. (See Removal And Installation on Page 60-20-1.)
Remove the belt tensioner pulley from the housing. Reverse the removal procedure to install the drive belt tensioner.
Remove the belt shield [Figure 30-50-9]. (See Shield Removal And Installation.)
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Installation: Tighten the bolt to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Stop the engine. Open rear door.
DRIVE BELT (CONT’D) Tensioner Pulley Parts Identification
1. Cover 2. Bolt 3. Washer 4. Pins 5. Washer 6. Spring 7. Snap Ring 8. Snap Ring 9. Bearing 10. Dust Shield 11. Pulley 12. Bushing 13. Hub 14. Washer 15. Seal 16. Arrow Indicator Plate 17. Locating Pin 18. Spring 19. Shaft 20. Bracket
1
2
11 3 12
4
13
6
14
5
NOTE: Drive idler parts are not available individually. Consult parts catalog for available sub-assemblies.
Dealer Copy -- Not for Resale
5
15
7
8
16 17
9
18 10
19
20
E-2296
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Figure 30-50-13
DRIVE BELT (CONT’D) Tensioner Pulley Disassembly Figure 30-50-11
3 1 1
4 2
P-8861
Remove the grease cover (Item 1) [Figure 30-50-11].
Remove the bracket assembly (Item 3) by tapping on the shaft (Item 4) [Figure 30-50-13] with a plastic hammer.
Figure 30-50-12 Figure 30-50-14
5 2
2
3
1 1
4 P-8859 P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the retainer washer (Item 3), the spring washer (Item 4) and the second retainer washer (Item 3) from the pulley assembly (Item 5) [Figure 30-50-12].
Remove the spring (Item 1) from the bracket (Item 2) [Figure 30-50-14].
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Remove the two pins (Item 1) from the hub assembly (Item 2) [Figure 30-50-13] only if they have been damaged.
P-8858
Figure 30-50-17
DRIVE BELT (CONT’D) Tensioner Pulley Assembly Figure 30-50-15
1 1
P-8873
2
Turn the pulley assembly over and install the two pins (Item 1) [Figure 30-50-17] into the hub.
P-8871
Figure 30-50-18
Figure 30-50-16
1
3
2 P-8874
Install a punch as shown and turn clockwise while applying down pressure on the pulley.
P-8872
Install the shaft from the bracket assembly (Item 1) into the pulley assembly (Item 2) and align the spring (Item 3) [Figure 30-50-16] over the alignment pin on the bracket.
Turn until the pulley snaps down into place; this procedure winds the spring and retains the end of the spring in proper location [Figure 30-50-18].
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Install the spring (Item 1) on the pulley (Item 2) [Figure 30-50-15] as shown.
Figure 30-50-21
DRIVE BELT (CONT’D) Tensioner Pulley Assembly (Cont'd) Figure 30-50-19
2 2 1
1
P-8877
Install the first retainer washer (Item 1) [Figure 30-50-19] and spring washer (Item 2) [Figure 30-50-19] over the roll pins. Figure 30-50-20
NOTE: When pressing the grease cap onto the pulley assembly, do not press down on the arrow indicator plate. Support the hub assembly so that it contacts only the hub and not the arrow indicator plate.
3
2 1
P-8876
Install the second retainer washer (Item 1) [Figure 3050-20], the washer (Item 2) [Figure 30-50-20] and the bolt (Item 3) [Figure 30-50-20]. Tighten the bolt to 28 32 ft.-lb. (38 - 45 N•m) torque. Fill the grease cap 1/4 full (approximately 1/2 - 3/4 oz.) of grease.
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Press the grease cap (Item 1) [Figure 30-50-21] onto the pulley assembly (Item 2) [Figure 30-50-21]. Press on the outer formed edge of the grease cap.
P-8875
Figure 30-60-2
OIL COOLER Removal And Installation
1
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888 N-19345
Figure 30-60-1
3
Dealer Copy -- Not for Resale
Install tool MEL1558 (Item 1) [Figure 30-60-2] to outside of rubber sleeve (Item 1) [Figure 30-60-3].
1
2 P-45101
Open the rear door of the loader. Remove the rear grille [Figure 30-60-1]. Move air conditioning condenser out of the way. (If equipped). (See Removal And Installation on Page 80120-1.)
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OIL COOLER (CONT’D) Removal And Installation (Cont’d) Figure 30-60-3
1
N-19540
Dealer Copy -- Not for Resale
Figure 30-60-4
N-19346
Slide the rubber sleeve in toward the radiator. The connector will release [Figure 30-60-3] and [Figure 3060-4] Disconnect the inlet and outlet hoses (Items 1 and 2) from the oil cooler (Item 3) [Figure 30-60-1]. NOTE: When installing the cooler hoses, the fittings should make a clicking sound when pushed together. Lift up the oil cooler and remove the cooler from the loader. Reverse the removal procedure to install the oil cooler.
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DRIVE SYSTEM
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Cover Removal And Installation. . . . . . . . . . . . . . . Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Removal And Installation . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Cover Removal And Installation . . . . . . . . . . . . . . . . Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40-30-1 40-30-3 40-30-1 40-30-2 40-30-2 40-30-4 40-30-1
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . Axle Sprocket And Bearings Removal And Installation . . . Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . .
40-20-1 40-20-1 40-20-3 40-20-8
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
SAFETY MAINTENANCE
DRIVE SYSTEM
SYSTEM ANALYSIS ENGINE SERVICE
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BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Disk Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Switch Operated Parking Brake. . . . . . . . . . . . . . . . . . . . . 40-10-2
SPECIFICATIONS
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Figure 40-10-2
BRAKE Disk Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect and remove the engine speed control. (See Removal And Installation on Page 70-20-1.)
N-19105
Inspect the traction lock guides (Item 1) [Figure 40-10-2] and the brake disc for damage or wear and replace as necessary. (See Inspecting The Control System on Page 60-110-2.), inspection procedure.
Remove the control panel from the loader. (See Removal And Installation on Page 50-100-1.) Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.) Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.) Figure 40-10-1
1
1 N-19081
The parking brake discs (Item 1) [Figure 40-10-1] are located beneath the center chaincase cover.
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W-2059-0598
1
BRAKE (CONT’D)
Switch Operated Parking Brake
Disk Removal And Installation (Cont’d)
Figure 40-10-5
Figure 40-10-3
1
2
1 P-21944 N-19082
The parking brake switch (Item 1) [Figure 40-10-5] is located in the front panel. (See INSTRUMENT PANEL on Page 60-50-1.)
Dealer Copy -- Not for Resale
Figure 40-10-4
1
N-19083
A snap ring pliers with 90° tips are necessary for removing the parking brake disc. Remove the snap ring (Item 1) [Figure 40-10-3] from the end of the sprocket on the hydrostatic motor carrier. Slide the disc (Item 2) [Figure 40-10-3] off the sprocket (Item 1) [Figure 40-10-4] and remove the disc through the front chaincase cover. Reverse the removal procedure to install the disc in the loader.
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Figure 40-20-2
DRIVE COMPONENTS Axle Seal Removal And Installation Figure 40-20-1
2
2
1
1
P-4159
2
Install the puller tool (Item 1) [Figure 40-20-2] on the axle hub.
P-4157
A driver tool (Item 2) [Figure 40-20-2] can be used for centering the threaded rod of the puller.
The tools listed are needed for the following procedure:
MEL1399 - Seal Driver Tool
WARNING
MEL1242 - Power Ram (may be used if desired) To loosen the axle hub mounting bolt (Item 1) [Figure 4020-1], use the following procedure: Before lifting and blocking the loader, loosen the hub mounting bolt (Item 1) [Figure 40-20-1]. NOTE: If the axle and bearings are being replaced, also loosen the sprocket mounting bolt inside the chaincase before lifting and blocking the loader. ((See Axle Sprocket And Bearings Removal And Installation on Page 40-20- 3.)) Lift and block the loader. (See Procedure on Page 10-101.)
NEVER STAND IN-LINE OF THE HUB WHEN REMOVING A HUB FROM AN AXLE. The hub has a tapered fit on the axle end and can come off the axle with great force and cause serious injury. W-2186-0395
Use a wrench with the puller and remove the axle hub from the axle tube. A spacer and a power ram can be used between the axle and the tool if available, instead of the wrench, threaded rod and driver tool.
Remove the front tire / wheel assembly. Installation: Tighten the wheel mounting nuts to 105 115 ft.-lb. (142 - 156 N•m) torque. Remove the hub mounting bolt (Item 1) [Figure 40-20-1] and washer from the axle. Installation: Tighten the hub mounting bolt to 725 - 800 ft.-lb. (983 - 1085 N•m) torque. Remove two of the wheel mounting studs (Item 2) [Figure 40-20-1]. Use a wheel mounting nut on each stud and remove the two studs with a hammer. Installation: Support the flange of the axle hub and install the two studs with a hammer. A hydraulic press can also be used to install the studs.
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Axle Hub Puller Tool
Figure 40-20-5
DRIVE COMPONENTS (CONT’D) Axle Seal Removal And Installation (Cont’d) Figure 40-20-3
P-4160
1
Installation: MEL1399 seal driver tool is necessary for the following procedure:
P-4161
Clean the seal area and inspect the shaft for wear. NOTE: If the shaft is damaged or worn, an axle repair sleeve kit is available from Bobcat Parts.
Figure 40-20-4
Place the new axle seal over the axle and into the axle tube. Install MEL1399 seal driver tool over the axle and put against the axle seal [Figure 40-20-5]. Hit the seal driver tool with a hammer until the tool is flush with the edge of the axle tube [Figure 40-20-5]. Reverse removal procedure to install the axle hub and wheel assembly.
1
P-4181
Drill a small hole in the axle seal. Install a slide hammer (Item 1) [Figure 40-20-4] with a screw tip end in the axle seal. Remove the axle seal.
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Remove the key (Item 1) [Figure 40-20-3] from the axle.
Figure 40-20-6
DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation The tools listed are needed for the following procedure: MEL1242 - Power Ram MEL1202B - Axle Bearing Service Set NOTE: The procedure shown is for removing the front axle, bearings and sprocket. This procedure can also be used for the rear axle, bearings and sprocket. (See Rear Cover Removal And Installation on Page 40-30-4.)
1 P-4147
Use jackstands to support the rear of the loader. (The loader wheels should remain on the ground.)
Loosen the axle sprocket mounting bolt (Item 1) [Figure 40-20-6].
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Remove the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.) Remove the axle hub. (See Axle Seal Removal And Installation on Page 40-20-1.) Remove the sprocket mounting bolt (Item 1) [Figure 4020-6]. Installation: Tighten the sprocket mounting bolt to 300 330 ft.-lb. (407 - 447 N•m) torque.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the control panel. (See Removal And Installation on Page 50-100-1.) Remove the front chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.)
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Lift and block the loader. (See Procedure on Page 10-101.)
Figure 40-20-9
DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation (Cont’d) Figure 40-20-7
1
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed for the following procedure:
1
Install the MEL1242 power ram (Item 1) [Figure 40-20-7] between the two sprockets.
Put the axle / outer bearing assembly in the bearing puller as shown and put in the hydraulic press [Figure 40-20-9]. Figure 40-20-10
Put a spacer between the power ram and axle. Push the axle out to the end of the power ram stroke. Add another spacer and push the axle again. Repeat this procedure until the axle is free from the sprocket and inner bearing. Figure 40-20-8
P-4171
Be sure the bearing puller makes good contact with the inner race of the bearing and press the bearing off the mounting surface of the axle.
2 1 P-4162
Remove the drive chain from the sprocket (Item 1) [Figure 40-20-8] and remove the sprocket from the chaincase. Remove the inner bearing (Item 2) [Figure 40-20-8] and remove the axle from the axle tube. (See Axle Sprocket And Bearings Removal And Installation on Page 40-203.)
Be sure to hold onto the axle during removal as it will slide freely along the axle shaft after removal from the bearing mounting surface and until the bearing contacts the spline on the shaft. Press the splined end of the axle free from the bearing [Figure 40-20-10].
Installation: Pack both axle bearings with grease before installing them.
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P-4158
Figure 40-20-12
DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation (Cont’d) Figure 40-20-11
3
4
1 P-4175
2
When the bearing reaches the bearing mounting surface, continue the installation until the bearing is fully seated [Figure 40-20-12].
P-4169
Dealer Copy -- Not for Resale
Installation: A piece of round tubing (Item 1) [Figure 4020-11] is needed to install the bearing on the axle shaft. The tubing needs to measure approximately 0.500 in. (12,7 mm) to 1.0 in. (25,4 mm) in length. The inside diameter of the tubing should not be under 2.100 in. (53,3 mm) and the outside diameter should not be over 2.400 in. (60 mm). A bearing puller (Item 2) [Figure 40-20-11] is also needed to install the bearing on the axle. Put the tubing (Item 1) on the bearing puller (Item 2) [Figure 40-20-11]. Put the bearing (Item 3) [Figure 40-20-11] on the tube as shown. Put the spline end of the axle shaft (Item 4) [Figure 4020-11] in the bearing and press the bearing onto the axle. Be sure to hold onto the axle during installation, as it will slide freely along the axle shaft after the spline end has passed through the bearing and until it reaches the bearing mounting surface on the axle.
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Figure 40-20-14
DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation (Cont’d) Figure 40-20-13
2 1 P-4179
To remove the outer bearing cup, place the bearing cup tool (Item 1) [Figure 40-20-14] on the slide hammer. P-4172
Use the tools provided in the MEL1202B Axle Bearing Service Set for bearing cup removal and installation. A slide hammer is also necessary for this procedure. Use the long rod and bearing cup tool to remove the inner bearing cup [Figure 40-20-13].
After the bearing cup tool is inside the axle tube, pull the tool against the bearing cup and tighten the nut (Item 2) [Figure 40-20-14] on the tool. Figure 40-20-15
Hit the long rod with a hammer to remove the bearing cup from the axle tube [Figure 40-20-13].
P-4180
Use the slide hammer and remove the bearing cup from the axle tube [Figure 40-20-15].
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Leave the bearing cup tool loose until the tool is installed inside the tube [Figure 40-20-14].
Put the installation tool (Item 1) [Figure 40-20-17] in the axle tube with the threaded rod through the hole in the tool.
DRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And Installation (Cont’d)
Secure the tool to the threaded rod with a nut [Figure 4020-17].
Figure 40-20-16
Hold the inside nut (Item 3) [Figure 40-20-16] with a wrench and tighten the outside nut as shown in photo [Figure 40-20-17].
1 2
Tighten the nut until the bearing cup is seated. Figure 40-20-18 3
P-4174
1
P-4173
To install the outer bearing cup, use the short rod and the bearing cup tool used for removing the bearing cups. Put the bearing cup tool on the short rod. 2
Put the bearing cup in the axle tube and put the tool into the tube over the bearing cup [Figure 40-20-18]. P-4164
Use the bearing cup installation tools (Item 1) [Figure 4020-16] and (Item 1) [Figure 40-20-17] and the long threaded rod (Item 2) [Figure 40-20-17] from the service set to install the inner and outer bearing cups.
Hit the short rod with a hammer until the bearing cup is seated inside the axle tube.
Put the inner bearing cup in the axle tube (Item 2) [Figure 40-20-16]. Put the installation tool (Item 1) [Figure 40-20-16] in the axle tube. Install the long threaded rod (Item 2) [Figure 40-20-17] into the axle tube and through the installation tool (Item 1) [Figure 40-20-16]. Secure the tool to the threaded rod with a nut (Item 3) [Figure 40-20-16].
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Figure 40-20-17
Figure 40-20-19
DRIVE COMPONENTS (CONT’D) Chain Removal And Installation
2
WARNING 1
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Lift and block the loader. (See Procedure on Page 10-101.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the fluid from the chaincase. (See Removing The Oil on Page 40-30-1.)
P-4152
Remove the parking brake disc (Item 1) [Figure 40-2019]. (See Disk Removal And Installation on Page 40-101.) Remove the six carrier mounting bolts (Item 2) [Figure 40-20-19] from inside the chaincase. Installation: Tighten the motor carrier mounting bolts to 125 - 140 ft.-lb. (170 - 190 N•m) torque. Figure 40-20-20
Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel. (See Removal And Installation on Page 50-100-1.) Remove the traction lock assembly. (See TRACTION LOCK on Page 60-110-1.)
1
Remove the center chaincase cover. (See Center Cover Removal And Installation on Page 40-30-3.) Remove the front (or rear) chaincase cover. (See Front Cover Removal And Installation on Page 40-30-2.) P-4167
Remove the front (or rear) axle and sprocket. (See Axle Sprocket And Bearings Removal And Installation on Page 40-20-3.)
Tip the end of the sprocket on the motor carrier toward the rear of the loader and remove the rear drive chain from the sprocket. NOTE: It may be necessary to tie the front drive chain up as shown in photo [Figure 40-20-20], so the carrier / motor assembly can be moved enough to free the rear drive chain (Item 1) [Figure 40-20-20] from the sprocket. Remove the front drive chain from the chaincase.
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Raise the loader lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.)
DRIVE COMPONENTS (CONT’D) Chain Removal And Installation (Cont’d)
WARNING DO NOT exceed the recommended torque. The tool may fail under too much torque. Put cloth around the tool to protect yourself from flying debris. W-2233-0307
Dealer Copy -- Not for Resale
Figure 40-20-21
B-13504
The tool listed is needed for the following procedure: MEL1037 - Chain Link Tool Installation: If a new chain is installed, a connector link must be used to connect the chain together. Use MEL1037 Chain Link Tool and #80 chain adapter. Secure the tool and place the connector link in the tool as shown [Figure 40-20-21]. Turn the threaded rod of the tool and press the connector link together on the chain [Figure 40-20-21]. Tighten the threaded rod of the chain link tool to 130 ft.-lb. (176 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
CHAINCASE
Removing The Oil
Checking And Adding Oil
Figure 40-30-2
Figure 40-30-1
1 1
P-64141 P-34453
Use a vacuum pump to extract the fluid from the chain case.
To check the chaincase oil level, use the following procedure: Drive the loader on a level surface. Stop the engine. Remove the plug (Item 1) [Figure 40-30-1] from the front of the chaincase housing. If oil can be reached with the tip of the your finger through the hole the oil level is correct. If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.
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Dealer Copy -- Not for Resale
The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic / hydrostatic system. (See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.)
Remove the chaincase cover (Item 1) [Figure 40-30-2] (See Front Cover Removal And Installation on Page 4030-2.)
CHAINCASE (CONT’D)
WARNING
General Information Early chaincase designs were assembled with gaskets and polyurethane sealant between the chaincase covers and chaincase housing. This was due to a weld that ran down the middle of the top of the chaincase.The gasket helps seal around the welded area. The polyurethane sealant should be used with the gasket to ensure a good seal. Later chaincase designs do not use a gasket because the weld was moved to the top edge of the chaincase. This creates a “flat top”, on the chaincase, for the cover to seal against. Polyurethane sealant is all that is needed to seal the covers. Note:
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Figure 40-30-3
3
Both the later “flat top” and early chaincase designs should use polyurethane sealer on the screw threads, to ensure a good seal.
3
1 2 3
Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
3
P-34255
Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the front chaincase cover mounting screws (Item 1) [Figure 40-30-3].
DANGER
Remove the front chaincase cover (Item 2) [Figure 4030-3] from the loader. Note:
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
On later “flat top” chaincases there are machined recesses (Item 3) [Figure 40-30-3] on the bottom side of the cover to help pry the covers off.
Installation: Install a new gasket (if equipped). When installing a cover on “flat top” chaincases, apply polyurethane sealer to mating surfaces. Polyurethane sealant should be applied to the screw threads and gasket (if equipped) to stop oil leakage. Tighten the mounting screws to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
D-1009-0409
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Front Cover Removal And Installation
Disconnect the lift control cross bar (Item 2) [Figure 4030-4] from the lift spool on the main control valve.
CHAINCASE COVERS (CONT’D) Center Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Disconnect the electrical connector (Item 3) [Figure 4030-4] from the traction lock solenoid. Remove the crossbar mounting bolt (Item 4) [Figure 4030-4]. Remove the crossbar and wire harness from the center chaincase cover.
WARNING
DANGER
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
•
•
Figure 40-30-5
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
Dealer Copy -- Not for Resale
P-90328
2 3
3 1
1
D-1009-0409
1
Remove the control panel. (See Removal And Installation on Page 50-100-1.)
3
3
Figure 40-30-4 P-34446
4 Remove the chaincase cover mounting screws (Item 1) [Figure 40-30-5].
3
2
Remove the center chaincase cover (Item 2) [Figure 4030-5] from the loader.
1
Note:
P-34257
Disconnect the lift control cross bar (Item 1) [Figure 4030-4] from the lift pedal linkage.
Installation: Install a new gasket (if equipped). When installing a cover on “flat top” chaincases, apply polyurethane sealer to mating surfaces. Polyurethane sealant should be applied to the screw threads and gasket (if equipped) to stop oil leakage. Tighten the mounting screws to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
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On later “flat top” chaincases there are machined recesses (Item 3) [Figure 40-30-5] on the bottom side of the cover to help pry the covers off.
S150, S160 Bobcat Loader Service Manual
Figure 40-30-6
CHAINCASE COVERS (CONT’D) Rear Cover Removal And Installation Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
3
3 1
Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.) 2
DANGER
3 3 P-34259
Remove the rear chaincase cover mounting screws (Item 1) [Figure 40-30-6].
P-90328
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Note:
On later “flat top” chaincases there are machined recesses (Item 3) [Figure 40-30-6] on the bottom side of the cover to help pry the covers off.
Installation: Install a new gasket (if equipped). When installing a cover on “flat top” chaincases, apply polyurethane sealer to mating surfaces. Polyurethane sealant should be applied to the screw threads and gasket (if equipped) to stop oil leakage. Tighten the mounting screws to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Disconnect the front steering linkage bars from the rear linkage bars. (See Removal And Installation on Page 50100-1.) Move the linkage bars to allow adequate space to remove the rear chaincase cover.
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Remove the rear chaincase cover (Item 2) [Figure 4030-6].
MAINFRAME BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . Pivot Pin Bushing And Seal Removal And Installation . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-40-1 50-40-2 50-40-3 50-40-1
SAFETY MAINTENANCE
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 Control Lever Removal And Installation. . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . Lever Assembly Removal (Right And Left) . . . . . . . . . . . Joystick Removal (Right And Left). . . . . . . . . . . . . . . . . . Joystick Testing (Right And Left) . . . . . . . . . . . . . . . . . . .
50-112-1 50-112-3 50-112-2 50-112-1
CONTROL PANEL (ADJUSTABLE PINTLES) . . . . . . . . . . . 50-101-1 Linkage Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . 50-101-17 Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . 50-101-13 Linkage Removal And Installation . . . . . . . . . . . . . . . . . . 50-101-7 Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . 50-101-11 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-2 Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . 50-101-6 Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-101-5 Shock Removal And Installation . . . . . . . . . . . . . . . . . . . 50-101-5
DRIVE SYSTEM
MAINFRAME
ELECTRICAL SYSTEM ANALYSIS ENGINE SERVICE
SPECIFICATIONS
CONTROL PANEL (NON-ADJUSTABLE PINTLES). . . . . . . 50-100-1 Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8 Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . 50-100-12 Linkage Removal And Installation . . . . . . . . . . . . . . . . . . 50-100-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1 Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . 50-100-4 Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-100-4 Shock Removal And Installation . . . . . . . . . . . . . . . . . . . 50-100-4 CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1 Continued On Next Page
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CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL. . . . . . . . . . . . . . . .50-111-1 Components Identification . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1 Control Handle Disassembly And Assembly . . . . . . . . . . .50-111-5 Control Handle Removal And Installation . . . . . . . . . . . . .50-111-4 Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-7 Control Lever Removal And Installation. . . . . . . . . . . . . . .50-111-6 Handle Sensor Removal And Installation . . . . . . . . . . . . .50-111-1
S150, S160 Bobcat Loader Service Manual
MAIN FRAME (CONT’D) CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossbar Linkage Removal And Installation . . . . . . . . . . . Lift Foot Pedal Linkage Removal And Installation . . . . . . . Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Foot Pedal Linkage Removal And Installation . . . . . . .
50-90-1 50-90-2 50-90-4 50-90-1 50-90-1 50-90-4
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . Foot Pedal Linkage Disassembly And Assembly. . . . . . . . Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . Foot Sensor Removal And Installation. . . . . . . . . . . . . . . .
50-91-1 50-91-3 50-91-2 50-91-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Fill Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-80-1 50-80-2 50-80-2 50-80-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Dealer Copy -- Not for Resale
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 50-20-1 50-20-3 50-20-1 50-20-4
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1 Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1 OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . 3-Point Seat Belt Removal And Installation . . . . . . . . . . . . Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . .
50-31-1 50-31-5 50-31-3 50-31-2 50-31-1 50-31-4 50-31-2
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot Pin Bushing And Seal Removal And Installation . . . Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-41-1 50-41-4 50-41-2 50-41-1
Continued On Next Page
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MAIN FRAME (CONT’D) REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting The Striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . Striker Removal And Installation . . . . . . . . . . . . . . . . . . . .
50-70-1 50-70-2 50-40-3 50-70-1 50-70-2 50-70-2
REAR GRILLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Spring Disassembly And Assembly . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
50-10-1 50-10-2 50-10-4 50-10-1
Dealer Copy -- Not for Resale
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
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Figure 50-10-3
SEAT BAR Removal And Installation Figure 50-10-1
1
P10564
P10563
Loosen the nut (both sides) at the front corners of the operator cab [Figure 50-10-3].
P-43383
Figure 50-10-2
Installation: Tighten the nuts to 40 - 50 ft.-lb. (54 - 68 N•m) torque. Figure 50-10-4
1
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2] from the cab harness. Lower the seat bar.
P-45261
Lift on the grab handle and bottom of the operator cab slowly until the cab is all the way up and the latching mechanism engages [Figure 50-10-4].
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Dealer Copy -- Not for Resale
Remove the nuts and plates (both sides) [Figure 50-103].
Raise the seat bar (Item 1) [Figure 50-10-1].
SEAT BAR (CONT’D)
Assembling Components
Removal And Installation (Cont’d)
Figure 50-10-7
Figure 50-10-5
4
6
5
7
3 1
2
9
8
10 1
N-19383 N-18572
Figure 50-10-8 Remove the seat bar mounting nuts (Item 1) [Figure 5010-5] (both sides).
5
Installation: Tighten the nuts to 28 ft.-lb. (38 N•m) torque.
9
3
6
2
Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
10
1
Figure 50-10-6
8
7
N-19219
1 Assemble the parts as shown for the left side of the seat bar pivot assembly [Figure 50-10-7] and [Figure 50-108].
P-43382
Remove the seat bar (Item 1) [Figure 50-10-6] from the operator cab. Reverse the above procedure to install the seat bar into the operator cab.
Seat Bar Mount (Item 1) Mounting Bolt (Item 2) Keyed Plastic Bushing (Item 3) Seat Bar (Item 4) Magnetic Bushing Assembly (Item 5) Pivot Bushing (Item 6) Sensor Bracket (Item 7) Sensor Mounting Nut (Item 8) Sensor Mounting Bolt (Item 9) Mounting Nut (Item 10) Installation: Tighten the mounting bolt (Item 2) [Figure 50-10-7] and [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9 N•m) torque.
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Dealer Copy -- Not for Resale
4
Figure 50-10-10
SEAT BAR (CONT’D) Assembling Components (Cont’d) Figure 50-10-9
4
5 4
6
5 6
3
2
3
7 2
7 1
1
Assemble the parts as shown for the right side of the seat bar pivot assembly [Figure 50-10-9] and [Figure 50-1010]. Seat Bar Mount (Item 1) Mounting Nut (Item 2) Pivot Bushing (Item 3) Spacer Bushing (Item 4) Seat Bar (Item 5) Keyed Plastic Bushing (Item 6) Mounting Bolt (Item 7)
N-19220
Installation: Tighten the mounting bolt (Item 7) [Figure 50-10-9] and [Figure 50-10-10] to 50 - 70 in.-lb. (5,6 - 7,9 N•m) torque.
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N-19340
Figure 50-10-12
SEAT BAR (CONT’D) Compression Spring Disassembly And Assembly
7
6
Figure 50-10-11 1 5 4
6
3 2 1 N-19384
Disassemble and assemble the seat bar compression spring and parts as shown in Fig. [Figure 50-10-12].
Dealer Copy -- Not for Resale
Bolt (Item 1) Bushing (Item 2) Spring (Item 3) Clevis (Item 4) Retaining Pin (Item 5) Pin (Item 6) Bushing (Item 7) N-19222
Turn the bolt (Item 1) [Figure 50-10-11] and [Figure 5010-12] out of the clevis. Assembly: Apply Loctite® #242 adhesive to the bolt threads. Adjust the compression spring by turning the bolt in past the end of the clevis three turns. NOTE: For procedures requiring the use of Loctite® #242 adhesive, thoroughly clean and dry affected parts before the application of Loctite® #242.
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Figure 50-20-2
OPERATOR CAB Gas Cylinder Removal And Installation
WARNING
1
Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W-2113-0288
P1528
P1518
WARNING
W-2059-0598
Remove the cab nut and holddown plate (Item 1) [Figure 50-20-2] (both sides). Installation: Tighten the nut to 40 - 50 ft.-lb. (54 - 68 N•m) torque.
Dealer Copy -- Not for Resale
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 50-20-3
Figure 50-20-1
1
1
P-48261
P-48265
Remove the operator cab stop (Item 1) (both sides) [Figure 50-20-1].
Install a strap (Item 1) [Figure 50-20-3] to the cab handles to prevent the cab from falling forward. To release the tension on the gas cylinder (See Raising The Operator Cab on Page 10-30-1.)
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Figure 50-20-6
OPERATOR CAB (CONT’D) Gas Cylinder Removal And Installation (Cont'd) Figure 50-20-4 SINGLE GAS CYLINDER
1
2 N-19184
1 Rotate the mounting bracket forward to relieve any remaining tension on the gas cylinder(s) [Figure 50-206].
P-48262
Remove the front bolt (Item 1) [Figure 50-20-6] from the gas cylinder mounting bracket.
DUAL GAS CYLINDER
Installation: Tighten the bolts to 100 - 130 in.-lb. (11,3 14,7 N•m) torque.
1
2 P-43354
Loosen the front bolt (Item 1) and remove the rear bolt (Item 2) [Figure 50-20-4] and [Figure 50-20-5] from the gas cylinder mounting bracket.
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Dealer Copy -- Not for Resale
Figure 50-20-5
OPERATOR CAB (CONT’D)
Gas Cylinder Disassembly
Gas Cylinder Removal And Installation (Cont'd)
Figure 50-20-9
Figure 50-20-7 SINGLE GAS CYLINDER
2
1 1
2 P1008 N-20618
Remove the clevis (Item 1) and washer (Item 2) [Figure 50-20-9] from the end of the gas cylinder. Figure 50-20-8
Dealer Copy -- Not for Resale
Remove the gas cylinder from the outer housing. DUAL GAS CYLINDER Figure 50-20-10 1
2
P-39601
Remove the retaining pin(s) (Item 1) [Figure 50-20-7] and [Figure 50-20-8] from the top pivot pin(s).
P1006
Remove the gas cylinder(s) (Item 2) [Figure 50-20-7] and [Figure 50-20-8] from the operator cab.
Assembly: Install a replacement cylinder inside the cylinder housing.
Reverse the above procedure to install the gas cylinders onto the operator cab.
Apply a small amount of Loctite® 242 on the threads of the cylinder rod [Figure 50-20-10]. Reinstall the washer and clevis on the cylinder rod.
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Figure 50-20-12
OPERATOR CAB (CONT’D) Removal And Installation
WARNING 1
AVOID INJURY OR DEATH Attach a chain hoist to the grab handles of the operator cab before removing the operator cab gas cylinders. If the operator cab is tilted forward without the gas cylinders operational, the cab will fall and could cause injury or death. W-2245-0796
Figure 50-20-11
P-43362
Remove bolt (Item 1) [Figure 50-20-12] from the cab ground.
Dealer Copy -- Not for Resale
Remove any sta-straps connected to the harness [Figure 50-20-12].
P-48265
Remove the operator cab gas cylinder(s). (See Gas Cylinder Removal And Installation on Page 50-20-1.) Remove the heater unit from the cab (if equipped). (See Removal And Installation on Page 80-160-1.) Use the hoist connected to the operator cab grab handles to lower or (raise) the operator cab when the gas cylinders are disconnected [Figure 50-20-11].
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Figure 50-20-15
OPERATOR CAB (CONT’D) Removal And Installation (Cont'd) Figure 50-20-13
1
1
1 P-39601
Remove the operator cab gas cylinder(s) (Item 1) [Figure 50-20-15]. (See Gas Cylinder Removal And Installation on Page 50-20-1.)
P-48263
Figure 50-20-14
Dealer Copy -- Not for Resale
Lower the cab. Figure 50-20-16
1 1
P-48264
Disconnect all harness(s) (Item 1) [Figure 50-20-13] [Figure 50-20-14] that connects the mainframe to the cab. The number of connectors will vary depending on the options equipped on your loader.
P-48267
Remove the rear mounting nut and bolt (Item 1) [Figure 50-20-16] (both sides) and nut from the operator cab. Installation: Tighten the bolt and nut to 25 - 35 ft.-lb. (34 - 47 N•m) torque.
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OPERATOR CAB (CONT’D) Removal And Installation (Cont'd) Figure 50-20-17
2
3
1
3
P-48266
Dealer Copy -- Not for Resale
N-20627A
Connect the slings (Items 1, 2 and 3) [Figure 50-20-17] to a chain hoist. Remove the operator cab from the loader. Reverse the above procedure to install the operator cab.
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OPERATOR SEAT
Seat Belt Removal And Installation
Removal And Installation
Figure 50-30-3
Figure 50-30-1
1
1
1
2
N-20729 N-20729
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the four seat mounting nuts (Item 1) [Figure 5030-1] and washers from the operator seat mounting studs.
Locate the seat belt bolts under seat pan insulation (Items 1 and 2) [Figure 50-30-3] and peel back or cut insulation to gain access to the head. Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27 N•m) torque. NOTE: Ensure the washers are installed. Figure 50-30-2 1
2 N-20655
Remove the two nuts (Items 1 and 2) [Figure 50-30-4].
P10564
Installation: Tighten nut (Item 1) to 54 ft.-lb. (73 N•m) torque. Tighten nut (Item 2) [Figure 50-30-4] to 34 ft.-lb. (46 N•m) torque.
P10563
Repeat for other half of seat belt and guide Lower the cab and install one mounting washer and nut [Figure 50-30-2]. NOTE: With the seat removed the cab will raise. Reverse the removal procedure to install the operator seat. 50-30-1 499 of 949
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Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
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Figure 50-31-3
OPERATOR SEAT (SUSPENSION) Removal And Installation Figure 50-31-1
1 1
1
2 N-20974
NOTE: Assure seat tethers are securely fastened to seatbelt studs (Item 1) and seat rail studs (Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Figure 50-31-4
Dealer Copy -- Not for Resale
N-20647
Remove the four seat mounting nuts (Item 1) [Figure 5031-1] and washers from the operator seat mounting studs. Installation: Tighten the mounting nuts to 20 ft.-lb. (27 N•m) torque. Figure 50-31-2 1
N-20973
NOTE: Verify the front two seat rail studs have washers attached (Item 1) [Figure 50-31-4].
P10564
P10563
Lower the cab and install one of the mounting washers and nuts [Figure 50-31-2]. NOTE: With the seat removed, the cab will raise. Reverse the removal procedure to install the operator seat.
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Figure 50-31-7
OPERATOR SEAT (SUSPENSION) (CONT’D) Slide Rail Removal And Installation
2
Figure 50-31-5
1
1
1
1
2
2
1
N-18582
1 Figure 50-31-8
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the operator seat. Installation on Page 50-30-1.)
(See
Removal
1
And
Remove the two slide rail mounting bolts (Item 1) from each slide rail (Item 2) [Figure 50-31-5]. Remove the slide rail (Item 2) [Figure 50-31-5] from the bottom of the seat frame. N-18581
Reverse the removal procedure to install the operator seat slide rail.
Remove the cushion (Item 2) [Figure 50-31-7] from the seat frame (Item 1) [Figure 50-31-8].
Cushion Removal And Installation Figure 50-31-6
1
N-18579
Press the two buttons (Item 1) [Figure 50-31-6] and [Figure 50-31-7] and lift the seat cushion. 50-31-2 502 of 949
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N-18587
OPERATOR SEAT (SUSPENSION) (CONT’D)
Back Removal And Installation
Cushion Removal And Installation (Cont’d)
Figure 50-31-10
Figure 50-31-9 1
N-18583 N-18580
Pull the seat back adjustment lever (Item 1) [Figure 5031-10] and tilt the seat back all the way forward. Inspect the seat ride adjustment [Figure 50-31-9].
Dealer Copy -- Not for Resale
Figure 50-31-11 Reverse the removal procedure to install the operator seat back.
1
1
N-18578
Remove the two mounting screws (Item 1) [Figure 5031-11] from the seat back and remove the back. Reverse the removal procedure to install the operator seat back.
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Figure 50-31-14
OPERATOR SEAT (SUSPENSION) (CONT’D) Shock Removal And Installation
1
Figure 50-31-12
1 1 2
N-18586
1
NOTE: The seat block mounting studs (Item 1) [Figure 50-31-14] are replaceable.
N-18584
Reverse the removal procedure to install the operator seat shock.
Dealer Copy -- Not for Resale
Figure 50-31-13
1 2
N-18585
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the operator seat. Installation on Page 50-30-1.)
(See
Removal
And
Remove the seat shock retaining pin (Item 1) [Figure 5031-12] and [Figure 50-31-13] (Both ends.) Remove the seat shock (Item 2) [Figure 50-31-12] and [Figure 50-31-13].
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Installation: Be sure tether strap (Item 3) [Figure 50-3116] is on the seat belt stud behind the seat belt retractor.
OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Figure 50-31-17 Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the operator seat. Installation on Page 50-30-1.)
(See
Removal
And
Figure 50-31-15 1 2 OUTSIDE OF CAB P16131
Remove the mounting bolt (Item 1) [Figure 50-31-17]
1
P16285
1
Remove the mounting nut (Item 1) [Figure 50-31-15] Remove the end release buckle (Item 2) [Figure 50-3115]
2 P16126
Installation: Be sure tether strap (Item 3) [Figure 50-3115] is on the seat belt stud behind the end release buckle. Figure 50-31-16 INSIDE OF CAB P16128
Remove the shoulder harness retractor (Item 1) [Figure 50-31-18] 2 Installation: Line up the bolt (Item 1) [Figure 50-31-17] with the mounting bracket (Item 2) [Figure 50-31-18] on the inside of the cab.
1
3 P16284
Remove the mounting nut (Item 1) [Figure 50-31-16] Remove the seat belt retractor (Item 2) [Figure 50-3116]
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Figure 50-31-18
3
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Figure 50-40-3
BOB-TACH Removal And Installation Figure 50-40-1
1
1 P-48132
Tilt the Bob-Tach forward, so it is parallel to the floor. Put blocks (approximately 76,2 mm (3 in) under each side of the Bob-Tach [Figure 50-40-1].
Remove the grease fitting (Item 1) (both sides) [Figure 50-40-3] out of the Bob-Tach frame. This allows grease to escape when driving the pivot pins into the Bob-Tach frame. Figure 50-40-4
Lower the Bob-Tach onto the blocks. Remove the retainer bolt (Item 1) [Figure 50-40-1] and nut from the tilt cylinder rod end pin (both sides). Installation: Tighten the retainer bolt and nut to 25 - 30 ft.-lb. (34 - 38 N•m) torque. Figure 50-40-2 1
1
N-18547
2 Strike the head of the bolt (Item 1) [Figure 50-40-4] to push the pivot pin into the Bob-Tach frame. Remove the bolt. Use a long punch to push the pivot pin all the way into the Bob-Tach.
N-18545
Remove the pivot pin (Item 1) [Figure 50-40-2] from the tilt cylinder rod end (both sides).
Remove the Bob-Tach from the lift arms.
Remove the tilt cylinder rod end from the Bob-Tach (both sides).
Remove the Bob-Tach pivot pin (both sides).
Loosen the bolt (Item 2) [Figure 50-40-2] at the BobTach pivot pin. Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 260 N•m) torque.
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N-18544
Figure 50-40-7
BOB-TACH (CONT’D) Bob-Tach Lever And Wedge Figure 50-40-5
1
N-18560
1 Remove the Wedge (Item 1) [Figure 50-40-7]. N-18558
Always replace bent or broken wedges. Figure 50-40-8
Figure 50-40-6
4 1
3 2 1 N-18561
Remove the lever mounting nut (Item 1), washer (Item 2), spring (Item 3) and lever (Item 4) [Figure 50-40-8].
N-18559
Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-40-6] from the Bob-Tach Wedge and spring clevis.
Installation: Tighten the nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Use the following procedure to remove and install the Bob-Tach lever (Item 1) [Figure 50-40-5], spring and wedge.
BOB-TACH (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Bob-Tach Lever And Wedge (Cont’d)
Figure 50-40-11
Figure 50-40-9
2
2
3
4
1
1
P-85669 N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), or clevis (Item 4) [Figure 50-40-9] are damaged, put the assembly in a vise.
Remove the seal (Item 1) [Figure 50-40-11] from the Bob-Tach.
Remove the bolt and replace the damaged parts as needed.
Remove the bushing (Item 2) [Figure 50-40-11] from the Bob-Tach.
Figure 50-40-10
Figure 50-40-12 3
2
1
1 N-18563
NA5472
Use a punch and hammer to drive the roll pin (Item 1) [Figure 50-40-10] flush with the face of the Bob-Tach.
Installation: The seal (Item 1) needs to be seated in the Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item 3) [Figure 50-40-12].
Reverse the removal procedure to install the Bob-Tach lever and wedge [Figure 50-40-10].
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Remove the Bob-Tach. (See Removal And Installation on Page 50-40-1.)
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Figure 50-41-2
POWER BOB-TACH Removal And Installation Figure 50-41-1
1
3
2
2
P-48185
1 Remove the pivot pin (Item 1) [Figure 50-41-2] from the tilt cylinder rod end (both sides).
Tilt the Bob-Tach forward, so it is parallel to the floor. Put blocks (approximately 76,2 mm (3 in) under each side of the Bob-Tach [Figure 50-41-1].
Remove the tilt cylinder rod end from the Bob-Tach (both sides). Loosen the bolt (Item 2) [Figure 50-41-2] at the BobTach pivot pin.
Lower the Bob-Tach onto the blocks. Remove the hoses [Figure 50-41-1].
to
the
cylinder
fittings
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 260 N•m) torque. Figure 50-41-3
NOTE: The hose with the 45° end (Item 1) [Figure 50-41-1] is connected to the base end fitting on the cylinder. Remove the hose clamp on the hoses and use the bolt (Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to secure the clamp. 1
Remove the retainer bolt (Item 3) [Figure 50-41-1] and nut from the tilt cylinder rod end pin (both sides). Installation: Tighten the retainer bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
P-48132
Remove the grease fitting (Item 1) (both sides) [Figure 50-41-3] out of the Bob-Tach frame. This allows the grease to escape when driving the pivot pins in to the Bob-Tach frame.
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P-48131
Figure 50-41-6
POWER BOB-TACH (CONT’D) Removal And Installation (Cont’d) Figure 50-41-4
1
1 N-18559
Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-41-6] from the Bob-Tach Wedge and spring clevis.
Strike the head of the bolt (Item 1) [Figure 50-41-4] to push the pivot pin into the Bob-Tach frame.
Figure 50-41-7
Dealer Copy -- Not for Resale
N-18547
Remove the bolt. Use a long punch to push the pivot pins all the way into the Bob-Tach frame. 1
Remove the Bob-Tach from the lift arms. Remove the Bob-Tach pivot pin (both sides). Power Bob-Tach Lever And Wedge Figure 50-41-5
N-18560
Remove the Wedge (Item 1) [Figure 50-41-7]. Always replace bent or broken wedges.
1
P-48135
Use the following procedure to remove and install the Bob-Tach lever (Item 1) [Figure 50-41-5], spring and wedge.
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Figure 50-41-9
POWER BOB-TACH (CONT’D) Power Bob-Tach Lever And Wedge (Cont’d) Figure 50-41-8
4
1
1 2
3
2 N-20625
3 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), or clevis (Item 4) [Figure 50-41-9] are damaged, put the assembly in a vise.
4 P-48135
Remove the washers and bolts (Item 1) [Figure 50-418].
Remove the bolt and replace the damaged parts as needed.
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Figure 50-41-10
Remove the cylinder off the lever pivots. Position the rod end to the left with the grease fitting holes to the top [Figure 50-41-8]. Remove the lever mounting nut (Item 2), washer (Item 3), spring (Item 4) and lever (Item 5) [Figure 50-41-8].
1
Installation: Tighten the nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
N-18563
Use a punch and hammer to drive the roll pin (Item 1) [Figure 50-41-10] flush with the face of the Bob-Tach. Reverse the removal procedure to install the Power BobTach lever and wedge [Figure 50-41-10].
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5
POWER BOB-TACH (CONT’D) Pivot Pin Bushing And Seal Removal And Installation Remove the Power Bob-Tach. Figure 50-41-11
2
1
Dealer Copy -- Not for Resale
P-85669
Remove the Bob-Tach. (See Removal And Installation on Page 50-41-1.) Remove the seal (Item 1) [Figure 50-41-11] from the Bob-Tach. Remove the bushing (Item 2) [Figure 50-41-11] from the Bob-Tach. Figure 50-41-12 3
2
1 NA5472
Installation: The seal (Item 1) needs to be seated in the Bob-Tach (Item 2) to a depth of 12,7 mm (0.050 in) (Item 3) [Figure 50-41-12].
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Figure 50-50-3
LIFT ARMS Removal And Installation Roll the Bob-Tach fully forward. Stop the engine.
1
Figure 50-50-1
2
P-45258
1
Remove the retainer bolt and nut (Item 1) [Figure 50-503] from the left side, rod end, lift cylinder pin.
At the right side of the loader, mark the two tilt hoses for proper installation.
Remove the lift cylinder rod pin (Item 2) [Figure 50-50-3]. Figure 50-50-4
Disconnect and cap the two tilt hoses (Item 1) [Figure 50-50-1] from the tubelines (right side of machine). Figure 50-50-2
1 1
2 P-45365
Remove the tubeline clamp (Item 1) [Figure 50-50-4]. P-45363
Remove the retainer bolt and nut (Item 1) [Figure 50-502] from the right side, rod end lift cylinder. Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the lift cylinder rod pin (Item 2) [Figure 50-50-2].
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Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
P-45367
Figure 50-50-7
LIFT ARMS (CONT'D) Removal And Installation (Cont'd) Figure 50-50-5
1
1 P-45366
Install a floor jack (Item 1) [Figure 50-50-7] under the front of the lift arms, and raise the lift arms 3 - 4 inches.
P-45364
Figure 50-50-8 Figure 50-50-6 1 1
1
P-45422
Install two lift straps (Item 1) [Figure 50-50-8] on the lift arms as shown.
P-34360
Remove the front auxiliary coupler mounting bolts (Item 1) [Figure 50-50-6]
NOTE: Position the lift straps as shown in [Figure 5050-8] to balance the lift arms for removal and installation.
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Remove the tubeline clamp (Item 1) [Figure 50-50-5].
LIFT ARMS (CONT'D) Removal And Installation (Cont'd) Figure 50-50-9
1
2
P-45259
Dealer Copy -- Not for Resale
Remove the retainer bolt and nut (Item 1) [Figure 50-509]. (Both sides.) Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the lift arm pivot pin (Item 2) [Figure 50-50-9]. (Both sides.) Remove the lift arms from the loader. Remove the Bob-Tach. (See Removal And Installation on Page 50-40-1.) Remove the tilt cylinders from the lift arms. (See Removal And Installation on Page 20-21-2.)
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Figure 50-60-3
REAR GRILLE Removal And Installation Figure 50-60-1
1
P-48252
P-48250
Lift up on the rear grille (Item 1) [Figure 50-60-2] and [Figure 50-60-3]. Lift the grille away from the loader.
Open the rear door [Figure 50-60-1].
Dealer Copy -- Not for Resale
Figure 50-60-4 Figure 50-60-2
2 1 1
P-48130 P-48251
Installation: Line up the tab (Item 1) on the grille with the slot (Item 2) [Figure 50-60-4] on the loader mainframe. Insert the tab fully and then push down. Reverse the removal procedure to install the grille.
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Connect a chain hoist (Item 2) [Figure 50-70-2] to the lifting chain.
REAR DOOR Removal And Installation
Figure 50-70-3 Figure 50-70-1 1 2
3
2
1 P-34606 P-24792
Remove both rear lights (Item 2) [Figure 50-70-1] from the door. (See Rear Removal And Installation on Page 60-60-1.)
Remove the top and bottom door hinge mounting bolts (Item 1) [Figure 50-70-3] and nuts. NOTE: Install the door stop (Item 2) and the door stop retainer (Item 3) [Figure 50-70-3] in the top hinge as shown. Installation: Tighten the mounting bolts and nuts to 25 28 ft.-lb. (34 - 38 N•m) torque.
Figure 50-70-2
Lift the door away from the loader frame and put the door flat on the floor. 2
1
P-34588
Secure the chain hooks (Item 1) [Figure 50-70-2] to the door as shown.
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Disconnect the light harness connector (Item 1) [Figure 50-70-1] from the engine harness.
Adjusting The Striker
REAR DOOR (CONT’D) Striker Removal And Installation
WARNING
Figure 50-70-4
AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.
1
W-2012-0497
Figure 50-70-6
1
1 P-31126
1
Remove the striker assembly from the loader. Installation: Tighten the mounting bolts to 90 - 100 ft.-lb. (125 - 135 N•m) torque. Striker Disassembly And Assembly
P-31126
Loosen the striker assembly mount bolts (Item 1) [Figure 50-70-6].
Figure 50-70-5 Align the striker assembly in the center of the mounting holes.
2
2 3
NOTE: Tighten the striker assembly, top mount bolt only, until it will hold the striker assembly in the center of the mounting slots. Close the rear door. (This will align the striker assembly to the correct position.)
4
1
Open the door. Installation: Tighten the mounting bolts (Item 1) [Figure 50-70-6] to 90 - 100 ft.-lb. (125 - 135 N•m) torque. P-31320
Close the rear door. Remove the lock nut (Item 1) [Figure 50-70-5]. Remove the rollers (Item 2) and the spacer (Item 3) from the bolt (Item 4) [Figure 50-70-5]. Check the parts for wear and replace as needed. Installation: Tighten the nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. 50-70-2 522 of 949
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Remove the two striker mount bolts (Item 1) [Figure 5070-4].
Figure 50-70-9
REAR DOOR (CONT’D) Latch Removal And Installation Figure 50-70-7
1
2
P-31128
1
Remove the door handle (Item 1) [Figure 50-70-9] from the rear door.
P-31125
Dealer Copy -- Not for Resale
Disconnect the spring (Item 1) [Figure 50-70-7] from the rear door. Remove the bolt and nut (Item 2) [Figure 50-70-7] from the latch. Figure 50-70-8
3
2
1 P-31127
Remove the spring (Item 1) [Figure 50-70-8] from the door handle. Remove the spring (Item 2) [Figure 50-70-8] from the door latch. Remove the door latch (Item 3) [Figure 50-70-8] from the door handle.
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Figure 50-80-3
FUEL TANK Removal And Installation Figure 50-80-1
2 1
1 P-28143
Open the rear door of the loader. P1616
Installation: Tighten the cover mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Remove the two mounting bolts (Item 1) [Figure 50-803] from the battery holder. Installation: Tighten the battery holder mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Figure 50-80-2 Remove the battery holder (Item 2) [Figure 50-80-3] from the loader. Figure 50-80-4
1
1
1
P1619
Drain the fuel from the tank through the fuel drain (Item 1) [Figure 50-80-2].
P-28144
Remove the mounting bolts (Item 1) [Figure 50-80-4] from the fuel tank retainer bracket. Installation: Tighten the mounting bolts to 15 - 20 in.-lb. (20 - 27 N•m) torque.
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Remove the cover (Item 1) [Figure 50-80-1] which is installed over the fuel drain near the rear of the chaincase.
Remove the engine / hydrostatic pump assembly from the loader. (See Removal And Installation on Page 7080-1.)
FUEL TANK (CONT’D)
Fuel Fill Screen
Removal And Installation (Cont’d)
Figure 50-80-7
Figure 50-80-5
2 1
P13874 P13876
Remove the clamp (Item 1) and remove the fuel fill hose (Item 2) [Figure 50-80-7] from the tank. Disconnect fuel sender.
Dealer Copy -- Not for Resale
Figure 50-80-8
Disconnect fuel vent hose. Disconnect fuel fill hose. Lift the fuel tank up and remove the tank from the loader [Figure 50-80-5].
1
Fuel Level Sender Figure 50-80-6
P13875
1
Remove the fuel fill screen (Item 1) [Figure 50-80-8] from the tank. Check the screen for damage and replace if necessary.
P13870
Loosen the fuel level sender (Item 1) [Figure 50-80-6] with a wrench. Turn the fuel level sender out and remove it from the fuel tank. Check the fuel level sender for damage and replace if necessary. Installation: tighten the fuel level sender to 50 - 60 in.-lb. (5,7 - 6,8 N•m) torque. 50-80-2 526 of 949
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FUEL TANK (CONT’D) Fuel Fill Screen (Cont’d) Figure 50-80-9
1
P13873
Dealer Copy -- Not for Resale
Remove the fitting (Item 1) [Figure 50-80-9] and grommet from the tank. Figure 50-80-10
1 P13872
Remove the fuel supply screen (Item 1) [Figure 50-8010] from the hose. Check the screen for damage and replace if necessary.
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Figure 50-90-2
CONTROL PEDALS Removal And Installation Figure 50-90-1
1
1
P-34375
Remove the two mounting bolts (Item 1) [Figure 50-902] from the pedal mounting bracket.
P-26008
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Check the rubber bushing in the pedal for wear and replace as needed.
Pedal Adjustment After installing the pedal, adjust the pedal so that there is clearance under the rear of the pedal. The valve spool must travel full stroke without the pedal hitting the floor panel.
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Remove the pedal assembly from the loader. Remove the bolt (Item 1) [Figure 50-90-1] and nut from the pedal linkage.
Figure 50-90-3
CONTROL PEDALS (CONT’D) Crossbar Linkage Removal And Installation
2 1
DANGER
P-34257
P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
Remove the bolt and nut (Item 1) [Figure 50-90-3] to disconnect the lift pedal linkage from the crossbar. Remove the cross bar pivot bolt (Item 2) [Figure 50-903].
Dealer Copy -- Not for Resale
•
Figure 50-90-4
D-1009-0409
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
1
W-2059-0598
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-34260
Remove the hairpin clip and cross-pin (Item 1) [Figure 50-90-4] from the control valve lift spool. Disconnect the cross bar from the control valve.
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CONTROL PEDALS (CONT’D) Crossbar Linkage Removal And Installation (Cont’d) Figure 50-90-5
1
P-34376
Dealer Copy -- Not for Resale
Remove the cross bar from the pivot [Figure 50-90-5]. Installation: Check the nylon bushing (Item 1) [Figure 50-90-5] for wear and replace as needed.
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CONTROL PEDALS (CONT’D)
Tilt Foot Pedal Linkage Removal And Installation
Lift Foot Pedal Linkage Removal And Installation
Figure 50-90-8
Figure 50-90-6
1
1
P-34258 P-34257
Remove the hairpin clip and cross-pin (Item 1) [Figure 50-90-8] from the control valve tilt spool. Figure 50-90-9
Dealer Copy -- Not for Resale
Remove the bolt and nut (Item 1) [Figure 50-90-6] to disconnect the lift foot pedal linkage from the crossbar linkage. Figure 50-90-7
1
1
P-26008
Remove the bolt and nut (Item 1) [Figure 50-90-9] to disconnect the lift foot pedal.
P-24759
Remove the bolt and nut (Item 1) [Figure 50-90-7] to disconnect the lift foot pedal.
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Figure 50-91-3
CONTROL PEDALS (ACS) Foot Sensor Removal And Installation Figure 50-91-1
2
1 P-21936
P-21927
Remove the two bolts (Item 1) [Figure 50-91-3] from the foot sensor shield.
P-21938
Pull the pin (Item 1) [Figure 50-91-1] holding the foot pedal linkage to the sensor.
Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2 N•m) torque.
Dealer Copy -- Not for Resale
1
Disconnect the two connectors (Item 2) [Figure 50-91-1] from the sensor and lock solenoid. Figure 50-91-2
1
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1) [Figure 50-91-2]. Remove the foot pedal and sensor assembly from the loader.
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CONTROL PEDALS (ACS) (CONT'D)
Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Cont’d)
Figure 50-91-5
Figure 50-91-4
1
2
1 P-21940 P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the linkage to the sensor. Figure 50-91-6 Installation: Apply a drop of oil to the solenoid threads and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m) lubed torque.
1
Remove the two bolts (Item 2) [Figure 50-91-4] from the bracket and sensor assembly. P-21935
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the sensor assembly. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
P-21934
Tip the foot pedal up and remove the two nuts (Item 1) [Figure 50-91-6]. Remove the foot pedal assembly. Reverse the procedure to install the foot pedal assembly.
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Remove foot lock solenoid (Item 1) [Figure 50-91-4].
CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Linkage Disassembly And Assembly Figure 50-91-7
2
1 P-21931
Dealer Copy -- Not for Resale
Remove the bolt (Item 1) holding the linkage (Item 2) [Figure 50-91-7] to the side of the foot pedal. Figure 50-91-8
2 3 1 P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut (Item 3) [Figure 50-91-8] from the foot pedal. Reverse the procedure to assemble the foot pedal assembly.
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Figure 50-100-1
CONTROL PANEL (NON-ADJUSTABLE PINTLES) Removal And Installation
2 1
DANGER
3
4
P-48462
P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Loosen the jam nut (Item 1) from the bypass control knob (Item 2) [Figure 50-100-1]. Remove the control knob (Item 2), jam nut (Item 1) and rubber washer (Item 3) [Figure 50-100-1]. Disconnect the control harness connectors (Item 4) [Figure 50-100-1] from right control levers.
WARNING
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
W-2059-0598
Figure 50-100-2 Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) 1
Remove the engine speed control. (See Removal And Installation on Page 70-20-1.)
P-48277
Disconnect the control harness connectors (Item 1) [Figure 50-100-2] from left control levers.
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•
Figure 50-100-4
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Removal And Installation (Cont’d)
2 1
3
1
Figure 50-100-3
1
2
2
1
P-26323
Remove the fuse / relay mounting bolts (Item 1) [Figure 50-100-4]. P-48235
Remove the four steering linkage mounting bolts (Item 2) [Figure 50-100-3].
Remove the fuse / relay cover (Item 3) [Figure 50-1004]. Figure 50-100-5
Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 25 28 ft.-lb. (34 - 38 N•m) torque.
P-26325
Remove the fuse / relay block [Figure 50-100-5].
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Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-100-3] which are connected to the steering shaft on the control panel.
Remove the fuse / relay shield (Item 2) [Figure 50-1004].
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D)
Figure 50-100-8
Removal And Installation (Cont’d) Figure 50-100-6 1
1
1
1
1
1 P-26327
Installation: Tighten the control panel mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Figure 50-100-7
Remove the control panel from the loader. Reverse the removal procedure to install the control panel.
1
P-26329
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P-34363
Remove the control panel mounting bolts (Item 1) [Figure 50-100-6], [Figure 50-100-7] and [Figure 50100-8] from both sides of the control panel.
Figure 50-100-10
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Shock Removal And Installation Figure 50-100-9
1
3 2
3
1
P-4146
P-34365
Remove the mounting nut (Item 1) [Figure 50-100-9] from the end of the shock connected to the steering linkage. Remove the mounting nut (Item 2) [Figure 50-100-9] from the other end of the shock connected to the bracket on the control panel. Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the steering shaft pivot bolt (Item 2) [Figure 50100-10] from both sides of the control panel. Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 38 N•m) torque. Remove the steering shaft from the control panel. Shaft Disassembly And Assembly Figure 50-100-11
Shaft Removal And Installation NOTE: The steering shaft can be removed without removing the control panel from the loader. Photo [Figure 50-100-10] shows the control panel removed for clarity purpose only.
1 1
Remove the steering linkage mounting bolts (Item 3) [Figure 50-100-9]. Remove the steering shock mounting nuts (Item 2) [Figure 50-100-9].
1
P-4154
Disassemble the right and left steering shafts from the cross shaft assembly [Figure 50-100-11]. Assembly: Install new nylon bushings (Item 1) [Figure 50-100-11] as needed when assembling the steering shaft. Be sure to apply grease on the cross shaft before installing the right and left steering shaft.
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Remove Control Handle Lever (Item 1) [Figure 50-10010]. (See Control Lever Removal And Installation on Page 50-110-1.)
2
Linkage Removal And Installation
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D)
Figure 50-100-13
Shaft Disassembly And Assembly (Cont’d) Figure 50-100-12 1
2
1
P-3729
1
To remove the steering shaft mounting bracket (Item 3) [Figure 50-100-10], remove the three mounting bolts (Item 1) [Figure 50-100-12] from the front of the control panel. Remove the steering shaft mounting bracket from each side of the control panel.
Remove the shoulder bolt / spring assembly. Installation: Tighten the centering spring shoulder bolt and a NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Figure 50-100-14
Installation: Tighten the mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque. 1
2
3
2
P-3736
Slide the plate (Item 1) to the right and remove it from the two guide pins (Item 2) [Figure 50-100-14]. NOTE: The two guide bushings (Item 3) will be loose and can fall out of the plate (Item 1) as soon as it is removed from the guide pins (Item 2) [Figure 50-100-14].
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Remove the nut (Item 1) from the end of the centering spring shoulder bolt (Item 2) [Figure 50-100-13].
P-26331
Figure 50-100-16
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation (Cont’d)
1
Figure 50-100-15 1
2 5 6 2
4 1
N-15312
3
2 N-15310
The centering plate / centering spring assembly consists of the following parts; ITEM
DESCRIPTION
1
Shoulder Bolt
2
Bushings
3
Spring
4
Lock Nut
5
Centering Plate
6
Guide Bushings
If the centering blocks need replacement, remove the bolts (Item 2) [Figure 50-100-16]. Remove the centering blocks. Installation: Tighten the centering block bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Figure 50-100-17
1
1
2
2
P-3733
If the surface of any of the four pintle cams (Item 1) are worn, loosen the bolt (Item 2) [Figure 50-100-17] and rotate the cams 1/4 turn. Tighten the bolts to 45 - 50 ft.-lb. (62 - 68 N•m) torque. When replacing the old style pintle levers, wear cams and cam bolts, install the latest style parts.
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2
Check the wear on the centering blocks (Item 1) [Figure 50-100-16].
Figure 50-100-20
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation (Cont’d) Figure 50-100-18
1 3 2
1
1 1 P-34365
Remove the nuts (Item 1) [Figure 50-100-20] from both shock absorber ball joint ends. P-3733
Remove the nut (Item 1) [Figure 50-100-18] from the torsion bushing / linkage bar. The bolt is threaded into the linkage bar, remove the bolt from underneath the pintle lever. Installation: Tighten the bolt to 11 - 13 ft.-lb. (21 - 25 N•m) torque, then tighten the nut to 21 - 25 ft.-lb. (28 - 33 N•m) torque. Figure 50-100-19
Installation: Tighten the nuts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the nuts (Item 2) from the linkage bar mounting bolt. The bolts (Item 3) are threaded into the linkage bars, remove the bolts (Item 3) [Figure 50-100-20]. The torsion bushings can now be removed from the steering bell cranks. Installation: Tighten the bolts to 11 - 13 ft.-lb. (21 - 25 N•m) torque, then tighten the nuts to 21 - 25 ft.-lb. (28 33 N•m) torque.
2
The linkage and the centering plate must be readjusted for neutral after the components have been reassembled. (See Page 50-100-12 for the neutral adjustment procedure.) 1
P-3734
Remove the linkage bar (Item 1) and remove the torsion bushing (Item 2) [Figure 50-100-19].
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Remove the shock absorbers.
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D)
Pre-load tension in the torsion bushings must be removed before adjusting the steering linkage.
Linkage Adjustment
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt (Item 2). The bolt (Item 2) is threaded into the linkage bar (Item 3). The bolt (Item 2) [Figure 50-100-21] must be loosened enough to allow the torsion bushing to turn freely between the steering bellcrank and the linkage bar.
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 50-100-22
1
W-2059-0598
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) 2
3 3 P-3726
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Figure 50-100-21
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt (Item 2). The bolt (Item 2) is threaded into the linkage bar (Item 3). The bolt (Item 2) [Figure 50-100-22] must be loosened enough to allow the torsion bushing to turn freely between the pintle arm and the linkage bar.
2
1 2 1 3 P-34365
Lift and block the loader. (See Procedure on Page 10-101.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool (MEL1429). (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
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WARNING
Figure 50-100-25
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Adjustment (Cont’d) Figure 50-100-23
2
1 1
3 P-3723
P-37574
Remove access plug from the top of the control valve. Turn the control lever drift adjustment bolts (Item 1) [Figure 50-100-23] (one on each control lever) out until it is flush with the bottom of the nut. Figure 50-100-24
This will allow the pintle arms to move freely while adjusting the steering linkage for full forward travel speed. Remove the 3/8 in. (10 mm) thick spacer (Item 1) [Figure 50-100-25]. Figure 50-100-26
4 2 1 3 3
1
2
4 P-3724 P-3730
Move the right side steering lever to the rear and install a 3/8 in. (10 mm) thick spacer (Item 1) between the pintle arm cam (Item 2) and the centering block (Item 3) [Figure 50-100-24].
Before adjusting the linkage, check that the pintle arm mounting bolt (Item 1) is tight, 25 - 28 ft.-lb. (34 - 38 N•m) torque and that there is no play between the pintle arm (Item 2) and the square pump shaft (Item 3). Also check that the cam mounting bolts (Item 4) [Figure 50-100-26] are tight, 45 - 50 ft.-lb. (62 - 68 N•m) torque.
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Move the right side steering lever forward and install a 15/16 in. (24 mm) thick spacer (Item 1) between the center plate (Item 2) and the mounting plate (Item 3) [Figure 50-100-25].
Figure 50-100-28
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Adjustment (Cont’d) Figure 50-100-27
P-3728
1
Loosen the two bolts and nuts (Item 1) [Figure 50-10027] on each steering linkage bar.
Installation: Tighten the nuts and bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Check the lever movement to make sure that the pintle arm and the control lever are both at full stroke at the same time. This will allow for maximum forward speed. Repeat the procedure for the right side linkage. After both sides of the linkage have been adjusted, the feel of both levers at full stroke should be the same. Readjust the linkage if necessary. Figure 50-100-29
1 P-3723
Remove the spacer (Item 1) [Figure 50-100-29]. Disconnect the remote start tool.
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P-3727
Move the left control lever to the full forward position, then pull forward on the left rear linkage bar until the pintle arm is rotated to the front as far as possible [Figure 50-100-28]. Use a locking plier and clamp the two linkage bars together.
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT'D) Linkage Adjustment (Cont'd) Figure 50-100-30
1
P-37574
Dealer Copy -- Not for Resale
Push the control lever to full stroke and turn drift adjustment bolt (Item 1) [Figure 50-100-30] in until it touches the U-bolt holding the control lever. Repeat steps on the other control lever. Drive the loader forward and check for drift. The traditional benchmark for drift is less than 10 ft. of “drift” in 100 ft. of travel distance. If the drift is excessive to the left, turn the right adjustment bolt (Item 1) [Figure 50-100-30] in. If the drift is excessive to the right, turn the left adjustment bolt in. NOTE: When using the drift adjustment bolts, only adjust one bolt for each test drive. In addition only move each bolt a maximum of one turn for each test drive. This will help prevent over correction and excess reduction in travel speed. Drift adjustment is for forward travel only. Adjust the drift to an acceptable level. Re-install the plug in the drift bolt access hole after adjustment.
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Figure 50-100-32
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment The following tool listed will be needed to do the following procedure:
1
2
2
1
MEL1563 - Remote Start Tool Kit Connect the remote start tool to the engine harness. (See REMOTE START TOOL KIT -MEL1563 on Page 10-601.)
WARNING
P-3731
W-2017-0286
Figure 50-100-31
Loosen the four bolts (Item 1) [Figure 50-100-32] holding the two centering blocks. Move the right hand centering block to the right as far as possible. NOTE: Bolt holes (Item 2) [Figure 50-100-32] are slotted for pintle arm centering adjustment. Figure 50-100-33
1
2
3 4 P-3726
P-3725
Loosen the nut (Item 1) a couple of turns, then loosen the bolt (Item 2). The bolt (Item 2) is threaded into the linkage bars (Items 3 and 4) [Figure 50-100-31].
Adjust the left centering block first [Figure 50-100-33].
The bolt (Item 2) [Figure 50-100-31] must be loose enough to allow the torsion bushing to turn freely between the pintle arm and the linkage bar.
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Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
Figure 50-100-35
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-100-34
1
P-3732
Adjust the right centering block [Figure 50-100-35].
Start the engine and run at high rpm. Move the traction lock override switch (Item 1) [Figure 50-100-34] to the OFF position so the traction function is unlocked. The wheels are now able to turn. Move the left control lever until the tires do not turn (neutral position). Move the left centering block to the left until it contacts both pintle cams and the control lever is still in the neutral position [Figure 50-100-33]. Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. NOTE: If the centering blocks are worn, they can be removed and rotated 180 degrees and reinstalled. If the cams are worn, they can be loosened and rotated 90 degrees and reinstalled.
Move the right centering block to the left until it contacts both pintle cams and the control lever is still in the neutral position [Figure 50-100-35]. Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Test both levers by moving them backward and forward and letting them return to neutral by the return spring force. If the levers do not return to neutral and the tires do not come to a complete stop, repeat the adjustment procedure again. Stop the engine.
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Move the right control lever until the tires do not turn (neutral position).
P16121
Figure 50-100-37
CONTROL PANEL (NON-ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-100-36
1 1 2
P-34365
2 Tighten the two bolts to 11 - 13 ft.-lb. (15 - 17 N•m) torque, then tighten the two nuts to 21 - 25 ft.-lb. (28 - 33 N•m) torque at the steering cross shaft (Items 1 and 2) [Figure 50-100-37].
P-3726
50-100-14 550 of 949
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Tighten the two bolts (Item 1) to 11 - 13 ft.-lb. (15 - 17 N•m) torque, then tighten the two nuts (Item 2) [Figure 50-100-36] to 21 - 25 ft.-lb. (28 - 33 N•m) torque.
S150, S160 Bobcat Loader Service Manual
CONTROL PANEL (ADJUSTABLE PINTLES) Description
Dealer Copy -- Not for Resale
Figure 50-101-1
P-54658
The steering system [Figure 50-101-1] consists of independent steering levers the operator uses to provide steering input to the loader. The steering levers are attached to pivoting bellcranks that pivot on a steering shaft and plastic bushings. The bellcranks have grease fittings.
Pintle arms are of a two-piece design that allow easy adjustment of the neutral or “creep”. Earlier designs use a “spring return” adjustment, later designs use a “thread return” adjustment. The steering system returns the levers to their starting position by means of the centering spring and the returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. The bellcranks are attached to steering linkage bars with rubber torsion bushings pressed into the bellcranks. Bellcranks mount to the control panel. Steering linkage bars are a two-piece design. Steering linkage bars are adjustable in length for “full travel adjustment”. Steering linkage bars attach to the pintle arms where a rubber torsion bushing is pressed into the pintle arms.
NOTE: Torsion bushings need to be replaced if torn or rotating in the housing. Loosen torsion bushing bolts slightly before adjustments are made. Do not fully tighten torsion bushing bolts again until all steering adjustments have been made first. Sequence of steering adjustments: 1. Set neutral of pintle arms, “creep” 2. Set full travel at steering linkage bars 3. Set drift at drift adjustment bolts
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CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)
Figure 50-101-2
Removal And Installation
2
DANGER
1
3
4
P-48462
P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Loosen the jam nut (Item 1) from the bypass control knob (Item 2) [Figure 50-101-2].
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Remove the control knob (Item 2), jam nut (Item 1) and rubber washer (Item 3) [Figure 50-101-2]. Figure 50-101-3
W-2059-0598
WARNING
4
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286 P-48277
Disconnect the control harness connectors (Item 4) [Figure 50-101-2] and [Figure 50-101-3] from the control levers.
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•
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)
Figure 50-101-5
Removal And Installation (Cont'd) 2
Figure 50-101-4
1
1
2
2
3
P-26323
1
Remove the fuse / relay mounting bolts (Item 1) [Figure 50-101-5].
P-54609
Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-101-4] which are connected to the steering shaft on the control panel.
Remove the fuse / relay cover (Item 2) and fuse / relay block retaining bracket (Item 3) [Figure 50-101-5].
Dealer Copy -- Not for Resale
1
Figure 50-101-6
Remove the four steering linkage mounting bolts (Item 2) [Figure 50-101-4]. Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 35 40 ft.-lb. (47,5 - 54,2 N•m) torque.
P-26325
Remove the fuse / relay block [Figure 50-101-6].
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CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)
Figure 50-101-9
Removal And Installation (Cont'd)
1
Figure 50-101-7 11
P-26329
1
P-26328
1
Figure 50-101-8
Remove the control panel mounting bolts (Item 1) [Figure 50-101-7], [Figure 50-101-8] and [Figure 50101-9] from both sides of the control panel. Installation: Tighten the control panel mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque. Remove the control panel from the loader. Reverse the removal procedure to install the control panel.
1
1 P-26327
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P-26326
P-26329
Shaft Removal And Installation
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D)
NOTE: The steering shaft can be removed without removing the control panel from the loader. Photo [Figure 50-101-11] shows the control panel removed for clarity purpose only.
Shock Removal And Installation Figure 50-101-10
Remove the steering linkage mounting bolts (Item 3) [Figure 50-101-10]. Remove the steering shock mounting nuts (Item 2) [Figure 50-101-10].
1 3
Figure 50-101-11
2
Remove the mounting nut (Item 1) [Figure 50-101-10] from the end of the shock connected to the steering linkage.
3
Remove the mounting nut (Item 2) [Figure 50-101-10] from the other end of the shock connected to the bracket on the control panel. Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
1
2 P-48278
Remove Control Handle Lever (Item 1) [Figure 50-10111]. (See Control Lever Removal And Installation on Page 50-110-1.) Remove the steering shaft pivot bolt (Item 2) [Figure 50101-11] from both sides of the control panel. Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 38 N•m) torque. Remove the steering shaft from the control panel.
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P-48275
Figure 50-101-13
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Shaft Disassembly And Assembly
1
Figure 50-101-12
1
2 2 1 1
P-26331
2 To remove the steering shaft mounting bracket (Item 3) [Figure 50-101-11], remove the three mounting bolts (Item 1) [Figure 50-101-13] from the front of the control panel.
Disassemble the right and left steering bellcranks (Item 1) from the cross shaft assembly [Figure 50-10112].
Remove the steering shaft mounting bracket. Installation: Tighten the mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Assembly: Install new nylon bushings (Item 2) [Figure 50-101-12] as needed when assembling the steering shaft. Be sure to apply grease on the cross shaft before installing the right and left bellcranks. NOTE: The bellcranks should pivot freely on the cross shaft when assembled correctly.
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P-4154
Figure 50-101-14
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation
WARNING
2
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
2
1
1
W-2059-0598 P-54609
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Lift and block the loader. (See Procedure on Page 10-101.)
Remove the four steering linkage mounting bolts (Item 2) [Figure 50-101-14]. Installation: Align the marks on the steering linkage bars. Tighten the steering linkage mounting bolts to 35 40 ft.-lb. (47,5 - 54,2 N•m) torque. NOTE: After removal and installation of the linkage, the linkage neutral adjustment procedure must be performed. (See Page 50-101-13 for Linkage Neutral Adjustment procedure.)
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Scribe a mark across the top of the steering linkage bars (Item 1) [Figure 50-101-14] which are connected to the steering shaft on the control panel.
WARNING
Figure 50-101-17
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Removal And Installation (Cont’d)
7
Figure 50-101-15
3
1
8
6
4
1
5
2
2 P-48630
The centering plate / centering spring assembly consists of the following parts:
2
ITEM
DESCRIPTION
Remove the nut (Item 1) from the end of the centering spring shoulder bolt (Item 2) [Figure 50-101-15].
1
Bolt
2
Bushings
Remove the bolt / spring assembly.
3
Washer
4
Bushing Spacer
5
Spring
6
Lock Nut
7
Centering Plate
8
Guide Bushings
Installation: Tighten the centering spring bolt and a NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Figure 50-101-16
Dealer Copy -- Not for Resale
P-48631
1
P-48632
Slide the centering plate (Item 1) [Figure 50-101-16] to the right to remove it from the hydrostatic pumps. NOTE: Directions are shown and stated as if you were sitting in the operators seat.
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Figure 50-101-19
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D)
SPRING RETURN STYLE Linkage Removal And Installation (Cont’d) Figure 50-101-18
2 1 3
6
3
2 5 1 4
2
1 1
P-48627
2
P-48629
Check the wear on the centering blocks (Item 1) [Figure 50-101-18]. If the centering blocks need replacement, remove the bolts (Item 2) [Figure 50-101-18]. Remove the centering blocks. Installation: Tighten the centering block bolts to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque. NOTE: The washers go between the bolts and the centering plate.
Remove the bolts and washers (Item 3) [Figure 50-10119] from the pintle. Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 54,2 N•m) torque. Loosen the creep adjustment bolt (Item 4) [Figure 50101-19]. Remove the pintle arm (Item 5) from the pintle base. (Item 6) [Figure 50-101-19]. Figure 50-101-20
NOTE: If the centering blocks are worn, they can be removed and rotated 180 degrees and reinstalled. If the solid cams are worn, they can be loosened and rotated 90 degrees and reinstalled.
SPRING RETURN STYLE
1
4
3
2 P-48625
NOTE: When installing the pintle arm (Item 1) onto the pintle base (Item 2) align the rear of pintle arm (engine side) (Item 3) into the spring (Item 4) [Figure 50-101-20]. (Spring Return Style Only)
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If the surface of any of the four solid pintle cams (Item 1) are worn, loosen the bolt (Item 2) and rotate the cams 1/4 turn [Figure 50-101-19].
Figure 50-101-23
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D)
SPRING RETURN STYLE
Linkage Removal And Installation (Cont’d)
1
Figure 50-101-21 THREAD RETURN STYLE
3
1
2
2
P-48621
3 Remove and inspect the spring (Item 1) [Figure 50-10123]. Spring return style only. P-54617
Remove the bolts and washers (Item 1) [Figure 50-10121] from the pintle.
THREAD RETURN STYLE
Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 54,2 N•m) torque.
3
Remove the pintle arm (Item 2) from the pintle base (Item 3) [Figure 50-101-21]. Figure 50-101-22
1
2 P-54615
2
Loosen the bolt (Item 2) and remove the pintle base (Item 3) [Figure 50-101-23] and [Figure 50-101-24].
4
3 2 1 P-48624
Remove the bolt and nut (Item 1) [Figure 50-101-22]. Inspect the washers (Item 2), pintle arm (Item 3) and the steering control link (Item 4) for damage and replace as needed [Figure 50-101-22]. NOTE: The washers (Item 2) [Figure 50-101-22] are hardened, and should only be replaced through Bobcat Parts.
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Figure 50-101-24
Pintle Arm Disassembly And Assembly
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D)
Figure 50-101-26
Linkage Removal And Installation (Cont’d)
2
Figure 50-101-25
2
2 1 3 P-54625
1
NOTE: When installing the pintle base (Item 1) onto the pump shaft, the cutouts on the pump shaft will not line up with the bolt (Item 3) [Figure 50-101-25]. Installation: Install the pintle base (Item 1) onto the pump shaft (Item 2) [Figure 50-101-25]. The top of the pintle base should be level with the top of the pump shaft. Tighten the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque.
Remove the bolt (Item 1) from the pintle solid cams (Item 2) [Figure 50-101-26] and inspect the pintle solid cams for damage or excessive wear. Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 54,2 N•m) torque. Figure 50-101-27 2 4
NOTE: After installing the linkage onto the hydrostatic pumps the linkage neutral adjustment procedure must be performed. (See Page 50-101-13 for Linkage Neutral Adjustment procedure.)
2 3
1 P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-10127] are used on ACS loaders only. Remove the nut (Item 1) from the pintle roller cams (Item 2) and inspect the pintle roller cams and washers (Item 3) for damage [Figure 50-101-27]. Inspect the torsion bushing (Item 4) [Figure 50-101-27] for damage and replace as needed. Installation: Tighten the nuts to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque.
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P-48659
Figure 50-101-29
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Pintle Arm Disassembly And Assembly (Cont’d) Figure 50-101-28
1
1
4
2
3
2 P-48619
3
P-54626
Remove the base pintle (Item 1) [Figure 50-101-28] from the pump shaft. Remove the retaining bolt (Item 2), adjusting screw (Item 3) and neoprene dampener (Item 4) [Figure 50-101-28] from the base pintle. Inspect parts for wear and damage, replace as needed [Figure 50-101-28].
Installation: Install the torsion bushing (Item 2) [Figure 50-101-29] into the pintle arm using the same procedure as the removal. NOTE: When the torsion bushing is installed, the amount of bushing on each side of the pintle arm should be the same.
NOTE: Anti-sieze should be used on the adjusting screw to prevent corrosion and allow free movement while adjusting.
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Using a bushing driver (Item 1) remove the torsion bushing (Item 2) by pressing the bushing through the pintle arm into an oversized socket (Item 3) to catch the torsion bushing [Figure 50-101-29].
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D)
Figure 50-101-31
Linkage Neutral Adjustment 1 The following tool listed will be needed to do the following procedure: MEL1563 - Remote Start Tool Kit Connect the remote start tool to the engine harness. (See REMOTE START TOOL KIT -MEL1563 on Page 10-601.) Lift and block the loader. (See Procedure on Page 10-101.)
P-48448
Figure 50-101-30 Loosen the bolt / nut (Item 1) [Figure 50-101-31] only until the tension is released from the torsion bushing.
3
2
1 1
2
P-48450
Tool that may assist in the neutral adjustment [Figure 50101-30]. To make this tool use a locking grip C-Clamp and grind one edge flat (Item 1) and grind the other edge (Item 2) [Figure 50-101-30] to a small rounded edge. A steering centering block (Item 3) [Figure 50-101-30] is also needed. The centering block can be placed as shown and welded to the C-clamp if desired.
P-54612
Loosen the nut (Item 1) only until the tension is released from the torsion bushing (Item 2) [Figure 50-101-32]. NOTE: The bolt must be loose enough to allow the torsion bushing (Item 2) [Figure 50-101-32] to turn freely between the torsion bushing and the steering linkage bar.
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
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Figure 50-101-32
Figure 50-101-35
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-101-33
2
1 1
P16121
Using the remote start tool, turn the key (Item 1) [Figure 50-101-35] to the run position.
2
Loosen the two bolts (Item 1) holding the right centering block. Move the right hand centering block (Item 2) [Figure 50-101-33] until both pintle cams contact the centering block. NOTE: The left centering block is not adjustable. By adjusting the right centering block the left centering block will also become aligned properly. Figure 50-101-34
Move the traction lock override switch (Item 2) [Figure 50-101-35] so the traction function is unlocked. (The traction lock override switch light will be ON.) On a standard loader the wedge brake will unlock. NOTE: When the engine is started, the wheels / tracks may begin to move. NOTE: In loaders equipped with manual steering and hydraulic brake, the steering levers may have to be moved during engine start-up to reduce the amount of creep. This reduction in creep will allow time for the engine to run and build up hydraulic charge pressure, which will release the hydraulic brake.
3 Using the remote start tool, turn the key (Item 1) [Figure 50-101-35] and start the engine and run at low idle. Tighten bolts (Item 3) [Figure 50-101-34] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).
1 2
NOTE: Check for slack between centering blocks and pintle cams. If there is excessive slack repeat above steps [Figure 50-101-33] and [Figure 50-101-34]. P-48451
A modified locking grip C-Clamp and steering block shown in [Figure 50-101-30] may be used to help in aligning the centering blocks. Install the centering block (Item 1) on the inside of the pintle cams and the C-Clamp (Item 2) [Figure 50-10134] around both centering blocks. Lock the C-Clamp in place. 50-101-14 564 of 949
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P-54614
Figure 50-101-37
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Start the neutral adjustment procedure with the left pump first and complete the neutral adjustment for the left pump before adjusting the right pump. Figure 50-101-36
2
1
1
P-54610
Move the engine speed control to high idle.
P-48632
Loosen the left pump pintle adjustment lock bolts (Item 1). (The right pump pintle adjustment lock bolts are (Item 2) [Figure 50-101-36].) Loosen the bolts enough to allow free movement between the pintle arm and the pintle base. NOTE: If the bolts are too loose or too tight, the neutral adjustment may be affected.
NOTE: This procedure is shown for neutral adjustment on the left side of the loader. The procedure is the same for the right side neutral adjustment. Turn the adjustment screw (Item 1) [Figure 50-101-37] counterclockwise until forward creep is seen. Turn the adjustment screw (Item 1) [Figure 50-101-37] counterclockwise to a point between forward and reverse where there is zero creep. Stroke the left steering lever to forward and allow the lever to return to neutral. Stroke the left steering lever to reverse and allow the lever to return to neutral. Check that there is zero creep when the lever returns from either direction, on the left side. Turn the adjustment screw (if necessary) until zero creep is obtained.
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NOTE: The neutral range (dead-band) will vary between the hydrostatic pumps.
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Neutral Adjustment (Cont’d) Figure 50-101-38
2
2
1
1
P-48632
Dealer Copy -- Not for Resale
Torque the left pump pintle adjustment lock bolts (Item 1) [Figure 50-101-38] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). Repeat the adjustment procedure for the right pump. Torque the right pump pintle adjustment lock bolts (Item 2) [Figure 50-101-38] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). Test both levers by moving them backward and forward and letting them return to neutral by the return spring force. If the levers do not return to neutral and the wheels / tracks do not come to a complete stop, repeat the adjustment procedure again. Stop the engine. Remove one pintle adjustment bolt (Item 1) [Figure 50101-38] at a time and apply Loctite® 242 or equivalent thread locker to the bolt and re-install the bolt. Torque the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). Repeat for the three remaining pintle adjustment lock bolts. NOTE: To maintain proper adjustment setting, remove and reinstall only one bolt at a time. New bolts can be installed with pre applied Loctite®. Remove the loader remote start tool. NOTE: After the neutral adjustment is completed on both pumps, the linkage travel adjustment MUST be completed. (See Page 50-101-17.)
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Figure 50-101-39
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Travel Adjustment
2 NOTE: When the linkage travel adjustment procedure is being done as part of the loader neutral adjustment procedure, check the torsion bushings at the pump and at the bell cranks to be sure they are not binding or too loose, which will affect the procedure.
1
2
1
WARNING P-48448
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt (Item 2). The bolt (Item 2) [Figure 50-101-39] must be loosened enough to allow the torsion bushing to turn freely between the steering bellcrank and the linkage bar.
Dealer Copy -- Not for Resale
Figure 50-101-40 Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
1
WARNING
2
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286 P-54613
Lift and block the loader. (See Procedure on Page 10-101.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Pre-load tension in the torsion bushings must be removed before adjusting the steering linkage.
Loosen the nut (Item 1) only until the tension is released from the torsion bushing (Item 2) [Figure 50-101-40]. The bolt must be loose enough to allow the torsion bushing (Item 2) [Figure 50-101-40] to turn freely between the torsion bushing and the linkage bar.
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Figure 50-101-43
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT’D) Linkage Travel Adjustment (Cont’d)
2
Figure 50-101-41
1
3
1
4
P-51174
P-37574
Remove access plug from the top of the control panel. Turn the control lever drift adjustment bolts (Item 1) [Figure 50-101-41] (one on each control lever) out until it is flush with the bottom of the nut. Figure 50-101-42
This will allow the pintle arms to move freely while adjusting the steering linkage for full forward travel speed. Remove the 3/8 in. (10 mm) thick spacer (Item 4) [Figure 50-101-43]. Figure 50-101-44
3
2 2
1
4 P-51173
1 P-51133
Move the right side steering lever to the rear and install a 3/8 in. (10 mm) thick spacer (Item 1) between the pintle arm cam (Item 2) and the centering block (Item 3) [Figure 50-101-42].
Before adjusting the linkage, check that the base pintle arm mounting bolt (Item 1) and both of the upper pintle mount bolts (Item 2) [Figure 50-101-44] and tighten to 35 - 40 ft.-lb. (48 - 54 N•m) torque. There should be no play between the pintle arm and the square pump shaft. Also check that the cam mounting nuts or bolts (Item 4) [Figure 50-101-42] are tight, 35 - 40 ft.-lb. (48 - 54 N•m) torque.
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Move the right side steering lever forward and install a 15/16 in. (24 mm) thick spacer (Item 1) between the center plate (Item 2) and the mounting plate (Item 3) [Figure 50-101-43].
CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)
Figure 50-101-47
Linkage Travel Adjustment (Cont'd) Figure 50-101-45
1
1
1
P-51175
Remove the spacer (Item 1) [Figure 50-101-47]. P-54609
Figure 50-101-48
Dealer Copy -- Not for Resale
Loosen the two bolts and nuts (Item 1) [Figure 50-10145] on each steering linkage bar.
Disconnect the remote start tool. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.)
Figure 50-101-46 2
1
P-54613 P-51134
Move the left control lever to the full forward position, then pull forward on the left rear linkage bar until the pintle arm is rotated to the front as far as possible [Figure 50-101-46]. Use a locking plier, clamp the two linkage bars together.
Tighten the two bolts (Item 1) and nuts (Item 2) to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) [Figure 50-101-48].
Installation: Tighten the nuts and bolts to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque. Check the lever movement to make sure that the pintle arm and the control lever are both at full stroke at the same time. This will allow for maximum forward speed. Repeat the linkage travel adjustment procedure for the right side linkage.
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CONTROL PANEL (ADJUSTABLE PINTLES) (CONT'D)
Figure 50-101-50
Linkage Travel Adjustment (Cont'd) Figure 50-101-49
1
2
1 P-37574
Push the control lever to full stroke and turn drift adjustment bolt (Item 1) [Figure 50-101-50] in until it touches the U-bolt holding the control lever.
Tighten the two bolts and nuts (Items 1 and 2) [Figure 50-101-49] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque at the steering bell cranks.
Repeat steps on the other control lever. Drive the loader forward and check for drift. The traditional benchmark for drift is less than 10 ft. of “drift” in 100 ft. of travel distance. If the drift is excessive to the left, turn the right adjustment bolt (Item 1) [Figure 50-101-50] in. If the drift is excessive to the right, turn the left adjustment bolt in. NOTE: When using the drift adjustment bolts, only adjust one bolt for each test drive. In addition, only move each bolt a maximum of one turn for each test drive. This will help prevent over-correction and excessive reduction in travel speed. Drift adjustment is for forward travel only. Adjust the drift to an acceptable level. Re-install the plug in the drift bolt access hole after adjustment.
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P-48448
Remove the engine speed control. (See Removal And Installation on Page 70-20-1.)
CONTROL PANEL (SJC) Removal And Installation
Figure 50-102-1
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
1
DANGER P-64311
Figure 50-102-2
P-90328
•
•
2
1
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
1
4
D-1009-0409
3
3 P-64319
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Remove the fuse cover mount screws (Item 1) [Figure 50-102-2]. Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m) torque. Remove the fuse / relay cover (Item 2) [Figure 50-1022].
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Remove the fuse / relay shield mounting screws (Item 3) [Figure 50-102-2].
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27 N•m) torque. Remove the fuse / relay shield (Item 4) [Figure 50-102-2]
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Remove the lift arm bypass control knob and rubber washer (Item 1) [Figure 50-102-1].
Figure 50-102-5
CONTROL PANEL (SJC) (CONT’D) Removal And Installation (Cont’d) Figure 50-102-3
1
1
1 1
P-64298
1 Disconnect the left joystick wire harness connector (Item 1) [Figure 50-102-5].
P-64309
Remove the control panel from the loader.
Dealer Copy -- Not for Resale
Remove the control panel mount screws (Item 1) [Figure 50-102-3] from the both sides of the control panel. Installation: Tighten the control panel mounting screws to 15 - 20 ft.-lb. (20 - 27 N•m) torque. Figure 50-102-4
1
P-64328
Disconnect the right joystick wire harness connector (Item 1) [Figure 50-102-4].
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CONTROL HANDLE
Control Lever Boot
Control Lever Removal And Installation
Figure 50-110-3
Figure 50-110-1
2
2
1 N-18884
1 P-34362
Drill out the four rivets (Item 2) [Figure 50-110-3] located on the flange of the rubber boot and remove the old boot.
Figure 50-110-2
Install the new boot and reinstall the control lever. 1
2
N-22658
Remove the nuts from the two U-bolts (Item 1) [Figure 50-110-2] used to mount the control lever. Remove the U-bolts from the control lever mount. Remove the control lever (Item 2) [Figure 50-110-2] by sliding the lever through the rubber boot (Item 1) [Figure 50-110-3] on the front of the control panel. Installation: Tighten the U-bolts so the lever can not be moved either right or left when seated in the operator seat. Be sure the control lever does not interfere with the operator cab when lowering or raising the cab.
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Disconnect the electrical connectors from the control lever [Figure 50-110-1].
To replace the rubber boot (Item 1) [Figure 50-110-3] on the control panel, remove the control lever (See above procedure).
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Figure 50-111-2
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL Components Identification Figure 50-111-1
1
1 P-21879
NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.) Handle Sensor Removal And Installation Figure 50-111-3
P16572
1
Control Handle (Item 1) [Figure 50-111-1].
P-21864
Loosen the nuts (Item 1) [Figure 50-111-3]. Installation: Tighten the u-bolts so the lever can not be moved either right or left when seated in the operator seat. Be sure the control lever does not interfere with the operator cab when lowering or raising the cab.
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Handle Sensor (Item 1) [Figure 50-111-2].
Figure 50-111-6
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL (CONT'D)
1
Handle Sensor Removal And Installation (Cont'd) Figure 50-111-4
2
P-21861
1 Remove the handle sensor connector (Item 1) [Figure 50-111-6] from the clip.
Tilt the control handle (Item 1) [Figure 50-111-4] to the center of the loader.
Dealer Copy -- Not for Resale
NOTE: Pry out with a small screw driver and push the connector down.
P-21837
Figure 50-111-7
Lift the boot cover (Item 2) [Figure 50-111-4]. Figure 50-111-5
1
1 P-21860
2
Remove the handle lock solenoid connector (Item1) [Figure 50-111-7] from the clip. P-21836
Disconnect the harness connector (Item 1) [Figure 50111-5] from the handle sensor connector.
NOTE: Pry out with a small screw driver and push the connector down.
Disconnect the harness connector (Item 2) [Figure 50111-5] from the handle lock solenoid connector.
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Figure 50-111-10
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL (CONT'D) Handle Sensor Removal And Installation (Cont'd)
4
7
3
Figure 50-111-8
1 1 4 3
5 2
4
5
6
2 P-21882
3 Remove the handle sensor (Item 1) [Figure 50-111-10] from the handle assembly. 1
Remove one of the two mounting screws (Item 1) [Figure 50-111-8] from the handle sensor. Installation: Tighten screws to 32 - 38 in.-lb. (3,6 - 4,3 N•m) torque.
Check the spacer (Item 2), screws (Item 3), mounting pin (Item 4), spring (Item 5), washer (Item 6) and stop strap (Item 7) [Figure 50-111-10], replace as needed.
While removing the mounting pin (Item 2) from the handle sensor, remove the one plastic spacer (Item 3), the spring (Item 4) and washer (Item 5) [Figure 50-1118]. Figure 50-111-9
1 P-21880
Remove one of the two mounting screws (Item 1) [Figure 50-111-9] from the handle sensor. Installation: Tighten bolt to 32 - 38 in.-lb. (3,6 - 4,3 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
NOTE: The handle sensor (Item 1) [Figure 50-111-10] can only be replaced as a complete assembly.
P-21862
Control Handle Removal And Installation
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL (CONT'D)
Figure 50-111-13
Handle Sensor Removal And Installation (Cont'd) Figure 50-111-11
3 2
1
P-21879
1
Figure 50-111-12
Dealer Copy -- Not for Resale
Remove the handle sensor (Item 1) [Figure 50-111-13]. (See Handle Sensor Removal And Installation on Page 50-111-1.)
P-21878
Figure 50-111-14 3 2 1
1 P-21799
P16534
Installation: When installing the handle sensor into the control handle, check the routing of the switch handle wire harness (Item 1) [Figure 50-111-11] and [Figure 50111-12] to assure proper return of the control handle to neutral and minimize harness movement.
Remove the switch handle (Item 1) [Figure 50-111-14]. (See Switch Handle Removal on Page 60-120-7.)
NOTE: Route wires (Item 2) [Figure 50-111-11] and [Figure 50-111-12] as shown away from stop strap (Item 3) [Figure 50-111-11] and [Figure 50-111-12] to avoid wire damage. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
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S150, S160 Bobcat Loader Service Manual
Control Handle Disassembly And Assembly
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL (CONT'D)
Figure 50-111-17
Control Handle Removal And Installation (Cont’d) Figure 50-111-15
1 2
1
2 N-17394
Remove the rubber handle cover (Item 1) [Figure 50111-15] from the handle.
Check all parts for wear and replace as needed. Figure 50-111-18
Figure 50-111-16
1
2
2 1
N-22796 N-17385
Using a small screwdriver, hold the handle spacer (Item 1) and remove the allen head screws (Item 2) [Figure 50-111-16] from the handle assembly.
Check the mounting bolt (Item 1) [Figure 50-111-18] that connects the handle to the handle sensor for wear, replace as needed.
Installation: Tighten the allen head screws to 35 in.-lb. (4 N•m) torque.
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Remove the handle sleeve (Item 1) and bushings (Item 2) [Figure 50-111-17] from the handle.
N-17384
Figure 50-111-21
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL (CONT'D) Control Lever Removal And Installation Figure 50-111-19
18.25”
1 1 1
1
B-16618
N-22667
Disconnect the electrical connectors (Item 1) [Figure 50111-19] from the control lever switch handle. Remove the electrical connectors from the control lever switch handle. (See ADVANCED CONTROL SYSTEM (ACS) on Page 60-120-1.) Figure 50-111-20
Installation: Tighten the u-bolts so the lever can not be moved either right or left when seated in the operator seat. Control lever end (Item 2) [Figure 50-111-20] should be flush with bellcrank. Be sure the control lever does not interfere with the operator cab when lowering or raising the cab. The distance between handles should be 18.25 inches [Figure 50-111-21]. Remove the control lever from the cross shaft and control panel.
1
2
N-22658
50-111-6 580 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Loosen the two u-clamps (Item 1) [Figure 50-111-20] nuts.
Control Lever Boot
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL (CONT'D)
Figure 50-111-23
Control Lever Removal And Installation (Cont’d) Figure 50-111-22
2
2
1 1
P13734
The control lever (Item 1) [Figure 50-111-22] must be replaced as a complete unit. The connector clip (Item 2) [Figure 50-111-22] can be replaced separately from the control lever.
To replace the rubber boot (Item 1) [Figure 50-111-23] on the control panel, remove the control lever. (See Control Lever Removal And Installation on Page 50-1101.) Drill out the four rivets (Item 2) [Figure 50-111-23] located on the flange of the rubber boot and remove the old boot. Install the new boot and reinstall the control lever. (See Control Lever Removal And Installation on Page 50-1101.)
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
N-22659
Dealer Copy -- Not for Resale 50-111-8 582 of 949
S150, S160 Bobcat Loader Service Manual
At the back side of the control panel, locate the left joystick wire connector (Item 1) [Figure 50-112-2].
CONTROL HANDLE (SJC) Joystick Testing (Right And Left)
Figure 50-112-3 Figure 50-112-1 1
3 2
P-28312 P-28301
Disconnect the joystick harness connector (Item 1) from the loader wiring harness (Item 2) [Figure 50-112-3]. Install the test harness (Item 3) [Figure 50-112-3] between the two connectors.
MEL1608-Joystick Test Harness [Figure 50-112-1] MEL1563-Remote Start Tool Multimeter
Turn the remote start key to ON position without starting the loader.
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Check the voltage between pin 3 and pin 5 on the joystick test harness (Item 3) [Figure 50-112-3]. The voltage should be between 2.45 and 2.55 volts. Figure 50-112-4
Connect the remote start tool to the loader. (See REMOTE START TOOL KIT -MEL1563 on Page 10-601.) Figure 50-112-2
1
1 P-64328
Repeat the procedure at the right joystick wiring harness connector (Item 1) [Figure 50-112-4]. (If needed.) P-64298
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
The tools listed will be needed to do the following procedure:
Figure 50-112-7
CONTROL HANDLE (SJC) (CONT'D) Joystick Removal (Right And Left) When replacing joystick assemblies, they are available as a complete assembly with the boot and lever already attached. This procedure is shown so the electrical connections can be checked at the bottom of the joystick, if suspected to be loose or disconnected.
1
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-26222
Figure 50-112-5 Remove the two outside joystick mount screws (Item 1) [Figure 50-112-7].
1
P-26220A
Roll the joystick rubber boot (Item 1) [Figure 50-112-5] down from the joystick handle.
P-26223A
Figure 50-112-6 Remove the joystick from the rubber boot [Figure 50112-8]. 1
P-26221
Remove the two inside joystick mount bolts (Item 1) [Figure 50-112-6].
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Figure 50-112-8
CONTROL HANDLE (SJC) (CONT'D)
Lever Assembly Removal (Right And Left)
Joystick Removal (Right And Left) (Cont'd)
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Figure 50-112-9
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
1
Figure 50-112-10
1
P-26224
P-64328
Remove the joystick from the loader.
Disconnect the joystick wiring harness connectors (Item 1) on both the right and left hand joysticks [Figure 50112-10].
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S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Disconnect the electrical harness (Item 1) [Figure 50112-9] from the joystick.
CONTROL HANDLE (SJC) (CONT'D) Lever Assembly Removal (Right And Left) (Cont'd) Figure 50-112-11
1
P-64303
Dealer Copy -- Not for Resale
Remove the two control lever mounting bolts (Item 1) [Figure 50-112-11]. The mounting bolts are secured with lock-nuts on the back of the control panel. Once removed, they need to be replaced with new. Figure 50-112-12
P-64308
Remove the control lever from the loader [Figure 50112-12].
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S150, S160 Bobcat Loader Service Manual
ELECTRICAL SYSTEM
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-30-1 60-30-1 60-30-1 60-30-7 60-30-3 60-30-9 60-30-2 60-30-7 60-30-4 60-30-3 60-30-6 60-30-4 60-30-8 60-30-8 60-30-8 60-30-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . .
60-20-1 60-20-1 60-20-2 60-20-3
SAFETY MAINTENANCE
DRIVE SYSTEM
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
Continued On Next Page
60-01 587 of 949
Dealer Copy -- Not for Resale
ADVANCED CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . 60-120-1 ACS Controller Removal And Installation . . . . . . . . . . . . 60-120-5 Actuators Disassembly And Assembly . . . . . . . . . . . . . 60-120-12 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-16 Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1 Controller, Connector And Wire Identification . . . . . . . . . 60-120-4 Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-120-20 Foot Lock Solenoid Removal And Installation . . . . . . . . 60-120-19 Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-18 Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-120-18 Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-120-15 Handle Lock Solenoid Disassembly And Assembly. . . . 60-120-14 Handle Lock Solenoid Removal And Installation . . . . . . 60-120-14 Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6 Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-120-9 Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-7 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
S150, S160 Bobcat Loader Service Manual
ELECTRICAL SYSTEM (CONT’D) BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1 Inspecting The BICS™ Controller (Engine STOPPED - Key ON) .60-90-1 Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . .60-90-1 Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . .60-90-1 Inspecting The Traction Lock (Engine RUNNING). . . . . . . . . . . . .60-90-1 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-2 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-3 BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-3
Dealer Copy -- Not for Resale
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1 Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1 Calibration Procedure (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1 Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . 60-160-5 Lift And Tilt Calibration Procedure (SJC) . . . . . . . . . . . . . . . . . . . 60-160-4 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . .60-71-1 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-4 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-1 DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1 Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-2 ELECTRICAL / HYDRAULIC CONTROLS REFERENCE . . . . . . . . 60-130-1 Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1 ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1 Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1 ELECTRICAL SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . .60-10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-4 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5 Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-3 FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1 Continued On Next Page
60-02 588 of 949
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ELECTRICAL SYSTEM (CONT’D) INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . 60-50-10 Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6 Front Accessory Panel Removal And Installation . . . . . . . . . . . . 60-50-12 Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Option And Field Accessory Panels (If Equipped) . . . . . . . . . . . . . 60-50-8 Passwords (Deluxe). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6 Right Panel (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . 60-50-3 Right Panel (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . 60-50-2 Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . . 60-50-5 Standard And Deluxe Panel Removal And Installation (Left Side)60-50-11 Standard Panel Removal And Installation (Right Side) . . . . . . . . . 60-50-9 LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1 Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1 Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Dealer Copy -- Not for Resale
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . 60-100-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 Connecting The Service PC To Remote Start Tool . . . . . . . . . . . 60-150-1 SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4 Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7 No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2 Continued On Next Page
60-03 589 of 949
S150, S160 Bobcat Loader Service Manual
ELECTRICAL SYSTEM (CONT’D) TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description Of The Control System . . . . . . . . . . . . . . . . . Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting The Control System . . . . . . . . . . . . . . . . . . . . Solenoid Removal And Installation . . . . . . . . . . . . . . . . . Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .
60-110-1 60-110-2 60-110-7 60-110-5 60-110-2 60-110-3 60-110-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
Dealer Copy -- Not for Resale
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
60-04 590 of 949
S150, S160 Bobcat Loader Service Manual
C105
+ -
C112 C107
-
3210 180 0
3200
1800
23
24
25
3010
9600
4730
UNSWITCHED BATTERY (3)
CAN SELECT
31
32
33
34
4350
8150
1130
9700
22
B
42
1400
8000
16
J1 P01
18 4460
26
19
3600
HYDRAULIC TEMP
47
48
27
28
8800 STARTER RELAY
29 4450
8210
OPEN
GROUND
MARKER LT RELAY
FUEL PULL RELAY
35
36
37
38
39
40
8550
3500
2100
6320
8110
HYD CHARGE PRESS SIGNAL
HORN
47
48
49
7200
3520
44
SPARE OUTPUT 2
45
46
3420
49
50
ENG OIL RESERVED PRESS SIGNAL (FAN OUTPUT)
50
39
42
19
12
36 9
20 32 40
30
38
10
44 14 24 34 16
33 28 13
22
8 48 17
40 30 20
4930
9100
9340 2900 4940
4920
19 29
4310
9
4300
43 36 26
4640 4840
16
4820
4320
4830
4810
J2
K K
LGN
D B
RGN
YEL
DGN
WHT/LGN
WHT
WHT/RED
120
C489
N
4550
K
K
9720
E
E
9620
D
G 9410 F 9400
S
S
R
R
E 9210
G
G
9520
C
C
2240
H
H
1740
B
B
1170
A
A
D 9110
F
F
D 9420
2710
B
C
G
C404
+
-
1310 1040
BATTERY
1080
A
1030
C426 ACD & REMOTE START CONNECTOR
TO OPTIONS (ATTACHMENT CONTROL)
V-0392 (7-11-05)
DETENT FLOW
N
SKI CTRL
TWO SPD
C488
2530
G A H
1490
4230
G A H
4940
4930
4920
4910
WHT/BLK
J E F C
D B
J E F C
4310
4320
4300
P
6510
A B
P
RNG/DBL
9710
1010
FUSE 12 25A
Printed in U.S.A.
9610
STARTER
9510
TRACTION PULL
F
FUEL PULL
ACS
25A
591 of 949
L
6410
1050 1300 1060
100A
D
GLOW PLUG
COMPUTER
25A
E
ATTCHMNT
9800
FUSE 4
FUSE 10
1730
FUSE 8
(ACS)
1160
ALT & KITS
K
1040
FUSE 11
REAR LT
15A
1070 FUSE 12 25A
J
L
B
FUSE / RELAY CENTER
1160
FUSE 9 25A (UNSWITCHED POWER)
M
J
4275
C492
FUSE 5 30A
FUSE 6 30A
M
7200
1080
FUSE 3
RIGHT HANDLE HORN
RNG/WHT
30
1360 2050 2060
2040 2050 1350
2060
FUSE 4 (COMPUTER)
85
4220
25A
85
1110
30
86
TRACTION 86 87 87A LOCK
1120
85
1130
87A 87
4100
30
86
4150
87A 87
4110
8100
8110
85
FUEL PULL
STARTER
1030
FUSE 3 15A
30
86
2030 2040 1060
2010 2020 1320
2020 2030 1330 FUSE 2 15A
85
87A 87
8150
30
86
8210
85
GLOW PLUG
REAR LIGHT 87A 87
8200
30
86
8510
85
87A 87
8550
30
86
8500
87A 87
(ATTACHMENT) FUSE 10 25A 1730
6210
MARKER LIGHT
SWITCHED POWER
1720
6200
6310
6320
1720
6000
2720
A
6300
B
(ACS CONNECTOR) 1055
2000 2010 1050
25A
FUSE 7
YEL
(ALTERNATOR & KITS) FUSE 11 25A
8010
15A
SKI CTRL
1740
25A
FR & MK LT
FLOAT
1150
FUSE 9
30A
DBL
1140
UNSWITCHED
FUEL PULL
PUR
A H
TO OPTIONS (ACCESSORY CONNECTOR)
1150
SWITCH POWER
WHT
1700
RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
REAR LIGHT
K D C B
C411
4550
S
1140
FRONT & MARKER LIGHT
4640
4275
E
(HEATER ) FUSE 1 25A
25A
4840
D A C E
6300
BRN
4235
C
DGN
4730
N
MAINFRAME HARNESS 7101181
HEATER
4830
SIDE SHIFT
6400
D
1700
FUSE 2
RGN
6500
F
1800
FUSE 1
YEL/RED
6600
L
6000
P M
K
30A
YEL/LGN
TURN SIGNAL
B
TRACTION
D C B G
LEFT HANDLE
C407
G
FUSE 5
4820
SEE CAB CONNECTOR
TO OPTIONS (BACKUP ALARM SWITCH)
R
FUSE 6
-
PWM
2730
J
TO OPTIONS (ACCESSORY CONNECTOR)
4810
A B
7100
A
TO OPTIONS (ACCESSORY CONNECTOR)
1480
E
PULL 0.3 ohm
F A J H
B
8500
6600
8580
6500
HOLD 10.9 ohm
8560
6400
8570
E
G F A J
H E
B
C409
C410
A C
HR HR HR HR
6310
D
4240
4100
C425
2200
A C
+
2600 6200
G C
SEE FUSE/RELAY CENTER (EUROPEAN LIGHTING)
4500
2520
1400
C109
9200
8200
8590
C103
46 5 15 44 4
Traction Lock
8250
GLOW PLUGS 1.0 ohm each
TO OPTIONS (ACCESSORY CONNECTOR)
1900
4910
4200
6410
7200
6510
Dealer Copy -- Not for Resale
8100
9700
9600
9500
9800
1110
1120
1130
4150
2100
4110
8110
8150
8800
8800
2800
A B
8210
C
8250
8100
8510
8800
8550
C A B
2800
A B
4200
F B H A
A
C407
J1 6210
B A
2770 2750 2760
9350 1200
24
41 4
6736515
A B
2900
2740
H
3920
14
3300
30
1120
9800
OPEN
OPEN
20
6210 DIVERTER
ENG OIL PRESS +8v
4470
+5V SUPPLY
ATTACHMENT KEY INPUT
17 4200
RESERVED UNSWITCHED (SENSOR GRND) BATTERY (2)
GLOW PLUG FEEDBACK
6320
B A
8200
43
8000
0.3 ohm 8250
OPEN
46
3900
6
4730
M
BRAKE SW IN
45
FUEL SHUTOFF HOLD PULL
B
SWITCH PWR / RESERVED ACC RELAY (CAN SHIELD)
41
25
1800 EXCITATION
2010
R S
HANDLE POWER
A
STARTER
BATTERY CABLE
SEE J2-8
J1
10.9 ohm 1010
A
C101
ALTERNATOR
B A
F&R AUX RELIEF
15
E3
A B
A
6510
TRAVEL CONTROL
D3
G
C110
SUPPLY 1020 B
B
3200
3400
CAN LOW
4150 TWO SPEED SOLENOID OPEN
C113
C104
A B
SEATBAR SIGNAL
44
3910
25 34
LEFT
A B
HEADLIGHT SWITCH
43
35 45
RIGHT
t
14 9500
FRONT WORKLIGHTS
ENGINE HARNESS 7101311
13 1110
FUEL PULL FEEDBACK
21
2350
ENGINE COOLANT SENDER 500-3000 ohm
FLOAT
42
2910
2710
12 8250
TRACTION LOCK SENSOR PULL FEEDBACK GROUNDS
40
2110
STATUS OUT
41
9340
11
SPARE DIGITAL 2
RH SKI UP
4940
HYD LOCK SOLENOID
GROUND
4840
HEADLIGHTS
3910
LEFT PANEL
49
1210
37
3520
3510
G D E
9350
PROTECTED POWER
3500
3520
C434
3500
C B
C435
39
1910
OPEN
38 38
9110
A
9210
GROUND
37
SYSTEM Tx
B
SYSTEM Rx
OPEN
36
COMPUTER POWER
4320
LH SKI UP
35
B
2910 2920 2930
6100
C
B
9300
C
F H K A
2120
2720
CLOCK/LATCH
3100
SEATBAR GROUND
34
A
B R P S F E D C M A J H 2900
FUEL RELAY HOLD
A
6100
3900
KEY/ENTER SWITCH
33
2900
1900
OPEN
9340
REAR WKLT RELAY
HIGH FLOW / 900 LOAD
9310
4110
9330
8510
9320
6410
B J C
4910
DATA
3430
START
9400
BUCKET POSITION
4500
BUZZER
4430
OPEN
G
9410
N K G L
9340
4930
4340
3920
A B
C408
See C492
9200
30
N K G L B R P S F E D C M A J
E
9100
RH SKI DOWN
29
25
9200
PWM SIGNAL
28
SEAT BAR +8v
24
9100
4920
FUEL SENDER
27
COMPUTER POWER
23
9340
9320
4310
OPEN
26
9200
STATUS IN
22
4640
BUZZER
3700
LH SKI DOWN
1200
REAR ROD
D F
4500
4440
21
9410
2930
10
RIGHT PANEL
9
6110 2750
4500
9110 FRONT BASE
9110 9210 9400
2740
18
AIR FILTER SIGNAL
1900
17
1900
SPARE DIGITAL 1
16
2740
LH AUX LEFT
15
4830
2770
SYSTEM Rx
14
32 4420
1930 BRAKE SWITCH
2730
A
ENGINE OIL PRESSURE SENDER 0.5-7.5 V
2740
20
PROTECTED POWER
13
1200
8
TRACTION LOCK HOLD
RH FRONT DETENT
19
SPARE ANALOG 2
12
9350
LEFT BLINKER
7
RIGHT BLINKER
PWM -
REAR BASE
11 7 23 42
3900
SPARE OUTPUT 1
66
HYD CHARGE PRESS +8V
10 3600
1200
TWO SPEED OPEN MAKE-UP
5
CAN HIGH
9 4300
9350
RESERVED (BOOTSTRAP)
4
UNSWITCHED BATTERY (1)
8 3200
3900
TWO SPEED SWITCH
3
STARTER FEEDBACK
7 9210
4820
B
A
C
HYD FILTER SIGNAL
2
RESERVED (hall)
6 4810
3100
28
ENG SPEED SIGNAL
PWM +8V SUPPLY
5 9100
J2 P05
B
6120
+8
3920
OPEN
1
4390
COOLANT TEMP SIGNAL
4 2900
GLOW PLUG TRACTION LOCK RELAY PULL / 963
RESERVED (AC INPUT)
2110
L HAND SERIAL IN
LH AUX RIGHT
3 4330
11
4410
DIFFERENTIAL SWITCH HARNESS 6728626
SYSTEM Tx
-
3910
3
3430
COMPUTER GROUND
FUEL SENDER 30-270 ohm
2760
48 8 18
38
R HAND SERIAL IN
2240 3430
FRONT ROD
B A
B
3010
31
2300
B A
AIR FILTER SWITCH
SEAT BAR
3920
3420
3410
2000
3610
B
3110
A B
3910
2
MAIN FRAME
A
SPARE ANALOG 1
1 4360
HYDRAULIC TEMPERATURE SENDER 500-3000 ohm
A B
CAB
3420
10
32 12 22 1 41 3 21
SPOOL LOCK
2200
2600
3710
C405 C406
C B
15 47 23
2370
3510
3200
3400
A B
SEE J1 B
3700
J2
B
B
A
J2 J1
SEE J2
A
2110
3400
2390
HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH
3300
A
2410
2800
A B
SEE C113
J1
2420
2380
4410
B
4340
B
4360
B
11 ohm 12V
4330
C
B
SPEED SENSOR
3700 4430
2100
A
A B
3310
4440
2490
A
9330
1 2
A C
B
3300
2340
HYDRAULIC CHARGE PRESSURE SENDER 0.5 - 7.5 V
A
3610
3.3 ohm PWM
LOCK VALVE
4420
A
18 29 26
2520
3600
1 2
3100
2430
2330
1 2
FRONT AUX RELIEF 4490
9310
LOCK VALVE
2 1
A
9300
2
9220
1
2480
9120
4485
1920
4481
REAR AUXILIARY HARNESS 7101973
FRONT BASE
2340
2000
2480
1220
4480
2
9350
1
START J DATA B CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H COMPUTER POWER F E
2480
3.3 ohm PWM
C108
1 2
4480
GREEN TIE STRAP
1 2
RUN/ENTER SWITCH
4455
1 2
9.8 ohm 12V
CAB 6727178
4451
2330
A B
2920
4450
GREEN TIE STRAP
4330
2420
4340
C417A
GREEN TIE STRAP
2 1
2450
2450
4420
D G C
4450
SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
2 1
A B
7.7 ohm PWM
2
OPEN
2 1
2450
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
A B
FRONT ROD
C419 C106
YELLOW TIE STRAP
YELLOW TIE STRAP
1
BICS HYDRAULIC LOCK
4410
WHITE TIE STRAP
C418
YELLOW TIE STRAP
C416A
B A
C423
A B
9.8 ohm 12V
WIRES CONNECT BY LETTER ACROSS CONNECTORS A B
7.7 ohm PWM
GROUND
2440
2
1 2
C420
4440
2
2380
2370
C421
1
1
C422
2
4380
1 2
4370
LIFT SPOOL LOCK (NOT Used With AHC or ACS)
BROWN TIE STRAP
2410
C424
2400
2430
BLUE TIE STRAP
4450
2440
2460
4460
2450
1
7.5 ohm 12V
4460
4470
2460
A B
C417
2470
4430
2
BUCKET POSITIONING
UNSWITCHED POWER 1000-1999 RED FUSED, UNSWITCHED POWER 1000-1999 RED/WHT SWITCHED POWER 1000-1999 RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
GROUNDS
B
C416
2530
A
C414
HIGH FLOW 7.5 ohm 12V
S150 (S/N 526811001 - 526815214) (S/N 526911001 - 526918500) S160 (S/N 526611001 - 526615269) (S/N 526711001 - 526716663) Click Here (PRINTED JULY 2005) V-0392 RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
1
REAR BASE
C415
Printable Version
C413
WIRING SCHEMATIC (Without Options)
2
PROTECTED POWER
TILT SPOOL LOCK (NOT Used With AHC or ACS)
REAR ROD
1
7.5 ohm 12V
C412 TO OPTIONS (ACCESSORY CONNECTOR)
C112 C107
1800
23
24
25
3010
9600
4730
CAN SELECT
31
32
33
34
4350
8150
1130
9700
SWITCH PWR / RESERVED ACC RELAY (CAN SHIELD)
41
42
1400
8000
19
26
27
28
8800 STARTER RELAY
29 4450
8210
OPEN
GROUND
MARKER LT RELAY
FUEL PULL RELAY
35
36
37
38
39
40
8550
3500
2100
6320
8110
HYD CHARGE PRESS SIGNAL
HORN
47
48
49
7200
3520
44
SPARE OUTPUT 2
45
46
3420
9800
3600
ENG OIL RESERVED PRESS SIGNAL (FAN OUTPUT)
50
39
42
19
12
36 9
20 32 40
30
38
10
44 14 24 34 16
33 28 13
22
8 48 17
9200
40 30 20
4930
4500 9100
9340 2900 4940
4920
19 29
4310
9 43
4300
4320
4640
36 26
4840
16
4820
4830
4810
J2
B
C
C450 B C A B C A
A
AHC TILT HALL SENSOR
B C A
B C
A B
RGN
C469 B C A 2750
B C A
ACS HARNESS 6733292
1610
2760
4750
120
A B
C404
K
2660
4760
4660
DETENT FLOW
B
SKI CTRL
C488
K
LGN
C489
2530
G A H
1520
1490
4230
G A H
A C
4940
1620
RIGHT HANDLE
C466
HANDLE LOCK TWO SPD
B
A C B
YEL
E
DGN
H
WHT/LGN
F
4930
G
4770
J
4920
4910
WHT
2670
4670
J2 BLACK
4670
V-0393 (7-11-05)
WHT/BLK
1
ACS Controller Advanced Control System
K
WHT/RED
BLK
J1
4650
1080
A C
C471
LIFT PEDAL
+
-
1040
BATTERY
A C B
C470
B
C426 ACD & REMOTE START CONNECTOR
G
A
1310
25A
C
ACS
1030
TO OPTIONS (ATTACHMENT CONTROL)
J E F C
A B
B
A
H
D B
RNG/DBL
RNG/WHT
YEL
B
1500
G
2280
2710
9710
9610
9510
1010
FUSE 12
F
STARTER
1060
100A
E
TRACTION PULL
25A
J E F C
SKI CTRL
FLOAT
1740
P
2250
1740
TILT PEDAL
D B
K
DBL
PUR
WHT
F
1050 1300
D
ALT & KITS
9800
FUSE 11
REAR LT
1730
FUSE 3
ATTCHMNT
4310
K D C B
A F
2240
B
A B C D
1160
25A
FUSE 7
FUSE 10
4320
4300
4640
4840
1170
D 9110
H
4680
B
D
1530
F
2 3 4
H
F E
9520
1 2
2240 1740
9720 9620 9520
3 4 5
4690
4680
D
4750
1040
15A
Printed in U.S.A.
A
GREY J3
1080
FR & MK LT
30A
25A
K
4690
C
R G
2770
C
J H
5 6 7 8
G
9520
C B G E C
4550
25A
FUEL PULL
FUEL PULL
6 7 8
E 9210
9420
4770 1630
S
1 2 3
G 9410 F 9400
9720 9620
FUSE 9
SWITCH POWER
25A FUSE 2
GLOW PLUG
4780
D
R
4780
E
4 5
E D
S
4790
(ACS)
4550
9720 9620
UNSWITCHED
REAR LIGHT
30A FUSE 6
COMPUTER
592 of 949
1070 FUSE 12 25A
K
C429
4790
FUSE / RELAY CENTER
FUSE 9 25A (UNSWITCHED POWER)
A N
K
6 7 8
RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
MAINFRAME HARNESS 7101181
1160
P N
4550
2260
1150
1170
6410 6510
C492
1140
4275
2270
1360 2050 2060
2040 2050 1350
2060
1030
FUSE 5 30A
FUSE 6 30A
L
1190
30
J
L
4220
85
J
4275
4260
85
2500
86
4220
7200
1180
30
4270
87A 87
85
M
M
2510
4280
86
FUSE 4 (COMPUTER)
30
4220
25A
87A 87
1110
85
TRACTION 86 87 87A LOCK
1120
86
1130
30
2030 2040 1060
FUSE 3 15A
87A 87
4100
85
2010 2020 1320
2020 2030 1330
2000 2010 1050 FUSE 2 15A
86
FUEL PULL
STARTER
4150
30
4110
87A 87
8100
85
8110
86
GLOW PLUG
REAR LIGHT
8150
30
8210
87A 87
8200
85
8510
86
8550
30
8500
87A 87
6210
MARKER LIGHT
SWITCHED POWER
1720
6200
6310
6320
1055
6000
1720
6300
2720
A
8010
B
DGN
A B
C428 (ALTERNATOR & KITS) FUSE 11 25A
RED
C468
RED
A B
C467
1 2 3 4 5 6 7 8
A B A B
BLK
1150
DGN
H
LIFT ACTUATOR
M
1740 BLK
1140
RED
A
TILT ACTUATOR
M RED
1700
BLK
S
TO OPTIONS (ACCESSORY CONNECTOR)
13 ohm 12V
FOOT PEDAL LOCK
(HEATER ) FUSE 1 25A
FUSE 4
4830
4550
(ATTACHMENT) FUSE 10 25A 1730
FUSE 8
YEL/LGN
4275
1700
15A
D C B G
6300
E
C412
TO OPTIONS (ACCESSORY CONNECTOR)
1510
4235
C
4650
4730
N
C411
C472
2650
F D
1800
FRONT & MARKER LIGHT
4820
6400
K
HEATER
DGN
6500
6000
6600
L
G
FUSE 1
HORN
2730
P M
B
TRACTION
SIDE SHIFT
C449
R
FUSE 5
YEL/RED
C407
D A C E
J
4810
TO OPTIONS (BACKUP ALARM SWITCH)
-
PWM
TURN SIGNAL
BRN
A B
SEE CAB CONNECTOR
+
HANDLE LOCK
LEFT HANDLE AHC LIFT HALL SENSOR
7100
TO OPTIONS (ACCESSORY CONNECTOR)
RGN
C465
A
TO OPTIONS (ACCESSORY CONNECTOR)
F A J H
6600
PULL 0.3 ohm
A B
6500
B
A B
B
HOLD 10.9 ohm
8500
6400
8580
8590
E
G F A J
E
4100
C409
C410
A C
8560
HR HR HR HR
6310
8570
2600 6200
D
4240
H E
2200
A C
C425
GLOW PLUGS 1.0 ohm each
G C
1480
2520
1400
4910
C109
46 5 15 44 4
8200
TO OPTIONS (ACCESSORY CONNECTOR)
C103
1900
Traction Lock
8250
4200
F B H A
1200
24
41 4
4200
6410
7200
8100
6510
Dealer Copy -- Not for Resale
8800
9700
9600
9500
9800
1110
1120
1130
4150
2100
4110
8110
8150
8800
8210
C A B
8250
C A B
8510
8800 8100
8550
B A
2800
A B
2800
6210
B A
SEE FUSE/RELAY CENTER (EUROPEAN LIGHTING)
J1 6736515
A B
2770 2750 2760
9350
14
3300
30
1120
4470
50
20
6210 DIVERTER
ENG OIL PRESS +8v
6320
8200
18 4460
RESERVED UNSWITCHED (SENSOR GRND) BATTERY (2)
GLOW PLUG FEEDBACK
+5V SUPPLY
ATTACHMENT KEY INPUT
8000
0.3 ohm 8250
43
J1 P01
17 4200
49
6
4730
M
HANDLE POWER
16
OPEN
OPEN
FUEL SHUTOFF HOLD PULL
B
15
UNSWITCHED BATTERY (3)
25
1800 EXCITATION
2010
R S
48
B
B
F&R AUX RELIEF
22
A
STARTER
BATTERY CABLE
SEE J2-8
J1
10.9 ohm 1010
A
C101
ALTERNATOR
3200
6510
TRAVEL CONTROL
E3
A B
B A
3400
CAN LOW
D3
G B
C110
SUPPLY 1020
A
C113
C104
180 0
HYDRAULIC TEMP
47
A
C407
A
-
3210
14 9500
4150 TWO SPEED SOLENOID OPEN
B
3200
OPEN
46
2900
2740
H
3920
C
-
A B
BRAKE SW IN
45
3900
A
C105
+
A B
SEATBAR SIGNAL
44
3910
25 34
LEFT
ENGINE HARNESS 7101311
13 1110
FUEL PULL FEEDBACK
21
t
HEADLIGHT SWITCH
43
35 45
RIGHT
2710
12 8250
TRACTION LOCK SENSOR PULL FEEDBACK GROUNDS
FRONT WORKLIGHTS
11
SPARE DIGITAL 2
2350
ENGINE COOLANT SENDER 500-3000 ohm
FLOAT
42
2910
49
40
2110
STATUS OUT
41
9340
37
3520
3510
RH SKI UP
4940
HYD LOCK SOLENOID
GROUND
4840
HEADLIGHTS
3910
LEFT PANEL
3500
3520
1210
3500
C B
G D E
9350
PROTECTED POWER
A
C434
FUEL RELAY HOLD
C435
39
1910
OPEN
38 38
9110
REAR WKLT RELAY
HIGH FLOW / 900 LOAD
9210
GROUND
37
SYSTEM Tx
4110
SYSTEM Rx
OPEN
36
COMPUTER POWER
4320
LH SKI UP
35
B
2910 2920 2930
6100
8510
9300
6410
F H K A
4910
CLOCK/LATCH
3100
SEATBAR GROUND
34
A
B R P S F E D C M A J H 2900
3430
A
6100
3900
KEY/ENTER SWITCH
33
G
9410
2900
1900
OPEN
4500
9310
9400
BUCKET POSITION
3920
9330
4430
OPEN
N K G L
9340
4930
4340
9340
A B
C408
See C492
9200
30
4640
6110
N K G L B R P S F E D C M A J
E F
9100
RH SKI DOWN
29
25
9340
PWM SIGNAL
28
SEAT BAR +8v
24
9200
4920
FUEL SENDER
27
COMPUTER POWER
23
9100
4310
OPEN
26
9200
STATUS IN
22
9410
9320
10
9320
9
DATA B START J C
8
BUZZER
3700
LH SKI DOWN
1200
REAR ROD
4500
4440
21
4830
B
A
2750
4500
9110 FRONT BASE
D
9110 9210 9400
2740
18
AIR FILTER SIGNAL
1900
17
1900
SPARE DIGITAL 1
16
2740
LH AUX LEFT
15
32 4420
2770
SYSTEM Rx
14
1200
B
20
PROTECTED POWER
13
1200
C
B
RH FRONT DETENT
19
SPARE ANALOG 2
12
9350
C
PWM -
REAR BASE
11
11 7 23 42
9350
A
ENGINE OIL PRESSURE SENDER 0.5-7.5 V
10 3600
3900
LEFT BLINKER
7 TRACTION LOCK HOLD
9 4300
3920
SPARE OUTPUT 1
66
RIGHT BLINKER
8 3200
3910
TWO SPEED OPEN MAKE-UP
5
HYD CHARGE PRESS +8V
7 9210
3900
RESERVED (BOOTSTRAP)
4 CAN HIGH
6 4810
3100
28
ENG SPEED SIGNAL
PWM +8V SUPPLY
5 9100
4820
B
6120
+8
3920
TWO SPEED SWITCH
3 UNSWITCHED BATTERY (1)
COOLANT TEMP SIGNAL
4 2900
J2 P05
-
3910
HYD FILTER SIGNAL
2
STARTER FEEDBACK
L HAND SERIAL IN
LH AUX RIGHT
3 4330
R HAND SERIAL IN
4410 OPEN
1
RESERVED (hall)
SYSTEM Tx
FUEL SENDER 30-270 ohm
B A
2760
48 8 18
38
GLOW PLUG TRACTION LOCK RELAY PULL / 963
RESERVED (AC INPUT)
4390
COMPUTER GROUND
AIR FILTER SWITCH
A
3
3430
DIFFERENTIAL SWITCH HARNESS 6728626
2120
2720
B A
SEAT BAR
C
3430
2110
2730
B
3110
A B
B
3010
FRONT ROD
MAIN FRAME
CAB
3420
3410
2240
2740
3710
C405 C406
2
31
2300
3200
SPARE ANALOG 1
1 4360
2000
3610
SEE J1 B
3700
3420
10
32 12 22 1 41 3 21
SPOOL LOCK
2200
2600
2110
C B
15 47 23
2370
3510
3300
3400
A B
4410
3400
B
B
4340
J2
SEE J2
A
4360
A
2390
HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH
A
J2 J1
HYDRAULIC TEMPERATURE SENDER 500-3000 ohm
A B
SEE C113
J1
2410
2800
A B
3100
2420
2380
SPEED SENSOR
3700
11 ohm 12V
BUZZER
A
4330
2490
A B
4430
B
A B
3310
HARNESS 7101973 A B
2930
1 2
4440
C
B
B
3300
4420
A
A
3610
3.3 ohm PWM
LOCK VALVE
A C
3600
1 2
FRONT AUX RELIEF 4490
RIGHT PANEL
1
2340
HYDRAULIC CHARGE PRESSURE SENDER 0.5 - 7.5 V
1 2
1930 BRAKE SWITCH
1 2
9330
2480
9310
4485
REAR AUXILIARY
9300
4481
2480
9220
4480
9120
1 2
GREEN TIE STRAP
LOCK VALVE
2
2000
2480
FRONT BASE
2340
C108
1 2
4480
3.3 ohm PWM
1920
1
1 2
1220
4455
1 2
9350
4451
GREEN TIE STRAP
2330
START J DATA B CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H COMPUTER POWER F E
4450
2
4330
2420
PROTECTED POWER
1
2450
4420
9.8 ohm 12V
2920
2450
A B
A B
CAB 6727178
2
C417A
GREEN TIE STRAP
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
A B
FRONT ROD
C419 C106
4450
SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
2330
BICS HYDRAULIC LOCK
4410
4340
YELLOW TIE STRAP
C416A
2 1
2450
18 29 26
2100
2
WHITE TIE STRAP
C418
YELLOW TIE STRAP
YELLOW TIE STRAP
C423
B A
A B
A B
9.8 ohm 12V
WIRES CONNECT BY LETTER ACROSS CONNECTORS
2430
2520
2380
OPEN
2440
C420
4440
2
C421
1
1
2370
C422
C414
2400
2
4380
1 2
4370
LIFT SPOOL LOCK (NOT Used With AHC or ACS)
BROWN TIE STRAP
2410
4460
2440
2430
BLUE TIE STRAP
4450
2450
2460
4470
2460
C413
2470
4430
2
BUCKET POSITIONING
UNSWITCHED POWER 1000-1999 RED FUSED, UNSWITCHED POWER 1000-1999 RED/WHT SWITCHED POWER 1000-1999 RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
GROUNDS
1
7.5 ohm 12V
4460
C424
2530
B
A B
C417
RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
A
7.5 ohm 12V
C416
Printable Version Click
S150 (S/N 526811001 - 526815214) (S/N 526911001 - 526918500) S160 (S/N 526611001 - 526615269) (S/N 526711001 - 526716663) Here (PRINTED JULY 2005) V-0393
1
REAR BASE HIGH FLOW
C415
WIRING SCHEMATIC (With ACS Option)
2
RUN/ENTER SWITCH D GROUND G C
TILT SPOOL LOCK (NOT Used With AHC or ACS)
REAR ROD
1
7.5 ohm 12V
C110
C105 C108
C416
C424 C417
3600
GROUND
OPEN
37
38 38
39
9350
3910
4840
C112
FLOAT
HEADLIGHT SWITCH
SEATBAR SIGNAL
BRAKE SW IN
OPEN
HYDRAULIC TEMP
42
43
44
45
46
47
48
C107
B
A
3500
3500
37
C B
3520
3520
49
TWO SPEED OPEN MAKE-UP
SPARE OUTPUT 1
LEFT BLINKER
5
66
7
8
9
10
3430
4910
6410
8510
4110
REAR WKLT RELAY
FUEL RELAY HOLD
STARTER FEEDBACK
RESERVED (hall)
11
3510
+ -
-
A B
3210 180 0
3200
1800
B
23
24
25
3010
9600
4730
UNSWITCHED BATTERY (3)
CAN SELECT
31
32
33
34
4350
8150
1130
9700
HANDLE POWER
SWITCH PWR / RESERVED ACC RELAY (CAN SHIELD)
41
42
1400
8000
17
18
4200
4460
19
RESERVED UNSWITCHED (SENSOR GRND) BATTERY (2)
26
27
28
8800 STARTER RELAY
29 4450
8210
OPEN
GROUND
MARKER LT RELAY
FUEL PULL RELAY
35
36
37
38
39
40
8550
3500
2100
6320
8110
HYD CHARGE PRESS SIGNAL
HORN
47
48
49
7200
3520
44
SPARE OUTPUT 2
45
46
3420
9800
ENG OIL RESERVED PRESS SIGNAL (FAN OUTPUT)
50
39
42
19
12
36 9
20 32 40
30
38
10
44 14 24 34 16
33 28 13
22
8 48 17
46 5 15 44 4
9200
40 30 20
4930
4500 9100
9340 2900 4940
4920
19 29
4310
9
4300
43 36 26
4640 4840
16
4820
4320
4830
4810
J2
K K
LGN
D B
RGN
YEL
DGN
WHT/LGN
WHT
WHT/RED
120
C489
N
4550
K
K
9720
E
E
9620
D
G 9410 F 9400
S
S
R
R
E 9210
G
G
9520
C
C
2240
H
H
1740
B
B
1170
A
A
D 9110
F
F
D 9420
2710
B
C
G
C404
+
-
1310 1040
BATTERY
1080
A
1030
C426 ACD & REMOTE START CONNECTOR
TO OPTIONS (ATTACHMENT CONTROL)
V-0712 (7-11-05)
DETENT FLOW
N
SKI CTRL
TWO SPD
C488
2530
G A H
1490
4230
G A H
4940
4930
4920
4910
WHT/BLK
J E F C
D B
J E F C
4310
4320
4300
P
6510
A B
P
RNG/DBL
9710
1010
FUSE 12 25A
Printed in U.S.A.
9610
STARTER
9510
TRACTION PULL
F
FUEL PULL
ACS
25A
593 of 949
L
6410
1050 1300 1060
100A
D
GLOW PLUG
COMPUTER
25A
E
ATTCHMNT
9800
FUSE 4
FUSE 10
1730
FUSE 8
(ACS)
1160
ALT & KITS
K
1040
FUSE 11
REAR LT
15A
1070 FUSE 12 25A
J
L
B
FUSE / RELAY CENTER
1160
FUSE 9 25A (UNSWITCHED POWER)
M
J
4275
C492
FUSE 5 30A
FUSE 6 30A
M
7200
1080
FUSE 3
RIGHT HANDLE HORN
RNG/WHT
30
1360 2050 2060
2040 2050 1350
2060
FUSE 4 (COMPUTER)
85
4220
25A
85
1110
30
86
TRACTION 86 87 87A LOCK
1120
85
1130
87A 87
4100
30
86
4150
87A 87
4110
8100
8110
85
FUEL PULL
STARTER
1030
FUSE 3 15A
30
86
2030 2040 1060
2010 2020 1320
2020 2030 1330
2000 2010 1050 FUSE 2 15A
85
87A 87
8150
30
86
8210
85
GLOW PLUG
REAR LIGHT 87A 87
8200
30
86
8510
85
87A 87
8550
30
86
8500
87A 87
(ATTACHMENT) FUSE 10 25A 1730
6210
MARKER LIGHT
SWITCHED POWER
1720
6200
6310
6320
1720
6000
2720
A
1055
6300
B
(ACS CONNECTOR) 8010
25A
FUSE 7
YEL
(ALTERNATOR & KITS) FUSE 11 25A
25A
15A
SKI CTRL
1740
FUSE 9
FR & MK LT
FLOAT
1150
UNSWITCHED
30A
DBL
1140
TO OPTIONS (ACCESSORY CONNECTOR)
1150
FUEL PULL
PUR
A H
RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
SWITCH POWER
WHT
1700
1140
REAR LIGHT
K D C B
C411
4550
S
(HEATER ) FUSE 1 25A
FRONT & MARKER LIGHT
4640
4275
E
MAINFRAME HARNESS 7112824
25A
4840
D A C E
6300
BRN
4235
C
DGN
4730
N
1700
HEATER
4830
SIDE SHIFT
6400
D
1800
FUSE 2
RGN
6500
F
K
FUSE 1
YEL/RED
6600
L
6000
P M
B
30A
YEL/LGN
TURN SIGNAL
G
TRACTION
D C B G
LEFT HANDLE
C407
R
FUSE 5
-
PWM
2730
J
FUSE 6
4820
B
8500
SEE CAB CONNECTOR
TO OPTIONS (BACKUP ALARM SWITCH)
8580
A B
7100
TO OPTIONS (ACCESSORY CONNECTOR)
4810
OPEN
2200
A
A
TO OPTIONS (ACCESSORY CONNECTOR)
1480
B
A B
C409
C410 E
4200
F A J H
B
A C
8560
6600
G F A J
H E
4100
C425
2200
A C
HR HR HR HR 8570
6500
4240
C109
1900
+
2600
6310 6400
SEE FUSE/RELAY CENTER (EUROPEAN LIGHTING)
9350 1200
24
Brake Valve
8590
C103
A
6732781
6200
E
H
C407
8250
D
2770 2750 2760
B R P S F E D C M A J H
3920
14
8200
G C
N K G L
2520
1400
Dealer Copy -- Not for Resale
GLOW PLUGS 1.0 ohm each
F B H A
2900
2740
C408
See C492
4910
4200
6410
7200
6510
9700
9600
9500
9800
1110
1120
1130
4150
2100
4110
8110
8100
8150
8800
8800
2800
A B
8210
C
8250
8100
8510
8800
8550
C A B
2800
A B
4200
TO OPTIONS (ACCESSORY CONNECTOR)
3900
B
2910 2920 2930
J1 6210
B A
3910
25 34
41 4
6736515
A B
35 45
3300
4500
30
1120 ENG OIL PRESS +8v
4470
50
20
6210 DIVERTER
GLOW PLUG FEEDBACK
6320
B A
8200
J1 P01
+5V SUPPLY
ATTACHMENT KEY INPUT
8000
0.3 ohm 8250
43
16
49
N K G L B R P S F E D C M A J
E G
9410
6
4730
M
F&R AUX RELIEF
15
3920
OPEN
OPEN
FUEL SHUTOFF HOLD PULL
B
6510
TRAVEL CONTROL
25
1800 EXCITATION
2010
R S
3400
CAN LOW
22
A
STARTER
BATTERY CABLE
SEE J2-8
J1
10.9 ohm 1010
A
C101
ALTERNATOR
B A
14 9500
HIGH FLOW / 900 LOAD
E3
A B
A
13 1110
TRACTION LOCK HOLD
D3
G
C110
SUPPLY 1020 B
B
3200
RIGHT BLINKER
12
4150 TWO SPEED SOLENOID OPEN
C113
C104
A B
HYD CHARGE PRESS +8V
FUEL PULL FEEDBACK
21
t
CAN HIGH
8250
TRACTION LOCK SENSOR PULL FEEDBACK GROUNDS
SPARE DIGITAL 2
ENGINE HARNESS 7101311
UNSWITCHED BATTERY (1)
4390
9340
4640
40
2110
STATUS OUT
41
9410
RH SKI UP
4940
HYD LOCK SOLENOID
D F
LEFT
OPEN
36
9110 9210 9400
RIGHT
C
B
RESERVED (BOOTSTRAP)
4
FRONT WORKLIGHTS
4320
LH SKI UP
35
2910
3100
SEATBAR GROUND
34
9340
3900
KEY/ENTER SWITCH
33
GROUND
1900
OPEN
HEADLIGHTS
9400
BUCKET POSITION
LEFT PANEL
C
TWO SPEED SWITCH
3
1210
A
ENGINE OIL PRESSURE SENDER 0.5-7.5 V
HYD FILTER SIGNAL
2
G D E
4430
OPEN
PROTECTED POWER
4930
4340
4410 OPEN
1
C434
30
GLOW PLUG TRACTION LOCK RELAY PULL / 963
RESERVED (AC INPUT)
C435
RH SKI DOWN
29
25
1910
PWM SIGNAL
28
SEAT BAR +8v
24
9110
3
3430
9210
4920
FUEL SENDER
27
COMPUTER POWER
23
SYSTEM Tx
4310
OPEN
26
9200
STATUS IN
22
4830
SYSTEM Rx
3700
LH SKI DOWN
1200
REAR ROD
21
COMPUTER POWER
4440
FRONT BASE
32 4420
A
A
6100
9110
AIR FILTER SIGNAL
2900
18
4820
A B
6100
17
2900
SPARE DIGITAL 1
16
9340
LH AUX LEFT
15
9340
SYSTEM Rx
14
9200
6
20
PROTECTED POWER
13
9100
6
RH FRONT DETENT
19
SPARE ANALOG 2
12
9200
3440
B
PWM -
REAR BASE
11
11 7 23 42
9100
A
10 3600
4500
A B
9 4300
3100
28
ENG SPEED SIGNAL
PWM +8V SUPPLY
8 3200
R HAND SERIAL IN
31 HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH
COOLANT TEMP SIGNAL
7 9210
J2 P05
6110 2750
4500
B
L HAND SERIAL IN
6 4810
2740
3010
LH AUX RIGHT
5 9100
1900
3420 3410
SYSTEM Tx
4 2900
1900
15 47 23
3400
4
COMPUTER GROUND
3 4330
2740
3 5
FRONT ROD
1200
4
2
9350
5
3410
J
SPARE ANALOG 1
1 4360
3900
3
3420
3310
SPOOL LOCK
1200
3400
H SEE J2-48
9350
A C B
3300
B
A
+8
3920
B
3310
1 2
B
6120
48 8 18
38
3910
C
B
1 2
-
3900
A
C
3300
FUEL SENDER 30-270 ohm
2760
C
A
A B
10
32 12 22 1 41 3 21
B A
3920
A B
HYDRAULIC CHARGE PRESSURE SENDER 0.5 - 7.5 V
ENGINE COOLANT SENDER 500-3000 ohm
B A
3910
2240
B
3110
AIR FILTER SWITCH
SEAT BAR
B
J2
HARNESS 7112802 HYDRAULIC TEMPERATURE SENDER 500-3000 ohm
2000
3710
A B
A
2390
2370 2200
A
J2 J1
29 26
18
9300
SEE C110
3100
J1
MAIN FRAME
2770
3200
B
3700
2110
3300
4410
4340
2380
4360
2350
B
4330
2710
2410
B
9.8 ohm 12V
4430
2420
2480
A
F H K A
SEE C110
SEE C113
3700 4440
2720
A
4470
2120
4450
2730
4460
2740 2100
4480
CLOCK/LATCH
H A
J
4420
2520
9310
SPEED SENSOR
CAB
2110
9330
A B
REAR AUX RELIEF
2330
9320
B
C405 C406
2340
B J C
11 ohm 12V
DATA
A
3610
1930 BRAKE SWITCH
A B
2600
START
3600
2000
A B
2490
BUZZER
7.5 ohm 12V
3.3 ohm PWM
FRONT AUX RELIEF 4490 GREEN TIE STRAP
9320
A B
2930
A B
2450
1 2
CAB 6727178
DIVERTER
C419 C106
1 2
2340
4450
9330
FRONT BASE 4340
YELLOW TIE STRAP
9310
3.3 ohm PWM
9300
1 2
9220
1 2
9120
2330
1920
4330
2420
1220
4420
9.8 ohm 12V
9350
A B
A B
2920
A B
FRONT ROD
BUZZER
A B
2410
RIGHT PANEL
BICS HYDRAULIC LOCK
4410
WHITE TIE STRAP
START J DATA B CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H COMPUTER POWER F E
2440
BLUE TIE STRAP
RUN/ENTER SWITCH
4440
2
7.7 ohm PWM
2
D G C
1
1 OPEN
2
2
7.7 ohm PWM
C420
2460
2380
1 2
GROUND
1
7.5 ohm 12V
4460
1
2370
C421
A B
4380
1 2
4370
LIFT SPOOL LOCK (NOT Used With AHC or ACS)
BROWN TIE STRAP
C418
2430
B
C423
2300
3510
A
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
3610 2400
2430
BUCKET POSITIONING
UNSWITCHED POWER 1000-1999 RED FUSED, UNSWITCHED POWER 1000-1999 RED/WHT SWITCHED POWER 1000-1999 RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
2800
2440
4430
2
C422
HIGH FLOW 7.5 ohm 12V
9.8 ohm 12V
2470
2450
A
1
REAR BASE
SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
GROUNDS
2460
B
2
C414
2530
B
C415
S150 (S/N 526815215 AND ABOVE) (S/N 526918501 AND ABOVE) S160 (S/N 526615270 AND ABOVE) (S/N 526716664 AND ABOVE) (PRINTED JULY 2005) RELAY GROUNDS 2000-2060 V-0712 ARE CONNECTED IN SERIES
A
TILT SPOOL LOCK (NOT Used With AHC or ACS)
REAR ROD
1
7.5 ohm 12V
WIRES CONNECT BY LETTER ACROSS CONNECTORS
PROTECTED POWER
Printable Version Click Here
C413
WIRING SCHEMATIC (Without Options)
C412 TO OPTIONS (ACCESSORY CONNECTOR)
C110
C416
C424
4110
REAR WKLT RELAY
FUEL RELAY HOLD
A
3500
3500
37
C B
3520
3520
49
11
3510
23
24
25
3010
9600
4730
UNSWITCHED BATTERY (3)
CAN SELECT
31
32
33
34
4350
8150
1130
9700
22
HANDLE POWER
SWITCH PWR / RESERVED ACC RELAY (CAN SHIELD)
41
42
1400
8000
17
18
4200
4460
19
RESERVED UNSWITCHED (SENSOR GRND) BATTERY (2)
26
27
28
20
6210
8800
DIVERTER
STARTER RELAY
29
30
1120
4450
8210
OPEN
GLOW PLUG FEEDBACK
ENG OIL PRESS +8v
GROUND
MARKER LT RELAY
FUEL PULL RELAY
35
36
37
38
39
40
8550
3500
2100
6320
8110
HYD CHARGE PRESS SIGNAL
HORN
47
48
49
7200
3520
4470
44
SPARE OUTPUT 2
45
46
3420
9800
39
42
19
ENG OIL RESERVED PRESS SIGNAL (FAN OUTPUT)
50
12
36 9
20 32 40
30
38
10
44 14 24 34 16
33 28 13
22
8 48 17
40 30 20
4930
4500 9100
9340 2900 4940
4920
19 29
4310
9 43
4300
4320
4640
36 26
4840
16
4820
4830
4810
J2
AHC TILT HALL SENSOR
B C A
B
A B
RGN
C450 B C A B C A
C469 B C A 2750
B C A
ACS HARNESS 6733292
1610
2760
4750
120
A B
C404
K
DETENT FLOW
SKI CTRL
C488
K
LGN
C489
2530
G A H
1490
4230
G A H
2660
4760
4660
4940
B
RIGHT HANDLE
C466
HANDLE LOCK TWO SPD
1520
YEL
A C
DGN
B
1620
WHT/LGN
E
4930
H
4920
V-0713 (7-11-05)
A C B
4910
WHT
2670
4670
1080
C471
LIFT PEDAL
+
-
1040
BATTERY
A C
C470
B
C426 ACD & REMOTE START CONNECTOR
G
A
1310
25A
C
ACS
1030
TO OPTIONS (ATTACHMENT CONTROL)
A C B
WHT/BLK
1
F
4770
G
4670
J
WHT/RED
BLK
J2 BLACK
4650
2710
9710
9610
9510
1010
FUSE 12
F
STARTER
1060
100A
E
TRACTION PULL
25A
TILT PEDAL
1050 1300
D
ALT & KITS
9800
FUSE 11
REAR LT
1730
FUSE 3
J E F C
A B
B
ACS Controller Advanced Control System
K
D B
RNG/DBL
RNG/WHT
YEL
A
J1
J E F C
SKI CTRL
FLOAT
B
1500
H
D B
K
DBL
PUR
WHT
1740
P
G
2280
4310
K D C B
F
2250
1740
4320
4300
4640
4840
A F
2240
B
4680
1170
D 9110
H
1530
F
2 3 4
B
D
1 2
H
F E
9520
3 4 5
4690
2240 1740
9720 9620 9520
A B C D
1160
25A
FUSE 7
FUSE 10 ATTCHMNT
594 of 949
D
4750
1040
15A
Printed in U.S.A.
4680
C
R G
1080
FR & MK LT
30A
25A
A
GREY J3
25A
FUEL PULL
COMPUTER
K
4690
C
J H
2770
G
9520
C B G E C
4550
5 6 7 8
E 9210
9420
FUSE 9
SWITCH POWER
25A FUSE 2
FUEL PULL
6 7 8
S
4770 1630
G 9410 F 9400
9720 9620
1 2 3
D
UNSWITCHED
REAR LIGHT
30A FUSE 6
GLOW PLUG
4780
E
R
4780
E D
4 5
(ACS)
4550
9720 9620
S
4790
1070 FUSE 12 25A
K
C429
4790
FUSE / RELAY CENTER
FUSE 9 25A (UNSWITCHED POWER)
A N
K
6 7 8
RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
MAINFRAME HARNESS 7112824
1160
P N
4550
2260
1150
1170
6410 6510
C492
1140
4275
2270
1360 2050 2060
2040 2050 1350
2060
1030
FUSE 5 30A
FUSE 6 30A
L
1190
30
J
L
4220
85
J
4275
4260
85
2500
86
4220
7200
1180
30
4270
87A 87
85
M
M
2510
4280
86
FUSE 4 (COMPUTER)
30
4220
25A
87A 87
1110
85
TRACTION 86 87 87A LOCK
1120
86
1130
30
2030 2040 1060
FUSE 3 15A
87A 87
4100
85
2010 2020 1320
2020 2030 1330
2000 2010 1050 FUSE 2 15A
86
FUEL PULL
STARTER
4150
30
4110
87A 87
8100
85
8110
86
GLOW PLUG
REAR LIGHT
8150
30
8210
87A 87
8200
85
8510
86
8550
30
8500
87A 87
6210
MARKER LIGHT
SWITCHED POWER
1720
6200
6310
6320
1055
6000
1720
6300
2720
A
8010
B
DGN
A B
C428 (ALTERNATOR & KITS) FUSE 11 25A
RED
C468
RED
A B
C467
1 2 3 4 5 6 7 8
A B A B
BLK
1150
DGN
H
LIFT ACTUATOR
M
1740 BLK
1140
RED
A
TILT ACTUATOR
M RED
1700
BLK
S
TO OPTIONS (ACCESSORY CONNECTOR)
13 ohm 12V
FOOT PEDAL LOCK
(HEATER ) FUSE 1 25A
FUSE 4
4830
4550
(ATTACHMENT) FUSE 10 25A 1730
FUSE 8
YEL/LGN
4275
1700
15A
D C B G
6300
E
C412
TO OPTIONS (ACCESSORY CONNECTOR)
1510
4235
C
4650
4730
N
C411
C472
2650
F D
1800
FRONT & MARKER LIGHT
4820
6400
K
HEATER
DGN
6500
6000
6600
L
G
FUSE 1
HORN
2730
P M
B
TRACTION
SIDE SHIFT
C449
R
FUSE 5
YEL/RED
C407
D A C E
J
4810
TO OPTIONS (BACKUP ALARM SWITCH)
-
PWM
TURN SIGNAL
BRN
A B
SEE CAB CONNECTOR
+
HANDLE LOCK
LEFT HANDLE AHC LIFT HALL SENSOR
7100
TO OPTIONS (ACCESSORY CONNECTOR)
RGN
C465
A
TO OPTIONS (ACCESSORY CONNECTOR)
F A J H
6600
G F A J
6500
OPEN
2200
A B
8500
6400
8580
8590
E
B
A B
A B
B
4200
A B
4100
A C
8560
HR HR HR HR
6310
8570
2600 6200
D
E
GLOW PLUGS 1.0 ohm each
C425
2200
A C
C409
C410
Brake Valve 6732781
8200
G C
4240
H E
8100
1480
2520
1400
4910
C109
9200
8250
TO OPTIONS (ACCESSORY CONNECTOR)
C103
46 5 15 44 4
Dealer Copy -- Not for Resale
8800
4200
F B H A
1900
41 4
4200
6410
7200
6510
9700
9600
9500
9800
1110
1120
1130
4150
2100
4110
8110
8150
8800
8210
C A B
8250
C A B
8510
8800 8100
8550
B A
A B
2800
6210
B A
2800
A B
SEE FUSE/RELAY CENTER (EUROPEAN LIGHTING)
J1 6736515
6320
8200
J1 P01
+5V SUPPLY
ATTACHMENT KEY INPUT
8000
0.3 ohm 8250
43
16
1200
24
6
4730
M
F&R AUX RELIEF
15
2770 2750 2760
9350
14
3300
FUEL SHUTOFF HOLD PULL
B
6510
TRAVEL CONTROL
25
1800 EXCITATION
2010
R S
3400
CAN LOW
50
A
C113
C104
C110
B
14 9500
4150
A
STARTER
BATTERY CABLE
SEE J2-8
J1
10.9 ohm 1010
A
C101
ALTERNATOR
1800
13 1110
HIGH FLOW / 900 LOAD
E3
A B
3200
12 8250
TRACTION LOCK HOLD
D3
G B
B A
RIGHT BLINKER
49
C
-
SUPPLY 1020
A
HYD CHARGE PRESS +8V
OPEN
OPEN
A
-
180 0
48
B C
+
3210
CAN HIGH
FUEL PULL FEEDBACK
TWO SPEED SOLENOID OPEN
B
3200
UNSWITCHED BATTERY (1)
TRACTION LOCK SENSOR PULL FEEDBACK GROUNDS
SPARE DIGITAL 2
ENGINE HARNESS 7101311 A B
HYDRAULIC TEMP
47
A
C407
B
B
STARTER FEEDBACK
21
A B
OPEN
46
2900
2740
H
3920
A
C
B
C107
C
3600
C417
8510
RESERVED (hall)
2710
t
BRAKE SW IN
45
3900
C
C105 C108 C112
6410
2350
ENGINE COOLANT SENDER 500-3000 ohm
SEATBAR SIGNAL
44
3910
25 34
LEFT
2120
2720
HEADLIGHT SWITCH
43
35 45
RIGHT
2730
A
ENGINE OIL PRESSURE SENDER 0.5-7.5 V
2740
FLOAT
42
4500
FRONT WORKLIGHTS
4910
4390
40
2110
STATUS OUT
2910
3430
2110
RH SKI UP
4940
41
9340
4840
GROUND
3910
HEADLIGHTS
9350
LEFT PANEL
39
3920
1210
OPEN
38 38
9340
G D E
GROUND
37
PROTECTED POWER
OPEN
36
4640
C434
4320
LH SKI UP
35
9410
C435
3100
SEATBAR GROUND
34
1910
3900
KEY/ENTER SWITCH
33
9110
10
9210
1900
OPEN
SYSTEM Tx
9
SYSTEM Rx
9400
BUCKET POSITION
COMPUTER POWER
4430
OPEN
B
2910 2920 2930
6100
8
9300
LEFT BLINKER
7
F H K A
SPARE OUTPUT 1
66
CLOCK/LATCH
4930
4340
G
9410
A
B R P S F E D C M A J H 2900
TWO SPEED OPEN MAKE-UP
5
A
6100
30
2900
RESERVED (BOOTSTRAP)
4
9310
TWO SPEED SWITCH
3
9330
RH SKI DOWN
29
25
N K G L
9340
HYD FILTER SIGNAL
2
A B
C408
See C492
9200
OPEN
1
6110
N K G L B R P S F E D C M A J
E F
9100
PWM SIGNAL
28
SEAT BAR +8v
24
9340
4920
FUEL SENDER
27
COMPUTER POWER
23
9200
4310
OPEN
26
9200
STATUS IN
22
D
9110 9210 9400
9100
3700
LH SKI DOWN
1200
REAR ROD
21
GLOW PLUG TRACTION LOCK RELAY PULL / 963
RESERVED (AC INPUT)
9320
4440
FRONT BASE
4410
2600
9320
9110
AIR FILTER SIGNAL
HYD LOCK SOLENOID
3
3430
DATA B START J C
6
BUZZER
18
4830
BUZZER
17
4500
SPARE DIGITAL 1
16
32 4420
2930
LH AUX LEFT
15
4820
RIGHT PANEL
SYSTEM Rx
14
J2 P05
B
A
2750
4500
PROTECTED POWER
13
2740
6
20
SPARE ANALOG 2
12
2240
3440
RH FRONT DETENT
19
REAR BASE
11
1900
3010
PWM -
R HAND SERIAL IN
11 7 23 42
1900
3410
10 3600
2740
4
15 47 23
2770
4
3420
1930 BRAKE SWITCH
3410
3400
9 4300
1200
B
3 5
8 3200
9350
5
7 9210
3900
3
3420
6 4810
3100
28
ENG SPEED SIGNAL
PWM +8V SUPPLY
5 9100
3920
3400
COOLANT TEMP SIGNAL
4 2900
3910
A C
9330
J
L HAND SERIAL IN
9310
H SEE J2-48
3310
LH AUX RIGHT
3 4330
1200
3300
2
SYSTEM Tx
9300
1
2
COMPUTER GROUND
B
6120
48 8 18
38
9350
1
3310
FRONT ROD
2760
+8
3900
2
-
3920
SPARE ANALOG 1
1
FUEL SENDER 30-270 ohm
B A
3910
SPOOL LOCK
AIR FILTER SWITCH
A
3300
B
10
32 12 22 1 41 3 21
31
2300
B A
SEAT BAR
C
J2
B
3610
B
3110
A B
B
A
A B
3710
J2 J1
29 26
4360
2000
A B
A
3100
2200
HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH
SEE C110
B
J1
MAIN FRAME
CAB
B
SPEED SENSOR
C405 C406
B
3200
B
SEE C110
SEE C113
3700
B
9.8 ohm 12V
2110
2480
A
3300
A
4410
4480
4340
A C
A B
3700 4360
A C
B
J
4330
HYDRAULIC CHARGE PRESSURE SENDER 0.5 - 7.5 V
A
3610
REAR AUX RELIEF 4430
B
H A
11 ohm 12V
9220
A B
9120
2490
4440
A
3600
3.3 ohm PWM
2000
A B
4490 GREEN TIE STRAP
1920
7.5 ohm 12V
1 2
FRONT AUX RELIEF
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
1220
A B
4420
HYDRAULIC TEMPERATURE SENDER 500-3000 ohm
1 2
CAB 6727178
2450
YELLOW TIE STRAP
C419 C106
A B
4450
SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
2410
3510
FRONT BASE
2340
HARNESS 7112802
2800
3.3 ohm PWM
DIVERTER
2520
2370
1 2
4340
2330
2390
1 2
9.8 ohm 12V
9350
2330
START J DATA B CLOCK/LATCH A SYSTEM Rx K SYSTEM Tx H COMPUTER POWER F E
4330
2420
PROTECTED POWER
4420
A B
2920
A B
B A
A B
A B
FRONT ROD
2340
2380
BICS HYDRAULIC LOCK
4410
C418
A B
9.8 ohm 12V
WIRES CONNECT BY LETTER ACROSS CONNECTORS
18
2420
2
WHITE TIE STRAP
2410
2430
2100
2380
OPEN
2440
2370
C420
4440
2
1
C421
1
4380
1 2
4370
LIFT SPOOL LOCK (NOT Used With AHC or ACS)
BROWN TIE STRAP
BLUE TIE STRAP
C423
2400
2
4470
2440
2460
4450
2450
1
7.5 ohm 12V
4460
4460
2460
B
A B
C414
2470
2430
BUCKET POSITIONING
UNSWITCHED POWER 1000-1999 RED FUSED, UNSWITCHED POWER 1000-1999 RED/WHT SWITCHED POWER 1000-1999 RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
GROUNDS
A
C415
2530
4430
2
REAR BASE HIGH FLOW 7.5 ohm 12V
S150 (S/N 526815215 AND ABOVE) (S/N 526918501 AND ABOVE) S160 (S/N 526615270 AND ABOVE) (S/N 526716664 AND ABOVE) (PRINTED JULY 2005) V-0713 RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
1
C422
WIRING SCHEMATIC (With ACS Option)
C413
Printable Version Click Here
2
RUN/ENTER SWITCH D GROUND G C
TILT SPOOL LOCK (NOT Used With AHC or ACS)
REAR ROD
1
7.5 ohm 12V
4310
4310
4320
4320
4300
4300
4640
2530
4840
4910
4830
4230
B K F G
16
4820
1490
A
6
4810 4640
D C B
4840 4830
2200
A C
4100
B
C416
C424 C417
4200
8250
A C
4200
B
OPEN
A B
2200
4240 2520
6500
13
1 4
LEFT FORWARD DRIVE
CAN LOW DRIVE
R QUAD A DRIVE
R QUAD B DRIVE
D
4235
21
22
23
N
6300
C
4275
E
4550
S
1700
A
1140
H
1150
4270
LEFT REVERSE DRIVE
8
4720
STEER MODE 2
OPEN
15
18
17
2 4
J5
25
19
4530
BRAKE LIGHT OUTPUT
DRIVE GRND
26
27
28
29
3070
4350
4210
2470
2490
2510
L QUAD B DRIVE
SAFETY OUT
BACK-UP ALARM
OPEN
OPEN
OPEN
36
37
38
39
33
34
35
3080
9410
7100
RIGHT RIGHT FORWARD REVERSE DRIVE DRIVE
RIGHT REVERSE GND
TWO UNSWITCHED UNSWITCHED OPEN BATTERY SPEED 2 BATTERY
41
42
43
44
45
46
47
48
2660
4260
4250
2650
4390
1250
1260
SWITCHED BATTERY
49
50
1750
2 5
2 0
3 7
3 8
4 6
3 9
5
3 6
1 9
1 8
1810
1640
2810 4720
3000 3070
1710 1820
4720
2860
4950 1770
3 4 3 4 2 4 4 4 5 3 1 4 1 2 1 1 1 2 6
4260
2 4 3 1 2 4 3 1 1 2 3
2660 4250
85
30
86 85
87A 87 30
86
87A 87
85
30
86 85
85
FUSE / RELAY CENTER
1160
FUSE 9 25A (UNSWITCHED POWER)
1070 FUSE 12 25A (ACS)
2
2860
1 3 2
4950 1770
1 2
4260
1 2 3
2660
1 2 1
4250
4 5
2650
2680
4270
6 7
4270
2 1
2670
8
8
2670
2
4280
4280
1040
RIGHT FORWARD DRIVE SOLENOID
RIGHT REVERSE DRIVE SOLENOID
1 2 1 2
LEFT REVERSE DRIVE SOLENOID
LEFT FORWARD DRIVE SOLENOID
A
TO OPTIONS (BRAKE LIGHT)
C474
6
6 4 2 3 5
9010
6
6
2070
4 2 3 5
4 2 3 5
2080
4275
L
R
9400
1520
1
1
1510
1
1
9110
6 4 2
6 4 2
9010
6 4 2
6 4 2
6410
P
S
9410
N
K
4550
K
M
4220
C441
C437
C404
9720
E
L
4275
P
6410
NOT USED FOR THIS MODEL
NOT USED FOR THIS MODEL
TO OPTIONS (BACKUP ALARM)
N
6510
9620
D
G 9410 F 9400
S R
J
7200
B A
B A C
9210
B A
B A
4750 4650
TO OPTIONS (HORN/BLINKER)
2070 1510
3 5 1
3 5 1
4750 4650
4750
2070 1510
G
9520
C
D
2240
H
C
9520
2630 4670
1740
B
B
1740
1610
1 2 3
1170
A
H
2240
D 9110
F
F
9110
4680
4 5
4690
6 7 8
E
9720 9620
1630
F
A
G
K
J1
ACS Controller
SJC HARNESS 7110406
4770
E
4670
D
4650
B
4750
C
1500
J
2250
H
9740
K
9540
A
9640
D
1760
F
2280
H
4690
J
4780
E
J3 (Gray)
4790
G
2270
V-0714 (7-11-05)
C
4680
B
TO OPTIONS (ATTACHMENT CONTROL)
4780 A
B
D
C
G
F
H
E
J
K
J2 (Black) 4790
3 5 1
4650
E 9210
2260
1080
1 2 1 2
9210
4550
LEFT SWASH PLATE POSITION SENSOR
SIG
G
1180
+
-
BATTERY
GRD
J
1040
595 of 949
PWR
7200
1190
B
ACD & REMOTE START CONNECTOR
1 3 2
RIGHT SWASH PLATE POSITION SENSOR
SIG
4540
G
A
C
F
E
D
1310
PWR
1170
2710
9710
9610
9510
9800
1730
1160
1030
GRD
2
4210
1080
1010
Printed in U.S.A.
C426
1 3
A
1050 1300
C454
1 3
1710
2770
1060
C453
4720
2810
4770
100A
SIG
M
6510
RIGHT SIDE WHEEL SPEED
SIG
4220
C497
FUSE 5 30A
FUSE 6 30A
PWR
4 2 3 5
C492
RELAY GROUNDS 2000-2060 ARE CONNECTED IN SERIES
30
1360 2050 2060
2040 2050 1350
FUSE 3 15A
87A 87
2060
FUSE 2 15A
86
7114735 RED TIE STRAPS
2 4 3 1 2 4 3 1
6 7
4 5
2650
2680
236 0
30
1030
FUSE 8
1 0
235 0
87A 87
120
GLOW PLUG
2
4530
5 0
7100
1 2
4540
2 2
4390
3 2
4350
1 6
1750
9410
6
9530
9400
4
9630
3 5
9730
1
4220
4 8
4550
4 7
4275
2 8
1260
85
1150
MAINFRAME HARNESS 7112824
2 7
2470
86
FUSE 4 (COMPUTER)
30
25A
87A 87
2030 2040 1060
1140
25A
85
2010 2020 1320
(HEATER ) FUSE 1
86
1110
30
TRACTION 86 87 87A LOCK
1120
87A 87
(ATTACHMENT) FUSE 10 25A 1730
STARTER
1130
1720
FUEL PULL
4100
1720
GLOW PLUG
REAR LIGHT
4150
A
MARKER LIGHT
SWITCHED POWER
4110
2720
8100
B
1055
8110
C489
40
3080
4530 8150
25A
SENSER SUPPLY 1 +5V
1640
2680
1250
(ALTERNATOR & KITS) 1800 FUSE 11 25A
8210
COMPUTER
30
GRD
3 1 2 4
3020
7 OPEN
J5 DRIVE
8200
TO OPTIONS (ACCESSORY CONNECTOR)
20
3000
3020
OPEN
4540
DRIVE MAIN SENSER GRND GRND
L QUAD A DRIVE
32
9730 RIGHT FORWARD GND
OPEN
16
10
LEFT LEFT JOYSTICK X JOYSTICK Y
4275 TWO SPEED 1
OPEN
9
R
8510
FUSE 4
9630 CAN SHIELD DRIVE
7
4950
31 LEFT REVERSE GND
8550
15A
9530
6
4220
4280
1740
8500
REAR LT
12
11
2670
6210
FUSE 3
OPEN
OPEN
4730
2020 2030 1330
FUSE 7
CAN HIGH DRIVE
6400
6200
15A
5
L
6310
FR & MK LT
4
4550
F
2000 2010 1050
30A
OPEN
3070
SIG
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
3 5 1
HDL SW X LEFT JOYSTICK
Y GRD PWR
HDL SW X RIGHT JOYSTICK
Y GRD PWR
GND SIG
M
LIFT ACTUATOR
M
B
FUEL PULL
3
LEFT FORWARD GND
6320
25A
2
STEERING MODE
2 4
LEFT SIDE WHEEL SPEED
SIG
M
TILT ACTUATOR
C488
FUEL PULL
6600
6000
HEATER
1
2490
FRONT & MARKER LIGHT
REAR LIGHT
TRACTION PULL
SWITCH POWER
P
6300
FUSE 2
OPEN
9400
8010
FUSE 1
OPEN
2730 6000
STARTER
J
SAFETY IN
RIGHT LEFT STEER SWASHPLATE SWASHPLATE OPEN MODE 1 ANGLE ANGLE
3000
PWR
C356
C407
3 1
1530
GRD
3 1 2 4
C355
SEE CAB CONNECTOR
TO OPTIONS (BACKUP ALARM SWITCH)
3070
2570
3080
3 1 2 4
C351 C352 C354 C353
A B
7100
2510
3 1 2 4
3020
C459
6600
1530
1540
C460
G C
2570
3000
4 3 1 2 4
2580
C429
6500
3080
3 1 2 4
C428
6400
C404
6310
E
DRIVE CONTROLLER
3020
3 1 2
C449
HR HR HR HR
1540
C454
6736808 2580 1 5 1 3 3 0 9 1 7 1 4 2 9 3 3 3 4 4 0 4 9 2 3 2 4 8
C450
2600 6200
1700
30A
NOT USED FOR THIS MODEL
F J H E
GLOW PLUGS 1.0 ohm each
K
TRACTION
4810
A B
NOT USED FOR THIS MODEL
C453
C101
Dealer Copy -- Not for Resale
1480
Brake Valve
G
FUSE 5
G K A
4820
1400
A
FUSE 6
E C D
36 26
8200
D
TO OPTIONS (ACCESSORY CONNECTOR)
H J
C350
C113 C109
4920
C360
C107
-
C103
4930
C500
C112 C111
2530
4920
2900
J2
C425
ACS
4940 4930
9100
9340
6732781
8100
SEE FUSE/RELAY CENTER
4500
C409
-
C104
40 30 20
41 4
4200
6410
25A
8 48 17
7200
6510
9700
9600
9500
9800
1110
1120
1130
FUSE 12
33 28 13
22
4150
2100
25A
10
4110
8110
8150
8800
25A
9200
8500
ALT & KITS
38
44 14 24 34 16
8800
8580
FUSE 11
1900
46 5 15 44 4
8560
25A
20 32 40
30
8210
8250
8510
2800
8550
8100
C A B
8570
F B H A
1200
24
4910
C A B
8590
ATTCHMNT
50
12
36 9
6210
8800
6320
A B
8000
B A
2800
A B
4730
FUSE 9
49 3520
19
14
9 43
ENG OIL RESERVED PRESS SIGNAL (FAN OUTPUT)
48 7200
A
C407
C410
C110
C105 C108
+
C110
39
42
HORN
47 3420
2770 2750 2760
9350
J1 6736515
HOLD PULL
UNSWITCHED
HYD CHARGE PRESS SIGNAL
46
9800
TO OPTIONS (ACCESSORY CONNECTOR)
FUSE 10
40 8110
3910
3900
19 29
FUEL SHUTOFF
B A
BATTERY CABLE
39 6320
LEFT
38 2100
RIGHT
37 3500
SPARE OUTPUT 2
45
GROUND
36 8550
FRONT WORKLIGHTS
44
8210 FUEL PULL RELAY
2910
ATTACHMENT KEY INPUT
4450 MARKER LT RELAY
GROUND
25
43
30
1120
LEFT PANEL
42 8000
+5V SUPPLY
ENG OIL PRESS +8v
C434
41 1400
4470
29
C435
34 9700
28
9340
35
33 1130
27
20 8800 STARTER RELAY
1210
J1
OPEN
32 8150
SWITCH PWR / RESERVED ACC RELAY (CAN SHIELD)
26
GLOW PLUG FEEDBACK
19 6210 DIVERTER
1910
4730
CAN SELECT
18
RESERVED UNSWITCHED (SENSOR GRND) BATTERY (2)
G D
9600
FUEL RELAY HOLD
HEADLIGHTS
3010 UNSWITCHED BATTERY (3)
REAR WKLT RELAY
HIGH FLOW / 900 LOAD
4460
50
3300
2900
2740
H
3920
25 34
OPEN
49
9110
4150 FUEL PULL FEEDBACK
10 4110
17
40
OPEN
48
PROTECTED POWER
25
9 8510
9210
24
J1 P01
8 6410
4200
HYDRAULIC TEMP
COMPUTER POWER
23
16
47
9300
F&R AUX RELIEF
46 4500
SYSTEM Tx
6510
TRAVEL CONTROL
OPEN
45 3920
SEATBAR SIGNAL
9310
15 3400
CAN LOW
BRAKE SW IN
44 9340
HEADLIGHT SWITCH
35 45
RH SKI UP
4940
2110
43
E F H K
14 9500
4840
4640
FLOAT
SYSTEM Rx
13 1110
TRACTION LOCK HOLD
3910
B
2910 2920 2930
6100
1800
RIGHT BLINKER
12
22
HANDLE POWER
HYD CHARGE PRESS +8V
9350
42
A
A
B R P S F E D C M A J H 2900
A
SEE J2-8
CAN HIGH
7
8250
21
A
UNSWITCHED BATTERY (1)
66
39
GLOW PLUG TRACTION LOCK RELAY PULL / 963
LEFT BLINKER
4390
OPEN
38 38
9410
A B
6100
3200
5
SPARE OUTPUT 1
GROUND
37
2900
A
B
4 4910
TRACTION LOCK SENSOR PULL FEEDBACK GROUNDS
SPARE DIGITAL 2
3510
3 3430
TWO SPEED OPEN MAKE-UP
OPEN
36
41
9330
37 49
RESERVED (BOOTSTRAP)
4320
LH SKI UP
35
4410
CLOCK/LATCH A DATA B J
C B
3520
TWO SPEED SWITCH
STATUS OUT
3100
SEATBAR GROUND
34
4830
START
3900
KEY/ENTER SWITCH
33
N K G L
9340
1900
OPEN
32 4420
6110
C408
See C492 G
9410
9340
9400
BUCKET POSITION
9320
4930
4430
OPEN
C
30
4340
BUZZER
RH SKI DOWN
29
N K G L B R P S F E D C M A J
E
9200
PWM SIGNAL
28
4820
J2 P05
9200
4920
FUEL SENDER
27
25
9100
3500
0.3 ohm
8200
4310
OPEN
26
9200 SEAT BAR +8v
24
9320
STARTER FEEDBACK
TWO SPEED SOLENOID OPEN
3210
8250
3700
LH SKI DOWN
1200 COMPUTER POWER
23
BUZZER
3500 3520
1800 EXCITATION
R S
4440
D F
9100
B
STARTER
M
9110
9110 9210 9400
4500
C
B
A
10.9 ohm
B
18
AIR FILTER SIGNAL
2740
A C
2010
1010
17
STATUS IN
B
A
2750
4500
2
A B
SPARE DIGITAL 1
16
1900
B
ALTERNATOR
LH AUX LEFT
15
11 7 23 42
2740
1
HYD FILTER SIGNAL
20
SYSTEM Rx
14
22
2770
OPEN
RH FRONT DETENT
19
PROTECTED POWER
13
REAR ROD
1930 BRAKE SWITCH
3430
RESERVED (AC INPUT)
PWM -
SPARE ANALOG 2
12
21
9330
3440
10 3600
FRONT BASE
2930
B A
9 4300
REAR BASE
HYD LOCK SOLENOID
3
8 3200
3100
28
ENG SPEED SIGNAL
PWM +8V SUPPLY
7 9210
11
31
3430
COOLANT TEMP SIGNAL
6 4810
R HAND SERIAL IN
3440
6
L HAND SERIAL IN
START
3010
LH AUX RIGHT
5 9100
1900
3410
SYSTEM Tx
4 2900
1200
4
15 47 23
COMPUTER GROUND
3 4330
1200
3420
FRONT ROD
B
6120
48 8 18
38
9350
3400
E3
A B
2
2760
+8
3900
3 5
D3
G
SPARE ANALOG 1
1
-
3920
4
A B
SPOOL LOCK
FUEL SENDER 30-270 ohm
B A
9350
3410
J
31 31
180 0
B A
3900
B
H SEE J2-48
3310
4350
SUPPLY 1020
B
3110
AIR FILTER SWITCH
3920
5
B
3200
3710
SEAT BAR
A
3
3420
3300
ENGINE HARNESS 7101311 A B
B
A B
C
3400
1 2
11
A B
A
3910
A C
ENGINE OIL PRESSURE SENDER 0.5-7.5 V
t
SEE C110
B
1 2
3310
RESERVED (hall)
ENGINE COOLANT SENDER 500-3000 ohm
J
3910
B A
3200
3300
6 HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH
SEE C110
MAIN FRAME
SEE C113
3700
A B
2110
A B
10
32 12 22 1 41 3 21
4360
B HYDRAULIC OIL FILTER (DIFFERENTIAL) SWITCH
3300
B
3600
B
4410
A C
4340
A C
4360
HYDRAULIC CHARGE PRESSURE SENDER 0.5 - 7.5 V
SPEED SENSOR
J2 J2
HARNESS 7112800 A B
4330
B
4430
B
9.8 ohm 12V
4440
2480
A
2350
2200 HYDRAULIC TEMPERATURE SENDER 500-3000 ohm
A B
3700
J1
29 26
18
2710
2000 2240
B
3310
4420
A
4470
4450
4460
4480
9310
H
11 ohm 12V
J B
A B
J1
2120
2720
2370
A
3610
3100
2730
2390
3600
REAR AUX RELIEF
2740
2380
A B
2490
A
2100
2410
7.5 ohm 12V
3.3 ohm PWM
FRONT AUX RELIEF 4490 GREEN TIE STRAP
2110
2420
A B
1 2
CAB
2520
2450
DATA
2600
A B
4450 YELLOW TIE STRAP
9300
2330
2300
1 2
2340
C405 C406
3510
FRONT BASE 4340
2000
2800
2340
3.3 ohm PWM
CAB 6727178
2450
3610
1 2
C419 C106
2460
2400
1 2
9220
2330
9120
4330
2420
1920
4420
9.8 ohm 12V
1220
A B
A B
9350
A B
9.8 ohm 12V
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
UNSWITCHED POWER 1000-1999 RED FUSED, UNSWITCHED POWER 1000-1999 RED/WHT SWITCHED POWER 1000-1999 RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
A B
FRONT ROD
2920
BUCKET POSITIONING
C418
B A
DIVERTER
GROUNDS
2430
BICS HYDRAULIC LOCK
4410
SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
2470
2440
2
2410
ARE CONNECTED IN SERIES 2530
2380
WHITE TIE STRAP
A K H F
2440
E D G C
4440
2
OPEN
1
1
2370
C420
2
C423
A B
C414
REAR BASE
1
7.5 ohm 12V
WIRES CONNECT BY LETTER ACROSS CONNECTORS
4380
1 2
4370
LIFT SPOOL LOCK (Not Use For This Model )
BROWN TIE STRAP
RIGHT PANEL
2430
CLOCK/LATCH
4430
2
SYSTEM Tx
1
GROUND
2
SYSTEM Rx
1
7.5 ohm 12V
BLUE TIE STRAP
C421
2460
C422
4460
B
C413
C415
S150 (S/N 526815215 AND ABOVE) (S/N 526918501 AND ABOVE) S160 (S/N 526615270 AND ABOVE) (S/N 526716664 AND ABOVE) (PRINTED JULY 2005) RELAY GROUNDS 2000-2060 V-0714
A
COMPUTER POWER
TILT SPOOL LOCK (NOT Used For This Model)
REAR ROD
A B
RUN/ENTER SWITCH
HIGH FLOW 7.5 ohm 12V
PROTECTED POWER
Printable Version Click Here
WIRING SCHEMATIC (With SJC Option)
PWR
RED
BLK
GND SIG PWR
RED
BLK
WIRING SCHEMATIC AIR CONDITIONER SWITCH
TO ENGINE OR MAINFRAME
WHT
A B
BLK
C
POTENTIOMETER
1010 2200
BLOWER SWITCH
3 2 1 4 5 6
WHT
10 8
BLK
7
RED
C B E F
POWER RELAY 86
85
1740
87
30
87A
A B C
1190
C426 D F C E A B G
9800
2740
TO HORN CONNECTOR
1730
C703
B OUTPUT
1140 1740
J OUTPUT
HVAC/ACCESSORY HARNESS - 6725390
K OUTPUT
C704
J3 - 10-PIN GRAY
ID #2 ID #3
ID #0
M
OPEN OPEN
2765 or BRN
7100
C
C608
A B
V M
C667
RED BLK
B C A
2755
7160 7210
B C A
WIPER HARNESS - 6729739
DOME LIGHT
C B A
41 40
C B A
6430 6730 2660
2300
7030
A B
40 42
2630
A B
HARNESS 6713994
TO ATTACHMENT
40
B J N
42
C B A
2640
M A D C E F G H L K
A B
BRN BLK DBL RED YEL
S LT TM CENTER GD RT
6430 6730 2660
TO STROBE/BEACON
A B
2785
2780 6440 6540
2775
E A C D F B
1730
EXTERIOR CAB HARNESS 6718872
ID #0 OPEN OPEN OPEN OPEN OPEN
TO ENGINE OR MAINFRAME
A B C D E F
RIGHT WORK
C103
C605
D E F
2620
A B C D E F
A B C D E F
6430
6720 6620
OPEN 6320
2640
OPEN 6330
6830 6630 2630 OPEN 6330
1720 2720
FRONT HORN HARNESS 6727498
30
TO OPTIONS (EXTERIOR CAB)
1 2 3
6540
86
87A
85
30
A B
4 WAY FLASHER HARNESS - 6718873
87
86
87A
85
87
30
86
87A
85
30
87
86
85
A B
B A
A B
Left Marker Fuse 10A
Right Marker Fuse 10A
1010
HARNESS 6726430
7 pin Octal ACD/Remote Start connector Left Side engine compartment KEY "RUN" UNSW POWER
CAN LOW CAN HIGH GROUND
Connector on Loader Boom
D 2 C 1 B A 3
A B
To Starter "B" Terminal
C490
A B
TO HANDLE CONNECT0R
7200
2660
2730
SW POWER 2730
87
2650
2670
CAN SHIELD ALARM HORN
87A
2640 2610
SSL 7-PIN CAN CONNECTOR
D F C E A
9800 1160 9700 1710 9600 9500 2700 7-PIN
Signal Fuse 10A
ROAD LIGHTS
B G
ATTACHMENT C426 C666 CONNECTOR CONTROL HARNESS - 6718426
To Mainframe Harness
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
WIRES CONNECT BY LETTER ACROSS CONNECTORS A B A B SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
BATTERY FEED 1000-1999 RED, RED/WHT, RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
V-0394 (7-11-05)
596 of 949
OPEN
A B C D E F 2550
A B C D E F G H
6610
A B C
OPEN
B A
6710
A B
HARNESS 6731239
TO MAINFRAME (ACCESSORY CONNECTOR)
C668 OR C670
C669 EVAPORATOR (AC) PRESSURE SWITCH
2 1 3
D E F
To Engine Ground
C402
7010
7020
B A
OPEN 2630
6440
2740
TO OPTIONS
AIR CONDITIONER HARNESS - 6726888
6520
RIGHT FLASHER LIGHT
RNG
1740
C632
A B C
2630
RNG
2 1
6700
ACD Input Connector to Engine Compartment
ID #4
HARNESS 6731239
C609 2 1
C D E F G H K
STOP LIGHT
ACCESSORY
2620
LEFT FLASHER LIGHT
ADDITIONAL POWER CONNECTOR
TO OPTIONS (4 WAY FLASHER)
A B C
TO OLDER MODEL ATTACHMENTS WHT
STROBE OR BEACON
DIODE
B A
OPEN 6330
C B A
HARNESS 6713994
C412
AIR CONDITIONER CLUTCH SOLENOID
B A
C612
C631
2310
OPEN
HARNESS 6713993
2785
B A
J3 - 10-PIN GRAY
6510
2 2 1 1
4720
46
GRADER HARNESS 6707303
TO OPTIONS (HVAC)
B A
K OUTPUT
C704
REGISTRATION
LEFT WORK
P
7310 2735
J OUTPUT
6230
7180
40
C B E A D F
B OUTPUT
J ID #1 A ID #2 B ID #3
5900
DELUXE ATTACHMENT CONTROL HARNESS 6732730
C604 A B C D E F
41
TO OPTIONS (DELUXE ACCESSORY)
DOME LIGHT SWITCH
TO OPTIONS
2 1
A B C D E F DOOR SENSOR
HARNESS 6713993 FRONT WIPER MOTOR
TO MAINFRAME
BACKUP ALARM
A OUTPUT
2640
6330
D OUTPUT
6310
2640
2 1
B C A
46
L X
14-PIN ATTACHMENT CONNECTOR
1370
C F G E A D H B
BACK-UP ALARM HARNESS - 6715659
C622
5450
5500
6350
2650
E D G
5510
C OUTPUT
6240
7190 4710
B C A
6800
6310
5000
ACD Output Connector to Engine Compartment
H OUTPUT
RIGHT TAILLIGHT
1020
LEFT TAILLIGHT
6210
5200
5910
G OUTPUT
BACK-UP ALARM
H A
6320
5250
5200
2510
7160
7210
C623
2610
5250
6250
2755
7150
RNG
C506
2630
RIGHT TAILLIGHT
2600 6200
5150
2520
2735
RNG/DGN
FRONT WIPER BOTTLE AND TANK
C610
LEFT WORKLIGHT
6200 6210
F B
5150
F OUTPUT
TO ENGINE OR MAINFRAME
2745
2620
M
5300
7310
C610
C B E A F D
BACK-UP ALARM
REAR LIGHT HARNESS 6716419
5050
5300
1320
B A
5400
5050
J2 - 10-PIN BLACK
E OUTPUT
LEFT TAILLIGHT
WIPER HARNESS - 6730885
ADDITIONAL POWER CONNECTOR 1740
5400
C H J B G D F E A K
2745
TO OPTIONS (DELUXE ACCESSORY)
C491
POWER BOB-TACH HARNESS 6730770
5350
1020
B
2720
BACK-UP ALARM SWITCHES HARNESS 6718820 & 7107544
C506
5100
5350
6200
TO MAINFRAME 1730 A
1720
OPEN
V M
C402
7110
OPEN
Dealer Copy -- Not for Resale
BACK-UP ALARM SWITCHES POWER BOB-TACH SOLENOID
TO REAR AUX. DIVERTER SOLENOID
CAN HIGH
FRONT WIPER MOTOR
2790
B A
1 2
2450
CAN LOW
C703
5100
FRONT WIPER BOTTLE AND TANK
C103
B A
4455
4451
2450
ID #4
C667
TO MAINFRAME 7100
2
REV. B
C404
C606 C607
C601
B A
A B
1 2
2480
TO REAR AUX. RELIEF SOLENOID
REAR AUX. JUMPER HARNESS 7101973
ID #1
G OPEN H OPEN K OPEN
POWER BOB-TACH SOLENOID
A B
3675725 4450
1
SW POWER
BOOM-MOUNTED ACD CONNECTORS 2740
OPEN
J A B C D E F
5900
C B A
2740
2480
ID (K TO P)
4485
CAN SHIELD
1740
OPEN
5450
14-PIN ATTACHMENT CONNECTOR
C B A
2
4481
J1 - 8-PIN
GROUND
G OPEN
6400
5000
5510
A OUTPUT
4480
9510
13
6310
5910
D OUTPUT
TO MAIN FRAME HARNESS
1
9610
14
6370
5200
C OUTPUT
TO OPTIONS (DELUXE ACCESSORY)
BLK
1720
9
2650
5200
TO OPTIONS (HVAC)
2730
9
6340
5250
ID (K TO L)
H OUTPUT
6700
5150
5250
M OUTPUT
G OUTPUT
1740
5150
A OUTPUT
F OUTPUT
1020
5300
D OUTPUT
2720
5300
TO OPTIONS
RIGHT WORKLIGHT
G OUTPUT
1720
5050
L X
2770
F OUTPUT
E OUTPUT
C622
7010
E OUTPUT
2670
5400
DELUXE ATTACHMENT CONTROL HARNESS - 6729380
2760
GROUND
C OUTPUT
6240
5350
5400
5500
7000
SW POWER
1320
5350
5050
C H J B G D F E A K
2530
5100
J N K B E F G H C D A M L P
H OUTPUT
2540
5100
PUR
7-PIN
AWS HORN/BLINKER HARNESS - 6726662
OPEN
C506
A D C B E
6010
J2 - 10-PIN BLACK
PUR
9520
H F B E D C A
C666 ATTACHMENT CONNECTOR
1740 2740
2540
ID (K TO L) ID (K TO P)
1720
6640
M OUTPUT
30
87A
C497 6515
OPEN
A OUTPUT
6510
86
B A
2720
6810
D OUTPUT
85 87
2790
TO MAINFRAME
B C A
6410
C OUTPUT
OPEN
C417
H OUTPUT
OPEN
C418
F OUTPUT G OUTPUT
TO AWS CONTROLS
RIGHT BLINKER RELAY
C669
E OUTPUT
6510
C642
GROUND
6000
A
BOOM-MOUNTED ACD CONNECTORS
K B E F G H C D A M L P
SW POWER
B
OPEN
RNG
9620
6360
J N
CAN HIGH
CAN LOW
1730
6210
9510
BLK
6020
9710
1370
9610
PUR
2730
1740
30
87A
B A
2740
6415
2720
PUR
2520
PUR
9520
6410
86
RED/WHT
9710
7100
9620
7-PIN ATTACHMENT CONNECTOR
6410
SW POWER
85 87
2780
2530
1720
E D C
CAN SHIELD
6600
RNG
GROUND
C705
PUR
1160
2660
1730
H F B E D C A G
GROUND
1730
9710
ADDITIONAL POWER CONNECTOR
2730
2720
PUR
CAN HIGH
2760
C490
2710
9600
9500
1710
9700
RED/WHT
9710
87A
LEFT BLINKER RELAY
CAN LOW
7200
To Mainframe Harness
9800
1320
C666
1160
J1 - 8-PIN
86 30
7200 or YEL
GROUND
PUR
7150 or DGN
CAN LOW CAN HIGH
C705
9800
2795
SW POWER
2750
C411
CAN SHIELD
CAN SHIELD SW POWER
85 87
2770
C636
UNSW POWER
1160
9800
D 2 C 1 B A 3
D F C E B A G
KEY "RUN" UNSW POWER
C412
B A
2750 HORN RELAY
KEY "RUN"
C431
TO OPTIONS (DELUXE ACCESSORY)
2210
To Mainframe Harness
TO OPTIONS (DELUXE ACCESSORY)
(TO "B" PIN)
M
BLK
C489 C401or C402
C426
C410
BLOWER MOTOR
YEL RED
RNG
HVAC HARNESS - 6725933
D F C E A B G
ADVANCED HAND CONTROL G SERIES FLOAT Rev. A HARNESS - 6727328
ADVANCED HAND CONTROL G SERIES JUMPER HARNESS - 6728742 Rev. A
M
(TO "D" PIN)
C433
C630
HEATER VALVE
A D
4640
2710
1200
+
9600
DELUXE EUROPEAN TAILLIGHT HARNESS - 6718198
3 2 1 4 5 6
5000
-
9700
L M
RIGHT TAILLIGHT
C B E F
2130
B
1000 RIGHT WORK
H
LEFT TAILLIGHT
2110
7200
BLK
6500
LEFT WORK
C
A D
1300
LGN
9500
6210
REGISTRATION LAMP
1110
3200
A C B
RNG
7100
F E D C B A
C
A B
A C B
2500
E F C A B D
2630
7000
C611
C605
2620
6340
6320
6610
2610
2640
6330
6620
F E D C B A
C604
2205
HERE OR TO OPTIONS (HVAC JUMPER) DBL
E F C A B D
2310
TO OPTIONS (AC)
HIGH
1160
2600
Printable Version Click Here
2100
MEDIUM
A B C
1710
6200
LOW
7010
C433
6500
A B
C617
6310
A B C
3100 OFF
C614
6400
F G E A D H B
C612
6600 BACK-UP ALARM
THERMOSTAT
C
C103
7100 2650
C613
OPTIONS S150 (S/N 526811001 AND ABOVE) (S/N 526911001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) (S/N 526711001 AND ABOVE) (PRINTED JULY 2005) V-0394
WIRING SCHEMATIC OPTIONS FLASHER 6668816-6665317
Printable Version Click Here WIRES CONNECT BY LETTER ACROSS CONNECTORS A B B A SOME CONNECTOR BODIES NOT SHOWN FOR DRAWING CLARITY
E D
6700
B F A C
6540 6440
6665316-6668815 HAZARD SWITCH 1130
TO LIGHT CONNECTOR TO OPTIONS (EXTERIOR CAB)
C670
3 1
2
1180
X
L
2
6010
1
3
7010
C B
6430
5
4
3 4 5
6
6
6530 2750
6676537 (AHC/AFC) ACS SWITCH 1
2755
2780
2 2745 2755
TO MAINFRAME
E
4550
3
R
4
D C K G B J
4235 4275
5 6
2730
S L M H N P F A
1700 6400 6500 BATTERY FEED 1000-1999 RED, RED/WHT, RNG GROUND 2000-2999 BLK MONITORING 3000-3999 LBL HYDRAULIC 4000-4999 LGN ATTACHMENT CONTROLS 5000-5999 YEL LIGHTS 6000-6999 PNK ACCESSORIES 7000-7999 WHT ENGINE 8000-8999 TAN COMMUNICATION 9000-9999 PUR
1150
STANDARD ACCESSORY HARNESS - 6727468 TO OPTIONS (HVAC OR HVAC/ACCESSORY) 1140 1740 2740 FLASHER
TO OPTIONS (POWER BOB-TACH)
2
2
1180
X
6010
HAZARD SWITCH 1 2
6700
B F A
6540
C
6300
6
6520
3
6430 5
7010
3
4
A C B
REAR WIPER SWITCH
7220
2
4
5
6530 2750
E
1710
1720
1
6
5
2725
2
4
2710 1110
TO LEFT HANDLE CONNECTOR
6510 6000
D A B C E
POWER PLUG
5
B A
1770
2 2755
TO MAINFRAME 4550
E R
4235 4275
D C K G B J L M H N P
3 4
5 6
2730 6400 6500 1150 6300 6600 TO EUR0. LIGHTS CONNECTOR
4730 1140 1700
4730 2715
3 4 5 7310 6
6
1190 2700 2790
TO OPTIONS (FRONT WIPER)
7210 ACS SWITCH 1
1
4710 1760 2735
C F A D E B
C488
6410
2 1
2
1730 1750
TO OPTIONS (DOME LIGHT)
6440
1 3 4
6
2780
TRAVEL CONTROL LOCKOUT SWITCH
FRONT WIPER SWITCH
3
6
C411
C670
E D
7000
2
3 4
5
1
C608
3 1
L
2770
V Dealer CopyD -- Not for M Resale 2760
6420
C667
5 1130
TO OPTIONS (EXTERIOR CAB)
POWER BOB-TACH SWITCH
1 6 4
C601
LIGHT SWITCH
BEACON SWITCH 2745
REAR WIPER MOTOR
B A C
C617 OR C642
RED = RED RNG = ORANGE BLK = BLACK LBL = LIGHT BLUE DBL = DARK BLUE LGN = LIGHT GREEN DGN = DARK GREEN YEL = YELLOW PNK = PINK WHT = WHITE BRN = BROWN TAN = TAN PUR = PURPLE GRY = GRAY
1 2
C488
V-0395
7000
E D A
2770 2760
BEACON SWITCH 6 5 4
(PRINTED JULY 2005)
TO OPTIONS (POWER BOB-TACH)
6676732-6674585 POWER BOB-TACH SWITCH
6557904
C601
S150 (S/N 526811001 AND ABOVE) (S/N 526911001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) (S/N 526711001 AND ABOVE)
F A S
DELUXE ACCESSORY HARNESS - 6727190 Printed in U.S.A. 597 of 949
V-0395 (7-12-05)
S150 WIRING SCHEMATIC
S160 WIRING SCHEMATIC
(WITHOUT ACS OPTION)
(WITHOUT ACS OPTION)
S/N 526811001 & ABOVE S/N 526911001 & ABOVE (PRINTED NOVEMBER 2003) V-0392
S/N 526611001 & ABOVE S/N 526711001 & ABOVE (PRINTED NOVEMBER 2003) V-0392
S150 WIRING SCHEMATIC
S160 WIRING SCHEMATIC
(WITH ACS OPTION)
(WITH ACS OPTION)
S/N 526811001 & ABOVE S/N 526911001 & ABOVE (PRINTED NOVEMBER 2003) V-0393
S/N 526611001 & ABOVE S/N 526711001 & ABOVE (PRINTED NOVEMBER 2003) V-0393
S150 WIRING SCHEMATIC
S160 WIRING SCHEMATIC
OPTIONS
OPTIONS
S/N 526811001 & ABOVE S/N 526911001 & ABOVE (PRINTED MAY 2004) V-0394
S/N 526611001 & ABOVE S/N 526711001 & ABOVE (PRINTED MAY 2004) V-0394
S150 WIRING SCHEMATIC
S160 WIRING SCHEMATIC
OPTIONS
OPTIONS
S/N 526811001 & ABOVE S/N 526911001 & ABOVE (PRINTED NOVEMBER 2003) V-0395
S/N 526611001 & ABOVE S/N 526711001 & ABOVE (PRINTED NOVEMBER 2003) V-0395
60-10-1 598 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
ELECTRICAL SYSTEM INFORMATION
Dealer Copy -- Not for Resale 60-10-2 599 of 949
S150, S160 Bobcat Loader Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
WARNING
Troubleshooting Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0807
PROBLEM
CAUSE 1, 2, 3, 4, 5 1, 2, 5 2, 3, 4, 6, 7, 8, 9
Dealer Copy -- Not for Resale
Battery will not take a charge. Alternator will not charge. Starter will not turn the engine.
KEY TO CORRECT THE CAUSE 1. Alternator belt is loose or damaged. 2. 3. 4. 5. 6. 7. 8. 9.
Battery connections are dirty or loose. Battery is damaged. The ground connection is not making a good contact. The alternator is damaged. The engine is locked. The starter is damaged. The wiring or solenoid is damaged. Check the fuses.
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S150, S160 Bobcat Loader Service Manual
Figure 60-10-3
ELECTRICAL SYSTEM INFORMATION (CONT’D) Description Figure 60-10-1
1 1 P-26323
Figure 60-10-2
The fuse panel cover (Item 1) [Figure 60-10-3] and [Figure 60-10-5] has a decal inside to show the location and amp ratings.
IMPORTANT Do Not use silicone base sprays and/or sealants on harness connectors or components. I-2123-0397
1 P-13848A
The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by a 100 amp master fuse (Item 1) [Figure 60-10-1] and [Figure 60-10-2] to protect against serious system overloads that could lead to burned up harness or loader damage. This fuse is located in the left-hand side engine compartment, just forward of the engine harness connector.
60-10-4 601 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
The electrical system is also protected by fuses and relays under the fuse panel cover (Item 1) [Figure 60-103] located in the cab on the control panel.
P-24651
The location and sizes are shown in [Figure 60-10-4] and [Figure 60-10-5].
ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse Location
REF
Figure 60-10-4
1
P-28846
Description
F1
Heater
F2
Front & Marker Lights
F3
Rear Lights
F4
Bobcat Controller
F5
Traction
F6
Fuel Shutoff
F7
Not Used
F8
Not Used
F9
Unswitched Attach.
F10
Switched Attach.
F11
Alternator & Kits
F12
ACS Power
Amp.
25 15 15 25 30 30 --25 25 25 25
F5
F1
F6
F2
F7
F3
F8
E
D
B
F9
Remove the cover to check or replace the relays. The location is shown in [Figure 60-10-4] and [Figure 60-10-5].
F10
F
G
H
J
F11
REF B C D E F G H J
F12
F4
Fuses
C
Relays
Fuses N-18465A
Figure 60-10-5
Description Switch Power Rear Lights Front & Marker Lights Not Used Glow Plugs Fuel Shutoff Traction Starter
1
P-28903
Remove the cover to check or replace the fuses (Item 1) [Figure 60-10-5].
60-10-5 602 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Relay Switch Location
Dealer Copy -- Not for Resale 60-10-6 603 of 949
S150, S160 Bobcat Loader Service Manual
Figure 60-20-2
BATTERY Removal And Installation
WARNING
1
AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.
N-18458
Disconnect the positive (+) battery cable (Item 1) [Figure 60-20-2]. Figure 60-20-3
Figure 60-20-1
2 1
P-3873
Remove the battery from the loader [Figure 60-20-3]. N-18456
Open the rear door. Disconnect the negative (-) battery cable (Item 1) [Figure 60-20-1]. Remove the battery hold down clamp (Item 2) [Figure 60-20-1].
60-20-1 604 of 949
S150, S160 Bobcat Loader Service Manual
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W-2065-0807
Servicing
BATTERY (CONT’D) Removal And Installation (Cont’d)
WARNING
Installation Figure 60-20-4
AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-0807 P9589
Dealer Copy -- Not for Resale
Figure 60-20-6 Figure 60-20-5
P9588 P9590
Always clean the terminals and cable ends when installing a new battery [Figure 60-20-4] and [Figure 6020-5].
The battery cables must be clean and the connections tight. Remove acid or corrosion from the battery and cables with a sodium bicarbonate (baking soda) and water solution [Figure 60-20-6].
When installing the battery in the loader, do not touch any metal parts with the battery terminal posts.
Clean the terminals and cable ends as shown in figure [Figure 60-20-4] and [Figure 60-20-5].
Connect and tighten the battery cables. Connect the negative (-) cable last to prevent sparks.
Check the electrolyte level in the battery. Add distilled water as needed.
Install the battery holddown clamp.
Put battery saver or grease on the battery terminals and cable ends to prevent corrosion.
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S150, S160 Bobcat Loader Service Manual
BATTERY (CONT’D)
Figure 60-20-7
Using A Booster Battery (Jump Starting) If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator's seat and one person to connect and disconnect the battery cables.
2
The key switch must be OFF (Standard Panel) OR the STOP Button must be pressed (Deluxe Panel). The booster battery must be 12 volt.
1 4 P-31861
WARNING 3
In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-0807
1
P-31860
Connect the end of the first cable (Item 1) to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 2) [Figure 60-20-7] to the positive terminal on the loader starter. Connect the end of the second cable (Item 3) to the negative (-) terminal of the booster battery. Connect the other end of the same cable (Item 4) [Figure 60-20-7] to the engine.
WARNING BATTERY GAS CAN EXPLODE AND CAUSE SERIOUS INJURY OR DEATH Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 16°C (60°F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.
Keep cables away from moving parts. Start the engine. (See REMOTE START TOOL KIT -MEL1563 on Page 10-60-1.) After the engine has started, remove the ground (-) cable (Item 4) [Figure 60-20-7] first. Remove the cable from the positive terminal (Item 2) [Figure 60-20-7].
W-2066-0910
60-20-3 606 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
BATTERY (CONT’D) Using A Booster Battery (Jump Starting) (Cont’d)
IMPORTANT Damage to the alternator can occur if: • Engine is operated with battery cables disconnected. • Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.) • Extra battery cables (booster cables) are connected wrong.
Dealer Copy -- Not for Resale
I-2023-1285
60-20-4 607 of 949
S150, S160 Bobcat Loader Service Manual
ALTERNATOR
Alternator Identification
Adjusting The Alternator Belt
Figure 60-30-2
Figure 60-30-1 2
2 P-24416
1
4 1 3
P-24417
1 P-24543
Figure 60-30-3 Stop the engine. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Loosen the alternator mounting bolt (Item 1) [Figure 6030-1].
3
Loosen the adjustment bolt (Item 2) [Figure 60-30-1] Move the alternator until the belt has 5/16 in. (8,0 mm) movement at the middle of the belt span with 15 lb. (66 N•m) of force.
1
1
1 2
Tighten the adjustment bolt and mounting bolt. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
P-24542
The black cover has been removed to show alternator rectifier / regulator assembly. The alternator contains field coil diodes (low current) (Item 1) [Figure 60-30-2], grounded heat sink (Item 2) [Figure 60-30-2] and [Figure 60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] and [Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] and [Figure 60-30-3], and four pair of large power diodes (Item 1) [Figure 60-30-3] on the underside of the rectifier. NOTE: The rectifier / regulator assembly has been removed from the alternator and flipped over for component identification [Figure 60-30-3].
60-30-1 608 of 949
S150, S160 Bobcat Loader Service Manual
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4
ALTERNATOR (CONT’D)
If the charging system malfunctions check the following:
Charging System Check
Check the condition and tension of the alternator belt. (See Adjusting The Alternator Belt on Page 60-30-1.) If belt is worn or deteriorated replace.
WARNING
Inspect the alternator wiring harness and connectors at alternator. Harness and connectors must be clean and tight.
In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention. W-2065-0807
WARNING
Check the fuse for the alternator in the fuse panel. If fuse is burned, find the cause and repair / replace. If fuse is in doubt, remove it and check for continuity. Check the electrolyte level in the battery. Add distilled water as needed. (Does not apply to maintenance free batteries.) Verify the charge of the battery. Make sure battery is fully charged. Disconnect the battery cables (negative first, then positive). Inspect the cable clamps and battery posts for corrosion. Remove acid or corrosion from the battery and cables with a sodium bicarbonate and water solution. Put grease on the cable ends and battery terminals to prevent corrosion. Reconnect the cable to the positive terminal.
BATTERY GAS CAN EXPLODE AND CAUSE SERIOUS INJURY OR DEATH Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 16°C (60°F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. W-2066-0910
IMPORTANT Damage to the alternator can occur if: • Engine is operated with battery cables disconnected. • Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.) • Extra battery cables (booster cables) are connected wrong. I-2023-1285
60-30-2 609 of 949
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AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
ALTERNATOR (CONT’D)
Low Voltage Test
Alternator Voltage Test
Figure 60-30-5
Figure 60-30-4 1
P-24547 P-34676
Turn engine OFF and remove the L & S terminal connector (Item 1) [Figure 60-30-5] off the alternator. Turn the remote start tool key to the ON position. Connect the remote start tool to the loader. (See REMOTE START TOOL KIT -MEL1563 on Page 10-601.)
Figure 60-30-6
Turn the engine on with the remote start tool and run at idle. With a voltmeter, check the voltage between the B+ terminal and ground at the starter [Figure 60-30-4]. 2 1
The voltage must be higher than 13.5 volts but lower than 14.7 volts at 70°F (Alternator Temperature).
P-24566 P-24566
If the voltage is higher that 14.7 volts, proceed to the following high voltage test. 2
If the voltage is lower than 13.5 volts, run the engine at high idle and recheck voltage. If voltage is still below 13.5 volts, proceed with the following low voltage test.
P-34677
Check the voltage across the “L” terminal (Item 1) and ground (Item 2) [Figure 60-30-6]. The voltage should be what the battery voltage is. If not, check wire harness, relay and fuses. If the wire harness, relay and fuses are ok then remove alternator for replacement or repair. To repair, (See Rectifier Continuity (Diode) Test on Page 6030-6.) for further component testing.
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S150, S160 Bobcat Loader Service Manual
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Open the rear door.
Removal And Installation
ALTERNATOR (CONT’D)
Place jackstands under the rear corners of the loader.
High Voltage Test Figure 60-30-7
DANGER
1
P-24568
2 P-90328
P-34679
P-34678
• Turn engine OFF and remove the L & S Terminal connector (Item 1) [Figure 60-30-5] off the alternator.
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged. D-1009-0409
Check the continuity between the “S” terminal (Item 1) [Figure 60-30-7] and the positive (+) terminal on the battery or starter terminal (Item 2)[Figure 60-307]. There should be continuity. If no continuity, replace wire harness. If voltage is still above 14.7 volts at 70°F (Alternator Temperature), then remove alternator for replacement or repair. To repair, (See Rectifier Continuity (Diode) Test on Page 60-30-6.) for further component testing.
60-30-4 611 of 949
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•
Disconnect the red wire (Item 1) [Figure 60-30-8] from the alternator which comes from the battery.
ALTERNATOR (CONT’D) Removal And Installation (Cont’d)
Disconnect the wiring harness connector (Item 2) [Figure 60-30-8] from the alternator.
WARNING
Figure 60-30-9
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
1
W-2059-0598
2
IMPORTANT
3
I-2023-1285
P-24543
Remove the adjustment bolt (Item 1) [Figure 60-30-9] from the mounting bracket. Remove the alternator belt (Item 2) [Figure 60-30-9] from the alternator pulley. Remove the mounting bolt (Item 3) [Figure 60-30-9].
Figure 60-30-8
2
1
P-24547
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the negative (-) cable from the battery.
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Dealer Copy -- Not for Resale
Damage to the alternator can occur if: • Engine is operated with battery cables disconnected. • Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.) • Extra battery cables (booster cables) are connected wrong.
Figure 60-30-12
ALTERNATOR (CONT’D) Rectifier Continuity (Diode) Test
1
Figure 60-30-10
1
3 2 1
1 P-24527
Touch the probes to the terminals (Item 1) [Figure 60-3012] of each diode and read the meter.
P-24416
Remove the two screws (Item 1), nut / washer (Item 2) and the plastic cover (Item 3) [Figure 60-30-10] from the alternator. NOTE: In the diode tests there should be continuity in one direction only. Meter readings should be different when probes are reversed. If the diode being tested shows no continuity or continuity in both directions, replace the rectifier assembly.
Reverse the probes to check the diode in the other direction. Meter readings should be different when probes are reversed. Figure 60-30-13
Figure 60-30-11
1 1
P-24558
Touch one probe to the diode (Item 1) [Figure 60-30-13] and the other probe to each heat sink and read the meter. Reverse the probes to check the diode in the other direction.
P-24532
NOTE: Use the diode function (Item 1) [Figure 60-3011] on the multimeter.
Meter readings should be different when probes are reversed.
60-30-6 613 of 949
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1
ALTERNATOR (CONT’D)
Disassembly
Alternator Regulator Test
Figure 60-30-16 1.Alternator 2.Nut 3.Pulley 4.Spacer 5.Bolt 6.Bracket 7.Bolt 8.Bearing 9.Retainer 10.Rotor
11. 12. 13. 14. 15. 16. 17. 18. 19.
Bearing Stator Bracket Sleeve Regulator Rectifier Cover Spacer 3 Nut
7 6
2 2
1
1
4 7 12 10
8
P-24533
13 14 5
11
9
1819
Touch one probe to the “L” terminal (Item 1) and the other probe to the ground (Item 2) [Figure 60-30-14].
17
Figure 60-30-15 15
16 C-3529
Disassemble the alternator. (See Parts Identification Figure [Figure 60-30-16].) Remove the regulator cover. Remove the four bolts holding halves together. Pry the halves apart (use a press if needed). Use a soft jaw vise to hold rotor while removing pulley nut.
P-24535
Reverse the probes to check in the other direction [Figure 60-30-15]. There should be continuity in one direction only. Meter readings should be different when probes are reversed. If there is no continuity or continuity in both directions, replace regulator.
Remove front case half from the rotor using a plastic hammer or press. Unsolder the stator leads from the rectifier. Remove the stator. Unsolder the two leads between the rectifier and regulator. Remove the regulator from rectifier.
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Figure 60-30-14
ALTERNATOR (CONT’D)
Rotor Continuity Test
Stator Continuity Test
Figure 60-30-19
Figure 60-30-17
P-24524 P-24537
Touch the probes to the slip rings [Figure 60-30-19]. The ohmmeter should read between 3.0 - 4.0 ohm.
Touch the probes to two of the bare stator wires [Figure 60-30-17].
If there is no continuity, replace the rotor.
Move one of the probes to the third wire.
Rotor Ground Test
The readings should be the same.
Figure 60-30-20
Dealer Copy -- Not for Resale
Use an ohmmeter to test the stator.
If there is no continuity, replace the stator. Stator Ground Test Figure 60-30-18
P-24525
Touch one probe to one of the slip rings and the other probe to the rotor shaft [Figure 60-30-20]. There should be no continuity.
P-24538
Replace the rotor if there is continuity. Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [Figure 6030-18]. There should be no continuity. Replace the stator if there is continuity.
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ALTERNATOR (CONT’D) Assembly Figure 60-30-21
1 P-24557
Dealer Copy -- Not for Resale
Reverse the order of disassembly. Do not assemble the rear case half. Place the rotor in soft jaws when tightening the shaft nut (Item 1) [Figure 60-30-21]. Tighten to 72 + 14.5 ft.-lb. (98 + 20 N•m) torque. Install the rear case half and the remaining parts.
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Figure 60-40-3
STARTER Checking Figure 60-40-1
2 1
Bat S M
Cranking Motor P-34673
Disconnect the negative cable from the battery. (See Removal And Installation on Page 60-20-1.)
A-1992
The battery must be at full charge. The cable connections on the battery must be clean and tight. Connect a jumper wire between S terminal and BAT terminal [Figure 60-40-1].
Hold-In Test: Use circuit tester, touch one probe to the S terminal (Item 1) and one probe to the mounting bolt (Item 2) [Figure 60-40-3] on the magnetic switch (solenoid). If there is no continuity replace the magnetic switch (solenoid). Figure 60-40-4
If the starter turns but does not turn the engine, the starter drive has a defect.
2
Figure 60-40-2
1 P-34675
1
Bat S M
2 Cranking Motor
P-34674
Disconnect the negative cable from the battery. (See Removal And Installation on Page 60-20-1.) A-1991
Disconnect the S terminal on the starter (Item 1) [Figure 60-40-4]. Connect a jumper wire (of at least 4 gauge in size) between the M terminal and the BAT terminal [Figure 6040-2]. If the starter turns, the defect is in the solenoid.
Pull-In Test: Use circuit tester, touch one probe to the S terminal (Item 1) and one probe to the starter motor terminal (Item 2) [Figure 60-40-4]. If there is no continuity replace the magnetic switch (solenoid).
If the starter does not turn, the starter is defective. 60-40-1 618 of 949
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Disconnect the S terminal on the starter (Item 1) [Figure 60-40-3].
The key switch must be in the OFF position.
STARTER (CONT’D) Removal And Installation Figure 60-40-5
4 2 5
3 1 P-34385
Dealer Copy -- Not for Resale
Stop the engine and open the rear door. Remove the negative (-) and positive (+) cables from the battery. Disconnect the ground wire (Item 1) [Figure 60-40-5] from the starter. Disconnect the engine harness power wire and positive (+) battery cable from the starter solenoid terminal (Item 2) [Figure 60-40-5]. Installation: Tighten the nut to 10.8 - 12.3 ft.-lb. (14,7 16,7 N•m) torque. Disconnect the tan wire (Item 3) [Figure 60-40-5] from the R terminal on the starter solenoid. Disconnect the brown wire (Item 4) [Figure 60-40-5] from the S terminal on the starter solenoid. Remove the mounting bolts (Item 5) [Figure 60-40-5] from the starter. Remove the starter from the engine. Installation: Tighten the three mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Reverse the removal procedure to install the starter.
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STARTER (CONT'D) Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
30
Starter Shaft Gear Washer Shaft Stop Ring Lever Holder Spring Spring Plate Seal
33
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
34 13
36 8* 10*
9*
11*
Lever Gear Bracket Spring Gear Stop Stop Ring Ball Armature Washer Seal Yoke
31 21
7*
32
15 12 20
16 19 18
Dealer Copy -- Not for Resale
37
14 17 5
8
14
6 1
29
4 3 28 2 27
35
22 23
25 23
24
* Not serviceable parts
Holder Bracket Ring Bolt Bolt Switch Seal Bolt Washer Nut Boot Bracket Bearing B-16488
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26
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
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Figure 60-40-8
STARTER (CONT'D) Disassembly And Assembly Figure 60-40-6
2 1
1 1
2
P-34596
Remove the bolts (Item 1) from the brush cover (Item 2) [Figure 60-40-8].
P-34594
Figure 60-40-9
Remove the bolts (Item 2) [Figure 60-40-6]. 2
Installation: Tighten the bolts to 63 - 129 in.-lb. (7,1 14,6 N•m) torque. Figure 60-40-7
1 1
2
4 3
3 N-00980
Using a needle nose pliers, pull the brush springs (Item 1) back and remove the brushes (Item 2) [Figure 60-409]. P-34595
Remove the armature, yoke, brush holder and rear bracket assemblies (Item 1) from the front assembly (Item 2) [Figure 60-40-7].
NOTE: The brushes are non-replaceable. If the brushes are worn order a new brush holder (for the negative brushes) and yolk (for the positive brushes). Remove the brush holder (Item 3) [Figure 60-40-9] from the end of the armature.
NOTE: When separating the parts there will be a steel ball (Item 3) located at the end of the armature shaft (Item 4) [Figure 60-40-7]. Installation: Apply grease to the steel ball (Item 3) and install into the end of the armature shaft (Item 4) [Figure 60-40-7]. 60-40-4 621 of 949
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Remove the cover (Item 2) [Figure 60-40-8]. Remove the cable (Item 1) [Figure 60-40-6] from the magnetic switch.
Figure 60-40-12
STARTER (CONT'D) Disassembly And Assembly (Cont'd)
1
Figure 60-40-10
2
3
1
2
P-34600
Inspect the magnetic switch (Item 1), the spring (Item 2),and the plunger (Item 3) [Figure 60-40-12] for wear and replace as needed.
Remove the armature (Item 1) [Figure 60-40-10] from the frame.
Figure 60-40-13
Dealer Copy -- Not for Resale
P-34598
Remove the bearing (Item 2) [Figure 60-40-10] from the end of the armature. Figure 60-40-11
3
2
1 1 P-34601
Remove the center bracket (Item 1) [Figure 60-40-13]
P-34599
Remove the bolts (Item 1) [Figure 60-40-11] from the magnetic switch. Installation: Tighten bolts to 34 - 69 in.-lb. (3,8 - 7,8 N•m) torque. Remove the front assembly (Item 2) from the magnetic switch (Item 3) [Figure 60-40-11].
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Figure 60-40-16
STARTER (CONT'D) Disassembly And Assembly (Cont'd) Figure 60-40-14
1 3
2 2
2
4
P-34604
P-34602
Remove the retainer (Item 2) [Figure 60-40-15] and [Figure 60-40-16] and pinion (Item 1) [Figure 60-40-15] and [Figure 60-40-16].
Remove the rubber retainer (Item 1) [Figure 60-40-14]. Remove the planetary gears (Item 2) [Figure 60-40-14] and inspect for damage. Figure 60-40-15
Remove the spring (Item 4) [Figure 60-40-16]. Installation: Inspect all parts for wear and replace as needed.
3
2 1
P-34603
Press down on the pinion (Item 1) [Figure 60-40-15] and [Figure 60-40-16] and retainer (Item 2) [Figure 60-4015] and [Figure 60-40-16].
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Remove the snap ring (Item 3) [Figure 60-40-15] and [Figure 60-40-16]
1
Figure 60-40-19
STARTER (CONT'D) Inspection And Repair Figure 60-40-17
N-00997
Inspect the brush cover for discoloration, indication the starter has been overheated.
Armature Winding Continuity Test: Use a circuit tester, touch the probes to two commutator segments [Figure 60-40-19]. There should be continuity at any point. If there is no continuity, the winding is open-circuited, replace the armature.
Dealer Copy -- Not for Resale
B-14455
Figure 60-40-20 Inspect the pinion teeth for wear and damage. Armature Short-Circuit Test: Use a growler tester, put the armature on the growler and hold a hack saw blade against the armature core while slowly rotating the armature [Figure 60-40-17]. A short circuited armature causes the blade to vibrate and be attracted to the core. An armature which is short-circuited must be replaced. Figure 60-40-18
B-14458
Commutator Run-Out Test: check the commutator runout as shown in [Figure 60-40-20]. Service Limit - 0.003 in. (0,07 mm) If the commutator exceeds the service limit, repair as needed. N-00996
Armature Winding Ground Test: Use a circuit tester, touch one probe to a commutator segment and the other probe to the armature core [Figure 60-40-18]. There should be no continuity. If there is continuity, the armature is grounded and must be replaced.
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Figure 60-40-22
STARTER (CONT'D) Inspection And Repair (Cont'd) Figure 60-40-21
1
N-00999
Check the field windings for wear and damage. B-14460
Measure the segment mica depth (Item 1) [Figure 60-4021]. Service Limit - 0.012 in. (0,3 mm) If it is worn, replace the armature. Check the commutator surface for burned spots which usually indicates an open-circuit, and correct it using #400 sand paper.
Field Winding Ground Test: Use a circuit tester, touch one probe to the field winding end of the brush and the other probe to the surface of the frame [Figure 60-4022]. There should be no continuity. If there is continuity, the field windings are grounded. Replace the frame. Figure 60-40-23
N-15005
Field Windings Continuity Test: Use a circuit tester, touch one probe to the wire and the other probe to the brush [Figure 60-40-23]. There should be continuity. If there is no continuity, the field windings are open-circuited. Replace the frame.
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Check all the connections for clean and tight solder joints.
STARTER (CONT'D)
No Load Test
Inspection And Repair (Cont'd)
Figure 60-40-25 Ammeter
Figure 60-40-24
S M.T.
Starter
B-14440
N-15006
The following test should be done after reassembling the starter: Replace the brush holder and yoke if the brushes need replacement. Check brush spring, for damage or rust. Replace as needed. Brush Holder Insulation Test: Use a circuit tester, touch one probe to the positive brush holder plate and the other probe to the holder plate [Figure 60-40-24]. There should be no continuity. If there is continuity, replace or repair.
Clamp the starter in a vise. Using a 12 volt battery and ammeter, connect the positive wire of the battery, and the ammeter to the terminal [Figure 60-40-25]. Connect the negative wire to the starter body. Using a jumper wire, connect the S terminal to the main terminal. The starter should show smooth and steady rotation immediately after the pinion is engaged, it should draw less than the specified current. Service Limit - 1150 Amp. Maximum @ Stall Condition Clean all parts and apply high temperature grease to the armature bearing, return spring, steel ball, over running clutch, and idler gear rollers.
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Inspect the brushes for wear and damage.
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INSTRUMENT PANEL
The left instrument panel is the same for both the Standard and Deluxe Instrument Panels [Figure 60-501].
Left Panel Figure 60-50-1
The table below shows the DESCRIPTION and FUNCTION / OPERATION for each of the components of the left panel.
2 1 3 4
6
5
13
9
7
10
14
8
11
Press and hold LIGHTS button (Item 4) [Figure 60-50-1] for two seconds to view SERVICE CODES in the HOURMETER / CODE DISPLAY (Item 2) [Figure 60-501]. If more than one SERVICE CODE is present, the codes will scroll on the HOURMETER / CODE DISPLAY.
12
REF. NO
DESCRIPTION
FUNCTION / OPERATION
1
TEMPERATURE GAUGE
Shows the engine coolant temperature.
2
HOURMETER / CODE DISPLAY / GLOW PLUG COUNTDOWN
HOURMETER - Records operating hours of loader. CODE DISPLAY - Display numeric SERVICE CODES* relating to the loader monitoring system. COUTNTDOWN - Glow Plug time remaining
3
FUEL GAUGE
Shows the amount of fuel in the tank.
4
LIGHTS / HOLD FOR CODES
LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third time to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE CODES (Item 2). (CODES* show only when there is an error found by loader monitoring system.)
5
BUCKET POSITIONING (Option)
Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold 2 seconds to view BASE or SHTDN (◆ SHUTDOWN) feature in HOURMETER / CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS 6
HIGH FLOW (Option)
7
MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXIMUM FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow-to-fast movement of auxiliary functions (The farther you move the switch, the faster the movement of auxiliary functions.) MAXIMUM FLOW allows for only fast movement.]
Press to engage the HIGH FLOW auxiliary hydraulics. Press again to disengage.
8
AUXILIARY PRESSURE RELEASE
Press and hold for two seconds. The engine will stop. Hydraulic pressure will be released in the rear auxiliary (If so equipped) or right side front auxiliary circuit (If so equipped).
BOBCAT INTERBLOCK CONTROL SYSTEM (BICS™)
(SEE TROUBLESHOOTING GUIDE ON PAGE 60-90-3.) 9
PRESS TO OPERATE LOADER
Press to activate BICS™ System when the Seat Bar is down and operator is seated in operating position.
10
SEAT BAR
The light comes ON when the seat bar is down.
11
LIFT & TILT VALVE
The light comes ON when the seat bar is down and the PRESS TO OPERATE Button is pressed. The lift and tilt functions can be operated when the light is ON.
12
TRACTION
The light comes ON when the seat bar is down, engine is running, and parking brake is released. The loader can be moved forward or backward when the light is ON.
13
TRACTION LOCK OVERRIDE
(Function Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes. Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See TRACTION LOCK on Page 60-110-1.) Press a second time to lock the brakes.
14
ALARM
The ALARM beeps when there is an Error, WARNING or ◆SHUTDOWN condition.
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B-15551
INSTRUMENT PANEL (CONT’D)
The right instrument panel shown [Figure 60-50-2] is the Standard Panel.
Right Panel (Standard) (With Key Switch) The table below shows the Icons and other components of the Right Standard Panel
Figure 60-50-2 15 17 19 21 23 25 27
* These functions are monitored and have SERVICE CODES associated with them. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.) for descriptions of DIAGNOSTICS SERVICE CODES.
16 18 20 22 24 26 28
29 B-15552B
ICON/ LIGHT
FUNCTION
ALARM
CODE
CONDITION
DESCRIPTION
Advanced Control System 15 (ACS)
ON
3 Beeps
*
Error
Error with Advanced Control System (ACS)
Attachment 16 Control Device (ACD)
FLASHING 3 Beeps
*
Error
Error with Attachment Control Device (ACD)
General 17 Warning
ON 3 Beeps * ON 3 Beeps * FLASHING Continuous *
Error Error with one or more engine or hydraulic functions. WARNING Engine speed high or in shutdown. SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
Fuel 19 Level
ON 3 Beeps FLASHING 3 Beeps
* *
Error WARNING
Fuel level sender system fault. Fuel level low.
Glow 20 Plugs
ON --FLAHSING 3 Beeps
*
--Error
Glow plugs are energized. Error with glow plugs
System Voltage
ON
3 Beeps
*
WARNING
Voltage low, high or very high.
Seat Belt
ON
---
-
---
Light stays on for 45 seconds to remind operator to fasten seat belt.
18 NOT USED
21 22 Engine 23 Oil Pressure
ON 3 Beeps * ON 3 Beeps * FLASHING Continuous *
Error Engine Oil Pressure sender out of range. WARNING Engine oil level low. SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic 24 Charge Pressure
ON 3 Beeps * ON 3 Beeps * FLASHING Continuous *
Error Hydraulic oil pressure sender out of range. WARNING Hydraulic oil pressure low. SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine 25 Coolant Temperature
ON 3 Beeps * ON 3 Beeps * FLASHING Continuous *
Error Engine coolant sender out of range WARNING Engine coolant temperature high. SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic 26 Oil Temperature
ON 3 Beeps * ON 3 Beeps * FLASHING Continuous *
Error Hydraulic oil temperature out of range. WARNING Hydraulic oil temperature high. SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine 27 Air Filter
ON 3 Beeps FLASHING 3 Beeps
* *
Error WARNING
Air filter with high restriction. Air filter switch not connected.
ON 3 Beeps FLASHING 3 Beeps
* *
Error WARNING
Hydraulic filter with high restriction. Hydraulic filter switch not connected.
-
-
-
Used to start and stop the engine.
28
Hydraulic Filter
29 Key Switch
-
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REF.
Figure 60-50-4
INSTRUMENT PANEL (CONT'D) Right Panel (Deluxe) (With Keyless Start) Figure 60-50-3
3
1
ENTER PASSWARD
2 LANGUAGES
B-16165
4
5
B-15553B
The right instrument panel shown [Figure 60-50-3] is the Deluxe Panel. 1. Display Panel: The Display Panel is where all system setup, monitoring, troubleshooting, and error conditions are displayed. 2. Function Icons: The lower left area of the Deluxe Panel has the same Icons as the Standard Panel (See Right Panel (Standard) (With Key Switch) on Page 60-50-2.) These Icons are only visible when the monitoring system has detected an error. 3. Selection Buttons: The four Selection Buttons allow you to select items from the Display Panel and scroll through screens. 4. Keypad: The numeric keypad (Item 4) [Figure 60-503] has two functions: (a) To enter a number code (password) to allow starting the engine (Keyless Start).
When this screen is on the display you can enter the password and start the engine or change the Display Panel setup features. NOTE: Your new loader (with Deluxe Instrument Panel) will have a Owner Password. Your dealer will provide you with this password. Change the password to one that you will easily remember to prevent unauthorized use of your loader. (See ELECTRICAL SYSTEM SERVICE MANUAL.) Keep your password in a safe place for future needs. Start Engine: Use the Keypad to enter the numbers (letters) of your password and press the RUN / ENTER key (Item 5) [Figure 60-50-3]. Press and hold the START Button (Item 6) [Figure 6050-3] until the engine starts. Change Language: Press the Selection Button at the end of the arrow [Figure 60-50-4] to go to the next screen.
(b) To enter a number as directed for further use of the Display Panel.
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The first screen you will see on your new loader will be as shown in [Figure 60-50-4].
6
INSTRUMENT PANEL (CONT'D) Right Panel (Deluxe) (With Keyless Start) (Cont’d) Figure 60-50-5
ENGLISH / INGLES Use keypad to select languages
1. English 2. Espanol 3. Francaia 4. Deutsch 5. Italiano 6. Nederlands
EXIT B-16160
Dealer Copy -- Not for Resale
Use the Keypad to select the number of the language [Figure 60-50-5] Press EXIT. The screen will return to [Figure 60-50-4]. You can then enter the password and start the engine.
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INSTRUMENT PANEL (CONT'D) Right Panel Setup Display Options (Deluxe)
ICON
Icon Identification
DESCRIPTION LOCK / UNLOCK: Allows machine to be locked / unlocked. You must lock machine to activate security system.
Figure 60-50-6
When system is unlocked, the user can press RUN / ENTER then press START to begin operation.
SELECTION BUTTON
A valid password will need to be entered at startup to run a locked machine. TOOL / SETUP: Access system options. EXAMPLE
Use to set clock, check system warnings, select language, set passwords, etc.
?
B-16162
HELP: Access help on current menu item.
EXIT
EXIT returns you to previous level menu.
11:23 0.0
CLOCK / JOB CLOCK: Press to clear or lock job clock; TOOL / SETUP to set time. DOWN ARROW: Goes forward one screen.
Make selection by pressing SELECTION BUTTON opposite the Icon [Figure 60-50-6].
OUTLINE ARROWS: No screen available (backward / forward). SELECTION ARROW: Use to select menu item. NEXT
Goes to the NEXT screen in series. EXAMPLE: the next Active Warning screen.
INFO
Goes to more information about an attachment.
YES / NO Answer yes / no to current setup question. CLEAR Removes previously installed password. SET
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Set accepts current installed password.
S150, S160 Bobcat Loader Service Manual
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UP ARROW: Goes backward one screen.
INSTRUMENTATION PANEL (CONT’D)
All new machines with Deluxe Instrumentation arrive at Bobcat Dealerships with the panel in locked mode. This means that a password must be used to start the engine [Figure 60-50-7].
Deluxe Panel Setup Display Options
Passwords (Deluxe) Figure 60-50-7
Press
For security purposes, your dealer may change the password and also set it in the locked mode. Your dealer will provide you with the password. Owner Password: Allows for full use of the loader and to setup the Deluxe Panel. Owner can select a password to allow starting and operating the loader and modify the setup of the Deluxe Panel. Owner should change the password as soon as possible for security of the loader.
Press LOADER FEATURES
User Password: Allows starting and operating the loader; cannot change password or any of the other setup features.
Dealer Copy -- Not for Resale
TOOL/SETUP
Press DISPLAY OPTIONS
Press ADJUST CONTRAST
Press UP OR DOWN
Arrow to change contrast. Press EXIT to return to previous level menu. B-16163/B16164/B-16161/B-16166/B-16167
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INSTRUMENTATION PANEL (CONT’D)
More EXAMPLES:
Passwords (Deluxe) (Cont’d)
Clocks
Figure 60-50-8 Changing the Password
TOOL / SETUP [Figure 60-50-8] Right Instrument Panel Display Screen
LOADER FEATURES. DISPLAY OPTIONS CLOCKS SET CLOCK Use the keypad to set time. Press RUN / ENTER to set clock. Press EXIT to return to previous level menu.
Press TOOL/SETUP
RESET JOB CLOCK (Password required) Press CLEAR to reset job clock to zero. Press LOCK / UNLOCK to unlock. Enter Password and press RUN / ENTER.
Press PASSWORD UTILITIES
Press MODIFY OWNER or MODIFY USER
TOOL / SETUP LOADER FEATURES. DISPLAY OPTIONS LANGUAGES Select the language, press RUN / ENTER. Press EXIT to return to previous level menu. Vitals (Monitor engine, hydraulic / hydrostatic, electrical functions when engine is running.) TOOL / SETUP LOADER FEATURES. VITALS Press SELECTION ARROW to select METRIC or ENGLISH (M/E) readouts
Enter Password on Keypad
You can monitor real-tim readouts of: Engine Oil Pressure Engine Coolant Temperature Hydraulic Charge Pressure Hydraulic Oil Temperature System Voltage Engine Speed
Press Enter to Continue
Re-enter new password. Press Enter to Continue (See left.)
The Display Panel is easy to use. Continue to set your own preferences for running / monitoring your Bobcat loader. Press Enter to Continue (See left.)
B-16163/B16164/B-16171/B-16172/B-16173/B-16174
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Languages
Side Accessory Panel [Figure 60-50-9] and [Figure 6050-10].
INSTRUMENTATION PANEL (CONT’D) Option And Field Accessory Panels (If Equipped)
REF. NO.
Figure 60-50-9
1.
SIDE ACCESSORY PANEL
2. 3.
4.
5. 6. 7.
8.
2
4
3
6
5
P-16000 P16000
Figure 60-50-10
9.
Provides a 12V receptacle for accessories.
--Press the top of the switch to start the front wiper (press and hold for washer fluid). Press the bottom of the switch to stop the wiper. REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of the switch to provide washer fluid to clean the rear window. NOT USED --NOT USED --FAN MOTOR Turn clockwise to increase fan speed; counterclockwise to decrease. There are four positions; OFF-1-2-3. AIR COND. Press top of switch to start; bottom to stop. Fan SWTICH Motor (Item 7) must be ON for A/C to operate. TEMP. Turn clockwise to increase the temperature; counterclockwise to decrease. CONTROL
Front Accessory Panel [Figure 60-50-11]
SIDE ACCESSORY PANEL
REF. NO. 10.
11. 12.
13. 14.
7
8
9
P16000
15.
Figure 60-50-11 10
POWER PLUG NOT USED FRONT WIPER
FUNCTION / OPERATION
16.
FRONT ACCESSORY PANEL 11 12 13 14 15 16
17.
DESC.
FUNCTION / OPERATION
ADVANCED CONTROL SYSTEM (ACS) NOT USED POWER BOB-TACH (If Equipped)
Press the top to select Hand Controls; bottom to select Foot Controls.
PARKING BRAKE TURN SIGNAL INDICATORS HAZARD LIGHTS ROTATING BEACON
--Press and hold the up arrow to disengage the the Bob-Tach wedges. Press and hold the down arrow to engage the wedges into the mounting frame holes. Press the top to engage the PARKING BRAKE; bottom to disengage. Indicates left or right TURN SIGNALS are ON.
Press the left side (or top) to turn the HAZARD LIGHTS ON; right side (or bottom) to turn OFF. Press the left side (or top) to turn the ROTATING BEACON ON; right side (or bottom) to turn OFF. SELECTABLE Press the top to select ‘ISO’ Control Pattern; JOYSTICK bottom to select ‘H’ Control Pattern. CONTROL (SJC)
OR
17
B-15993B B-15993
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1
DESC.
Figure 60-50-14
INSTRUMENTATION PANEL (CONT’D) Standard Panel Removal And Installation (Right Side) Figure 60-50-12
1
1
1 N-20140
Ignition Switch Removal And Installation (Standard Panel)
Remove the three mounting bolts (Item 1) [Figure 60-5012].
Disconnect the key switch wiring harness (Item 1) [Figure 60-50-14] from the back of the control panel.
Dealer Copy -- Not for Resale
P-28360A
Figure 60-50-15 Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded holes in the panels. Figure 60-50-13 2
1
1
P-28360
Remove the ignition key (Item 1) from the switch. Remove the ignition switch retaining nut (Item 2) [Figure 60-50-15] from the switch.
N-20158
Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-13] from the panel. Remove the panel from the loader cab.
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S150, S160 Bobcat Loader Service Manual
Figure 60-50-18
INSTRUMENTATION PANEL (CONT’D) Standard Panel Removal And Installation (Right Side) (Cont’d) Ignition Switch Removal And Installation Standard Panel (Cont'd) Figure 60-50-16 1
1
N-20163
Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-18] from the panel.
Figure 60-50-19 Remove the ignition switch (Item 1) [Figure 60-50-16] from the control panel. Deluxe Panel Removal And Installation (Right Side) Figure 60-50-17 1
1
1
N-20142
NOTE: The instrument panel (Item 1) [Figure 60-5019] must be replaced as a complete unit.
N-20103
Remove the three mounting bolts (Item 1) [Figure 60-5017]. Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded holes in the panels.
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Remove the panel from the loader cab. N-20141
Figure 60-50-22
INSTRUMENT PANEL (CONT'D) Standard And Deluxe Panel Removal And Installation (Left Side) Figure 60-50-20
1 1
1
N-20144
Alarm Removal And Installation
Remove the three mounting bolts (Item 1) [Figure 60-5020].
Remove the retaining nut (Item 1) [Figure 60-50-22] from the loader alarm. Remove the alarm from the loader instrument panel.
Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded holes in the panels.
Figure 60-50-23
Figure 60-50-21
1 3 1 2
N-20145
Bulb Removal And Installation
N-20165
Remove the left side instrument panel. Pull the left instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-21] from the loader alarm.
Remove the two light bulb covers (Item 1) [Figure 60-5023] from the back of the instrument panel.
Disconnect the wire harness connector (Item 2) [Figure 60-50-21] from the loader instrument panel. NOTE: The wiring harness (Item 3) [Figure 60-50-21] is an optional accessory harness. Remove the instrument panel from the loader. 60-50-11 638 of 949
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Remove the left side instrument panel.
N-18409
INSTRUMENT PANEL (CONT'D)
Front Accessory Panel Removal And Installation
Standard And Deluxe Panel Removal And Installation (Left Side) (Cont'd)
Figure 60-50-26
Figure 60-50-24
1 1
P-26255
With a flat blade screw driver, turn the light bulb counterclockwise [Figure 60-50-24] and remove from the panel.
Installation: Be careful to not overtighten the front accessory panel mounting bolts to prevent damage to the plastic panel.
Figure 60-50-25
Figure 60-50-27
2 1
N-20147
P-26251
To install the bulbs, place them in the sockets and turn clockwise [Figure 60-50-25].
Pull the front accessory panel down and disconnect the wire harness connector(s) (Items 1 and 2) [Figure 60-5027] from the switches. Remove the panel. Reverse the procedure to install the front accessory panel.
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Remove the two mounting bolts (Item 1) [Figure 60-5026].
N-20146
Figure 60-60-3
LIGHTS Front Removal And Installation Figure 60-60-1
1
1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the socket.
N-19348
Reverse the above procedure to install the bulb. Rear Removal And Installation Disconnect the negative(-) cable from the battery. (See Removal And Installation on Page 60-20-1.).
Figure 60-60-4
Remove the light housing (Item 1) [Figure 60-60-1] from the operator cab. 1
Figure 60-60-2
2
3
1
P-34372
Remove the bulb assembly (Items 1 and 2) from the light housing (Item 3) [Figure 60-60-4] by turning bulb assembly a 1/4 turn.
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2] from the light housing by turning bulb assembly a 1/4 turn.
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Open the rear door.
LIGHTS (CONT’D) Rear Removal And Installation (Cont’d) Figure 60-60-5
N-19339
Dealer Copy -- Not for Resale
Using care press the rear light and housing from the door [Figure 60-60-5]. Reverse this procedure for installation.
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S150, S160 Bobcat Loader Service Manual
BOBCAT CONTROLLER Identification Chart
41 31
50 40 30 20 10
21 11 1 9 8 7 6
41 31 21 11 1
50 40 30 20 10 9 8 7 6
5 4 3 2
J1
5 4 3 2
J2
Dealer Copy -- Not for Resale
Controller
Harness Connector View
Harness Connector View
50
41
40
31
21
30
21
30
11
20
11
20
41
J1
31
1 2 3 4
5
6
J2
1 2 3 4 5
7 8 9 10
50 40
6 7 8
9 10
V-171/V-172
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S150, S160 Bobcat Loader Service Manual
BOBCAT CONTROLLER (CONT’D)
Harness Connector View
3420
7200
3520
X
8550
3500
2100
6320
8110
40
4730
4470
X
1120
4450
8210
30
9500
3400
6510
4200
4460
6210
8800
3430
4910
X
X
X
6410
8510
4110
3
4
8
9 10
8000
X
9800
X
31
X
8150
1130
9700
X
21
X
4150
3010
9600
X
8250
1110
X
X
2
11
1
J1
50
X
1400
5
6
7
20
Harness Connector View
41
4410
9410
4640
9340
3920
J2
X
3300
X
X
4840
X
2110
X
4940
40 30
31
X
4420
X
9350
3910
21
4340
4430
9400
1900
3900
4830
X
3100
4320
4930
9110
4440
X
1200
9200
4820
X
3700
4310
4920
4360
X
4330
2900
9100
4810
9210
3200
4300
3600
1
2
3
4
5
6
7
8
9 10
11
50
4500
20
V-172
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41
Figure 60-70-2
BOBCAT CONTROLLER (CONT’D) Removal And Installation
WARNING
1 1
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598 P-34842
Figure 60-70-1
Loosen the harness connectors mounting bolts (Item 1) [Figure 60-70-2] from the Bobcat controller.
NOTE: The connectors are keyed and will only plug in one way. 1
1 N-19390
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Stop the engine. Raise the seat bar. Lift and block the rear of the loader. (See Procedure on Page 10-10-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the left front side panel (Item 1) [Figure 60-701].
60-70-3 644 of 949
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Remove the connectors.
1
BOBCAT CONTROLLER (CONT'D) Removal And Installation (Cont’d) Figure 60-70-3
1
2
P-34843
Dealer Copy -- Not for Resale
Remove the top mounting bolt (Item 1) [Figure 60-70-3]. Loosen the two mounting bolts (Item 2) [Figure 60-70-3] of the system controller. Installation: Tighten the nuts to 12 - 14 ft.-lb. (17 - 19,2 N•m) torque. Remove the system controller. Reverse the above procedure to install the system controller.
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S150, S160 Bobcat Loader Service Manual
Figure 60-71-2
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) Removal And Installation
WARNING 1 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598 P-64327
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Remove the inside access panel (right side) (Item 1) [Figure 60-71-2]. Figure 60-71-3
Figure 60-71-1 1
2
1
P-64297
Remove the top controller mounting bolt (Item 1). Loosen the two bottom controller mounting bolts (Item 2) [Figure 60-71-3] from the right side fender.
P-64300
Remove the foot portion of the engine speed control (Item 1) [Figure 60-71-1]. (See Removal And Installation on Page 70-20-1.)
Lift and remove the controller from the fender. Installation: Tighten the mounting bolts to 12 - 14 ft.-lb. (16 - 19 N•m) torque.
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Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Figure 60-71-6
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Removal And Installation (Cont’d) Figure 60-71-4
1
P-64325
Remove the SJC controller [Figure 60-71-6].
Pull the controller out from the fender and loosen the connector screw (Item 1) [Figure 60-71-4] to release the connector. Installation: Tighten the connector screw to 30 - 35 in.lb. (3,39 - 3,96 N•m) torque. DO NOT OVERTIGHTEN!
S
J
Figure 60-71-5 1
P-64324
1 The wire location (Item 1) [Figure 60-71-7] is printed on the connector, in the locations shown.
P-64325
Installation: Note the keyed hole in the controller socket. (Item 1) [Figure 60-71-5]. The keyed hole matches a tab on the connector on the wire harness.
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Figure 60-71-7
P-64322
Dealer Copy -- Not for Resale 60-71-3 648 of 949
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CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D)
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Identification Chart
P-64295
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CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D)
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Identification Chart (Cont'd)
P-64296
60-71-5 650 of 949
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DIAGNOSTICS SERVICE CODES Display Figure 60-80-1 2
1
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B-15551B
The left instrument panel is the same for both the Standard and Deluxe Instrumentation [Figure 60-80-1]. NOTE: Corroded or loose grounds can cause multiple service codes and / or abnormal symptoms. All dash lights flashing, buzzer going off, headlights and taillights flashing, could indicate a bad ground. The same symptoms could apply if the voltage is low, such as loose or corroded battery cables. If you observe these symptoms, check grounds and positive leads first. Press and hold LIGHTS Button (Item 1) [Figure 60-80-1] for two seconds to view SERVICE CODES in the HOURMETER / CODE DISPLAY (Item 2) [Figure 60-801]. If more than one SERVICE CODE is present, the codes will scroll on the HOURMETER / CODE DISPLAY. The following word errors may be displayed. REPLY One or both instrument panel(s) communicating with the controller.
not
INPUT
The controller not communicating with the left instrument panel.
CODE
The controller is asking for a password. (Deluxe instrument panel only.)
ERROR The wrong password was entered. (Deluxe instrument panel only.)
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S150, S160 Bobcat Loader Service Manual
DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List CODE
01-16 01-17
Air filter not connected Air filter plugged
10-16 10-17
Hydraulic Charge filter not connected Hydraulic Charge filter plugged
02-16 02-17
Hydraulic implement filter not connected Hydraulic implement filter plugged
11-05 11-06
Seat bar sensor short to battery Seat bar sensor short to ground
03-09 03-10 03-11 03-14 03-22
Battery voltage low Battery voltage high Battery voltage extremely high Battery voltage extremely low Battery voltage out of range low
12-21 12-22 12-23
Front auxiliary PWM switch out of range high Front auxiliary PWM switch out of range low Front auxiliary PWM switch not in neutral
04-09 04-14 04-15 04-21 04-22
Engine oil pressure low Engine oil pressure extremely low Engine oil pressure shutdown level Engine oil pressure out of range high Engine oil pressure out of range low
13-05 13-06 13-07
Fuel shut-off hold solenoid short to battery Fuel shot-off hold solenoid short to ground Fuel shut-off solenoid open circuit
14-02 14-03
Fuel shut-off pull solenoid error ON Fuel shut-off pull solenoid error OFF
15-02 15-03
Traction lock pull solenoid error ON Traction lock pull solenoid error OFF
16-05 16-06 16-07
Traction lock hold solenoid short to battery Traction lock hold solenoid short to ground Traction lock hold solenoid open circuit
17-05 17-06 17-07
Hydraulic lock valve solenoid short to battery Hydraulic lock valve solenoid short to ground Hydraulic lock valve solenoid open circuit
18-05 18-06 18-07
Spool Lock Solenoid short to battery Spool Lock Solenoid short to ground Spool Lock Solenoid open circuit
05-09 05-10 05-11 05-14 05-15 05-21 05-22 06-10 06-11 06-13 06-15 06-18 07-10 07-11
Hydraulic charge pressure low Hydraulic charge pressure high Hydraulic charge pressure extremely high Hydraulic charge pressure extremely low Hydraulic charge pressure shutdown level Hydraulic charge pressure out of range high Hydraulic charge pressure of range low Engine speed high Engine speed extremely high Engine speed no signal Engine speed shutdown level Engine speed out of range Hydraulic oil temperature high Hydraulic oil temperature extremely high
07-15
Hydraulic oil temperature shutdown level
19-02
Bucket position solenoid error ON
07-21
Hydraulic oil temperature out of range high
19-03
Bucket position solenoid error OFF
07-22
Hydraulic oil temperature out of range low 20-02
Two-speed solenoid error ON
20-03
Two-speed solenoid error OFF
08-10
Engine coolant temperature high
08-11
Engine coolant temperature extremely high
08-15
Engine coolant temperature shutdown level
21-02
Glow plug error ON
08-21 08-22
Engine coolant temperature out of range high Engine coolant temperature out of range low
21-03
Glow plug error OFF
22-02 22-03
Starter error ON Starter error OFF
23-02
Rear base solenoid error ON
23-03
Rear base solenoid error OFF
09-09
Fuel level low
09-21
Fuel level out of range high
09-22
Fuel level out of range low
60-80-2 653 of 949
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CODE
DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List (Cont’d) CODE
24-02 24-03
Rear rod solenoid error ON Rear rod solenoid error OFF
32-57 32-58 32-59 32-60
Lift actuator reduced performance Tilt actuator reduced performance Lift actuator wrong direction Tilt actuator wrong direction
25-02 25-03
Rear auxiliary relief solenoid error ON Rear auxiliary relief solenoid error Off
32-61 32-62
Handle lock short to ground Handle lock short to battery
26-02 26-03
Front base solenoid error ON Front base solenoid error OFF
27-02 27-03
Front rod solenoid error ON Front rod solenoid error OFF
28-02 28-03
Diverter solenoid error ON Diverter solenoid error OFF
32-63 32-64 32-65 32-66 32-67 32-68 32-69 32-70 32-71 32-75
Pedal lock short to ground Pedal lock short to battery Sensor supply voltage out of range Battery voltage out of range Switch flipped while operating Lift handle information error Control pattern switch flipped while operating Right drive handle short to ground Right drive handle short to battery Interrupted unswitched power
29-02 29-03
High flow solenoid error ON High flow solenoid error OFF
33-23
Main Controller (Bobcat Controller) not programmed
30-28
Controller Memory failure
34-04
Deluxe panel no communication to Bobcat controller
31-28
Interrupted power failure
35-02 35-03
Hydraulic fan error ON Hydraulic fan error OFF
32-04 32-23 32-31 32-32 32-33 32-34 32-35 32-36 32-37 32-38 32-39 32-40 32-41 32-49 32-50 32-51 32-52 32-53 32-54 32-55 32-56
ACS not communicating with Bobcat Controller ACS Not calibrated Tilt actuator fault Tilt actuator wiring fault Tilt handle wiring fault Tilt actuator not in neutral Tilt handle / pedal not in neutral Lift actuator fault Lift actuator wiring fault Lift handle wiring fault Lift actuator not in neutral Lift handle / pedal not in neutral No communication Lift actuator short to ground Tilt actuator short to ground Lift actuator short to battery Tilt actuator short to battery Lift handle / pedal short to ground Tilt handle / pedal short to ground Lift handle / pedal short to battery Tilt handle / pedal short to battery
36-48
ACD multiple controllers present
37-02 37-03
Two-speed secondary error ON Two-speed secondary error OFF
60-80-3 654 of 949
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CODE
DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List (Cont’d) CODE
38-04 38-05 38-06 38-07 38-08 38-09 38-11 38-12 38-13 38-14 38-15 38-16 38-17 38-18 38-19 38-20 38-21 38-22 38-23 38-24 38-25
No communication from joystick controller Left joystick X axis not in neutral Right joystick X axis not in neutral Left joystick Y as not in neutral Right joystick Y axis not in neutral Control pattern switch - Short to Battery or Ground Lift actuator not in neutral Tilt actuator not in neutral Lift actuator fault Tilt actuator fault Right wheel speed fault Left wheel speed fault Tilt actuator reduced performance Lift actuator reduced performance Left joystick X axis out of range high Right joystick X axis out of range low Left joystick Y axis out of range high Right joystick Y axis out of range high Front right steering sensor out of range high Front left steering sensor out of range high Rear right steering sensor out of range high
38-53 38-54 38-55 38-56 38-57 38-58 38-59 38-60 38-61 38-62 38-63 38-64 38-65 38-66 38-67 38-68 38-69 38-70 38-71 38-72 38-73
38-26 38-27 38-28 38-29 38-30 38-31 38-32 38-33 38-34 38-35 38-36 38-37 38-38 38-39 38-40 38-41 38-42 38-43 38-44 38-45 38-46 38-47 38-48 38-49 38-50 38-51
Rear left steering sensor out of range high Lift actuator out of range high Tilt actuator out of range high Left joystick X axis out of range low Right joystick X axis out of range low Left joystick Y axis out of range low Right joystick Y axis out of range low Front right steering sensor out of range low Front left steering sensor out of range low Rear right steering sensor out of range low Rear left steering sensor out of range low 5 volt sensor supply 1 out of range low 5 volt sensor supply 2 out of range low Lift actuator short to ground / out of range low Tilt actuator short to ground / out of range low Tilt actuator wrong direction Lift actuator wrong direction Left forward drive solenoid error ON Left reverse drive solenoid error ON Right forward drive solenoid error ON Right reverse drive solenoid error ON Front right steering solenoid error ON Front left steering solenoid error ON Rear right steering solenoid error ON Rear left steering solenoid error ON Steering pressure solenoid error ON
38-74 38-75 38-76 38-77 38-78 38-79 38-80 38-81 38-82 38-83 38-84 38-85 38-86 38-87 38-88 38-89 38-90 38-91 38-92 38-93 38-94 38-95 38-96 38-98 38-99
38-52
Back-up alarm error ON
60-80-4 655 of 949
Left forward drive solenoid error OFF Left reverse drive solenoid error OFF Right forward drive solenoid error OFF Right reverse drive solenoid error OFF Front right extend steering solenoid error OFF Front right retract steering solenoid error OFF Front left extend steering solenoid error OFF Front left retract steering solenoid error OFF Rear right extend steering solenoid error OFF Rear right retract steering solenoid error OFF Rear left extend steering solenoid error OFF Rear left retract steering solenoid error OFF Steering pressure solenoid error OFF Back-up alarm error OFF No communication from Bobcat controller Wheel angles (alignment) not calibrated Lift & tilt actuators not calibrated Interrupted power Battery out of range Drive pump not calibrated Steering mode / drive mode switch flipped while operating Uncommanded right wheel speed error ON Uncommanded left wheel speed error ON Undercurrent steer pressure solenoid Undercurrent front right extend steer solenoid Undercurrent front right retract steer solenoid Undercurrent front left extend steer solenoid Undercurrent front left retract steer solenoid Undercurrent rear right extend steer solenoid Undercurrent rear right retract steer solenoid Undercurrent rear left extend steer solenoid Undercurrent rear left retract steer solenoid 5 Volt sensor supply 1 out of range high 5 Volt sensor supply 2 out of range high Front right wheel blocked (steering mechanical failure) Front left wheel blocked (steering mechanical failure) Rear right wheel blocked (steering mechanical failure) Rear left steering error Right speed sensor missing pulses Left speed sensor missing pulses Unresponsive right speed sensor Unresponsive left speed sensor Left speed sensor reverse direction Right speed sensor reverse direction Controller in drive calibration mode Controller in wheel position calibration mode.
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
CODE
DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List (Cont’d) CODE
39-04
Left joystick no communication to Bobcat controller
40-04
Right joystick no communication to Bobcat controller
44-02 44-03
Horn error ON Horn error OFF
45-02 45-03
Right blinker error ON Right blinker error OFF
46-02 46-03
Left blinker error ON Left blinker error OFF
47-21 47-22
8 volt sensor supply out of range high 8 volt sensor supply out of range low
48-02 48-03
Front light relay error ON Front light relay error OFF
49-02 49-03
Rear light relay error ON Rear light relay error OFF
50-01 50-02 50-03 50-04 50-05 50-06 50-07 50-08 50-09 50-10 50-11 50-12 50-13 50-14 50-15 50-24 50-27 50-28 50-29 50-30 50-31 50-33 50-34 50-35 50-36 50-37
Travel pedal out of range high Travel pedal out of range low Travel pedal not calibrated Brake Pedal out of range high Brake Pedal out of range low Brake Pedal not calibrated Drive selector switch no signal Drive selector switch multiple inputs Front wheel speed sensor out of range high Front wheel speed sensor out of range low Rear wheel speed sensor out of range high Rear wheel speed sensor out of range low Front wheel speed sensor no signal Rear wheel speed sensor no signal Dual wheel speed sensor fault Battery voltage over voltage 5V sensor #1 over voltage 5V sensor #1 under voltage 5V sensor #2 over voltage 5V sensor #2 under voltage Front PWM error on Front PWM no signal Front PWM not calibrate Front forward error ON Front forward error OFF Front reverse error ON
50-38
Front reverse error OFF
50-39 50-41
Rear PWM error on Rear PWM no signal
50-42 50-43 50-44 50-45 50-46 50-47 50-48 50-49 50-50 50-51 50-52 50-53 50-54 50-55 50-56 50-57
Rear PWM not calibrate Rear forward error ON Rear forward error OFF Rear reverse error ON Rear reverse error OFF Two speed error OFF Two speed error ON Brake solenoid error ON Brake solenoid error OFF Brake solenoid no signal Brake light relay error ON Brake light relay error OFF Differential lock error ON Differential lock error OFF CAN communications fault Drive controller not calibrated
50-59 50-60
Front speed sensor missing pulses Rear speed sensor missing pulses
50-63
Front angle sensor not calibrated
50-66 50-67 50-68 50-69 50-70 50-99
Rear angle sensor not calibrated Front forward no signal Front reverse no signal Rear forward no signal Rear reverse no signal In calibration mode
60-21 60-22 60-23
Rear auxiliary control out of range high Rear auxiliary control out of range low Rear auxiliary control not returning to neutral
62-04
Load moment monitoring in error
63-05 63-06
Short to battery Short to ground
64-02 64-03
Switched power relay error ON Switched power relay error OFF
60-80-5 656 of 949
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CODE
DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List (Cont’d) CODE
65-02 65-03 65-05 65-06 65-07
Workgroup lockout error on Workgroup lockout error off Workgroup lockout short to battery Workgroup lockout short to ground Workgroup lockout open circuit
66-05 66-06
Pilot pressure short to battery Pilot pressure short to ground
74-72 74-73
Bobcat controller in boot code Left hand panel system RX error
75-04 75-05 75-07 75-08 75-09 75-17 75-18 75-19 75-21 75-22 75-27 75-28 75-29 75-31 75-32 75-37 75-39 75-40 75-41 75-42 75-43 75-44 75-45 75-46 75-52 75-53 75-54 75-55 75-56 75-66 75-67 75-69 75-70
No communication from Drive Controller Left joystick X-Axis not in neutral Left joystick Y-Axis not in neutral Right joystick Y-Axis not in neutral ISO/H pattern switch short to ground or battery Left swash plate not in neutral Right swash plate not in neutral Left joystick X-Axis out of range high Left joystick Y-Axis out of range high Right joystick Y-Axis out of range high Left swash plate out of position Right swash plate out of position Left joystick X-Axis out of range low Left joystick Y-Axis out of range low Right joystick Y-Axis out of range low 5 volt sensor supply 1 out of range low Left swash plate sensor out of range high Left swash plate sensor out of range low Right swash plate sensor out of range high Right swash plate sensor out of range low Left forward drive solenoid error ON Left reverse drive solenoid error ON Right forward drive solenoid error ON Right reverse drive solenoid error ON Back-up alarm error ON Left forward drive solenoid error OFF Left reverse drive solenoid error OFF Right forward drive solenoid error OFF Right reverse drive solenoid error OFF Back-up alarm error OFF No communication from Bobcat Controller Battery voltage out of range high Interrupted power (also occurs after software update) Battery voltage out of range low Drive pump not calibrated ISO/H pattern switch flipped while operating
75-71 75-72 75-73
75-74 75-75 75-76 75-77 75-78 75-79 75-80 75-85 75-91 75-92 75-93 75-94 75-95 75-96 75-98
Left wheel speed uncommanded motion Right wheel speed uncommanded motion No communication from ACS Controller Left speed sensor out of range high Right speed sensor out of range high Left speed sensor out of range low Right speed sensor out of range low 5 volt sensor supply 1 out of range high Left swash plate sensor reversed Right swash plate sensor reversed Unresponsive right speed sensor Unresponsive left speed sensor Left speed sensor reversed direction Left speed sensor reversed direction Controller in Calibration Mode
76-73
Left display panel RX error
77-48
Key Switch - Multiple
78-74
Door / Transport Lock - Open / Active
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CODE
DIAGNOSTICS SERVICE CODES (CONT'D) Number Codes List (Cont’d) CODE
80-02 80-03
ACD output ‘A’ error ON ACD output ‘A’ error OFF
81-02 81-03
ACD output ‘B’ error ON ACD output’ B’ error OFF
82-02 82-03
ACD output ‘C’ error ON ACD output ‘C’ error OFF
83-02 83-03
ACD output ‘D’ error ON ACD output ‘D’ error OFF
84-02 84-03
ACD output ‘E’ error ON ACD output ‘E’ error OFF
85-02 85-03
ACD output ‘F’ error ON ACD output ‘F’ error OFF
86-02 86-03
ACD output ‘G’ error ON ACD output ‘G’ error OFF
87-02 87-03
ACD output ‘H’ error ON ACD output ‘H’ error OFF
90-02 90-03
Service tool output ‘C’ error ON Service tool output ‘C’ error OFF
91-02 91-03
Service tool output ‘D’ error ON Service tool output ‘D’ error OFF
92-02 92-03
Service tool output ‘E’ error ON Service tool output ‘E’ error OFF
93-02 93-03
Service tool output ‘F’ error ON Service tool output ‘F’ error OFF
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CODE
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NOTE: Record what lights are blinking (if any) and number of light flashes. See Troubleshooting Guide on Page 60-90-3.
BICS™ SYSTEM Inspecting The BICS™ Controller (Engine STOPPED Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
Figure 60-90-1
3. Sit in the operator's seat, lower the Seat Bar, and press the PRESS TO OPERATE LOADER Button. Press the auxiliary hydraulics FLOW Button. The auxiliary FLOW Button light will come ON. Raise the Seat Bar. The light should be OFF. Inspecting The Seat Bar Sensor (Engine RUNNING) 4. Sit in the operator's seat, lower the seat bar, engage the parking brake pedal and fasten the seat belt.
N-18409
Inspecting The Traction Lock (Engine RUNNING)
1
2
3
6. Fasten the seat belt, disengage the parking brake pedal, press the PRESS TO OPERATE LOADER Button and raise the Seat Bar fully. Move the steering levers slowly forward and backward. The TRACTION lock should be engaged. Lower the Seat Bar. Press the PRESS TO OPERATE LOADER Button.
4 B-15551G
7. Engage the parking brake pedal and move the control levers slowly forward and backward. The TRACTION lock should be engaged.
WARNING AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS™) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.
NOTE: * The TRACTION light on the left instrument panel will remain OFF until the engine is started, the PRESS TO OPERATE LOADER Button is pressed and the parking brake is disengaged. Inspecting The Lift Arm Bypass Control
W-2151-0394
1. Sit in the operator's seat. Turn key ON (Standard Panel), press RUN / ENTER Button (Deluxe Panel, lower the Seat Bar and disengage the parking brake pedal. Press the PRESS TO OPERATE LOADER Button. Three BICS™ lights (Items 1, 2, and 3) [PRESS TO OPERATE LOADER, SEAT BAR, and LIFT & TILT VALVE] on left instrument panel should be ON [Figure 60-90-1].
8. Raise the lift arms 6 feet (2 meters) off the ground. Stop the engine. Turn the lift arm bypass control knob clockwise 1/4 turn. Pull up and hold the lift arm bypass control knob until the lift arms slowly lower.
2. Raise the Seat Bar fully. All four BICS™ lights (Items 1, 2, 3, and 4) [PRESS TO OPERATE LOADER, SEAT BAR, LIFT & TILT VALVE and TRACTION*] on left instrument panel should be OFF [Figure 60-90-1]
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5. Start the engine and operate at low idle. Press the PRESS TO OPERATE LOADER Button. While raising the lift arms, raise the Seat Bar fully. The lift arms should stop. Repeat using the tilt function.
BICS™ SYSTEM (CONT'D)
WARNING
Troubleshooting Chart The following troubleshooting guide is provided for assistance in locating and correcting BICS™ system problems. It is recommended that these procedures be done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W-2004-1285
PROBLEM
SOLUTION#
All indicator lights flashing. One of the indicator lights flashing. Intermittent indicator lights.
5 1 2, 3, 4 SOLUTION SUGGESTIONS
2. Check wire connections on Bobcat controller to make sure connectors are locked into place. 3. Check pins in connectors for pins pushed back or bent. 4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring. 5. Possible low or high voltage.
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1. Refer to BICS™ troubleshooting guide.(See Troubleshooting Guide on Page 60-90-3.)
Figure 60-90-2
BICS™ (CONT'D) Troubleshooting Guide The following chart shows the effects which can happen to the loader, and the probable causes when the BICS™ Instrument Panel lights are off. See [Figure 60-90-2] for location of BICS™ lights and Icons. Have service procedures performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
6
5
Press and hold LIGHTS Button (Item 5) for two seconds to view SERVICE CODES in the HOURMETER / CODE DISPLAY (Item 6) [Figure 60-90-2]. If more than one SERVICE CODE is present, the codes will scroll on the HOURMETER / CODE DISPLAY.
1
2
3
4
SEAT BAR
Light ON
Light OFF
3
4
1
B-15551
SERVICE CODES Means System Error (See Your Bobcat Dealer for Service) No. of Service Flashes Code
Causes
PRESS TO OPERATE LOADER Button is pressed.
PRESS TO OPERATE LOADER Button is not pressed.
Lift, tilt and traction functions will not operate.
----
----
Seat Bar is down.
Seat Bar is up.
Lift and tilt functions will not operate.
2
11-05
3
11-06
Seat Bar sensor circuit shorted to battery voltage*. Seat Bar sensor circuit shorted to ground.
Control valve can Control valve Lift, tilt and be used. cannot be used. traction functions will not operate.
1 2 3 3
17-07 17-05 17-06 17-06
Valve output circuit is open. Valve output circuit shorted to battery voltage*. Valve output circuit shorted to ground. Controller not grounded or intermittent ground.
Loader can be Loader cannot moved forward & be moved backward forward and backward.
1 2
16-07 16-05
3
16-06
5
15-02
6
15-03
Traction lock hold solenoid circuit is open. Traction lock hold solenoid circuit shorted to battery voltage*. Traction lock hold solenoid circuit shorted to ground. Traction lock pull solenoid circuit is shorted to battery voltage* - ERROR ON (Should be OFF). Traction lock pull solenoid circuit ERROR OFF (Should be ON). System voltage low System voltage high
2
LIFT & TILT VALVE
3
Loader cannot be moved forward and backward.
TRACTION
4
03-09 Flashing 03-10 Continuous
----
NOTES: Multiple SERVICE CODES and / or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and both battery connections. ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller. ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay. *Normal BICS™ operating voltage is less than the electrical system voltage.
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Indicator Light
Effect on Operation of Loader When Light is OFF
2
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SEAT BAR SENSOR
Troubleshooting
Description
The following troubleshooting chart is provided for assistance in locating and correcting BICS™ system problems. It is recommended that these procedures be performed by authorized Bobcat Service Personnel only.
The seat bar sensor is part of the BICS™ system. The seat bar sensor sends a signal that indicates whether the seat bar is in the down or up position. The sensor is located on the left side of the seat bar.
WARNING Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W-2004-1285
PROBLEM
SOLUTION #
Indicator light does not turn OFF when seat bar is lowered.
1, 2, 3, 4, 5
1. Check sensor wire connection. 2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller. 3. Check for loose hardware. 4. Check keyed bushing to make sure magnet collar rotates with seat bar. 5. Check magnet collar magnets for contamination such as metal particles.
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SOLUTION SUGGESTIONS
Figure 60-100-3
SEAT BAR SENSOR (CONT'D) Testing Figure 60-100-1
2
1 1 P-4698
If there is no power light (Item 1) [Figure 60-100-3] on the sensor tester, check the tester or wiring harness.
P-85653
Figure 60-100-4
Connect the seat bar sensor adapter leads (MEL1567) to the sensor tester. 1 Disconnect the seat bar sensor connector (Item 1) [Figure 60-100-1]. Figure 60-100-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1) [Figure 60-100-4] should illuminate.
1
Raise the seat bar. The Sensor Test light (Item 1) [Figure 60-100-4] should go off. If the above test fails, there is a problem with the seat bar sensor or with the sensor harness.
P-85925
Disconnect the Sensor Tester. Connect the Sensor Tester (Item 1) [Figure 60-100-2] inline, to the seat bar sensor connectors. [Figure 60-1002]. Turn the key to the ON position. DO NOT START THE ENGINE.
Replace the Seat Bar Sensor. (See Removal And Installation on Page 60-100-3.) If the above test passes, run the seat bar sensor BICS™ circuit test. (See Bobcat Interlock Control System (BICS™) Circuit Test on Page 60-100-6.)
The toggle switch (Item 2) [Figure 60-100-3] can be in either the Absent or Present position.
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Use Sensor Tester (MEL1428) and seat bar sensor adapter (MEL1567) for the following procedure:
Figure 60-100-7
SEAT BAR SENSOR (CONT'D) Removal And Installation NOTE: This procedure is performed with the seat bar in the raised position and the technician in the operators seat.
3
Figure 60-100-5 2
1
1
P100745
Remove the retaining pin (Item 1) and clevis pin (Item 2) [Figure 60-100-7]. Remove the seat bar mounting bolt and nut (Item 3) [Figure 60-100-7]. 2
Dealer Copy -- Not for Resale
P100742
Remove the sensor mounting bolt and nut (Item 1) [Figure 60-100-5]. Disconnect the sensor wiring connector (Item 2) [Figure 60-100-5]. Figure 60-100-6
2
1 P100743 P100759
Tighten the clevis bolt (Item 1) until spring tension is released from the clevis pin (Item 2) [Figure 60-100-6]. NOTE: Approximately 4 turns of the clevis bolt should be adequate to release the spring tension. When tension is released, the clevis pin can easily be rotated using the retaining pin.
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Remove and save the metal pivot bushing (Item 6) [Figure 60-100-9].
SEAT BAR SENSOR (CONT'D) Removal And Installation (Cont’d)
Figure 60-100-10 Figure 60-100-8 3 2 1 4
5
P100748
Pull the front of the seat bar down slightly from the top of the cab, while raising the sensor end of the seat bar up, away from the mount [Figure 60-100-8].
Install the new keyed bushing (Item 1), magnet bushing (Item 2) and seat bar sensor (Item 3) [Figure 60-100-10]. Reinstall the metal pivot bushing (Item 4) [Figure 60100-10].
NOTE: The sensor end of the seat bar will raise easily ONLY if the front of the seat bar is pulled slightly down from the top of the cab.
NOTE: The sensor must be centered on the metal pivot bushing. When centered, the assembly will slide freely into the mount.
Figure 60-100-9
Figure 60-100-11
5 4 3 3 1 1
6
2 2 P100747 P100749
Place a soft jaw locking pliers (Item 1) [Figure 60-100-9] on the cab side screen to hold the seat bar above the mount. Remove the clevis pin bushing (Item 2) [Figure 60-1009]. Apply grease to the shoulder of the bushing to help retain it during assembly. Reinstall the clevis pin bushing. Remove and dispose of the keyed bushing (Item 3), magnet bushing (item 4), and seat bar sensor (Item 5)[Figure 60-100-9].
Position the clevis (Item 1) over the mount (Item 2) and lower the end of the seat bar until the mounting bolt (Item 3) [Figure 60-100-11] is resting on the top of the mount. Remove the nut from the mounting bolt. Remove the mounting bolt and lower the seat bar until the seat bar and mount holes align and the clevis is over the clevis pin bushing. Reinstall the seat bar mounting bolt. Apply Loctite® 243 to the nut threads. Install the nut and tighten to 46 N•m (34 ft-lb) torque.
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P100746
SEAT BAR SENSOR (CONT'D) Removal And Installation (Cont’d) Figure 60-100-12
1 2
3
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P100751 P100759
Reinstall the clevis pin (Item 1), and retaining pin (Item 2) [Figure 60-100-12]. Loosen the clevis bolt (Item 3) until the end of the bolt is flush with the clevis, then tighten the clevis bolt three full turns to set proper tension of the compression spring. Reconnect the sensor wiring connector (Item 2) [Figure 60-100-5 on Page 60-100-3]. Reinstall the sensor mounting bolt and nut (Item 1) [Figure 60-100-5 on Page 60-100-3] and tighten to 6,8 N•m (60 in-lb) torque.
IMPORTANT Be careful to not overtighten the sensor mounting bolt and nut to prevent breakage of the sensor. I-2088-1095
Verify correct seat bar sensor function by performing all of the steps in the Bobcat Interlock Control System (BICS™) inspection as described in the loader Operation & Maintenance Manual.
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Figure 60-100-14
SEAT BAR SENSOR (CONT'D) Bobcat Interlock Control System (BICS™) Circuit Test Figure 60-100-13
3
2
1 1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-100-14] inline to the seat bar sensor connectors. P-85653
Use Sensor Tester (MEL1428) and seat bar sensor adapter (MEL1567) for the following procedure: Connect the seat bar sensor adapter leads (MEL1567) to the sensor tester. Disconnect the seat bar sensor connector (Item 1) [Figure 60-100-13].
If the above test fails, there is a problem with the seat bar sensor or with the sensor harness. When the power light is illuminated, move the toggle switch (Item 2) [Figure 60-100-14] on the sensor tester to the Present position. NOTE: The sensor test light (Item 3) [Figure 60-10014] is only activated by the seat bar. It will be off with the seat bar up or on with the seat bar down.
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Turn the key to the ON position. DO NOT START THE ENGINE.
SEAT BAR SENSOR (CONT'D) Bobcat Interlock Control System (BICS™) Circuit Test (Cont’d) Figure 60-100-15
1
N-18409
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The BICS™ seat bar indicator light (Item 1) [Figure 60100-15] should turn OFF. Figure 60-100-16
1
P-4699
Move the toggle switch (Item 1) [Figure 60-100-16] on the sensor tester to the Absent position. The Seat Bar light (Item 1) [Figure 60-100-15] should illuminate. If the above test fails, there is a problem with the Bobcat Controller or the wiring harness.
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TRACTION LOCK
WARNING
Troubleshooting Chart The following troubleshooting chart is provided for assistance in locating and correcting BICS™ system problems. It is recommended that these procedures be done by authorized Bobcat Service Personnel only.
Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W-2004-1285
PROBLEM
CAUSE
Traction lock stays engaged.
1, 2, 3, 4, 5, 6, 7,11,12,13
Intermittent activation of traction lock.
8, 9, 10, 11 KEY TO CORRECT THE CAUSE
1. Make sure brake pedal is not engaged. 2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract. 3. If all lights indicate the brake should be released, but it has not released, check the brake 30 amp. fuse.
5. To test the solenoid, the pull coil should be about 0.3 ohm and the hold coil should be about 10.9 ohm. 6. Check brake solenoid and cover mounting hardware for the correct torque. 7. Remove brake cover and check wedges for binding in the wedge guides. 8. Check wire connections for loose connector body. 9. Check for loose or bent pins in connectors. 10. Check for loose spade connectors in fuse holder. 11. Check flywheel rpm sensor and wiring. 12. Check the Display Panel for an error code. 13. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
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4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses. (See ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.)
TRACTION LOCK (CONT'D)
Inspecting The Control System
Description Of The Control System
Fasten the seat belt, disengage the parking brake button, press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-110-1] and raise the Seat Bar fully. Move the steering levers slowly forward and backward. The TRACTION lock (Item 4) [Figure 60-110-1] should be engaged. Lower the Seat Bar. Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-110-1].
Figure 60-110-1
Engage the parking brake pedal and move the steering levers slowly forward and backward. The TRACTION lock should be engaged. NOTE: The TRACTION light on the left instrument panel will remain OFF until the engine is started, the PRESS TO OPERATE LOADER Button is pressed and the parking brake is disengaged.
1
1
2
3
4
B-15551G P-48521
The Traction Lock Control System will lock the traction drive system when the engine stops. The Traction Lock Control System is incorporated into the BICS™ System.
Check the wire connections at the engine flywheel rpm speed sensor (Item 1) [Figure 60-110-2]. NOTE: When the Traction Lock Override Button is activated, the Traction Lock Override Control System will NOT engage the Traction Lock if the engine stops. For Flywheel rpm sensor adjustment (See Adjustment on Page 60-140-1.)
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Figure 60-110-2
TRACTION LOCK (CONT'D) Solenoid Removal And Installation
WARNING AVOID INJURY OR DEATH Do not modify the electrical wiring connected to the traction lock solenoid or any part of the traction lock system. The traction lock provides the locking function of the parking brake. Service work on the traction lock system should only be performed by a qualified technician. Use only genuine Bobcat Company parts if repair is necessary. W-2165-0100
Raise the loader operator cab. (See Raising The Operator Cab on Page 10-30-1.)
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Figure 60-110-3
2
P-4712
1
P-34256
NOTE: The loader control panel and crossbar linkage has been removed for clarity purpose only. The traction lock can be removed without removing the control panel. Remove the two mounting screws (Item 1) [Figure 60110-3] from the electric solenoid mounting bracket. Installation: Tighten the mounting screws to 80 - 90 in.lb. (9 - 10 N•m) torque. Remove the electric solenoid (Item 2) from the chaincase cover [Figure 60-110-3].
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Figure 60-110-6
TRACTION LOCK (CONT'D) Solenoid Removal And Installation (Cont'd) Figure 60-110-4
1 1
N-19079
Inspect the guides (Item 1) [Figure 60-110-6] for wear or damage. Replace if necessary.
P-34377
1 2
Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. 3
Be sure the solenoid mounting bracket is installed in the same position. The solenoid mounting surface has a slight angle which tips the top of the solenoid toward the rear of the loader when installed correctly. See inset photo [Figure 60-110-3]. Figure 60-110-5
P7926
1 Remove and inspect the compression spring (Item 1) and spring cap washer (Item 2) [Figure 60-110-7] for wear or damage. Replace if necessary. The spring may also stay with the shaft when the electric solenoid and bracket are removed from the chaincase. Installation: Install the compression spring (Item 1) [Figure 60-110-7] on the collar located on the electric solenoid. Remove the traction lock assembly (Item 3) [Figure 60110-7] from the chaincase.
N-19108
Remove the traction lock assembly (Item 1) [Figure 60110-5] from the chaincase.
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Figure 60-110-7 Remove the bracket (Item 1) [Figure 60-110-4] from the chaincase cover.
TRACTION LOCK (CONT'D)
Guide Removal
Solenoid Removal And Installation (Cont'd)
The part number listed below will be needed to do the following procedure:
Figure 60-110-8 Raise the loader lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.)
2 3
P/N 6633583 - Polyurethane
WARNING
1
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
P-7964
Installation: Thoroughly clean and dry the shaft mounting bolt (Item 1), the shaft (Item 2) and wedge (Item 3) [Figure 60-110-8]. Use Loctite® #242 when assembling these parts to the traction lock assembly.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the engine speed control. (See Removal And Installation on Page 70-20-1.) Remove the control panel from the loader. (See Removal And Installation on Page 50-100-1.) Remove the traction lock solenoid assembly. (See Solenoid Removal And Installation on Page 60-110- 3.)
IMPORTANT WARNING
Failure to use Loctite® may allow the traction lock assembly to loosen up which can cause damage to the traction lock system. I-2090-1095
Install the engine speed control. (See Removal And Installation on Page 70-20-1.) Lower operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
AVOID INJURY OR DEATH Do not modify the electrical wiring connected to the traction lock solenoid or any part of the traction lock system. The traction lock provides the locking function of the parking brake. Service work on the traction lock system should only be performed by a qualified technician. Use only genuine Bobcat Company parts if repair is necessary.
Perform the BICS™ inspection procedure. (See BICS™ SYSTEM on Page 60-90-1.)
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W-2059-0598
Remove the shaft mounting bolt (Item 1), spring from the assembly shaft (Item 2). Remove the wedge (Item 3) [Figure 60-110-8] and inspect all parts for damage or wear. Replace if necessary.
Figure 60-110-11
TRACTION LOCK (CONT'D) Guide Removal (Cont’d) Figure 60-110-9
1
1 P11330
To remove the traction lock guides remove the four bolts (Item 1) [Figure 60-110-11].
N-19079
1
3
Figure 60-110-10
1
2
2 P11332
Thoroughly clean the polyurethane from the chaincase cover (Item 1), bolts (Item 2) and traction lock guides (Item 3) [Figure 60-110-12] and dry.
P11331
NOTE: Bolt (Item 1) is on the rear of the chaincase cover, notice the direction of the groove (Item 2) [Figure 60-110-10] in the traction lock guides.
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Figure 60-110-12 Remove the center chaincase cover [Figure 60-110-9] (See Center Cover Removal And Installation on Page 4030-3.)
Figure 60-110-15
TRACTION LOCK (CONT'D) Guide Installation
INCORRECT
CORRECT
Figure 60-110-13 3 2
1 N-19106
N-19105
Install the traction lock guides (Item 1) to the chaincase cover (Item 2) [Figure 60-110-15] using the four bolts (removed earlier).
Apply a bead of polyurethane (P/N 6633583) on the traction lock guides and bolts [Figure 60-110-13].
Do not tighten at this time.
Dealer Copy -- Not for Resale
P11333
Figure 60-110-16 Figure 60-110-14
1 2 3 2 4
4 1
P11337 P11334
Install the electric solenoid / bracket assembly (Item 1) to the center chaincase cover (Item 2) [Figure 60-110-14].
Install the traction wedge assembly (Item 1) into the solenoid and traction lock guides (Item 2) [Figure 60110-16].
NOTE: Bolt (Item 3) [Figure 60-110-14] and [Figure 60110-15] represents the rear of the chaincase cover.
After the bolts have been tightened recheck to make sure the shaft assembly is moving freely in the guides.
Install and tighten the two bolts (Item 4) [Figure 60-11014].
Remove the wedge assembly (Item 1) [Figure 60-11016]. NOTE: The wedge assembly must slide freely in the grooves of the guides. Tighten the four guide bolts to 90 - 100 ft.-lb. (123 - 135 N•m) torque.
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Figure 60-110-19
TRACTION LOCK (CONT'D) Guide Installation (Cont'd) Figure 60-110-17
1
2
1
2
1
N-19109
Install the wedge assembly (Item 1) [Figure 60-110-19] into the grooves in the traction lock guides making sure that there is no binding.
Remove the two bolts (Item 1) and remove the electric solenoid (Item 2) [Figure 60-110-17] from the center chaincase cover.
Install the gasket (Item 2) [Figure 60-110-19].
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P11334
Figure 60-110-18
1 2
N-19079
Install the chaincase cover (Item 1) using the ten mounting bolts (Item 2) [Figure 60-110-18]. Tighten to 15 - 20 ft.-lb. (20 - 27 N•m) torque. NOTE: Thoroughly clean and dry the bolts and apply polyurethane sealant to the bolt threads. Install a new gasket between the chaincase cover and the chaincase. Apply polyurethane sealant to the gasket also.
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Figure 60-120-2
ADVANCED CONTROL SYSTEM (ACS) Components Identification
2
Figure 60-120-1
1 11 2 P-21938
P-16536
P-21939
Foot control / sensor assembly (Item 1) [Figure 60-1202].
P-21879
The ACS system allows the operator to quickly switch between foot and hand control modes.
NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
Control Handle (Item 1) [Figure 60-120-1].
Figure 60-120-3
Handle sensor (Item 2) [Figure 60-120-1]. 1
NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
1 P-24203
Control Valve Actuators (Item 1) [Figure 60-120-3]. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
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Foot sensor (Item 2) [Figure 60-120-2]. The Advanced Control System (ACS) is a selectable foot / hand control system.
Figure 60-120-5
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Components Identification (Cont'd) Figure 60-120-4
1
P-21769
1
ACS error indicator (Item 1) [Figure 60-120-5]. NOTE: The ACS icon will illuminate when an error occurs. The error is stored as a service code. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.)
ACS Controller (Item 1) [Figure 60-120-4]. NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
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P-21767
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Troubleshooting Guide The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code. The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will stop its check at the first problem and then illuminate the icon. The system starts its diagnostics and calibration when the ignition key is turned ON.
Advanced Control System
Attachment Control Device
General Warning
Fuel Level
System Voltage
Engine Oil Pressure
Engine Coolant Temperature
Air Filter
Two Speed
Glow Plugs
Seat Belt
Hydraulic Charge Pressure
Hydraulic Oil Temperature
Hydraulic Filter
Advanced Control System Errors-lights solid with 3 beeps 32-04- ACS in error 32-23- ACS not calibrated 32-31- Tilt actuator fault 32-34- Tilt actuator not calibrated 32-35- Tilt handle / pedal not calibrated 32-36- Lift actuator fault 32-39- Lift actuator not calibrated 32-40- Lift handle / pedal not calibrated 32-49- Lift actuator short to ground 32-50- Tilt actuator short to ground 32-51- Lift actuator short to battery 32-52- Tilt actuator short to battery 32-53- Lift handle / pedal short to ground
32-54- Tilt handle / pedal short to ground 32-55- Lift handle / pedal short to battery 32-56- Tilt handle / pedal short to battery 32-57- Lift actuator reduced performance 32-58- Tilt actuator reduced performance 32-59- Lift actuator wrong direction 32-60- Tilt actuator wrong direction 32-61- Handle lock short to ground 32-62- Handle lock short to battery 32-63- Pedal lock short to ground 32-64- Pedal lock short to battery 32-65- Sensor supply voltage out of range 32-66- Battery out of range 32-67- Switch flipped while operating
To see what error occurred. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.)
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The following list shows the probable causes when the icon is illuminated.
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Controller, Connector And Wire Identification
H J K
G F E D
F E
A B C
H J K
G F E
G H A B
D
C J2
B
J3
J2
A
J1
C
J3 J1
J2
P-21843
P/N J1 Orange Orange Green Purple Purple Purple Black Black J2
Green Green Green Green Green Green
PIN A B C D E F G H A B C D E F G H J K
DESCRIPTION
P/N
CONNECTOR, METRI-PACK 5V HALL EFFECT SUPPLY SWITCHED ACS POWER HAND / FOOT INPUT CAN SIGNAL HIGH ACS CAN SIGNAL LOW ACS CAN SHIELD ACS ACS GROUND ACS GROUND CONNECTOR, METRI-PACK OPEN OPEN OPEN OPEN TILT SPOOL SIGNAL LIFT HANDLE SIGNAL TILT HANDLE SIGNAL LIFT SPOOL SIGNAL LIFT PEDAL SIGNAL TILT PEDAL SIGNAL
J3 Red Red/White Red/White Black Green Red Green Black Black Black
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PIN A B C D E F G H J K
DESCRIPTION CONNECTOR, METRI-PACK TILT ACTUATOR FORWARD UNSWITCHED ACS POWER UNSWITCHED ACS POWER LIFT ACTUATOR REVERSE HANDLE LOCK POWER LIFT ACTUATOR FORWARD PEDAL LOCK POWER ACS GROUND ACS GROUND TILT ACTUATOR REVERSE
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
D
J3
J1
Figure 60-120-8
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) ACS Controller Removal And Installation Figure 60-120-6
1
1 P-21840
Remove the two mounting bolts (Item 1) [Figure 60-1208] from the controller.
P-21839
Remove the right front panel (Item 1) [Figure 60-120-6] from the loader.
NOTE: The calibration procedure must be followed when replacing handle sensor, foot pedal sensor, actuator or ACS Controller. (See Calibration Procedure on Page 60-120-16.)
Figure 60-120-7
1
P-21843
Disconnect the wiring harness connectors (Item 1) [Figure 60-120-7] from the controller.
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Remove the controller from the loader. Loosen the bottom bolts and remove the top bolt on the right front panel [Figure 60-120-6].
Figure 60-120-11
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Handle Sensor Connector Figure 60-120-9
1 2
3
1
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-12011] and pull the wire from the connector.
The wire connector (Item 1) [Figure 60-120-9] can be removed from the handle sensor wires, using the following procedure.
Installation: Install the wires into the connector as listed below [Figure 60-120-11]:
Figure 60-120-10
Dealer Copy -- Not for Resale
P16578
1-Terminal - Red 2-Terminal - Black 3-Terminal - Green
1 1
P13725
P13732
Remove the wedge (Item 1) [Figure 60-120-10] from the connector.
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Figure 60-120-14
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Removal Figure 60-120-12
1
3 2 1
P13735
1
2
Using a pointed tool, press down on the tab (Item 1) [Figure 60-120-14] and pull the wire from the connector.
P-21879
Figure 60-120-15
Disconnect the harness connector (Item 1) [Figure 60120-12] from the handle sensor connector. Disconnect the harness connector (Item 2) [Figure 60120-12] from the handle lock solenoid connector. 1
Figure 60-120-13
1 P13725
P13732
Remove the wedge (Item 1) [Figure 60-120-15] from the harness connector (Black) that connects to the handle lock solenoid connector.
1
1 P13725
P13732
Remove the wedge (Item 1) [Figure 60-120-13] from the harness connector (Gray) that connects to the handle sensor connector.
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NOTE: Switch handle can be removed and installed while in loader.
Figure 60-120-18
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Removal (Cont'd) Figure 60-120-16
2
3
1
4
1
3 2
N-17772
1 Disconnect the left switch handle connectors (Items 1, 2, 3 and 4) [Figure 60-120-18] from the loader wiring harness connectors.
Using a pointed tool, press down on the tab (Item 1) [Figure 60-120-16] and pull the wire from the connector.
Figure 60-120-19
Dealer Copy -- Not for Resale
P13735
Figure 60-120-17
1 2
2
1
N-22783
2 Roll the pistol grip handle cover (Item 1) [Figure 60-12019] down.
N-17779
Disconnect the right switch handle connectors (Items 1 and 2) [Figure 60-120-17] from the loader wiring harness connectors.
Using a small screwdriver, lift the handle tabs (Item 2) [Figure 60-120-19] and slightly rotate the switch handle.
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ADVANCED CONTROL SYSTEM (ACS) (CONT'D)
Switch Handle Installation
Switch Handle Removal (Cont'd)
Figure 60-120-22
Figure 60-120-20
2
Tape 1/2 of Wires Tape back 1/2 of Wires
P-24233
1
P-21699 N-22784
Pull the switch handle and wiring harness assembly (Item 1) [Figure 60-120-20] from the control lever. Cut the wires (Item 2) [Figure 60-120-20] below the switch handle and remove switch handle. NOTE: Only cut the wires if the switch handle is bad and needs replacement. If the switch handle is good and just needs to be removed for control handle or lever replacement, then remove the connectors on the end of the harness and pull switch handle and harness up through the top of the lever tube.
The switch handle comes with a 6 inch piece of heat shrink tube slid over the end of the wires. Remove the heat shrink tube from the end of the wires before routing the harness through handle and control lever tube. NOTE: Leave all the other heat shrink tube on the wires for protection. Tape half of the wires back and half forward [Figure 60120-22] to keep the harness small enough to route through the control lever tube.
Figure 60-120-21
1
P-24234
If the harness has been cut: pull the harness (Item 1) [Figure 60-120-21] out through the bottom of the control lever tube.
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When installing the new switch handle, tape the wire terminals together.
ADVANCED CONTROL SYSTEM (ACS) (CONT'D)
Install the wires into the connectors as listed below:
Switch Handle Installation (Cont'd)
Right Switch Handle
Figure 60-120-23
Ten-Pin Connector A-Terminal - Orange B-Terminal - White C-Terminal - White/Black D-Terminal - White/Red E-Terminal - Dk. Green F-Terminal - White/Lt. Green G-Terminal - Yellow/Red H-Terminal - Lt. Green J-Terminal - Yellow K-Terminal - Orange/Black
1
Three-Pin Connector A-Terminal - Red/White B-Terminal - Black/White C-Terminal - Purple/White
Install the new switch handle and wires from the top of the control lever. Route wire (Item 1) [Figure 60-120-23] through the casting, along side the handle sensor and into the control lever tube. NOTE: Do not pull the wire harness tight. Allow a small amount of slack or slight bend at the handle pivot area. Verify the control handle returns to neutral position. Figure 60-120-24
Left Switch Handle Ten-Pin Connector A-Terminal - Orange B-Terminal - Dk. Blue C-Terminal - White D-Terminal - Purple E-Terminal - Yellow/Red F-Terminal - Tan G-Terminal - Pink H-Terminal - Orange/Black J-Terminal - Blank K-Terminal - Blank
Dealer Copy -- Not for Resale
P-21700A
Three-Pin Connector A-Terminal - Red/White B-Terminal - Black/White C-Terminal - Purple/White
2
Two-Pin Connector A-Terminal - Black B-Terminal - Red Five-Pin Connector A-Terminal - Dk. Green B-Terminal - Brown C-Terminal - Blank D-Terminal - Yellow E-Terminal - Blank
1
P-21695
Remove tape from wires for installation and install the 6 inches of heat shrink tube (Item 1) [Figure 60-120-24] approximately 3 inches into the control lever. Apply heat to the exposed heat shrink tube. Inspect the wire terminal tabs (Item 2) [Figure 60-12024] and re-bend tabs if necessary. 60-120-10 689 of 949
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Figure 60-120-27
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation (Cont'd) Figure 60-120-25
1 1
3 2
P13735
1
Install the wires into the connectors as listed below: N-17779
Left And Right Control Lever Switch Handle [Figure 60120-27] Figure 60-120-26
1
Dealer Copy -- Not for Resale
1-Terminal - Red/White 2-Terminal - Black/White 3-Terminal - Purple/White Figure 60-120-28
1
3
N-17772
2
Connect the handle harness connectors (Item 1) [Figure 60-120-25] and [Figure 60-120-26] to the loader harness connectors.
P13735
Left And Right Control Lever Switch Handle [Figure 60120-28] 1-Terminal - Yellow/Red 2-Terminal - Open 3-Terminal - Orange/Black
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Figure 60-120-31
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation (Cont'd)
1 Figure 60-120-29
N-18940
Check the mounting block (Item 1) [Figure 60-120-31] and bolts for wear and replace as needed.
P-21804
Dealer Copy -- Not for Resale
Connect the handle harness connectors to the sensor and lock solenoid connectors [Figure 60-120-29]. Actuators Disassembly And Assembly Figure 60-120-30
1
N-18912
Remove the control panel. (See Removal And Installation on Page 50-100-1.) Remove the actuator (Item 1) [Figure 60-120-30] from the hydraulic control valve. (See Actuator Removal And Installation on Page 20-41-12.) Installation: Tighten the mount bolts to 90 - 100 in.-lb. (10,2 - 11,3 N•m) torque.
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ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Actuators Disassembly And Assembly (Cont’d) Figure 60-120-32
2
1 N-17742
N-17741
Dealer Copy -- Not for Resale
Check the actuator wiring harness connector (Item 1) [Figure 60-120-32] and replace if broken. Installation: Install the wires into the connector as listed below. The terminal numbers are written on the back of the connector (Item 2) [Figure 60-120-32]. Lift And Tilt Actuator 1. Terminal-Black/Green-Larger diameter wire (16 gauge) 2. Terminal-Green-Larger diameter wire (16 gauge) 3. Terminal-Red/Green-Larger diameter wire (16 gauge) 4. Terminal-Open 5. Terminal-Red-Smaller diameter wire (18 gauge) 6. Terminal-Open 7. Terminal-Open 8. Terminal-Black-Smaller diameter wire (18 gauge) NOTE: The calibration procedure must be followed when replacing a handle sensor, foot pedal sensor, actuator or ACS controller. (See Calibration Procedure on Page 60-120-16.)
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ADVANCED CONTROL SYSTEM (ACS) (CONT'D)
Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation
Figure 60-120-35
Figure 60-120-33
2
1 2 P-21878A
1 P-21836
Disconnect the harness connector (Item 1) [Figure 60120-33] from the handle sensor connector. Disconnect the harness connector (Item 2) [Figure 60120-33] from the handle lock solenoid connector.
Installation: Apply a drop of oil to the solenoid threads and tighten solenoid to 35 - 40 ft.-lb. (47 - 54 N•m) lubed torque. Figure 60-120-36
Figure 60-120-34
1
1
P-21789 P-21832
Remove the two screws (Item 1) [Figure 60-120-34] holding the handle lock solenoid to the handle.
Check the O-ring (Item 1) [Figure 60-120-36] for damage. Replace as necessary.
Installation: Tighten the screws to 32 - 38 in.-lb. (3,6 4,3 N•m) torque. Remove handle lock solenoid assembly from handle.
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Remove solenoid (Item 1) from the solenoid mount (Item 2) [Figure 60-120-35].
Figure 60-120-39
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Connector Figure 60-120-37
1
2
3
1
P-21802
1
With a pointed tool, lift the tab (Item 1) [Figure 60-12039] and pull the wire from the connector.
The wire connector (Item 1) [Figure 60-120-37] can be removed from the solenoid, using the following procedure: Figure 60-120-38
1
Installation: Install the wires into the connector as listed below [Figure 60-120-39].
Dealer Copy -- Not for Resale
P-21787
1 - Terminal - Black 2 - Terminal - Open 3 - Terminal - Black
1
P-21801
Remove the wedge (Item 1) [Figure 60-120-38] from the connector.
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Figure 60-120-42
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Calibration Procedure The new controller uses a calibration sequence to optimize the control system. The optimizing ensures full spool stroke (full flow) while preventing over stroke (loading) of the actuator. NOTE: This calibration procedure must be followed when replacing a handle sensor, actuator or ACS controller. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s).
2
1
Figure 60-120-40 B-16627
Push the PRESS TO OPERATE button (Item 1) [Figure 60-120-42] to unlock the hand controls.
1 Stroke Both Handles Fully In and Hold Them
P-24182
Update the loader service software to the latest version. Place the rocker switch (Item 1) [Figure 60-120-40] in the hand control mode. B-16628
Figure 60-120-41
Fully stroke both control handles in toward the center of the cab and hold the handles [Figure 60-120-43]. Lift the seat bar, high enough for the PRESS TO OPERATE light (Item 2) [Figure 60-120-42] to go OFF.
Turn the Key On or
Lower the seat bar.
Press the RUN/ENTER
B-16626
With the seat bar down, turn the ignition key ON (keyless panel press RUN / ENTER) [Figure 60-120-41]. NOTE: Do not start the engine. 60-120-16 695 of 949
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Figure 60-120-43
Figure 60-120-45
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Calibration Procedure (Cont'd)
Stroke Both Handles Fully In and Hold Them
Figure 60-120-44
2
2
1
1 B-16628
Push the PRESS TO OPERATE button (Item 1) [Figure 60-120-44] to begin calibration.
Fully move both handles out toward the cab side screens and hold for one second (Item 2) [Figure 60-120-45].
NOTE: The ACS icon will light up and if you listen closely the cycling of the actuators can be heard. The ACS icon will stay lit until the ignition key is cycled or the loader is started and a function is operated.
Allow both handles to return to neutral. Figure 60-120-46
NOTE: During the calibration cycle, the system will beep three times. The calibration process generates two codes 32-35 (tilt handle not in neutral) and 32-40 (lift handle not in neutral). Ignore these two codes, this is normal during the calibration procedure.
1
Release the control handles. 2 NOTE: The remaining portion of the procedure must be completed in twenty seconds or less. If not the handles and pedals will lock and the procedure must be started over from the beginning.
B-16628
Fully press the toe of the lift and tilt pedals (Item 1) [Figure 60-120-46] down and hold for one second. Fully press the heel of the lift and tilt pedals (Item 2) [Figure 60-120-46] down and hold for one second. Allow both pedals to return to neutral. At the end of the twenty second time frame, the handles and pedals will lock. Calibration is complete.
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Fully move both handles in toward the center of the cab and hold the handles for one second (Item 1) [Figure 60120-45].
B-16627
ADVANCED CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Connector
Foot Sensor Disassembly And Assembly
Figure 60-120-49
Figure 60-120-47
1
1 P-24271
1 P-24269
Figure 60-120-50 Installation: Tighten the bolts to 90 in.-lb. (10,2 N•m) torque. Apply Loctite® 242 to the threads. 1
Figure 60-120-48 5
1
1
4 2 1
P-24272
3
P-24273 P-24273
Remove the wedge (Item 1) [Figure 60-120-50] from the connector.
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool stop plate (Item 3), O-ring (Item 4) [Figure 60-120-48]. NOTE: Do not disassemble the sensor assembly (Item 5) [Figure 60-120-48]. The sensor assembly is a calibrated assembly and cannot be serviced. Order through Bobcat Parts.
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Remove the two bolts (Item 1) [Figure 60-120-47] from the end of the foot sensor.
The wire connector (Item 1) [Figure 60-120-49] can be removed from the sensor wires, using the following procedure:
Figure 60-120-53
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Connector (Cont'd)
1
Figure 60-120-51
1 2
3
1 2
P-21939
Disconnect the foot lock solenoid connector (Item 1) [Figure 60-120-53] from the harness.
P-24274
Installation: Install the wires into the connector as listed below [Figure 60-120-51]:
Installation: Apply a drop of oil on the solenoid threads and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m) lubed torque. Figure 60-120-54
1 - Terminal - Red 2 - Terminal - Black 3 - Terminal - Green Foot Lock Solenoid Removal And Installation Figure 60-120-52
2
1
P-21790
Check the O-ring (Item 1) [Figure 60-120-54] for damage. Replace as necessary. 1 P-21938
Remove the two bolts (Item 1) [Figure 60-120-52] from the foot sensor shield. Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2 N•m) torque.
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Remove foot lock solenoid (Item 2) [Figure 60-120-53]. With a pointed tool, lift the tab (Item 1) [Figure 60-12051] and pull the wire from the connector.
ADVANCED CONTROL SYSTEM (ACS) (CONT'D) Foot Lock Solenoid Connector The wire connector (Item 2) [Figure 60-120-54] can be removed from the solenoid wires, using the following procedure: Figure 60-120-55
1
1
P-21801
Dealer Copy -- Not for Resale
P-21800
Remove the wedge (Item 1) [Figure 60-120-55] from the connector. Figure 60-120-56
3
1 2 1
P-21802
With a pointed tool, lift the tab (Item 1) [Figure 60-12056] and pull the wire from the connector. Installation: Install the wires into the connector as listed below [Figure 60-120-56]: 1 - Terminal - Black 2 - Terminal - Open 3 - Terminal - Black
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ELECTRICAL / HYDRAULIC CONTROLS REFERENCE Controls Identification Chart
B-16447
Solenoid Number Activated RH
HFH
Attachment Harness Attachment Harness Terminal Connector Activated
1
1
1
1, 8
K
2
2
2
2
K
3
1
1
1, 8
K
4
2
2, 3
6, 7
K, A, D
5
1
1, 3
5, 7
K, A, C
6
1
1, 3
5, 7
K, E
7
1
1, 3
5, 7
K, F
8
1
1, 3
5, 7
K, G
9
1
1, 3
5, 7
K, H
10, 11, 12, 13, 14
-
--
--
K
Fourteen Pin Connector Viewed from front (pin side of connector) of loader.
Right Side Control Handle Switches
B-16449 B-16448
1
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed kit.) The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin connector when connected. If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for the proper procedure. RH - Loaders with Rear Hydraulics Option. HFH - Loaders with High Flow Hydraulics Option. * If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 and 2. * Terminal K is activated with Key switch ON.
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Left Side Control Handle Switches
xxxxxxxxx Switch Number
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (CONT’D) Controls Identification Chart (Cont’d)
S150
Solenoid Number 1
4
2
1
2 3
3
4
5
5 6
S160
Hydraulic Coupler Front Female (Base) Front Male (Rod) Diverter & Bleed Rear Aux Base Rear Aux Rod High Flow
Wiring Number 4340
4330 4450/4480 4440 4430 4460
6
Dealer Copy -- Not for Resale
1 4
2
3
5
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in at the front auxiliary block. The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so equipped.) The Hi-Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6 at the High Flow Block.
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ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) Controls Identification Chart
RIGHT HAND
17
18 1
2 8
11 9 16
P-24802
1. Front Aux. 2. Front Aux. 3. Auxiliary Detent 8. Right Ski (Up) 9. Right Ski (Down) 10. Right Blink 11. Left Blink 16. Float (Yellow in Color) 17. Future Function 18. Future Function
3
P-28316
LEFT HAND
19 4
20 5
4. Rear Aux. (Side Shift 5. Rear Aux. (Side Shift) 6. Left Skit (Up) 7. Left Ski (Down) 12. Two-Speed (High) 13. Two-Speed (Low) 14. Horn 15. Inching Control (Grey in Color) 19. Future Function 20. Future Function
12 6 7
13 15
14
P-24820
P-28317
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10
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Controls Identification Chart (Cont’d)
4
Solenoid Number Activated
Attachment Harness Terminal Activated
STD
RH
HFH
HRH
1
1
1
1, 6
1, 6
K
2
2
2
2
2
K
3
1
1
1, 6
1, 6
K
4
2
3, 5
2
3, 5
K, A, D
5
1
3, 4
1
3, 4
K, A, C
6
1
3, 4
1
3, 4
K, E
7
1
3, 4
1
3, 4
K, F
8
1
3, 4
1
3, 4
K, G
9 1 3, 4 Attachment Harness Connector
1
3, 4
K, H
5
6
7
Fourteen Pin Connector Viewed from front (pin side of connector) of loader.
Right Side Control Handle Switches
8
9 2
1
3
1 B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed kit.) The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin connector when connected. If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for the proper procedure. RH - Loaders with Rear Hydraulics Option. HFH - Loaders with High Flow Hydraulics Option. * If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 and 2. * Terminal K is activated with Key switch ON. HRH - Loaders with High Flow and Rear Hydraulics Option.
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xxxxxxxxx Switch Number
Left Side Control Handle Switches
ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) (CONT’D) Controls Identification Chart (Cont’d) Solenoid Number
S150
1 4
2
1
2 3 4
3
5
5 6
Hydraulic Coupler Front Female (Base) Front Male (Rod) Diverter & Bleed Rear Aux Base Rear Aux Rod High Flow
Wiring Number 4340
4330 4450/4480 4440 4430 4460
1 4
6
2
3
5
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in at the front auxiliary block. The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so equipped.) The Hi-Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6 at the High Flow Block.
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Figure 60-140-2
FLYWHEEL RPM SENSOR Adjustment Figure 60-140-1
1
1
2
P-48666
When reinstalling the rpm sensor, turn the rpm sensor (Item 1) [Figure 60-140-1] in until it makes contact with the engine flywheel. Turn the jam nut (Item 2) [Figure 60-140-1] until it contacts the flywheel housing. The jam nut should not be tightened, it needs to turn with the rpm sensor when the sensor is turned back out for adjustment.
NOTE: New rpm sensors have a plastic tip which is used as a gauge during installation. The plastic tip is designed to come off after the engine is started.
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Turn the rpm sensor and the jam nut out from the flywheel. Set a clearance of 0.050 in. (1,27 mm) between the jam nut and the housing with a feeler gauge (Item 1) [Figure 60-140-2].
P-48665
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SERVICE PC (LAPTOP COMPUTER) Connecting The Service PC To Remote Start Tool Figure 60-150-1 2
1
3
P16119
Dealer Copy -- Not for Resale
Tools that will be needed to complete the following steps are: MEL1563 - Remote Start Tool MEL1565 - Service Tool Harness Control MEL1566 -Service Tool Harness Communicator (Computer Interface) NOTE: Make all connections with the key in the OFF position. The Service PC (Item 1) with the remote start tool (Item 2) [Figure 60-150-1]. When connected to the loader, the Service PC is used to monitor, conduct diagnostic and load software. Connect the Service Tool Harness Communicator (MEL1566) (Item 3) [Figure 60-150-1] to the designated serial port on the Service PC. NOTE: The recommended serial cable length should not exceed 15 feet. A serial cable longer than 15 feet will create a degraded signal causing communication errors. Connect the other end to the connector on the remote start tool. Connect the remote start tool to the loader. (See Remote Start Tool - MEL1563 on Page 10-60-1.)
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CALIBRATION
Actuator Testing
Description
The Actuator Test is performed with the Service PC and Remote Start Tool. The Actuator Test should be used if reduced performance codes are present and when replacing a controller or actuator. The Actuator Test should be used as the preferred method of actuator and valve spool calibration.
Calibration procedures must be followed when replacing a handle sensor, actuator, or any controller. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s). Figure 60-160-1
NOTE: Warm the hydraulic oil to room temperature 72o F (22o C), stop the engine and clear all active service codes before running the test.
Control Valve Actuators
Once the test is initiated, an automatic calibration sequence will start. When calibration is complete, the test will be performed and the results can be viewed on the Service PC (Laptop) monitor.
P-24203
[Figure 60-160-1] Excessive actuator loading can occur if the actuator and valve spool components are misaligned. Misalignment may reduce spool stroke performance and reduce the life of the actuator. Starting with version 36, the Bobcat Service Analyzer software will be able to perform tests to diagnose actuator and valve spool misalignment. The Actuator Test is performed with the Service PC and Remote Start Tool. The Actuator Test should be used if reduced performance codes are present and when replacing a controller or actuator. The Actuator Test should be used as the preferred method of actuator and valve spool calibration.
When complete, the Actuator Test will show a pass mode or fail mode. The pass mode indicates that no problems were detected. The fail mode indicates one or a combination of three problems below. •
Actuator slow return to neutral. The spool returns to neutral too slowly.
•
Actuator did not fully extend / retract. During the test, the spool was not able to fully stroke in both directions.
•
Actuator out of neutral. The spool did not return to the neutral window during the test.
NOTE: A time out will occur if the test cannot be completed within 8 seconds. If this happens, retry the test.
If a Service PC is not available, see: See Lift And Tilt Calibration Procedure (SJC) on page 60-160-4 or See Calibration Procedure (ACS) on page 60-160-11.
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This test will engage both actuators to fully stroke the spools then allow the centering springs to return the spools to neutral. Next, both actuators are engaged to move the spools just past the neutral points then allow the centering springs to return the spools to neutral.
Figure 60-160-3
CALIBRATION (CONT’D) Actuator Testing (Cont’d)
Actuator
Pin
Spool Hole
Figure 60-160-2 Run Actuator Test Pass
Fail
Retest With Warm Hydraulic Oil Fail
Adapter Bolts
Loosen Actuator Pass
Column 1 Probable Cause 1 - Misaligned Assembly 2 - Adapter / Pin 3 - Spool
N-18940
Fail
[Figure 60-160-3] If the Actuator Test fails after the hydraulic oil is warmed, go to the next step and loosen the bolts that mount the actuator to the control valve. Loosen the bolts just enough so the actuator can be moved slightly up / down or side / side.
Column 2 Probable Cause 1 - Actuator 2 - End Cap / Center Spring 3 - Wire Harness 4 - Controller
[Figure 60-160-2] If the initial Actuator Test results in a fail mode due to a slow return to neutral, follow the troubleshooting tree to pinpoint the probable cause.
Rerun the Actuator Test, if the test passes, check the following probable causes in Column 1 [Figure 60-1602]. Check the probable causes in the order they are listed. Repairing one cause may be all that is required. Rerun the test to verify. 1. Actuator and spool misalignment. Re-tighten the two bolts evenly, turn the first bolt one turn, then turn the other bolt one turn until both bolts are tight. Figure 60-160-4
Thickness Difference on Opposite Sides Must be Within 0.004” (0.102mm)
P-54928B
2. [Figure 60-160-4] The adapter may not be machined correctly. Adapters with a large difference in thickness measured on opposite sides should be replaced. The pin may be too large. Oversized pins exceeding 0.248 in (6.30mm) in diameter should be replaced.
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Pass
If the initial Actuator Test results in the fail mode actuator did not fully extend / retract, check the following.
CALIBRATION (CONT’D) Actuator Testing (Cont’d)
1. The actuator connectors may be reversed between the lift and tilt actuator. Reverse the connectors and rerun the Actuator Test.
Figure 60-160-5 This spool hole is not centered.
2. The actuator may be weak, replace the actuator. 3. The end cap may be defective or the centering spring may be broken. Inspect the end cap and the centering spring, replace if necessary.
The Hole is Shifted Off Center
If the initial Actuator Test results in the fail mode actuator out of neutral, check the following. 1. The actuator may be defective, replace the actuator.
3. [Figure 60-160-5] The spool hole may not be centered, visually inspect both sides. Replace the spool if the hole is not centered.
This letter is provided as technical information. Normal warranty applies.
NOTE: Later model spools have a slotted hole to reduce misalignment. If the Actuator Test failed due to a slow return to neutral after checking the probable causes in Column 1 [Figure 60-160-2], check the following probable causes in Column 2 [Figure 60-160-2]. 1. The actuator may be weak, replace the actuator. 2. The end cap may be defective or the centering spring may be broken. Inspect the end cap and the centering spring, replace if necessary. 3. The wire harness or connectors may have an intermittent short. Check the connections and wire harnesses. 4. The controller may be defective, replace the controller.
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2. The end cap may be defective or the centering spring may be broken. Inspect the end cap and the centering spring, replace if necessary.
P-54927
Figure 60-160-8
CALIBRATION (CONT’D) Lift And Tilt Calibration Procedure (SJC) NOTE: This calibration procedure must be followed when replacing the lift or tilt actuator, SJC controller or joystick. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s). Figure 60-160-6
1
P-26475
1
P-45240
With an operator in the seat and the seat bar down. Close the cab door. (If loader is so equipped.)
1
Place the loader Control Pattern Switch (Item 1) [Figure 60-160-6] in the ISO position.
P-26480
Figure 60-160-7 Turn the key (Item 1) [Figure 60-160-8] to the RUN position or press the RUN / ENTER button (Item 1) [Figure 60-160-9] for power, without starting the loader. The loader Control Pattern Switch (Item 1) [Figure 60160-6] will start flashing and will continue to flash until the calibration procedure is completed. B-19874
P-28063
Move the right joystick to the forward-right corner position [Figure 60-160-7] and hold in position.
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Figure 60-160-9
Hydrostatic Pump Calibration (SJC)
CALIBRATION (CONT’D) Lift And Tilt Calibration Procedure (SJC) (Cont’d)
WARNING
Figure 60-160-10
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.
2
W-2017-0286
Place the loader on jackstands. (See Procedure on Page 10-10-1.) Operator must be in the seat and the seat bar down. Figure 60-160-11
1
At the left panel, press the PRESS TO OPERATE Button (Item 1) [Figure 60-160-10] while holding the right joystick in position.
1
Release the joystick. 2 An audible beep will sound and an error code (Item 2) [Figure 60-160-10] (32-35 and 32-40) will be displayed if the operator presses the HOLD FOR CODES, (LIGHTS) switch. The SJC controller will cycle the actuators. The lift and tilt calibration is complete.
P-45238
Close the cab door. (If loader is so equipped.) Place the loader Control Pattern Switch (Item 1) [Figure 60-160-11] in the ISO position. Verify the parking brake (Item 2) [Figure 60-160-11] is OFF.
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P-26477A
Figure 60-160-14
CALIBRATION (CONT'D) Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-12
1
P-45238
1
The Control Pattern ISO Switch (Item 1) [Figure 60-16014] will start flashing.
P-26475
Figure 60-160-15
1
B-19873 P-26476
P-26480
Turn the key (Item 1) [Figure 60-160-12] to the RUN position or press the RUN / ENTER button (Item 1) [Figure 60-160-13] for power, without starting the loader.
Move the left joystick to the forward-left corner position [Figure 60-160-15] and hold in position.
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Figure 60-160-13
CALIBRATION (CONT'D)
Figure 60-160-18
Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-16
1 P-26477A
1
Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-160-18] while holding the left joystick in position.
Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-160-16] while holding the left joystick in position.
Three audible beeps will sound.
Dealer Copy -- Not for Resale
P-26477A
Figure 60-160-19
Three audible beeps will sound. Figure 60-160-17
B-19873 P-26474
Allow the left joystick to go to the neutral position [Figure 60-160-19].
P-26476
Move the left joystick to the reverse-right corner position [Figure 60-160-17] and hold in position.
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Figure 60-160-22
CALIBRATION (CONT'D) Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-20
1 2
75-98
3 P-34548
1
Move the throttle (Item 1) [Figure 60-160-22] to high idle.
Press the PRESS TO OPERATE LOADER Button (Item 1) [Figure 60-160-20].
NOTE: If at any time, during calibration, the operator needs to stop the loader, turn the key OFF, lift the seat bar, or return the joystick to the neutral position.
Three audible beeps will sound and the error code (Item 2) (75-98) will be displayed if the operator presses the HOLD FOR CODES (LIGHTS) switch (Item 3) [Figure 60-160-20].
The calibration procedure will stop. To return to calibration mode, the operator must start the complete procedure from the beginning.
Start the engine from the RUN, RUN / ENTER position. DO NOT TURN TO OFF POSITION. This would cancel the calibration mode and the procedure would have to be repeated.
WARNING
Figure 60-160-21 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
1
P-45238
The Control Pattern ISO Switch (Item 1) [Figure 60-16021] will stop flashing, and will remain ON for the rest of the calibration procedure.
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P-26477A
Figure 60-160-24
CALIBRATION (CONT'D) Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-23
1
2
B-19873 P-64321
Move and hold the left joystick to the forward position [Figure 60-160-23] until the forward calibration is completed.
The loader will then “stair step” the speed (Item 2) [Figure 60-160-24] until it reaches full speed and then come to a stop. Continue to hold the left joystick in the forward position until the loader tracks come to a stop and an audible beep is heard. Forward calibration is complete. NOTE: If the wheels do not stop moving in Full Speed Forward in 2 minutes or less, there was an error in the calibration procedure. The operator must shut the loader OFF, and start the calibration procedure from the beginning. Figure 60-160-25
B-19873
P-26483
Move and hold the left joystick to the reverse position [Figure 60-160-25] until the reverse calibration is completed.
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The loader speed will “ramp up” quickly (Item 1) [Figure 60-160-24] and slow down 3 times in a row.
P-26482
NOTE: If the wheels do not stop moving in Full Speed Reverse in 2 minutes or less, there was an error in the calibration procedure. The operator must shut the loader OFF, and start the calibration procedure from the beginning.
CALIBRATION (CONT'D) Hydrostatic Pump Calibration (SJC) (Cont'd) Figure 60-160-26
1
There will be an audible beep and the PRESS TO OPERATE LOADER and TRACTION lights will go out. The SEAT BAR and LIFT AND TILT lights will remain on. The 75-98 error code will clear. There should be no other codes in the display area.
2
Allow the joystick to go to the neutral position. The calibration procedure is completed. Press the PRESS TO OPERATE LOADER button. Move the left joystick to forward position [Figure 60-160-23] and check for normal forward wheel rotation. P-64321
The loader will then “stair step” the speed (Item 2) [Figure 60-160-26] until it reaches full speed and then come to a stop.
Stop the engine, and remove the loader from jackstands. Start the loader, press the PRESS TO OPERATE LOADER button and return to normal loader operation.
Continue to hold the left joystick in the reverse position until the loader wheels come to a stop and an audible beep is heard. Reverse calibration is complete.
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The loader speed will “ramp up” quickly (Item 1) [Figure 60-160-26] and slow down 3 times in a row.
Move the left joystick to the reverse position [Figure 60160-25] and check for normal reverse wheel rotation.
Figure 60-160-29
CALIBRATION (CONT’D) Calibration Procedure (ACS) The new controller uses a calibration sequence to optimize the control system. The optimizing ensures full spool stroke (full flow) while preventing over stroke (loading) of the actuator.
2
NOTE: This calibration procedure must be followed when replacing a handle sensor, actuator or ACS controller. Failure to calibrate after component replacement may result in poor performance or reduced life of actuator(s).
1
Figure 60-160-27
B-16627
Push the PRESS TO OPERATE button (Item 1) [Figure 60-160-29] to unlock the hand controls. Figure 60-160-30
Stroke Both Handles Fully In and Hold Them
P-24826
Update the loader service software to the latest version. Place the rocker switch (Item 1) [Figure 60-160-27] in the hand control mode. Figure 60-160-28
B-16628
Fully stroke both control handles in toward the center of the cab and hold the handles [Figure 60-160-30]. Lift the seat bar, high enough for the PRESS TO OPERATE light (Item 2) [Figure 60-160-29] to go OFF.
Turn the Key On or
Lower the seat bar. Press the RUN/ENTER
B-16626
With the seat bar down, turn the ignition key ON (keyless panel press RUN / ENTER) [Figure 60-160-28]. NOTE: Do not start the engine.
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1
Figure 60-160-32
CALIBRATION (CONT’D) Calibration Procedure (ACS) (Cont'd)
Stroke Both Handles Fully In and Hold Them
Figure 60-160-31
2
2
1
1 B-16628
Push the PRESS TO OPERATE button (Item 1) [Figure 60-160-31] to begin calibration.
Fully move both handles out toward the cab side screens and hold for one second (Item 2) [Figure 60-160-32].
NOTE: The ACS icon will light up and if you listen closely the cycling of the actuators can be heard. The ACS icon will stay lit until the ignition key is cycled or the loader is started and a function is operated.
Allow both handles to return to neutral. Figure 60-160-33
NOTE: During the calibration cycle, the system will beep three times. The calibration process generates two codes 32-35 (tilt handle not in neutral) and 32-40 (lift handle not in neutral). Ignore these two codes, this is normal during the calibration procedure.
1
Release the control handles. 2 NOTE: The remaining portion of the procedure must be completed in twenty seconds or less. If not the handles and pedals will lock and the procedure must be started over from the beginning.
B-16628
Fully press the toe of the lift and tilt pedals (Item 1) [Figure 60-160-33] down and hold for one second. Fully press the heel of the lift and tilt pedals (Item 2) [Figure 60-160-33] down and hold for one second. Allow both pedals to return to neutral. At the end of the twenty second time frame, the handles and pedals will lock. Calibration is complete.
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Fully move both handles in toward the center of the cab and hold the handles for one second (Item 1) [Figure 60160-32].
B-16627
SPEED SENSOR
Testing
Description
Figure 60-170-2
Figure 60-170-1
1 P-28302 P-64765
On SJC equipped loaders, the speed sensor [Figure 60170-1] is used by the loader’s controllers to sense if the drive motor is rotating. The end of the sensor is magnetic and counts the magnetic pulses as a rotating disc attached to the motor carrier shaft rotates by the sensor end. The speed sensor is sealed with an O-ring (Item 1) [Figure 60-170-1] to keep hydraulic oil inside the motor carrier and dirt out.
MEL1609-Wheel Speed Sensor Test Harness [Figure 60-170-2] MEL1563-Remote Start Tool Multimeter Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool to the loader. (See Remote Start Procedure on Page 10-60-4.)
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The tools listed will be needed to do the following procedure:
Figure 60-170-4
SPEED SENSOR (CONT'D) Testing (Cont’d) Figure 60-170-3
3 2 1 2
1
P-64976
Locate the speed sensor (Item 1) [Figure 60-170-3] on the top of the right or left hydrostatic motor carrier.
Turn the remote start key to ON position without starting the loader.
Remove the transmission cover screw (Item 2) [Figure 60-170-3], to loosen the connector clamp.
Take a voltage reading, with the multimeter, at the speed sensor test harness, between pin 1 and pin 3 (Item 2) [Figure 60-170-4].
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m) torque. Disconnect the speed sensor wire connector (Item 3) [Figure 60-170-3] from the loader harness wire connector.
The voltage should be approximately 5 volts. Repeat the procedure for the opposite side speed sensor. (If needed.)
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Connect the speed sensor test harness (Item 1) [Figure 60-170-4] in line, between the loader wiring harness and the speed sensor harness.
P-64762
Disconnect the speed sensor electrical connector (Item 2) [Figure 60-170-6].
SPEED SENSOR (CONT'D)
harness
Removal And Installation Figure 60-170-7 Figure 60-170-5
1 2
1
P-64764
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Lift the speed sensor (Item 1) [Figure 60-170-7] out from the motor carrier. DO NOT pull on the wires, gently pry up with a screwdriver if necessary. Figure 60-170-8
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the two, speed sensor mount bolts (Item 1) [Figure 60-170-5] from the top of the hydrostatic motor carrier. Remove the mount plate (Item 2) [Figure 60-170-5]. Figure 60-170-6 2 1
P-64765
Remove the speed sensor [Figure 60-170-8].
P-64762
Remove the transmission cover screw (Item 1) [Figure 60-170-6], to loosen the connector clamp. Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
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P-64762
Figure 60-170-11
SPEED SENSOR (CONT'D) Removal And Installation (Cont'd) Figure 60-170-9
1 1
P-26292
Installation: Be sure to install the speed sensor (Item 1) [Figure 60-170-11] pointing toward the transmission case.
P-26293
The electrical connector can be replaced.
Dealer Copy -- Not for Resale
Figure 60-170-12
Remove the connector wedge (Item 1) [Figure 60-1709]. Figure 60-170-10
1 2 1
P-26295
Installation: The alignment pin (Item 1) at the bottom of the speed sensor must be installed in the hole (Item 2) [Figure 60-170-12] in the motor carrier.
P-26294
With a thin screwdriver lift the tabs and remove the wires from the connector (Item 1) [Figure 60-170-10]. Wire Code 1 2 3 4
Red White Black Blue
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ENGINE SERVICE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1 COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 Blower Disassembly And Assembly. . . . . . . . . . . . . . . . . . 70-60-4 Blower Housing Grille Removal And Installation . . . . . . . . 70-60-4 Drive Tension Pulley Removal And Installation . . . . . . . . . 70-60-1 Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-11 Gearbox / Blower Housing Removal And Installation . . . . 70-60-2 Gearbox Checking Backlash . . . . . . . . . . . . . . . . . . . . . . 70-60-16 Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7 Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . 70-60-6
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-70-1 Testing Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . 70-70-15 Compression Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1 Fuel Injection Pump Removal And Installation (Non-Turbo)70-70-8 Fuel Injection Pump Removal And Installation (Turbo) . . . 70-70-5 Fuel Injector Removal And Installation . . . . . . . . . . . . . . 70-70-14 Fuel Shut-Off Solenoid, Testing . . . . . . . . . . . . . . . . . . . . . 70-70-3 Fuel Shut-Off Solenoid Removal And Installation . . . . . . . 70-70-4 Glow Plugs Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2 Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . 70-70-2 Nozzle Spraying Condition. . . . . . . . . . . . . . . . . . . . . . . . 70-70-16 Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . 70-70-12 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . 70-70-17 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16 Valve Timing, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18
ENGINE SERVICE
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . Housing Removal And Installation . . . . . . . . . . . . . . . . . . . Ring Gear Removal And Installation . . . . . . . . . . . . . . . . .
70-90-1 70-90-1 70-90-2 70-90-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 Continued On Next Page
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ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . 70-80-9 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE SERVICE (CONT’D) RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Dealer Copy -- Not for Resale
RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1 Camshaft Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14 Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . 70-100-19 Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . 70-100-25 Crankshaft And Bearings Removal And Installation . . . 70-100-25 Crankshaft And Bearings, Servicing . . . . . . . . . . . . . . . 70-100-27 Crankshaft Gear Removal And Installation . . . . . . . . . . 70-100-17 Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . 70-100-31 Cylinder Head Disassembly And Assembly. . . . . . . . . . . 70-100-4 Cylinder Head Removal And Installation . . . . . . . . . . . . . 70-100-1 Cylinder Head Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5 Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . 70-100-5 Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . 70-100-17 Fuel Camshaft Removal And Installation . . . . . . . . . . . . 70-100-16 Idler Gear And Camshaft Removal And Installation. . . . 70-100-13 Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . 70-100-15 Oil Pump Removal And Installation . . . . . . . . . . . . . . . . 70-100-18 Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-18 Piston And Connecting Rod Removal And Installation . 70-100-20 Piston And Connecting Rod Servicing . . . . . . . . . . . . . . 70-100-22 Reconditioning The Valve And Valve Seat. . . . . . . . . . . . 70-100-8 Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . 70-100-10 Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . 70-100-16 Timing Gearcase Cover Removal And Installation . . . . 70-100-10 Valve Guide Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6 Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9 Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-20 Water Pump Disassembly And Assembly . . . . . . . . . . . 70-100-32 Water Pump Removal And Installation . . . . . . . . . . . . . 70-100-32 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .
70-110-1 70-110-1 70-110-1 70-110-2
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY. 70-02 727 of 949
S150, S160 Bobcat Loader Service Manual
TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
Slow cranking speed. Engine will not start. Difficult to start. No power for engine. Engine is mis-firing. Too much fuel consumption. Black exhaust. Blue / white exhaust. Low oil pressure. Engine knocking. Engine running rough. Vibration. High oil pressure warning. Overheating. Too much crankcase pressure. Poor compression. Start and stop.
CAUSE 1, 2, 3, 54 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50 4, 31, 32, 33, 34, 35, 37, 38, 39, 52 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43 4, 33, 36 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51 22, 27, 29, 30, 40, 49 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53 9, 10, 11
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PROBLEM
TROUBLESHOOTING (CONT’D) Chart (Cont’d) KEY TO CORRECT THE CAUSE 28. Worn valve and seats. 29. Broken or worn piston rings. 30. Worn valve stems or guides. 31. Worn or damaged bearings. 32. Not enough oil in the crankcase. 33. Switch / sensor is defective. 34. Oil pump worn. 35. Relief valve is sticking open. 36. Relief valve is sticking closed. 37. Broken relief valve spring. 38. Faulty suction pipe. 39. Plugged oil filter. 40. Piston seizure. 41. Incorrect piston height. 42. Faulty engine mounting. 43. Incorrect flywheel alignment. 44. Faulty thermostat. 45. Restriction in water jacket. 46. Loose alternator belt. 47. Plugged radiator. 48. Faulty water pump. 49. Plugged breather pipe. 50. Damaged valve stem deflectors. 51. Coolant level to low. 52. Plugged oil pump pipe strainer. 53. Broken valve spring. 54. Damaged Battery
70-10-2 729 of 949
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1. Alternator belt is loose or damaged. 2. Bad electrical connections. 3. Faulty starter motor. 4. Incorrect grade of oil. 5. Low cranking speed. 6. Fuel tank empty. 7. Faulty stop control operation. 8. Plugged fuel line. 9. Plugged fuel filter. 10. Restriction in the air cleaner. 11. Air in the fuel system. 12. Faulty fuel injection pump. 13. Faulty fuel injectors. 14. Broken injection pump drive. 15. Incorrect injection pump timing. 16. Incorrect valve timing. 17. Poor compression. 18. Plugged fuel tank vent. 19. Incorrect grade of fuel. 20. Exhaust pipe restriction. 21. Cylinder head gasket leaking. 22. Overheating. 23. Cold running. 24. Incorrect tappet adjustment. 25. Sticking valves. 26. Incorrect fuel lines. 27. Worn cylinder bores.
S150, S160 Bobcat Loader Service Manual
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
ENGINE SPEED CONTROL Removal And Installation
Remove the two mounting bolts (Item 1) [Figure 70-201] and nuts from the speed control mounting bracket.
DANGER
Installation: Tighten the mounting bolts and nuts evenly until the speed control lever moves back and forth at a comfortable tension. Figure 70-20-2
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
1
D-1009-0409 P-4072
WARNING
Pull the speed control away from the loader frame and disconnect the speed control rod (Item 1) [Figure 70-202] from the control.
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Installation: Be sure to install the control rod in the bottom hole of the speed control.
W-2059-0598
Figure 70-20-1
1
1
2
N-18878
Raise the lift arms and install an approved lift arm device. (See Installing Lift Arm Support Device on Page 10-201.)
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P-90328
ENGINE SPEED CONTROL (CONT’D)
Disassembly
Removal And Installation (Cont’d)
Loosen the two control lever mounting bolts (Item 2) [Figure 70-20-1] and remove the mounting nuts (Item 2) [Figure 70-20-3].
Figure 70-20-3
Assembly: Do not lubricate the engine speed control. Replace any worn or damaged parts if necessary. 1 2
P-34156
Dealer Copy -- Not for Resale
Installation: Install the stop bracket (Item 1) [Figure 7020-3] in the same location. It is necessary for the front and rear stop on the bracket to be located correctly. Reverse the removal procedure to install the engine speed control.
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MUFFLER Removal And Installation Figure 70-30-1
3 3 2
P-48866
Open the rear door and raise the rear grille. Remove the exhaust pipe clamp (Item 1) from the muffler (Item 2) [Figure 70-30-1]. Disconnect the exhaust pipe from the muffler. Remove both muffler mounting bolts (Item 3) [Figure 70-30-1] from the muffler. Installation: Tighten the muffler mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the muffler from the loader. Reverse the removal procedure to install the engine muffler.
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1
Dealer Copy -- Not for Resale 70-30-2 733 of 949
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Figure 70-40-3
AIR CLEANER Removal And Installation Figure 70-40-1
1 1
2 P-28915
2
Disconnect the wire harness connector (Item 1) [Figure 70-40-1] from the air cleaner sensor on the air cleaner.
Installation: Tighten the three mounting bolts to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Loosen the clamp (Item 2) [Figure 70-40-1] from the hose on the engine manifold.
Remove the air cleaner from the engine compartment. Reverse the removal procedure to install the air cleaner.
Figure 70-40-2
2
1
P-34450
Loosen the hose clamp (Item 1) [Figure 70-40-2] on the air cleaner hose. Remove the two mounting bolts (Item 2) [Figure 70-402] from the top mount of the air cleaner.
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S150, S160 Bobcat Loader Service Manual
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Remove the lower mounting bolt (Item 1) and engine harness mounting bracket (Item 2) [Figure 70-40-3] from the air cleaner.
P-34449
Dealer Copy -- Not for Resale 70-40-2 735 of 949
S150, S160 Bobcat Loader Service Manual
Figure 70-50-2
RADIATOR Removal And Installation Stop the engine and open the rear door.
1 Remove the rear grille. (See Removal And Installation on Page 50-60-1.) Remove the oil cooler. (See Removal And Installation on Page 30-60-1.)
WARNING P-48551
AVOID BURNS Do not remove radiator cap when the engine is hot. You can be seriously burned. W-2070-1203
Open the drain valve (Item 1) [Figure 70-50-2] on the engine block and drain the coolant into a container. Figure 70-50-3
1 1
1
P-48242
P-45245
Loosen the radiator cap (Item 1) [Figure 70-50-1] from the pressurized expansion tank.
Remove the two sta-straps (Item 1) [Figure 70-50-3] holding the pressurized expansion tank fill hose (Item 3) [Figure 70-50-4].
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Figure 70-50-1
Figure 70-50-6
RADIATOR (CONT'D) Removal And Installation (Cont'd) Figure 70-50-4
1
1
3 2 2 P-48570
P-48554
Remove the hose clamp (Item 1) [Figure 70-50-6] from the inlet hose.
Remove the two pressurized expansion tank mounting bolts (Item 1) [Figure 70-50-4]. Disconnect the pressurized expansion tank fill hose (Item 3) [Figure 70-50-4] at the radiator end. Remove the pressurized expansion tank (Item 2) with the pressurized expansion tank fill hose (Item 3) attached. [Figure 70-50-4].
Remove the radiator mounting bolt and block off plate (Item 2) [Figure 70-50-6]. Installation: Tighten the radiator mounting bolt to 11 - 13 ft.-lb. (15 - 17 N•m) torque. Use sealant on the block off plate and bolt head (Item 2) [Figure 70-50-6]. Figure 70-50-7
Figure 70-50-5
3
1 2 1 P-48553
Remove the clamp (Item 1) [Figure 70-50-7] from the hydraulic fill tube.
P-48552
Remove the hose clamp (Item 1) [Figure 70-50-5] from the outlet hose.
Remove the radiator mounting bolt (Item 2) [Figure 7050-7]. Remove the two hydraulic fill tube mounting bolts (Item 3) [Figure 70-50-7].
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P-45245
RADIATOR (CONT'D) Removal And Installation (Cont'd) Figure 70-50-8
1
P-48841
Dealer Copy -- Not for Resale
Remove the hydraulic fill tube (Item 1) [Figure 70-50-8]. Lift the radiator up and remove it from the loader. Reverse the above procedure to install the radiator.
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S150, S160 Bobcat Loader Service Manual
Figure 70-60-3
COOLING FAN Drive Tension Pulley Removal And Installation Figure 70-60-1
1 1 2
P0581
Installation: Put a small amount of grease around the outside edge (Item 1) [Figure 70-60-3] on the grease rings.
P0585
Loosen the idler pulley bolt (Item 1) [Figure 70-60-1].
Figure 70-60-4
Installation: Install the retainer bracket (Item 2) [Figure 70-60-1] for the fan belt at the 3 o'clock position.
6
3 Figure 70-60-2 4
1
3 2 5
1
N-00303
Remove the bolt (Item 1) [Figure 70-60-2] and [Figure 70-60-4] from the idler pulley pivot arm (Item 6) [Figure 70-60-4].
P0582
Remove the spacers, bolt and washer from the arm [Figure 70-60-2].
Remove the thrust washer (Item 2), O-rings (Item 3) and spring (Item 4) [Figure 70-60-4]. Check all parts for damage or wear and replace them as needed. NOTE: When making any repairs, replace the bushing (Item 5) [Figure 70-60-4] with a new bushing, if worn. Clean all parts and assemble dry. Do not lubricate. Installation: Reverse the removal procedure to install the tension pulley.
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P0580
Figure 70-60-5
COOLING FAN (CONT'D) Gearbox / Blower Housing Removal And Installation Put jackstands under the rear corners of the loader
DANGER
1
N-19169
•
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
Remove the left gas cylinder mounting bracket (Item 1) [Figure 70-60-5]. (See Gas Cylinder Removal And Installation on Page 50-20-1.) Figure 70-60-6
Dealer Copy -- Not for Resale
P-90328
1
D-1009-0409
2
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
N-19188
W-2059-0598
Raise the lift arms and install an approved lift arm device. (See Installing Lift Arm Support Device on Page 10-201.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
Remove the nuts (Item 1) from the u-bolt which mounts the fan belt shield (Item 2) [Figure 70-60-6] to the blower fan. Remove the fan belt shield (Item 2) [Figure 70-60-6] from the blower fan. Installation: The shield must not interfere with the fan belt. Tighten the nuts to 15 - 17 ft.-lb. (21 - 23 N•m)
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S150, S160 Bobcat Loader Service Manual
Remove the rear mounting bolt (Item 3) [Figure 70-608].
COOLING FAN (CONT'D) Gearbox / Blower Housing Removal And Installation (Cont'd)
Remove the front mounting bolt (Item 4) [Figure 70-608].
Figure 70-60-7 Figure 70-60-9 1 1
2
Oil Level N-19375
Disconnect the breather hose (Item 1) [Figure 70-60-7] from the electrical harnesses on the loader frame. Installation: Make sure the breather hose is unrestricted when routing. Attach the breather hose with cable ties.
NOTE: Mounting bolts (Items 3 and 4) [Figure 70-60-8] use wave washer (Item 1) [Figure 70-60-9] to prevent tubes and bolts from falling out of the housing during installation.
Remove the fan drive belt (Item 2) [Figure 70-60-7] from the pulley on the blower fan.
Installation: Tighten the four mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
NOTE: When checking the fan gearbox oil level, be sure the level does not go above the top of the shaft in the gearbox [Figure 70-60-7]. Use a light colored 90W gear lube if the level is low.
Figure 70-60-10
Figure 70-60-8 2 1
4
P13920
3
1
Lower the blower fan from the housing until it rests on the steering linkage plate [Figure 70-60-10].
2 N-19376
Remove the two mounting bolts (Item 1) and the two spacer tubes (Item 2) [Figure 70-60-8] from the blower fan.
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P-4301
Blower Disassembly And Assembly
COOLING FAN (CONT'D)
Figure 70-60-13
Gearbox / Blower Housing Removal And Installation (Cont'd) Figure 70-60-11
1 2
CD-9952
Remove the lock nut (Item 1) and spacer (Item 2) [Figure 70-60-13].
Remove the strip of sealant along the top of the blower housing [Figure 70-60-11].
Installation: Tighten the nut to 45 - 55 ft.-lb. (61 - 75 N•m) torque.
WARNING
Installation: Use R.T.V. sealant to reseal the blower housing. Loosen the electrical harnesses from the frame of the loader and the blower housing.
AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding. W-2108-1186
Slide the blower fan and housing forward and remove both from the loader. Figure 70-60-14 Blower Housing Grille Removal And Installation
2
Figure 70-60-12
1
1
1 P3006
Use the following procedure to remove the fan from the shaft.
P-43448
To replace the blower housing grille, remove the four mounting screws (Item 1) [Figure 70-60-12] from the grille. Install the new grille and replace the mounting screws.
Install the nut (Item 1) [Figure 70-60-14] on the tapered shaft to protect the shaft and threads. Install the puller on the fan as shown [Figure 70-60-14]. As the center bolt (Item 2) [Figure 70-60-14] is tightened, periodically strike the bolt head to loosen the fan from the shaft.
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N-19378
Figure 70-60-17
COOLING FAN (CONT'D) Blower Disassembly And Assembly (Cont'd) Figure 70-60-15
CD-8954
Installation: Clean the surface where the blower housing contacts the loader frame. Put a bead of R.T.V. sealant on the blower housing [Figure 70-60-17]
CD-9953
Dealer Copy -- Not for Resale
Remove the fan from the tapered shaft [Figure 70-6015]. Figure 70-60-16
1
1 1
CD-9954
To remove the blower housing mounting plate, remove the six bolts (Item 1) [Figure 70-60-16].
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COOLING FAN (CONT'D) Gearbox Parts Identification
1 18 1
2
6
3
4
7 5
4
8 22 4
12
13 14
9 21
10
*16 11 15 17 12
20
3 4 13 14 18 19 * Individual Part not available. (See Note Page 70-60-7.)
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1. Seal 2. Snap Ring (Small) 3. Shims (1.0 inch O.D.) 4. Bearing 5. Shaft (Long) 6. Shims (2.0 inch O.D.) 7. Long Key 8. Shaft (Short) 9. Short Key 10. Long Housing 11. Nut 12. Gear 13. Washer 14. Screw 15. Square Shim *16. Short Housing 17. Bolt 18. Snap Ring (Large) 19. Cap 20. Long Housing Assy. 21. Short Housing Assy. 22. Fill Plug
Figure 70-60-19
COOLING FAN (CONT'D) Gearbox Disassembly NOTE: When repairing the gearbox order the following as needed. 1. 2. 3. 4. 5.
Complete Assembly Long Housing Assembly Long Housing Short Housing Assembly (See Note Below) Internal Parts
Part Number Tag
NOTE: The short housing is only available as an assembly. (See Gearbox Parts Identification on Page 70-60-6.) (Order parts from Bobcat Parts Sales.) NOTE: Be sure to count the number and thickness of shims during disassembly. Install the shims in the original location during assembly.
P2983
Remove the four mounting bolts and the part number tag [Figure 70-60-19].
Remove the fan and blower housing mounting plate. (See Drive Tension Pulley Removal And Installation on Page 70-60-1.) Long Housing
WARNING AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding. W-2108-1186
Figure 70-60-18 Figure 70-60-20
2 1
3 P-37891 P2999
Loosen the set screws (Item 1) and remove the pulley (Item 2) [Figure 70-60-18]. Remove the long key (Item 3) [Figure 70-60-18].
Drill an 1/8 in. (3 mm) hole in the seal. Use a slide hammer tool to remove the seal [Figure 70-60-20].
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Remove the oil from the gearbox. NOTE: Always replace seals during assembly. Replace the parts in the gearbox as needed.
Figure 70-60-23
COOLING FAN (CONT’D) Gearbox Disassembly (Cont'd) Figure 70-60-21
P2966
P2964
Remove the screw and washer from the shaft [Figure 70-60-23]. Figure 70-60-24
Figure 70-60-22
P3004
P2963
Remove the small shims [Figure 70-60-22].
Support the lower flange and press the shaft from the bearing [Figure 70-60-24]. NOTE: The gear and the other bearing (pulley end) will be removed with the shaft.
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Remove the small snap ring [Figure 70-60-21].
COOLING FAN (CONT'D)
WARNING
Gearbox Disassembly (Cont'd)
AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding.
WARNING
W-2108-1186
AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding.
Figure 70-60-27
W-2108-1186
P2996
Drill an 1/8 in. (3 mm) hole in the seal. Use a slide hammer tool to remove the seal [Figure 70-60-27]
P3298
Figure 70-60-28 Support the bearing and press the shaft from the bearing [Figure 70-60-25]. Short Housing Figure 70-60-26
P2970
Remove the large snap ring from the flange end of the housing [Figure 70-60-28]. P2997
Remove the end cap [Figure 70-60-26]. Use care not to damage the housing.
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Figure 70-60-25
Figure 70-60-31
COOLING FAN (CONT'D) Gearbox Disassembly (Cont'd) Figure 70-60-29
P2973
Remove the snap ring from the cap end of the housing [Figure 70-60-31].
P2969
Figure 70-60-32
NOTE: Use the same size and thickness of shims during assembly. Figure 70-60-30
1 P2998
Press the shaft from the housing [Figure 70-60-32]. NOTE: Both bearings may come out of the housing with the shaft. If one bearing remains in the housing use a non metal object to tap the bearing from the housing.
P2978
Remove the screw and washer (Item 1) [Figure 70-6030] from the shaft.
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Remove the large shims from the housing [Figure 70-6029].
Figure 70-60-35
COOLING FAN (CONT'D) Gearbox Disassembly (Cont'd) Figure 70-60-33
P2972
Remove the key from the shaft [Figure 70-60-35]. Gearbox Assembly
P3088
Long Housing Figure 70-60-36
Dealer Copy -- Not for Resale
Press the bearing from the tapered end of the shaft [Figure 70-60-33]. Figure 70-60-34
P2961
Press a bearing on the short keyed end of the long shaft [Figure 70-60-36].
P3001
Press the bearing, shims and gear from the shaft [Figure 70-60-34].
NOTE: See Gearbox Parts Identification on Page 7060-6. When ordering parts for the Fan Gearbox. NOTE: Do not install the seals and cap in the housing until after the backlash has been checked. NOTE: Use care when pressing the bearings into the aluminum housing. The housing can be damaged if too much pressure is used. NOTE: For procedures requiring the use of Loctite® #242 adhesive, thoroughly clean and dry affected parts before the application of Loctite® #242.
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Figure 70-60-39
COOLING FAN (CONT'D) Gearbox Assembly (Cont'd) Figure 70-60-37
P2963
Install on the bearing, the same number and size shims that were removed during disassembly [Figure 70-6039]
P2960
Install the long housing on the shaft [Figure 70-60-37].
Dealer Copy -- Not for Resale
Figure 70-60-40
Be sure the bearing is seated in the bore at the lower end of the housing. Figure 70-60-38
P2964
Install the small snap ring in the groove above the shims [Figure 70-60-40]. P2962
Install a bearing on the long keyed end of the shaft [Figure 70-60-38]. Support the lower bearing and press the other bearing in the housing until the bearings seat in the housing [Figure 70-60-38].
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Figure 70-60-43
COOLING FAN (CONT'D) Gearbox Assembly (Cont'd) Figure 70-60-41
1
P2966
Install the washer (Item 1) [Figure 70-60-43] P2965
Install the gear key in the flange end of the shaft [Figure 70-60-41].
Short Housing
Figure 70-60-42
Figure 70-60-44
P2967
P2968
Align the key and gear. While supporting the bearing on the other end, press the gear on the shaft until it seats against the bearing [Figure 70-60-42].
Install bearing in the flanged end of the housing [Figure 70-60-44].
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Put liquid adhesive (Loctite® #242) on the screw threads. Install and tighten the screw [Figure 70-60-43].
S150, S160 Bobcat Loader Service Manual
Figure 70-60-47
COOLING FAN (CONT'D) Gearbox Assembly (Cont'd) Figure 70-60-45
1 P2971
Install the short key (Item 1) [Figure 70-60-47]. P2969
Align and press the gear on the shaft (teeth toward the tapered end of the shaft) [Figure 70-60-47]. Figure 70-60-48
Dealer Copy -- Not for Resale
Install the large shims on the bearing (flanged end) [Figure 70-60-45]. Figure 70-60-46
P2975 P2970
After the gear is seated, drive the key down inside the gear key way [Figure 70-60-48]. Install the large snap ring in the groove above the shims [Figure 70-60-46].
NOTE: This will prevent damage to the shims when the bearing is installed later.
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Figure 70-60-51
COOLING FAN (CONT'D) Gearbox Assembly (Cont'd) Figure 70-60-49
P2974
Install bearing on the gear end of the shaft [Figure 7060-51].
P2976
Figure 70-60-52
Figure 70-60-50
P2973
Install the snap ring in the groove above the bearing [Figure 70-60-52].
P2977
Install on the shaft, the same number and size shims that were removed during disassembly [Figure 70-60-50].
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Install the shaft in the housing, tapered end in the bearing at the round flange end of the housing [Figure 70-60-49].
COOLING FAN (CONT'D)
Gearbox Checking Backlash
Gearbox Assembly (Cont’d)
NOTE: For procedures requiring the use of Loctite® #518 adhesive, thoroughly clean and dry affected parts before the application of Loctite® #518. Loctite® #518 is a gasket eliminator that cures to a flexible seal between the mounting surfaces.
Figure 70-60-53
The backlash tolerance between the gears should be 0.005 - 0.008 in. (0,127 - 0,203 mm). To check the gear backlash use the following procedure: Figure 70-60-54 1
Install the washer (Item 1) [Figure 70-60-53] on the shaft. Put liquid adhesive (Loctite® #242) on the screw threads and install the screw [Figure 70-60-53].
P2987
Put the short housing in a vise, square flange facing up as shown [Figure 70-60-54].
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P2978
Figure 70-60-57
COOLING FAN (CONT'D) Gearbox Checking Backlash (Cont'd) Figure 70-60-55
2
1.0” (25,4 mm)
1 P-37894
Install the same size and number of square shims (if present during disassembly) between the two housings [Figure 70-60-55].
Install a bolt in the set screw hole to maintain a 1.0 in. (25,4 mm) distance from the shaft center to the bolt head (to be used with a dial indicator) [Figure 70-60-57]. Figure 70-60-58
NOTE: If square shims are used, put a small amount of (Loctite® 518) on both sides of all shims. Figure 70-60-56
1
Part Number Tag
P-37892
Put the fan nut (Item 1) [Figure 70-60-58] on the shaft and tighten snugly.
P2983
Install the four mounting bolts through the flange holes [Figure 70-60-56].
Install a locking pliers on the fan nut and support the handle against the long housing [Figure 70-60-58].
Install the part number tag [Figure 70-60-56]. Install and tighten the nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
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Install the long key (Item 1) and the pulley (Item 2) [Figure 70-60-57].
P2981
Figure 70-60-60
COOLING FAN (CONT'D) Gearbox Checking Backlash (Cont'd) Figure 70-60-59
1 P3089
When the backlash is correct, install the seals, cap and gear oil as follows:
Using a magnetic based dial indicator mounted on a bench vise, touch the dial stem on the bolt (Item 1) [Figure 70-60-59].
Remove the bolts from the flanges and separate the two housings. Put liquid adhesive (Loctite® #242) on the outside diameter of the seal [Figure 70-60-60].
Hold the locking pliers against the long housing and rotate the pulley back and forth to read the dial gauge [Figure 70-60-59]. If the backlash is GREATER than 0.008 in. (0,203 mm), do the following: 1. Remove a square shim(s) (if present) between the two housings. 2. Remove a large shim(s) from the tapered end of the short shaft and add a small shim (s) of the same thickness between the bearing and the gear on the screw end of the shaft. If the backlash is LESS than 0.005 in. (0,127 mm) do the following: 1. Add a square shim(s) between the two housings. 2. Remove a small shim(s) between the bearing and the gear on the screw end of the short shaft and add a large shim(s) of the same thickness between the snap ring and the bearing on the tapered end of the shaft.
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P-37893
COOLING FAN (CONT'D) Gearbox Checking Backlash (Cont'd) Figure 70-60-61
LONG HOUSING
P2985
Dealer Copy -- Not for Resale
Figure 70-60-62
SHORT HOUSING
P2986
Install the seal(s) flush with the housing surface [Figure 70-60-61] and [Figure 70-60-62]. Clean any oil from the flange surface. Install the long housing on the short housing flange. Install the four bolts and part number tag. Install and tighten the nuts to 25 - 28 ft.-lb. (34 - 38 N•m) torque. NOTE: When filling the fan gearbox with oil, be sure the level does not go above the top of the shaft in the gearbox. Use a light colored 90W gear lube.
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Figure 70-70-2
ENGINE COMPONENTS AND TESTING Compression Testing Figure 70-70-1
1
P-48710
Connect the compression gauge to the adapter [Figure 70-70-2]. P-48709
Make sure the engine speed control is fully backward (engine idle). Disconnect the fuel stop solenoid. Crank the engine with the starter cranking rpm. MEL10630 - Engine Compression Kit MEL1631 - Compression Adapter
If the measurement is below the allowable limit, check the cylinder, piston ring, top clearance, valve and cylinder head.
The engine must be at operating temperature. Remove the glow plugs. (See Glow Plugs Removal And Installation on Page 70-70-2.) Install the correct compression adapter (Item 1) [Figure 70-70-1] into the cylinder head.
Compression Pressure should be 2944,1 - 3233,6 kPa (29,44 - 32,33 bar) (427 - 469 psi) Allowable Limit (minimum) is 2351,1 kPa (23,51 bar) (341 psi) No more than 10% variance among cylinders. Figure 70-70-3
P-48711
Push the button on the compression gauge to release pressure [Figure 70-70-3]. Connect the fuel stop solenoid.
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The tools listed will be needed to do the following procedure:
ENGINE COMPONENTS AND TESTING (CONT'D)
Glow Plugs Removal And Installation
Glow Plugs Testing
Figure 70-70-6
Figure 70-70-4
1
2
3
P-48698 P-48702
Disconnect the glow plug cables and leads.
Remove the nut (Item 1) [Figure 70-70-6] from the top of each glow plug.
Use an ohmmeter to check the glow plugs [Figure 70-704].The resistance should be approximately one ohm.
Disconnect the engine harness wire (Item 2) [Figure 7070-6] from the glow plug.
Figure 70-70-5 Remove the glow plug connecting strap (Item 3) [Figure 70-70-6]. Figure 70-70-7 1 1
P-48701
Touch one probe to the end of the glow plug and the other probe to the body of glow plug (Item 1) [Figure 7070-5]. Repeat the procedure for each glow plug.
P-48699
Loosen and remove the glow plug (Item 1) [Figure 7070-7]. Installation: Tighten the glow plug to 14.5 - 18.1 ft.-lb. (19,6 - 24,5 N•m) torque.
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Disconnect the negative (-) cable from the battery.
Figure 70-70-10
ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Removal And Installation (Cont’d) Figure 70-70-8
P-48706
Photo [Figure 70-70-8] shows the glow plug assembly removed from the engine. Inspect the glow plugs and replace when necessary.
The reading between electrical connector terminal C and terminal B must be between approximately 0.35 - 0.4 ohm.
Fuel Shut-Off Solenoid, Testing Figure 70-70-9
1
P-48586
Stop the engine and open the rear door [Figure 70-70-9]. Disconnect the connector (Item 1) [Figure 70-70-9] from the fuel shut-off solenoid. Use an ohmmeter to check the fuel shut-off solenoid.
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The reading between electrical connector terminal C and terminal A must be between approximately 15.6 ohm [Figure 70-70-10].
P-48708
ENGINE COMPONENTS AND TESTING (CONT'D)
Figure 70-70-12
Fuel Shut-Off Solenoid Removal And Installation Stop the engine and open the rear door. Figure 70-70-11 1
P-48704
1 Remove the mounting nuts (Item 1) [Figure 70-70-12] of the fuel shut-off solenoid. Reverse the above procedure to install the fuel shut-off solenoid.
Dealer Copy -- Not for Resale
P-48586
Disconnect the connector (Item 1) [Figure 70-70-11].
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Cap the inlets on the injection pump vent where the hoses were removed [Figure 70-70-14].
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (Turbo)
Remove the four oil fill bolts (Item 3) [Figure 70-70-14]. Figure 70-70-13 Figure 70-70-15 1 1
1
P-48700 P-48730
Disconnect the high pressure fuel lines (Item 1) [Figure 70-70-13] from the fuel injectors.
Remove the high pressure fuel lines (Item 1) [Figure 7070-15] from the injection pump.
IMPORTANT Do not bend the high pressure fuel injection tubes when removing or installing them. I-2029-0289
Figure 70-70-14
1 2 3
3 P-48705
Disconnect the fuel inlet hose (Item 1) and the fuel return hose (Item 2) [Figure 70-70-14] from the injection pump vent.
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Clean the area around the injection pump thoroughly.
Figure 70-70-17
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (Turbo) (Cont'd) Figure 70-70-16
1
P-51683
2 Remove the high-idling body (Item 1) [Figure 70-70-17] from the engine block.
1 P-48826
Remove the seven mounting bolts (Item 1) from the intake manifold (Item 2) [Figure 70-70-16].
Dealer Copy -- Not for Resale
Installation: Tighten the high-idling body to 32.6 - 36.3 ft.-lb. (44 - 49 N•m) torque. Figure 70-70-18
Installation: Tighten the mounting bolts to 16 - 20 ft.-lb. (22 - 27 N•m) torque. Remove the intake manifold from the engine. Installation: Replace the manifold gasket if it is worn or damaged. Remove the fuel shut-off solenoid. (See Fuel Shut-Off Solenoid Removal And Installation Page 70-70-4.) 1
2 P-4357
Remove the four mounting bolts (Item 1) and two nuts (Item 2) [Figure 70-70-18] from the injection pump. Installation: Tighten the mounting bolts to 16 - 20 ft.-lb. (22 - 27 N•m) torque.
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Figure 70-70-20
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (Turbo) (Cont'd)
2
CORRECT 1
Figure 70-70-19
2
1
2 1 1
P-51628
1
Figure 70-70-21
NOTE: Before removing the injection pump assembly, be sure to remove the stop solenoid and high idling body. Also check to see if the stop solenoid guide (Item 1) touches the boost lever (Item 2) [Figure 70-70-19]. 1
Remove the injection pump and shim(s) from the engine.
P-51627
Installation: Check to see if the stop solenoid guide (Item 1) [Figure 70-70-20] and [Figure 70-70-21] touches the boost lever (Item 2) [Figure 70-70-20].
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INCORRECT
P-51626
ENGINE COMPONENTS AND TESTING (CONT'D)
Fuel Injection Pump Removal And Installation (NonTurbo)
Fuel Injection Pump Removal And Installation (Turbo) (Cont'd)
Figure 70-70-24
Figure 70-70-22 1
1 1
P-51933 P-4364
Install the shim(s) (Item 1) [Figure 70-70-22] on the injection pump mounting surface. For information on the number of shims used. (See Timing The Injection Pump on Page 70-70-12.)
Disconnect the high pressure fuel lines (Item 1) [Figure 70-70-24] from the fuel injectors.
Figure 70-70-23
IMPORTANT 2
Do not bend the high pressure fuel injection tubes when removing or installing them.
1
I-2029-0289
P-64218
Install the injection pump in the engine. Ensure the control rack pin (Item 1) is to the left side of the fork lever (Item 2) [Figure 70-70-23].
IMPORTANT Do not attempt to maintain or adjust unless you are trained and have the correct equipment. I-2028-0289
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Clean the area around the injection pump thoroughly.
Figure 70-70-27
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd)
2
Figure 70-70-25
1 1
2 3
P-48820
Remove the mounting bolts (Item 1) from the intake manifold (Item 2) [Figure 70-70-27].
3
P-51944
Disconnect the fuel inlet hose (Item 1) and the fuel return hose (Item 2) from the injection pump vent [Figure 7070-25].
Remove the intake manifold from the engine. (See Removal And Installation on Page 70-80-1.)
Cap the inlets on the injection pump vent where the hoses were removed [Figure 70-70-25].
Installation: Replace the manifold gasket if it is worn or damaged.
Remove the four oil fill tube bolts (Item 3) [Figure 70-7025].
Figure 70-70-28
Figure 70-70-26 1
1
2
P-51942
Remove the fuel shut-off solenoid (Item 1) [Figure 70-7028]. (See Fuel Shut-Off Solenoid Removal And Installation Page 70-70-4.)
P-51945
Remove the high pressure fuel lines (Item 1) [Figure 7070-26] from the injection pump. Note:
Do not loosen the clamp screws (Item 2) [Figure 70-70-15] on the injection pump. This is to be done only when the entire injection pump is sent out to be serviced.
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Installation: Tighten the mounting bolts to 16 - 20 ft.-lb. (22 - 27 N•m) torque.
Figure 70-70-31
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd) Figure 70-70-29
P-51952
1
P-51953
1
Remove the stop solenoid guide (Item 1) [Figure 70-7031]. P-51683
Remove the high-idling body (Item 1) [Figure 70-70-29] from the engine block. Figure 70-70-30 1
1
2
3 P-4357
2
Remove the four mounting bolts (Item 1) and two nuts (Item 2) [Figure 70-70-32] from the injection pump. P-51951
Installation: Tighten the mounting bolts to 16 - 20 ft.-lb. (22 - 27 N•m) torque. Remove the cover plate bolts (Item 1) and nuts (Item 2) [Figure 70-70-30]. Remove the cover plate (Item 3) [Figure 70-70-30].
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Figure 70-70-32
ENGINE COMPONENTS AND TESTING (CONT'D)
Figure 70-70-35
Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd) 1
Figure 70-70-33
2
P-4364
1 Install the shim(s) (Item 1) [Figure 70-70-35] on the injection pump mounting surface. For information on the number of shims used. (See Timing The Injection Pump on Page 70-70-12.)
Remove the injection pump (Item 1) [Figure 70-70-33] and shim(s) from the engine.
Figure 70-70-36
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P-4359
NOTE: The pin (Item 2) [Figure 70-70-33] located on the control rack, needs to be installed correctly during installation. See the following procedure for correct installation. 1
IMPORTANT Do not attempt to maintain or adjust unless you are trained and have the correct equipment. I-2028-0289
P-48779
Figure 70-70-34
The size of shims are identified by a symbol (Item 1) [Figure 70-70-36] on the shims. (1) Two holes means 0.008 in (0,20 mm) shim. (2) One hole means 0.010 in (0,25 mm) shim. (3) Without hole means 0.012 in (0,30 mm) shim.
1
(4) Three holes means 0.014 in (0,35 mm) shim.
2 1 P-51944
Installation: Remove the bolts (Item 1) that secure the fill cover (Item 2) [Figure 70-70-34] from the injection pump chamber. 70-70-11 770 of 949
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Figure 70-70-38
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Removal And Installation (NonTurbo) (Cont'd) Figure 70-70-37
2 1
1
P-54133
Turn the fuel supply lever (Item 1) to the ON position. [Figure 70-70-38] P-64218
Figure 70-70-39
Ensure the control rack pin (Item 1) is to the left side of the fork lever (Item 2) [Figure 70-70-37].
1
Timing The Injection Pump
IMPORTANT Do not attempt to maintain or adjust unless you are trained and have the correct equipment.
P-4361
I-2028-0289
Timing the injection pump is done by changing the number of shims between the injection pump and the injection pump mounting surface.
Install a short plastic tube (Item 1) [Figure 70-70-39] in the number one cylinder port of the injection pump. The tube should fit securely in the port and point upward.
Disconnect the number one cylinder high pressure line from the injection pump.
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Install the injection pump in the engine.
Figure 70-70-41
ENGINE COMPONENTS AND TESTING (CONT'D) Timing The Injection Pump (Cont’d) Figure 70-70-40
1
Rotation Direction 1
P-4364
Add or subtract shim(s) (Item 1) [Figure 70-70-41] as needed to adjust the fuel delivery timing.
Rotate the engine in the direction shown [Figure 70-7040].
NOTE: Adding or removing one shim will vary the timing by 1.5°. Adding shims retards timing.
Dealer Copy -- Not for Resale
P-48726
Figure 70-70-42 Continue rotation until flywheel timing mark just appears in the window (Item 1) [Figure 70-70-40]. NOTE: The flywheel has three timing marks. The first mark to appear in the window with the rotation is 9.25° which is used for loaders with the Kubota V2003T engine.
1
The second mark to appear in the window is 8.2° which is used for loaders with the Kubota V2203 engine. The third mark to appear in the window is 6.75° which is used for loaders with the Kubota V2403 engine.
P-48779
Rotate slowly until fuel just starts to flow upward into the plastic tube.
The size of shims are identified by a symbol on the shims.
At this instant, the 9.25° BTDC timing mark on the flywheel should be aligned with the mark in the window (Item 1) [Figure 70-70-40] for the V2003T engine[Figure 70-70-40] for the V2203 engine.
(1) Two holes means 0.0008 in (0,20 mm) shim. (2) One hole means 0.0010 in (0,25 mm) shim. (3) Without hole means 0.0012 in (0,30 mm) shim. (4) Three holes means 0.0014 in (0,35 mm) shim.
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ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injector Removal And Installation
IMPORTANT Do not bend the high pressure fuel injection tubes when removing or installing them.
WARNING
I-2029-0289
AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.
Figure 70-70-44
1
W-2072-0807
Figure 70-70-43
1
1
P-48727
2 Remove the four retainer bolts from the top of the fuel injectors (Item 1) [Figure 70-70-44]. Remove the fuel return tube (Item 2) [Figure 70-70-44] from the fuel injectors. Figure 70-70-45 P-48712
The following are some problems caused by faulty injectors:
1
-Engine is hard to start or will not start -Rough engine operation and idle -Engine will not have full power -Excessive exhaust smoke Disconnect the fuel return hoses (Item 1) [Figure 70-7043] from the injectors. Disconnect the high pressure fuel lines (Item 2) [Figure 70-70-43] from the fuel injectors and from the injection pump. Remove the high pressure fuel lines from the engine.
P-48728
Remove the injector nozzle holder bolt (Item 1) [Figure 70-70-45] from the cylinder head. Pull on the injector nozzle to remove the injector nozzle from the cylinder head.
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2
ENGINE COMPONENTS AND TESTING (CONT'D)
Testing Nozzle Injection Pressure
Fuel Injector Removal And Installation (Cont'd)
The tools listed will be needed to do the following procedures:
Figure 70-70-46 MEL 4200 - Injector Nozzle Tester MEL 4201 - Injector Nozzle Tester Adaptor Set Figure 70-70-47 1
2
[Figure 70-70-46] shows the injector nozzle removed from the cylinder. Inspect the injector and replace if necessary. Inspect and replace the injector nozzle O-rings (Item 1) and the nozzle washer (Item 2) before installing new or used injectors. [Figure 70-70-46].
3EEABAC1P012A
Install the injection nozzle assembly onto to the nozzle tester (MEL 4200). Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle. If the measurement is not within the factory specifications, replace the injection nozzle assembly. NOTE: Injection nozzle gasket must be replaced when the injection nozzle is removed for testing. Injection pressure
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Factory spec.
18.6 to 20.1 MPa 190 to 205 kgf/cm² 2702 to 2916 PSI
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P-37583
ENGINE COMPONENTS AND TESTING (CONT'D)
Valve Seat Tightness
Nozzle Spraying Condition
The tool listed will be needed to do the following procedure:
The tool listed will be needed to do the following procedure:
MEL 4200 - Injector Nozzle Tester
MEL 4200 - Injector Nozzle Tester
Figure 70-70-49
Figure 70-70-48 Correct
Incorrect
3EEABAC1P013A
Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition. If the spraying condition is defective, replace or repair the injection nozzle assembly.
Install the injection nozzle assembly onto the nozzle tester (MEL 4200) and check the nozzle spraying condition. Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/ cm², 2418 PSI) for 10 seconds. If any fuel leak is found, replace or repair the injection nozzle assembly. Valve seat tightness
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Factory spec.
No fuel leak at 16.67 MPa 170 kgf/cm² 2418 PSI
S150, S160 Bobcat Loader Service Manual
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3EEABAC1P014A
Figure 70-70-52
ENGINE COMPONENTS AND TESTING (CONT'D) Valve Clearance Adjustment Figure 70-70-50
1
2
2
3
4
5
6
7
8
1
B-05569
Adjust the valve clearance as follows:
3
B-5568
0.0071 - 0.0087 in. (0,18 - 0,22 mm) Exhaust
Intake
and
Use the following sequence to set the valves [Figure 7070-52] and [Figure 70-70-51]:
Loosen the lock nut (Item 1) [Figure 70-70-50]. Turn the adjustment screw (Item 2) [Figure 70-70-50] until the correct clearance is obtained. NOTE: The clearance is measured between the rocker arm and valve stem tip (Item 3) [Figure 70-70-50].
1. With the rocker arm rocking (valves 7 and 8) on No. 4 cylinder set clearance at No. 1 cylinder (valves 1 and 2). 2. With the rocker arm rocking (valves 3 and 4) on No. 2 cylinder set clearance at No. 3 cylinder (valves 5 and 6).
Figure 70-70-51
1
Cylinder Number
2
3
3. With the rocker arm rocking (valves 1 and 2) on No. 1 cylinder set clearance at No. 4 cylinder (valves 7 and 8).
4
Valve Number
1
2
3
4
5
6
7
8
Valve I=Intake E=Exhaust
I
E
I
E
I
E
I
E
4. With the rocker arm rocking (valves 5 and 6) on No. 3 cylinder set clearance at No. 2 cylinder (valves 3 and 4).
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Adjust the valve clearance as follows:
ENGINE COMPONENTS AND TESTING (CONT'D) Valve Timing, Testing Figure 70-70-53
4 3 5
1 (1) Idle Gear (2) Idle Collar (3) External Snap Ring (4) Cam Gear (5) Camshaft
2
B-14341
Dealer Copy -- Not for Resale
Stop the engine and open the rear door. Remove the engine. (See Removal And Installation on Page 70-80-1.) Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Make sure the timing marks are in correct alignment [Figure 70-70-53].
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Drain the engine coolant from the cooling system. (See Replacing The Coolant on Page 10-90-2.)
ENGINE Removal And Installation
Remove the air cleaner. (See Removal And Installation on Page 70-40-1.)
DANGER
Remove the muffler. (See Removal And Installation on Page 70-30-1.) Figure 70-80-1
3
P-90328
•
AVOID DEATH Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Keep out of this area when lift arms are raised unless supported by an approved lift arm support. Replace if damaged.
1 2
3 P-48519
D-1009-0409
Remove the nut from the speed control linkage (Item 1) and unplug the rear lights electrical connector (Item 2) [Figure 70-80-1].
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Remove the bracket mounting bolts (Item 3) [Figure 7080-1] for the fuel fill to make installation easier. Figure 70-80-2
W-2059-0598
Put jackstands under the rear corners of the loader.
1
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) 2 Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Drain the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Disconnect the steering linkage. (See Linkage Removal And Installation on Page 50-101-7.)
P-48580
Remove the two mounting bolts (Item 1) to remove the oil filter drip shield (Item 2) [Figure 70-80-2].
Remove the battery from the loader. (See Removal And Installation on Page 60-20-1.)
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•
Figure 70-80-5
ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-3
1
1 2 P-26965
3 Remove battery cable bracket (Item 1) [Figure 70-80-5]. P-28237
Figure 70-80-6
Disconnect the temperature sender connector (Item 2) [Figure 70-80-3] from the filter housing.
3
Disconnect the wire connector (Item 3) [Figure 70-80-3] from the differential pressure switch on the filter housing. Figure 70-80-4 1 2 P-34385
1
Disconnect negative battery cables from starter mount bolt (Item 1) [Figure 70-80-6]. Disconnect positive battery cable (Item 2) from starter terminal (Item 3) [Figure 70-80-6].
P-48581
Disconnect radiator hose (Item 1) [Figure 70-80-4].
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Disconnect the wires from the charge pressure sender (Item 1) [Figure 70-80-3] from the filter housing.
Figure 70-80-9
ENGINE (CONT'D) Removal And Installation (Cont'd)
2
Figure 70-80-7
2 1
3 3
P-48595
2
1
Disconnect glow plug wire (Item 1) [Figure 70-80-9]. P-48586
Disconnect the fuel stop wire harness (Item 1) [Figure 70-80-7]. Remove the tie straps (Item 2) [Figure 70-80-7] from wiring harness clamp.
Remove the tie strap (Item 3) [Figure 70-80-9] from wiring harness clamp and move the wire harness to the left side of loader to allow clearance for engine removal. Figure 70-80-10
Disconnect engine oil pressure wire harness (Item 3) [Figure 70-80-7]. Figure 70-80-8
1
3 4
P-48593
1 2
Disconnect engine coolant hose (Item 1) [Figure 70-8010].
P-48585
Cap or plug all hoses and fittings. Disconnect fuel line (Item 1) [Figure 70-80-8]. Cut tie straps (Item 2) [Figure 70-80-8]. Mark and disconnect loader harness wire connectors (Item 3) [Figure 70-80-8]. Disconnect engine speed harness (Item 4) [Figure 7080-8].
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Disconnect and plug fuel return line (Item 2) [Figure 7080-9].
Figure 70-80-13
ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-11 2
1
3 1 P-26957
Remove fan belt shield (Item 1) [Figure 70-80-13]. P-48845
Figure 70-80-14
Disconnect outlet hose (Item 2) [Figure 70-80-11]. Disconnect high flow outlet hose (Item 3) [Figure 70-8011] (If so equipped). Cap or plug all hoses and fittings.
1
Figure 70-80-12
P-26958
1 Remove fan belt (Item 1) [Figure 70-80-14] from pulley.
P-28137
Disconnect inlet hydrostatic motor hose from hydraulic filter tubeline (Item 1) [Figure 70-80-12]. Cap or plug all hoses and fittings.
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Disconnect power Bob-Tach hoses (Item 1) [Figure 7080-11] and solenoid connectors (If so equipped).
Figure 70-80-17
ENGINE (CONT'D) Removal And Installation (Cont'd)
1 Figure 70-80-15 1
P-28142
1 Mark and disconnect the left drive motor hoses (Item 1) [Figure 70-80-17].
P-26068
Cap or plug all hoses and fittings.
NOTE: Due to the left drive motor hoses (Item 1) [Figure 70-80-17] orientation, hoses may not be completely removed from fittings until engine and pump is partially removed.
Figure 70-80-16 Installation: Install the left drive motor hoses prior to alignment with engine mount bolts. Figure 70-80-18
1
1
P-26959
Mark and disconnect the two right drive motor hoses (Item 1) [Figure 70-80-16].
P-26068
Remove the mounting bolt and nut (Item 1) [Figure 7080-18] from the right front engine mount. Installation: Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.
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Cap or plug all hoses and fittings. Disconnect inlet gear pump hose (Item 1) [Figure 70-8015].
Figure 70-80-20
ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-19
1
2 P-28231
1 P-48583
Remove the mounting bolt and nut (Item 1) [Figure 7080-20] from the right rear engine mount.
Remove the mounting bolt (Item 1) [Figure 70-80-19] and nut from the left front engine mount.
Installation: Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.
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P-28139
Figure 70-80-21 Installation: Slide the engine mount slot (Item 2) [Figure 70-80-19] in between engine mount washer and nut. Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque. NOTE: To aid in the removal of the left front engine mount bolt, remove the control panel. (See Removal And Installation on Page 50-100-1.) 1
Use 1/2 inch drive impact wrench, with a 12 inch extension, on a 3/4 inch flex socket. Removal will be accomplished by reaching under the hydraulic reservoir to the engine mount bolt.
P-28140
Remove the mounting bolt and nut (Item 1) [Figure 7080-21] from the left rear engine mount. Installation: Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.
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Figure 70-80-23
ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-22
13”
2.5” 1-1/2” I.S. Dia. 2-1/2” O.S. Dia.
1 2.5” 1/4” (4) Thick Gusset
1-1/2” Square Tubing
P-48594
1” 28”
Fasten securely one end of the chain to the lifting eye (Item 1) [Figure 70-80-23].
2” 45°
9”
1”
4” 2”
1 1”
.5” .3125” (2)
.375”
Use Two 3/8” x 1-1/4” Bolts for Drilled and Tapped Holes.
MC-1799
A tool needs to be fabricated to use in the removal procedure. This tool allows the engine / hydrostatic pump assembly to be lifted evenly for easier removal. Use the dimensions shown in [Figure 70-80-22] to make the engine removal tool.
P-48592
Fasten securely one end of the chain to the other lifting eye (Item 1) [Figure 70-80-24]. NOTE: You may need to adjust the chain which fastens to the engine a couple of times to reach the correct lifting position.
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Figure 70-80-24
4”
ENGINE (CONT'D) Removal And Installation (Cont'd) Figure 70-80-25
Dealer Copy -- Not for Resale
1
P-48596
Install the chain hoist on the eyelet [Figure 70-80-25] of the removal tool. Fasten a chain to other end of the removal tool with two bolts as shown in (Item 1) [Figure 70-80-25]. Remove the engine / hydrostatic pump assembly from the loader. Reverse the removal procedure to install the engine.
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Figure 70-80-27
ENGINE (CONT'D) Engine Mount Replacement Figure 70-80-26 1
Washer
2
Engine Mounting Bracket
Loader Frame
3
Engine Mount
4 Spacer
5
Snubbing Washer MC-1765
6
Install the new engine mount as shown in the cut away side view [Figure 70-80-27].
7 MC-1771
Tighten the mounting bolts to 70 ft.-lb. (95 N•m) torque.
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Use the following procedure to install new engine mounts: Remove the existing mount from the engine. Refer to engine removal and installation for engine mount locations. Replace all four engine mounts two front and two rear. Use the parts shown to install the new engine mounts [Figure 70-80-26]: Square Nut - (Item 1) - Used on left side engine mounts Hex Nut - (Item 2) - Used on right side engine mounts Mount Washer - (Item 3) Engine Mount - (Item 4) Tube Spacer - (Item 5) Snubbing Washer - (Item 6) Mounting Bolt - (Item 7)
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FLYWHEEL AND HOUSING
Ring Gear Removal And Installation
Flywheel Removal And Installation
Figure 70-90-2
Remove the drive belt shield. (See Shield Removal And Installation on Page 30-50-1.) Remove the drive belt. (See Drive Belt Replacement on Page 30-50-3.) Remove the drive belt tension pulley. (See Tensioner Pulley Removal And Installation on Page 30-50-4.) Figure 70-90-1
1
The ring gear (Item 1) [Figure 70-90-2] on the flywheel is an interference fit. Heat the ring gear enough to expand the gear. Hit the ring gear evenly around the gear to remove it from the flywheel.
1
Clean the outer surface of the flywheel thoroughly so the new ring gear will fit smoothly onto the flywheel. 2 Clean the new ring gear and heat it to a temperature of 450° - 500° F (232° - 260° C)
P-48649
Remove the six mounting bolts (Item 1) from the engine flywheel (Item 2) [Figure 70-90-1].
Fit the ring on the flywheel and be sure the gear is seated correctly.
Installation: Apply engine oil to the threads and seats before tightening. Tighten to 72 - 80 ft.-lb. (98 - 108 N•m) torque. Remove the flywheel from the engine. Installation: Be sure to align the hole in the flywheel with the pin located on the crankshaft. Reverse the removal procedure to install the flywheel.
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P-48850
Figure 70-90-4
FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation Remove the drive belt shield. (See Shield Removal And Installation on Page 30-50-1.) Remove the engine / hydrostatic pump package from the loader.(See Removal And Installation on Page 70-80-1.) Remove the drive belt. (See Drive Belt Replacement on Page 30-50-3.) Remove the drive belt tension pulley. (See Tensioner Pulley Removal And Installation on Page 30-50-4.)
P-48651A
Remove the starter. (See Removal And Installation on Page 60-40-2.) Remove the flywheel. (See Flywheel Removal And Installation on Page 70-90-1.)
Install a puller in the drive pulley and remove the pulley from the hydrostatic pump shaft [Figure 70-90-4]. Installation: Install the pulley key in the shaft before installing the drive pulley.
Dealer Copy -- Not for Resale
Figure 70-90-3
1
P-48651
Remove the hydrostatic pump drive pulley mounting nut (Item 1) [Figure 70-90-3] and washer. Installation: Tighten the mounting nut to 175 - 200 ft.-lb. (237 - 271 N•m) torque.
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Figure 70-90-7
FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation (Cont’d) Figure 70-90-5
2
1
1
1
1
1
P-48648
1 Remove the seven mounting bolts (Item 1) [Figure 7090-7] which fasten the housing on the engine.
Remove the two mounting bolts (Item 1) [Figure 70-905] from the drive belt housing which mount the hydrostatic pump to the housing. Installation: Tighten the mounting bolts to 65 - 70 ft.-lb. (88 - 95 N•m) torque. Figure 70-90-6
Installation: Tighten the mounting bolts to 35 - 40 ft.-lb. (48 - 54 N•m) torque. Remove the bolt (Item 2) [Figure 70-90-7] which fasten the two drain hoses to the housing. Installation: Tighten the mounting bolts to 60 - 65 ft.-lb. (82 - 88 N•m) torque. Remove the housing. Reverse the removal procedure to install the housing.
2
1
P-4231
Remove the mounting bolt (Item 1) [Figure 70-90-6] from engine coolant tubeline mounting bracket which is attached to the belt shield housing. Installation: Tighten the mounting bolt to 25 - 28 ft.-lb. (34 - 38 N•m) torque. Remove the blower fan drive belt tensioner assembly (Item 2) [Figure 70-90-6] from the housing.
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P-48650
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Figure 70-100-3
RECONDITIONING THE ENGINE-V2203-M-DI AND V2003-M-DI-T (TURBO) Cylinder Head Removal And Installation Figure 70-100-1
1
4
2
2 3
1 P-47243
Remove the glow plugs (Item 1) and fuel injector holder assemblies (Item 2) [Figure 70-100-3]. P-47241
Remove the valve cover (Item 4) [Figure 70-100-1] and gasket.
Tighten the injector holders to 19 - 22 ft.-lb. (25,5 - 29,4 N•m) torque. Figure 70-100-4
Installation: Tighten the valve cover bolts to 5 - 8 ft.-lb. (7 - 11 N•m) 1 Figure 70-100-2 1
2 2
2
2 B-14332
Remove the rocker arm bolts and remove the rocker arm assembly (Item 1) [Figure 70-100-4]. P-47242
Loosen the bolts on the clamps (Item 1) and remove the injection tubes (Item 2) [Figure 70-100-2].
Installation: Tighten the bolts to 17 - 20 ft.-lb. (23,5 27,5 N•m) torque. Remove the pushrods (Item 2) [Figure 70-100-4].
Remove the overflow tube assembly.
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Remove the glow plug lead (Item 1), breather hose (Item 2), and valve cover bolts (Item 3) [Figure 70-100-1].
Installation: Tighten the glow plugs to 11 - 14.5 ft.-lb. (15 - 19,6 N•m) torque.
Figure 70-100-7
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
6
14
Cylinder Head Removal And Installation (Cont'd)
18
10
17
9
3
11
2
7
1
8
15
Figure 70-100-5
1 2
13
5
4
16 12 P-47247
Remove the cylinder head bolts in order of #18 to #1 [Figure 70-100-7]. P-47245
After installing the rocker arm assembly and push rods, the valve lash must be adjusted. ((See Valve Tappets on Page 70-100-20.)). Figure 70-100-6
Installation: Put oil on the bolt threads. Tighten the bolts in the correct sequence in order of #1 - #18 to 68 - 72 ft.lb. (93 - 98 N•m). NOTE: Re-tighten the cylinder head bolts in the correct sequence after the engine has been run for 30 minutes. Figure 70-100-8
2
1 1
2 P-47246 P-47248
Remove the clamps (Item 1) and remove the hose (Item 2) [Figure 70-100-6].
Remove the cylinder head (Item 1) and gasket (Item 2) [Figure 70-100-8].
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Installation: The push rod (Item 1) must be seated in the tappet (Item 2) [Figure 70-100-5] correctly or the push rods will be damaged.
NOTE: (A) is the gearcase side, (B) is the flywheel side.
Figure 70-100-11
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Gasket Size (Number)
Cylinder Head Removal And Installation (Cont'd) Figure 70-100-9
15 20 25 30 35
Piston Protrusion 0,475 - 0,525 mm 0.0187 - 0.0207 in. 0,525 - 0,575 mm 0.0207 - 0.0226 in. 0,575 - 0,625 mm 0.0226 - 0.0246 in. 0,625 - 0,067 mm 0.0246 - 0.0266 in. 0,675 - 0,725 mm 0.0266 - 0.0285 in.
Select the correct gasket size (thickness) from the chart [Figure 70-100-11].
1
When replacing just the gasket, use a new gasket that has the same mark (Item 1) [Figure 70-100-9] as the original gasket. When replacing the gasket after an engine rebuild, the piston protrusion must be measured. ((See Cylinder Head Top Clearance on Page 70-100-5.))
Find the measurement of the highest piston protrusion and the lowest piston protrusion (recorded earlier) for each piston. If the highest measurement exceeds the piston protrusion of the selected gasket, use the gasket which is one size larger. If the measurement exceeds gasket size 35, the engine must be disassembled, clearances checked, and reassembled. If the measurement is two sizes smaller than the selected gasket or smaller than gasket size 15, the engine must be disassembled, clearances checked, and reassembled.
Figure 70-100-10
1
After the gasket and cylinder head have been installed, turn the crankshaft by hand to be sure there is no interference between the piston, cylinder, and valves.
P-47252
Measure and record the protrusion of each piston in the four places shown (Item 1) [Figure 70-100-10]. Find the average of each piston, then find the combined average of the four pistons.
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P-47249A
Figure 70-100-14
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
1
2
Cylinder Head Disassembly And Assembly 1 Figure 70-100-12
3 4 5
7 6
8 5
5
7 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item 3) and thermostat (Item 4) [Figure 70-100-14].
Use a valve spring compressor to compress the valve spring [Figure 70-100-12].
Remove bolts (Item 5), nut (Item 6), top and bottom housing (Item 7), and gasket (Item 8) from the cylinder head [Figure 70-100-14].
Figure 70-100-13
1 Cap
2 Collets
6 Seal
3 Retainer
4
5 Valve
Spring
B-4122C
Remove the valve cap (Item 1) and valve spring collet (Item 2) [Figure 70-100-12] and [Figure 70-100-13]. Remove the valve spring retainer (Item 3) and the spring (Item 4) [Figure 70-100-12] and [Figure 70-100-13]. Remove the seal (Item 6) and the valve (Item 5) [Figure 70-100-12] and [Figure 70-100-13].
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PI-9987
Cylinder Head Top Clearance
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-17
Cylinder Head Servicing Clean the surface of the cylinder head.
2
Figure 70-100-15 1
1
3
P-51631
2
Install the cylinder head gasket. Put the piston (Item 1) [Figure 70-100-17] being checked at T.D.C.
Put a straight edge (Item 1) [Figure 70-100-15] on the cylinder head. NOTE: Do not put the straight edge across combustion chambers. Put a feeler gauge (Item 2) [Figure 70-100-15] between the straight edge and the surface of the cylinder head. Figure 70-100-16
Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2) [Figure 70-100-17] on the top of the piston. Use grease to hold them in position. NOTE: Put the solder in position so they do not touch the valves. Turn the piston to bottom dead center. Install the cylinder head and tighten to the correct torque in the correct sequence. ((See Cylinder Head Removal And Installation on Page 70-100-1.)) Turn the crankshaft until the piston exceeds T.D.C. Remove the cylinder head. Remove the solder wire (Item 3) [Figure 70-100-17] and measure it. If the measurement exceeds the specifications, check the oil clearance of the crank pin journal or the piston pin. Top Clearance
0.0236 - 0.0276 in. (0,6 - 0,7 mm)
PI-9988
Put the straight edge on the cylinder head's four sides and two diagonal as shown in figure [Figure 70-100-16]. The maximum distortion of the head surface is ± 0.002 in. (± 0,05 mm). If the measurement exceeds the specification, replace the cylinder head.
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P-51629
Figure 70-100-20
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Valve Guide Checking Remove the valve and spring from the cylinder head. ((See Cylinder Head Disassembly And Assembly on Page 70-100-4.)) Clean the valve seat and combustion chamber. Figure 70-100-18
B-14335
Measure the valve stem O.D. [Figure 70-100-20].
Calculate the clearance. If the clearance exceeds the allowable limit, replace the valve and / or valve guide. Valve Guide I.D. P-51632
Valve Stem O.D. Install the valve into the guide. Measure the valve recessing or protrusion with a depth gauge [Figure 70100-18]. Figure 70-100-19
Clearance Between Valve Stem and Guide Allowable Limit
0.3156 - 0.3161 in. (8,015 - 8,03 mm) 0.3134 - 0.3140 in. (7,96 - 7,98 mm) 0.0016 - 0.0028 in. (0,04 - 0,07 mm) 0.004 in. (0,1 mm)
1. Cylinder Head Surface 2. Recessing 3. Protrusion PI-9990
If the measurement exceeds the allowable limit, replace the valve or cylinder head [Figure 70-100-19]. Protrusion Recessing Allowable Limit (Recessing)
0.002 in. (0,5 mm) 0.006 in. (0,15 mm) 0.016 in. (0,4 mm)
Remove the carbon from the valve guide.
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Measure the valve guide I.D. [Figure 70-100-20].
Figure 70-100-22
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Valve Guide Checking (Cont’d) Figure 70-100-21 8.86” (225 mm) 0.787”
2.76” (70mm)
0.460-0.468” (11,7-11,9 mm) 0.2” (5,0 mm)
0.263-0.275” 0.98” (6,7-7 mm) (25,0 mm)
1
1.77” (45 mm)
(20 mm)
2 0.256-0.259” (6,5-6,6 mm)
0.350-0.358” (8.9-9.1 mm)
0.787” (20,0 mm)
PI-9992
Press the used valve guide out of the cylinder head using the special driver tool [Figure 70-100-22].
0.490-0.50” (12.5-12.8 mm)
To remove and replace the valve guide, make the driver tool as shown in figure [Figure 70-100-21].
Put oil on the outside diameter of the new valve guide. Press the new valve guide into the cylinder head from the top side. Use the special driver tools (Items 1 and 2) [Figure 70-100-22], press the new guide until the tool contacts the cylinder head. Ream the valve guide to the correct specifications.
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MC-1364
Figure 70-100-25
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
2
1
Reconditioning The Valve And Valve Seat
15° Exhaust 30° Intake
Figure 70-100-23
3
PI-9995
Check the seat surface and valve face (Item 1) [Figure 70-100-25]. PI-9993
Grind the valve face to the correct angle using a valve refacer [Figure 70-100-23]. Figure 70-100-24
If the seat surface (b) is too wide, use a 30 degree cutter (Item 2) on the intake, and a 15 degree cutter on the exhaust to get the correct width (Item 3) [Figure 70-10025]. Valve Seat Width Intake Exhaust
0.0835 in. (2,12 mm) 0.0835 in. (2,12 mm)
Valve Seat And Face Angle 15° Exhaust 30° Intake
45° Exhaust 60° Intake
Intake Exhaust
60° 45°
PI-9994
Grind the valve seat surface in the cylinder head to the correct angle [Figure 70-100-24].
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(a) identical dimensions above and below the valve seat
Figure 70-100-27
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Valve Spring Figure 70-100-26
A-2759
Put the spring on a tester and compress to specified length [Figure 70-100-27].
Measure the length of the valve spring. If the measurement is less than the allowable limit, replace the spring [Figure 70-100-26]. Free Length Allowable Limit
Read the compressed load on the gauge. If the measurement exceeds allowable limit, replace the spring.
1.6417 - 1.6614 in. (41,7 - 42,2 mm) 1.622 in. (41,2 mm)
Setting Length Setting Load Allowable Limit
1.378 in. (35,0 mm) 26.4 lb. (117,6 N) 22.5 lb. (100,0 N)
Put the spring on a flat surface, place a square on the side of the spring [Figure 70-100-26]. Rotate the spring and measure the maximum tilt. If the measurement excess the allowable limit, replace the spring. Tilt Allowable Limit
0.039 in. (1,0 mm)
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B-3680
Timing Gearcase Cover Removal And Installation
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Remove the fuel injection pump. (See Contents Page 7001.)
Rocker Arm And Shaft Checking Figure 70-100-28
Remove the cylinder head, rocker arms and push rods. ((See Cylinder Head Removal And Installation on Page 70-100-1.)) Figure 70-100-29 1 2 7.87” (200 mm)
Measure the rocker arm I.D. (Item 1) [Figure 70-100-28] with an inside micrometer. P-47254
Measure the rocker arm shaft O.D. (Item 2) [Figure 70100-28] with an outside micrometer. If the clearance exceeds the allowable limit, replace the bushing. If the clearance still exceeds the allowable limit after the bushing is replace, replace the rocker arm shaft. Oil Clearance Between Rocker Arm & Shaft Allowable Limit Rocker Arm Shaft O.D. Rocker Arm I.D.
Bend a hook on the end of a 7.87 in. (200 mm) long, 0.050 in. (1.2 mm) diameter hard wire [Figure 70-10029]. Figure 70-100-30
0.0006 - 0.0018 in. (0,016 - 0,045 mm) 0.004 in. (0,10 mm) 0.5501 - 0.5506 in. (13,973 - 13,984 mm) 0.5512 - 0.5519 in. (14,0 - 14,02 mm)
1
P-47255
Disconnect the two governor springs (Item 1) [Figure 70100-30].
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B-3697
Figure 70-100-33
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Timing Gearcase Cover Removal And Installation (Cont'd) Figure 70-100-31
P-47258
1 Use a puller and remove the crankshaft pulley. [Figure 70-100-33].
Remove the speed control plate (Item 1) [Figure 70-10031]. Figure 70-100-32
2
1
1
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2) [Figure 70-100-34]. Remove the bolts from the timing gearcase cover.
P-47257
Remove the wire (Item 1) [Figure 70-100-32] from the springs.
Installation: Tighten the bolts to 13 - 15 ft.-lb. (18 - 20 nm) torque.
Installation: Do not drop the governor springs into the gear case. Remove the crankshaft pulley nut. Installation: Tighten the nut to 101 - 116 ft.-lb. (137 - 157 N•m) torque.
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Figure 70-100-34
P-47256
Figure 70-100-37
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Timing Gearcase Cover Removal And Installation (Cont'd) Figure 70-100-35
Oil Seal
O-rings B-3617B
Installation: Install new O-rings and oil seal into the timing gearcase cover [Figure 70-100-37]. P-47259
Dealer Copy -- Not for Resale
Remove the timing gearcase cover [Figure 70-100-35]. Figure 70-100-36
3 2
1
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2) and oil slinger (Item 3) [Figure 70-100-36].
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Figure 70-100-40
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Idler Gear And Camshaft Removal And Installation
2 Remove the timing gearcase cover. ((See Timing Gearcase Cover Removal And Installation on Page 70100-10.)) 1
Figure 70-100-38
2
1 P-47262
Installation: Tighten the camshaft retainer bolts to 18 20 ft.-lb. (24 - 27 N•m) torque. P-47260
Remove the camshaft from the engine block. Remove the snap ring (Item 1) and collar from the idler gear shaft (Item 2) [Figure 70-100-38].
Figure 70-100-41
Installation: Make sure the timing marks are in correct alignment when installing the timing gears [Figure 70100-38]. Figure 70-100-39
1
PI-10002B
Installation: Check the camshaft end play. If clearance exceeds the allowable limit, replace the camshaft retainer plate [Figure 70-100-41]. B-3699
Camshaft End Play
Remove the idler gear (Item 1) [Figure 70-100-39]. Installation: Check the idler gear end play. If the clearance exceeds the allowable limit, replace the gear collar. Idler Gear End Play Allowable Limit
0.0047 - 0.0189 in. (0,12 - 0,48 mm)
0.0354 in. (0,9 mm)
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Allowable Limit
0.0028 - 0.0087 in. (0,07 - 0,22 mm) 0.0118 in. (0,3 mm)
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Align the holes (Item 1) on the camshaft gear with the camshaft retainer plate bolts (Item 2) [Figure 70-100-40]. Remove the bolts.
Figure 70-100-44
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Camshaft Servicing Figure 70-100-42
B-5001
Measure the cam lobes at their highest point [Figure 70100-44]. P-47263
Cam Lobe Height Allowable Limit
Figure 70-100-43
1.3346 in. (33,9 mm) 1.3327 in. (33,85 mm)
Figure 70-100-45
A-2761 A-2760
Measure the camshaft journal [Figure 70-100-43]. Calculate the oil clearance. If the clearance exceeds the allowable limit, replace the camshaft. Cylinder Block Bore I.D. Journal O.D. Oil Clearance of Camshaft Journal Allowable Limit
1.5748 - 1.5758 in. (40,0 - 40,03 mm) 1.5722 - 1.5728 in. (39,93 - 39,95 mm) 0.002 - 0.0036 in. (0,05 - 0,091 mm) 0.0059 in. (0,15 mm)
Put the camshaft in V-blocks. Install a dial indicator [Figure 70-100-45]. Turn the camshaft at a slow rate. If the misalignment exceeds the allowable limit, replace the camshaft. Camshaft Alignment Allowable Limit
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0.0004 in. (0,01 mm)
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Measure the cylinder block bore in the engine block [Figure 70-100-42].
If the measurement is less than the allowable limit, replace the camshaft.
Figure 70-100-47
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Idler Gear And Shaft Servicing
1.49” (38 mm)
Figure 70-100-46
6.89” (175 mm) 1.77” (45 mm)
1.575” (40 mm)
1.650-1.652” (41,9-41,95 mm) 1.494-1.495” (37,95-37,97 mm) MC-1366
To replace the idler gear bushing, make a driver tool as shown in figure [Figure 70-100-47]. PI-10003
Measure the O.D. of the idler gear shaft [Figure 70-10046]. Measure the I.D. of the idler gear bushing [Figure 70100-46]. If the clearance exceeds the allowable limit, replace the bushing. Idler Gear Shaft O.D. Idler Gear Bushing I.D. Clearance Between Idler Shaft & Gear Bushing Allowable Limit
1.4945 - 1.4951 in. (37,96 - 37,98 mm) 1.4961 - 1.4970 in. (38,0 - 38,03 mm) 0.001 - 0.0026 in. (0,025 - 0,07 mm) 0.0039 in. (0,1 mm)
PI-10004
Use a press and special driver tool, to remove the old bushing and install the new bushing [Figure 70-100-48].
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Figure 70-100-48
Fuel Camshaft Removal And Installation
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Timing Gears Checking Backlash When the gears are installed, check the backlash of the gears. Figure 70-100-49
Remove the timing gearcase cover. ((See Timing Gearcase Cover Removal And Installation on Page 70100-10.)) Remove the idler gear. ((See Idler Gear And Camshaft Removal And Installation on Page 70-100-13.)) Figure 70-100-50
2
1 P-47265
Install a dial indicator [Figure 70-100-49]. Hold one gear while turning the other gear [Figure 70100-49]. If the backlash exceeds the allowable limit, check the oil clearance of the shaft and gear. If the oil clearance is correct, replace the gear. Crank Gear & Idler Gear Allowable Limit Cam Gear & Idler Gear Allowable Limit Injection Pump Gear & Idler Gear Allowable Limit Oil Pump Gear & Crankgear Allowable Limit
0.0016 - 0.0044 in. (0,042 - 0,112 mm) 0.0059 in. (0,15 mm) 0.0016 - 0.0045 in. (0,042 - 0,115 mm) 0.0059 in. (0,15 mm) 0.0016 - 0.0045 in. (0,042 - 0,115 mm) 0.0059 in. (0,15 mm) 0.0016 - 0.0043 in. (0,042 - 0,109 mm) 0.0059 in. (0,15 mm)
Remove the three bolts (Item 1) [Figure 70-100-50]. Remove the two bolts and fuel camshaft retainer plate (Item 2) [Figure 70-100-50]. Figure 70-100-51
P-47266
Remove the fuel camshaft and fork lever assembly at the same time [Figure 70-100-51].
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1
P-47264
Crankshaft Gear Removal And Installation
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Fuel Camshaft Governor The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. Figure 70-100-52
Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Remove the idler gear. (See Idler Gear And Camshaft Removal And Installation on Page 70-100-13.)
B-3686
1. Start Spring 2. Governor Spring 3. Governor Spring 4. Fork Lever 5. Fork Lever 6. Fork Lever Shaft 7. Fork Lever Holder 8. Governor Lever 9. Fuel Camshaft 10. Governor Ball Case 11. Steel Balls 12. Governor Sleeve 13. Steel Ball
Remove the crankshaft gear with a puller [Figure 70100-53]. Remove the crankshaft key.
PI-10008
Disassemble and assemble the governor and fuel camshaft as shown in figure [Figure 70-100-52]. Check all the parts for wear or damage and replace as needed.
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Figure 70-100-53
Oil Pump Service
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-55
Oil Pump Removal And Installation Remove the timing gearcase cover. (See Timing Gearcase Cover Removal And Installation on Page 70100-10.) Remove the crankshaft gear. Figure 70-100-54
1
B-3616
2
Measure the clearance between the lobes of the inner rotor and outer rotor [Figure 70-100-55].
Dealer Copy -- Not for Resale
Figure 70-100-56
B-3658
Remove the nut from the oil pump shaft. Use a puller to remove the oil pump gear (Item 1) [Figure 70-100-54]. Remove the oil pump mounting bolts. Remove the oil pump (Item 2) [Figure 70-100-54]. Installation: Tighten the oil pump mounting bolts to 60 72 in.-lb. (6,9 - 8,1 N•m) torque. A-2732
Measure the clearance between the outer rotor and pump body [Figure 70-100-56]. If the clearance exceeds the allowable limit, replace the oil pump. Clearance Between Inner & Outer Rotor Clearance Between Outer Rotor & Body
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0.0012 - 0.0055 in. (0,03 - 0,14 mm) 0.0043 - 0.0075 in. (0,11 - 0,19 mm)
S150, S160 Bobcat Loader Service Manual
Checking Engine Oil Pressure
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Remove the oil pressure sender.
Oil Pump Service (Cont’d)
Figure 70-100-58
Figure 70-100-57
PI-10010 PI-10009
Install the cover and tighten the bolts. Remove the cover carefully. Measure the width of the press gauge [Figure 70-100-57]. If the clearance exceeds the allowable limit replace the oil pump. End Clearance
0.0041 - 0.0059 in. (0,11 - 0,15 mm)
Install a pressure gauge [Figure 70-100-58]. Start the engine and run until it is at operating temperature. If the oil pressure is less than the allowable limit, check the following items: * Engine Oil Level Low * Oil Pump Defective * Oil Galley Plugged * Oil Strainer Plugged * Excessive Clearance at the Rod & Main Bearings * Oil Pump Relief Valve Stuck At Idle Speed Allowable Limit 7 PSI (0.50 bar) At Rated Speed 43 - 64 PSI (2,94 - 4,41 bar) Allowable Limit 36 PSI (2.45 bar)
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Put a piece of press gauge on the rotor face [Figure 70100-57].
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Piston And Connecting Rod Removal And Installation
Valve Tappets
Remove the cylinder head. (See Cylinder Head Removal And Installation on Page 70-100-1.)
Figure 70-100-59
Remove the top edge from the cylinder bore with a ridge reamer. Remove the oil pan. Figure 70-100-61 1
1
2 P-47267
Figure 70-100-60 P-47269
Remove the oil pump strainer (Item 1) and O-ring (Item 2) [Figure 70-100-61] by tapping the edge of the strainer with a soft faced hammer. Turn the flywheel and put a pair of connecting rods at bottom dead center. Remove the connecting rod bolts. Installation: Tighten the connecting rod bolts to 33 - 36 ft.-lb. (44 - 49 N•m) torque. P-47268
Measure the O.D. of the tappet [Figure 70-100-60]. Measure the ID of the tappet bore [Figure 70-100-60]. If the clearance exceeds the allowable limit, replace the tappets. Tappet OD Tappet Bore ID Clearance Between Tappet and Tappet Bore Allowable limit
0.9433 - 0.9441 in. (23,96 - 23,98mm) 0.9449 - 0.9457 in. (24 - 24,02 mm) 0.0008 - 0.0024 in. (0,02 - 0,06 mm)
0.0028 in. (0,07 mm)
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Remove the valve tappets (Item 1) [Figure 70-100-59].
Figure 70-100-64
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Piston And Connecting Rod Removal And Installation (Cont’d)
4 1
3
Figure 70-100-62 2 1
P-47270
Remove the piston rings [Figure 70-100-64].
Separate the piston (Item 3) from the connecting rod (Item 4) [Figure 70-100-64].
Remove the rod cap and bearing [Figure 70-100-62]. Use a hammer handle and push the piston / connecting rod assembly out of the cylinder bore [Figure 70-10062].
Figure 70-100-65 2
NOTE: Make sure the pistons are marked so they will be returned to the same cylinder bore. 3
Figure 70-100-63
1
PI-10015
1 Installation: When installing new rings, assemble the ring so the mark (Item 1) near the gap faces the top of the piston. When installing the oil ring, place the expander joint (Item 2) on the opposite side of the oil ring gap (Item 3) [Figure 70-100-65].
A-2903
Installation: Make sure the marks on the connecting rod and bearing are aligned when installing the bearing cap [Figure 70-100-63]. Repeat the procedure to remove the other piston / connecting rod assemblies from the engine block.
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Remove the snap ring (Item 1) and piston pin (Item 2) [Figure 70-100-64].
PI-10013
Piston And Connecting Rod Servicing
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-67
Piston And Connecting Rod Removal And Installation (Cont’d) Figure 70-100-66 3
1 2
P-47272
5 4
Installation: When reassembling, align the marks (Item 1) on the connecting rod and piston (Item 2). Heat the piston in clean engine oil to 176° F (80° C) and tap the piston pin into position. Place the piston rings so that there are gaps every 120° (Items 3, 4 and 5) [Figure 70100-66] with no gap facing the piston pin in the cylinder.
If the measurement exceeds the allowable limit, replace the piston.
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Piston Bore I.D. Allowable Limit
0.9843 - 0.9848 in. (25,0 - 25,013 mm) 0.9862 in. (25,05 mm)
S150, S160 Bobcat Loader Service Manual
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Measure the I.D. of the piston pin bore in both horizontal and vertical directions [Figure 70-100-67].
P-47271
Figure 70-100-69
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
1.38” (35 mm)
Piston And Connecting Rod Servicing (Cont’d)
1.063” (27 mm)
Figure 70-100-68
6.38” (162 mm) 1.378” (35 mm)
1
2
1.098-1.1004” (27,9-27,95 mm) 0.984-0.985” (25,0-25,01 mm) MC-1366
To replace the connecting rod small end bushing, make a driver tool as shown in figure [Figure 70-100-69]. P-47273
Measure the O.D. of the piston pin (Item 1) [Figure 70100-68]. Measure the I.D. of the connecting rod small end (Item 2) [Figure 70-100-68]. Calculate the oil clearance. If the clearance exceeds the allowable limit, replace the bushing. If it still exceeds the specifications, replace the piston pin. Piston Pin O.D. Bushing I.D. Oil Clearance Between Piston Pin & Bushing Allowable Limit
0.9843 - 0.9847 in. (25,0 - 25,011 mm) 0.9852 - 0.9858 in. (25,03 - 25,04 mm) 0.0006 - 0.0015 in. (0,014 - 0,038 mm) 0.0059 in. (0,15 mm)
PI-10016
Use a press and special driver tool to remove the small end bushing [Figure 70-100-70]. Installation: Clean the small end bushing and bore. Put oil on the bushing and press into the connecting rod until it is flush [Figure 70-100-70].
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Figure 70-100-70
Figure 70-100-72
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Piston And Connecting Rod Servicing (Cont’d) Figure 70-100-71
PI-10017
B-3622
Install a piston ring into the lower part of the cylinder bore. Measure the ring gap with a feeler gauge [Figure 70-100-71]. If the gap exceeds the allowable limit, replace the ring.
If the clearance exceeds the allowable limit, replace the ring. If the clearance still exceeds the allowable limit, replace the piston. Kubota V2203-M-DI Compression Rings
Kubota V2203-M-DI Top Ring Gap Oil Ring Gap Allowable Limit Second Ring Gap
0.0079 - 0.0138 in. (0,2 - 0,35 mm) 0.0079 - 0.0157 in. (0,20 - 0,40 mm) 0.0492 in. (1,25 mm) 0.0138 - 0.0197 in. (0,35 - 0,50 mm)
Allowable Limit Oil Ring Allowable Limit
Kubota V2003-M-DI-T (Turbo) Compression Rings Allowable Limit Oil Ring
Kubota V2003-M-DI-T (Turbo) Top Ring Gap Oil Ring Gap Allowable Limit Second Ring Gap
0.0079 - 0.0138 in. (0,2 - 0,35 mm) 0.0098 - 0.0177 in. (0,25 - 0,45 mm) 0.0492 in. (1,25 mm) 0.0157 - 0.0217 in. (0.40 - 0,55 mm)
Allowable Limit
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0.0020 - 0.0035 in. (0,05 - 0,09 mm) 0.0079 in. (0,2 mm) 0.0012 - 0.0028 in. (0,03 - 0,07 mm) 0.0059 in. (0,15 mm)
0.0037 - 0.0050 in. (0,093 - 0,128 mm) 0.0079 in. (0,2 mm) 0.0008 - 0.0024 in. (0,02 - 0,06 mm) 0.0059 in. (0,15 mm)
S150, S160 Bobcat Loader Service Manual
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Remove the carbon from the ring grooves. Measure the clearance between the ring and groove with a feeler gauge [Figure 70-100-72].
Crankshaft And Bearings Removal And Installation
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Connecting Rod Alignment NOTE: The small end bushing is the basis of this check, check the bushing for wear before doing this check.
Remove the piston and connecting rod assemblies. (See Piston And Connecting Rod Removal And Installation on Page 70-100-20.) Figure 70-100-74 2
Install the piston pin into the connecting rod.
5
Install the connecting rod on an alignment tool. 4 Put the gauge over the piston pin and move it against the face plate. 1
Figure 70-100-73
3
Mark and remove the inside screws (Item 1) first, then remove the outside screws (Item 2) [Figure 70-100-74]. NOTE: The inside bolts are different length than the outside bolts. Install two screws in the bearing case cover and remove the cover (Item 3) [Figure 70-100-74].
B-4067
If the gauge does not fit squarely against the face plate, measure the space between the gauge and face plate [Figure 70-100-73].
Remove the two gaskets (Item 4) and oil seal (Item 5) [Figure 70-100-74] from the cover. Figure 70-100-75
If the measurement exceeds the allowable limit, replace the connecting rod. Rod Alignment
0.002 in. (0,05 mm)
1 2
P-47275
Installation: Install the gaskets (Item 1) and (Item 2) [Figure 70-100-75] as shown.
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P-47274
Figure 70-100-78
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Crankshaft And Bearings Removal And Installation (Cont’d)
1
Figure 70-100-76 2
2
1 P-47278
P-47276
Install the bearing case cover (Item 1) [Figure 70-10076] with the casting mark (Item 2) [Figure 70-100-76] in the upward position. Tighten the bolts to 17 - 20 ft.-lb. (23,5 - 27,5 N•m) torque.
Installation: Align the bearing case hole (Item 2) [Figure 70-100-78] with the hole in the block. Put oil on the bolt threads and tighten to 51 - 54 ft.-lb. (69 - 73 N•m) torque. Figure 70-100-79
Figure 70-100-77 1
P-47279
Remove the crankshaft / main bearing assembly from the engine block [Figure 70-100-79].
P-47277
Before removing the crankshaft / main bearings, check the end play. Install a dial indicator. Move the crankshaft [Figure 70-100-77] to the flywheel side, zero the dial indicator. Measure the end play by pulling the crankshaft toward the gear case side.
NOTE: Turn the crankshaft as needed to allow the crank pin journals to pass through the cut out (Item 1) [Figure 70-100-79] of the engine block. Mark the bearing case halves for correct installation.
If the measurement exceeds the allowable limit, replace the thrust washers [Figure 70-100-77]. End Play Allowable Limit
0.0059 - 0.0138 in. (0,15 - 0,35 mm) 0.0197 in. (0,5 mm)
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Remove the main bearing case bolt (Item 1) [Figure 70100-78].
Crankshaft And Bearings, Servicing
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-82
Crankshaft And Bearings Removal And Installation (Cont’d) Figure 70-100-80
A-2763
Remove the two bearing case bolts [Figure 70-100-80]. Remove the bearing case and bearing. Installation: Tighten the bearing case bolts to 34 - 38 ft.lb. (46 - 51 N•m) torque. Figure 70-100-81
Turn the crankshaft at a slow rate to obtain the misalignment (one half of the alignment measurement). If the misalignment exceeds the allowable limit, replace the crankshaft. Alignment
0.0008 in. (0,02 mm)
Tighten the connecting rod bolts to 33 - 36 ft.-lb. (45 - 49 N•m) torque. Figure 70-100-83
120
PI-10021
Installation: When installing the main bearing case assemblies, face the mark FLYWHEEL to the flywheel side of the engine block [Figure 70-100-81]. The thrust washers oil grooves must face outward.
A-2727
Measure the crankpin bearing I.D. [Figure 70-100-83].
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Put the crankshaft on V-blocks. Install a dial indicator on the center journal [Figure 70-100-82].
B-4092
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-85 1
Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-84
PI-10022
Check the wear on the crankshaft sleeve (Item 1) [Figure 70-100-85]. A-2716
Wear of Sleeve
Calculate the oil clearance. Crankpin Bearing I.D. Crankpin O.D. Oil Clearance Allowable limit
1.8504 - 1.8522 in. (47,0 - 47,05 mm) 1.8488 - 1.8494 in. (46,96 - 46,98 mm) 0.0010 - 0.0034 in. (0,025 - 0,087 mm) 0.0079 in. (0,2 mm)
The special tool set will be needed to replace the crankshaft sleeve. Remove the sleeve.
70-100-28 819 of 949
0.0039 in. (0,1 mm)
S150, S160 Bobcat Loader Service Manual
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Measure the crankpin O.D. [Figure 70-100-84].
If the wear exceeds the allowable limit or the seal leaks oil, replace the sleeve.
Figure 70-100-88
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D) Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-86
2
2 1
3
B-3618
Measure the O.D. of the crankshaft journal [Figure 70100-88]. PI-10023
Install the sleeve guide (Item 1) and stop (Item 2) [Figure 70-100-86].
If the clearance exceeds the allowable limit, replace the crankshaft bearing.
Heat the sleeve to approximately 300° F (150° C). Install the sleeve on the crankshaft using the special driver tool (Item 3) [Figure 70-100-86].
Bearing 1:
NOTE: The sleeve is installed with the larger chamfered surface to the front of the crankshaft (Item 1) [Figure 70-100-85 on Page 28].
Bearing I.D. Journal O.D. Oil Clearance Allowable Limit
Figure 70-100-87
2.3614 - 2.3637 in. (59,98 - 60,04 mm) 2.3591 - 2.3598 in. (59,92 - 59,94 mm) 0.0016 - 0.0046 in. (0,040 - 0,12 mm) 0.0079 in. (0,2 mm)
B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure 70-100-87].
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Calculate the oil clearance.
Figure 70-100-91
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
1. Seam 2. Bearing 3. Engine Block 4. Bearing Recession
Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-89 Removal Tool
4
3
5.31” (135 mm) 0.8” (20 mm) 2.354-2.358” (59,80-59,90 mm)
2.83” (72 mm)
2
1
2
P-48778
1.57” (40 mm)
0.4” (10 mm)
2.551-2.555 (64,80-64,90 mm) MC-1367
To remove the front bearing make the tool as shown in figure [Figure 70-100-89].
Installation Tool 5.12” (130 mm)
2.83”
0.8” (20 mm)
Bearing Number 1 Recession
2.551-2.555” (64,80-64,90 mm) 2.68” (68 mm)
0.8” (20 mm) 0.4” (9mm)
0.1654 - 0.1772 in. (4,2 - 4,5 mm)
Clean the crankshaft journal and bearing. Put a strip of press gauge on the center journal.
(72 mm)
1.57” (40 mm)
Installation: Clean the new bearing (Item 2) and bore, apply oil to the bearing and bore. Install the new bearing with the seam (Item 1) [Figure 70-100-91] towards the exhaust manifold side, using the installation driver tool. Check the depth (Item 4) of the bearing (Item 2) from the face of the engine block (Item 3) [Figure 70-100-91]. This will ensure proper bearing alignment with the crankshaft.
Figure 70-100-90
0.16” (4 mm)
Remove the front bearing with the special removal tool [Figure 70-100-89].
2.354-2.358” (59,80-59,90 mm)
Install the main bearing case halves and tighten the bolts. Remove the bearing case halves. NOTE: DO NOT turn the crankshaft with the press gauge installed. Incorrect measurements will be obtained.
MC-1365
To install the front bearing make the tool as shown in figure [Figure 70-100-90].
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0.8” (20 mm)
Cylinder Bore, Checking
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-93
Crankshaft And Bearings, Servicing (Cont’d) Figure 70-100-92
B-4066
Use a gauge to check the inside measurement of the cylinder bore [Figure 70-100-93].
Measure the flattened press gauge [Figure 70-100-92].
Figure 70-100-94
Dealer Copy -- Not for Resale
PI-10025
If the clearance exceeds the allowable limit, replace the No. 2 crankshaft bearing. Crankshaft Journal O.D. Bearing I.D. Oil Clearance Allowable Limit
2.3591 - 2.3598 in. (59,92 - 59,94 mm) 2.3614 - 2.3632 in. (59,98 - 60,02 mm) 0.0016 - 0.0041 in. (0,04 - 0,12 mm) 0.0079 in. (0,2 mm)
A-2717
Measure the six points as shown in figure [Figure 70100-94] to find the maximum wear. The factory specifications are: Kubota V2203-M-DI 3.4252 - 3.4261 in. (87,0 - 87,022 mm) The wear limit is: +0.0059 in. (+0,15 mm). Kubota V2003-M-DI-T (Turbo) 3.2677 - 3.2686 in. (83 - 83,02 mm). The wear limit is +0.0059 in. (+0,15 mm). If the cylinder bore is not within specifications, re-bore the cylinder for oversize piston.
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Water Pump Disassembly And Assembly
RECONDITIONING THE ENGINE V2203-M-DI AND V2003-M-DI-T (TURBO) (CONT’D)
Figure 70-100-96
Water Pump Removal And Installation
2
Drain the cooling system. 1
Remove the alternator belt. Remove the water pump bolts.
3 4
Figure 70-100-95
B-14424
Press the shaft (Item 2) and impeller (Item 3) [Figure 70100-96] out the impeller side of the water pump. Remove the impeller (Item 3) [Figure 70-100-96] from the shaft.
B-5318
Remove the seal (Item 4) [Figure 70-100-96].
Remove the water pump [Figure 70-100-95]. Installation: Always use a new gasket when installing the water pump.
Install a new seal (Item 4) [Figure 70-100-96] when assembling the water pump.
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Remove the flange (Item 1) [Figure 70-100-96].
Figure 70-110-2
TURBOCHARGER Checking Inspect the turbine fins and the turbo housing for damage.
1
Spin turbine by hand. Turbine should spin freely. If the turbine is damaged replace the turbocharger.
2
Check the oil tubelines for leaks. Description P-48783
Turbochargers, operate at high speed and high temperatures. Keep fingers, tools and other objects away from the inlet and outlet ports. Avoid contact with hot surfaces.
The oil flows from the fitting (Item 1) on the front of the engine to the turbocharger and returns to the engine block through the fitting (Item 2) [Figure 70-110-2]. The turbocharger serviceable.
internal
components
are
not
Dealer Copy -- Not for Resale
WARNING
W-2257-1196
Figure 70-110-1
1
P-48893
The turbocharger (Item 1) [Figure 70-110-1] is placed between the exhaust and intake manifolds. It is driven by hot exhaust gases and supplies air at more than atmospheric pressure to the intake. It is lubricated by oil from the main galley.
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Figure 70-110-4
TURBOCHARGER (CONT'D) Removal And Installation Remove the muffler. (See Contents Page 70-01.)
1 Figure 70-110-3
2
1
P-48598
Figure 70-110-5
Remove the compressor outlet hose (Item 1) [Figure 70110-3] from the turbo.
1
Remove the air cleaner hose (Item 2) [Figure 70-110-3] from the turbocharger.
P16230
Remove the oil supply line fitting (Item 1) [Figure 70-1104] and the brass washer(s) (Item 1) [Figure 70-110-5] from the turbocharger. Installation: Tighten to 12 - 15 ft.-lb. (16,0 - 20,3 N•m) torque.
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P-48599
Figure 70-110-8
TURBOCHARGER (CONT'D) Removal And Installation (Cont'd) Figure 70-110-6
1
1
P-48780
Remove the mounting bolts (Item 1) [Figure 70-110-8] from the exhaust muffler flange.
P-48597
Dealer Copy -- Not for Resale
Installation: Tighten to 17 - 20 ft.-lb. (23,0 - 27,0 N•m) torque.
Figure 70-110-7
Figure 70-110-9 1
1 1
2 P-48785
Remove the mounting bolts (Item 1) [Figure 70-110-6] and [Figure 70-110-7] from the oil return line (Item 2) [Figure 70-110-6] and [Figure 70-110-7]. Installation: Tighten to 84 - 132 in.-lb. (9,5 - 15,0 N•m) torque.
P-48781
Remove the mounting bolts (Item 1) [Figure 70-110-9] from the exhaust muffler flange. Installation: Tighten to 17 - 20 ft.-lb. (23,0 - 27,0 N•m) torque.
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TURBOCHARGER (CONT'D) Removal And Installation (Cont'd) Figure 70-110-10
1 1
P-48601
Dealer Copy -- Not for Resale
Remove the mounting nuts and washers (Item 1) [Figure 70-110-10] from the turbocharger. Installation: Tighten to 17 - 20 ft.-lb. (23,0 - 27,0 N•m) torque. Figure 70-110-11
1
P16230
Remove the turbocharger assembly (Item 1) [Figure 70110-11] from the engine.
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HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1 AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3 Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2 BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1 Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-3 Cleaning The A/C Evaporator Coil And Heater Coil . . . . . 80-50-1 Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-50-2 Engine Coolant Bypassing The Heater Valve . . . . . . . . . 80-50-10 Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-11 Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
SAFETY MAINTENANCE
DRIVE SYSTEM
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
ELECTRICAL SYSTEM ANALYSIS ENGINE SERVICE
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1 EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . 80-160-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1
HVAC
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1 GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . Component Replacement And Refrigeration Leaks. . . . . . Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . .
80-60-1 80-60-3 80-60-1 80-60-2
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1 Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1 Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2 Continued On Next Page
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COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
HEATING, VENTILATION, AIR CONDITIONING (CONT’D) HEATER / A/C FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . Wire Connector Removal And Installation . . . . . . . . . . . .
80-210-1 80-210-2 80-210-1 80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-220-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1 PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1 PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1 RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1 80-40-1 80-40-3 80-40-2 80-40-1
Dealer Copy -- Not for Resale
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . Filter Elements Removal And Installation . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1 Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1 SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Procedure With A Manifold Gauge Set . . . . . . Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .
80-100-1 80-100-5 80-100-4 80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1 Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2 TEMPERATURE / PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . 80-80-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
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AIR CONDITIONING SYSTEM FLOW Principals In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit. At these five points in the system the refrigerant goes through pressure and temperature changes. The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3. Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the refrigerant from a gas to a liquid.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, lowpressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan (Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and drips into the drain pan, which directs the water out of the cab. The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
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The liquid refrigerant moves on to the receiver / drier (Item 3) See Chart on Page 80-10-3. where impurities such as moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3.
AIR CONDITIONING SYSTEM FLOW (CONT'D) Chart
Thermostat
Cold Air Evaporator 5 Evaporator
4 Expansion Valve
6
Dealer Copy -- Not for Resale
Blower
1 Compressor
2 Condenser
Sight Glass
Pressure Switch
Fan Dessicant 3
Receiver Drier
Status Of R134a_______________________________________________ High Pressure Gas
Low Pressure Liquid
High Pressure Liquid
Low Pressure Gas b-16691
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Figure 80-20-3
COMPONENTS Identification
2
Figure 80-20-1
1 1
P-24219
Compressor: The compressor (Item 1) [Figure 80-20-1] is the pump that circulates the refrigerant throughout the system. It raises the pressure of the refrigerant for heat transfer through the condenser and evaporator.
Receiver / Drier: The receiver / drier (Item 1) [Figure 8020-3] is the unit that receives the liquid refrigerant from the condenser and removes moisture and foreign matter from the system. It also serves as a storage tank for the extra liquid refrigerant until it is needed by the evaporator.
Dealer Copy -- Not for Resale
P-24288
Figure 80-20-4
NOTE: The A/C system (Compressor) is recommended to be turned on for at least 5 minutes weekly throughout the year to lubricate the internal components. 1
Figure 80-20-2
1
N-22206
Pressure Relief Valve: The pressure relief valve (Item 2) [Figure 80-20-3] is located on the receiver drier assembly. This small brass valve (Item 1) [Figure 80-204] is a safety feature that is designed to open and release the A/C charge if the pressure reaches 535 PSI. P-48011
Condenser: The condenser (Item 1) [Figure 80-20-2] is the unit that receives the high pressure, high temperature refrigerant vapor from the compressor and condenses it into a high temperature liquid.
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Figure 80-20-7
COMPONENTS (CONT'D) Identification (Cont'd) Figure 80-20-5
3
1 2 N-22087
1
Heater / Evaporator Unit: The heater / evaporator unit (Item 1) [Figure 80-20-5] is located behind the loader cab. The unit delivers the cold air for the A/C and warm air for heat into the cab. The unit contains the blower, heat and A/C coils, thermostat and expansion valve.
Thermostat: The thermostat (Item 2) [Figure 80-20-7] controls the temperature of the evaporator coil. Heater Coil: The heater coil (Item 3) [Figure 80-20-7] supplies the warm air into the cab by passing air through the coil.
Figure 80-20-6 Figure 80-20-8
1
1 P-21902 N-22100
Expansion Valve: The expansion valve (Item 1) [Figure 80-20-6] controls the amount of refrigerant entering the evaporator coil.
Heater / Evaporator Blower: The blower (Item 1) [Figure 80-20-8] is used to push air through the heater and evaporator coils and into the cab.
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Evaporator Coil: The evaporator coil (Item 1) [Figure 8020-7] cools and dehumidifies the air before it enters the cab.
P-24227
Figure 80-20-11
COMPONENTS (CONT'D) Identification (Cont'd)
1
Figure 80-20-9
1
2 3
4 P-24229
Control Panel: The panel (Item 1) [Figure 80-20-9] has three separate components.
Pressure Switch: The pressure switch (Item 1) [Figure 80-20-11] will disengage the compressor clutch at high pressure readings over 384 PSI. (2647 kPa) on the high side, or at very low pressure of 28 PSI (193 kPa) or less on the high side, which indicates loss of refrigerant.
Dealer Copy -- Not for Resale
N-22261
Fan Switch: This is a four position rotary switch (Item 2) [Figure 80-20-9]. When the fan switch is in the off position the A/C will not engage, but the heat valve will operate, as it is controlled by the ignition power. A/C Switch: The rocker switch (Item 3) [Figure 80-20-9] will be illuminated when the A/C is engaged. Potentiometer: The potentiometer (Item 4) [Figure 8020-9] controls the Heat Valve from fully Off to fully On. This can be used in conjunction with the A/C for defrost of the windows and temperature control. Figure 80-20-10
1
P-24232
Heater Valve: The heater valve (Item 1) [Figure 80-2010] is used to control the amount of engine coolant that flows to the heater coil. 80-20-3 836 of 949
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SAFETY
WARNING
Safety Equipment Figure 80-30-1
In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
R-134a inside a canister or in an A/C system is a liquid under pressure. When it escapes or releases into the air, ITS TEMPERATURE DROPS TO 21.6°F DEGREES “INSTANTLY”. If it spills on your skin or in your eyes you should flood the area with cool water and SEEK MEDICAL ATTENTION FAST! It is a good idea to wear gloves [Figure 80-30-2] to prevent frost bite if you should get refrigerant on your hands.
P16398
WARNING
P16399
In servicing A/C and heater systems you will be exposed to high pressures, temperatures and several chemical hazards. Moving belts and pulleys are normal shop hazards.
HFC 134A refrigerant can be dangerous if not properly handled. Liquid 134A may cause blindness if it contacts the eyes and may cause serious frostbite if it contacts the skin. • Gaseous 134A becomes lethal (phosgene) gas when it contacts open flame or very hot substances. • NEVER SMOKE when there is the possibility of even small amounts of 134A in the air. Any servicing work that involves release or addition of 134A to the system must be done by a competent refrigeration dealer who has the proper equipment, knowledge, and experience to service refrigeration equipment. W-2373-0500
In addition to exercising caution in your work, DO WEAR SAFETY GLASSES OR A FACE SHIELD [Figure 8030-1] when you are using R-134a or a leak detector, adjusting service valves or the manifold gage set connectors. Safety glasses or a transparent face shield are practical safety items and one or the other is absolutely required.
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Figure 80-30-2
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Figure 80-40-3
REGULAR MAINTENANCE Filter Elements Removal And Installation Figure 80-40-1
1
P-28820
1
Remove the two mount bolts (Item 1) [Figure 80-40-1] from the fresh air filter cover at the rear of the loader cab. Figure 80-40-2
The fresh air filter must be cleaned sometimes as often as twice a day, depending on the environment. The filter can be cleaned by removing and shaking it. A small amount of air pressure can be used to clean the filter. However the fresh air filter should be changed at least 2 4 times per year in normal conditions. In extremely dusty conditions the fresh air filter many need to be changed weekly. Figure 80-40-4
1
P-28819
Remove the filter cover and filter (Item 1) [Figure 80-402] from the loader.
2
1 P-48005
Remove the two retaining knobs (Item 1) [Figure 80-404] from the recirculating air filter cover, at the back of the cab. Remove the retaining cover (Item 2) [Figure 80-40-4] from the loader cab.
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Remove the filter (Item 1) [Figure 80-40-3] from the cover.
P-48012
REGULAR MAINTENANCE (CONT’D)
Compressor Drive Belt Inspection
Filter Elements Removal And Installation (Cont’d)
Figure 80-40-7
Figure 80-40-5
P-48008
1
1 P-24288 P-48006
Remove the recirculating air filter (Item 1) [Figure 80-405] from the rear of the cab. Installation: Make sure the arrows on the filter are facing the front of the loader. (Inset) [Figure 80-40-5].
Open the rear door. Remove the drive belt cover. Remove the compressor drive belt cover.
Figure 80-40-6 Check the tension on the compressor belt (Item 1) [Figure 80-40-7].
P-48007
The recirculating air filter is made of a paper filtering media with a rubber seal. A small amount of air can be used to clean the filter. It does not require cleaning as frequently as the fresh air intake filter [Figure 80-40-6].
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It is a good rule to regularly inspect (weekly) the compressor drive belt for tension and wear.
Figure 80-40-10
REGULAR MAINTENANCE (CONT’D) Cleaning The Condenser Figure 80-40-8 1
1
P-48010
With water or air, the condenser (Item 1) [Figure 80-4010] can be cleaned.
P-48011
Dealer Copy -- Not for Resale
Open the rear door. Remove the rear grille on the loader. Check the condenser (Item 1) [Figure 80-40-8] for mud or dirt. Figure 80-40-9
2 1 P-24213A
P-48011
Lift the rear of the condenser and pull towards rear of machine until the front tabs (Item 1) slide out of mount (Item 2) [Figure 80-40-9]. With the condenser removed from the machine, the oil cooler can also be lifted.
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Check the belt tension on the A/C compressor. (See COMPRESSOR on Page 80-110-1.)
BASIC TROUBLESHOOTING Poor A/C Performance
Check the A/C condenser for dirt or mud, and clean if necessary. (See CONDENSER on Page 80-120-1.)
Figure 80-50-1
Check the A/C evaporator coil for dirt or mud, and clean if necessary. (See EVAPORATOR on Page 80-190-1.) Inspect the sight glass located on the receiver / drier for air bubbles. (See RECEIVER / DRIER on Page 80-1301.) 1
Check the engine coolant to see if it is bypassing the heater valve. (See HEATER VALVE on Page 80-220-1.)
N-22273
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
Figure 80-50-2
W-2059-0598
Cleaning The A/C Evaporator Coil And Heater Coil Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Figure 80-50-3 N-22411
Start the loader, engage the parking brake. Engage the A/C system with the blower fan on high. Run the loader at full rpm for approximately 15 minutes, with the loader cab door closed.
1
1
Check the temperature at the louvers (Item 1) [Figure 80-50-1] with a thermometer [Figure 80-50-2]. The louver temperature should be between 36° - 53° F (2,2° - 11,6° C) depending on the amount of humidity in the air.
2
P-39463
If louver temperature is too high, (See SYSTEM TROUBLESHOOTING CHART on Page 80-70-1.) Check the blower fan for proper operation or noise, and replace if necessary. (See HEATER / A/C FAN on Page 80-210-1.)
At the rear of the cab, Remove the six mounting screws (Item 1) [Figure 80-50-3]. Remove the access cover (Item 2) [Figure 80-50-3] from the loader.
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WARNING
BASIC TROUBLESHOOTING (CONT'D)
Compressor Drive Belt Inspection
Cleaning The A/C Evaporator Coil And Heater Coil (Cont'd)
Figure 80-50-6
Figure 80-50-4
1
1 P-48013
1 P-24288
The access cover is sealed to the heater unit with a foam gasket (Item 1) that keeps out dirt and debris. Check the gasket for rips and tears. Replace as needed.
Open the rear door.
The cover is held in place with screws that are held to the cover with plastic retainers (Inset). These help hold the screws when installing the cover.
Remove the compressor belt cover.
Remove the drive belt cover.
Check the tension on the compressor belt (Item 1) [Figure 80-50-6].
Figure 80-50-5
2 1
P-39464
With air or water, clean the heater coil (Item 1) and evaporator coil (Item 2) [Figure 80-50-5]. Replace the cover. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
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Regularly inspect (weekly) the compressor drive belt for wear.
P-48014
Figure 80-50-9
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System Figure 80-50-7
1
1
P-24300
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
N-22284
Check to see if the compressor clutch is engaging. With an operator in the loader seat and the cab door open, turn the loader key switch to RUN (Standard Panel) OR press the RUN / ENTER Button (Deluxe Panel), without starting the loader. Push the A/C switch (Item 1) to the ON position. Turn the blower fan switch (Item 2) [Figure 80-50-7] to the first On position.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Disconnect the loader harness (Item 1) [Figure 80-50-9] from the compressor clutch wire. Figure 80-50-10
The compressor clutch should make a click sound, which indicates the clutch is engaging. Figure 80-50-8 1 1
P-24314
With a multimeter, check the resistance to the compressor clutch (Item 1) [Figure 80-50-10]. P-21912
If the compressor clutch does not engage, check the loader fuse (Item 1) [Figure 80-50-8] located on the control panel in the loader cab.
If there is no resistance value, replace the compressor clutch. (See Compressor Clutch Disassembly on Page 80-110-2.)
Replace the fuse if burned out. NOTE: The decal inside the fuse cover, refers to the fuse as HEATER. This fuse controls the power for both the Heater and the A/C systems.
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2
Figure 80-50-13
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-11
1 1
P-24315
Using a multimeter check the loader wiring harness (Item 1) [Figure 80-50-13] for voltage.
P-24314
If there is no voltage at the wiring harness, check the harness for broken wires.
The voltage reading should be around 12 volts. Figure 80-50-14 If there is no power at the clutch, check the wiring harness for broken wires. If there is power at the clutch, reconnect the wiring harness to the compressor clutch. Figure 80-50-12
2 1
P-24315
1 If there is voltage at the harness, check the resistance at the pressure switch (Item 1) [Figure 80-50-14]. If there is no resistance value, check for low refrigerant level.
P-24299
Disconnect the loader harness (Item 1) from the pressure switch (Item 2) [Figure 80-50-12].
If a resistance value is observed, the pressure switch is good. Reconnect the loader harness to the pressure switch.
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The voltage should be around 12 volts. With a multimeter, check the voltage to the compressor clutch at the loader harness (Item 1) [Figure 80-50-11]
Figure 80-50-17
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-15
1
1
N-22259
If there is voltage at the wiring harness, check the thermostat (Item 1) [Figure 80-50-17] for resistance.
Disconnect the thermostat wiring connector (Item 1) [Figure 80-50-15] from the loader wiring harness.
The resistance value of the thermostat should be 10 ohm at 68° F (20° C). If there is no resistance value, replace the thermostat. (See Removal And Installation on Page 80-170-1.)
Figure 80-50-16
If there is a resistance value, check the blower fan. Figure 80-50-18
2 1
N-22259
1 Check the loader harness (Item 1) [Figure 80-50-16] for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
N-22130
Remove the mount bolt (Item 1) [Figure 80-50-18] from the left side cab access cover. Remove the access cover (Item 2) [Figure 80-50-18] from the loader.
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N-22258
Figure 80-50-21
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-19
1
1
N-22260
Disconnect the blower fan wiring connector (Item 1) [Figure 80-50-19] from the loader wiring harness.
If there is no resistance value replace the blower fan. (See Removal And Installation on Page 80-210-1.)
Figure 80-50-20
If there is a resistance value check the climate controls at the control panel inside the loader cab. Figure 80-50-22
1
1
1
N-22260
Check the loader harness (Item 1) [Figure 80-50-20] for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
N-22261
Remove the three mount bolts (Item 1) [Figure 80-50-22] from the cab control panel.
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If there is voltage at the wiring harness, check the resistance to the blower fan at the blower fan wiring connector (Item 1) [Figure 80-50-21].
N-22129
Figure 80-50-25
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-23
C
H
B
M
L
N-22288
If there is voltage at the wiring harness, check the blower switch [Figure 80-50-25] for resistance.
Remove the control panel and wiring harness from the cab [Figure 80-50-23].
With the switch in the OFF position, there should be zero resistance between all terminals. With the switch in the 1 position, there should be resistance between C terminal and the B terminal, between the C terminal and the L terminal, and also between the B terminal and the L terminal frame [Figure 80-50-25].
Figure 80-50-24
With the switch in the 2 position, there should be resistance between C terminal and the B terminal, between the C terminal and the M terminal, and also between the B terminal and the M terminal frame [Figure 80-50-25].
1
With the switch in the 3 position, there should be resistance between C terminal and the B terminal, between the C terminal and the H terminal, and also between the B terminal and the H terminal frame [Figure 80-50-25].
N-22265
Disconnect the loader wiring harness (Item 1) [Figure 80-50-24] from the blower switch. Check the loader harness for voltage. The voltage should be 12 volts.
If any of the above resistance tests fail, replace the blower switch. If the above resistance tests are good, check the A/C switch.
If there is no voltage at the wiring harness, check the harness for broken wires.
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N-22262
Figure 80-50-28
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-26
1 1
N-22262
The potentiometer will effect the A/C system and also effect the operation of the heater.
At the loader cab, disconnect the loader harness (Item 1) [Figure 80-50-26] from the A/C switch. Check the harness for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
If heater valve does not open, or close, or the A/C does not work, check the potentiometer. At the loader cab, disconnect the loader harness (Item 1) [Figure 80-50-28] from the potentiometer. Figure 80-50-29
Figure 80-50-27
1
1 2
N-22263 N-22289
If there is voltage at the wiring harness, check the A/C switch [Figure 80-50-27] for resistance. With the switch in the OFF position there should be no resistance between any of the three terminals on the A/C switch.
Check the loader harness (Item 1) [Figure 80-50-29] for voltage. The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
With the switch in the ON position there should be resistance between terminal (Item 1) and terminal (Item 2) [Figure 80-50-27]. If no resistance value is found, replace the A/C switch. If a resistance value is found, check the potentiometer.
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N-22264
Figure 80-50-32
BASIC TROUBLESHOOTING (CONT'D) Checking The Electrical System (Cont'd) Figure 80-50-30
C
A
1
N-22175
B To check the resistance of the white wire, turn the potentiometer control (Item 1) to the full A/C position [Figure 80-50-32].
If there is voltage at the wiring harness, check the potentiometer [Figure 80-50-30] for resistance.
Figure 80-50-33
Dealer Copy -- Not for Resale
N-22290
The resistance should be 10K ohm between wire terminal A and wire terminal C frame [Figure 80-50-30]. If no resistance is found, replace the potentiometer. C
A
Figure 80-50-31
B N-22290
The resistance between the wire terminal A and wire terminal B frame [Figure 80-50-33] should be approximately 49K ohm.
1
Check the resistance between the wire terminal C and wire terminal B frame [Figure 80-50-33] should be approximately 39K ohm.
N-22201
The white wire B, (Item 1) [Figure 80-50-31], on the potentiometer, is a resistor wire.
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BASIC TROUBLESHOOTING (CONT'D)
Engine Coolant Bypassing The Heater Valve
Checking The Electrical System (Cont'd)
Figure 80-50-36
Figure 80-50-34
2
3 1
1 N-22284
To check the resistance of the white wire, turn the potentiometer control (Item 1) [Figure 80-50-34] to the full Heater position. Figure 80-50-35
Raise the lift arms and install an approved lift arm support device.(See Installing Lift Arm Support Device on Page 10-20-1.) Push the A/C switch (Item 1) to the OFF position. Turn the fan switch (Item 2) to the High Speed position. Turn the temperature control (Item 3) [Figure 80-50-36] to the High A/C position, with the loader ignition switch OFF. Figure 80-50-37
1 C
A
B N-22290 P-48009
Check the resistance between the wire terminal A and wire terminal B frame [Figure 80-50-35] should be approximately 39K ohm. Check the resistance between the wire terminal C and wire terminal B frame [Figure 80-50-35] should be approximately 49K ohm.
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool to the loader. (See REMOTE START TOOL KIT -MEL1563 on Page 10-601.) Start the loader and run at high idle, for ten minutes.
If the resistance is not found, replace the potentiometer.
Check the heater hose (Item 1) [Figure 80-50-37] for temperature. If the hose is hot, the heater valve is leaking by, and needs to be replaced.
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N-22175
Figure 80-50-39
BASIC TROUBLESHOOTING (CONT'D) Heater Valve Not Opening Or Closing Figure 80-50-38
1 P-48015
2
3 1
P-48009
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Push the A/C switch (Item 1) to the OFF position. Turn the fan switch (Item 2) to position 1. Turn the temperature control (Item 3) [Figure 80-50-38] to the High A/C position, with the loader ignition switch OFF.
Place the remote start tool on the left fender of the loader, so the heater valve can be clearly seen. Watch the valve shaft (Item 1) [Figure 80-50-39], as the key of the remote start is turned to the ON position without starting the loader. The heater valve should rotate. If it does not rotate, check the potentiometer (See HEATER VALVE on Page 80-220-1.) for proper function. Replace the heater valve. (See HEATER VALVE on Page 80-220-1.)
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Connect the remote start tool to the loader. (See Remote Start Procedure on Page 10-60-4.) Place the remote start tool on the left fender of the loader, so the heater valve can be clearly seen. Watch the valve shaft (Item 1) [Figure 80-50-39], as the key of the remote start tool is turned to the ON position without starting the loader. The heater valve should rotate. Place a mark on the loader shaft. Turn the key of the remote start tool to the OFF position and remove the remote start tool from fender. Lower operator cab. Turn the temperature control (Item 3) [Figure 80-50-38] to the High Heater position, with the loader ignition switch OFF. Raise the operator cab.
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N-22284
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GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Figure 80-60-1
1
N-22243
Dealer Copy -- Not for Resale
The compressor (Item 1) [Figure 80-60-1] is factory filled with 150-170 cc's of PAG oil (Poly Alkelene Glycol). Unlike engine oil, it is not necessary to frequently check or change the compressor oil. It is necessary to check, replenish or replace the compressor oil in the following cases: 1. When the evaporator, condenser or receiver-drier is replaced. 2. When refrigerant has leaked from the system. 3. When refrigerant is suddenly released from the cooling cycle. 4. When any oil related problems occur in the cooling cycle. When one of the components (the evaporator, condenser or receiver-drier) is replaced, one ounce (30 cc) of PAG oil should be added for each component replaced. If the A/C compressor is changed, no oil should be added to the system, because the compressor comes factory filled with oil. NOTE: Only PAG oil should be used. Never mix R-12 and R-134a Oils.
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GENERAL AIR CONDITIONING SERVICE GUIDELINES (CONT'D)
Run the compressor for at least 20 minutes at 800 - 1200 rpm.
Compressor Oil Check
Remove the compressor from the COMPRESSOR on Page 80-110-1.)
Figure 80-60-2
loader.
(See
Remove the oil drain plug (Item 1) [Figure 80-60-2] and drain the oil through the connectors and the oil drain hole [Figure 80-60-3]. Installation: Tighten the oil drain plug to 9.4 - 10.8 ft.-lb. (13 - 15 N•m) torque. Figure 80-60-4 1
N-22245
1
N-22246
NOTE: After draining the oil through the drain hole and the connectors, extract the remaining oil through the discharge-side connector by rotating the drive pulley (Item 1) [Figure 80-604] several times by hand.
P-16534A
The compressor oil should be checked as follows when oil is being added to an in service loader. There is a close affinity between oil and refrigerant. During normal operation, part of the oil circulates with the refrigerant in the system. Therefore, when checking the amount of oil in the system or replacing any system component, the compressor must be run in advance to insure return of oil to the compressor. If the amount of refrigerant in the system has decreased, charge the system. (See CONDENSER on Page 80-1201.) Open the cab door and windows. Run the blower at maximum speed.
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Figure 80-60-3
Component Replacement And Refrigeration Leaks
GENERAL AIR CONDITIONING SERVICE GUIDELINES (CONT'D)
Figure 80-60-6
Compressor Oil Check (Cont'd) Figure 80-60-5
1
1
P-24229
Measure the drained oil in a measuring cylinder. Check the oil for contamination, dirt, metal shavings, or varnish color, discard the oil if contaminated.
Never leave hose fittings, compressor fittings or components uncapped while working on the A/C system.
NOTE: If metal shavings are found in the compressor oil, replace the complete compressor assembly. Add new compressor oil through the suction side connector (Item 1) [Figure 80-60-5]. Installation: Add 150 -170 cc's of PAG oil. NOTE: The suction port on the compressor is marked with an S and is the larger port on the compressor.
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Whenever the A/C system is opened to the atmosphere or there has been a leak in the system, the receiver / drier (Item 1) [Figure 80-60-6] must be changed.
N-22245
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SYSTEM TROUBLESHOOTING CHART Blower motor does not operate 1. Blown fuse. 2. Broken wiring or bad connection. 3. Fan motor malfunction.
Inspection Inspect the fuse / wiring. Check the fan motor ground and connectors.
Check the lead wires form the motor with a circuit tester. 4. Resistor malfunction. Check resistor using a circuit tester. 5. Fan motor malfunction. Check power into and out of the fan switch. Blower motor operates normally, but air flow is insufficient
Possible Cause
Solution Replace fuse / repair wiring. Repair the wiring or connector. Replace Motor. Replace Resistor. Replace Fan Switch.
Inspection
1. Evaporator inlet obstruction.
Check evaporator for plugging.
2. Air leak.
Check to make sure air hoses are properly hooked to Louvers, and air ducts. Check thermostat using a circuit tester.
3. Defective thermo. switch (frozen evaporator). Insufficient cooling although air flow and compressor operation are normal
Possible Cause
Solution Remove obstruction and clean evaporator fins with air or water. Repair of adjust. Replace thermostat.
Inspection
1. System low on refrigerant.
The high side pressure will be low and bubbles may be present in sight glass on receive drier.
2. Excessive refrigerant.
The high pressure side pressure will be high.
Solution Repair any leaks and recharge the refrigerant to the correct level. Use refrigerant recovery equipment to capture excess refrigerant. Charge to the correct refrigerant level.
The compressor does not operate at all, or operates improperly
Possible Cause 1. Loose drive belt. 2. Internal compressor malfunction.
Inspection The belt is vibrating or oscillating. The compressor is locked up and the belt slips.
Solution Adjust tension. Replace compressor.
Magnetic clutch related 3. Low battery voltage. 4. Faulty coil. 5. Oil on the clutch surface.
Clutch slips. Clutch slips. Clutch slips.
6. Open oil.
Clutch does not engage and there is no reading when a circuit tester is connected between the coil and terminals. Clutch will not engage. Inspect the ground and connections. Test the conductance of the pressure switch, thermostat, Relay, etc.
7. Broken wiring or poor ground. 8. Wiring harness components.
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Recharge the battery. Replace the magnetic clutch. Replace or clean the clutch surface. Replace clutch.
Repair. Check operation.
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Possible Cause
SYSTEM TROUBLESHOOTING CHART (CONT'D) Gauge Pressure Related Troubleshooting Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86 - 96°F (30 - 38°C) and compressor speed of approximately 2000 rpm are: High pressure side pressure: 210-265 PSI Low pressure side pressure: 15-33 PSI As a rule of thumb, the high side pressure will be around eight times greater than the low side pressure.
Low pressure side too high.
1. Expansion valve opens too far. 2. Defective compressor. Low pressure side Too low. 1. Low refrigerant charge. 2. Clogged or closed expansion valve. 3. Restriction between drier and expansion valve. High pressure side Too high. 1. Poor condenser performance. 2. Excessive refrigerant.
Inspection The low pressure side pressure normally becomes too high when the high pressure side pressure is too high. As this is explained below, the following inspection is only used when the low pressure side is too high. Frost is present on the suction hose.
Replace expansion valve.
The high and low pressure side gauge pressures equalize when the compressor is engaged.
Replace compressor.
The high side pressure will be low and bubbles may be present in sight glass on receive drier.
Repair any leaks and recharge the refrigerant to the correct level. Clean or replace the expansion Valve. Flush system or replace hose.
The expansion valve’s inlet side is frosted. Moisture or other Contaminants can be the cause. Frost on the line between drier and expansion valve. A Negative low pressure reading may be shown.
Dirty or clogged condenser fins. Condenser fans not Operating. The high pressure side pressure will be high.
3. Excessive oil charge.
The high pressure side will be high.
4. Air in system.
Pressure is high on both high and low sides.
5. Restriction in drier, condenser or high pressure line. High pressure side Too low. 1. Low refrigerant charge.
High pressure side will be high, and low pressure side will be low.
The high side pressure will be low and bubbles may be present in sight glass on receive drier.
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Solution
Clean fins, and / or repair the fan. Use refrigerant recovery equipment to capture excess refrigerant. Charge to the correct refrigerant level. Evacuate system. Remove oil from condenser and compressor. Measure oil from compressor and add correct oil charge back into compressor. Flush system with nitrogen. Replace drier. Evacuate and recharge with Refrigerant. Evacuate and flush system replacing defective parts.
Repair any leaks and recharge the refrigerant to the correct level.
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Possible Cause
SYSTEM TROUBLESHOOTING CHART (CONT'D) Gauge Pressure Related Troubleshooting (Cont'd)
Possible Cause
Inspection See magnetic clutch related topics above. Equal high and low pressures.
Solution
Replace compressor.
Dealer Copy -- Not for Resale
System pressures equal 1. Clutch not operating. 2. Compressor not pumping.
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TEMPERATURE / PRESSURE Chart NORMAL CONDENSER RANGE
TEMP F
PSIG
TEMP F
PSIG
16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 45 50 55 60 65 70 75 80 85 90 91 92
15.69 17.04 18.43 19.87 21.35 22.88 24.47 26.10 27.79 29.52 31.32 33.17 35.07 37.03 39.05 40.09 45.48 51.27 57.47 64.10 71.19 78.75 86.80 95.40 104.40 106.30 108.20
93 94 95 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 135 140 145 150 155 160 165 170
110.20 112.10 114.10 124.30 128.50 132.90 137.30 141.90 146.50 151.30 156.10 161.10 166.10 171.30 176.60 182.00 187.50 193.10 198.90 213.70 229.40 245.80 263.00 281.10 300.10 320.10 340.80
Evaporator Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air coming off the coil add 8° - 10° F to the temperature on the chart. Condenser Temperatures are not ambient temperatures but condensing temperatures. Add 40° F to the ambient temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature. Example: Ambient
Temperature=90° F 90° F +40° F 130° F condenser temperature=200 psig
Conditions and pressures will vary from system to system.
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NORMAL EVAPORATOR RANGE
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AIR CONDITIONING SERVICE Chart
Machine Dealer: Customer: 15 Minutes
30 Minutes
Notes
15 Minutes
30 Minutes
Notes
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Service Company / Phone Number: Date: Machine Model: Machine Serial Number: Machine Hours: Pre Service Conditions Ambient Temperature: Louver Temperature: Cab Temperature At Head Position: Temperature Into Condenser: High Side Pressure Low Side Pressure Ambient Humidity Observations:
Explain Services Required:
Post Service Conditions Ambient Temperature: Louver Temperature: Cab Temperature at Head Position: Temperature Into Condenser: High Side Pressure Low Side Pressure Ambient Humidity Observations:
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SYSTEM CHARGING AND RECLAMATION
Figure 80-100-3
Reclamation Procedure 1 Figure 80-100-1
1
2
P-24208
Open the rear door and locate the low pressure port (Item 1), and high pressure port (Item 2) [Figure 80-1001]. Figure 80-100-2
NOTE: Before reclaiming a refrigeration system, it is recommended to identify the type of refrigerant that is in the A/C system and if it is pure enough to use. The tool MEL 1592, Refrigerant Identifier (Item 1) [Figure 80-100-3] will determine, the kind of refrigerant and any possible harmful or dangerous substances that may be present in the system. Thus preventing mixing of dangerous material with your reclaimed R-134a in your reclaimer, and further contamination to other A/C systems that are reclaimed and charged from your MEL 1581 Recovery / Recycling / Recharging Machine.
1
P-24230
NOTE: Do not use this port (Item 1) [Figure 80-100-2] for testing or charging.
WARNING In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
NOTE: This test is run with the loader engine OFF, and the A/C switch in the OFF position. 80-100-1 868 of 949
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N-23024
Figure 80-100-5
SYSTEM CHARGING AND RECLAMATION (CONT'D) Reclamation Procedure (Cont'd) Figure 80-100-4
1
N-22291
Remove the protective cap and connect the Refrigerant Identifier to the low pressure hose (Item 1) [Figure 80100-4]. Connect the Refrigerant Identifier to its power source. Follow the steps displayed on the refrigerant identifier screen. Allow two minutes for the refrigerant identifier to display the type of refrigerant and air content. An alarm will sound if potentially flammable hydrocarbons are present and will also indicate on the visual display. Disconnect the refrigerant identifier from the loader A/C. If the refrigerant is dangerous or flammable, it must be evacuated from the A/C system into a separate container and properly and safely disposed of. If R134a is found, evacuate the system.
WARNING HFC 134A refrigerant can be dangerous if not properly handled. Liquid 134A may cause blindness if it contacts the eyes and may cause serious frostbite if it contacts the skin. • Gaseous 134A becomes lethal (phosgene) gas when it contacts open flame or very hot substances. • NEVER SMOKE when there is the possibility of even small amounts of 134A in the air. Any servicing work that involves release or addition of 134A to the system must be done by a competent refrigeration dealer who has the proper equipment, knowledge, and experience to service refrigeration equipment. W-2373-0500
Use an approved recovery / charging unit [Figure 80100-5] to evacuate the system.
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IMPORTANT: Only A/C trained technicians should perform the reclaiming and recharging.
P-24316
Figure 80-100-8
SYSTEM CHARGING AND RECLAMATION (CONT'D) Reclamation Procedure (Cont'd) Figure 80-100-6
1 2
P-24317
Connect the reclaimer to the loader A/C charge ports. Connect the Red hose (Item 1) [Figure 80-100-6] to the high pressure port and open the valve.
NOTE: The reclaimer unit, has a complete step by step set of instructions [Figure 80-100-8] to follow for reclamation and recharging of the A/C system. A trained technician should follow these instructions as they may very slightly depending on the model and brand of reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-100-6] to the low pressure port and open the valve. Figure 80-100-7
N-22292
Turn the reclaimer unit [Figure 80-100-7] to the ON position and follow the on screen instructions.
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N-22381
Connect the Red hose (Item 1) [Figure 80-100-10] to the high pressure port and open the valve.
SYSTEM CHARGING AND RECLAMATION (CONT'D) Charging Procedure With A Manifold Gauge Set
Connect the Blue hose (Item 2) [Figure 80-100-10] to the low pressure port and open the valve.
WARNING
Figure 80-100-11
In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
1 Figure 80-100-9
Connect the Yellow hose (Item 1) [Figure 80-100-11] to the vacuum pump. Figure 80-100-12 1 P-24318
Open the rear door. Check to see that the hand valves (Item 1) [Figure 80100-9] are closed on the manifold gauge set. If there is any refrigerant in the A/C system, it must be recovered by an approved A/C reclamation procedure. (See Reclamation Procedure on Page 80-100-1.)
1
Figure 80-100-10 P-24321
Start the vacuum pump and open ISO-valve (Item 1) [Figure 80-100-12] on the vacuum pump. Run the vacuum pump for at least 5-10 minutes to insure that a vacuum has been pulled on the system. 1
Close the ISO-valve (Item 1) [Figure 80-100-12] (which isolates the vacuum pump from the A/C system) and turn OFF the vacuum pump.
2
P-24319
Connect the gauges to the loader A/C charge ports.
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P-24320
Start the vacuum pump and open ISO-valve on the vacuum pump.
SYSTEM CHARGING AND RECLAMATION (CONT'D) Charging Procedure
Be sure that both hand valves, and both charge port valves are open.
Figure 80-100-13
Run the vacuum pump for at least 45 minutes to insure that all the moisture is boiled out of the system. Stop the vacuum pump and close the ISO-valve on the vacuum pump. Close both hand valves on the manifold gauge set and remove the yellow hose from the vacuum pump that goes to the manifold gauge set.
1
Remove the vacuum pump and thermistor vacuum gauge.
NOTE: Vacuum pressure indicated on the low pressure (Blue) gauge (Item 1) [Figure 80-10013]. Let stand for 5 - 10 min. and recheck the pressure for changes.
1 3
If the pressure drops, this may be an indication of a leak in the A/C system. Determine the problem with the A/C system and repair it.
2
Figure 80-100-14
P-24323
Place a refrigerant container with R134a (Item 1) on a charging scale (Item 2) [Figure 80-100-15] and zero out the scale. Connect the yellow hose (Item 3) [Figure 80-100-15] from the manifold gauge set to the valve on the refrigerant tank. 1 P-24322
A thermistor vacuum gauge (Item 1) [Figure 80-100-14] can be used to determine the critical vacuum level during evacuation. It is a solid state instrument that constantly monitors and visually indicates the vacuum level. The thermistor vacuum gauge is used with the vacuum pump [Figure 80-100-14].
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Figure 80-100-15
P-24319
SYSTEM CHARGING AND RECLAMATION (CONT'D)
The A/C system holds 2.0 lb. (0,91 kg) of refrigerant.
Charging Procedure (Cont'd)
Turn OFF the valve on the refrigerant container, and hand valves on the manifold gauge set.
Figure 80-100-16 Turn OFF the engine, and remove the A/C charging equipment from the loader. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.) 2 1
P-24324
Dealer Copy -- Not for Resale
Open the valve on the refrigerant container (Item 1) and open the low pressure hand valve (Blue) (Item 2) [Figure 80-100-16] on the manifold gauge set. Allow the vacuum to pull in the refrigerant until the pressure stabilizes. Figure 80-100-17
2
1
N-22284
Connect the remote start tool to the loader. (See Remote Start Procedure on Page 10-60-4.) Press the A/C (Item 1) [Figure 80-100-17] switch to ON position. Turn fan switch (Item 2) [Figure 80-100-17] to HIGH position. Start loader engine, with the remote start switch, and run at medium speed. Watch the scale and run system until the predetermined amount of refrigerant is added to the A/C system. 80-100-6 873 of 949
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COMPRESSOR
WARNING
Removal And Installation Figure 80-110-1
In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
Remove the compressor hoses (Item 3) [Figure 80-1102] from the compressor.
1
Installation: Tighten the compressor hoses to 22 ft.-lb. (29,8 N•m) torque. Cap and plug the compressor hoses and the fittings with with the proper A/C caps and plugs.
P-24325
Figure 80-110-3
Remove A/C belt guard (Item 1), by removing the mounting bolt and nut (Item 2) [Figure 80-110-1]. Evacuate the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.)
1
Remove the compressor adjustment bolt (Item 1) [Figure 80-110-1]. Installation: Tighten the compressor adjustment bolt to 34 ft.-lb. (46 N•m) torque. Figure 80-110-2
P-24327
Remove the compressor mount bolt (Item 1) [Figure 80110-3]. Remove the compressor from the loader.
3 1 2 P-24326
Remove the compressor belt (Item 2) [Figure 80-110-2]. Mark the compressor hoses for proper installation.
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Remove drive belt guard.
Figure 80-110-6
COMPRESSOR (CONT'D) Compressor Clutch Disassembly Figure 80-110-4
1.32”
1.32” 1.32” 2 1
1 N-22275
Remove the center armature bolt (Item 1) [Figure 80110-4].
Attach the puller to the armature plate using three 8 mm bolts (Item 2) [Figure 80-110-6].
Installation: Tighten the armature bolt to 8 - 10 ft.-lb. (12 - 14 N•m) torque.
Figure 80-110-7
Figure 80-110-5
1
2
N-22278
Turn the bolts into the three 8 mm holes (Item 2) [Figure 80-110-5] on the armature plate as shown in [Figure 80110-7].
N-22277
To remove the armature plate (Item 1) [Figure 80-110-5] from the clutch face, you must make an armature plate puller.
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The armature plate puller, (Item 1) can be constructed by drilling three 10 mm holes in a flat circular plate, located 1.32 inches apart [Figure 80-110-6].
N-22244
Figure 80-110-10
COMPRESSOR (CONT'D) Compressor Clutch Disassembly (Cont'd) Figure 80-110-8
1
N-22283
1
Remove the snap ring (Item 1) [Figure 80-110-10] from the pulley assembly.
N-22279
Figure 80-110-11
Remove the armature plate from the compressor clutch. Figure 80-110-9
1 N-22369
Install the pulley puller tool MEL 1595 on the compressor pulley [Figure 80-110-11]. N-22280
Remove the shims (Item 1) [Figure 80-110-9] from either the armature shaft or armature plate. Installation: Insure that the clutch has the correct clearance by adding the shims (Item 1) [Figure 80-1109]. The specified clearance for the clutch is 0.01-0.02 in. (0.3-0.6 mm). Adjusting shims are available in the following thicknesses: 0.0039 in. (0,1 mm) 0.0118 in. (0,3 mm) 0.0197 in. (0,5 mm)
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Attach a slide hammer puller (Item 1) [Figure 80-110-8] to the armature puller disk.
Figure 80-110-14
COMPRESSOR (CONT'D) Compressor Clutch Disassembly (Cont'd) Figure 80-110-12
1
N-22373
Slide the wire grommet (Item 1) [Figure 80-110-14] from the wire holder.
N-22370
Figure 80-110-15
Figure 80-110-13
1
N-22374
Remove the coil lead wire (Item 1) [Figure 80-110-15] from the wire holder on the compressor.
N-22371
The pulley assembly and bearing [Figure 80-110-13] must be replaced as a complete unit.
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Remove the pulley from the compressor [Figure 80-11012].
COMPRESSOR (CONT'D) Compressor Clutch Disassembly (Cont'd) Figure 80-110-16
1
1
N-22372
Dealer Copy -- Not for Resale
Remove the three coil mount bolts (Item 1) [Figure 80110-16] from the compressor. Installation: Tighten the mount bolts to 2.9 - 4.3 ft.-lb. (4 - 6 N•m) torque. Remove the coil from the compressor. Figure 80-110-17
N-22375
The compressor [Figure 80-110-17] must be replaced as a complete unit.
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Figure 80-120-2
CONDENSER Removal And Installation Figure 80-120-1
LIFT HERE
1
P-48011
Lift the rear of the condenser [Figure 80-120-2], and pull toward the rear of the loader until the front tabs (Item 1) [Figure 80-120-4] slide out of bracket (Item 2) [Figure 80-120-4]
Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80100-1.)
Figure 80-120-3
Dealer Copy -- Not for Resale
P-48011
Open the rear door of the loader. Open the rear grille on the loader. Mark the two A/C hoses (Item 1) [Figure 80-120-1] for proper installation.
WARNING In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
P-48010
Remove the condenser from the loader [Figure 80-1203].
Disconnect the two hoses from the condenser (Item 1) [Figure 80-120-1]. Cap and plug the hoses and the condenser fittings with the proper A/C caps and plugs.
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CONDENSER (CONT’D) Removal And Installation (Cont’d) Figure 80-120-4
2
1
P-24303
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Installation: Make sure to insert tabs (Item 1), into the mounts (Item 2) [Figure 80-120-4], evenly for ease of installation.
S150, S160 Bobcat Loader Service Manual
Figure 80-130-2
RECEIVER / DRIER Removal And Installation
1
WARNING
2
Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
3
W-2059-0598 P-24298
Figure 80-130-1
1
WARNING In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500 P-24299
Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 1030-1.) Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper installation.
Remove the two A/C hoses (Item 2) [Figure 80-130-2] from the receiver / drier. Cap and plug the hoses and the receiver / drier fittings with the proper A/C caps and plugs. Loosen the hose clamps (Item 3) [Figure 80-130-2] that holds the receiver / drier to the mount. Remove the receiver / drier from the loader. NOTE: When replacing a receiver / drier in an A/C system 1 fl. oz. (30 cc) of PAG oil must be added to the system when recharging.
Both fittings on the drier are the same size, so the hoses can be hooked up incorrectly.
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Note the flow direction on the drier (Item 1) [Figure 80130-2] for proper installation.
RECEIVER / DRIER (CONT’D) Removal And Installation (Cont’d) Figure 80-130-3
1
P-24295
Dealer Copy -- Not for Resale
Remove the two mount bolts (Item 1) [Figure 80-130-3] from the receiver / drier mount bracket.
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Figure 80-140-2
PRESSURE RELIEF VALVE Removal And Installation Figure 80-140-1
1
N-22206
The pressure relief valve (Item 1) [Figure 80-140-1] is located on the receiver drier assembly.
This will cause the A/C system to shut down, saving the compressor. The Pressure Relief Valve is a secondary protection device in the A/C system, with the Pressure Switch shutting down the system at 384 PSI (2648 kPa). NOTE: If a Pressure Relief Valve is found open, check the A/C system for problems. Replace the complete receiver / drier unit.
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The pressure relief valve [Figure 80-140-2] is designed to open and release the A/C charge if the pressure reaches 535 PSI (3689 kPa).
N-22205
Dealer Copy -- Not for Resale 80-140-2 885 of 949
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PRESSURE SWITCH
WARNING
Removal And Installation Figure 80-150-1
In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
Remove the pressure switch (Item 1) [Figure 80-150-2] from the A/C high pressure hose. 1
Remove the pressure switch from the loader. Shraeder Valve Removal And Installation
Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) 1
Disconnect the loader wire harness (Item 1) [Figure 80150-1] from the pressure switch wire harness. NOTE: The pressure switch can be changed without evacuating the A/C system.
N-22166
Figure 80-150-2 The shraeder valve (Item 1) [Figure 80-150-3] is located in the A/C high pressure hose and is located under the pressure switch. Raise the loader lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
P-24298
Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80100-1.) Remove the pressure switch. With a tire valve core removal tool, remove the valve core from the hose. Replace with a new core.
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Figure 80-150-3
P-24299
Dealer Copy -- Not for Resale 80-150-2 887 of 949
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Figure 80-160-3
EVAPORATOR / HEATER UNIT Removal And Installation Figure 80-160-1
1 1
N-22129
Disconnect the blower fan wiring connector (Item 1) [Figure 80-160-3] from the loader wiring harness.
N-22122
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Evacuate the A/C system.(See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) 1 At the rear of the cab, disconnect the thermostat wiring connector (Item 1) [Figure 80-160-1]. Figure 80-160-2 N-22119
Remove the two mounting nuts (Item 1) [Figure 80-1604].
2
1 N-22130
Remove the mount bolt (Item 1) [Figure 80-160-2] from the left side cab access cover. Remove the access cover (Item 2) [Figure 80-160-2] from the loader.
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Figure 80-160-4 Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
EVAPORATOR / HEATER UNIT (CONT'D)
Figure 80-160-7
Removal And Installation (Cont'd) Figure 80-160-5
1 1 N-22128
Remove the two A/C hoses (Item 1) [Figure 80-160-6] from the expansion valve.
Remove the two mounting nuts (Item 1) [Figure 80-1605].
Installation: Tighten the A/C hoses to 22 ft.-lb. (29,8 N•m) torque. Cap and plug the hoses and the expansion valve fittings with the proper A/C caps and plugs.
Figure 80-160-6
Remove the heater hoses (Item 1) [Figure 80-160-7] from the heater coil. Installation: Tighten the Heater hoses to 22 ft.-lb. (29,8 N•m) torque. 1
Remove the evaporator / heater unit from the loader.
N-22126
Remove the Evaporator / Heater Unit from the rear of the cab. Place it on the fenders of the loader supported by 2 X 4's (blocking) [Figure 80-160-6].
WARNING In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas. W-2371-0500
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N-22120
EVAPORATOR / HEATER UNIT (CONT'D) Disassembly And Assembly Figure 80-160-8
1
1
1
N-22065
Dealer Copy -- Not for Resale
Remove the six mount bolts (Item 1) [Figure 80-160-8] from the Evaporator / Heater Unit rear cover. Remove the rear cover from the unit.
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S150, S160 Bobcat Loader Service Manual
Figure 80-170-3
THERMOSTAT Removal And Installation Figure 80-170-1
2
1 N-22072
Remove the thermostat from the unit [Figure 80-170-3]. N-22069
Figure 80-170-4
B
Remove the rear cover from the evaporator / heater unit. (See EVAPORATOR / HEATER UNIT on Page 80-1601.)
C 1
Remove the two thermostat mount bolts (Item 1), and remove the wiring harness and grommet (Item 2) [Figure 80-170-1] from the evaporator / heater housing. Figure 80-170-2
N-22072
The wire connector (Item 1) [Figure 80-170-4] can be changed. The wiring position and color in the connector is: A B C
1
Blue White Black
N-22071
Remove the thermostat probe (Item 1) [Figure 80-170-2] from the A/C evaporator coil.
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A
NOTE: The thermostat can be changed without evacuating the A/C system, or removing the evaporator / heater unit from the loader.
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Figure 80-180-2
EXPANSION VALVE Removal And Installation Figure 80-180-1
1 2 1
N-22073
Remove the two evaporator fittings (Item 1) [Figure 80180-2] from the expansion valve.
NOTE: The expansion valve can be changed without removing the evaporator / heater unit from the loader. Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Installation: Tighten the two evaporator fittings to 22 ft.lb. (29,8 N•m) torque. Remove the two mount bolts (Item 2) [Figure 80-180-2]. Remove the expansion valve from the loader. Figure 80-180-3
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Evacuate the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) 1
WARNING In the event of a leak, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas.
N-22074
W-2371-0500
Remove the two A/C hoses (Item 1) [Figure 80-180-1] from the expansion valve.
Cap and plug the evaporator tubelines (Item 1) [Figure 80-180-3] and the expansion valve fittings with the proper A/C caps and plugs.
Installation: Tighten the two A/C hose fittings to 22 ft.-lb. (29,8 N•m) torque. Cap and plug the hoses and the expansion valve fittings with the proper A/C caps and plugs.
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N-22150
EXPANSION VALVE (CONT'D) Removal And Installation (Cont'd) Figure 80-180-4
1 1
N-22074
Dealer Copy -- Not for Resale
Remove the two mount bolts (Item 1) [Figure 80-180-4] from the expansion valve mount. Remove the expansion valve mount from the unit. Figure 80-180-5
N-22085
The expansion valve [Figure 80-180-5] is replaced as a complete unit.
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Figure 80-190-3
EVAPORATOR Removal And Installation Figure 80-190-1
2
1
N-22075
Remove the two mount bolts (Item 1) from the mount plate (Item 2) [Figure 80-190-3].
1 N-22073
Remove the mount plate from the unit. Figure 80-190-4
Dealer Copy -- Not for Resale
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Evacuate the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 80-100-1.) Remove the evaporator / heater unit from the back of the cab. (See EVAPORATOR / HEATER UNIT on Page 80160-1.) Remove the expansion valve (Item 1) [Figure 80-190-1] from the unit. (See EXPANSION VALVE on Page 80-1801.)
1 N-22076
Figure 80-190-2 Remove the two retaining clips (Item 1) [Figure 80-1904] that connect the evaporator coil, to the heater coil. Remove the evaporator coil from the unit.
1
N-22074
Remove the expansion valve mount bracket (Item 1) [Figure 80-190-2] from the unit. 80-190-1 896 of 949
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EVAPORATOR (CONT'D) Removal And Installation (Cont'd) Figure 80-190-5
N-22078
Dealer Copy -- Not for Resale
Inspect the evaporator coil [Figure 80-190-5] for leaks, and replace as needed. Clean with low water or air pressure.
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HEATER COIL
Remove the rear cover from the evaporator / heater unit. (See EVAPORATOR / HEATER UNIT on Page 80-1601.)
Removal And Installation With A/C
Remove the two mount bolts (Item 1) [Figure 80-200-2] from the heater coil at the expansion valve end of the unit.
Figure 80-200-1
Figure 80-200-3
1
1 N-22128
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Remove the evaporator / heater unit from the back of the cab. (See EVAPORATOR / HEATER UNIT on Page 80160-1.)
Remove the two retaining clips (Item 1) [Figure 80-2003] that connect the evaporator coil, to the heater coil. Figure 80-200-4
Mark the heater hoses (Item 1) [Figure 80-200-1] for proper installation.
1
1 Remove the two heater hoses from the heater coil. Cap the hoses and the heater coil with hydraulic caps and plugs to prevent oil loss from the system.
2 2
Installation: Tighten the two heater hose fittings to 22 ft.lb. (29,8 N•m) torque. Figure 80-200-2
N-22089
1
Remove the three mount bolts (Item 1) [Figure 80-200-4] and remove the mount plate from the end of the unit. Remove the two mount bolts (Item 2) [Figure 80-200-4] that support the heater coil tubelines to the unit. Remove the heater coil from the unit.
1 N-22086
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Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
N-22087
HEATER COIL (CONT'D)
Mark the heater hoses (Item 1) [Figure 80-200-6] for proper installation.
Removal And Installation With A/C (Cont'd) Remove the two heater hoses from the heater coil. Figure 80-200-5
Cap the hoses and the heater coil with hydraulic caps and plugs to prevent oil loss from the system. Installation: Tighten the two heater hose fittings to 22 ft.lb. (29,8 N•m) torque. Figure 80-200-7
1
1
2
N-22090
The heater coil [Figure 80-200-5] can be cleaned with low air or water pressure. If the heater coil needs replacement it must be replaced as complete unit. Removal And Installation Without A/C
N-22093
Remove the rear cover from the evaporator / heater unit. (See EVAPORATOR / HEATER UNIT on Page 80-1601.)
Figure 80-200-6
Remove the three mount bolts (Item 1) [Figure 80-200-7] and remove the mount plate from the end of the unit. Remove the two mount bolts (Item 2) [Figure 80-200-7] that support the heater coil tubelines to the unit. Figure 80-200-8
1
1 N-22128
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the heater unit from the back of the cab. (See EVAPORATOR / HEATER UNIT on Page 80-160-1.)
N-22094
Remove the two mount bolts (Item 1) [Figure 80-200-8] from the heater coil. Remove the heater coil from the unit.
80-200-2 899 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
2
Figure 80-210-3
HEATER / A/C FAN Removal And Installation Figure 80-210-1
1 1
N-22099
Remove the blower fan wiring harness and grommet (Item 1) [Figure 80-210-3] from the unit
N-22096
1
Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the evaporator / heater unit from the back of the cab. (See EVAPORATOR / HEATER UNIT on Page 80160-1.) NOTE: The heater / A/C fan assembly can be removed from the evaporator / heater unit without disconnecting the heater or A/C plumbing. The unit is removed here for photo clarity. Remove the grommet (Item 1) [Figure 80-210-1] from the side of the evaporator / heater unit.
N-22100
Remove the three mount bolts (Item 1) [Figure 80-210-4] from the blower fan housing.
Figure 80-210-2 Remove the blower fan housing from the evaporator / heater unit.
1
N-22097
80-210-1 900 of 949
S150, S160 Bobcat Loader Service Manual
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Figure 80-210-4 Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
Figure 80-210-6
HEATER / A/C FAN (CONT'D) Disassembly And Assembly Figure 80-210-5
2
1 2 1
1 N-22107
Check the blower housing (Item 1) and fan motor mount (Item 2) [Figure 80-210-6] for wear and replace as needed.
N-22102
Remove the eight mount bolts (Item 1) [Figure 80-210-5] from the blower wheel cover.
Figure 80-210-7
Remove the blower wheel cover from the fan housings.
Dealer Copy -- Not for Resale
2
1
Remove the four mount bolts (Item 2) [Figure 80-210-5] from the fan motor mount.
1
Remove the fan motor mount. Remove the fan motor assembly from the housing.
2 N-22108
Remove the outside rings (Item 1) and fan wheel covers (Item 2) [Figure 80-210-7] from the fan motor and blower wheels.
80-210-2 901 of 949
S150, S160 Bobcat Loader Service Manual
Figure 80-210-10
HEATER / A/C FAN (CONT'D) Disassembly And Assembly (Cont'd) Figure 80-210-8
1
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure 80-210-9] and [Figure 80-210-10] from the blower wheel.
Inspect the end rings and fan wheel covers for wear and replace as needed [Figure 80-210-8].
Figure 80-210-11
Dealer Copy -- Not for Resale
N-22109
Figure 80-210-9
1
1 N-22111
N-22110
Remove the inside blower wheel clamp (Item 1) [Figure 80-210-11] from the blower wheel.
80-210-3 902 of 949
S150, S160 Bobcat Loader Service Manual
HEATER / A/C FAN (CONT'D)
Wire Connector Removal And Installation
Disassembly And Assembly (Cont'd)
Figure 80-210-13
Figure 80-210-12
1 1
2
N-22103 N-22116
Note: Before removing blower wheels, mark their orientation to ensure they are assembled back on the correct side and the fins are facing the same direction. Remove the blower wheel (Item 1) and inside ring (Item 2) [Figure 80-210-12] from the blower fan motor shaft.
1
Repeat the procedure for the other blower wheel.
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-13] and [Figure 80-210-14] from the center of the blower fan motor wiring connector.
80-210-4 903 of 949
S150, S160 Bobcat Loader Service Manual
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Figure 80-210-14
HEATER / A/C FAN (CONT'D) Wire Connector Removal And Installation (Cont'd) Figure 80-210-15
1
1
1
1
N-22105
Dealer Copy -- Not for Resale
With a pointed screw driver lightly press in on the tabs (Item 1) [Figure 80-210-15] and remove the individual wires from the connector. Figure 80-210-16
N-22106
The wiring code for the blower fan connectors [Figure 80-210-16]: Number on Connector 1 2 3 4 5 6
Wire Color Orange Red Yellow Black Open Open
80-210-5 904 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale 80-210-6 905 of 949
S150, S160 Bobcat Loader Service Manual
HEATER VALVE
Disassembly And Assembly
Removal And Installation
Figure 80-220-2
Figure 80-220-1
1 2
3 1
2 3 N-22155 P-48009
Remove the three mount screws (Item 1) [Figure 80220-2] from the heater valve actuator. Figure 80-220-3
Dealer Copy -- Not for Resale
Disconnect the loader wiring harness (Item 1) [Figure 80-220-1]. Remove the two coolant hoses (Item 2) [Figure 80-2201] from the heater valve. NOTE: Cap the hoses and the heater valve to prevent contamination and coolant loss from the system. Remove the two heater valve mounting screws (Item 3) [Figure 80-220-1].
2
1
Remove the heater valve from the loader.
N-22156
Remove the actuator (Item 1) and the three mounting spacers (Item 2) [Figure 80-220-3] from the heater valve mount plate.
80-220-1 906 of 949
S150, S160 Bobcat Loader Service Manual
Figure 80-220-6
HEATER VALVE (CONT'D) Disassembly And Assembly (Cont'd) Figure 80-220-4
1 1
N-22159
Remove the two mounting screws (Item 1) [Figure 80220-6] from the heater valve.
N-22157
Figure 80-220-7
Figure 80-220-5
1 1
N-22160
Remove the heater valve mount bracket (Item 1) [Figure 80-220-7] from the heater valve.
N-22158
Replace the parts as needed. Remove the mount plate (Item 1) [Figure 80-220-5] from the heater valve bracket.
80-220-2 907 of 949
S150, S160 Bobcat Loader Service Manual
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Remove the three mounting screws (Item 1) [Figure 80220-4] from the heater valve mount plate.
SPECIFICATIONS
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-21-1 SPEC-21-2 SPEC-21-3 SPEC-21-4 SPEC-21-1 SPEC-21-3 SPEC-21-1 SPEC-21-1 SPEC-21-3 SPEC-21-3 SPEC-21-3 SPEC-21-2 SPEC-21-2 SPEC-21-4 SPEC-21-4 SPEC-21-1 SPEC-21-2 SPEC-21-2
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-20-1 SPEC-20-2 SPEC-20-3 SPEC-20-4 SPEC-20-3 SPEC-20-1 SPEC-20-1 SPEC-20-1 SPEC-20-3 SPEC-20-3 SPEC-20-3 SPEC-20-2 SPEC-20-2 SPEC-20-4 SPEC-20-4 SPEC-20-1 SPEC-20-2 SPEC-20-2
SAFETY MAINTENANCE
DRIVE SYSTEM
ELECTRICAL SYSTEM ANALYSIS ENGINE SERVICE
SPECIFICATIONS
Continued On Next Page
SPEC-01 908 of 949
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CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 Decimal And Millimeter Equivalent Chart. . . . . . . . . . . . . . . . . . SPEC-60-1 U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
S150, S160 Bobcat Loader Service Manual
SPECIFICATIONS (CONT’D) HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Straight Thread O-ring Fitting. . . . . . . . . . . . . . . . . . . . Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEC-40-1 SPEC-40-2 SPEC-40-1 SPEC-40-3 SPEC-40-5 SPEC-40-2 SPEC-40-2
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS SPEC-50-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 SPEC-10-1 SPEC-10-4 SPEC-10-2 SPEC-10-4 SPEC-10-3 SPEC-10-2 SPEC-10-3 SPEC-10-1 SPEC-10-2 SPEC-10-4
Dealer Copy -- Not for Resale
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-30-1 Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-30-2 Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-30-1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.
SPEC-02 909 of 949
S150, S160 Bobcat Loader Service Manual
LOADER SPECIFICATIONS Machine Dimensions • •
Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses. Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
C
95°
83.7 in. (2166 mm)
148.0 in. (3759 mm) 44°
86.5 in. (2197 mm)
76.3 in. (1938 mm) 23°
25° 40.6 in. (1030 mm) 101.8 in. (2586 mm) 130.3 in. (3309 mm)
7.5 in. (191 mm)
B A B-22355
TIRE DESCRIPTION 10-16.5 TIRES
A
B
WIDTH (OVER TIRES)
WHEEL TREAD
B-22354
C
66.0in. (1676mm) or 60.0in (1524mm)
54.5in. (1385mm) or 48.5in. (1232mm)
31-15x15 TIRES
72.0in. (1829mm)
55.9in. (1420mm)
31.5x13-16.5 Tires
66.0 in. (1676 mm)
52.3in. (1328 mm)
BUCKET WIDTH 62” 68” 74”
WIDTH (OVER BUCKET) 62.0in. (1575mm) 68.0in. (1727mm) 74.0in. (1880mm)
* Recommended Pressure-Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.
SPEC-10-1 910 of 949
S150, S160 Bobcat Loader Service Manual
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114.5 in. (2908 mm)
18.13 in. (461 mm)
LOADER SPECIFICATIONS (CONT’D) Performance S150
S160
Rated Operating Capacity (ISO)
1500 lb. (680kg)
1600 lb. (726kg)
Tipping Load (SAE Rating)
3000 lb. (1361kg)
3200 lb. (1451kg)
Operating Weight
5662 lb. (2568 kg)
5752 lb. (2609 kg)
SAE Breakout Force-Lift
4350 lb. (19350 N)
-Tilt
3600 lb. (16014 N)
Axle Torque
4900 ft.- lb. (6644N•m)
Travel Speed
0-7.3 MPH (11,7 km/hr.)
Controls
Loader Hydraulics Lift and Tilt
Direction and Speed controlled by two hand levers. Controlled by separate foot pedals or optional hand controls.
Front Auxiliary
Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option)
Controlled by electrical switch on LH steering lever.
Engine
Hand lever throttle: Key-type starter switch and shutdown. Keyless start and shutdown with deluxe instrumentation.
Starting Aid Service Brake Secondary Brake Parking Brake
Glow Plugs Automatically activated by standard or deluxe instrumentation. Two independent hydrostatic systems controlled by two hand operated steering levers. One of the hydrostatic transmissions. Mechanical Disc, switch in control panel.
Engine Make / Model
Kubota V2203-M-DI
Kubota V2003-M-DI-T
Fuel / Cooling
Diesel / Liquid
Diesel / Liquid
Horsepower (SAE Net)
46 HP (34kW)
56 HP (42kW)
2800 rpm
2800 rpm
107 ft.-lb. (145N•m) @ 1700 rpm
120.8 ft.-lb. (164N•m) @ 1825 rpm
Four
Four
Displacement
134 cu.in. (2,2L)
122 cu.in. (2,0L)
Bore / Stroke
3.425 / 3.638 (87.0 / 92.4)
3.268 / 3.638 (83.0 / 92.4)
Lubrication
Pressure System W/Filter
Pressure System W/Filter
Closed Breathing
Open Breathing
Air Induction
Naturally aspirated
Turbocharged
Air Cleaner
Dry replaceable cartridge w/safety element
Dry replaceable cartridge w/safety element
Diesel-Compression
Diesel-Compression
High Idle rpm
2860 - 3000
2860 - 3000
Low Idle rpm
1075 - 1225
1195 - 1245
Maximum Governed rpm Torque (SAE Net) Number of Cylinders
Crankcase Ventilation
Ignition
SPEC-10-2 911 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Vehicle Steering
LOADER SPECIFICATIONS (CONT’D) Hydraulic System S150
S160
Pump
Engine Driven, Gear Type
Pump Capacity
16.9 GPM (64 L/min.) at High Idle
Charge Pump Capacity (SJC)
12.8 GPM (48,5 L/min.) at High Idle
High Flow (Option S160)
26.4 GPM (99,9 L/min.) at High Idle
System Relief at Quick Couplers
Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders
Doubleacting; Tilt cylinders have cushioning feature on dump
Bore Diameter: Lift Cylinder (2)
2.25 (57,2)
Tilt Cylinder (1)
2.75 (69,9)
Rod Diameter: Lift Cylinder (2)
1.50 (38,1)
Tilt Cylinder (1)
1.38 (35,1)
Stroke: Lift Cylinder (2)
27.9 (708,7)
Tilt Cylinder (1)
13.19 (335,0)
Control Valve
3-spool, open center type w/float detent on lift and electrically controlled auxiliary spool.
Fluid Lines
SAE standard tubelines, hoses and fittings
Fluid Type
BOBCAT FLUID, Hydraulic / Hydrostatic 6903117 - (Two - 2.5 gal. containers) 6903118 - (5 gal.) 6903119 - (55 gal.)
Hydraulic Function Time: Raise Lift Arms
3.67 Seconds
Lower Lift Arms
2.10 Seconds
Bucket Dump
2.37 Seconds
Bucket Rollback
1.85 Seconds
Electrical Alternator
Belt driven, 90 amp., open
Battery
12 volt, 600 cold cranking amps. @ 0° F (-18°C); 115 minute reserve capacity at 25 amps.
Starter
12 volt, Gear reduction type, 3.62 HP (2,7kW)
Instrumentation
Gauges: Hourmeter, Fuel, Engine Coolant Temperature. Warning lights: Fuel Level, Glow Plugs, System Voltage, Seat Belt, Engine Coolant Temperature, Engine Oil Pressure, Hydrostatic Charge Pressure, Hydraulic Oil Temperature, Engine Air Filter and Hydraulic Filter. Other: Audible Alarm, BICS™ Function, Lights, Opt. / Accessory Switches. Optional Deluxe Instrumentation: *Same gauges and warning lights as standard instrumentation. *Additional bar-type gauges for: Engine Oil Pressure, System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature. *Additional Features Incl.: Keyless Start, Clock, Job Clock, Help Screens, Diagnostic Capability, Automatic Shutdown Function, Attachment Info, Digital Tachometer, High Flow Lock-Outs, Multi Language Display.
SPEC-10-3 912 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Filter
3300 PSI (206 Bar)
LOADER SPECIFICATIONS (CONT’D) Drive System S150 Main Drive
S160 Hydrostatic 4 wheel drive
Transmission
Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors.
Final Drive
#80 HSOC endless roller chain and sprockets in sealed chaincase with oil lubrication.
Total Engine To Wheel Reduction
33:1
Axle Size
2.00 (50,8)
Wheel Bolts
(8) 9/16”
Capacities Cooling System W/Heater (Includes Recovery Bottle)
12 qt. (11,4 L)
Cooling System W/O Heater (Includes Recovery Bottle)
11 qt. (10,4 L) 23.0 Gal. (87,1 L)
Engine Oil W/Filter
9.5 qt. (9,0 L)
Hydraulic / Hydro. System W/ Reservoir
8.5 Gal. (32,2 L)
Chaincase Reservoir
9 Gal. (34,1 L)
Tires Standard Size Recommended Pressure
10 - 16.5, 8 Ply Rating (Optional Tires Available) Inflate Tires to Maximum Pressure Shown On The Side Wall Of The Tire. Do Not Mix Brands Of Tires Used On The Same Loader.
SPEC-10-4 913 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Fuel
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Fuel Injection Nozzles Opening Pressure Fuel Tightness Nozzle Seat
2702 - 2916 PSI (18600 - 20100 kPa) Dry Nozzle at 2418 PSI (16672 kPa) for 10 seconds
Fuel Injection Pump Injection Timing High Idle Low Idle
6.2 - 8.2 degrees B.T.D.C. 2860 - 3000 rpm 1195 - 1245 rpm
Cylinder Head 0.002 (0,05) Max. 0.0453 - 0.0492 (1,15 - 1,25) 0.0512 - 0.0551 (1,3 - 1,4) 0.0236 - 0.0276 (0,60 - 0,70) 427 - 469 PSI (2940 - 3240 kPa) 341 PSI (2350 kPa) 10%
Dealer Copy -- Not for Resale
Cylinder Head Surface Distortion Thickness of Gasket (Used) (New) Top Clearance (Piston to Head) Compression Allowable Limit Difference Between Cylinders Valves Valve Seat Width (Intake & Exhaust) Valve Seat Angle O.D. of Valve Stems I.D. of Valve Guides Clearance Between Valve Stem & Guide Allowable Limit Valve Clearance (Cold) Valve Recessing (Protrusion) (Recess)
0.084 (2,12) Intake 60 degrees, Exhaust 45 degrees 0.3134 - 0.3140 (7,96 - 7,98) 0.3156 - 0.3161 (8,015 - 8,03) 0.0016 - 0.0028 (0,04 - 0,07) 0.004 (0,1) 0.0071 - 0.0087 (0,18 - 0,22) 0.002 (0,05) 0.006 (0,15)
SPEC-20-1 914 of 949
S150, S160 Bobcat Loader Service Manual
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Valve Springs Free Length Allowable Limit Fitted Length Compress to Fitted Length Allowable Limit
1.642 - 1.661 (41,7 - 42,2) 1.622 (41,2) 1.378 (35,0) 26.4 lb. (117,6 N) 22.5 lb. (100,0 N)
Valve Timing Intake Valve (Open) (Close) Exhaust Valve (Open) (Close)
9 degrees B.T.D.C. 45 degrees A.T.D.C. 50 degrees B.T.D.C. 12 degrees A.T.D.C.
O.D. of Rocker Arm Shaft I.D. of Rocker Arm Bushings Clearance Between Rocker Arm & Bushing Allowable Limit
0.5501 - 0.5506 (13,973 - 13,984) 0.5512 - 0.5519 (14,0 - 14,018) 0.0006 - 0.0018 (0,016 - 0,045) 0.0039 (0,10)
Camshaft Journal O.D. Bearing I.D. Oil Clearance Allowable Limit Alignment Allowable Limit Cam Lobe Height Allowable Limit End Clearance Allowable Limit
1.5722 - 1.5728 (39,934 - 39,95) 1.5748 - 1.5758 (40,0 - 40,025) 0.002 - 0.0036 (0,05 - 0,091) 0.006 (0,15) 0.0004 (0,01) 1.3346 (33,90) 1.3327 (33,85) 0.0028 - 0.0087 (0,07 - 0,22) 0.012 (0,3)
Tappet Clearance Between Tappet & Guide Tappet O.D. Tappet Guide I.D.
0.0071 - 0.0087 (0,18 - 0,22) 0.9433 - 0.9441 (23,959 - 23,98) 0.9449 - 0.9457 (24,0 - 24,021)
SPEC-20-2 915 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Rocker Arms
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Cylinders Cylinder Bore I.D. Allowable Limit
3.4252 - 3.4261 (87,00 - 87,022) +0.0059 (+0,15)
Piston Rings 0.0079 - 0.0138 (0,20 - 0,35) 0.0492 (1,25) 0.0138 - 0.0197 (0,35 - 0,50) 0.0492 (1,25) 0.079 - 0.0157 (0,20 - 0,40) 0.0492 (1,25) 0.0037 - 0.0047 (0,093 - 0,12) 0.0037 - 0.0047 (0,094 - 0,12) 0.0008 - 0.002 (0,02 - 0,052)
Pistons Piston Pin Bore Limit Permitted
0.9843 - 0.9848 (25,0 - 25.013) 0.9862 (25,05)
Connecting Rod Piston Pin O.D. Small End Bushing I.D. Clearance Between Piston Pin & Small End Bushing Allowable Limit Connecting Rod Alignment Allowable Limit
0.9843 - 0.9847 (25,002 - 25,011) 0.9852 - 0.9858 (25,025 - 25,04) 0.0006 - 0.0015 (0,014 - 0,038) 0.0059 (0,15 mm) 0.002 (0,05)
Oil Pump Oil Pressure Rated RPM Limit Permitted Idle Speed Limit Permitted Clearance Between Inner Rotor & Outer Rotor Outer Rotor & Pump Body End Clearance Between Inner Rotor & Cover Limit Permitted
43 - 64 PSI (294 - 441 kPa) 36 PSI (248 kPa) 14 PSI (98 kPa) 7 PSI (49 kPa) 0.0012 - 0.0055 (0,03 - 0,14) 0.0043 - 0.0075 (0,11 - 0,19) 0.0041 - 0.0059 (0,105 - 0,15) 0.0079 (0,20)
SPEC-20-3 916 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Ring Gap (Top Ring) Limit Permitted Ring Gap (2nd Ring) Limit Permitted Ring Gap (Oil Ring) Limit Permitted Side Clearance of Ring Groove: Top Ring Second Ring Oil Ring
ENGINE SPECIFICATIONS-KUBOTA V2203-M-DI (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Crankshaft Alignment Limit Permitted Oil Clearance Between Journal & Bearing #1 Limit Permitted Journal O.D. #1 Bearing I.D. #1 Oil Clearance Between Journal & Bearing #2 Limit Permitted Journal O.D. #2 Bearing I.D. #2 Oil Clearance Between Crank Pin & Bearing Limit Permitted Crank Pin O.D. Crank Pin Bearing I.D. Crankshaft Side Clearance Limit Permitted
0.00079 (0,02) 0.0016 - 0.0046 (0,04 - 0,118) 0.0079 (0,2) 2.3591 - 2.3598 (59,921 - 59,940) 2.3614 - 2.3637 (59,98 - 60,039) 0.0016 - 0.0041 (0,04 - 0,104) 0.0079 (0,2) 2.3591 - 2.3598 (59,921 - 59,940) 2.3614 - 2.3632 (59,98 - 60,025) 0.0010 - 0.0034 (0,025 - 0,087) 0.0079 (0,2) 1.8488 - 1.8494 (46,96 - 46,97) 1.8504 - 1.8522 (47,0 - 47,046) 0.0059 - 0.0138 (0,15 - 0,35) 0.0197 (0,5)
Timing Gear Timing Gear Backlash: Crank Gear-Idle Gear Idle Gear-Cam Gear Idle Gear-Injection Pump Gear Crank Gear-Oil Pump Gear Limit Permitted Clearance Between Idle Gear Shaft & Idle Gear Bushing Limit Permitted Idle Gear Side Clearance Idle Gear
0.0016 - 0.0044 (0,042 - 0,112) 0.0016 - 0.0045 (0,042 - 0,115) 0.0016 - 0.0045 (0,042 - 0,115) 0.0016 - 0.0043 (0,042 - 0,109) 0.006 (0,15) 0.001 - 0.0026 (0,025 - 0,066) 0.004 (0,10) 0.005 - 0.019 (0,12 - 0,48)
Thermostat Valve Opening Temperature Valve Fully Open
176.9° - 182.3° F (80.5° - 83.5° C) 203° F (95° C)
SPEC-20-4 917 of 949
S150, S160 Bobcat Loader Service Manual
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Crankshaft
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Fuel Injection Nozzles Opening Pressure Fuel Tightness Nozzle Seat
2702 - 2916 PSI (18.6 - 20.1 MPa) Dry Nozzle at 2418 PSI (16.67 MPA)
Fuel Injection Pump Injection Timing High Idle Low Idle Cylinder Bore I.D. of Bore Allowable Limit
8.5 - 10 degrees B.T.D.C. 2860 - 3000 rpm 1075 - 1225 rpm 3.2677 - 3.2686 (83,0 - 83,022) +0.0059 (+0,15)
Cylinder Head Surface Distortion Top Clearance (Piston to Head) Compression Allowable Limit Difference Between Cylinders
0.002 (0,05) Max. 0.0236 - 0.0276 (0,60 - 0,70) 427 - 469 PSI (2944,1 - 3233,6 kPa) 341 PSI (2351,1 kPa) 10% or less
Valves Valve Seat Width (Intake & Exhaust) Valve Seat Angle O.D. of Valve Stems I.D. of Valve Guides Clearance Between Valve Stem & Guide Allowable Limit Valve Clearance (Cold) Valve Recessing (Protrusion) (Recess)
0.0835 (2,12) Intake 60 degrees, exhaust 45 degrees 0.3134 - 0.3140 (7,96 - 7,98) 0.3156 - 0.3161 (8,015 - 8,03) 0.0016 - 0.0028 (0,04 - 0,07) 0.0039 (0,1) 0.0071 - 0.0087 (0,18 - 0,22) 0.002 (0,05) 0.0059 (0,15)
SPEC-21-1 918 of 949
S150, S160 Bobcat Loader Service Manual
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Cylinder Head
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT’D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Valve Springs Free Length Allowable Limit Fitted Length Compress to Fitted Length Allowable Limit Tilt Allowable Limit
1.6417 - 1.6614 (41,7 - 42,2) 1.622 (41,2) 1.378 (35,0) 26.4 lb. (117,6 N) 22.5 lb. (100,0 N) 0.039 (1,0)
Valve Timing Intake Valve (Open) (Close) Exhaust Valve (Open) (Close)
9 degrees B.T.D.C. 45 degrees A.B.D.C. 50 degrees B.B.D.C. 12 degrees A.T.D.C.
O.D. of Rocker Arm Shaft I.D. of Rocker Arm Bushings Clearance Between Rocker Arm & Bushing Allowable Limit
0.5501 - 0.5506 (13,973 - 13,984) 0.5512 - 0.5519 (14,0 - 14,018) 0.0006 - 0.0018 (0,016 - 0,045) 0.0039 (0,1)
Camshaft Journal O.D. Bearing I.D. Oil Clearance Allowable Limit Alignment Allowable Limit Cam Lobe Height (Intake) Allowable Limit (Intake) Cam Lobe Height (Exhaust) Allowable Limit (Exhaust) Side Clearance Allowable Limit
1.5722 - 1.5728 (39,934 - 39,95) 1.5748 - 1.5758 (40,0 - 40,025) 0.002 - 0.0036 (0,05 - 0,091) 0.0059 (0,15) 0.0004 (0,01) 1.3346 (33,90) 1.3327 (33,85) 1.3346 (33,90) 1.3327 (33,85) 0.0028 - 0.0087 (0,07 - 0,22) 0.0118 (0,3)
Tappet Clearance Between Tappet & Guide Allowable Limit Tappet O.D. Tappet Guide I.D.
0.0008 - 0.0024 (0,02 - 0,062) 0.0028 (0,07) 0.9433 - 0.9441 (23,959 - 23,98) 0.9449 - 0.9457 (24,0 - 24,021)
SPEC-21-2 919 of 949
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Rocker Arms
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT'D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Cylinder Liner Cylinder Bore I.D. Allowable Limit Oversized Cylinder Liner (Bore) I.D. Allowable Limit
3.2677 - 3.2686 (83,0 - 83,022) +0.0059 (+0,15) 3.2776 - 3.2784 (83,25 - 83,27) +0.0059 (+0,15)
Piston Rings 0.0079 - 0.0138 (0,2 - 0,35) 0.0492 (1,25) 0.0157 - 0.0217 (0,4 - 0,55) 0.0492 (1,25) 0.0098 - 0.0177 (0,25 - 0,45) 0.0492 (1,25) 0.0037 - 0.0050 (0,093 - 0,128) 0.20 (0,0079) 0.0008 - 0.0021 (0,02 - 0,060) 0.0059 (0,15)
Pistons Piston Pin Bore Allowable Limit
0.9843 - 0.9848 (25,0 - 25,013) 0.9862 (25,05)
Connecting Rod Piston Pin O.D. Small End Bushing I.D. Clearance Between Piston Pin & Small End Bushing Allowable Limit Connecting Rod Alignment Allowable Limit
0.9843 - 0.9847 (25,002 - 25,011) 0.9852 - 0.9858 (25,025 - 25,04) 0.0006 - 0.0015 (0,014 - 0,038) 0.0059 (0,15) 0.002 (0,05)
Oil Pump Oil Pressure Rated rpm Allowable Limit Idle Speed Allowable Limit Clearance Between Inner Rotor & Outer Rotor Clearance Between Outer Rotor & Pump Body End Clearance Between Inner Rotor & Cover
43 - 64 PSI (294 - 441 kPa) 36 PSI (245 kPa) 7 PSI (49 kPa) 0.0012 - 0.0055 (0,03 - 0,14) 0.0043 - 0.0075 (0,11 - 0,19) 0.0041 - 0.0059 (0,105 - 0,15)
SPEC-21-3 920 of 949
S150, S160 Bobcat Loader Service Manual
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Ring Gap (Top Ring) Allowable Limit Ring Gap (2nd Ring) Allowable Limit Ring Gap (Oil Ring) Allowable Limit Side Clearance of Ring Groove: Second Ring Allowable Limit Oil Ring Allowable Limit
ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T (TURBO) (CONT'D) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Crankshaft Alignment Limit Permitted Oil Clearance Between Journal & Bearing #1 Limit Permitted Journal O.D. #1 Bearing I.D. #1 Oil Clearance Between Journal & Bearing #2 Limit Permitted Journal O.D. #2 Bearing I.D. #2 Oil Clearance Between Crank Pin & Bearing Limit Permitted Crank Pin O.D. Crank Pin Bearing I.D. Crankshaft Side Clearance Limit Permitted
0.00079 (0,02) 0.0016 - 0.0046 (0,04 - 0,118) 0.0079 (0,2) 2.3591 - 2.3598 (59,921 - 59,940) 2.3614 - 2.3637 (59,98 - 60,039) 0.0016 - 0.0041 (0,04 - 0,104) 0.0079 (0,2) 2.3591 - 2.3598 (59,921 - 59,940) 2.3614 - 2.3632 (59,98 - 60,025) 0.0010 - 0.0034 (0,025 - 0,087) 0.0079 (0,2) 1.8488 - 1.8494 (46,96 - 46,97) 1.8504 - 1.8522 (47,0 - 47,046) 0.0059 - 0.0138 (0,15 - 0,35) 0.0197 (0,5)
Timing Gear Timing Gear Backlash: Crank Gear-Idle Gear Allowable Limit Idle Gear-Cam Gear Allowable Limit Idle Gear-Injection Pump Gear Allowable Limit Crank Gear-Oil Pump Gear Allowable Limit Clearance Between Idle Gear Shaft & Idle Gear Bushing: Idle Gear Allowable Limit Idle Gear Bushing I.D. Allowable Limit Idle Gear Shaft O.D. Idle Gear Side Clearance Idle Gear Allowable Limit
0.0016 - 0.0044 (0,0415 - 0,1122) 0.0059 (0,15) 0.0016 - 0.0045 (0,0415 - 0,1154) 0.0059 (0,15) 0.0016 - 0.0045 (0,0415 - 0,1154) 0.0059 (0,15) 0.0016 - 0.0043 (0,0415 - 0,109) 0.0059 (0,15) 0.001 - 0.0026 (0,025 - 0,066) 0.0039 (0,10) 1.4961 - 1.4970 (38,0 - 38,025) 0.0039 (0,10) 1.4944 - 1.4951 (37,959 - 37,975) 0.0079 - 0.020 (0,2 - 0,51) 0.0315 (0,8)
Thermostat Valve Opening Temperature Valve Fully Open
176.9 - 182.3°F (80.5 - 83.5°C) 203°F (95°C)
SPEC-21-4 921 of 949
S150, S160 Bobcat Loader Service Manual
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Crankshaft
TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts
in.-lb. (N•m)
Thread Size 0.250 0.3125
ft.-lb. (N•m)
0.375 0.4375 0.500 0.5625 0.625 0.750 0.875 1.000 1.125 1.250 1.375 1.500 1.625 1.750 1.875 2.000
SAE Grade 5
SAE Grade 8
80 - 90 (9,0 - 10,2) 180 - 200 (20,3 - 22,6) 25 - 28 (34 - 38) 40 - 45 (54 - 61) 65 - 70 (88 - 95) 90 - 100 (122 - 136) 125 - 140 (170 - 190) 220 - 245 (300 - 330) 330 - 360 (450 - 490) 475 - 525 (645 - 710) 650 - 720 (880 - 975) 900 - 1000 (1200 - 1360) 1200 - 1350 (1630 - 1830) 1500 - 1650 (2040 - 2240) 2000 - 2800 (2720 - 2980) 2500 - 2750 (3390 - 3730) 3150 - 3500 (4270 - 4750) 3800 - 4200 (5150 - 5700)
110 - 120 (12,4 - 13,6) 215 - 240 (24,2 - 27,1) 35 - 40 (47 - 54) 60 - 65 (81 - 88) 90 - 100 (122 - 136) 125 - 140 (170 - 190) 175 - 190 (240 - 260) 300 - 330 (410 - 450) 475 - 525 (645 - 710) 725 - 800 (985 - 1085) 1050 - 1175 (1425 - 1600) 1475 - 1625 (2000 - 2200) 2000 - 2200 (2720 - 2980) 2600 - 2850 (3530 - 3870) 3450 - 3800 (4680 - 5150) 4300 - 4800 (5830 - 6500) 5500 - 6100 (7450 - 8300) 6500 - 7200 (8800 - 9800)
SPEC-30-1 922 of 949
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The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
S150, S160 Bobcat Loader Service Manual
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D) Torque For General Metric Bolts THREAD SIZE (DIA. X PITCH)
MATERIAL HEAD MARK 4
HEAD MARK 7
HEAD MARK 10
6 - 9 ft.-lb. (8 - 12 N•m) 13 - 18 ft.-lb. (18 - 24 N•m) 22 - 30 ft.-lb. (30 - 41 N•m) 36 - 50 ft.-lb. (49 - 68 N•m)
3 - 4 ft.-lb. (4 - 5 N•m) 6 - 7 ft.-lb. (8 - 9 N•m) 11 - 16 ft.-lb. (15 - 22 N•m) 22 - 30 ft.-lb. (30 - 41 N•m) 40 - 54 ft.-lb. (54 - 73 N•m) 58 - 80 ft.-lb. (79 - 108 N•m)
6 - 9 ft.-lb. (8 - 12 N•m) 18 - 25 ft.-lb. (24 - 34 N•m) 36 - 50 ft.-lb. (49 - 68 N•m) 69 - 87 ft.-lb. (94 - 118 N•m) 116 - 137 ft.-lb. (157 - 186 N•m)
M 5 x 0.8 M 6 x 1.0 M 8 x 1.25 M 10 x 1.25 M 12 x 1.25
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M 14 x 1.25
SPEC-30-2 923 of 949
S150, S160 Bobcat Loader Service Manual
Figure SPEC-40-2
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Tightening Torque
IMPORTANT When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I-2003-0888
Figure SPEC-40-1
xTubeline Outside Diameter
xx x Thread Size
TORQUE ft.-lb. (N•m)
1/4”
9/16” - 18
13 (18)
3/8”
11/16” - 16
22 (30)
1/2”
13/16” - 16
40 (54)
5/8”
1” - 14
60 (81)
3/4”
1-3/16” - 12
84 (114)
7/8”
1-3/16” - 12
98 (133)
1”
1-7/16” - 12
118 (160)
1-1/4”
1-11/16” - 12
154 (209)
1-1/2”
2” - 12
163 (221)
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O-ring Face Seal Connection
B-7575
When the fitting is tightened, you can feel when the fitting is tight to eliminate leakage caused by under or over torqued fittings. Use vaseline petroleum jelly to hold the O-ring in position until the fittings are assembled [Figure SPEC-40-1].
SPEC-40-1 924 of 949
S150, S160 Bobcat Loader Service Manual
Flare Fitting
HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)
Figure SPEC-40-4
Straight Thread O-ring Fitting Figure SPEC-40-3
1 Nut
Nut Washer
Washer
2
O-ring O-ring TS-1619
Lubricate the O-ring before installing the fitting. Loosen the jam nut and install the fitting. Tighten the jam nut until the washer is tight against the surface [Figure SPEC-403]. Tubelines And Hoses Replace any tubelines that are bent or flattened. They will restrict flow, which will slow hydraulic action and cause heat.
Tighten the nut until it makes contact with the seat. Make a mark across the flats of both the male and female parts of the connection (Item 1) [Figure SPEC-40-4] Use the chart [Figure SPEC-40-5 on Page 3] to find the correct tightness needed (Item 2) [Figure SPEC-40-4]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.
Replace hoses which show signs of wear, damage or weather cracked rubber. Always use two wrenches when loosening and tightening hose or tubeline fittings.
SPEC-40-2 925 of 949
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Use the following procedure to tighten the flare fitting:
A-1852
Figure SPEC-40-7
HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)
Hex Flat Tightening Method
Flare Fitting (Cont’d) Figure SPEC-40-5 1
Flare Fitting Tightening Torque x x Thread Size
TORQUE ft.-lb. (N•m)
1/4”
7/16” - 20
13 (18)
5/16”
1/2” - 20
17 (23)
3/8”
9/16” - 18
22 (30)
1/2”
3/4” - 16
40 (54)
5/8”
7/8” - 14
60 (81)
3/4”
1-1/16” - 12
84 (114)
7/8”
1-3/16” - 12
98 (133)
1”
1-5/16” - 12
118 (160)
1-1/4”
1-5/8” - 12
154 (209)
1-1/2”
1-7/8” - 12
163 (221)
2”
2-1/2” - 12
252 (342)
2
TS-1619
Tighten the nut until it contacts with the seat. Make a mark across the flats of both the male and female parts of the connection (Item 1) [Figure SPEC-40-7]. Use the chart [Figure SPEC-40-8 on Page 4] to find the correct tightness needed (Item 2) [Figure SPEC-40-7]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.
O-ring Flare Fitting Figure SPEC-40-6 Primary Seal
O-ring Flare
Secondary Seal P13009
The flare is the primary seal, the O-ring is the secondary seal and helps absorb vibration and pressure pulses at the connection [Figure SPEC-40-6]. If necessary, the O-ring-flare fitting can be used without an O-ring. Use the following procedure to tighten the O-ring flare fitting.
SPEC-40-3 926 of 949
S150, S160 Bobcat Loader Service Manual
Dealer Copy -- Not for Resale
Tubeline Outside Diameter
When a O-ring flare fitting is used as a straight thread port adapter the O-ring flare face is not used to seal. The O-ring may come off the fitting and enter the system.
HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D) O-ring Flare Fitting (Cont’d)
Figure SPEC-40-10
Figure SPEC-40-8 O-ring Flare Fitting Tightening Torque x x Thread Size
TORQUE ft.-lb. (N•m)
1/4”
7/1” - 20
13 (18)
5/16”
1/2” - 20
17 (23)
3/8”
9/16” - 18
22 (30)
1/2”
3/4” - 16
40 (54)
5/8”
7/8” - 14
60 (81)
3/4”
1-1/16” - 12
84 (114)
7/8”
1-3/16 - 12
98 (133)
1”
1-5/16” - 12
118 (160)
1-1/4”
1-5/8” - 12
154 (209)
1-1/2”
1-7/8” - 12
163 (221)
2”
2-1/2” - 12
252 (342)
2
1
P13573
NOTE: Always remove the O-ring (Item 1) [Figure SPEC-40-10] from the flare face as shown. An O-ring (Item 2) [Figure SPEC-40-10] is added to the flat boss of the fitting to seal the connection in this application.
Figure SPEC-40-9
Copper Bonnet Orifice
1
P13572
NOTE: O-ring flare fittings are not recommended in all applications. Use the standard flare fittings in these applications. Do not use a O-ring flare fitting when a copper bonnet orifice is used. When tightened the connection at the bonnet may distort the flare face and prevent it from sealing. Use a standard flare fitting (Item 1) [Figure SPEC-40-9] as shown.
SPEC-40-4 927 of 949
S150, S160 Bobcat Loader Service Manual
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Tubeline Outside Diameter
HYDRAULIC CONNECTION SPECIFICATIONS (CONT'D)
If a torque wrench cannot be used, use the following method.
Port Seal Fitting
Tighten the nut until it just makes metal to metal contact, you can feel the resistance.
Figure SPEC-40-11
Tighten the nut with a wrench no more than one hex flat maximum. Do not over tighten the port seal fitting. NOTE: If a torque wrench cannot be used, use the hex flat tightening method as an approximate guideline. Nut Seals To Fitting
NOTE: Port seal fittings are not recommended in all applications. Use O-ring boss fittings in these applications.
Secondary O-ring Seal
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Nut Seals To Port
P-13008
The nut is the primary seal, the O-ring is the secondary seal and helps absorb vibration and pressure pulses at the connection [Figure SPEC-40-11]. The hex portion of the nut does not contact the surface of the component when the nut is tight. Figure SPEC-40-12 Port Seal and O-ring Boss Tightening Torque x x Thread Size
TORQUE ft.-lb. (N•m)
7/16” - 20
13 18)
9/16” - 18
22 (30)
3/4” -1 6
40 (54)
7/8” - 14
60 (81)
1-1/16” - 12
84 (114)
1-3/16” - 12
98 (133)
1-5/16” - 12
118 (160)
1-7/16” - 12
154 (209)
1-5/8” - 12
163 (221)
Use the following procedure to tighten the port seal fitting: Port seal and nut, washer and O-ring (O-ring Boss) fittings use the same tightening torque valve chart.
SPEC-40-5 928 of 949
S150, S160 Bobcat Loader Service Manual
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S150, S160 Bobcat Loader Service Manual
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
WARNING
Specifications HYDRAULIC / HYDROSTATIC FLUID RECOMMENDED ISO VISCOSITY GRADE (VG) AND VISCOSITY INDEX (VI)
During cold weather (0°C [32°F] and below), do not operate machine until the engine has run for at least 5 minutes at less than half throttle. This warm-up period is necessary for foot pedal operation and safe stopping. Do not operate controls during warm-up period. When temperatures are below -30°C (-20°F), the hydrostatic oil must be heated or kept warm. The hydrostatic system will not get enough oil at low temperatures. Park the machine in an area where the temperature will be above -18°C (0°F) if possible. W-2027-0311
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TEMPERATURE RANGE ANTICIPATED DURING MACHINE USE [1] VG 100; Minimum VI 130 [2] VG 46; Minimum VI 150 [3] BOBCAT All-Season Fluid [4] BOBCAT Synthetic Fluid [5] BOBCAT Biodegradable Hydraulic / Hydrostatic Fluid (Unlike biodegradable fluids that are vegetable based, Bobcat biodegradable fluid is formulated to prevent oxidation and thermal breakdown at operating temperatures.) DO NOT use automatic transmission fluids in the loader or permanent damage to the transmission will result.
WARNING AVOID INJURY OR DEATH Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. W-2072-0807
When temperatures below 0°F (-18°C) are common, the loader must be kept in a warm building. Extra warm-up time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by TRANS light ON) can cause transmission damage in less than 60 seconds.
SPEC-50-1 930 of 949
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S150, S160 Bobcat Loader Service Manual
CONVERSIONS
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Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SPEC-60-1 932 of 949
S150, S160 Bobcat Loader Service Manual
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S150, S160 Bobcat Loader Service Manual
ROUTE TO ATTENTION
SERVICE MANUAL REVISION
NOTICE
Insert This Sheet With The Below Listed Manual For Future Reference.
S150, S160 - 1 12 January 2004 Bobcat Loader S150, S160 6902730 (11-03)
The following Sections are a revision to the above Service Manual. Take out existing pages and put in the new pages as listed below: TAKE OUT
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50-100-1 thru 50-100-14
50-100-1 thru 50-100-14
Revised Text
50-101-1 thru 50-101-20
Added CONTROL PANEL (ADJUSTABLE PINTLES)
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S150, S160 - 2 13 April 2004 Bobcat Loader S150, S160 6902730 (11-03)
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REVISION DESCRIPTION
10-70-1 thru 10-70-2
10-70-1 thru 10-70-2
Revised Text
10-110-1 thru 10-110-2
10-110-1 thru 10-110-2
Revised Text
10-130-1 thru 10-130-2
10-130-1 thru 10-130-2
Revised Text
10-150-1 thru 10-150-2
10-150-1 thru 10-150-2
Revised Text
10-170-1 thru 10-170-2
10-170-1 thru 10-170-2
Revised Text
20-01 thru 20-04
20-01 thru 20-06
Revised Text
Revised Text HYD./HYDRO.SCHEMATIC HYD./HYDRO.SCHEMATIC S150 (S/N 526811001 AND ABOVE) S150 (S/N 526811001 AND ABOVE) (S/N 526911001 AND ABOVE) (S/N 526911001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) (S/N 526711001 AND ABOVE) (S/N 526711001 AND ABOVE) (PRINTED NOVEMEBER 2003) (PRINTED APRIL 2004) V-0400 V-0400 title & legend title & legend Revised Text HYD./HYDO SCHEMATIC HYD./HYDO SCHEMATIC WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) (S/N 526711001 AND ABOVE) (S/N 526711001 AND ABOVE) (PRINTED APRIL 2004) (PRINTED NOVEMBER 2003) V-0401 V-0401 title & legend title & legend Continued On Next Page
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REVISION DESCRIPTION
20-20-1 thru 20-20-8
20-20-1 thru 20-20-8
Revised Text
20-21-1 thru 20-21-10
20-21-1 thru 20-21-10
Revised Text
20-40-1 thru 20-40-32
20-40-1 thru 20-40-32
Revised Text
20-41-1 thru 20-41-24
20-41-1 thru 20-41-24
Revised Text
20-42-1 thru 20-42-34
Added Hyd. Control Valve (1 Piece Casting) (Foot Control)
20-60-1 thru 20-60-12
20-60-1 thru 20-60-12
Added Hyd. Control Valve (1 Piece Casting) (Advanced Control System) (ACS) Revised Text
20-61-1 thru 20-61-16 20-100-1 thru 20-100-8
20-61-1 thru 20-61-16 20-100-1 thru 20-100-8
Revised Text Revised Text
30-30-1 thru 30-30-2
30-30-1 thru 30-30-2
Revised Text
50-01 thru 50-02 50-30-1 thru 50-30-2 50-31-1 thru 50-31-6 50-40-1 thru 50-40-4 50-41-1 thru 50-41-4 50-100-1 thru 50-100-14 50-101-1 thru 50-101-20
50-01 thru 50-04 50-30-1 thru 50-30-2 50-31-1 thru 50-31-6 50-40-1 thru 50-40-4 50-41-1 thru 50-41-4 50-100-1 thru 50-100-14 50-101-1 thru 50-101-20
Revised Text Revised Text Revised Text Revised Text Revised Text Revised Text Revised Text
60-30-1 thru 60-30-10 60-40-1 thru 60-40-10 60-80-1 thru 60-80-4 60-120-1 thru 60-120-20
60-30-1 thru 60-30-10 60-40-1 thru 60-40-10 60-80-1 thru 60-80-6 60-120-1 thru 60-120-20
Revised Text Revised Text Revised Text Revised Text
70-01 thru 70-02 70-70-1 thru 70-70-14 70-100-1 thru 70-100-32
70-01 thru 70-02 70-70-1 thru 70-70-18 70-100-1 thru 70-100-32
Revised Text Revised Text Revised Text
80-50-1 thru 80-50-12 80-70-1 thru 80-70-4
80-50-1 thru 80-50-12 80-70-1 thru 80-70-4
Revised Text Revised Text
20-43-1 thru 20-43-30
SPEC-10-1 thru SPEC-10-4 SPEC-10-1 thru SPEC-10-4 Revised Text
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S150, S160 - 3 13 May 2004 Bobcat Loader S150, S160 6902730 (11-03)
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20-01 thru 20-06
20-01 thru 20-06
REVISION DESCRIPTION Revised Text
HYD./HYDRO. SCHEMATIC S/N breaks ON THE TITLE, LEGEND HYD./HYDRO. SCHEMATIC S150 (S/N 526811001 AND ABOVE) S150 (S/N 526811001- 526814999) AND CHART (S/N 526911001 AND ABOVE) (S/N 526911001 - 526914999) S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 - 526614999) (S/N 526711001 AND ABOVE) (S/N 526711001- 526714999) (PRINTED APRIL 2004) (PRINTED MAY 2004) V-0400 V-0400 HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC S/N breaks ON THE TITLE, LEGEND WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION AND CHART S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 - 526614999) (S/N 526711001 AND ABOVE) (S/N 526711001- 526714999) (PRINTED APRIL 2004) (PRINTED MAY 2004) V-0401 V-0401 ADDED TITLE, LEGEND AND CHART HYD./HYDRO. SCHEMATIC S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED MAY 2004) V-0573 ADDED TITLE, LEGEND AND CHART HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED MAY 2004) V-0574
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REVISION DESCRIPTION
20-40-1 Thru 20-40-32
20-40-1 Thru 20-40-32
Revised Text
20-41-1 thru 20-41-24
20-41-1 thru 20-41-24
Revised Text
20-42-1 thru 20-42-34
20-42-1 thru 20-42-34
Revised Text
20-43-1 thru 20-43-30
20-43-1 thru 20-43-30
Revised Text
60-10-1 thru 60-10-6
60-10-1 thru 60-10-6
Revised Text
60-40-1 thru 60-40-10
60-40-1 thru 60-40-10
Revised Text
70-01 thru 70-02
70-01 thru 70-02
Revised Text
SPEC-21-1 thru SPEC-21-6
SPEC-21-1 thru SPEC-21-6
Revised Text
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Revised Text WIRING SCHEMATIC WIRING SCHEMATIC OPTIONS OPTIONS (S150 S/N 526811001 AND ABOVE) (S150 S/N 526811001 AND ABOVE) (S/N 526911001 AND ABOVE) (S/N 526911001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 AND ABOVE) (S/N 526711001 AND ABOVE) (S/N 526711001 AND ABOVE) (PRINTED MAY 2004) (PRINTED NOVEMBER 2003) V-0394 V-0394
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S150, S160 - 4 14 April 2005 Bobcat Loader S150, S160 6902730 (11-03)
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REVISION DESCRIPTION
Section 10-50
Section 10-50
Revised Text
Section 10-110 Section 10-130
Section 10-110 Section 10-130
Revised Text Revised Text
Revised Text HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC S150 (S/N 526811001 AND ABOVE) S150 (S/N 526811001- 526814999) (S/N 526911001 AND ABOVE) (S/N 526911001 - 526914999) S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 - 526614999) (S/N 526711001 AND ABOVE) (S/N 526711001- 526714999) (PRINTED MAY 2004) (PRINTED APRIL 2005) V-0400 V-0400 Revised Text HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION S160 (S/N 526611001 AND ABOVE) S160 (S/N 526611001 - 526614999) (S/N 526711001- 526714999) (S/N 526711001 AND ABOVE) (PRINTED APRIL 2005) (PRINTED MAY 2004) V-0401 V-0401 Revised Text HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC S150 (S/N 526815000 AND ABOVE) S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED MAY 2004) (PRINTED APRIL 2005) V-0573 V-0573
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Section 20-21 Section 20-30 Section 20-40 Section 20-41 Section 20-110
Section 20-21 Section 20-30 Section 20-40 Section 20-41 Section 20-110
Revised Text Revised Text Revised Text Revised Text Revised Text
30-01, 30-02 Section 30-20 Section 30-30
30-01, 30-02 Section 30-20 Section 30-30
Revised Text Revised Text Revised Text
40-01, 40-02 Section 40-30
40-01, 40-02 Section 40-30
Revised Text Revised Text
Section 50-40 Section 50-41 Section 50-101
Section 50-40 Section 50-41 Section 50-101
Revised Text Revised Text Revised Text
Section 60-30 Section 60-120
Section 60-30 Section 60-120
Revised Text Revised Text
70-01, 70-02 Section 70-70 Section 70-100
70-01, 70-02 Section 70-70 Section 70-100
Revised Text Revised Text Revised Text
Section SPEC-10 Section SPEC-20 Section SPEC-21 Section SPEC-50
Section SPEC-10 Section SPEC-20 Section SPEC-21 Section SPEC-50
Revised Text Revised Text Revised Text Revised Text
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Revised Text HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED MAY 2004) (PRINTED APRIL 2005) V-0574 V-0574
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S150, S160 - 5 6 July 2005 Bobcat Loader S150, S160 6902730 (11-03)
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Maintenance Safety ALPHABETICAL INDEX
ALPHABETICAL INDEX
Foreword i-x Section 10-120
Foreword i-x Section 10-120
20-01
20-01
Maintenance Safety
REVISION DESCRIPTION Revised Revised Text Updated Safety pages Revised Text Revised Text
Revised HYD/HYDRO SCHEMATIC HYD/HYDRO SCHEMATIC S150 (S/N 526815000 AND ABOVE) S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED APRIL 2005) (PRINTED JULY 2005) V-0573 V-0573 Revised HYD/HYDRO SCHEMATIC HYD/HYDRO SCHEMATIC WITH HIGH FLOW OPTION WITH HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED APRIL 2005) (PRINTED JULY 2005) V-0574 V-0574 HYD/HYDRO SCHEMATIC Added WITH SJC OPTION S150 (S/N 526815000 AND ABOVE) (S/N 526915000 AND ABOVE) S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED JULY 2005) V-0710
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Section 20-62
Added Hydraulic Pump (SJC)
Section 20-63 Section 20-70
Section 20-70
Added Hydraulic Pump (High Flow) (SJC) Revised Text
30-01 Section 30-20
30-01 Section 30-20 Section 30-21 Section 30-22 Section 30-30 Section 30-41
Revised Text Revised Text Added Hydrostatic Motor Carrier Added Hydrostatic Motor Carrier (SJC) Revised Text Added Hydrostatic Pump (SJC)
50-01
50-01 Section 50-102 Section 50-112
Revised Text Added Control Panel (SJC) Added Control Handle (SJC)
60-01
60-01
ALL WIRING SCHEMATICS
ALL WIRING SCHEMATICS
Section 60-50
Section 60-50 Section 60-71
Section 60-80
Section 60-80 Section 60-131
Section 30-30
Section 60-150 Section 60-160 Section 60-170 Section SPEC-10
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Section SPEC-10
Revised Text Revised and Added Revised Text Added Controller (Selectable Joystick Control) (SJC) Revised Text Added Electrical/Hydraulic Controls Reference (Selectable Joystick Control) (SJC) Added Service PC (Laptop Computer) Added Calibration Added Speed Sensor Revised Text
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Added HYD/HYDRO SCHEMATIC WITH SJC AND HIGH FLOW OPTION S160 (S/N 526615000 AND ABOVE) (S/N 526715000 AND ABOVE) (PRINTED JULY 2005) V-0711
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S150, S160 - 6 23 February 2006 Bobcat Loader S150, S160 6902730 (11-03)
S150, S160 Service Manual (P/N 6902730) Dated (2-06) contains updated service information which replaces the previous S150, S160 Service Manual (P/N 6902730) Dated (11-03).
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S150, S160 - 7 1 July 2009 Bobcat Loader S150, S160 6902730 (7-09)
The following Sections are a revision to the above Service Manual. COVER MAINTENANCE SAFETY FOREWORD 10-01 20-01 30-01 40-01 50-01 60-01 70-01 70-70 80-01 SPEC-01
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S150, S160 - 8 15 May 2011 Bobcat Loader S150, S160 6902730 (5-11)
S150, S160 Service Manual (P/N 6902730) Dated (5-11) contains updated service information which replaces the previous S150, S160 Service Manual (P/N 6902730) Dated (7-09).
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