Bobcat S100 Skid-Steer Loader Service Manual 6987401 – PDF DOWNLOAD

Description

Bobcat S100 Skid-Steer Loader Service Manual 6987401 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S100 Skid-Steer Loader Service Manual 6987401 – PDF DOWNLOAD

Language : English
Pages : 734
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S100 Skid-Steer Loader Service Manual 6987401 – PDF DOWNLOAD

S/N AB6420001 & Above
S/N A8ET20001 & Above
S/N B4KH11001 & Above

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:

TABLE OF CONTENTS:

Bobcat S100 Skid-Steer Loader Service Manual 6987401 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Installing 25
Removing 26
OPERATOR CAB 27
Description 27
Raising 27
Lowering 29
Cab Door Sensor 30
Special Applications Kit 31
Special Applications Kit Inspection And Maintenance 31
TRANSPORTING THE LOADER ON A TRAILER 33
Loading And Unloading 33
Fastening 33
TOWING THE LOADER 35
Procedure 35
REMOTE START TOOL KIT – MEL1563 37
Remote Start Tool – MEL1563 37
Service Tool Harness Control – MEL1565 38
Service Tool Harness Communicator – MEL1566 39
Remote Start Procedure 40
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 43
Description 43
Remote Start Tool (Service Tool) – 7022042 44
Loader Service Tool Harness – 6689747 45
Computer Service Tool Harness – 6689746 46
Remote Start Procedure 47
SERVICE SCHEDULE 51
Chart 51
AIR CLEANER SERVICE 53
Replacing Filter Elements 53
ENGINE COOLING SYSTEM 55
Cleaning 55
Checking Level 55
Removing And Replacing Coolant 56
FUEL SYSTEM 57
Fuel Specifications 57
Biodiesel Blend Fuel 57
Filling The Fuel Tank 58
Fuel Filter 59
Removing Air From The Fuel System 59
ENGINE LUBRICATION SYSTEM 61
Checking And Adding Engine Oil 61
Engine Oil Chart 61
Removing And Replacing Oil And Filter 62
HYDRAULIC / HYDROSTATIC SYSTEM 63
Checking And Adding Fluid 63
Hydraulic / Hydrostatic Fluid Chart 63
Removing And Replacing Hydraulic Fluid 64
Removing And Replacing Hydraulic / Hydrostatic Filter 65
Removing And Replacing Case Drain Filters 66
Removing And Replacing Hydraulic Charge Filter 67
Breather Cap 67
FINAL DRIVE TRANSMISSION (CHAINCASE) 69
Checking And Adding Oil 69
Removing And Replacing Oil 69
BOB-TACH (HAND LEVER) 71
Inspection And Maintenance 71
BOB-TACH (POWER) 73
Inspection And Maintenance 73
LUBRICATING THE LOADER 75
Lubrication Locations 75
TIRE MAINTENANCE 77
Wheel Nuts 77
Rotating 77
Mounting 77
SPARK ARRESTER MUFFLER 79
Cleaning Procedure 79
PIVOT PINS 81
Inspection And Maintenance 81
LOADER STORAGE AND RETURN TO SERVICE 83
Storage 83
Return To Service 83
STOPPING THE ENGINE AND LEAVING THE LOADER 85
Procedure 85
EMERGENCY EXIT 87
Rear Window 87
Front Door 87
SEAT BELT 89
Inspection And Maintenance 89
HYDRAULIC SYSTEM 91
HYDRAULIC / HYDROSTATIC SCHEMATICS 95
HYDRAULIC SYSTEM INFORMATION 99
Glossary Of Hydraulic / Hydrostatic Symbols 99
Troubleshooting 103
CYLINDER (LIFT) 105
Testing 105
Removal And Installation 106
Parts Identification 107
Disassembly And Assembly 108
CYLINDER (TILT) 111
Testing 111
Removal And Installation 111
Rod End Pivot Pin Bushing And Seal Removal And Installation 113
Base End Pivot Pin Removal And Installation 113
Parts Identification 114
Disassembly And Assembly 115
CYLINDER (BOB-TACH) 119
Testing 119
Removal And Installation 120
Parts Identification 121
Disassembly And Assembly 122
MAIN RELIEF VALVE 125
Description 125
Testing 125
Adjusting 126
Removal And Installation 126
MAIN RELIEF VALVE (SJC) 127
Description 127
Testing 127
Adjusting 128
Removal And Installation 129
HYDRAULIC CONTROL VALVE 131
Description 131
Removal And Installation 131
Identification Chart 133
BICS™ Load Check Valve Removal And Installation 134
Load Check Valve Removal And Installation (Tilt And Auxiliary) 135
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 136
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 137
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 137
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 138
Port Relief / Anti-Cavitation Valve Removal And Installation 138
Plug Removal And Installation 139
Rubber Boot Removal And Installation 139
End Cap / Spool Lock Block Removal And Installation 140
Lift Spool And Detent Removal And Installation 140
Tilt Spool Removal And Installation 149
Auxiliary Spool Removal And Installation 152
Solenoid Removal And Installation 159
Lock Valve Removal And Installation 160
Lift Arm Bypass Orifice Removal And Installation 162
Main Relief Valve Removal And Installation 163
HYDRAULIC CONTROL VALVE (SJC) 165
Description 165
Removal And Installation 165
Actuator Removal And Installation 168
Identification Chart 171
BICS™ Load Check Valve Removal And Installation 172
Load Check Valve Removal And Installation (Tilt And Auxiliary) 173
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 174
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 175
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 175
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 176
Port Relief / Anti-Cavitation Valve Removal And Installation 176
Plug Removal And Installation 177
End Cap Block Removal And Installation 178
Lift Spool And Detent Removal And Installation 178
Tilt Spool Removal And Installation 182
Auxiliary Spool Removal And Installation 184
Auxiliary Solenoid Removal And Installation 186
Solenoid Removal And Installation 187
Lock Valve Removal And Installation 188
Lift Arm Bypass Orifice Removal And Installation 189
Main Relief Valve Removal And Installation 190
Check Valve Removal And Installation 190
LIFT ARM BYPASS CONTROL VALVE 193
Description 193
Testing 193
Removal And Installation 193
Disassembly And Assembly 195
HYDRAULIC PUMP 197
Description 197
Pump Test At Quick Couplers 197
Direct Pump Test (Standard Section) 198
Direct Pump Test (Charge Section) 199
Removal And Installation 202
Hydraulic Pump Startup 204
Parts Identification 205
Disassembly And Assembly 206
HYDRAULIC PUMP (SJC) 211
Description 211
Pump Test At Quick Couplers 211
Direct Pump Test (Standard Section) 212
Removal And Installation 213
Hydraulic Pump Startup 214
Parts Identification 215
Disassembly And Assembly 216
HYDRAULIC / HYDROSTATIC FILTERS 221
Description 221
Housing Removal And Installation 221
Charge Filter Housing Removal And Installation 222
HYDRAULIC FLUID RESERVOIR 223
Description 223
Removal And Installation 223
Hydraulic Fluid Screen 225
OIL COOLER 227
Description 227
Removal And Installation 227
BUCKET POSITION VALVE 229
Description 229
Solenoid Removal And Installation 229
Solenoid Testing 230
Removal And Installation 230
Disassembly And Assembly 233
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 235
Description 235
Removal And Installation 235
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC) 237
Description 237
Removal And Installation 238
Disassembly And Assembly (FFI/FI) 238
Disassembly And Assembly (FFH/FH) 240
AUXILIARY HYDRAULIC INTERLOCK VALVE 243
Description 243
Removal And Installation 243
Disassembly And Assembly 244
BOB-TACH (POWER) BLOCK 245
Description 245
Removal And Installation 245
Disassembly And Assembly 247
HYDROSTATIC SYSTEM 251
HYDROSTATIC SYSTEM INFORMATION 253
Description 253
Troubleshooting 254
HYDROSTATIC MOTOR 255
Description 255
Removing And Replacing Oil 255
Removal And Installation 255
Parts Identification 257
Disassembly And Assembly 258
CHARGE PRESSURE 263
Description 263
Testing 263
Sender Removal And Installation 264
Adjusting 265
HYDROSTATIC PUMP 267
Description 267
Replenishing / High Pressure Relief Valve Removal And Installation 267
Removal And Installation 268
Hydrostatic Pump Startup 270
Parts Identification 271
Disassembly 272
Assembly 277
HYDROSTATIC PUMP (SJC) 283
Description 283
Hydraulic Controller Removal And Installation 284
Removal And Installation 285
Hydrostatic Pump Startup 287
Parts Identification 288
High Pressure Relief And Bypass Valve 289
Charge Relief Valve 290
Disassembly And Assembly 291
Mechanical Neutral Adjustment 304
Hydraulic Controller Neutral Adjustment 306
DRIVE BELT 311
Description 311
Shield Removal And Installation 311
Adjusting 311
Belt Removal And Installation 312
Tensioner Pulley Removal And Installation 312
Tensioner Pulley Disassembly And Assembly 312
CASE DRAIN FILTER 313
Description 313
Disassembly And Assembly 313
DRIVE SYSTEM 315
BRAKE 317
Description 317
Disc Removal And Installation 317
DRIVE COMPONENTS 319
Description 319
Axle Seal Removal And Installation 320
Axle, Sprocket And Bearings Removal And Installation 322
Chain Removal And Installation 326
CHAINCASE 329
Description 329
Front Cover Removal And Installation 329
Center Cover Removal And Installation 330
MAINFRAME 333
SEAT BAR 337
Description 337
Removal And Installation 337
Disassembly And Assembly 338
Compression Spring Disassembly And Assembly 339
OPERATOR CAB 341
Gas Cylinder Removal And Installation 341
Gas Cylinder Bracket Disassembly And Assembly 343
Removal And Installation 344
OPERATOR SEAT 347
Removal And Installation 347
Seat Belt Removal And Installation 347
OPERATOR SEAT (SUSPENSION) 349
Removal And Installation 349
Slide Rail Removal And Installation 350
Seat Belt Removal And Installation 350
Lower Cushion Removal And Installation 351
Back Cushion Removal And Installation 351
Shock Removal And Installation 352
3-Point Seat Belt Removal And Installation 352
BOB-TACH (HAND LEVER) 355
Description 355
Removal And Installation 355
Lever And Wedge Disassembly And Assembly 357
Bob-Tach Stops 359
Pivot Pin Bushing And Seal Removal And Installation 360
BOB-TACH (POWER) 361
Description 361
Removal And Installation 361
Lever And Wedge Disassembly And Assembly 363
Bob-Tach Stops 365
Pivot Pin Bushing And Seal Removal And Installation 365
LIFT ARMS 367
Removal And Installation 367
REAR GRILLE 373
Removal And Installation 373
REAR DOOR 375
Removal And Installation 375
Striker Removal And Installation 376
Striker Disassembly And Assembly 376
Striker (Adjusting) 377
Latch Removal And Installation 378
FUEL TANK 379
Removal And Installation 379
Fuel Level Sender Removal And Installation 380
Fuel Fill Screen Removal And Installation 380
Fuel Pickup Screen 380
CONTROL PEDALS AND LINKAGES 381
Description 381
Pedal Removal And Installation 381
Linkage Removal And Installation 382
Pedal (Adjusting) 382
CONTROL PANEL 383
Description 383
Removal And Installation 384
Shaft Removal And Installation 387
Shaft Disassembly And Assembly 387
Shock Removal And Installation 388
Linkage Removal And Installation 388
Pintle Arm Removal And Installation 389
Pintle Arm Disassembly And Assembly 392
Linkage Neutral (Adjusting) 393
Linkage Travel (Adjusting) 396
CONTROL PANEL (SJC) 401
Description 401
Removal And Installation 401
CONTROL HANDLE / LEVER 403
Description 403
Lever Removal And Installation 403
Boot Removal And Installation 403
CONTROL HANDLE / LEVER (SJC) 405
Description 405
Joystick Testing 405
Joystick Removal And Installation 406
Joystick Mount Removal And Installation 407
WINDOW (REAR) 409
Removal 409
Installation (Split Molding) 410
Installation (Continuous Molding) 411
WINDOW (TOP) 413
Removal And Installation 413
WINDOW (SIDE) 415
Removal And Installation 415
WINDOW (CAB DOOR) 417
Removal (Standard Window) 417
Installation (Standard Window) 418
Removal And Installation (Special Applications Window) 419
CAB DOOR 421
Description 421
Removal And Installation 421
Aligning 422
Adjusting 423
Checking Operation 423
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR) 425
Description 425
Removal And Installation 425
Aligning 426
Adjusting 427
Checking Operation 427
ELECTRICAL SYSTEM AND ANALYSIS 429
ELECTRICAL SCHEMATICS 433
ELECTRICAL SYSTEM INFORMATION 447
Glossary Of Electrical Symbols 447
Standard Cab Harness Connectors 450
Deluxe Cab Harness Connectors 451
Mainframe Harness Connectors 452
Description 453
Troubleshooting 454
Fuse And Relay Location / Identification 455
Solenoid Testing 456
BATTERY 457
Removal And Installation 457
Servicing 458
Using A Booster Battery (Jump Starting) 459
ALTERNATOR 461
Belt Adjustment 461
Belt Replacement 461
Charging System Inspection 462
Alternator Voltage Testing 463
Low Voltage Testing 463
High Voltage Testing 464
Removal And Installation 464
Parts Identification 466
STARTER 467
Testing 467
Removal And Installation 468
Parts Identification 469
INSTRUMENT PANELS 471
Left Panel 471
Standard Key Panel 473
Keyless Start Panel 473
Deluxe Instrumentation Panel 474
Side Panel 475
Front Panel 475
Front Panel Removal And Installation 476
Removal And Installation (Left And Right) 477
Key Switch Removal And Installation 477
Alarm Removal And Installation 478
LIGHTS 479
Front Removal And Installation 479
Rear Removal And Installation 479
Cab Light Removal And Installation (Earlier Models) 480
Cab Light Removal And Installation (Later Models) 480
BOBCAT CONTROLLER (GATEWAY) 481
Description 481
Connector Identification 482
Removal And Installation 485
BOBCAT CONTROLLER (AUXILIARY) (SJC) 487
Description 487
Connector Identification 488
Removal And Installation 491
BOBCAT CONTROLLER (ACS) (SJC) 493
Description 493
Connector And Wire Identification 494
Removal And Installation 495
BOBCAT CONTROLLER (DRIVE) (SJC) 497
Description 497
Connector Identification 498
Removal And Installation 500
DIAGNOSTIC SERVICE CODES 503
Viewing Service Codes 503
Service Codes List 504
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 509
Description 509
Inspecting The BICS™ (Engine STOPPED – Key ON) 510
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 510
Inspecting The Seat Bar Sensor (Engine RUNNING) 510
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 510
Inspecting The Lift Arm Bypass Control 510
Inspecting Deactivation Of Lift And Tilt Functions (SJC) 510
Troubleshooting 511
SEAT BAR SENSOR 513
Description 513
Troubleshooting 513
Testing 514
Removal And Installation 515
Bobcat Interlock Control System (BICS™) Circuit Test 518
TRACTION LOCK 519
Description 519
Troubleshooting 519
Removal And Installation 520
Inspecting 523
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 525
Identification Chart 525
SERVICE PC (LAPTOP COMPUTER) 529
Connecting Remote Start Tool 529
Connecting Remote Start Tool (Service Tool) 529
CALIBRATION 531
Description 531
Actuator Testing 531
Lift And Tilt Calibration (SJC) 533
Hydrostatic Pump Calibration (SJC) 535
STEERING DRIFT COMPENSATION 541
Description 541
Operation 541
FLYWHEEL RPM SENSOR 543
Description 543
Adjusting 543
CONTROL PANEL SETUP 545
Right Panel Setup (Deluxe Instrumentation Panel) 545
Attachment Control Information (Deluxe Instrumentation Panel) 546
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 547
Password Description 547
Changing The Owner Password 547
Changing The User Passwords 548
Password Lockout Feature 548
PASSWORD SETUP (KEYLESS START PANEL) 549
Password Description 549
Changing The Owner Password 549
Password Lockout Feature 549
MAINTENANCE CLOCK 551
Description 551
Setup 552
Reset 555
BACK-UP ALARM SYSTEM 557
Description 557
Inspecting 557
Adjusting Switch Position 558
Troubleshooting (Standard) 559
Troubleshooting (Joystick) 560
Alarm Removal And Installation 561
Switch Removal And Installation 561
ENGINE SERVICE 563
ENGINE INFORMATION (S/N A8ET20001 & ABOVE) 565
Description 565
Specifications 566
Torque Values 573
Troubleshooting 574
Engine Removal And Installation 575
Engine Mount Replacement 587
Compression – Testing 588
ENGINE INFORMATION (S/N B4KH11001 & ABOVE) 589
Description 589
Torque Values 593
Troubleshooting 594
Engine Removal And Installation 595
Engine Mount Replacement 607
Compression – Testing 608
ENGINE SPEED CONTROL 609
Removal And Installation 609
ENGINE SPEED CONTROL (SJC) 611
Removal And Installation 611
Disassembly And Assembly 613
MUFFLER 615
Removal And Installation 615
AIR CLEANER 617
Housing Removal And Installation 617
ENGINE COOLING SYSTEM 619
Radiator Removal And Installation 619
Fan Removal And Installation 620
Water Pump Removal And Installation 621
Water Pump Disassembly And Assembly 621
Thermostat Housing Removal And Installation 622
Thermostat – Inspecting 622
LUBRICATION SYSTEM 623
Oil Pan Removal And Installation 623
Oil Pump Removal And Installation 623
Oil Pump Inspection 624
Engine Oil Pressure – Testing 625
FUEL SYSTEM 627
Fuel Shutoff Solenoid – Checking 627
Fuel Shutoff Solenoid Removal And Installation 627
Fuel Injection Pump – Checking 628
Fuel Injection Pump Removal And Installation 629
Governor Disassembly And Assembly 631
Fuel Camshaft Removal And Installation 632
Fuel Injection Pump – Timing 633
Fuel Injector Removal And Installation 635
Fuel Injector Nozzle Pressure – Checking 636
Nozzle Spray Condition 637
Valve Seat Tightness 638
CYLINDER HEAD 639
Glow Plug – Testing 639
Glow Plug Removal And Installation 640
Valve Clearance Adjustment 640
Valve Timing – Checking 641
Cylinder Head Removal And Installation 642
Cylinder Head Disassembly And Assembly 644
Cylinder Head – Servicing 644
Cylinder Head Top Clearance 645
Valve Guide – Checking 645
Reconditioning The Valve And Valve Seat 646
Valve Spring 648
Valve Tappets 649
Rocker Arm And Shaft – Checking 649
Push Rod Alignment – Checking 650
CRANKSHAFT AND PISTONS 651
Piston And Connecting Rod Removal And Installation 651
Piston And Connecting Rod – Servicing 652
Cylinder Bore – Checking 655
Connecting Rod Alignment 655
Crankshaft And Bearings Removal And Installation 656
Crankshaft And Bearings – Servicing 658
CAMSHAFT AND TIMING GEARS 663
Timing Gearcase Cover Removal And Installation 663
Timing Gears Backlash – Checking 665
Idler Gear And Shaft Removal And Installation 665
Camshaft – Servicing 666
Idler Gear And Shaft Servicing 668
FLYWHEEL AND HOUSING 669
Flywheel Removal And Installation 669
Ring Gear Removal And Installation 669
Housing Removal And Installation 670
HEATER 673
HEATER SYSTEM 675
Description 675
REGULAR MAINTENANCE 677
Filters 677
Heater Coil 677
TROUBLESHOOTING 679
Blower Motor Does Not Operate 679
Blower Motor Operators Normally, But Air Flow Is Insufficient 679
Electrical System 680
Engine Coolant Bypassing The Heater Valve 684
Heater Valve Not Opening Or Closing 684
HEATER UNIT 687
Removal And Installation 687
HEATER COIL 689
Removal And Installation 689
BLOWER FAN 691
Removal And Installation 691
Disassembly And Assembly 692
Connector Identification 694
HEATER VALVE 695
Removal And Installation 695
Disassembly And Assembly 696
SPECIFICATIONS 697
(S100) LOADER SPECIFICATIONS 699
Machine Dimensions 699
Performance 700
Engine 700
Engine E4B 701
Drive System 701
Controls 702
Hydraulic System 702
Electrical 703
Capacities 703
Tires 703
TECHNICAL SERVICE GUIDE SPECIFICATIONS 705
Engine 705
Engine Torques 705
Cooling System 705
Loader Torques 706
Hydraulic / Hydrostatic System 706
Fuel Consumption 706
TORQUE SPECIFICATIONS FOR BOLTS 707
Torque For General SAE Bolts 707
Torque For General Metric Bolts 708
HYDRAULIC CONNECTION SPECIFICATIONS 709
O-ring Face Seal Connection 709
Straight Thread O-ring Fitting 710
Tubelines And Hoses 710
Flare Fitting 710
Port Seal Fitting 711
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 713
Specifications 713
CONVERSIONS 715
Decimal And Millimeter Equivalent Chart 715
U S To Metric Conversion Chart 715
SERVICE TOOLS REQUIRED 717
Remote Start Tools 717
Hydraulic Tools 718
Mainframe And Drive Tools 721
Electrical Tools 724
Engine Tools 725
HVAC Tools 730
ALPHABETICAL INDEX 731

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