Bobcat S100 Skid-Steer Loader Service Manual SN AB6411001 – AB6419999 – PDF DOWNLOAD

Description

Bobcat S100 Skid-Steer Loader Service Manual SN AB6411001 – AB6419999 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S100 Skid-Steer Loader Service Manual SN AB6411001 – AB6419999 – PDF DOWNLOAD

Language : English
Pages : 514
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S100 Skid-Steer Loader Service Manual SN AB6411001 – AB6419999 – PDF DOWNLOAD

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 SN AB6411001 – AB6419999 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 12
FIRE PREVENTION 14
Maintenance 14
Operation 14
Electrical 14
Hydraulic System 14
Fueling 14
Starting 14
Spark Arrestor Exhaust System 14
Welding And Grinding 15
Fire Extinguishers 15
SERIAL NUMBER LOCATIONS 16
Loader Serial Number 16
Engine Serial Number 16
DELIVERY REPORT 17
LOADER IDENTIFICATION 18
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Installing 23
Removing 24
OPERATOR CAB 25
Description 25
Raising 25
Lowering 26
Cab Door Sensor 27
TRANSPORTING THE LOADER ON A TRAILER 29
Loading And Unloading 29
Fastening 29
TOWING THE LOADER 31
Procedure 31
REMOTE START TOOL KIT-MEL1563 33
Remote Start Tool – MEL1563 33
Service Tool Harness Control – MEL1565 34
Service Tool Harness Communicator – MEL1566 35
Remote Start Procedure 36
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031 39
Description 39
Remote Start Tool (Service Tool) – 7003030 40
Loader Service Tool Harness – 6689747 41
Computer Service Tool Harness – 6689746 42
Remote Start Procedure 43
SERVICE SCHEDULE 47
Chart 47
AIR CLEANER SERVICE 49
Replacing Filter Elements 49
ENGINE COOLING SYSTEM 51
Cleaning 51
Checking Level 51
Removing And Replacing Coolant 52
FUEL SYSTEM 53
Fuel Specifications 53
Biodiesel Blend Fuel 53
Filling The Fuel Tank 54
Fuel Filter 55
Removing Air From The Fuel System 55
ENGINE LUBRICATION SYSTEM 57
Checking And Adding Engine Oil 57
Engine Oil Chart 57
Removing And Replacing Oil And Filter 58
HYDRAULIC / HYDROSTATIC SYSTEM 59
Checking And Adding Fluid 59
Hydraulic / Hydrostatic Fluid Chart 59
Removing And Replacing Hydraulic Fluid 60
Removing And Replacing Hydraulic / Hydrostatic Filter 61
Removing And Replacing Case Drain Filters 62
Removing And Replacing Hydraulic Charge Filter 63
Breather Cap 63
FINAL DRIVE TRANSMISSION (CHAINCASE) 65
Checking And Adding Oil 65
Removing And Replacing Oil 65
BOB-TACH (HAND LEVER) 67
Inspection And Maintenance 67
LUBRICATING THE LOADER 69
Lubrication Locations 69
TIRE MAINTENANCE 71
Wheel Nuts 71
Rotating 71
Mounting 71
SPARK ARRESTER MUFFLER 73
Cleaning Procedure 73
PIVOT PINS 75
Inspection And Maintenance 75
LOADER STORAGE AND RETURN TO SERVICE 77
Storage 77
Return To Service 77
STOPPING THE ENGINE AND LEAVING THE LOADER 79
Procedure 79
Emergency Exit 80
HYDRAULIC SYSTEM 81
HYDRAULIC / HYDROSTATIC SCHEMATICS 83
HYDRAULIC SYSTEM INFORMATION 85
Glossary Of Hydraulic / Hydrostatic Symbols 85
Troubleshooting 89
CYLINDER (LIFT) 91
Testing 91
Removal And Installation 92
Parts Identification 93
Disassembly And Assembly 94
CYLINDER (TILT) 97
Testing 97
Removal And Installation 97
Parts Identification 99
Disassembly And Assembly 100
MAIN RELIEF VALVE 103
Description 103
Testing 103
Adjusting 104
Removal And Installation 104
HYDRAULIC CONTROL VALVE 105
Description 105
Removal And Installation 105
Identification Chart 108
Load Check Valve Removal And Installation (Tilt And Auxiliary) 109
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 110
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 111
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 111
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 112
Port Relief Valve Removal And Installation 112
Rubber Boot Removal And Installation 113
End Cap / Spool Lock Block Removal And Installation 113
Lift Spool And Detent Removal And Installation 114
Tilt Spool Removal And Installation 123
Auxiliary Spool Removal And Installation 125
Solenoid Removal And Installation 133
Lock Valve Removal And Installation 134
Main Relief Valve Removal And Installation 136
LIFT ARM BYPASS CONTROL VALVE 137
Description 137
Testing 137
Removal And Installation 138
Disassembly And Assembly 140
HYDRAULIC PUMP 141
Description 141
Pump Test At Quick Couplers 141
Direct Pump Test 142
Direct Pump Test (Charge Section) 143
Removal And Installation 146
Parts Identification 149
Disassembly And Assembly 150
Hydraulic Pump Start Up 154
HYDRAULIC / HYDROSTATIC FILTERS 155
Description 155
Hydraulic / Hydrostatic Filter Housing Removal And Installation 155
HYDRAULIC FLUID RESERVOIR 157
Description 157
Removal And Installation 157
Hydraulic Fluid Screen 158
OIL COOLER 159
Description 159
Removal And Installation 159
BUCKET POSITION VALVE 161
Description 161
Solenoid Removal And Installation 161
Solenoid Testing 162
Removal And Installation 162
Disassembly And Assembly 165
FRONT AUXILIARY HYDRAULIC COUPLERS 167
Description 167
Removal And Installation 167
HYDROSTATIC SYSTEM 169
HYDROSTATIC SYSTEM INFORMATION 171
Description 171
Troubleshooting 172
HYDROSTATIC MOTOR 173
Description 173
Removal And Installation 173
Parts Identification 175
Disassembly And Assembly 176
CHARGE PRESSURE 181
Description 181
Testing 181
Sender Removal And Installation 182
Adjusting 183
HYDROSTATIC PUMP 185
Description 185
Replenishing / High Pressure Relief Valve Removal And Installation 185
Removal And Installation 186
Hydrostatic Pump Startup 188
Parts Identification 189
Disassembly 190
Assembly 195
DRIVE BELT 201
Description 201
Shield Removal And Installation 201
Adjusting 201
Belt Removal And Installation 202
Tensioner Pulley Removal And Installation 202
Tensioner Pulley Disassembly And Assembly 202
CASE DRAIN FILTER 203
Description 203
Disassembly And Assembly 203
DRIVE SYSTEM 205
BRAKE 207
Description 207
Disk Removal And Installation 207
DRIVE COMPONENTS 209
Description 209
Axle Seal Removal And Installation 210
Axle Sprocket And Bearings Removal And Installation 212
Chain Removal And Installation 216
CHAINCASE 219
Description 219
Front Cover Removal And Installation 219
Center Cover Removal And Installation 220
MAINFRAME 223
SEAT BAR 225
Description 225
Removal And Installation 225
Disassembly And Assembly 227
Compression Spring Disassembly And Assembly 228
OPERATOR CAB 229
Gas Cylinder Removal And Installation 229
Gas Cylinder Bracket Disassembly And Assembly 231
Removal And Installation 232
OPERATOR SEAT 235
Removal And Installation 235
Seat Belt Removal And Installation 235
OPERATOR SEAT (SUSPENSION) 237
Removal And Installation 237
Slide Rail Removal And Installation 238
Seat Belt Removal And Installation 238
Lower Cushion Removal And Installation 239
Back Cushion Removal And Installation 239
Shock Removal And Installation 240
3-Point Seat Belt Removal And Installation 240
BOB-TACH HAND LEVER 243
Description 243
Removal And Installation 243
Lever And Wedge Disassembly And Assembly 245
Pivot Pin Bushing And Seal Removal And Installation 246
LIFT ARMS 247
Removal And Installation 247
REAR GRILLE 253
Removal And Installation 253
REAR DOOR 255
Removal And Installation 255
Striker Removal And Installation 256
Striker Disassembly And Assembly 256
Striker (Adjusting) 256
Latch Removal And Installation 257
FUEL TANK 259
Removal And Installation 259
Fuel Level Sender Removal And Installation 260
Fuel Fill Screen Removal And Installation 260
Fuel Pickup Screen 260
CONTROL PEDALS AND LINKAGES 261
Description 261
Pedal Removal And Installation 261
Linkage Removal And Installation 262
Pedal (Adjusting) 262
CONTROL PANEL 265
Description 265
Removal And Installation 266
Shaft Removal And Installation 269
Shaft Disassembly And Assembly 269
Linkage Removal And Installation 270
Pintle Arm Removal And Installation 271
Pintle Arm Disassembly And Assembly 274
Linkage Neutral Adjusting 275
Linkage Travel Adjusting 278
CONTROL HANDLE / LEVER 283
Description 283
Lever Removal And Installation 283
Boot Removal And Installation 283
WINDOW (REAR) 285
Removal 285
Installation 285
WINDOW (TOP) 287
Removal And Installation 287
WINDOW (SIDE) 289
Removal And Installation 289
WINDOW (FRONT DOOR) 291
Removal (Standard Window) 291
Installation (Standard Window) 292
Removal And Installation (Special Applications Window) 293
CAB DOOR 295
Description 295
Removal And Installation 295
Aligning 296
Adjusting 297
Checking Operation 297
ELECTRICAL SYSTEM & ANALYSIS 299
ELECTRICAL SCHEMATICS 303
ELECTRICAL SYSTEM INFORMATION 307
Glossary Of Electrical Symbols 307
Cab Harness Connectors 310
Mainframe Harness Connectors 311
Description 312
Troubleshooting 313
Fuse And Relay Location / Identification 314
Solenoid Testing 315
BATTERY 317
Removal And Installation 317
Servicing 318
Using A Booster Battery (Jump Starting) 319
ALTERNATOR 321
Belt Adjustment 321
Belt Replacement 321
Charging System Inspection 322
Alternator Voltage Testing 323
Low Voltage Testing 323
High Voltage Testing 324
Removal And Installation 325
Parts Identification 327
STARTER 329
Testing 329
Removal And Installation 330
Parts Identification 331
INSTRUMENT PANELS 333
Left Panel 333
Display Screen 335
Standard Key Panel 335
Deluxe Instrumentation Panel 336
Side Panel 337
Front Panel 337
Removal And Installation (Left And Right) 338
Key Switch Removal And Installation 339
Alarm Removal And Installation 339
Front Accessory Panel Removal And Installation 340
LIGHTS 341
Front Removal And Installation 341
Rear Removal And Installation 341
Cab Light Removal And Installation 342
BOBCAT CONTROLLER (MAIN) 343
Description 343
Connector Identification 344
Removal And Installation 346
DIAGNOSTIC SERVICE CODES 347
Viewing Service Codes (Standard Key Panel) 347
Viewing Service Codes (Deluxe Instrumentation Panel) 347
Service Codes List 348
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 353
Description 353
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 353
Inspecting The Seat Bar Sensor (Engine RUNNING) 353
Inspecting The Traction Lock (Engine RUNNING) 353
Inspecting The Lift Arm Bypass Control 353
Troubleshooting 354
Troubleshooting Chart 355
SEAT BAR SENSOR 357
Description 357
Troubleshooting 357
Testing 358
Removal And Installation 359
Bobcat Interlock Control System (BICS™) Circuit Test 361
TRACTION LOCK 363
Description 363
Troubleshooting 363
Removal And Installation 364
Inspecting 367
SERVICE PC (LAPTOP COMPUTER) 369
Connecting To The Remote Start Tool 369
Connecting Remote Start Tool (Service Tool) 369
FLYWHEEL RPM SENSOR 371
Description 371
Adjusting 371
CONTROL PANEL SETUP 373
Right Panel Setup (Deluxe Instrumentation Panel) 373
Attachment Control Information (Deluxe Instrumentation Panel) 374
PASSWORD SETUP 375
Password Description 375
Changing The Owner Password 375
Changing The User Passwords 376
Password Lockout Feature 376
MAINTENANCE CLOCK 377
Description 377
Setup 378
Reset 381
BACK-UP ALARM SYSTEM 383
Description 383
Inspecting 383
Adjusting Switch Position 384
Troubleshooting 385
Alarm Removal And Installation 386
Switch Removal And Installation 386
ENGINE SERVICE 389
ENGINE INFORMATION 391
Description 391
Specifications 392
Torque Values 396
Troubleshooting 397
Engine Removal And Installation 398
Engine Mount Replacement 406
Compression – Checking 406
ENGINE SPEED CONTROL 407
Removal And Installation 407
MUFFLER 409
Removal And Installation 409
AIR CLEANER 411
Removal And Installation 411
ENGINE COOLING SYSTEM 413
Radiator Removal And Installation 413
Fan Removal And Installation 414
Water Pump Removal And Installation 415
Water Pump Disassembly And Assembly 415
Thermostat Housing Removal And Installation 416
Testing The Thermostat 416
LUBRICATION SYSTEM 417
Oil Pan Removal And Installation 417
Oil Pump Removal And Installation 417
Oil Pump Inspection 418
Engine Oil Pressure – Testing 419
FUEL SYSTEM 421
Fuel Camshaft Removal And Installation 421
Fuel Camshaft Governor Disassembly And Assembly 421
Fuel Shutoff Solenoid – Checking 422
Fuel Shutoff Solenoid Removal And Installation 423
Fuel Injection Pump Removal And Installation 424
Timing The Injection Pump 426
Fuel Injector Removal And Installation 428
Fuel Injector Nozzles Pressure – Checking 429
Nozzle Spray Condition 430
Valve Seat Tightness 431
CYLINDER HEAD 433
Glow Plug – Testing 433
Glow Plug Removal And Installation 434
Valve Clearance Adjustment 434
Valve Timing – Checking 435
Cylinder Head Removal And Installation 436
Cylinder Head Disassembly And Assembly 438
Cylinder Head – Servicing 438
Cylinder Head Top Clearance 439
Valve Guide – Checking 439
Reconditioning The Valve And Valve Seat 440
Valve Spring 442
Valve Tappets 443
Rocker Arm And Shaft – Checking 443
CRANKSHAFT AND PISTONS 445
Piston And Connecting Rod Removal And Installation 445
Piston And Connecting Rod – Servicing 446
Cylinder Bore – Checking 449
Connecting Rod Alignment 449
Crankshaft And Bearings Removal And Installation 450
Crankshaft And Bearings – Servicing 452
CAMSHAFT AND TIMING GEARS 457
Timing Gearcase Cover Removal And Installation 457
Timing Gears Backlash – Checking 459
Idler Gear And Shaft Removal And Installation 459
Camshaft – Servicing 460
Idler Gear And Shaft Servicing 462
FLYWHEEL 463
Flywheel Removal And Installation 463
HEATING, VENTILATION, AIR CONDITIONING 465
HEATER SYSTEM 467
Description 467
REGULAR MAINTENANCE 469
Filter Elements Removal And Installation 469
Cleaning The Heater Coil 470
TROUBLESHOOTING 471
Blower Motor Does Not Operate 471
Blower Motor Operators Normally, But Air Flow Is Insufficient 471
Electrical System 472
Engine Coolant bypassing The Heater Valve 476
Heater Valve Not Opening Or Closing 476
HEATER UNIT 479
Removal And Installation 479
HEATER COIL 481
Removal And Installation 481
HEATER FAN 483
Blower Removal And Installation 483
Disassembly And Assembly 484
Connector Identification 486
HEATER VALVE 487
Removal And Installation 487
Disassembly And Assembly 488
SPECIFICATIONS 489
(S100) LOADER SPECIFICATIONS 491
Machine Dimensions 491
Performance 492
Engine 492
Controls 492
Drive System 493
Hydraulic System 493
Electrical 494
Capacities 494
Tires 494
TORQUE SPECIFICATIONS FOR BOLTS 495
Torque For General SAE Bolts 495
Torque For General Metric Bolts 496
HYDRAULIC CONNECTION SPECIFICATIONS 497
O-ring Face Seal Connection 497
Straight Thread O-ring Fitting 498
Tubelines And Hoses 498
Flare Fitting 498
Port Seal Fitting 499
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 501
Specifications 501
CONVERSIONS 503
Decimal And Millimeter Equivalent Chart 503
U S To Metric Conversion Chart 503
ALPHABETICAL INDEX 505
SERVICE MANUAL REVISION 507
Revision No: S100 – 1 507
Revision No: S100 – 2 509
Revision No: S100 – 3 511
Revision No: S100 – 4 513

IMAGES PREVIEW OF THE MANUAL:

Questions? Email us: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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