BOBCAT S150 SKID STEER LOADER Service Repair Manual SN 526911001 & Above PDF

Service
Manual
S/N 526611001 & Above
S/N 526711001 & Above
S/N 526811001 & Above
S/N 526911001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902730 (2-06) Printed in U.S.A. ©Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-15590 B-15591

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-15592 B-15593 B-15599

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
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.
MSW08-0805
ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM (ACS) FAN GEARBOX .......................................................10-01

SELECTABLE HAND/FOOT CONTROL .............. 60-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01
AIR CLEANER .................................................... 70-01 FLYWHEEL AND HOUSING ................................ 70-01
AIR CLEANER SERVICE ....................................... 10-01 FLYWHEEL RPM SENSOR ....................................60-01
AIR CONDITIONING SERVICE.............................. 80-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FUEL SYSTEM........................................................10-01
ALTERNATOR ........................................................ 60-01 FUEL TANK .............................................................50-01
GENERAL AIR CONDITIONING SERVICE
BATTERY................................................................ 60-01 GUIDELINES .........................................................80-01
BASIC TROUBLESHOOTING ................................80-01
BICS™ SYSTEM .................................................... 60-01 HEATER COIL .........................................................80-01
BOBCAT CONTROLLER .....................................60-01 HEATER/AC FAN ....................................................80-01
BOB-TACH ............................................... 10-01, 50-01 HEATER VALVE ......................................................80-01
BRAKE .................................................................... 40-01 HIGH FLOW VALVE ................................................20-01
BUCKET POSITION VALVE ................................ 20-01 HYDRAULIC CONNECTION SPECS. .............. SPEC-01
HYDRAULIC CONTROL VALVE .............................20-01
CALIBRATION ........................................................ 60-01 HYDRAULIC FILTER HOUSING .............................20-01
CHAINCASE ........................................................... 40-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
CHARGE PRESSURE ............................................ 30-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
COMPONENTS ...................................................... 80-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC PUMP ................................................20-01
CONDENSER ......................................................... 80-01 HYDRAULIC PUMP (HIGH FLOW).........................20-01
CONTROL HANDLE ............................................... 50-01 HYDRAULIC PUMP (HIGH FLOW) (SJC)...............20-01
CONTROL HANDLE (SJC)..................................... 50-01 HYDARULIC PUMP (SJC) ......................................20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDRAULIC SYSTEM INFORMATION ..................20-01
(ACS) SELECTABLE HAND/FOOT CONTROL.... 50-01 HYDROSTATIC MOTOR ..................................... 30-01
CONTROL PANEL .................................................. 50-01 HYDROSTATIC MOTOR CARRIER ........................30-01
CONTROL PANEL (SJC)........................................ 50-01 HYDROSTATIC MOTOR CARRIER (SJC)..............30-01
CONTROL PEDALS ............................................... 50-01 HYDROSTATIC PUMP ........................................ 30-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDROSTATIC SYSTEM INFORMATION ..........30-01
CONTROLLER (SELECTABLE JOYSTICK CONTROL)
(SJC) ..................................................................... 50-01 INSTRUMENT PANEL.............................................60-01
CONVERSIONS ............................................SPEC-01
COOLING FAN ....................................................... 70-01 LIFT ARMS ..............................................................50-01
CYLINDER (LIFT) ................................................... 20-01 LIFT ARM BY-PASS CONTROL VALVE .............. 20-01
CYLINDER (POWER BOB-TACH).......................... 20-01 LIFT ARM SUPPORT DEVICE ........................... 10-01
CYLINDER (TILT) ................................................ 20-01 LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS ................................................................60-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 LOADER SPECIFICATIONS ............................. SPEC-01
DRIVE BELT ........................................................... 30-01 LUBRICATING THE LOADER.................................10-01
DRIVE COMPONENTS .......................................... 40-01
MAIN RELIEF VALVE ..............................................20-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 MUFFLER................................................................70-01
ELECTRICAL/HYRAULIC CONTROLS REF. ......... 60-01
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE OIL COOLER...........................................................30-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01 OPERATOR CAB .........................................10-01, 50-01
ENGINE ................................................................. 70-01 OPERATOR SEAT...................................................50-01
ENGINE COMPONENTS AND TESTING .............. 70-01 OPERATOR SEAT (SUSPENSION)........................50-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 POWER BOB-TACH .................................10-01, 50-01
ENGINE SPECIFICATIONS ...........................SPEC-01 POWER BOB-TACH BLOCK...................................20-01
ENGINE SPEED CONTROL .................................. 70-01 PRESSURE RELIEF VALVE ...................................80-01
EVAPORATOR........................................................ 80-01 PRESSURE SWITCH..............................................80-01
EVAPORATOR/HEATER UNIT ............................... 80-01
EXPANSION VALVE ............................................... 80-01
ALPHABETICAL INDEX (CONT’D)
RADIATOR.............................................................. 70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ...........................................................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...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR ...............................................60-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR 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
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .IX
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X HYDROSTATIC

SYSTEM
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 70-01 SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
S150, S160 Bobcat Loader

I 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:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers and foot 15. Inspect for fuel, oil or

pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct function of 16. Lubricate the loader.

the work lights

II Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Recommend to the owner
pressure. that all necessary corrections
be made before the machine
is returned to service.
21. Inspect for loose or broken

parts or connections.
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.

III Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• 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
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 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.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Skid-Steer Loader Operator Training Course is

available through your local dealer or at
IMPORTANT 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
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• 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.
SI SSL-0206 SM

V Service Manual
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.
Call Before You Dig

1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM

VI Service Manual
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler 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.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
• The operator cab, engine compartment, and engine

• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the 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 a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI SSL-0206 SM

VII Service Manual
SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 2

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 1
P-21821
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.

IX Service Manual
DELIVERY REPORT
Figure 3
B-16315
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].

X Service Manual
BOBCAT LOADER IDENTIFICATION
FRONT
LIGHTS
OPERATOR SEAT
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
BUCKET
STEPS
STEPS
■ BUCKET B-19880
● OPERATOR CAB
(ROPS / FOPS)
◆ REAR AUXILIARY LIFT ARM

QUICK COUPLERS SUPPORT DEVICE
LIFT ARM
REAR
GRILL 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.

XI Service Manual
SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 SAFETY &
MAINTENANCE
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 DRIVE
SYSTEM
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 ELECTRICAL
SYSTEM &
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 ANALYSIS
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing Oil From The Chaincase. . . . . . . . . . . . . . . . . 10-130-1
ENGINE
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2 SPECIFICATIONS
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . 10-120-1
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

10-01 Service Manual
SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . 10-151-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Figure 10-10-1
P-45481
B-7023A
Put a floor jack under the rear of the loader.
Lift the rear of the loader and install jackstands [Figure

10-10-2].
WARNING Figure 10-10-3
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
Procedure
Always park the loader on a level surface. P-45482
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.
NOTE: Make sure the jackstands do not touch the
Failure to use jackstands can allow the machine to
tires. Make sure tires clear the floor and any
fall or move and cause injury or death.
obstacles.
W-2017-0286

10-10-1 Service Manual
LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing Lift Arm Support Device
WARNING P-45481
Never work on a machine with the lift arms up unless 2

the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-45251
Put jackstands under the rear corners of the loader frame

WARNING (Inset) [Figure 10-20-1].
Service lift arm support device if damaged or if parts Disconnect the spring from the lift arm support device
are missing. Using a damaged lift arm support or retaining pin (Item 1). Support the lift arm support device
with missing parts can cause lift arms to drop (Item 2) [Figure 10-20-1] with your hand and remove the
causing injury or death. retaining pin.
Figure 10-20-2
P-45252
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [Figure 10-20-
2] 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.

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
P-45484
Remove the pin from the lift arm support device.
Connect the spring (Item 1) [Figure 10-20-4] from the lift
Raise the lift arms until the lift arm support device drops arm support device to the bracket below the lift arms.
onto the lift cylinder rod [Figure 10-20-3].
The operator must be in the operator's seat, with the seat
Lower the lift arms slowly until the lift arm support device belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
is held between the lift arms and lift cylinder [Figure 10- all the way.
20-3]. Stop the engine. Raise the seat bar, and move
both the pedals until both pedals lock. 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: The lift arm support device must be tight Raise the seat bar and move the pedals until both pedals
against the cylinder rod. The tabs of the lift lock.
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.
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
P-45481
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

P10564 P10563
J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available. 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.

OPERATOR CAB (CONT'D) Lowering The Operator Cab
Raising The Operator Cab (Cont’d) Figure 10-30-4
Figure 10-30-3
N-20120
P-45262
P-45261
Always stop the engine before raising or lowering the

cab.
WARNING NOTE: Always use the grab handles to lower the cab.
Never modify operator cab by welding, grinding, Pull down on the bottom of the operator cab until it stops
drilling holes or adding attachments unless at the latching mechanism [Figure 10-30-4].
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover Release the latching mechanism (Inset) [Figure 10-30-4]
and falling objects, and result in injury or death. and pull the cab all the way down.
W-2069-1299
Figure 10-30-5
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].
P10563
P10564 P10563
Install the plates and nuts [Figure 10-30-5] (both sides).
Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.

OPERATOR CAB (CONT’D) Figure 10-30-8
Emergency Exit
Figure 10-30-6
N-20171
Front Door (If Equipped)

P0660
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
The front opening on the operator cab and rear window used as an emergency exit. [Figure 10-30-8].
provide exits.
NOTE: If the loader has a Special Application Door
Rear Window (If Equipped) Kit installed, the window of the front door is
NOT an emergency exit.
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.
Push the window out with your foot [Figure 10-30-9] at
Exit through the rear of the operator cab [Figure 10-30- any corner of the window.
7].
Exit through the front door.

TRANSPORTING THE BOBCAT LOADER Figure 10-40-2
Procedure
WARNING N-19048 P-24785
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.
W-2058-0494
Figure 10-40-1
ALTERNATE FRONT TIE DOWN
N-18520
P-45989 P-45218
1
P-45215
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
• Lower the bucket or attachment to the floor.
Be sure the transport and towing vehicles are of
adequate size and capacity (See Capacities on Page • Stop the engine.
SPEC-10-4.), for weight of loader.).
• Engage the parking brake.
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader • Install chains at the front and rear loader tie down
to prevent the front end of the trailer from raising up. positions (Inset) [Figure 10-40-2].
• Fasten each end of the chain to the transport vehicle.

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.
The towing chain (or cable) must be rated at 1 & 1/2

times the weight of the loader (See LOADER
SPECIFICATIONS on Page SPEC-10-1.)

REMOTE START Figure 10-60-2
Procedure
Figure 10-60-1
P-24651
Figure 10-60-3
P16115
The tool listed below will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit

1
The remote start (Item 1) [Figure 10-60-1] 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: control handle linkage
neutral adjustment.
P-24653
Lift and block the loader. (See Procedure on Page 10-10-

1.)
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
Lift Arm Support Device on Page 10-20-1.)
Raise the operator cab (if required by the procedure).

(See Raising The Operator Cab on Page 10-30-1.)
Open the rear door of the loader.
Remove the plug (Item 1) [Figure 10-60-2] or disconnect

the attachment control harness (Item 1) [Figure 10-60-3]
if connected.

REMOTE START (CONT'D) Figure 10-60-5
Procedure (Cont'd)
WARNING 1
2
AVOID INJURY OR DEATH

With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
P-16116
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
The remote start tool (Item 1) has three rocker switches
(Item 2) [Figure 10-60-5].
Figure 10-60-4
P-24652
Connect the remote start tool to the engine harness

connector (Item 1) [Figure 10-60-4].
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.

REMOTE START (CONT'D)
Procedure (Cont'd)
Figure 10-60-6
2
3 1
P16118
The traction lock switch (Item 1) [Figure 10-60-6] 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

10-60-6] 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.
The auxiliary pressure release (Item 3) [Figure 10-60-6]

is used to release hydraulic pressure to the right hand
and/or rear auxiliary couplers ONLY.
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 COMPLETELY stopped.

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.
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
WARNING 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
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED ■ ■ ■

8-10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and damaged
components.
Engine Cooling System Clean debris from oil cooler, radiator & grill. Check coolant level COLDand add
premixed coolant as needed.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure
shown on sidewall of tire.
Seat Belt, Seat Bar, Control Check the condition of seat belt. Check the seat bar and control interlocks for
Interlocks and Seat Belt correct operation. Clean dirt and debris from moving parts. Clean or replace seat
Retractors belt retractors as needed.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
Indicators & Lights Check for correct operation of all indicators and lights.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Fuel Filter Remove the trapped water.
Heater Filters Clean or replace filters as needed during heating/cooling season.
Bobcat Interlock Control System Check the four (4) BICS™ indicator lights and functions are activated. See details
(BICS™) in this Manual.
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 oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls Check for correct operation. Repair or adjust as needed.
and Steering Levers
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See Wheel Nuts on Page ❏
10-170-1.)
Parking Brake Check operation.
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease two fittings.
Engine/Hydrostatic Drive Belt Check for wear or damage. Adjust as needed. *
Fan Drive Gearbox Check gear lube level. Add as needed.
Alternator Belt Check belt tension and adjust as needed.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^
Fuel Filter Replace the filter element.
Bobcat Interlock Control System Check the function of the lift arm by-pass control
(BICS™)
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter Replace the filter element. ●
Hydraulic Reservoir Replace the fluid
Final Drive Trans. (Chaincase) Replace the fluid
Case Drain Filters Replace the filters
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
■ Or every 12 months.

AIR CLEANER SERVICE Replacing Filter Element(s)
Checking OUTER FILTER
Figure 10-80-1 Figure 10-80-3
P-21769A P-31836
It is important to change the air filter element only when Remove the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. 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
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 10-80-

2] for two seconds.
If the filter element needs replacement, the CODE [01-

17] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (Item 2) [Figure 10-80-2].

AIR CLEANER SERVICE (CONT’D) Figure 10-80-6
Replacing Filter Element(s) (Cont’d)
Figure 10-80-5
P-43241
Remove the inner filter wing nut (Item 1) [Figure 10-80-

P-31837 6].
Figure 10-80-7
NOTE: Be sure all sealing surfaces are clean.
Install the new filter element and washer. Tighten the

wing nut [Figure 10-80-5].
NOTE: Be sure sealing washer is in place on each

wing nut [Figure 10-80-4].
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
P-31838
Only replace the inner filter element under the following
conditions:
Remove the inner filter (Item 1) [Figure 10-80-7].
• Replace the inner filter element every third time the
outer filter is replaced. Install a new filter and tighten the wing nut.
• 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.

ENGINE COOLING SYSTEM Figure 10-90-2
WARNING
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.
W-2019-1285
Check the cooling system every day to prevent over- P-45501

heating, loss of performance or engine damage.
Cleaning The Cooling System Raise the oil cooler. Clean the top of the radiator [Figure
10-90-2].
Figure 10-90-1
NOTE: Use low air pressure or low water pressure to
clean the radiator or damage to the radiator
fins may result.
Lower the oil cooler and air conditioning condenser (if

equipped).
Check cooling system for leaks.
Install the rear grill and close the rear door.
P-45101
Open the rear door and remove the rear grill.
Raise the air conditioning condenser (if equipped). (See

CONDENSER on Page 80-120-1.)
Use air pressure or water pressure to clean the top of the

oil cooler [Figure 10-90-1].
WARNING
Do not use your bare hands to remove debris from
the oil cooler. Cooling fins are sharp and may cause
injury.
W-2460-0303

ENGINE COOLING SYSTEM (CONT’D) Replacing the Coolant
Checking The Coolant Level
Figure 10-90-3
WARNING
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
P-45106 Figure 10-90-4
P-45102
Look at the side of the coolant recovery tank [Figure 10-

90-3]. Check the coolant level. The level markers are on
the side of the tank. Coolant must be at the bottom
P-45102
marker when the engine is cold; top marker when hot.
Install the rear grill and close the rear door before Open the rear door and remove the rear grill.
operating the loader.
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

ENGINE COOLING SYSTEM (CONT’D) Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
Replacing the Coolant (Cont’d)
Mix the coolant in a separate container. (See Capacities
KUBOTA V2203-M-DI on Page SPEC-10-4.)
Figure 10-90-5 One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34°F (-37°C) freeze protection.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Fill the radiator with the premixed coolant. Install the

radiator cap.
1
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.
Stop the engine.
Check the coolant level in the recovery tank when cool.

P-48512
Add coolant as needed.
Connect a hose to the engine block drain valve (Item 1) Install the rear grill and close the rear door.
[Figure 10-90-5]. Open the drain valve and drain the
coolant into a container.
KUBOTA V2003T-M-DIT (TURBO)
Figure 10-90-6
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.

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:
Temp. F°/ C° No. 2 No.1

+15° (-9° ) 100% 0%
Down to -20° / (-29° ) 50% 50%
Below -20° / (-29° ) 0% 100% 1
P-48074
Contact your fuel supplier for local recommendations.
Filling The Fuel Tank Open the rear door.
Remove the fuel fill cap (Item 1) [Figure 10-100-1]
WARNING Figure 10-100-2
Stop and cool the engine before adding fuel. NO WRONG

SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
WARNING
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 which can result in injury or death. B-19895
W-2103-1285
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 10-
100-1].

FUEL SYSTEM (CONT’D)
Fuel Filter
WARNING
Figure 10-100-3
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-2072-0496
2 Figure 10-100-4
1
3
P-45960
(See SERVICE SCHEDULE on Page 10-70-1), for the

service interval for removing water from, or replacing the
fuel filter.
Removing Water 1
2
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
P-48076
filter.
Replacing Element Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
housing.
Remove the filter element (Item 2) [Figure 10-100-3].
Squeeze the hand pump (priming bulb) (Item 2) [Figure
Clean the area around the filter housing. Put clean oil on 10-100-4] until fuel flows from the vent with no air
the seal of the new filter element. Install the fuel filter, and bubbles.
hand tighten.
Close the vent (Item 1) [Figure 10-100-4] on the fuel
Remove the air from the fuel system. (See Below.) filter housing.
Removing Air From The Fuel System Open the vent (Item 3) [Figure 10-100-4] on the fuel
injection pump.
After replacing the filter element or when the fuel tank has
run out of fuel, the air must be removed from the fuel Squeeze the hand pump (priming bulb) (Item 2) [Figure
system before starting the engine. 10-100-4] until the pump feels solid.
Tighten the vent plug (Item 3) [Figure 10-100-4].
Start the engine.
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.

ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-110-1
P-48079
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. (See Oil Chart.)
Install the dipstick and close the rear door.

ENGINE LUBRICATION SYSTEM (CONT’D)
Replacing Oil And Filter

WARNING
service interval for replacing the engine oil and filter. Always clean up spilled fuel or oil. Keep heat, flames,
Run the engine until it is at operating temperature. Park Failure to use care around combustibles can cause
the loader on level ground and stop the engine. explosion or fire which can result in injury or death.
W-2103-1285
Open the rear door.

Figure 10-110-3
Figure 10-110-2
1
3
1 P-1575
P-48078
Put oil in the engine. (See Capacities on Page SPEC-10-

Remove the drain plug (Item 1) [Figure 10-110-2]. 4.) [Figure 10-110-3] (See Oil Chart on Page 10-110-1.)
Drain the oil into a container and dispose of used oil in an Start the engine and let it run for several minutes.
environmentally safe manner.
Stop the engine and check for leaks at the oil filter.
Remove the oil filter (Item 2) [Figure 10-110-2].
Remove the dipstick and check the oil level.
Clean the filter housing surface.
Add oil until it reaches the top mark (Item 1) [Figure 10-
Put clean oil on the new oil filter gasket. 110-3] on the dipstick. DO NOT OVERFILL.
Install the filter and hand tighten. Install the dipstick and the fill plug.
Install and tighten the drain plug. Close the rear door.
Remove the fill cap (Item 3) [Figure 10-110-2].

HYDRAULIC/HYDROSTATIC SYSTEM Install the fill cap. Replace the rear grill and close the rear
door.
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
Figure 10-120-1
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.
Install and hand tighten the filter element.
Close the rear door before operating the loader.
Replacing Hydraulic Fluid

N-18445

service interval.
Use only recommended fluid in the hydraulic system.
(See HYDRAULIC/HYDROSTATIC FLUID The fluid must be replaced if it becomes contaminated or
SPECIFICATIONS on Page SPEC-50-1.) after major repairs. If the fluid is replaced, the hydrostatic
filter and both case drain filters must be replaced.
Stop the loader on a level surface.
Use only recommended fluid in the hydraulic system.
Lower the lift arms and tilt the Bob-Tach fully back. (See HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-50-1.)
Stop the engine.
Check fluid level in the sight gauge [Figure 10-120-1].
Lower the lift arms and tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-2
Check fluid level in the sight gauge [Figure 10-120-1].
Figure 10-120-3
2
P-45243
1
1
P-45243 P-48866
Remove the fill cap (Item 1) [Figure 10-120-2].
P-45245
Add the fluid as needed to bring the level to the center of
the sight gauge [Figure 10-120-1].
Remove the reservoir fill cap (Item 1) [Figure 10-120-3].

HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Replacing Hydraulic Fluid (Cont’d)
WARNING
1
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 2
immediately.
W-2145-0290
P-45493
Disconnect the hose (Item 1) [Figure 10-120-5] from the

WARNING case drain filter located on the right drive motor. Use a
plug and cap on the filter and case drain hose to prevent
leakage.
Always clean up spilled fuel or oil. Keep heat, flames,
Remove the case drain filters (Item 2) [Figure 10-120-4]
Failure to use care around combustibles can cause
& [Figure 10-120-5] and drain the fluid into a container.
explosion or fire which can result in injury or death.
W-2103-1285
Replace the hydraulic/hydrostatic filter element. (See
Replacing Hydraulic/Hydrostatic Filter on Page 10-120-
Figure 10-120-4 1.)
Replace both hydrostatic motor case drain filters (Item 2)

[Figure 10-120-4] & [Figure 10-120-5].
Connect the hoses to the case drain filters.

2
P-45499
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1)
Drain the hydraulic fluid reservoir. (See Replacing

Hydraulic Fluid on Page 10-120-1)
Disconnect the hoses (Item 1) [Figure 10-120-4] 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.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Breather Cap
Replacing Hydraulic Fluid (Cont’d) Figure 10-120-7
Figure 10-120-6
P-34227
P-64317
correct replacement interval.
On SJC equipped loaders, the hydrostatic charge
pressure filter (Item 1) [Figure 10-120-6] is located on a Raise the operator cab. (See Raising The Operator Cab
bracket mounted to the transmission. on Page 10-30-1)
Remove and replace the hydrostatic charge pressure Remove the breather cap (Item 1) [Figure 10-120-7] and
filter. discard.
Add the correct fluid to the reservoir until the fluid level is Install new cap.
at the center of the sight gauge (Do not overfill).
Lower the operator cab. (See Lowering The Operator
Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2)
Cab on Page 10-30-2)
Start the engine and operate the loader hydraulic

controls.
Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing Oil From The Chaincase
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
P-64141
P-45496
Remove the chaincase cover (Item 1) [Figure 10-130-2]
(See CHAINCASE on Page 40-30-1.)
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the hydraulic/ Use a vacuum pump to extract the fluid from the chain
hydrostatic system. (See LOADER SPECIFICATIONS on case.
Page SPEC-10-1.)
To check the chaincase oil level, use the following

procedure:
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.

FAN GEARBOX
Checking And Maintaining
Figure 10-140-1
N-18460

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] to check the

lubricant level.
If the level is low, add SAE 90W gear lubricant through

the check plug hole until lubricant flows from the hole.
Lower the operator cab. (See Lowering The Operator

Cab on Page 10-30-2.)

BOB-TACH Figure 10-150-3
Inspection And Maintenance

Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1
In The Attachment 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].
1
If the wedge does not contact the lower edge of the hole
[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
1
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
N-16044A
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1) and (See LUBRICATION OF THE
The wedges must extend through the holes in the BOBCAT LOADER on Page 10-160-1.)
attachment mounting frame (Item 1) [Figure 10-150-1].

POWER BOB-TACH (OPTION) Figure 10-151-3
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 wedge does not contact the lower edge of the hole
B-15891 [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 Figure 10-151-4
until wedges are fully raised. Push and hold the BOB-
TACH "WEDGES DOWN" switch [Figure 10-151-1] until
the wedges are fully down. The wedges must move
freely.
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the

1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
N-16043A decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1) and (See LUBRICATION OF THE
BOBCAT LOADER on Page 10-160-1.)

LUBRICATION OF THE BOBCAT LOADER Figure 10-160-2
Procedure
Figure 10-160-1
2
P-45256
P-45255
Access
Hole
Lubricate the loader as specified in the (SERVICE
SCHEDULE Page 10-01), for the best performance of
the loader. P-45973
Record the operating hours each time you lubricate the

2. Lift Cylinder Base End (Both Sides)
Bobcat loader.
[Figure 10-160-2].
Always use a good quality lithium based multi-purpose
Figure 10-160-3
grease when you lubricate the loader. Apply lubricant
until extra grease shows.
Lubricate the following locations on the loader:
1. Lift Cylinder Rod End (Both Sides) [Figure 10-160-1] 3
N-18510
3. Tilt Cylinder Base End (Both Sides)

[Figure 10-160-3].

LUBRICATION OF THE BOBCAT LOADER (CONT’D) Figure 10-160-6
Procedure (Cont’d)
Figure 10-160-4
4
5
P-45253
8. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-6].

P-45975
Figure 10-160-7
4. Tilt Cylinder Rod End. [Figure 10-160-4].
5. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-4].
Figure 10-160-5
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].

TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
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
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
service interval to check the wheel nuts [Figure 10-170- Avoid excessive pressure which can rupture the tire and
1]. cause serious injury or death.
When installing wheel nuts, tighten to 160 ft.-lbs. (217 During inflation of the tire, check the tire pressure
Nm) torque. frequently to avoid over inflation.
When checking wheel nut torque, set the torque wrench
to 140 ft.-lbs. (190 Nm) torque to prevent over-tightening.
Rotating IMPORTANT
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 loader.
I-2057-0794
WARNING
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-2078-1285
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].

SPARK ARRESTOR MUFFLER
Cleaning Procedure
WARNING
Never use machine in atmosphere with explosive
IMPORTANT dust or gases or where exhaust can contact

flammable material. Failure to obey warnings can
cause injury or death.
This loader is factory equipped with a U.S.D.A. W-2068-1285
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark
Figure 10-180-1
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation.
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.
Make reference to local laws and regulations for 1

spark arrestor requirements.
I-2022-0595
P-45498
WARNING (See SERVICE SCHEDULE on Page 10-70-1), for

service interval for cleaning the spark arrestor muffler.
When the engine is running during service, the
steering levers must be in neutral and the parking
Do not operate the loader with a defective exhaust
brake engaged. Failure to do so can cause injury or
system.
death.
W-2006-0284
Stop the engine. Open the rear door and remove the rear
grill.
Remove the plug (Item 1) [Figure 10-180-1] from the

WARNING bottom of the muffler.
Start the engine and run for about ten seconds while a
When an engine is running in an enclosed area, fresh
second person, wearing safety glasses, holds a piece of
air must be added to avoid concentration of exhaust
wood over the outlet of the muffler.
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
This will force contaminants out through the cleanout
gases which can kill without warning.
W-2050-1285 hole.
Stop the engine.

WARNING Install the rear grill and close the rear door.
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285

HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-90-4 HYDRAULIC
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2 SAFETY
SYSTEM &
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . 20-90-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . 20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2 ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Base End Pivot Pin Replacement . . . . . . . . . . . . . . . . . . . 20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ENGINE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6 SERVICE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2
Rod End Pivot Pin Bushing And Seal Replacement . . . . . 20-21-4
SPECIFICATIONS
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . 20-130-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Checking The High Flow Relief Valve . . . . . . . . . . . . . . . 20-100-1
High Flow Relief Valve Adjustment Procedure . . . . . . . . 20-100-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8

HYDRAULIC SYSTEM (CONT’D)
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 By-Pass 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 & 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

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 By-Pass 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
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . 20-40-7
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . . . 20-40-6
BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-40-8
BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-40-9
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-11
Lift And Tilt Lock Block Removal And Installation . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26

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 By-Pass 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 & 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

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1

Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
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

HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . 20-63-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-63-9
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . 20-63-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . 20-63-2
Test The Output Of The Hydraulic Pump (High Flow) . . . . 20-63-4
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-62-7
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . 20-62-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . 20-62-2
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . 20-50-1

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . 20-110-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS
OTHERWISE SPECIFIED.

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BOBCAT S150 SKID STEER LOADER Service Repair Manual SN 526911001 & Above PDF

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BOBCAT S150 SKID STEER LOADER Service Repair Manual SN 526911001 & Above PDF

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Service

CORRECT CORRECT CORRECT

B-10731a B-15590 B-15591

WRONG WRONG WRONG

B-15592 B-15593 B-15599

B-15600 B-15601 B-6589

ADVANCED CONTROL SYSTEM (ACS) FAN GEARBOX .......................................................10-01

TEMPERATURE/PRESSURE ................................ 80-01

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

S150, S160 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

4. The seat bar must be 12. Safety treads must be in good

6. Machine signs must be 14. Check hydraulic fluid level,

7. Steering levers and foot 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

S150, S160 Bobcat Loader

21. Inspect for loose or broken

S150, S160 Bobcat Loader

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

S150, S160 Bobcat Loader

The dealer and owner/operator review the recommended

Call Before You Dig

S150, S160 Bobcat Loader

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

S150, S160 Bobcat Loader

Always use the serial number of the loader when Figure 2

The engine serial number is located on the side of the

Loader Serial Number

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

Module 1. - Model / Engine

1. The four digit Model/Engine Combination Module

2. The five digit Production Sequence Number identifies

S150, S160 Bobcat Loader

The delivery report must be filled out by the dealer and

S150, S160 Bobcat Loader

◆ REAR AUXILIARY LIFT ARM

◆ Optional or Field Accessory (Not Standard Equipment)

S150, S160 Bobcat Loader

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

LUBRICATION OF THE BOBCAT LOADER. . . . . . . . . . . . . 10-160-1

Continued On Next Page

S150, S160 Bobcat Loader

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1