Bobcat S175 S185 Skid Steer Loader Service Manual 6901828-21416B320124.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Fire Prevention SERIAL NUMBER LOCATION Loader Serial Number Engine Serial Number DELIVERY REPORT BOBCAT LOADER IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE LOADER Procedure LIFT ARM SUPPORT DEVICE Installing Lift Arm Support Device Removing Lift Arm Support Device OPERATOR CAB Description Raising The Operator Cab Lowering The Operator Cab Emergency Exit TRANSPORTING THE BOBCAT LOADER Procedure TOWING THE LOADER Procedure REMOTE START Procedure SERVICE SCHEDULE Chart AIR CLEANER SERVICE Checking Replacing Filter Element(s) ENGINE COOLING SYSTEM Cleaning The Cooling System Checking The Coolant Level Replacing the Coolant KUBOTA V2203-EB KUBOTA V2003T-EB (TURBO) FUEL SYSTEM Fuel Specifications Filling The Fuel Tank Fuel Filter Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking Engine Oil Oil Chart Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Replacing Hydraulic Replacing Hydraulic Fluid Breather Cap FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Removing Oil From The Chaincase FAN GEARBOX Checking And Maintaining BOB-TACH Inspection And Maintenance POWER BOB-TACH (OPTION) Inspection And Maintenance LUBRICATION OF THE BOBCAT LOADER Procedure TIRE MAINTENANCE Wheel Nuts Rotating Mounting SPARK ARRESTOR MUFFLER Cleaning Procedure HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Tighten Procedures Troubleshooting Chart CYLINDER (LIFT) Checking Removal And Installation Identification Disassembly Assembly CYLINDER (TILT) Checking Removal And Installation Rod End Pivot Pin Bushing And Seal Replacement Base End Pivot Pin Replacement Identification Disassembly Assembly CYLINDER (POWER BOB-TACH) Checking Removal And Installation Identification Disassembly Assembly MAIN RELIEF VALVE Checking Adjustment Removal and Installation HYDRAULIC CONTROL VALVE (FOOT CONTROL) Removal And Installation BICS� Valve Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Removal And Installation BICS� Valve, Check Valve Removal And Installation BICS� Valve Lock Valve Removal And Installation BICS� Valve Solenoid Removal And Installation BICS� Valve Solenoid Testing Identification Chart Load Check Valve Main Relief Valve Port Relief Valve Anti-Cavitation Valve Anti-Cavitation Valve Rubber Boot Lift And Tilt Lock Block Removal And Installation Lift Spool and Detent Tilt Spool Removal And Installation Auxiliary Spool Removal And Installation Auxiliary Electric Solenoid Port-Auxiliary Section Cleaning And Inspection HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) Description Removal and Installation BICS� Valve Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Removal And Installation BICS� Valve, Check Valve Removal And Installation BICS� Valve Lock Valve Removal And Installation BICS� Valve Solenoid Removal And Installation BICS� Valve Solenoid Testing Actuator Removal And Installation Identification Chart (ACS) Lift Base End Restrictor Load Check Valve Main Relief Valve Port Relief Valve Anti-Cavitation Valve Anti-Cavitation Valve Tilt Spool Removal And Installation Lift Spool Removal And Installation Lift and Tilt Spool Disassembly And Assembly Auxiliary Spool Removal And Installation Auxiliary Electric Solenoid Port-Auxiliary Section Cleaning And Inspection LIFT ARM BY-PASS CONTROL VALVE Inspecting Removal and Installation Disassembly and Assembly HYDRAULIC PUMP Check The Output Of The Hydraulic Pump Without Power Bob-Tach Check The Output Of The Hydraulic Pump With Power Bob-Tach. Removal And Installation Identification Disassembly And Assembly HYDRAULIC PUMP (HI FLOW) Check The Output Of The Hydraulic Pump Without Power Bob-Tach Check The Output Of The Hydraulic Pump With Power Bob-Tach. Removal And Installation Identification Disassembly And Assembly HYDRAULIC FILTER HOUSING Removal and Installation HYDRAULIC FLUID RESERVOIR Fluid Removal Removal And Installation BUCKET POSITION VALVE Solenoid Removal And Installation Solenoid Testing Removal and Installation Disassembly And Assembly SELECT VALVE Checking The High Flow Pump Relief Valve Removal and Installation Disassembly And Assembly Solenoid Testing REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) Removal And Installation Disassembly And Assembly Solenoid Testing Inspection POWER BOB-TACH BLOCK Removal And Installation Disassembly And Assembly FRONT AUXILARY HYDRAULIC COUPLER BLOCK Removal and Installation Disassembly And Assembly HYDROSTATIC SYSTEM HYDROSTATIC SYSTEM INFORMATION Troubleshooting Chart Replenishing Valve Function HYDROSTATIC MOTOR Removal And Installation Parts Identification Disassembly Assembly Carrier Shaft Seal Replacement Carrier Parts Identification Carrier Disassembly Carrier Assembly CHARGE PRESSURE Sender Removal And Installation Checking Charge Pressure Adjusting HYDROSTATIC PUMP Replenishing Removal And Installation Parts Identification (Right Half) Parts Identification (Left Half) Hydraulic Pump Removal And Installation Pump Separation Disassembly Assembly DRIVE BELT Shield Removal And Installation Adjusting Drive Belt Replacement Tensioner Pulley Removal And Installation Tensioner Pulley Parts Indentification Tensioner Pulley Disassembly Tensioner Pulley Assembly OIL COOLER Removal and Installation DRIVE SYSTEM BRAKE Disk Removal And Installation Switch Operated Parking Brake DRIVE COMPONENTS Axle Seal Removal And Installation Axle Sprocket And Bearings Removal And Installation Chain Removal And Installation CHAINCASE Checking And Adding Oil Removing The Oil Front Cover Removal And Installation Center Cover Removal And Installation Rear Cover Removal And Installation MAIN FRAME SEAT BAR Removal And Installation Assembling Components Compression Spring Disassembly And Assembly OPERATOR CAB Gas Cylinder Removal And Installation Gas Cylinder Disassembly Removal And Installation OPERATOR SEAT Removal And Installation Seat Belt Removal And Installation OPERATOR SEAT (SUSPENSION) Removal And Installation Slide Rail Removal And Installation Cushion Removal And Installation Back Removal And Installation Shock Removal And Installation BOB-TACH Removal And Installation Bob-Tach Lever And Wedge Pivot Pin Bushing And Seal Replacement POWER BOB-TACH Removal And Installation Power Bob-Tach Lever And Wedge Pivot Pin Bushing And Seal Replacement LIFT ARM Removal And Installation Link Removal And Installation Stabilizer Bar Removal And Installation REAR GRILL Gas Cylinder Removal And Installation Removal And Installation REAR DOOR Removal And Installation Striker Removal and Installation Striker Disassembly and Assembly Adjusting The Striker Latch Removal and Installation FUEL TANK Removal And Installation Fuel Level Sender Fuel Fill Screen CONTROL PEDALS Removal And Installation Pedal Adjustment Crossbar Linkage Removal and Installation Lift Foot Pedal Linkage Removal and Installation Tilt Foot Pedal Linkage Removal and Installation CONTROL PEDALS (ACS) Foot Sensor Removal And Installation Foot Pedal Removal And Installation Foot Pedal Linkage Disassembly And Assembly CONTROL PANEL Removal and Installation Shock Removal And Installation Shaft Removal And Installation Shaft Disassembly And Assembly Linkage Removal And Installation Linkage Adjustment Linkage Neutral Adjustment CONTROL HANDLE Control Lever Removal And Installation Control Lever Boot CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL Components Identification Handle Sensor Removal And Installation Control Handle Removal and Installation Control Handle Disassembly and Assembly Control Lever Removal and Installation Control Lever Boot CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND Components Identification Handle Sensor Removal And Installation Control Handle Removal and Installation Control Handle Disassembly and Assembly Control Lever Removal and Installation Control Lever Boot ELECTRICAL SYSTEM ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Troubleshooting Chart Description Fuse Location Relay Switch Location BATTERY Removal And Installation Servicing Using A Booster Battery (Jump Starting) ALTERNATOR (90 AMP) Adjusting The Alternator Belt Alternator Identification Charging System Check Alternator Voltage Test Low Voltage Test High Voltage Test Removal And Installation Rectifier Continuity (Diode) Test Alternator Regulator Test Disassembly Stator Continuity Test Stator Ground Test Rotor Continuity Test Rotor Ground Test Assembly STARTER Checking Removal And Installation Parts Identification Disassembly and Assembly Inspection And Repair No Load Test INSTRUMENT PANEL Left Panel Right Panel (Standard) (With Key Switch) Right Panel - (Deluxe) (With Keyless Start) Option and Field Accessory Panels Removal And Installation Front Accessory Panel Removal And Installation LIGHTS Front Removal And Installation Rear Removal And Installation BOBCAT CONTROLLER Identification Chart (S Identification Chart (S Removal And Installation DIAGNOSTICS Service Codes BICS� SYSTEM Inspecting The BICS� Controller (Engine STOPPED - Key ON) Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON) Inspecting The Seat Bar Sensor (Engine RUNNING) Inspecting The Traction Lock (Engine RUNNING) Inspecting The Lift Arm By-Pass Control Additional Inspection For Loaders With Advanced Hand Controls (AHC) Troubleshooting Chart Troubleshooting Guide SEAT BAR SENSOR Troubleshooting Chart Test Removal And Installation BICS� Circuit Test TRACTION LOCK Troubleshooting Chart Inspecting Solenoid Removal And Installation Guide Removal Guide Installation ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL Components Identification Troubleshooting Guide Controller, Connector And Wire Identification ACS Controller Removal And Installation Handle Sensor Connector Switch Handle Removal Switch Handle Installation Actuators Disassembly and Assembly ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND Components Identification Troubleshooting Guide Controller, Connector And Wire Identification ACS Controller Removal And Installation Handle Sensor Connector Switch Handle Removal Switch Handle Installation Actuators Disassembly and Assembly Handle Lock Solenoid Removal And Installation Handle Lock Solenoid Disassembly And Assembly Handle Lock Solenoid Connector Calibration Of The ACS System Switchable Hand Hand Controls Only Calibration Procedure Foot Sensor Disassembly And Assembly Foot Sensor Connector Foot Lock Solenoid Removal And Installation Foot Lock Solenoid Connector ELECTRICAL Controls Identification Chart ENGINE SERVICE TROUBLESHOOTING Chart ENGINE SPEED CONTROL Removal And Installation Disassembly MUFFLER Removal And Installation AIR CLEANER Removal And Installation RADIATOR Removal And Installation COOLING FAN Drive Tension Pulley Removal And Installation Gearbox Blower Housing Grill Removal And Installation Blower Disassembly And Assembly Gearbox Parts Identification Gearbox Disassembly Gearbox Assembly Gearbox Checking Backlash ENGINE COMPONENTS AND TESTING Compression Checking Glow Plugs Checking Glow Plugs Removal And Installation Fuel Shut-Off Solenoid, Checking Fuel Shut-Off Solenoid, Adjusting Fuel Shut-Off Solenoid Removal And Installation Checking Fuel Injection Pump Removal And Installation Timing The Injection Pump Fuel Injector Removal And Installation Fuel Injector Checking Fuel Injector Disassembly Fuel Injector Assembly Valve Clearance Adjustment Rocker Arm And Shaft Checking Valve Timing, Checking ENGINE Removal And Installation Engine Mount Replacement FLYWHEEL AND HOUSING Flywheel Removal And Installation Ring Gear Removal And Installation Housing Removal And Installation RPM SENSOR Adjustment RECONDITIONING THE ENGINE-KUBOTA V2203-EB AND V2003T-EB (TURBO) Cylinder Head Removal And Installation Cylinder Head Disassembly And Assembly Cylinder Head Servicing Cylinder Head Top Clearance Checking The Valve Guide Reconditioning The Valve And Valve Seat Valve Spring Rocker Arm And Shaft Checking Timing Gearcase Cover Removal And Installation Idler Gear And Camshaft Removal And Installation Servicing The Camshaft Servicing The Idle Gear And Shaft Timing Gears Checking Backlash Fuel Camshaft Removal And Installation Fuel Camshaft Governor Crankshaft Gear Removal And Installation Oil Pump Removal And Installation Oil Pump Service Checking Engine Oil Pressure Relief Valve Piston And Connecting Rod Removal And Installation Servicing The Piston And Connecting Rod Servicing The Piston And Connecting Rod (Cont�d) Connecting Rod Alignment Crankshaft And Bearings Removal And Installation Servicing The Crankshaft And Bearings Checking The Cylinder Bore Water Pump Disassembly And Assembly TURBOCHARGER Troubleshooting Description Removal and Installation HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SYSTEM FLOW Principals Chart COMPONENTS Identification SAFETY Safety Equipment REGULAR MAINTENANCE Filter Elements Removal And Installation Compressor Drive Belt Inspection Cleaning The Condenser BASIC TROUBLESHOOTING Poor A Cleaning The A Compressor Drive Belt Inspection: Checking The Electrical System Engine Coolant By-Passing The Heater Valve Heater Valve Not Opening Or Closing GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Compressor Oil Check Component Replacement And Refrigeration Leaks SYSTEM TROUBLESHOOTING CHART Gauge Pressure Related Troubleshooting TEMPERATURE Chart AIR CONDITIONING SERVICE Chart SYSTEM CHARGING AND RECLAMATION Reclamation Procedure Charging Procedure With A Manifold Gauge Set Charging Procedure COMPRESSOR Removal And Installation Compressor Clutch Disassembly CONDENSER Removal And Installation RECEIVER Removal And Installation PRESSURE RELIEF VALVE Removal And Installation PRESSURE SWITCH Removal And Installation EVAPORATOR Removal And Installation Disassembly And Assembly THERMOSTAT Removal And Installation EXPANSION VALVE Removal And Installation EVAPORATOR Removal And Installation HEATER COIL Removal And Installation With A Removal And Installation Without A HEATER Removal And Installation Disassembly And Assembly Wire Connector Removal and Installation HEATER VALVE Removal And Installation Disassembly And Assembly SPECIFICATIONS LOADER SPECIFICATIONS Machine Dimensions Performance Controls Engine Hydraulic System Electrical Drive System Capacities Tires ENGINE SPECIFICATIONS - KUBOTA V2203-EB Fuel Injection Nozzles Fuel Injection Pump Cylinder Head Valves Valve Springs Valve Timing Rocker Arms Camshaft Tappet Cylinders Piston Rings Pistons Connecting Rod Oil Pump Crankshaft Timing Gear Thermostat Crankshaft Re-Grind Data ENGINE SPECIFICATIONS - KUOBTA V2003T-EB (TURBO) Fuel Injection Nozzles Fuel Injection Pump Cylinder Head Valves Valve Springs Valve Timing Rocker Arms Camshaft Tappet Cylinder Liner Piston Rings Pistons Connecting Rod Oil Pump Crankshaft Timing Gear Thermostat Crankshaft Re-Grind Data LOADER TORQUE Specifications TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts Torque For General Metric Bolts HYDRAULIC CONNECTION SPECIFICATIONS O-ring Face Seal Connection Straight Thread O-ring Fitting Tubelines And Hoses Flare Fitting O-ring Flare Fitting Port Seal Fitting HYDRAULIC FLUID SPECIFICATIONS Specifications CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion SMR Revision No: S175, S185-1 smr-2 . 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