Bobcat S160 Skid Steer Troubleshooting

The Bobcat S160 skid steer loader driveline system components: Kubota V2003 diesel engine with a rated power of 56 hp (41.7 kW) or Kubota V2607 diesel engine with a rated power of 61 hp (45.2 kW), and 1-speed or 2-speed transmission. The hydraulic system has a pump with a rated capacity of 16.9 gal/min (64 l/min). The system pressure is 3350 psi (231 bar). The Bobcat S160 is equipped with a radial-lift loader boom, 80 HSOC roller chains, and 10x16.5 standard tires. The skid steer has a max lift height of 114.5" (2905 mm) to hinge pin and dump height of 86.5" (2195 mm). The rated operating capacity is 1600 lbs (726 kg), and tipping load is 3200 lbs (1452 kg).

Engine Troubleshooting

Engine starts up hard or won't start

Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter plugging - Service the filter.
Clogged or burnt injection nozzle - Test injection nozzles and change if necessary.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is not correct - Adjust to proper valve clearance.
Fuel injection pump is faulty - Rebuild or install a new injection pump.

Engine starts but stalls immediately

Air cleaner is clogged - Install new air cleaner element.
Fuel filter element is clogged - Install new filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Defective or clogged fuel injectors - Inspect fuel injectors and change as required.
Fuel injection pump is faulty - Repair or change injection pump.

Engine stalls while running

Low coolant temperature - Warm up engine as required.
Clogged fuel filter - Clean the filter or install new filter element.
Air trapped in fuel system - Bleed air.
Defective injection nozzle - Replace injection nozzles.
Fuel injection pump timing is wrong - Adjust according to specifications.

Engine stalls when idling

Low idle speed set incorrectly - Adjust as required.
Fuel injection pump malfunction - Rebuild or replace pump.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Excessive valve clearance - Have it adjusted.

Engine power is too low

Dirty air filter - Clean or replace element.
Dirty or faulty injection nozzles - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is wrong - Adjust to proper pressure.
The valve clearance is not adjusted - Adjust to proper valve clearance.
Low idle speed set incorrectly - Correct the settings.
Dirty fuel hoses or lines - Clean fuel system lines and hoses.
Cylinder-head gasket is leaking - Replace cylinder head gasket.
Defective or worn piston rings - Change piston rings.

Engine is overheated

Insufficient coolant fluid - Refill to the correct level and inspect system for leaks.
Not enough engine oil - Fill up the oil to required level.
Dirty radiator fins or defective radiator cap - Clean radiator or replace cap.
Fan belt is loose or defective - Change the fan belt.
Diesel engine overloaded - Reduce engine load.

Oil pressure too low

Engine oil level low - Fill the crankcase with oil.
Clogged oil filter element - Clean or replace engine oil filter element.
Incorrect engine oil Use the specified type of engine oil.
Incorrect oil clearance in crankshaft bearing - Bearing replacement required.
Oil pump failure - Repair or change.

Engine knocking sound or abnormal noise

Not enough engine oil - Fill up the oil to required level.
Low coolant temperature - Warm up the engine.
Wrong setting of fuel injection pump timing - Adjust according to specifications.
Improperly adjusted low idle speed - Adjust as required.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Connecting rod misalignment or failure - Alignment procedure or replacement is required.
Pistons are worn or scored - Pistons replacement required.

Drive System Troubleshooting

Drive system doesn't function in one direction or either direction

Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.
Drive chain failure - Check drive chain and change faulty components.
Damaged input drive shaft - Repair or replace drive shaft.
Relief valve is defective - Repair or replace.
Plugged suction line or hydraulic filter - Service suction line or replace hydraulic filter.
Foot or hand controls are damaged - Repair or change.
Drive motor or pump is defective - Inspect and replace as necessary.

Low power

Dirty hydraulic oil filter - Replace or service hydraulic filter.
Opened or worn relief valve - Close or replace relief valve.
Defective or worn transmission parts - Check and change faulty components.
Worn input drive shaft - Repair or replace faulty drive shaft.
Air in the hydraulic system - Bleed hydraulic system.

Overheated drive system

Low hydraulic fluid level - Add fluid as required.
Hydraulic fluid filter is clogged - Check, clean, or replace as required.
Stuck relief valve - Change or repair defective relief valve.
Defective drive pump or hydraulic motor - Inspect and replace as necessary.
Hydraulic oil cooler is plugged - Clean the cooling fins.
Transmission overloading - Reduce the load.

Excessive noise

Improper oil viscosity - Drain and refill with correct oil.
Air in hydraulic system - Need to bleed air.
Defective drive pump or hydraulic motor - Inspect and replace as necessary.
Mechanical components of drive system are damaged or worn - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system overheating

Hydraulic pressure is not correct - Hydraulic pressure must be set correctly.
Main relief valve is defective or unadjusted - Set up or change the relief valve.
Hydraulic oil is contaminated - Change hydraulic oil.
Hydraulic oil level is low - Fill the hydraulic system with oil.
Worn hydraulic oil pump - Replace or repair pump if necessary.

Boom does not raise or lower

Damaged lift controls - Inspect and repair if necessary.
Damaged hydraulic oil pump - Repair or change pump if required.
Faulty hydraulic control valve - Repair or change the valve.
Hydraulic cylinder is defective - Repair or replace hydraulic cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket won't move

Bucket controls are faulty - Repair or replace.
Hydraulic pump is broken - Repair or change pump if required.
Faulty hydraulic control valve - Repair or change the valve.
Hydraulic bucket cylinder is defective - Repair or install a new cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket or lift arm moves slowly

Hydraulic pump is faulty - Check pump flow and change pump if necessary.
Hydraulic cylinder leaking - Correct leakage by changing the seals.
Hydraulic fluid is insufficient - Add fluid as required.
Defective or not adjusted hydraulic control valve - Repair or set correctly.
Hydraulic system loosing pressure - Adjust it correctly.

Jerky operation of the bucket or boom

Hydraulic system is leaking air - Bleed hydraulic system.
Hydraulic oil filter element is dirty - Clean or replace the filter.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Cylinder tube or rod scoring - Change defective component.

Hydraulic pump is noisy

Insufficient oil level or leaking hydraulic system - Add hydraulic oil or correct system leaks.
Dirty hydraulic filter - Clean or change the filter.
Dirty suction line - Suction line needs to be cleaned.
Pump is sucking air - Bleed air from hydraulics.
Faulty pump components - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery is not charging

Corroded or loose electrical wire connections - Clean or tighten wiring connections.
Battery terminal connectors are faulty - Replace terminal connectors.
Battery is defective - Replace the battery.
Belt is worn or loose - Change belt or adjust belt tension.

Starter cranks slow

Low battery voltage - Battery is drained, charge it.
Battery drains quickly - Service or change the battery.
Wires are disconnected or battery terminals are corroded - Connect cables correctly or replace terminals.

Starter doesn't crank

Battery is drained or defective - Change or recharge battery.
Battery cables are disconnected or incorrectly connected - Check cables and connect as needed.
Battery capacity is low - Battery needs to be recharged.
Starter motor is damaged - Repair or replace starter.