Bobcat Skid-Steer Loaders S70, S100 Repair Service Manuals + Operation & Maintenance Manuals
Complete repair service manual with electrical wiring diagrams for Bobcat S70, S100 Skid-Steer with technical information to maintain, diagnose, repair, and service like professional mechanics.
Bobcat Skid-Steer Loaders S70, S100 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
6904925 (8-07) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6904925 (9-12) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6904926 (1-09) - S100 Skid-Steer Loader Service Manual.pdf
6904926 (4-11) - S100 Skid-Steer Loader Service Manual.pdf
6904926 (9-08) - S100 Skid-Steer Loader Service Manual.pdf
6904926 (10-12) - S100 Skid-Steer Loader Service Manual.pdf
6986660 (5-14) - S70 Skid-Steer Loader Operation & Maintenance Manual.pdf
6986660 (11-10) - S70 Skid-Steer Loader Operation & Maintenance Manual.pdf
6986662 (2-09) - S70 Skid-Steer Loader Service Manual.pdf
6986662 (4-14) - S70 Skid-Steer Loader Service Manual.pdf
6987130 (9-12) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987130 (10-09) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987131 (3-09) - S100 Skid-Steer Loader Service Manual.pdf
6987131 (4-11) - S100 Skid-Steer Loader Service Manual.pdf
6987131 (10-12) - S100 Skid-Steer Loader Service Manual.pdf
6987370 (5-14) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987370 (11-10) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987401 (1-11) - S100 Skid-Steer Loader Service Manual.pdf
6987401 (4-11) - S100 Skid-Steer Loader Service Manual.pdf
6987401 (10-12) - S100 Skid-Steer Loader Service Manual.pdf
6987402 (5-14) - S100 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987403 (10-12) - S100 Skid-Steer Loader Service Manual.pdf
Total Pages: 8,592 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
6904925 (8-07) - S100 Skid-Steer Loader Operation & Maintenance Manual....1
OPERATOR SAFETY WARNINGS....3
CONTENTS....5
FOREWORD....7
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....9
REGULAR MAINTENANCE ITEMS....9
SERIAL NUMBER LOCATIONS....10
Loader Serial Number....10
Engine Serial Number....10
LOADER IDENTIFICATION....11
FEATURES, ACCESSORIES AND ATTACHMENTS....12
Buckets Available....13
Attachments....13
Special Applications Kit....14
SAFETY & TRAINING RESOURCES....15
SAFETY INSTRUCTIONS....17
Before Operation....17
Safe Operation Is The Operator?s Responsibility....18
Safe Operation Needs A Qualified Operator....18
Fire Prevention....19
MACHINE SIGNS (DECALS)....20
PUBLICATIONS AND TRAINING RESOURCES....22
OPERATING INSTRUCTIONS....23
INSTRUMENT PANEL IDENTIFICATION....25
Left Panel....25
Display Screen Functions....26
Right Instrument Panel (Key Switch)....26
Cab Light....26
Option And Field Accessory Panels....27
HORN (OPTION)....28
Operation....28
SEAT BAR RESTRAINT SYSTEM....28
Operation....28
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....29
Operation....29
LIFT ARM BYPASS CONTROL....30
Operation....30
TRACTION LOCK OVERRIDE....30
Operation....30
BACK-UP ALARM SYSTEM....31
Operation....31
ENGINE SPEED CONTROL....31
Operation....31
PARKING BRAKE....31
Operation....31
DRIVING AND STEERING THE LOADER....32
Operation....32
Stopping The Loader....32
HYDRAULIC CONTROLS....33
Description....33
Bucket Position Valve Operation (If Equipped)....33
Auxiliary Control Lockout....33
Auxiliary Hydraulics....34
Relieving Hydraulic Pressure (Loader and Attachment)....34
Quick Couplers....34
DAILY INSPECTION....35
Daily Inspection And Maintenance....36
PRE-STARTING PROCEDURE....37
Entering The Loader....37
Operation & Maintenance Manual and Operator?s Handbook Locations....37
Seat Adjustment....37
Seat Belt Adjustment....38
Seat Bar....39
STARTING THE ENGINE....39
Key Switch....39
Warming The Hydraulic / Hydrostatic System....41
Cold Temperature Starting....41
MONITORING THE DISPLAY PANELS....42
Left Panel....42
Warning And Shutdown....42
STOPPING THE ENGINE AND LEAVING THE LOADER....43
Procedure....43
Emergency Exit....44
ATTACHMENTS....45
Choosing The Correct Bucket....45
Pallet Forks....45
Installing And Removing The Attachment....46
OPERATING PROCEDURE....48
Inspecting The Work Area....48
Operating With A Full Bucket....48
Operating With An Empty Bucket....49
Filling And Emptying The Bucket....50
Leveling The Ground Using Float....51
Digging And Filling A Hole....51
TOWING THE LOADER....52
Procedure....52
LIFTING THE LOADER....53
Single Point Lift....53
TRANSPORTING THE LOADER ON A TRAILER....54
Loading And Unloading....54
Fastening....54
PREVENTIVE MAINTENANCE....55
MAINTENANCE SAFETY....59
SERVICE SCHEDULE....61
Chart....61
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....62
Inspecting The BICS Controller (Engine STOPPED - Key ON)....62
Inspecting The Seat Bar Sensor (Engine RUNNING)....62
Inspecting The Traction Lock (Engine RUNNING)....62
Inspecting The Lift Arm Bypass Control....62
SEAT BAR RESTRAINT SYSTEM....63
Description....63
Inspecting....63
Maintaining....63
SEAT BELT....64
Inspection And Maintenance....64
LIFT ARM SUPPORT DEVICE....65
Installing....65
Removing....66
BACK-UP ALARM SYSTEM....67
Description....67
Inspecting....67
Adjusting Switch Position....67
OPERATOR CAB....68
Description....68
Raising....68
Lowering....69
Cab Door Sensor (If Equipped)....70
REAR DOOR....71
Opening And Closing....71
Adjusting....71
REAR GRILL....72
Removing....72
Installing....72
CAB FILTERS....72
Cleaning And Maintenance....72
AIR CLEANER SERVICE....73
Replacing Filter Elements....73
FUEL SYSTEM....74
Fuel Specifications....74
Filling The Fuel Tank....74
Fuel Filter....75
Removing Air From The Fuel System....75
ENGINE LUBRICATION SYSTEM....76
Checking And Adding Engine Oil....76
Engine Oil Chart....76
Removing And Replacing Oil And Filter....76
ENGINE COOLING SYSTEM....77
Cleaning....77
Checking Level....77
Removing And Replacing Coolant....78
ELECTRICAL SYSTEM....79
Description....79
Fuse And Relay Location / Identification....79
Battery Maintenance....80
Using A Booster Battery (Jump Starting)....80
Removing And Installing Battery....82
HYDRAULIC / HYDROSTATIC SYSTEM....83
Checking And Adding Fluid....83
Hydraulic / Hydrostatic Fluid Chart....83
Removing And Replacing Hydraulic / Hydrostatic Filter....83
Removing And Replacing Hydraulic Fluid and Case Drain Filters....84
Removing And Replacing Charge Filter....85
SPARK ARRESTOR MUFFLER....86
Cleaning Procedure....86
TIRE MAINTENANCE....87
Wheel Nuts....87
Rotating....87
Mounting....87
FINAL DRIVE TRANSMISSION (CHAINCASE)....88
Checking And Adding Oil....88
Removing And Replacing Oil....88
ALTERNATOR BELT....89
Belt Adjustment....89
Belt Replacement....89
DRIVE BELT....90
Belt Replacement....90
LUBRICATING THE LOADER....90
Lubrication Locations....90
PIVOT PINS....92
Inspection And Maintenance....92
BOB-TACH....93
Inspection And Maintenance....93
LOADER STORAGE AND RETURN TO SERVICE....95
Storage....95
Return To Service....95
SYSTEM SETUP & ANALYSIS....97
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....99
Troubleshooting....99
DIAGNOSTIC SERVICE CODES....100
Viewing Service Codes....100
Service Codes List....101
Service Codes List (Cont?d)....103
MACHINE SIGN TRANSLATIONS....105
SERVICE SCHEDULE (6734534)....107
DANGER (6702301)....110
DANGER (6702302)....110
DANGER (6717343)....110
WARNING (6579528)....110
WARNING (6577754)....111
WARNING (6733996)....111
IMPORTANT (7139929)....111
WARNING (6728539)....112
WARNING (6704786)....113
WARNING (6726423)....113
WARNING (7136754)....114
WARNING (6710358)....115
WARNING (6809511)....115
WARNING (6725370)....115
WARNING (6737189)....116
LIFT ARM SUPPORT DEVICE (6706558)....116
SPECIFICATIONS....117
(S100) LOADER SPECIFICATIONS....119
Machine Dimensions....119
Performance....120
Controls....120
Engine....121
Hydraulic System....121
Electrical....122
Drive System....122
Capacities....122
Tires....122
WARRANTY....123
ALPHABETICAL INDEX....127
6904925 (9-12) - S100 Skid-Steer Loader Operation & Maintenance Manual....129
OPERATOR SAFETY WARNINGS....131
CONTENTS....133
FOREWORD....135
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....137
REGULAR MAINTENANCE ITEMS....137
SERIAL NUMBER LOCATIONS....138
Loader Serial Number....138
Engine Serial Number....138
LOADER IDENTIFICATION....139
FEATURES, ACCESSORIES AND ATTACHMENTS....140
Buckets Available....141
Attachments....141
Special Applications Kit....142
SAFETY & TRAINING RESOURCES....143
SAFETY INSTRUCTIONS....145
Before Operation....145
Safe Operation Is The Operator?s Responsibility....146
Safe Operation Needs A Qualified Operator....146
Fire Prevention....147
MACHINE SIGNS (DECALS)....148
PUBLICATIONS AND TRAINING RESOURCES....150
OPERATING INSTRUCTIONS....151
INSTRUMENT PANEL IDENTIFICATION....153
Left Panel....153
Display Screen Functions....154
Right Instrument Panel (Key Switch)....154
Cab Light....154
Option And Field Accessory Panels....155
HORN (OPTION)....156
Operation....156
SEAT BAR RESTRAINT SYSTEM....156
Operation....156
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....157
Operation....157
LIFT ARM BYPASS CONTROL....158
Operation....158
TRACTION LOCK OVERRIDE....158
Operation....158
BACK-UP ALARM SYSTEM....159
Operation....159
ENGINE SPEED CONTROL....159
Operation....159
PARKING BRAKE....159
Operation....159
DRIVING AND STEERING THE LOADER....160
Operation....160
Stopping The Loader....160
HYDRAULIC CONTROLS....161
Description....161
Bucket Position Valve Operation (If Equipped)....161
Auxiliary Control Lockout....161
Auxiliary Hydraulics....162
Relieving Hydraulic Pressure (Loader and Attachment)....162
Quick Couplers....162
DAILY INSPECTION....163
Daily Inspection And Maintenance....164
PRE-STARTING PROCEDURE....165
Entering The Loader....165
Operation & Maintenance Manual and Operator?s Handbook Locations....165
Seat Adjustment....165
Seat Belt Adjustment....166
Seat Bar....167
STARTING THE ENGINE....167
Key Switch....167
Warming The Hydraulic / Hydrostatic System....169
Cold Temperature Starting....169
MONITORING THE DISPLAY PANELS....170
Left Panel....170
Warning And Shutdown....170
STOPPING THE ENGINE AND LEAVING THE LOADER....171
Procedure....171
Emergency Exit....172
ATTACHMENTS....173
Choosing The Correct Bucket....173
Pallet Forks....173
Installing And Removing The Attachment....174
OPERATING PROCEDURE....176
Inspecting The Work Area....176
Operating With A Full Bucket....176
Operating With An Empty Bucket....177
Filling And Emptying The Bucket....178
Leveling The Ground Using Float....179
Digging And Filling A Hole....179
TOWING THE LOADER....180
Procedure....180
LIFTING THE LOADER....181
Single Point Lift....181
TRANSPORTING THE LOADER ON A TRAILER....182
Loading And Unloading....182
Fastening....182
PREVENTIVE MAINTENANCE....183
MAINTENANCE SAFETY....187
SERVICE SCHEDULE....189
Chart....189
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....190
Inspecting The BICS Controller (Engine STOPPED - Key ON)....190
Inspecting The Seat Bar Sensor (Engine RUNNING)....190
Inspecting The Traction Lock (Engine RUNNING)....190
Inspecting The Lift Arm Bypass Control....190
SEAT BAR RESTRAINT SYSTEM....191
Description....191
Inspecting....191
Maintaining....191
SEAT BELT....192
Inspection And Maintenance....192
LIFT ARM SUPPORT DEVICE....193
Installing....193
Removing....194
BACK-UP ALARM SYSTEM....195
Description....195
Inspecting....195
Adjusting Switch Position....195
OPERATOR CAB....196
Description....196
Raising....196
Lowering....197
Cab Door Sensor (If Equipped)....198
REAR DOOR....199
Opening And Closing....199
Adjusting....199
REAR GRILL....200
Removing....200
Installing....200
CAB FILTERS....200
Cleaning And Maintenance....200
AIR CLEANER SERVICE....201
Replacing Filter Elements....201
FUEL SYSTEM....202
Fuel Specifications....202
Filling The Fuel Tank....202
Fuel Filter....203
Removing Air From The Fuel System....203
ENGINE LUBRICATION SYSTEM....204
Checking And Adding Engine Oil....204
Engine Oil Chart....204
Removing And Replacing Oil And Filter....204
ENGINE COOLING SYSTEM....205
Cleaning....205
Checking Level....205
Removing And Replacing Coolant....206
ELECTRICAL SYSTEM....207
Description....207
Fuse And Relay Location / Identification....207
Battery Maintenance....208
Using A Booster Battery (Jump Starting)....208
Removing And Installing Battery....210
HYDRAULIC / HYDROSTATIC SYSTEM....211
Checking And Adding Fluid....211
Hydraulic / Hydrostatic Fluid Chart....211
Removing And Replacing Hydraulic / Hydrostatic Filter....211
Removing And Replacing Hydraulic Fluid and Case Drain Filters....212
Removing And Replacing Charge Filter....213
SPARK ARRESTOR MUFFLER....214
Cleaning Procedure....214
TIRE MAINTENANCE....215
Wheel Nuts....215
Rotating....215
Mounting....215
FINAL DRIVE TRANSMISSION (CHAINCASE)....216
Checking And Adding Oil....216
Removing And Replacing Oil....216
ALTERNATOR BELT....217
Belt Adjustment....217
Belt Replacement....217
DRIVE BELT....218
Belt Replacement....218
LUBRICATING THE LOADER....218
Lubrication Locations....218
PIVOT PINS....220
Inspection And Maintenance....220
BOB-TACH....221
Inspection And Maintenance....221
LOADER STORAGE AND RETURN TO SERVICE....223
Storage....223
Return To Service....223
SYSTEM SETUP & ANALYSIS....225
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....227
Troubleshooting....227
DIAGNOSTIC SERVICE CODES....228
Viewing Service Codes....228
Service Codes List....229
Service Codes List (Cont?d)....231
MACHINE SIGN TRANSLATIONS....233
SERVICE SCHEDULE (6734534)....235
DANGER (6702301)....238
DANGER (6702302)....238
DANGER (6717343)....238
WARNING (6579528)....238
WARNING (6577754)....239
WARNING (6733996)....239
IMPORTANT (7139929)....239
WARNING (6728539)....240
WARNING (6704786)....241
WARNING (6726423)....241
WARNING (7136754)....242
WARNING (6710358)....243
WARNING (6809511)....243
WARNING (6725370)....243
WARNING (6737189)....244
LIFT ARM SUPPORT DEVICE (6706558)....244
SPECIFICATIONS....245
(S100) LOADER SPECIFICATIONS....247
Machine Dimensions....247
Performance....248
Controls....248
Engine....249
Hydraulic System....249
Electrical....250
Drive System....250
Capacities....250
Tires....250
WARRANTY....251
ALPHABETICAL INDEX....255
6904926 (1-09) - S100 Skid-Steer Loader Service Manual....257
MAINTENANCE SAFETY....259
ALPHABETICAL INDEX....261
CONTENTS....263
FOREWORD....264
SAFETY INSTRUCTIONS....267
FIRE PREVENTION....269
Maintenance....269
Operation....269
Electrical....269
Hydraulic System....269
Fueling....269
Starting....269
Spark Arrestor Exhaust System....269
Welding And Grinding....270
Fire Extinguishers....270
SERIAL NUMBER LOCATIONS....271
Loader Serial Number....271
Engine Serial Number....271
DELIVERY REPORT....272
LOADER IDENTIFICATION....273
SAFETY AND MAINTENANCE....275
LIFTING AND BLOCKING THE LOADER....277
Procedure....277
LIFT ARM SUPPORT DEVICE....279
Installing....279
Removing....280
OPERATOR CAB....281
Description....281
Raising....281
Lowering....282
Cab Door Sensor (If Equipped)....283
TRANSPORTING THE LOADER ON A TRAILER....285
Loading And Unloading....285
Fastening....285
TOWING THE LOADER....287
Procedure....287
REMOTE START TOOL KIT-MEL1563....289
Remote Start Tool - MEL1563....289
Service Tool Harness Control - MEL1565....290
Service Tool Harness Communicator - MEL1566....291
Remote Start Procedure....292
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....295
Description....295
Remote Start Tool (Service Tool) - 6689778....296
Loader Service Tool Harness - 6689747....297
Computer Service Tool Harness - 6689746....298
Remote Start Procedure....299
SERVICE SCHEDULE....303
Chart....303
AIR CLEANER SERVICE....305
Replacing Filter Elements....305
ENGINE COOLING SYSTEM....307
Cleaning....307
Checking Level....307
Removing And Replacing Coolant....308
FUEL SYSTEM....309
Fuel Specifications....309
Filling The Fuel Tank....309
Fuel Filter....310
Removing Air From The Fuel System....310
ENGINE LUBRICATION SYSTEM....311
Checking And Adding Engine Oil....311
Engine Oil Chart....311
Removing And Replacing Oil And Filter....311
HYDRAULIC / HYDROSTATIC SYSTEM....313
Checking And Adding Fluid....313
Hydraulic / Hydrostatic Fluid Chart....313
Removing And Replacing Hydraulic / Hydrostatic Filter....313
Removing And Replacing Hydraulic Fluid and Case Drain Filters....314
Removing And Replacing Charge Filter....315
FINAL DRIVE TRANSMISSION (CHAINCASE)....317
Checking And Adding Oil....317
Removing And Replacing Oil....317
BOB-TACH (HAND LEVER)....319
Inspection And Maintenance....319
BOB-TACH (POWER OPTION)....321
Inspection And Maintenance....321
LUBRICATING THE LOADER....323
Lubrication Locations....323
TIRE MAINTENANCE....325
Wheel Nuts....325
Rotating....325
Mounting....325
SPARK ARRESTOR MUFFLER....327
Cleaning Procedure....327
PIVOT PINS....329
Inspection And Maintenance....329
LOADER STORAGE AND RETURN TO SERVICE....331
Storage....331
Return To Service....331
STOPPING THE ENGINE AND LEAVING THE LOADER....333
Procedure....333
Emergency Exit....334
BACK-UP ALARM SYSTEM....335
Description....335
Operation....335
HYDRAULIC SYSTEM....337
HYDRAULIC / HYDROSTATIC SCHEMATIC....341
HYDRAULIC SYSTEM INFORMATION....343
Glossary Of Hydraulic / Hydrostatic Symbols....343
Troubleshooting....347
CYLINDER (LIFT)....349
Testing....349
Removal And Installation....350
Parts Identification....351
Disassembly And Assembly....352
CYLINDER (TILT)....355
Testing....355
Removal And Installation....355
Parts Identification....357
Disassembly And Assembly....358
CYLINDER (BOB-TACH)....361
Testing....361
Removal And Installation....362
Parts Identification....363
Disassembly and Assembly....364
MAIN RELIEF VALVE....367
Description....367
Testing....367
Adjusting....368
Removal And Installation....368
HYDRAULIC CONTROL VALVE....369
Description....369
Removal And Installation....369
Identification Chart....372
Load Check Valve Removal And Installation (Tilt and Auxiliary)....373
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....374
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....375
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....375
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....376
Port Relief Valve Removal And Installation....376
Rubber Boot Removal And Installation....377
End Cap / Spool Lock Block Removal And Installation....377
Lift Spool And Detent Removal And Installation....378
Tilt Spool Removal And Installation....387
Auxiliary Spool Removal And Installation....389
Solenoid Removal And Installation....397
Lock Valve Removal And Installation....398
Main Relief Valve Removal And Installation....400
LIFT ARM bypass CONTROL VALVE....401
Description....401
Testing....401
Removal and Installation....401
Disassembly And Assembly....403
HYDRAULIC PUMP....405
Description....405
Pump Test at Quick Couplers....405
Direct Pump Test....406
Direct Pump Test (Charge Section)....407
Removal And Installation....410
Parts Identification....413
Disassembly And Assembly....414
Hydraulic Pump Start Up....418
HYDRAULIC / HYDROSTATIC FILTERS....419
Description....419
Hydraulic / Hydrostatic Filter Housing Removal And Installation....419
HYDRAULIC FLUID RESERVOIR....421
Description....421
Removal And Installation....421
Hydraulic Fluid Screen....422
OIL COOLER....423
Description....423
Removal And Installation....423
BUCKET POSITION VALVE....425
Description....425
Solenoid Removal And Installation....425
Solenoid Testing....426
Removal And Installation....426
Disassembly And Assembly....429
BOB-TACH (POWER) BLOCK....431
Description....431
Removal And Installation....431
Disassembly And Assembly....433
FRONT AUXILIARY HYDRAULIC COUPLERS....437
Description....437
Removal And Installation....437
HYDROSTATIC SYSTEM....439
HYDROSTATIC SYSTEM INFORMATION....441
Description....441
Troubleshooting....442
HYDROSTATIC MOTOR....443
Description....443
Removal And Installation....443
Disassembly And Assembly....444
CHARGE PRESSURE....449
Description....449
Testing....449
Sender Removal And Installation....450
Adjusting....451
HYDROSTATIC PUMP....453
Description....453
Replenishing / High Pressure Relief Valve Removal And Installation....453
Removal And Installation....454
Parts Identification....457
Disassembly....458
Assembly....463
Hydrostatic Pump Start Up....467
DRIVE BELT....469
Description....469
Shield Removal And Installation....469
Adjusting....469
Belt Removal And Installation....470
Tensioner Pulley Removal And Installation....470
Tensioner Pulley Disassembly And Assembly....470
CASE DRAIN FILTER....471
Description....471
Disassembly And Assembly....471
DRIVE SYSTEM....473
BRAKE....475
Description....475
Disk Removal And Installation....475
DRIVE COMPONENTS....477
Description....477
Axle Seal Removal And Installation....478
Axle Sprocket And Bearings Removal And Installation....480
Chain Removal And Installation....484
CHAINCASE....487
Description....487
Front Cover Removal And Installation....487
Center Cover Removal And Installation....488
MAIN FRAME....491
SEAT BAR....495
Description....495
Removal And Installation....495
Disassembly And Assembly....497
Compression Spring Disassembly And Assembly....498
OPERATOR CAB....499
Gas Cylinder Removal And Installation....499
Gas Cylinder Bracket Disassembly And Assembly....501
Removal And Installation....502
OPERATOR SEAT....505
Removal And Installation....505
Seat Belt Removal And Installation....505
OPERATOR SEAT (SUSPENSION)....507
Removal And Installation....507
Slide Rail Removal And Installation....508
Seat Belt Removal and Installation....508
Lower Cushion Removal And Installation....509
Back Cushion Removal And Installation....509
Shock Removal And Installation....510
3-Point Seat Belt Removal And Installation....510
BOB-TACH HAND LEVER....513
Description....513
Removal And Installation....513
Lever And Wedge Disassembly And Assembly....515
Pivot Pin Bushing And Seal Removal And Installation....516
BOB-TACH (POWER OPTION)....517
Description....517
Removal And Installation....517
Lever And Wedge Disassembly And Assembly....519
Pivot Pin Bushing And Seal Removal And Installation....520
LIFT ARMS....521
Removal And Installation....521
REAR GRILL....527
Removal And Installation....527
REAR DOOR....529
Removal And Installation....529
Striker Removal and Installation....530
Striker Disassembly and Assembly....530
Striker (Adjusting)....530
Latch Removal And Installation....531
FUEL TANK....533
Removal And Installation....533
Fuel Level Sender Removal And Installation....534
Fuel Fill Screen Removal And Installation....534
Fuel Pickup Screen....535
CONTROL PEDALS AND LINKAGES....537
Description....537
Pedal Removal And Installation....537
Linkage Removal And Installation....538
Pedal (Adjusting)....538
CONTROL PANEL....539
Description....539
Removal and Installation....540
Shaft Removal And Installation....543
Shaft Disassembly And Assembly....543
Linkage Removal And Installation....544
Pintle Arm Removal And Installation....545
Pintle Arm Disassembly and Assembly....548
Linkage Neutral Adjusting....549
Linkage Travel Adjusting....552
CONTROL HANDLE / LEVER....557
Description....557
Lever Removal And Installation....557
Boot Removal And Installation....557
WINDOW (REAR)....559
Removal....559
Installation....559
WINDOW (TOP)....561
Removal And Installation....561
WINDOW (SIDE)....563
Removal And Installation....563
WINDOW (FRONT DOOR)....565
Removal (Standard Window)....565
Installation (Standard Window)....566
Removal And Installation (Special Applications Window)....567
CAB DOOR....569
Description....569
Removal And Installation....569
Aligning....570
Adjusting....571
Checking Operation....571
ELECTRICAL SYSTEM & ANALYSIS....573
ELECTRICAL SCHEMATIC....577
ELECTRICAL SYSTEM INFORMATION....578
Glossary Of Electrical Symbols....578
Cab Harness Connectors....581
Mainframe Harness Connectors....582
Description....583
Troubleshooting....584
Fuse And Relay Location / Identification....585
Solenoid Testing....586
BATTERY....588
Removal And Installation....588
Servicing....589
Using A Booster Battery (Jump Starting)....590
ALTERNATOR....592
Belt Adjustment....592
Charging System Inspection....592
Alternator Voltage Testing....593
Low Voltage Testing....594
High Voltage Testing....594
Removal And Installation....595
Parts Identification....597
STARTER....598
Testing....598
Removal And Installation....599
Parts Identification....600
INSTRUMENT PANELS....602
Left Panel....602
LCD Screen Functions....604
Standard Key Panel....604
Deluxe Instrumentation Panel....605
Option And Field Accessory Panels....606
Removal And Installation (Left And Right)....607
Key Switch Removal And Installation....608
Alarm Removal And Installation....608
Front Accessory Panel Removal And Installation....609
LIGHTS....610
Front Removal And Installation....610
Rear Removal And Installation....610
Cab Light Removal And Installation....611
BOBCAT CONTROLLER (MAIN)....612
Description....612
Connector Identification....613
Removal And Installation....615
DIAGNOSTIC SERVICE CODES....616
Viewing Service Codes (Standard Key Panel)....616
Viewing Service Codes (Deluxe Instrumentation Panel)....616
Service Codes List....617
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....622
Description....622
Inspecting The BICS Controller (Engine STOPPED - Key ON)....622
Inspecting The Seat Bar Sensor (Engine RUNNING)....622
Inspecting The Traction Lock (Engine RUNNING)....623
Inspecting The Lift Arm Bypass Control....623
Troubleshooting....624
Troubleshooting Chart....625
SEAT BAR SENSOR....626
Description....626
Troubleshooting....626
Testing....627
Removal And Installation....628
Bobcat Interlock Control System (BICS) Circuit Test....630
TRACTION LOCK....632
Description....632
Troubleshooting....632
Removal And Installation....633
Inspecting....636
SERVICE PC (LAPTOP)....638
Connecting To The Remote Start Tool....638
Connecting Remote Start Tool (Service Tool)....638
FLYWHEEL RPM SENSOR....640
Description....640
Adjusting....640
CONTROL PANEL SETUP....642
Right Panel Setup (Deluxe Instrumentation Panel)....642
Attachment Control Information (Deluxe Instrumentation Panel)....643
PASSWORD SETUP....644
Password Description....644
Changing The Owner Password....644
Changing The User Passwords....645
Password Lockout Feature....645
MAINTENANCE CLOCK....646
Description....646
Setup....647
Reset....650
BACK-UP ALARM SYSTEM....652
Description....652
Inspecting....652
Adjusting Switch Position....653
Troubleshooting....654
Alarm Removal And Installation....655
Switch Removal And Installation....655
ENGINE SERVICE....658
ENGINE INFORMATION....660
Description....660
Specifications....661
Torque Values....665
Troubleshooting....667
Engine Removal And Installation....668
Engine Mount Replacement....676
Compression-Checking....677
ENGINE SPEED CONTROL....678
Removal And Installation....678
MUFFLER....680
Removal And Installation....680
AIR CLEANER....682
Removal And Installation....682
ENGINE COOLING SYSTEM....684
Radiator Removal And Installation....684
Fan Removal And Installation....685
Water Pump Removal And Installation....685
Water Pump Disassembly And Assembly....686
Thermostat Housing Removal And Installation....686
Testing The Thermostat....687
LUBRICATION SYSTEM....688
Oil Pan Removal And Installation....688
Oil Pump Removal And Installation....688
Oil Pump Inspection....689
Oil Pump Inspection (Cont?d)....690
Engine Oil Pressure - Testing....690
FUEL SYSTEM....692
Fuel Camshaft Removal And Installation....692
Fuel Camshaft Governor Disassembly And Assembly....692
Fuel Shutoff Solenoid - Checking....693
Fuel Shutoff Solenoid Removal And Installation....694
Fuel Injection Pump Removal And Installation....695
Timing The Injection Pump....697
Fuel Injector Removal And Installation....699
Fuel Injector Nozzles Pressure - Checking....700
Nozzle Spray Condition....701
Valve Seat Tightness....702
CYLINDER HEAD....704
Glow Plug - Testing....704
Glow Plug Removal And Installation....705
Valve Clearance Adjustment....705
Valve Timing - Checking....706
Cylinder Head Removal And Installation....707
Cylinder Head Disassembly and Assembly....709
Cylinder Head - Servicing....709
Cylinder Head Top Clearance....710
Valve Guide - Checking....710
Reconditioning The Valve And Valve Seat....711
Valve Spring....713
Valve Tappets....714
Rocker Arm And Shaft - Checking....714
CRANKSHAFT AND PISTONS....716
Piston And Connecting Rod Removal And Installation....716
Piston And Connecting Rod - Servicing....718
Cylinder Bore Checking....720
Connecting Rod Alignment....720
Crankshaft And Bearings Removal And Installation....721
Crankshaft And Bearings - Servicing....722
CAMSHAFT AND TIMING GEARS....728
Timing Gearcase Cover Removal And Installation....728
Timing Gears Backlash - Checking....730
Idler Gear And Shaft Removal And Installation....730
Camshaft - Servicing....731
Idler Gear And Shaft Servicing....733
FLYWHEEL....734
Flywheel Removal And Installation....734
HEATER....736
HEATER SYSTEM....738
Description....738
REGULAR MAINTENANCE....740
Filter Elements Removal And Installation....740
Cleaning The Heater Coil....741
TROUBLESHOOTING....742
Blower Motor Does Not Operate....742
Blower Motor Operators Normally, But Air Flow Is Insufficient....742
Electrical System....743
Engine Coolant Bypassing The Heater Valve....747
Heater Valve Not Opening Or Closing....747
HEATER UNIT....750
Removal And Installation....750
HEATER COIL....752
Removal And Installation....752
HEATER FAN....754
Blower Removal And Installation....754
Disassembly And Assembly....755
Connector Identification....757
HEATER VALVE....758
Removal and Installation....758
Disassembly And Assembly....759
SPECIFICATIONS....760
LOADER SPECIFICATIONS....762
Machine Dimensions....762
Machine Rating....763
Function Time....763
Weights....763
Engine....763
Electrical....764
Hydraulic System....764
Hydraulic Cylinders....764
Drive System....764
Traction....765
Environmental....765
Fluid Capacities....765
Fluid Specifications....766
Controls....766
Instrumentation....767
TORQUE SPECIFICATIONS FOR BOLTS....768
Torque For General SAE Bolts....768
Torque For General Metric Bolts....769
HYDRAULIC CONNECTION SPECIFICATIONS....770
O-ring Face Seal Connection....770
Straight Thread O-ring Fitting....771
Tubelines And Hoses....771
Flare Fitting....771
Port Seal Fitting....772
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....774
Specifications....774
CONVERSIONS....776
Decimal And Millimeter Equivalent Chart....776
U.S. To Metric Conversion Chart....776
6904926 (10-12) - S100 Skid-Steer Loader Service Manual....778
MAINTENANCE SAFETY....780
ALPHABETICAL INDEX....782
CONTENTS....784
FOREWORD....785
SAFETY INSTRUCTIONS....788
FIRE PREVENTION....790
Maintenance....790
Operation....790
Electrical....790
Hydraulic System....790
Fueling....790
Starting....790
Spark Arrestor Exhaust System....790
Welding And Grinding....791
Fire Extinguishers....791
SERIAL NUMBER LOCATIONS....792
Loader Serial Number....792
Engine Serial Number....792
DELIVERY REPORT....793
LOADER IDENTIFICATION....794
SAFETY AND MAINTENANCE....796
LIFTING AND BLOCKING THE LOADER....800
Procedure....800
LIFT ARM SUPPORT DEVICE....802
Installing....802
Removing....803
OPERATOR CAB....804
Description....804
Raising....804
Lowering....805
Cab Door Sensor....806
TRANSPORTING THE LOADER ON A TRAILER....808
Loading And Unloading....808
Fastening....808
TOWING THE LOADER....810
Procedure....810
REMOTE START TOOL KIT-MEL1563....812
Remote Start Tool - MEL1563....812
Service Tool Harness Control - MEL1565....813
Service Tool Harness Communicator - MEL1566....814
Remote Start Procedure....815
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....818
Description....818
Remote Start Tool (Service Tool) - 7003030....819
Loader Service Tool Harness - 6689747....820
Computer Service Tool Harness - 6689746....821
Remote Start Procedure....822
SERVICE SCHEDULE....826
Chart....826
AIR CLEANER SERVICE....828
Replacing Filter Elements....828
ENGINE COOLING SYSTEM....832
Cleaning....832
Checking Level....832
Removing And Replacing Coolant....833
FUEL SYSTEM....834
Fuel Specifications....834
Biodiesel Blend Fuel....834
Filling The Fuel Tank....835
Fuel Filter....836
Removing Air From The Fuel System....836
ENGINE LUBRICATION SYSTEM....838
Checking And Adding Engine Oil....838
Engine Oil Chart....838
Removing And Replacing Oil And Filter....838
HYDRAULIC / HYDROSTATIC SYSTEM....840
Checking And Adding Fluid....840
Hydraulic / Hydrostatic Fluid Chart....840
Removing And Replacing Hydraulic Fluid....841
Removing And Replacing Hydraulic / Hydrostatic Filter....842
Removing And Replacing Case Drain Filters....843
Removing And Replacing Hydraulic Charge Filter....844
Breather Cap....844
FINAL DRIVE TRANSMISSION (CHAINCASE)....846
Checking And Adding Oil....846
Removing And Replacing Oil....846
BOB-TACH (HAND LEVER)....848
Inspection And Maintenance....848
LUBRICATING THE LOADER....850
Lubrication Locations....850
TIRE MAINTENANCE....852
Wheel Nuts....852
Rotating....852
Mounting....852
SPARK ARRESTOR MUFFLER....854
Cleaning Procedure....854
PIVOT PINS....856
Inspection And Maintenance....856
LOADER STORAGE AND RETURN TO SERVICE....858
Storage....858
Return To Service....858
STOPPING THE ENGINE AND LEAVING THE LOADER....860
Procedure....860
Emergency Exit....861
HYDRAULIC SYSTEM....862
HYDRAULIC / HYDROSTATIC SCHEMATIC....864
HYDRAULIC SYSTEM INFORMATION....866
Glossary Of Hydraulic / Hydrostatic Symbols....866
Troubleshooting....870
CYLINDER (LIFT)....872
Testing....872
Removal And Installation....873
Parts Identification....874
Disassembly And Assembly....875
CYLINDER (TILT)....878
Testing....878
Removal And Installation....878
Parts Identification....880
Disassembly And Assembly....881
MAIN RELIEF VALVE....884
Description....884
Testing....884
Adjusting....885
Removal And Installation....885
HYDRAULIC CONTROL VALVE....886
Description....886
Removal And Installation....886
Identification Chart....889
Load Check Valve Removal And Installation (Tilt and Auxiliary)....890
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....891
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....892
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....892
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....893
Port Relief Valve Removal And Installation....893
Rubber Boot Removal And Installation....894
End Cap / Spool Lock Block Removal And Installation....894
Lift Spool And Detent Removal And Installation....895
Tilt Spool Removal And Installation....904
Auxiliary Spool Removal And Installation....906
Solenoid Removal And Installation....914
Lock Valve Removal And Installation....915
Main Relief Valve Removal And Installation....917
LIFT ARM bypass CONTROL VALVE....918
Description....918
Testing....918
Removal and Installation....918
Disassembly And Assembly....920
HYDRAULIC PUMP....922
Description....922
Pump Test at Quick Couplers....922
Direct Pump Test....923
Direct Pump Test (Charge Section)....924
Removal And Installation....927
Parts Identification....930
Disassembly And Assembly....931
Hydraulic Pump Start Up....935
HYDRAULIC / HYDROSTATIC FILTERS....936
Description....936
Hydraulic / Hydrostatic Filter Housing Removal And Installation....936
HYDRAULIC FLUID RESERVOIR....938
Description....938
Removal And Installation....938
Hydraulic Fluid Screen....939
OIL COOLER....940
Description....940
Removal And Installation....940
BUCKET POSITION VALVE....942
Description....942
Solenoid Removal And Installation....942
Solenoid Testing....943
Removal And Installation....943
Disassembly And Assembly....946
FRONT AUXILIARY HYDRAULIC COUPLERS....948
Description....948
Removal And Installation....948
HYDROSTATIC SYSTEM....950
HYDROSTATIC SYSTEM INFORMATION....952
Description....952
Troubleshooting....953
HYDROSTATIC MOTOR....954
Description....954
Removal And Installation....954
Parts Identification....956
Disassembly And Assembly....957
CHARGE PRESSURE....962
Description....962
Testing....962
Sender Removal And Installation....963
Adjusting....964
HYDROSTATIC PUMP....966
Description....966
Replenishing / High Pressure Relief Valve Removal And Installation....966
Removal And Installation....967
Hydrostatic Pump Start Up....969
Parts Identification....970
Disassembly....971
Assembly....976
DRIVE BELT....982
Description....982
Shield Removal And Installation....982
Adjusting....982
Belt Removal And Installation....983
Tensioner Pulley Removal And Installation....983
Tensioner Pulley Disassembly And Assembly....983
DRIVE SYSTEM....984
BRAKE....986
Description....986
Disk Removal And Installation....986
DRIVE COMPONENTS....988
Description....988
Axle Seal Removal And Installation....989
Axle Sprocket And Bearings Removal And Installation....991
Chain Removal And Installation....995
CHAINCASE....998
Description....998
Front Cover Removal And Installation....998
Center Cover Removal And Installation....999
MAIN FRAME....1002
SEAT BAR....1006
Description....1006
Removal And Installation....1006
Disassembly And Assembly....1008
Compression Spring Disassembly And Assembly....1009
OPERATOR CAB....1010
Gas Cylinder Removal And Installation....1010
Gas Cylinder Bracket Disassembly And Assembly....1012
Removal And Installation....1013
OPERATOR SEAT....1016
Removal And Installation....1016
Seat Belt Removal And Installation....1016
OPERATOR SEAT (SUSPENSION)....1018
Removal And Installation....1018
Slide Rail Removal And Installation....1019
Seat Belt Removal and Installation....1019
Lower Cushion Removal And Installation....1020
Back Cushion Removal And Installation....1020
Shock Removal And Installation....1021
3-Point Seat Belt Removal And Installation....1021
BOB-TACH (HAND LEVER)....1024
Description....1024
Removal And Installation....1024
Lever And Wedge Disassembly And Assembly....1026
Pivot Pin Bushing And Seal Removal And Installation....1027
LIFT ARMS....1028
Removal And Installation....1028
REAR GRILL....1034
Removal And Installation....1034
REAR DOOR....1036
Removal And Installation....1036
Striker Removal and Installation....1037
Striker Disassembly and Assembly....1037
Striker (Adjusting)....1037
Latch Removal And Installation....1038
FUEL TANK....1040
Removal And Installation....1040
Fuel Level Sender Removal And Installation....1041
Fuel Fill Screen Removal And Installation....1041
Fuel Pickup Screen....1041
CONTROL PEDALS AND LINKAGES....1042
Description....1042
Pedal Removal And Installation....1042
Linkage Removal And Installation....1043
Pedal (Adjusting)....1043
CONTROL PANEL....1046
Description....1046
Removal and Installation....1047
Shaft Removal And Installation....1050
Shaft Disassembly And Assembly....1050
Linkage Removal And Installation....1051
Pintle Arm Removal And Installation....1052
Pintle Arm Disassembly and Assembly....1055
Linkage Neutral Adjusting....1056
Linkage Travel Adjusting....1059
CONTROL HANDLE / LEVER....1064
Description....1064
Lever Removal And Installation....1064
Boot Removal And Installation....1064
WINDOW (REAR)....1066
Removal....1066
Installation....1066
WINDOW (TOP)....1068
Removal And Installation....1068
WINDOW (SIDE)....1070
Removal And Installation....1070
WINDOW (FRONT DOOR)....1072
Removal (Standard Window)....1072
Installation (Standard Window)....1073
Removal And Installation (Special Applications Window)....1074
ELECTRICAL SYSTEM & ANALYSIS....1076
ELECTRICAL SCHEMATICS....1080
ELECTRICAL SYSTEM INFORMATION....1082
Glossary Of Electrical Symbols....1082
Cab Harness Connectors....1085
Mainframe Harness Connectors....1086
Description....1087
Troubleshooting....1088
Fuse And Relay Location / Identification....1089
Solenoid Testing....1090
BATTERY....1092
Removal And Installation....1092
Servicing....1093
Using A Booster Battery (Jump Starting)....1094
ALTERNATOR....1096
Belt Adjustment....1096
Charging System Inspection....1096
Alternator Voltage Testing....1097
Low Voltage Testing....1098
High Voltage Testing....1098
Removal And Installation....1099
Parts Identification....1101
STARTER....1102
Testing....1102
Removal And Installation....1103
Parts Identification....1104
INSTRUMENT PANELS....1106
Left Panel....1106
Display Screen....1107
Standard Key Panel....1107
Option And Field Accessory Panels....1108
Removal And Installation (Left And Right)....1109
Key Switch Removal And Installation....1110
Alarm Removal And Installation....1110
Front Accessory Panel Removal And Installation....1111
LIGHTS....1112
Front Removal And Installation....1112
Rear Removal And Installation....1112
Cab Light Removal And Installation....1113
BOBCAT CONTROLLER (MAIN)....1114
Description....1114
Connector Identification....1115
Removal And Installation....1117
DIAGNOSTIC SERVICE CODES....1118
Viewing Service Codes (Standard Key Panel)....1118
Service Codes List....1119
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....1124
Description....1124
Inspecting The BICS Controller (Engine STOPPED - Key ON)....1124
Inspecting The Seat Bar Sensor (Engine RUNNING)....1124
Inspecting The Traction Lock (Engine RUNNING)....1124
Inspecting The Lift Arm Bypass Control....1125
Troubleshooting....1126
Troubleshooting Chart....1127
SEAT BAR SENSOR....1128
Description....1128
Troubleshooting....1128
Testing....1129
Removal And Installation....1130
Bobcat Interlock Control System (BICS) Circuit Test....1132
TRACTION LOCK....1134
Description....1134
Troubleshooting....1134
Removal And Installation....1135
Inspecting....1138
SERVICE PC (LAPTOP COMPUTER)....1140
Connecting To The Remote Start Tool....1140
Connecting Remote Start Tool (Service Tool)....1140
FLYWHEEL RPM SENSOR....1142
Description....1142
Adjusting....1142
MAINTENANCE CLOCK....1144
Description....1144
Setup....1145
Reset....1148
BACK-UP ALARM SYSTEM....1150
Description....1150
Inspecting....1150
Adjusting Switch Position....1151
Troubleshooting....1152
Alarm Removal And Installation....1153
Switch Removal And Installation....1153
ENGINE SERVICE....1156
ENGINE INFORMATION....1158
Description....1158
Specifications....1159
Torque Values....1163
Troubleshooting....1165
Engine Removal And Installation....1166
Engine Mount Replacement....1174
Compression-Checking....1175
ENGINE SPEED CONTROL....1176
Removal And Installation....1176
MUFFLER....1178
Removal And Installation....1178
AIR CLEANER....1180
Removal And Installation....1180
ENGINE COOLING SYSTEM....1182
Radiator Removal And Installation....1182
Fan Removal And Installation....1183
Water Pump Removal And Installation....1183
Water Pump Disassembly And Assembly....1184
Thermostat Housing Removal And Installation....1184
Testing The Thermostat....1185
LUBRICATION SYSTEM....1186
Oil Pan Removal And Installation....1186
Oil Pump Removal And Installation....1186
Oil Pump Inspection....1187
Engine Oil Pressure - Testing....1188
FUEL SYSTEM....1190
Fuel Camshaft Removal And Installation....1190
Fuel Camshaft Governor Disassembly And Assembly....1190
Fuel Shutoff Solenoid - Checking....1191
Fuel Shutoff Solenoid Removal And Installation....1192
Fuel Injection Pump Removal And Installation....1193
Timing The Injection Pump....1195
Fuel Injector Removal And Installation....1197
Fuel Injector Nozzles Pressure - Checking....1198
Nozzle Spray Condition....1199
Valve Seat Tightness....1200
CYLINDER HEAD....1202
Glow Plug - Testing....1202
Glow Plug Removal And Installation....1203
Valve Clearance Adjustment....1203
Valve Timing - Checking....1204
Cylinder Head Removal And Installation....1205
Cylinder Head Disassembly and Assembly....1207
Cylinder Head - Servicing....1207
Cylinder Head Top Clearance....1208
Valve Guide - Checking....1208
Reconditioning The Valve And Valve Seat....1209
Valve Spring....1211
Valve Tappets....1211
Rocker Arm And Shaft - Checking....1212
CRANKSHAFT AND PISTONS....1214
Piston And Connecting Rod Removal And Installation....1214
Piston And Connecting Rod - Servicing....1215
Cylinder Bore Checking....1217
Connecting Rod Alignment....1218
Crankshaft And Bearings Removal And Installation....1218
Crankshaft And Bearings - Servicing....1220
CAMSHAFT AND TIMING GEARS....1226
Timing Gearcase Cover Removal And Installation....1226
Timing Gears Backlash - Checking....1228
Idler Gear And Shaft Removal And Installation....1228
Camshaft - Servicing....1229
Idler Gear And Shaft Servicing....1231
FLYWHEEL....1232
Flywheel Removal And Installation....1232
HEATER....1234
HEATER SYSTEM....1236
Description....1236
REGULAR MAINTENANCE....1238
Filter Elements Removal And Installation....1238
Cleaning The Heater Coil....1239
TROUBLESHOOTING....1240
Blower Motor Does Not Operate....1240
Blower Motor Operators Normally, But Air Flow Is Insufficient....1240
Electrical System....1241
Engine Coolant bypassing The Heater Valve....1245
Heater Valve Not Opening Or Closing....1245
HEATER UNIT....1248
Removal And Installation....1248
HEATER COIL....1250
Removal And Installation....1250
HEATER FAN....1252
Blower Removal And Installation....1252
Disassembly And Assembly....1253
Connector Identification....1255
HEATER VALVE....1256
Removal and Installation....1256
Disassembly And Assembly....1257
SPECIFICATIONS....1258
(S100) LOADER SPECIFICATIONS....1260
Dimensions....1260
Performance....1261
Controls....1261
Engine....1262
Hydraulic System....1262
Electrical....1263
Drive System....1263
Capacities....1264
Tires....1264
TORQUE SPECIFICATIONS FOR BOLTS....1266
Torque For General SAE Bolts....1266
Torque For General Metric Bolts....1267
HYDRAULIC CONNECTION SPECIFICATIONS....1268
O-ring Face Seal Connection....1268
Straight Thread O-ring Fitting....1269
Tubelines And Hoses....1269
Flare Fitting....1269
Port Seal Fitting....1270
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....1272
Specifications....1272
CONVERSIONS....1274
Decimal And Millimeter Equivalent Chart....1274
U.S. To Metric Conversion Chart....1274
SMR....1276
S100-1....1276
S100-2....1278
S100-3....1280
6904926 (4-11) - S100 Skid-Steer Loader Service Manual....1282
MAINTENANCE SAFETY....1284
ALPHABETICAL INDEX....1286
CONTENTS....1288
FOREWORD....1289
SAFETY INSTRUCTIONS....1292
FIRE PREVENTION....1294
Maintenance....1294
Operation....1294
Electrical....1294
Hydraulic System....1294
Fueling....1294
Starting....1294
Spark Arrestor Exhaust System....1294
Welding And Grinding....1295
Fire Extinguishers....1295
SERIAL NUMBER LOCATIONS....1296
Loader Serial Number....1296
Engine Serial Number....1296
DELIVERY REPORT....1297
LOADER IDENTIFICATION....1298
SAFETY AND MAINTENANCE....1300
LIFTING AND BLOCKING THE LOADER....1304
Procedure....1304
LIFT ARM SUPPORT DEVICE....1306
Installing....1306
Removing....1307
OPERATOR CAB....1308
Description....1308
Raising....1308
Lowering....1309
Cab Door Sensor....1310
TRANSPORTING THE LOADER ON A TRAILER....1312
Loading And Unloading....1312
Fastening....1312
TOWING THE LOADER....1314
Procedure....1314
REMOTE START TOOL KIT-MEL1563....1316
Remote Start Tool - MEL1563....1316
Service Tool Harness Control - MEL1565....1317
Service Tool Harness Communicator - MEL1566....1318
Remote Start Procedure....1319
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....1322
Description....1322
Remote Start Tool (Service Tool) - 7003030....1323
Loader Service Tool Harness - 6689747....1324
Computer Service Tool Harness - 6689746....1325
Remote Start Procedure....1326
SERVICE SCHEDULE....1330
Chart....1330
AIR CLEANER SERVICE....1332
Replacing Filter Elements....1332
ENGINE COOLING SYSTEM....1336
Cleaning....1336
Checking Level....1336
Removing And Replacing Coolant....1337
FUEL SYSTEM....1338
Fuel Specifications....1338
Biodiesel Blend Fuel....1338
Filling The Fuel Tank....1339
Fuel Filter....1340
Removing Air From The Fuel System....1340
ENGINE LUBRICATION SYSTEM....1342
Checking And Adding Engine Oil....1342
Engine Oil Chart....1342
Removing And Replacing Oil And Filter....1342
HYDRAULIC / HYDROSTATIC SYSTEM....1344
Checking And Adding Fluid....1344
Hydraulic / Hydrostatic Fluid Chart....1344
Removing And Replacing Hydraulic Fluid....1345
Removing And Replacing Hydraulic / Hydrostatic Filter....1346
Removing And Replacing Case Drain Filters....1347
Removing And Replacing Hydraulic Charge Filter....1348
Breather Cap....1348
FINAL DRIVE TRANSMISSION (CHAINCASE)....1350
Checking And Adding Oil....1350
Removing And Replacing Oil....1350
BOB-TACH (HAND LEVER)....1352
Inspection And Maintenance....1352
LUBRICATING THE LOADER....1354
Lubrication Locations....1354
TIRE MAINTENANCE....1356
Wheel Nuts....1356
Rotating....1356
Mounting....1356
SPARK ARRESTOR MUFFLER....1358
Cleaning Procedure....1358
PIVOT PINS....1360
Inspection And Maintenance....1360
LOADER STORAGE AND RETURN TO SERVICE....1362
Storage....1362
Return To Service....1362
STOPPING THE ENGINE AND LEAVING THE LOADER....1364
Procedure....1364
Emergency Exit....1365
HYDRAULIC SYSTEM....1366
HYDRAULIC / HYDROSTATIC SCHEMATIC....1368
HYDRAULIC SYSTEM INFORMATION....1370
Glossary Of Hydraulic / Hydrostatic Symbols....1370
Troubleshooting....1374
CYLINDER (LIFT)....1376
Testing....1376
Removal And Installation....1377
Parts Identification....1378
Disassembly And Assembly....1379
CYLINDER (TILT)....1382
Testing....1382
Removal And Installation....1382
Parts Identification....1384
Disassembly And Assembly....1385
MAIN RELIEF VALVE....1388
Description....1388
Testing....1388
Adjusting....1389
Removal And Installation....1389
HYDRAULIC CONTROL VALVE....1390
Description....1390
Removal And Installation....1390
Identification Chart....1393
Load Check Valve Removal And Installation (Tilt and Auxiliary)....1394
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1395
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1396
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1396
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1397
Port Relief Valve Removal And Installation....1397
Rubber Boot Removal And Installation....1398
End Cap / Spool Lock Block Removal And Installation....1398
Lift Spool And Detent Removal And Installation....1399
Tilt Spool Removal And Installation....1408
Auxiliary Spool Removal And Installation....1410
Solenoid Removal And Installation....1418
Lock Valve Removal And Installation....1419
Main Relief Valve Removal And Installation....1421
LIFT ARM bypass CONTROL VALVE....1422
Description....1422
Testing....1422
Removal and Installation....1422
Disassembly And Assembly....1424
HYDRAULIC PUMP....1426
Description....1426
Pump Test at Quick Couplers....1426
Direct Pump Test....1427
Direct Pump Test (Charge Section)....1428
Removal And Installation....1431
Parts Identification....1434
Disassembly And Assembly....1435
Hydraulic Pump Start Up....1439
HYDRAULIC / HYDROSTATIC FILTERS....1440
Description....1440
Hydraulic / Hydrostatic Filter Housing Removal And Installation....1440
HYDRAULIC FLUID RESERVOIR....1442
Description....1442
Removal And Installation....1442
Hydraulic Fluid Screen....1443
OIL COOLER....1444
Description....1444
Removal And Installation....1444
BUCKET POSITION VALVE....1446
Description....1446
Solenoid Removal And Installation....1446
Solenoid Testing....1447
Removal And Installation....1447
Disassembly And Assembly....1450
FRONT AUXILIARY HYDRAULIC COUPLERS....1452
Description....1452
Removal And Installation....1452
HYDROSTATIC SYSTEM....1454
HYDROSTATIC SYSTEM INFORMATION....1456
Description....1456
Troubleshooting....1457
HYDROSTATIC MOTOR....1458
Description....1458
Removal And Installation....1458
Parts Identification....1460
Disassembly And Assembly....1461
CHARGE PRESSURE....1466
Description....1466
Testing....1466
Sender Removal And Installation....1467
Adjusting....1468
HYDROSTATIC PUMP....1470
Description....1470
Replenishing / High Pressure Relief Valve Removal And Installation....1470
Removal And Installation....1471
Hydrostatic Pump Start Up....1473
Parts Identification....1474
Disassembly....1475
Assembly....1480
DRIVE BELT....1486
Description....1486
Shield Removal And Installation....1486
Adjusting....1486
Belt Removal And Installation....1487
Tensioner Pulley Removal And Installation....1487
Tensioner Pulley Disassembly And Assembly....1487
DRIVE SYSTEM....1488
BRAKE....1490
Description....1490
Disk Removal And Installation....1490
DRIVE COMPONENTS....1492
Description....1492
Axle Seal Removal And Installation....1493
Axle Sprocket And Bearings Removal And Installation....1495
Chain Removal And Installation....1499
CHAINCASE....1502
Description....1502
Front Cover Removal And Installation....1502
Center Cover Removal And Installation....1503
MAIN FRAME....1506
SEAT BAR....1510
Description....1510
Removal And Installation....1510
Disassembly And Assembly....1512
Compression Spring Disassembly And Assembly....1513
OPERATOR CAB....1514
Gas Cylinder Removal And Installation....1514
Gas Cylinder Bracket Disassembly And Assembly....1516
Removal And Installation....1517
OPERATOR SEAT....1520
Removal And Installation....1520
Seat Belt Removal And Installation....1520
OPERATOR SEAT (SUSPENSION)....1522
Removal And Installation....1522
Slide Rail Removal And Installation....1523
Seat Belt Removal and Installation....1523
Lower Cushion Removal And Installation....1524
Back Cushion Removal And Installation....1524
Shock Removal And Installation....1525
3-Point Seat Belt Removal And Installation....1525
BOB-TACH (HAND LEVER)....1528
Description....1528
Removal And Installation....1528
Lever And Wedge Disassembly And Assembly....1530
Pivot Pin Bushing And Seal Removal And Installation....1531
LIFT ARMS....1532
Removal And Installation....1532
REAR GRILL....1538
Removal And Installation....1538
REAR DOOR....1540
Removal And Installation....1540
Striker Removal and Installation....1541
Striker Disassembly and Assembly....1541
Striker (Adjusting)....1541
Latch Removal And Installation....1542
FUEL TANK....1544
Removal And Installation....1544
Fuel Level Sender Removal And Installation....1545
Fuel Fill Screen Removal And Installation....1545
Fuel Pickup Screen....1545
CONTROL PEDALS AND LINKAGES....1546
Description....1546
Pedal Removal And Installation....1546
Linkage Removal And Installation....1547
Pedal (Adjusting)....1547
CONTROL PANEL....1550
Description....1550
Removal and Installation....1551
Shaft Removal And Installation....1554
Shaft Disassembly And Assembly....1554
Linkage Removal And Installation....1555
Pintle Arm Removal And Installation....1556
Pintle Arm Disassembly and Assembly....1559
Linkage Neutral Adjusting....1560
Linkage Travel Adjusting....1563
CONTROL HANDLE / LEVER....1568
Description....1568
Lever Removal And Installation....1568
Boot Removal And Installation....1568
WINDOW (REAR)....1570
Removal....1570
Installation....1570
WINDOW (TOP)....1572
Removal And Installation....1572
WINDOW (SIDE)....1574
Removal And Installation....1574
WINDOW (FRONT DOOR)....1576
Removal (Standard Window)....1576
Installation (Standard Window)....1577
Removal And Installation (Special Applications Window)....1578
ELECTRICAL SYSTEM & ANALYSIS....1580
ELECTRICAL SCHEMATICS....1584
ELECTRICAL SYSTEM INFORMATION....1586
Glossary Of Electrical Symbols....1586
Cab Harness Connectors....1589
Mainframe Harness Connectors....1590
Description....1591
Troubleshooting....1592
Fuse And Relay Location / Identification....1593
Solenoid Testing....1594
BATTERY....1596
Removal And Installation....1596
Servicing....1597
Using A Booster Battery (Jump Starting)....1598
ALTERNATOR....1600
Belt Adjustment....1600
Charging System Inspection....1600
Alternator Voltage Testing....1601
Low Voltage Testing....1602
High Voltage Testing....1602
Removal And Installation....1603
Parts Identification....1605
STARTER....1606
Testing....1606
Removal And Installation....1607
Parts Identification....1608
INSTRUMENT PANELS....1610
Left Panel....1610
Display Screen....1611
Standard Key Panel....1611
Option And Field Accessory Panels....1612
Removal And Installation (Left And Right)....1613
Key Switch Removal And Installation....1614
Alarm Removal And Installation....1614
Front Accessory Panel Removal And Installation....1615
LIGHTS....1616
Front Removal And Installation....1616
Rear Removal And Installation....1616
Cab Light Removal And Installation....1617
BOBCAT CONTROLLER (MAIN)....1618
Description....1618
Connector Identification....1619
Removal And Installation....1621
DIAGNOSTIC SERVICE CODES....1622
Viewing Service Codes (Standard Key Panel)....1622
Service Codes List....1623
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....1628
Description....1628
Inspecting The BICS Controller (Engine STOPPED - Key ON)....1628
Inspecting The Seat Bar Sensor (Engine RUNNING)....1628
Inspecting The Traction Lock (Engine RUNNING)....1628
Inspecting The Lift Arm Bypass Control....1629
Troubleshooting....1630
Troubleshooting Chart....1631
SEAT BAR SENSOR....1632
Description....1632
Troubleshooting....1632
Testing....1633
Removal And Installation....1634
Bobcat Interlock Control System (BICS) Circuit Test....1636
TRACTION LOCK....1638
Description....1638
Troubleshooting....1638
Removal And Installation....1639
Inspecting....1642
SERVICE PC (LAPTOP COMPUTER)....1644
Connecting To The Remote Start Tool....1644
Connecting Remote Start Tool (Service Tool)....1644
FLYWHEEL RPM SENSOR....1646
Description....1646
Adjusting....1646
MAINTENANCE CLOCK....1648
Description....1648
Setup....1649
Reset....1652
BACK-UP ALARM SYSTEM....1654
Description....1654
Inspecting....1654
Adjusting Switch Position....1655
Troubleshooting....1656
Alarm Removal And Installation....1657
Switch Removal And Installation....1657
ENGINE SERVICE....1660
ENGINE INFORMATION....1662
Description....1662
Specifications....1663
Torque Values....1667
Troubleshooting....1669
Engine Removal And Installation....1670
Engine Mount Replacement....1678
Compression-Checking....1679
ENGINE SPEED CONTROL....1680
Removal And Installation....1680
MUFFLER....1682
Removal And Installation....1682
AIR CLEANER....1684
Removal And Installation....1684
ENGINE COOLING SYSTEM....1686
Radiator Removal And Installation....1686
Fan Removal And Installation....1687
Water Pump Removal And Installation....1687
Water Pump Disassembly And Assembly....1688
Thermostat Housing Removal And Installation....1688
Testing The Thermostat....1689
LUBRICATION SYSTEM....1690
Oil Pan Removal And Installation....1690
Oil Pump Removal And Installation....1690
Oil Pump Inspection....1691
Engine Oil Pressure - Testing....1692
FUEL SYSTEM....1694
Fuel Camshaft Removal And Installation....1694
Fuel Camshaft Governor Disassembly And Assembly....1694
Fuel Shutoff Solenoid - Checking....1695
Fuel Shutoff Solenoid Removal And Installation....1696
Fuel Injection Pump Removal And Installation....1697
Timing The Injection Pump....1699
Fuel Injector Removal And Installation....1701
Fuel Injector Nozzles Pressure - Checking....1702
Nozzle Spray Condition....1703
Valve Seat Tightness....1704
CYLINDER HEAD....1706
Glow Plug - Testing....1706
Glow Plug Removal And Installation....1707
Valve Clearance Adjustment....1707
Valve Timing - Checking....1708
Cylinder Head Removal And Installation....1709
Cylinder Head Disassembly and Assembly....1711
Cylinder Head - Servicing....1711
Cylinder Head Top Clearance....1712
Valve Guide - Checking....1712
Reconditioning The Valve And Valve Seat....1713
Valve Spring....1715
Valve Tappets....1715
Rocker Arm And Shaft - Checking....1716
CRANKSHAFT AND PISTONS....1718
Piston And Connecting Rod Removal And Installation....1718
Piston And Connecting Rod - Servicing....1719
Cylinder Bore Checking....1721
Connecting Rod Alignment....1722
Crankshaft And Bearings Removal And Installation....1722
Crankshaft And Bearings - Servicing....1724
CAMSHAFT AND TIMING GEARS....1730
Timing Gearcase Cover Removal And Installation....1730
Timing Gears Backlash - Checking....1732
Idler Gear And Shaft Removal And Installation....1732
Camshaft - Servicing....1733
Idler Gear And Shaft Servicing....1735
FLYWHEEL....1736
Flywheel Removal And Installation....1736
HEATER....1738
HEATER SYSTEM....1740
Description....1740
REGULAR MAINTENANCE....1742
Filter Elements Removal And Installation....1742
Cleaning The Heater Coil....1743
TROUBLESHOOTING....1744
Blower Motor Does Not Operate....1744
Blower Motor Operators Normally, But Air Flow Is Insufficient....1744
Electrical System....1745
Engine Coolant bypassing The Heater Valve....1749
Heater Valve Not Opening Or Closing....1749
HEATER UNIT....1752
Removal And Installation....1752
HEATER COIL....1754
Removal And Installation....1754
HEATER FAN....1756
Blower Removal And Installation....1756
Disassembly And Assembly....1757
Connector Identification....1759
HEATER VALVE....1760
Removal and Installation....1760
Disassembly And Assembly....1761
SPECIFICATIONS....1762
(S100) LOADER SPECIFICATIONS....1764
Dimensions....1764
Performance....1765
Controls....1765
Engine....1766
Hydraulic System....1766
Electrical....1767
Drive System....1767
Capacities....1768
Tires....1768
TORQUE SPECIFICATIONS FOR BOLTS....1770
Torque For General SAE Bolts....1770
Torque For General Metric Bolts....1771
HYDRAULIC CONNECTION SPECIFICATIONS....1772
O-ring Face Seal Connection....1772
Straight Thread O-ring Fitting....1773
Tubelines And Hoses....1773
Flare Fitting....1773
Port Seal Fitting....1774
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....1776
Specifications....1776
CONVERSIONS....1778
Decimal And Millimeter Equivalent Chart....1778
U.S. To Metric Conversion Chart....1778
SMR....1780
S100-1....1780
S100-2....1782
6904926 (9-08) - S100 Skid-Steer Loader Service Manual....1784
MAINTENANCE SAFETY....1786
ALPHABETICAL INDEX....1788
CONTENTS....1790
FOREWORD....1791
SAFETY INSTRUCTIONS....1794
FIRE PREVENTION....1796
Maintenance....1796
Operation....1796
Electrical....1796
Hydraulic System....1796
Fueling....1796
Starting....1796
Spark Arrestor Exhaust System....1796
Welding And Grinding....1797
Fire Extinguishers....1797
SERIAL NUMBER LOCATIONS....1798
Loader Serial Number....1798
Engine Serial Number....1798
DELIVERY REPORT....1799
LOADER IDENTIFICATION....1800
SAFETY AND MAINTENANCE....1802
LIFTING AND BLOCKING THE LOADER....1806
Procedure....1806
LIFT ARM SUPPORT DEVICE....1808
Installing....1808
Removing....1809
OPERATOR CAB....1810
Description....1810
Raising....1810
Lowering....1811
Cab Door Sensor....1812
TRANSPORTING THE LOADER ON A TRAILER....1814
Loading And Unloading....1814
Fastening....1814
TOWING THE LOADER....1816
Procedure....1816
REMOTE START TOOL KIT-MEL1563....1818
Remote Start Tool - MEL1563....1818
Service Tool Harness Control - MEL1565....1819
Service Tool Harness Communicator - MEL1566....1820
Remote Start Procedure....1821
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....1824
Description....1824
Remote Start Tool (Service Tool) - 6689778....1825
Loader Service Tool Harness - 6689747....1826
Computer Service Tool Harness - 6689746....1827
Remote Start Procedure....1828
SERVICE SCHEDULE....1832
Chart....1832
AIR CLEANER SERVICE....1834
Replacing Filter Elements....1834
ENGINE COOLING SYSTEM....1838
Cleaning....1838
Checking Level....1838
Removing And Replacing Coolant....1839
FUEL SYSTEM....1840
Fuel Specifications....1840
Biodiesel Blend Fuel....1840
Filling The Fuel Tank....1841
Fuel Filter....1842
Removing Air From The Fuel System....1842
ENGINE LUBRICATION SYSTEM....1844
Checking And Adding Engine Oil....1844
Engine Oil Chart....1844
Removing And Replacing Oil And Filter....1844
HYDRAULIC / HYDROSTATIC SYSTEM....1846
Checking And Adding Fluid....1846
Hydraulic / Hydrostatic Fluid Chart....1846
Removing And Replacing Hydraulic Fluid....1847
Removing And Replacing Hydraulic / Hydrostatic Filter....1848
Removing And Replacing Case Drain Filters....1849
Removing And Replacing Hydraulic Charge Filter....1850
Breather Cap....1850
FINAL DRIVE TRANSMISSION (CHAINCASE)....1852
Checking And Adding Oil....1852
Removing And Replacing Oil....1852
BOB-TACH (HAND LEVER)....1854
Inspection And Maintenance....1854
LUBRICATING THE LOADER....1856
Lubrication Locations....1856
TIRE MAINTENANCE....1858
Wheel Nuts....1858
Rotating....1858
Mounting....1858
SPARK ARRESTOR MUFFLER....1860
Cleaning Procedure....1860
PIVOT PINS....1862
Inspection And Maintenance....1862
LOADER STORAGE AND RETURN TO SERVICE....1864
Storage....1864
Return To Service....1864
STOPPING THE ENGINE AND LEAVING THE LOADER....1866
Procedure....1866
Emergency Exit....1867
HYDRAULIC SYSTEM....1868
HYDRAULIC / HYDROSTATIC SCHEMATIC....1870
HYDRAULIC SYSTEM INFORMATION....1872
Glossary Of Hydraulic / Hydrostatic Symbols....1872
Troubleshooting....1876
CYLINDER (LIFT)....1878
Testing....1878
Removal And Installation....1879
Parts Identification....1880
Disassembly And Assembly....1881
CYLINDER (TILT)....1884
Testing....1884
Removal And Installation....1884
Parts Identification....1886
Disassembly And Assembly....1887
MAIN RELIEF VALVE....1890
Description....1890
Testing....1890
Adjusting....1891
Removal And Installation....1891
HYDRAULIC CONTROL VALVE....1892
Description....1892
Removal And Installation....1892
Identification Chart....1895
Load Check Valve Removal And Installation (Tilt and Auxiliary)....1896
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1897
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1898
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1898
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1899
Port Relief Valve Removal And Installation....1899
Rubber Boot Removal And Installation....1900
End Cap / Spool Lock Block Removal And Installation....1900
Lift Spool And Detent Removal And Installation....1901
Tilt Spool Removal And Installation....1910
Auxiliary Spool Removal And Installation....1912
Solenoid Removal And Installation....1920
Lock Valve Removal And Installation....1921
Main Relief Valve Removal And Installation....1923
LIFT ARM bypass CONTROL VALVE....1924
Description....1924
Testing....1924
Removal and Installation....1924
Disassembly And Assembly....1926
HYDRAULIC PUMP....1928
Description....1928
Pump Test at Quick Couplers....1928
Direct Pump Test....1929
Direct Pump Test (Charge Section)....1930
Removal And Installation....1933
Parts Identification....1936
Disassembly And Assembly....1937
Hydraulic Pump Start Up....1941
HYDRAULIC / HYDROSTATIC FILTERS....1942
Description....1942
Hydraulic / Hydrostatic Filter Housing Removal And Installation....1942
HYDRAULIC FLUID RESERVOIR....1944
Description....1944
Removal And Installation....1944
Hydraulic Fluid Screen....1945
OIL COOLER....1946
Description....1946
Removal And Installation....1946
BUCKET POSITION VALVE....1948
Description....1948
Solenoid Removal And Installation....1948
Solenoid Testing....1949
Removal And Installation....1949
Disassembly And Assembly....1952
FRONT AUXILIARY HYDRAULIC COUPLERS....1954
Description....1954
Removal And Installation....1954
HYDROSTATIC SYSTEM....1956
HYDROSTATIC SYSTEM INFORMATION....1958
Description....1958
Troubleshooting....1959
HYDROSTATIC MOTOR....1960
Description....1960
Removal And Installation....1960
Parts Identification....1962
Disassembly And Assembly....1963
CHARGE PRESSURE....1968
Description....1968
Testing....1968
Sender Removal And Installation....1969
Adjusting....1970
HYDROSTATIC PUMP....1972
Description....1972
Replenishing / High Pressure Relief Valve Removal And Installation....1972
Removal And Installation....1973
Hydrostatic Pump Start Up....1975
Parts Identification....1976
Disassembly....1977
Assembly....1982
DRIVE BELT....1988
Description....1988
Shield Removal And Installation....1988
Adjusting....1988
Belt Removal And Installation....1989
Tensioner Pulley Removal And Installation....1989
Tensioner Pulley Disassembly And Assembly....1989
DRIVE SYSTEM....1990
BRAKE....1992
Description....1992
Disk Removal And Installation....1992
DRIVE COMPONENTS....1994
Description....1994
Axle Seal Removal And Installation....1995
Axle Sprocket And Bearings Removal And Installation....1997
Chain Removal And Installation....2001
CHAINCASE....2004
Description....2004
Front Cover Removal And Installation....2004
Center Cover Removal And Installation....2005
MAIN FRAME....2008
SEAT BAR....2012
Description....2012
Removal And Installation....2012
Disassembly And Assembly....2014
Compression Spring Disassembly And Assembly....2015
OPERATOR CAB....2016
Gas Cylinder Removal And Installation....2016
Gas Cylinder Bracket Disassembly And Assembly....2018
Removal And Installation....2019
OPERATOR SEAT....2022
Removal And Installation....2022
Seat Belt Removal And Installation....2022
OPERATOR SEAT (SUSPENSION)....2024
Removal And Installation....2024
Slide Rail Removal And Installation....2025
Seat Belt Removal and Installation....2025
Lower Cushion Removal And Installation....2026
Back Cushion Removal And Installation....2026
Shock Removal And Installation....2027
3-Point Seat Belt Removal And Installation....2027
BOB-TACH (HAND LEVER)....2030
Description....2030
Removal And Installation....2030
Lever And Wedge Disassembly And Assembly....2032
Pivot Pin Bushing And Seal Removal And Installation....2033
LIFT ARMS....2034
Removal And Installation....2034
REAR GRILL....2040
Removal And Installation....2040
REAR DOOR....2042
Removal And Installation....2042
Striker Removal and Installation....2043
Striker Disassembly and Assembly....2043
Striker (Adjusting)....2043
Latch Removal And Installation....2044
FUEL TANK....2046
Removal And Installation....2046
Fuel Level Sender Removal And Installation....2047
Fuel Fill Screen Removal And Installation....2047
Fuel Pickup Screen....2047
CONTROL PEDALS AND LINKAGES....2048
Description....2048
Pedal Removal And Installation....2048
Linkage Removal And Installation....2049
Pedal (Adjusting)....2049
CONTROL PANEL....2052
Description....2052
Removal and Installation....2053
Shaft Removal And Installation....2056
Shaft Disassembly And Assembly....2056
Linkage Removal And Installation....2057
Pintle Arm Removal And Installation....2058
Pintle Arm Disassembly and Assembly....2061
Linkage Neutral Adjusting....2062
Linkage Travel Adjusting....2065
CONTROL HANDLE / LEVER....2070
Description....2070
Lever Removal And Installation....2070
Boot Removal And Installation....2070
WINDOW (REAR)....2072
Removal....2072
Installation....2072
WINDOW (TOP)....2074
Removal And Installation....2074
WINDOW (SIDE)....2076
Removal And Installation....2076
WINDOW (FRONT DOOR)....2078
Removal (Standard Window)....2078
Installation (Standard Window)....2079
Removal And Installation (Special Applications Window)....2080
ELECTRICAL SYSTEM & ANALYSIS....2082
ELECTRICAL SCHEMATICS....2086
ELECTRICAL SYSTEM INFORMATION....2088
Glossary Of Electrical Symbols....2088
Cab Harness Connectors....2091
Mainframe Harness Connectors....2092
Description....2093
Troubleshooting....2094
Fuse And Relay Location / Identification....2095
Solenoid Testing....2096
BATTERY....2098
Removal And Installation....2098
Servicing....2099
Using A Booster Battery (Jump Starting)....2100
ALTERNATOR....2102
Belt Adjustment....2102
Charging System Inspection....2102
Alternator Voltage Testing....2103
Low Voltage Testing....2104
High Voltage Testing....2104
Removal And Installation....2105
Parts Identification....2107
STARTER....2108
Testing....2108
Removal And Installation....2109
Parts Identification....2110
INSTRUMENT PANELS....2112
Left Panel....2112
Display Screen....2113
Standard Key Panel....2113
Option And Field Accessory Panels....2114
Removal And Installation (Left And Right)....2115
Key Switch Removal And Installation....2116
Alarm Removal And Installation....2116
Front Accessory Panel Removal And Installation....2117
LIGHTS....2118
Front Removal And Installation....2118
Rear Removal And Installation....2118
Cab Light Removal And Installation....2119
BOBCAT CONTROLLER (MAIN)....2120
Description....2120
Connector Identification....2121
Removal And Installation....2123
DIAGNOSTIC SERVICE CODES....2124
Viewing Service Codes (Standard Key Panel)....2124
Service Codes List....2125
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2130
Description....2130
Inspecting The BICS Controller (Engine STOPPED - Key ON)....2130
Inspecting The Seat Bar Sensor (Engine RUNNING)....2130
Inspecting The Traction Lock (Engine RUNNING)....2130
Inspecting The Lift Arm Bypass Control....2131
Troubleshooting....2132
Troubleshooting Chart....2133
SEAT BAR SENSOR....2134
Description....2134
Troubleshooting....2134
Testing....2135
Removal And Installation....2136
Bobcat Interlock Control System (BICS) Circuit Test....2138
TRACTION LOCK....2140
Description....2140
Troubleshooting....2140
Removal And Installation....2141
Inspecting....2144
SERVICE PC (LAPTOP COMPUTER)....2146
Connecting To The Remote Start Tool....2146
Connecting Remote Start Tool (Service Tool)....2146
FLYWHEEL RPM SENSOR....2148
Description....2148
Adjusting....2148
MAINTENANCE CLOCK....2150
Description....2150
Setup....2151
Reset....2154
BACK-UP ALARM SYSTEM....2156
Description....2156
Inspecting....2156
Adjusting Switch Position....2157
Troubleshooting....2158
Alarm Removal And Installation....2159
Switch Removal And Installation....2159
ENGINE SERVICE....2162
ENGINE INFORMATION....2164
Description....2164
Specifications....2165
Torque Values....2169
Troubleshooting....2171
Engine Removal And Installation....2172
Engine Mount Replacement....2180
Compression-Checking....2181
ENGINE SPEED CONTROL....2182
Removal And Installation....2182
MUFFLER....2184
Removal And Installation....2184
AIR CLEANER....2186
Removal And Installation....2186
ENGINE COOLING SYSTEM....2188
Radiator Removal And Installation....2188
Fan Removal And Installation....2189
Water Pump Removal And Installation....2189
Water Pump Disassembly And Assembly....2190
Thermostat Housing Removal And Installation....2190
Testing The Thermostat....2191
LUBRICATION SYSTEM....2192
Oil Pan Removal And Installation....2192
Oil Pump Removal And Installation....2192
Oil Pump Inspection....2193
Engine Oil Pressure - Testing....2194
FUEL SYSTEM....2196
Fuel Camshaft Removal And Installation....2196
Fuel Camshaft Governor Disassembly And Assembly....2196
Fuel Shutoff Solenoid - Checking....2197
Fuel Shutoff Solenoid Removal And Installation....2198
Fuel Injection Pump Removal And Installation....2199
Timing The Injection Pump....2201
Fuel Injector Removal And Installation....2203
Fuel Injector Nozzles Pressure - Checking....2204
Nozzle Spray Condition....2205
Valve Seat Tightness....2206
CYLINDER HEAD....2208
Glow Plug - Testing....2208
Glow Plug Removal And Installation....2209
Valve Clearance Adjustment....2209
Valve Timing - Checking....2210
Cylinder Head Removal And Installation....2211
Cylinder Head Disassembly and Assembly....2213
Cylinder Head - Servicing....2213
Cylinder Head Top Clearance....2214
Valve Guide - Checking....2214
Reconditioning The Valve And Valve Seat....2215
Valve Spring....2217
Valve Tappets....2217
Rocker Arm And Shaft - Checking....2218
CRANKSHAFT AND PISTONS....2220
Piston And Connecting Rod Removal And Installation....2220
Piston And Connecting Rod - Servicing....2221
Cylinder Bore Checking....2223
Connecting Rod Alignment....2224
Crankshaft And Bearings Removal And Installation....2224
Crankshaft And Bearings - Servicing....2226
CAMSHAFT AND TIMING GEARS....2232
Timing Gearcase Cover Removal And Installation....2232
Timing Gears Backlash - Checking....2234
Idler Gear And Shaft Removal And Installation....2234
Camshaft - Servicing....2235
Idler Gear And Shaft Servicing....2237
FLYWHEEL....2238
Flywheel Removal And Installation....2238
HEATER....2240
HEATER SYSTEM....2242
Description....2242
REGULAR MAINTENANCE....2244
Filter Elements Removal And Installation....2244
Cleaning The Heater Coil....2245
TROUBLESHOOTING....2246
Blower Motor Does Not Operate....2246
Blower Motor Operators Normally, But Air Flow Is Insufficient....2246
Electrical System....2247
Engine Coolant bypassing The Heater Valve....2251
Heater Valve Not Opening Or Closing....2251
HEATER UNIT....2254
Removal And Installation....2254
HEATER COIL....2256
Removal And Installation....2256
HEATER FAN....2258
Blower Removal And Installation....2258
Disassembly And Assembly....2259
Connector Identification....2261
HEATER VALVE....2262
Removal and Installation....2262
Disassembly And Assembly....2263
SPECIFICATIONS....2264
(S100) LOADER SPECIFICATIONS....2266
Dimensions....2266
Performance....2267
Controls....2267
Engine....2268
Hydraulic System....2268
Electrical....2269
Drive System....2269
Capacities....2270
Tires....2270
TORQUE SPECIFICATIONS FOR BOLTS....2272
Torque For General SAE Bolts....2272
Torque For General Metric Bolts....2273
HYDRAULIC CONNECTION SPECIFICATIONS....2274
O-ring Face Seal Connection....2274
Straight Thread O-ring Fitting....2275
Tubelines And Hoses....2275
Flare Fitting....2275
Port Seal Fitting....2276
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....2278
Specifications....2278
CONVERSIONS....2280
Decimal And Millimeter Equivalent Chart....2280
U.S. To Metric Conversion Chart....2280
SMR....2282
S100-1....2282
6986660 (11-10) - S70 Skid-Steer Loader Operation & Maintenance Manual....2284
OPERATOR SAFETY WARNINGS....2286
CONTENTS....2288
FOREWORD....2290
BOBCAT COMPANY IS IS0 9001 CERTIFIED....2292
REGULAR MAINTENANCE ITEMS....2292
SERIAL NUMBER LOCATIONS....2293
Loader Serial Number....2293
Engine Serial Number....2293
LOADER IDENTIFICATION....2294
FEATURES, ACCESSORIES AND ATTACHMENTS....2295
Options And Accessories....2295
Buckets Available....2296
Attachments....2296
Special Applications Kit....2297
SAFETY & TRAINING RESOURCES....2298
SAFETY INSTRUCTIONS....2300
Before Operation....2300
Safe Operation Is The Operator?s Responsibility....2301
Safe Operation Needs A Qualified Operator....2301
Avoid Silica Dust....2302
FIRE PREVENTION....2302
Maintenance....2302
Operation....2302
Electrical....2302
Hydraulic System....2303
Fueling....2303
Starting....2303
Spark Arrestor Exhaust System....2303
Welding And Grinding....2303
Fire Extinguishers....2303
MACHINE SIGNS (DECALS)....2305
PUBLICATIONS AND TRAINING RESOURCES....2307
OPERATING INSTRUCTIONS....2308
INSTRUMENT PANEL IDENTIFICATION....2310
Left And Right Panels....2310
Standard Key Panel....2311
Keyless Start Panel....2311
Option And Field Accessory Panel....2312
CONTROL IDENTIFICATION....2313
Standard Controls....2313
SEAT BAR RESTRAINT SYSTEM....2314
Operation....2314
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2315
Operation....2315
LIFT ARM BYPASS CONTROL....2316
Operation....2316
PARKING BRAKE....2316
Operation....2316
TRACTION LOCK OVERRIDE....2317
Operation....2317
EMERGENCY EXIT....2318
Rear Window....2318
Front Door....2318
BACK-UP ALARM SYSTEM....2319
Description....2319
Operation....2319
ENGINE SPEED CONTROL....2320
Operation....2320
DRIVING AND STEERING THE LOADER....2321
Operation....2321
STOPPING THE LOADER....2321
Using The Control Levers....2321
HYDRAULIC CONTROLS....2322
Description....2322
Hydraulic Bucket Positioning....2322
Auxiliary Hydraulic Control Lockout....2322
Front Auxiliary Hydraulics Operation....2323
Quick Couplers....2324
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....2324
ATTACHMENT CONTROL DEVICE (ACD)....2325
Description....2325
DAILY INSPECTION....2326
Daily Inspection And Maintenance....2327
PRE-STARTING PROCEDURE....2328
Entering The Loader....2328
Operation & Maintenance Manual And Operator?s Handbook Locations....2328
Seat Adjustment....2329
Seat Belt Adjustment....2330
Seat Bar....2330
STARTING THE ENGINE....2331
Standard Key Panel....2331
Keyless Start Panel....2333
Cold Temperature Starting....2335
Warming The Hydraulic / Hydrostatic System....2335
MONITORING THE DISPLAY PANELS....2335
Right Panel....2335
STOPPING THE ENGINE AND LEAVING THE LOADER....2336
Procedure....2336
ATTACHMENTS....2337
Choosing The Correct Bucket....2337
Pallet Forks....2337
Installing And Removing The Attachment....2338
OPERATING PROCEDURE....2341
Inspect The Work Area....2341
Basic Operating Instructions....2341
Driving On Public Roads....2341
Operating With A Full Bucket....2342
Operating With An Empty Bucket....2342
Filling And Emptying The Bucket....2343
Leveling The Ground Using Float....2344
Digging And Filling A Hole....2344
TOWING THE LOADER....2345
Procedure....2345
LIFTING THE LOADER....2346
Single-Point Lift....2346
TRANSPORTING THE LOADER ON A TRAILER....2346
Loading And Unloading....2346
Fastening....2347
PREVENTIVE MAINTENANCE....2348
MAINTENANCE SAFETY....2352
SERVICE SCHEDULE....2354
Chart....2354
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2355
Inspecting The BICS (Engine STOPPED - Key ON)....2355
Inspecting The Seat Bar Sensor (Engine RUNNING)....2355
Inspecting The Traction Lock (Engine RUNNING)....2355
Inspecting The Lift Arm Bypass Control....2355
Inspecting Deactivation Of The Auxiliary Hydraulics System....2356
SEAT BAR RESTRAINT SYSTEM....2357
Description....2357
Inspecting....2357
Maintaining....2357
SEAT BELT....2358
Inspection And Maintenance....2358
LIFT ARM SUPPORT DEVICE....2359
Installing....2359
Removing....2360
BACK-UP ALARM SYSTEM....2361
Description....2361
Inspecting....2361
Adjusting Switch Position....2362
OPERATOR CAB....2363
Description....2363
Raising....2363
Lowering....2364
REAR DOOR (TAILGATE)....2366
Opening And Closing....2366
AIR CLEANER SERVICE....2367
Replacing Filter Elements....2367
FUEL SYSTEM....2368
Fuel Specifications....2368
Biodiesel Blend Fuel....2368
Filling The Fuel Tank....2369
Fuel Filter....2370
Removing Air From The Fuel System....2370
ENGINE LUBRICATION SYSTEM....2371
Checking And Adding Engine Oil....2371
Engine Oil Chart....2371
Removing And Replacing Oil And Filter....2371
ENGINE COOLING SYSTEM....2372
Cleaning....2372
Checking Level....2372
Removing And Replacing Coolant....2373
ELECTRICAL SYSTEM....2374
Description....2374
Fuse And Relay Location / Identification....2374
Battery Maintenance....2375
Using A Booster Battery (Jump Starting)....2375
Removing And Installing Battery....2377
HYDRAULIC / HYDROSTATIC SYSTEM....2378
Checking And Adding Fluid....2378
Hydraulic / Hydrostatic Fluid Chart....2378
Removing And Replacing Hydraulic Fluid....2379
Removing And Replacing Hydraulic / Hydrostatic Filter....2380
Breather Cap....2380
SPARK ARRESTOR MUFFLER....2381
Cleaning Procedure....2381
TIRE MAINTENANCE....2382
Wheel Nuts....2382
Rotating....2382
Mounting....2382
FINAL DRIVE TRANSMISSION (CHAINCASE)....2383
Checking And Adding Oil....2383
Removing And Replacing Oil....2383
ALTERNATOR BELT....2384
Belt Adjustment....2384
Belt Replacement....2384
DRIVE BELT....2385
Belt Adjustment....2385
Belt Replacement....2385
LUBRICATING THE LOADER....2386
Lubrication Locations....2386
PIVOT PINS....2388
Inspection And Maintenance....2388
BOB-TACH....2389
Inspection And Maintenance....2389
LOADER STORAGE AND RETURN TO SERVICE....2390
Storage....2390
Return To Service....2390
SYSTEM SETUP & ANALYSIS....2392
TROUBLESHOOTING....2394
Troubleshooting The Engine....2394
Troubleshooting The Hydraulic System....2395
Troubleshooting The Hydrostatic System....2395
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2396
Troubleshooting....2396
Viewing Diagnostic Service Codes....2396
MACHINE SIGN TRANSLATIONS....2398
MACHINE SIGN TRANSLATIONS....2400
Service Schedule (6734534)....2400
Warning (6579510)....2403
Danger (6702301)....2404
Danger (6702302)....2404
Danger (6717343)....2404
Warning (6579528)....2404
Lift Arm Support Device (6711659)....2405
Danger (6809511)....2405
Warning (6737189)....2406
Warning (6804233)....2406
Warning (6576048)....2406
Important (6732775)....2406
Warning (6565491)....2407
Important (6560573)....2407
Warning (6710358)....2408
Warning (6702255)....2408
Warning (6577754)....2409
SPECIFICATIONS....2410
(S70) LOADER SPECIFICATIONS....2412
Machine Dimensions....2412
Performance....2413
Engine....2413
Controls....2413
Drive System....2414
Hydraulic System....2414
Electrical....2415
Capacities....2415
Tires....2415
WARRANTY....2416
WARRANTY....2418
ALPHABETICAL INDEX....2420
6986660 (5-14) - S70 Skid-Steer Loader Operation & Maintenance Manual....2422
OPERATOR SAFETY WARNINGS....2424
CONTENTS....2426
FOREWORD....2428
BOBCAT COMPANY IS IS0 9001 CERTIFIED....2430
REGULAR MAINTENANCE ITEMS....2430
SERIAL NUMBER LOCATIONS....2431
Loader Serial Number....2431
Engine Serial Number....2431
DELIVERY REPORT....2431
LOADER IDENTIFICATION....2432
FEATURES, ACCESSORIES AND ATTACHMENTS....2433
Options And Accessories....2433
Buckets Available....2434
Attachments....2434
Special Applications Kit....2435
SAFETY AND TRAINING RESOURCES....2436
SAFETY INSTRUCTIONS....2438
Before Operation....2438
Safe Operation Is The Operator?s Responsibility....2439
Safe Operation Needs A Qualified Operator....2439
Avoid Silica Dust....2440
FIRE PREVENTION....2440
Maintenance....2440
Operation....2440
Electrical....2440
Hydraulic System....2441
Fueling....2441
Starting....2441
Spark Arrester Exhaust System....2441
Welding And Grinding....2441
Fire Extinguishers....2441
MACHINE SIGNS (DECALS)....2443
PUBLICATIONS AND TRAINING RESOURCES....2445
OPERATING INSTRUCTIONS....2446
INSTRUMENT PANEL IDENTIFICATION....2450
Left And Right Panels....2450
Standard Key Panel....2451
Keyless Start Panel....2451
Option And Field Accessory Panel....2452
Cab Heater Panel....2452
CONTROL IDENTIFICATION....2453
Standard Controls....2453
SEAT BAR RESTRAINT SYSTEM....2454
Operation....2454
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....2455
Operation....2455
LIFT ARM BYPASS CONTROL....2456
Operation....2456
PARKING BRAKE....2456
Operation....2456
TRACTION LOCK OVERRIDE....2457
Operation....2457
EMERGENCY EXIT....2458
Rear Window....2458
Front Door....2458
BACK-UP ALARM SYSTEM....2459
Description....2459
Operation....2459
ENGINE SPEED CONTROL....2460
Operation....2460
DRIVING AND STEERING THE LOADER....2461
Operation....2461
STOPPING THE LOADER....2461
Using The Control Levers....2461
HYDRAULIC CONTROLS....2462
Description....2462
Hydraulic Bucket Positioning....2462
Auxiliary Hydraulic Control Lockout....2462
Front Auxiliary Hydraulics Operation....2463
Quick Couplers....2464
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....2464
ATTACHMENT CONTROL DEVICE (ACD)....2465
Description....2465
DAILY INSPECTION....2466
Daily Inspection And Maintenance....2467
PRE-STARTING PROCEDURE....2468
Entering The Loader....2468
Operation & Maintenance Manual And Operator?s Handbook Locations....2468
Seat Adjustment....2469
Seat Belt Adjustment....2470
Seat Bar....2470
STARTING THE ENGINE....2471
Standard Key Panel....2471
Keyless Start Panel....2473
Cold Temperature Starting....2475
Warming The Hydraulic / Hydrostatic System....2475
MONITORING THE DISPLAY PANELS....2475
Right Panel....2475
STOPPING THE ENGINE AND LEAVING THE LOADER....2476
Procedure....2476
ATTACHMENTS....2477
Choosing The Correct Bucket....2477
Pallet Forks....2477
Installing And Removing The Attachment....2478
OPERATING PROCEDURE....2481
Inspect The Work Area....2481
Basic Operating Instructions....2481
Driving On Public Roads....2481
Operating With A Full Bucket....2482
Operating With An Empty Bucket....2482
Filling And Emptying The Bucket....2483
Leveling The Ground Using Float....2484
Digging And Filling A Hole....2484
TOWING THE LOADER....2485
Procedure....2485
LIFTING THE LOADER....2486
Single-Point Lift....2486
TRANSPORTING THE LOADER ON A TRAILER....2486
Loading And Unloading....2486
Fastening....2487
PREVENTIVE MAINTENANCE....2488
MAINTENANCE SAFETY....2492
SERVICE SCHEDULE....2494
Chart....2494
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....2495
Inspecting The BICS? (Engine STOPPED - Key ON)....2495
Inspecting The Seat Bar Sensor (Engine RUNNING)....2495
Inspecting The Traction Lock (Engine RUNNING)....2495
Inspecting The Lift Arm Bypass Control....2495
Inspecting Deactivation Of The Auxiliary Hydraulics System....2496
SEAT BAR RESTRAINT SYSTEM....2497
Description....2497
Inspecting....2497
Maintaining....2497
SEAT BELT....2498
Inspection And Maintenance....2498
LIFT ARM SUPPORT DEVICE....2499
Installing....2499
Removing....2500
BACK-UP ALARM SYSTEM....2501
Description....2501
Inspecting....2501
Adjusting Switch Position....2502
OPERATOR CAB....2503
Description....2503
Raising....2503
Lowering....2504
REAR DOOR (TAILGATE)....2506
Opening And Closing....2506
AIR CLEANER SERVICE....2507
Replacing Filter Elements....2507
FUEL SYSTEM....2508
Fuel Specifications....2508
Biodiesel Blend Fuel....2508
Filling The Fuel Tank....2509
Fuel Filter....2510
Removing Air From The Fuel System....2510
ENGINE LUBRICATION SYSTEM....2511
Checking And Adding Engine Oil....2511
Engine Oil Chart....2511
Removing And Replacing Oil And Filter....2511
ENGINE COOLING SYSTEM....2512
Cleaning....2512
Checking Level....2512
Removing And Replacing Coolant....2513
ELECTRICAL SYSTEM....2514
Description....2514
Fuse And Relay Location / Identification....2514
Battery Maintenance....2515
Using A Booster Battery (Jump Starting)....2515
Removing And Installing Battery....2517
HYDRAULIC / HYDROSTATIC SYSTEM....2518
Checking And Adding Fluid....2518
Hydraulic / Hydrostatic Fluid Chart....2518
Removing And Replacing Hydraulic Fluid....2519
Removing And Replacing Hydraulic / Hydrostatic Filter....2520
Breather Cap....2520
SPARK ARRESTER MUFFLER....2521
Cleaning Procedure....2521
TIRE MAINTENANCE....2522
Wheel Nuts....2522
Rotating....2522
Mounting....2522
FINAL DRIVE TRANSMISSION (CHAINCASE)....2523
Checking And Adding Oil....2523
Removing And Replacing Oil....2523
ALTERNATOR BELT....2524
Belt Adjustment....2524
Belt Replacement....2524
DRIVE BELT....2525
Belt Adjustment....2525
Belt Replacement....2525
LUBRICATING THE LOADER....2526
Lubrication Locations....2526
PIVOT PINS....2528
Inspection And Maintenance....2528
BOB-TACH....2529
Inspection And Maintenance....2529
LOADER STORAGE AND RETURN TO SERVICE....2530
Storage....2530
Return To Service....2530
SYSTEM SETUP AND ANALYSIS....2532
TROUBLESHOOTING....2534
Troubleshooting The Engine....2534
Troubleshooting The Hydraulic System....2535
Troubleshooting The Hydrostatic System....2535
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....2536
Troubleshooting....2536
Viewing Diagnostic Service Codes....2536
MACHINE SIGN TRANSLATIONS....2538
MACHINE SIGN TRANSLATIONS....2540
Service Schedule (6734534)....2540
Warning (6579510)....2543
Danger (6702301)....2544
Danger (6702302)....2544
Danger (6717343)....2544
Warning (6579528)....2544
Lift Arm Support Device (6711659)....2545
Danger (7170355)....2545
Warning (6737189)....2546
Warning (6804233)....2546
Warning (6576048)....2546
Important (6732775)....2546
Warning (6565491)....2547
Important (6560573)....2547
Warning (6710358)....2548
Warning (6702255)....2548
Warning (6577754)....2549
SPECIFICATIONS....2550
(S70) LOADER SPECIFICATIONS....2552
Machine Dimensions....2552
Performance....2553
Engine....2553
Drive System....2553
Controls....2554
Hydraulic System....2554
Electrical....2555
Capacities....2555
Tires....2555
WARRANTY....2556
WARRANTY....2558
ALPHABETICAL INDEX....2560
6986662 (2-09) - S70 Skid-Steer Loader Service Manual....2562
MAINTENANCE SAFETY....2564
ALPHABETICAL INDEX....2566
CONTENTS....2568
FOREWORD....2569
SAFETY INSTRUCTIONS....2572
FIRE PREVENTION....2574
Maintenance....2574
Operation....2574
Electrical....2574
Hydraulic System....2574
Fueling....2574
Starting....2574
Spark Arrestor Exhaust System....2574
Welding And Grinding....2575
Fire Extinguishers....2575
SERIAL NUMBER LOCATIONS....2576
Bobcat Loader Serial Number....2576
Engine Serial Number....2576
DELIVERY REPORT....2576
BOBCAT LOADER IDENTIFICATION....2577
SAFETY AND MAINTENANCE....2578
LIFTING AND BLOCKING THE LOADER....2580
Procedure....2580
LIFT ARM SUPPORT DEVICE....2582
Installing....2582
Removing....2583
OPERATOR CAB....2586
Description....2586
Raising....2586
Lowering....2587
Emergency Exit....2589
TRANSPORTING THE LOADER ON A TRAILER....2590
Loading And Unloading....2590
Fastening....2590
TOWING THE LOADER....2592
Procedure....2592
REMOTE START TOOL-MEL 1563....2594
Remote Start Tool - MEL1563....2594
Service Tool Harness Control - MEL1565....2595
Service Tool Harness Communicator - MEL1566....2595
Remote Start Procedure....2596
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....2600
Description....2600
Remote Start Tool (Service Tool) - 6689778....2601
Loader Service Tool Harness - 6689747....2602
Computer Service Tool Harness - 6689746....2603
Remote Start Procedure....2604
SERVICE SCHEDULE....2608
Chart....2608
AIR CLEANER SERVICE....2610
Replacing Filter Elements....2610
ENGINE COOLING SYSTEM....2612
Cleaning....2612
Checking Level....2612
Removing And Replacing Coolant....2613
FUEL SYSTEM....2614
Fuel Specifications....2614
Filling The Fuel Tank....2614
Fuel Filter....2615
Removing Air From The Fuel System....2615
ENGINE LUBRICATION SYSTEM....2616
Checking And Adding Engine Oil....2616
Engine Oil Chart....2616
Removing And Replacing Oil And Filter....2616
HYDRAULIC/HYDROSTATIC SYSTEM....2618
Checking And Adding Fluid....2618
Hydraulic / Hydrostatic Fluid Chart....2618
Removing And Replacing Hydraulic / Hydrostatic Filter....2619
Removing And Replacing Hydraulic / Hydrostatic Fluid....2620
FINAL DRIVE TRANSMISSION (CHAINCASE)....2622
Checking And Adding Oil....2622
Removing And Replacing Oil....2622
AUXILIARY CONTROL LOCKBOLT....2624
Procedure....2624
BOB-TACH....2626
Inspection And Maintenance....2626
LUBRICATING THE LOADER....2628
Lubrication Locations....2628
TIRE MAINTENANCE....2630
Wheel Nuts....2630
Rotating....2630
Mounting....2630
SPARK ARRESTOR MUFFLER....2632
Cleaning Procedure....2632
PIVOT PINS....2634
Inspection And Maintenance....2634
SEAT BAR RESTRAINT SYSTEM....2636
Operation....2636
LOADER STORAGE AND RETURN TO SERVICE....2638
Storage....2638
Return To Service....2638
STOPPING THE ENGINE AND LEAVING THE LOADER....2640
Procedure....2640
HYDRAULIC SYSTEM....2642
HYDRAULIC / HYDROSTATIC SCHEMATICS....2644
HYDRAULIC SYSTEM INFORMATION....2646
Glossary Of Hydraulic / Hydrostatic Symbols....2646
Troubleshooting Chart....2650
CYLINDER (LIFT)....2652
Testing....2652
Removal And Installation....2653
Parts Identification....2655
Disassembly And Assembly....2656
CYLINDER (TILT)....2660
Testing....2660
Removal And Installation....2660
Parts Identification....2662
Disassembly And Assembly....2663
MAIN RELIEF VALVE....2666
Description....2666
Testing Without Auxiliaries....2666
Testing With Auxiliaries....2667
Removal And Installation....2668
HYDRAULIC CONTROL VALVE....2670
Description....2670
BICS? Valve Removal And Installation....2670
BICS? Valve, Lift Arm By-Pass Orifice Removal And Installation....2671
Pressure Differential Valve Removal And Installation....2672
BICS? Valve, Check Valve Removal And Installation....2672
BICS? Valve, Solenoid Removal And Installation....2673
BICS? Valve, Solenoid Testing....2674
BICS? Valve, Identification Chart....2674
Removal And Installation....2675
Identification Chart....2677
Disassembly And Assembly....2678
Load Check Valves Removal And Installation....2678
Main Relief Valve Removal And Installation....2678
Port Relief/Anti-Cavitation Valve Removal And Installation....2679
Anti Cavitation/Check Valves Removal And Installation....2680
Rubber Boot Removal And Installation....2681
Lift And Tilt Lock Block Removal And Installation....2681
Lift Spool And Detent Removal And Installation....2682
Lift Spool And Detent Disassembly....2683
Lift Spool And Detent Assembly....2685
Tilt Spool Removal And Installation....2687
Tilt Spool Disassembly And Assembly....2688
Auxiliary Spool Removal And Installation....2689
Auxiliary Spool Disassembly And Assembly....2689
Spool Seal Installation....2692
Auxiliary Pivot Bracket Removal And Installation....2693
Auxiliary Pivot Bracket Disassembly And Assembly....2693
LIFT ARM BY-PASS CONTROL VALVE....2694
Description....2694
Testing....2694
Removal And Installation....2694
Disassembly And Assembly....2695
HYDRAULIC PUMP....2696
Description....2696
Direct Pump Testing....2696
Removal And Installation....2698
Hydraulic Pump Start Up....2700
Parts Identification....2701
Disassembly And Assembly....2702
HYDRAULIC/HYDROSTATIC FILTER....2704
Description....2704
Housing Removal And Installation....2704
Housing Disassembly And Assembly....2706
HYDRAULIC FLUID RESERVOIR....2708
Description....2708
Removal And Installation....2708
OIL COOLER....2710
Description....2710
Removal And Installation....2710
AUXILIARY HYDRAULIC INTERLOCK VALVE....2712
Description....2712
Removal And Installation....2712
Disassembly And Assembly....2713
HYDROSTATIC SYSTEM....2716
HYDROSTATIC SYSTEM INFORMATION....2718
Description....2718
Troubleshooting....2719
HYDROSTATIC MOTOR....2720
Description....2720
Removal And Installation....2720
Parts Identification....2722
Disassembly....2723
Assembly....2729
CHARGE PRESSURE....2734
Description....2734
Testing....2734
Sender Removal And Installation....2735
HYDROSTATIC PUMP....2736
Description....2736
Replenishing / High Pressure Relief Valve Removal And Installation....2736
Removal And Installation....2737
Parts Identification....2740
Disassembly....2741
Assembly....2746
DRIVE BELT....2750
Description....2750
Adjusting....2750
Belt Removal And Installation....2750
Tensioner Pulley Removal And Installation....2751
Tensioner Pulley Disassembly And Assembly....2751
DRIVE SYSTEM....2752
BRAKE....2754
Description....2754
Disc Removal And Installation....2754
DRIVE COMPONENTS....2756
Description....2756
Axle Seal Removal And Installation....2757
Axle, Sprocket And Bearings Removal And Installation....2759
Chain Removal And Installation....2764
CHAINCASE....2766
Description....2766
Chaincase Cover Removal And Installation....2766
Chaincase Cover Disassembly And Assembly....2766
MAIN FRAME....2768
SEAT BAR....2770
Description....2770
Removal And Installation....2770
Disassembly And Assembly....2773
Compression Spring Disassembly And Assembly....2774
OPERATOR CAB....2776
Gas Cylinder Removal And Installation....2776
Removal And Installation....2778
OPERATOR SEAT....2780
Removal And Installation....2780
Seat Belt Removal And Installation....2780
BOB-TACH....2782
Description....2782
Removal And Installation....2782
Lever And Wedge Disassembly And Assembly....2784
LIFT ARMS....2786
Removal And Installation....2786
REAR DOOR....2790
Removal And Installation....2790
FUEL TANK....2792
Removal And Installation....2792
CONTROL PEDALS AND LINKAGES....2794
Description....2794
Pedal Removal And Installation....2794
Pedal Interlock Linkage Removal And Installation....2795
CONTROL PANEL....2796
Description....2796
Control Shield And Steering Lever Panels Removal And Installation....2796
CONTROL LEVER....2798
Description....2798
Lever Removal And Installation....2798
Lever Disassembly And Assembly....2800
Linkage Neutral Adjustment....2801
Pintle Arm Removal....2802
Pintle Arm Installation....2804
Pintle Arm Disassembly And Assembly....2806
WINDOW (REAR)....2808
Removal....2808
Installation....2808
ELECTRICAL SYSTEM & ANALYSIS....2810
ELECTRICAL SCHEMATICS....2812
ELECTRICAL SYSTEM INFORMATION....2817
Glossary Of Electrical Symbols....2817
Cab Harness Connectors....2820
Mainframe Harness Connectors....2821
Description....2822
Troubleshooting....2823
Fuse And Relay Location / Identification....2824
Solenoid Testing....2825
BATTERY....2827
Removal And Installation....2827
Servicing....2828
Using A Booster Battery (Jump Starting)....2828
ALTERNATOR....2831
Belt Adjustment....2831
Belt Replacement....2831
Charging System Inspection....2832
Alternator Voltage Testing....2833
Low Voltage Testing....2833
High Voltage Testing....2834
Removal And Installation....2835
Parts Identification....2836
STARTER....2837
Testing....2837
Removal And Installation....2839
Parts Identification....2840
INSTRUMENT PANELS....2841
Left And Right Removal And Installation....2841
LIGHTS....2843
Front Removal And Installation....2843
Rear Removal And Installation....2844
Cab Light Removal And Installation....2845
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2847
Inspecting Procedure....2847
Inspecting The BICS Controller (Engine STOPPED - Key ON)....2847
Inspecting The Seat Bar Sensor (Engine RUNNING)....2847
Inspecting The Traction Lock (Engine RUNNING)....2847
Inspecting The Lift Arm Bypass Control....2847
Inspecting The Auxiliary Hydraulic Interlock Valve....2848
BICS CONTROLLER (GATEWAY)....2849
Description....2849
Troubleshooting....2849
Viewing Diagnostic Service Codes....2850
Removal And Installation....2851
SEAT BAR SENSOR....2853
Description....2853
Troubleshooting....2853
Testing....2854
Removal And Installation....2855
Bobcat Interlock Control System (BICS) Circuit Test....2857
TRACTION LOCK....2859
Description....2859
Troubleshooting....2859
Removal And Installation....2860
BACK-UP ALARM SYSTEM....2863
Description....2863
Inspecting....2863
Adjusting Switch Position....2864
Troubleshooting....2865
Alarm Removal And Installation....2866
Switch Removal And Installation....2866
ENGINE SERVICE....2869
ENGINE INFORMATION....2871
Description....2871
Specifications....2872
Torque Values....2876
Troubleshooting....2877
Engine Removal And Installation....2879
Engine Mount Replacement....2885
Compression - Checking....2886
ENGINE SPEED CONTROL....2887
Removal And Installation....2887
MUFFLER....2889
Removal And Installation....2889
AIR CLEANER....2891
Housing Removal And Installation....2891
ENGINE COOLING SYSTEM....2893
Radiator Removal And Installation....2893
Fan Removal And Installation....2895
Water Pump Removal And Installation....2896
Water Pump Disassembly And Assembly....2897
Thermostat Housing Removal And Installation....2897
LUBRICATION SYSTEM....2899
Oil Pan Removal And Installation....2899
Oil Pump Removal And Installation....2900
Oil Pump Inspection....2900
Engine Oil Pressure - Testing....2902
FUEL SYSTEM....2903
Fuel Camshaft Removal And Installation....2903
Governor Shaft Removal And Installation....2905
Governor Fork Lever Removal And Installation....2908
Fuel ShutOff Solenoid - Checking....2910
Fuel ShutOff Solenoid Removal And Installation....2910
Fuel Injection Pump Removal And Installation....2911
Fuel Injection Pump Timing....2913
Fuel Injector Nozzles Removal And Installation....2914
Fuel Injector Nozzle Pressure - Checking....2915
Nozzle Spray Condition....2916
Valve Seat Tightness....2917
CYLINDER HEAD....2919
Glow Plug - Checking....2919
Glow Plug Removal And Installation....2919
Valve Clearance Adjustment....2920
Valve Timing Checking....2921
Cylinder Head Removal And Installation....2921
Cylinder Head Disassembly And Assembly....2924
Cylinder Head - Servicing....2924
Cylinder Head Top Clearance....2925
Valve Guide - Checking....2925
Reconditioning The Valve And Valve Seat....2927
Valve Spring....2928
Valve Tappets....2929
Rocker Arm And Shaft - Checking....2929
CRANKSHAFT AND PISTONS....2931
Piston And Connecting Rod Removal And Installation....2931
Piston And Connecting Rod - Servicing....2932
Cylinder Bore - Checking....2935
Connecting Rod Alignment....2935
Crankshaft And Bearings Removal And Installation....2936
Crankshaft And Bearings - Servicing....2938
CAMSHAFT AND TIMING GEARS....2943
Timing Gearcase Cover Removal And Installation....2943
Timing Gears Backlash - Checking....2945
Idler Gear And Shaft Removal And Installation....2945
Camshaft - Servicing....2946
Idler Gear And Shaft Servicing....2948
FLYWHEEL AND HOUSING....2949
Flywheel Removal And Installation....2949
Ring Gear Removal And Installation....2949
Housing Removal And Installation....2950
HEATER....2951
HEATER SYSTEM....2953
Description....2953
REGULAR MAINTENANCE....2955
Heater Coil....2955
TROUBLESHOOTING....2957
Electric System....2957
Heater Valve Not Opening Or Closing....2957
Blower Motor Does Not Operate....2957
Blower Motor Operates Normally, But Air Flow Is Insufficient....2957
HEATER UNIT....2959
Removal And Installation....2959
HEATER COIL....2961
Removal And Installation....2961
HEATER FAN....2965
Removal And Installation....2965
HEATER VALVE....2967
Removal And Installation....2967
HEATER SWITCH....2969
Removal And Installation....2969
Checking....2970
SPECIFICATIONS....2971
(S70) LOADER SPECIFICATIONS....2973
Machine Dimensions....2973
Performance....2974
Controls....2974
Engine....2975
Hydraulic System....2975
Electrical....2976
Drive System....2976
Capacities....2976
Tires....2976
TORQUE SPECIFICATIONS FOR BOLTS....2977
Torque For General SAE Bolts....2977
Torque For General Metric Bolts....2978
HYDRAULIC CONNECTION SPECIFICATIONS....2979
O-ring Face Seal Connection....2979
Straight Thread O-ring Fitting....2980
Tubelines And Hoses....2980
Flare Fitting....2980
Port Seal Fitting....2981
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....2983
Specifications....2983
CONVERSIONS....2985
Decimal And Millimeter Equivalent Chart....2985
U.S. To Metric Conversion Chart....2985
SERVICE MANUAL REVISION....2987
Revision No: S70 - 1....2987
Revision No: S70 - 2....2989
Revision No: S70 - 3....2991
6986662 (4-14) - S70 Skid-Steer Loader Service Manual....2993
MAINTENANCE SAFETY....2995
CONTENTS....2997
FOREWORD....2999
FOREWORD....3001
SAFETY INSTRUCTIONS....3003
FIRE PREVENTION....3005
Maintenance....3005
Operation....3005
Electrical....3005
Hydraulic System....3005
Fueling....3005
Starting....3005
Spark Arrester Exhaust System....3005
Welding And Grinding....3006
Fire Extinguishers....3006
SERIAL NUMBER LOCATIONS....3007
Loader Serial Number....3007
Engine Serial Number....3007
LOADER IDENTIFICATION....3008
SAFETY AND MAINTENANCE....3009
LIFTING AND BLOCKING THE LOADER....3013
Procedure....3013
LIFT ARM SUPPORT DEVICE....3015
Installing....3015
Removing....3016
OPERATOR CAB....3017
Description....3017
Raising....3017
Lowering....3018
Special Applications Kit....3020
Special Applications Kit Inspection And Maintenance....3020
TRANSPORTING THE LOADER ON A TRAILER....3021
Loading And Unloading....3021
Fastening....3021
TOWING THE LOADER....3023
Procedure....3023
REMOTE START TOOL KIT - MEL1563....3025
Remote Start Tool - MEL1563....3025
Service Tool Harness Communicator - MEL1566....3026
Remote Start Procedure....3027
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....3031
Description....3031
Remote Start Tool (Service Tool) - 7022042....3032
Loader Service Tool Harness - 6689747....3033
Computer Service Tool Harness - 6689746....3034
Remote Start Procedure....3035
SERVICE SCHEDULE....3039
Chart....3039
AIR CLEANER SERVICE....3041
Replacing Filter Elements....3041
ENGINE COOLING SYSTEM....3043
Cleaning....3043
Checking Level....3043
Removing And Replacing Coolant....3044
FUEL SYSTEM....3045
Fuel Specifications....3045
Biodiesel Blend Fuel....3045
Filling The Fuel Tank....3046
Fuel Filter....3047
Removing Air From The Fuel System....3047
ENGINE LUBRICATION SYSTEM....3049
Checking And Adding Engine Oil....3049
Engine Oil Chart....3049
Removing And Replacing Oil And Filter....3049
HYDRAULIC / HYDROSTATIC SYSTEM....3051
Checking And Adding Fluid....3051
Hydraulic / Hydrostatic Fluid Chart....3051
Removing And Replacing Hydraulic Fluid....3052
Removing And Replacing Hydraulic / Hydrostatic Filter....3053
Breather Cap....3053
FINAL DRIVE TRANSMISSION (CHAINCASE)....3055
Checking And Adding Oil....3055
Removing And Replacing Oil....3055
AUXILIARY CONTROL LOCKBOLT....3057
Procedure....3057
BOB-TACH....3059
Inspection And Maintenance....3059
LUBRICATING THE LOADER....3061
Lubrication Locations....3061
TIRE MAINTENANCE....3063
Wheel Nuts....3063
Rotating....3063
Mounting....3063
SPARK ARRESTER MUFFLER....3065
Cleaning Procedure....3065
PIVOT PINS....3067
Inspection And Maintenance....3067
SEAT BAR RESTRAINT SYSTEM....3069
Description....3069
Inspecting....3069
Maintaining....3069
LOADER STORAGE AND RETURN TO SERVICE....3071
Storage....3071
Return To Service....3071
STOPPING THE ENGINE AND LEAVING THE LOADER....3073
Procedure....3073
EMERGENCY EXIT....3075
Rear Window....3075
Front Door....3075
SEAT BELT....3077
Inspection And Maintenance....3077
HYDRAULIC SYSTEM....3079
HYDRAULIC / HYDROSTATIC SCHEMATICS....3083
HYDRAULIC SYSTEM INFORMATION....3085
Glossary Of Hydraulic / Hydrostatic Symbols....3085
Troubleshooting Chart....3089
CYLINDER (LIFT)....3091
Testing....3091
Removal And Installation....3092
Parts Identification....3094
Disassembly And Assembly....3095
CYLINDER (TILT)....3099
Testing....3099
Removal And Installation....3099
Parts Identification....3101
Disassembly And Assembly....3102
MAIN RELIEF VALVE....3105
Description....3105
Testing Without Auxiliaries....3105
Testing With Auxiliaries....3106
Removal And Installation....3107
HYDRAULIC CONTROL VALVE....3109
Description....3109
BICS? Valve Removal And Installation....3109
BICS? Valve, Lift Arm Bypass Orifice Removal And Installation....3110
Pressure Differential Valve Removal And Installation....3111
BICS? Valve, Check Valve Removal And Installation....3111
BICS? Valve, Solenoid Removal And Installation....3112
BICS? Valve, Solenoid Testing....3113
BICS? Valve, Identification Chart....3113
Removal And Installation....3114
Identification Chart....3116
Disassembly And Assembly....3117
Load Check Valves Removal And Installation....3117
Main Relief Valve Removal And Installation....3117
Port Relief / Anti-Cavitation Valve Removal And Installation....3118
Anti-Cavitation / Check Valves Removal And Installation....3119
Rubber Boot Removal And Installation....3120
Lift And Tilt Lock Block Removal And Installation....3120
Lift Spool And Detent Removal And Installation....3121
Lift Spool And Detent Disassembly....3122
Lift Spool And Detent Assembly....3124
Tilt Spool Removal And Installation....3126
Tilt Spool Disassembly And Assembly....3127
Auxiliary Spool Removal And Installation....3128
Auxiliary Spool Disassembly And Assembly....3128
Spool Seal Installation....3131
Auxiliary Pivot Bracket Removal And Installation....3132
Auxiliary Pivot Bracket Disassembly And Assembly....3132
LIFT ARM BYPASS CONTROL VALVE....3133
Description....3133
Testing....3133
Removal And Installation....3133
Disassembly And Assembly....3134
HYDRAULIC PUMP....3135
Description....3135
Direct Pump Testing....3135
Removal And Installation....3137
Hydraulic Pump Start Up....3139
Parts Identification....3140
Disassembly And Assembly....3141
HYDRAULIC / HYDROSTATIC FILTER....3143
Description....3143
Housing Removal And Installation....3143
Housing Disassembly And Assembly....3145
HYDRAULIC FLUID RESERVOIR....3147
Description....3147
Removal And Installation....3147
OIL COOLER....3149
Description....3149
Removal And Installation....3149
BUCKET POSITION VALVE....3151
Description....3151
Solenoid Removal And Installation....3151
Solenoid Testing....3152
Removal And Installation....3152
Disassembly And Assembly....3154
AUXILIARY HYDRAULIC INTERLOCK VALVE....3157
Description....3157
Removal And Installation....3157
Disassembly And Assembly....3158
HYDROSTATIC SYSTEM....3161
HYDROSTATIC SYSTEM INFORMATION....3163
Description....3163
Troubleshooting....3164
HYDROSTATIC DRIVE MOTOR....3165
Description....3165
Removal And Installation....3165
Parts Identification....3167
Disassembly....3168
Assembly....3174
CHARGE PRESSURE....3179
Description....3179
Testing....3179
Sender Removal And Installation....3180
HYDROSTATIC PUMP....3181
Description....3181
Replenishing / High Pressure Relief Valve Removal And Installation....3181
Removal And Installation....3182
Parts Identification....3185
Disassembly....3186
Assembly....3191
DRIVE BELT....3195
Description....3195
Adjusting....3195
Belt Removal And Installation....3195
Tensioner Pulley Removal And Installation....3196
Tensioner Pulley Disassembly And Assembly....3196
DRIVE SYSTEM....3197
BRAKE....3199
Description....3199
Disc Removal And Installation....3199
DRIVE COMPONENTS....3201
Description....3201
Axle Seal Removal And Installation....3202
Axle, Sprocket And Bearings Removal And Installation....3204
Chain Removal And Installation....3209
CHAINCASE....3211
Description....3211
Chaincase Cover Removal And Installation....3211
Chaincase Cover Disassembly And Assembly....3211
MAINFRAME....3213
SEAT BAR....3215
Description....3215
Removal And Installation....3215
Disassembly And Assembly....3218
Compression Spring Disassembly And Assembly....3219
OPERATOR CAB....3221
Gas Cylinder Removal And Installation....3221
Removal And Installation....3223
OPERATOR SEAT....3225
Removal And Installation....3225
Seat Belt Removal And Installation....3225
BOB-TACH....3227
Description....3227
Removal And Installation....3227
Lever And Wedge Disassembly And Assembly....3229
LIFT ARMS....3231
Removal And Installation....3231
REAR DOOR....3235
Removal And Installation....3235
FUEL TANK....3237
Removal And Installation....3237
CONTROL PEDALS AND LINKAGES....3239
Description....3239
Pedal Removal And Installation....3239
Pedal Interlock Linkage Removal And Installation....3240
CONTROL PANEL....3241
Description....3241
Control Shield And Steering Lever Panels Removal And Installation....3241
CONTROL LEVER....3243
Description....3243
Lever Removal And Installation....3243
Lever Disassembly And Assembly....3245
Linkage Neutral Adjustment....3246
Pintle Arm Removal....3247
Pintle Arm Installation....3249
Pintle Arm Disassembly And Assembly....3251
WINDOW (REAR)....3253
Removal....3253
Installation....3253
ELECTRICAL SYSTEM AND ANALYSIS....3255
ELECTRICAL SCHEMATICS....3257
ELECTRICAL SYSTEM INFORMATION....3267
Glossary Of Electrical Symbols....3267
Cab Harness Connectors....3270
Mainframe Harness Connectors....3271
Description....3272
Troubleshooting....3273
Fuse And Relay Location / Identification....3274
Solenoid Testing....3275
BATTERY....3277
Removal And Installation....3277
Servicing....3278
Using A Booster Battery (Jump Starting)....3278
ALTERNATOR....3281
Belt Adjustment....3281
Belt Replacement....3281
Charging System Inspection....3282
Alternator Voltage Testing....3283
Low Voltage Testing....3283
High Voltage Testing....3284
Removal And Installation....3285
Parts Identification....3286
STARTER....3287
Testing....3287
Removal And Installation....3289
Parts Identification....3290
INSTRUMENT PANELS....3291
Left And Right Panels....3291
Standard Key Panel....3292
Keyless Start Panel....3292
Option And Field Accessory Panel....3293
Left And Right Removal And Installation....3294
LIGHTS....3295
Front Removal And Installation....3295
Rear Removal And Installation....3296
Cab Light Removal And Installation....3297
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....3299
Description....3299
Inspecting The BICS? Controller (Engine STOPPED - Key ON)....3299
Inspecting The Seat Bar Sensor (Engine RUNNING)....3300
Inspecting The Traction Lock (Engine RUNNING)....3300
Inspecting The Lift Arm Bypass Control....3300
Inspecting Deactivation Of The Auxiliary Hydraulics System....3301
BICS? CONTROLLER (GATEWAY)....3303
Description....3303
Troubleshooting....3303
Viewing Diagnostic Service Codes....3304
Removal And Installation....3305
SEAT BAR SENSOR....3307
Description....3307
Troubleshooting....3307
Testing....3308
Removal And Installation....3309
Bobcat Interlock Control System (BICS?) Circuit Test....3311
TRACTION LOCK....3313
Description....3313
Troubleshooting....3313
Removal And Installation....3314
BACK-UP ALARM SYSTEM (S/N A3W611001 - A3W613689 AND A3W711001 - A3W713379)....3317
Description....3317
Inspecting....3317
Adjusting Switch Position....3318
Troubleshooting....3319
Alarm Removal And Installation....3320
Switch Removal And Installation....3320
BACK-UP ALARM SYSTEM (S/N A3W613690 & above AND A3W713380 & above)....3323
Description....3323
Inspecting....3323
Troubleshooting....3324
Switch Removal And Installation....3325
Alarm Removal And Installation....3326
ENGINE SERVICE....3327
ENGINE INFORMATION....3329
Description....3329
Specifications....3330
Torque Values....3334
Troubleshooting....3335
Engine Removal And Installation....3337
Engine Mount Replacement....3343
Compression - Checking....3344
ENGINE SPEED CONTROL....3345
Removal And Installation....3345
MUFFLER....3347
Removal And Installation....3347
AIR CLEANER....3349
Housing Removal And Installation....3349
ENGINE COOLING SYSTEM....3351
Radiator Removal And Installation....3351
Fan Removal And Installation....3353
Water Pump Removal And Installation....3354
Water Pump Disassembly And Assembly....3355
Thermostat Housing Removal And Installation....3355
LUBRICATION SYSTEM....3357
Oil Pan Removal And Installation....3357
Oil Pump Removal And Installation....3358
Oil Pump Inspection....3358
Engine Oil Pressure - Testing....3360
FUEL SYSTEM....3361
Fuel Camshaft Removal And Installation....3361
Governor Shaft Removal And Installation....3363
Governor Fork Lever Removal And Installation....3366
Fuel ShutOff Solenoid - Checking....3368
Fuel ShutOff Solenoid Removal And Installation....3368
Fuel Injection Pump Removal And Installation....3369
Fuel Injection Pump Timing....3371
Fuel Injector Nozzles Removal And Installation....3372
Fuel Injector Nozzle Pressure - Checking....3373
Nozzle Spray Condition....3374
Valve Seat Tightness....3375
CYLINDER HEAD....3377
Glow Plug - Checking....3377
Glow Plug Removal And Installation....3377
Valve Clearance Adjustment....3378
Valve Timing Checking....3379
Cylinder Head Removal And Installation....3379
Cylinder Head Disassembly And Assembly....3382
Cylinder Head - Servicing....3382
Cylinder Head Top Clearance....3383
Valve Guide - Checking....3383
Reconditioning The Valve And Valve Seat....3385
Valve Spring....3386
Valve Tappets....3387
Rocker Arm And Shaft - Checking....3387
CRANKSHAFT AND PISTONS....3389
Piston And Connecting Rod Removal And Installation....3389
Piston And Connecting Rod - Servicing....3390
Cylinder Bore - Checking....3393
Connecting Rod Alignment....3393
Crankshaft And Bearings Removal And Installation....3394
Crankshaft And Bearings - Servicing....3396
CAMSHAFT AND TIMING GEARS....3401
Timing Gearcase Cover Removal And Installation....3401
Timing Gears Backlash - Checking....3403
Idler Gear And Shaft Removal And Installation....3403
Camshaft - Servicing....3404
Idler Gear And Shaft Servicing....3406
FLYWHEEL AND HOUSING....3407
Flywheel Removal And Installation....3407
Ring Gear Removal And Installation....3407
Housing Removal And Installation....3408
HEATER....3409
HEATER SYSTEM....3411
Description....3411
REGULAR MAINTENANCE (S/N A3W611001 - A3W613399 AND A3W711001 - A3W713235)....3413
Heater Coil....3413
REGULAR MAINTENANCE (S/N A3W63400 & aBOVE AND A3W713236 & ABOVE)....3415
Heater Coil....3415
TROUBLESHOOTING....3417
Electric System....3417
Heater Valve Not Opening Or Closing....3417
Blower Motor Does Not Operate....3417
Blower Motor Operates Normally, But Air Flow Is Insufficient....3417
HEATER UNIT (S/N A3W611001 - A3W613399 AND A3W711001 - A3W713235)....3419
Removal And Installation....3419
HEATER UNIT (S/N A3W613400 & ABOVE AND A3W713236 & ABOVE)....3421
Removal And Installation....3421
HEATER COIL (S/N A3W611001 - A3W613399 AND A3W711001 - A3W713235)....3423
Removal And Installation....3423
HEATER COIL (S/N A3W613400 & ABOVE AND A3W713236 & ABOVE)....3427
Removal And Installation....3427
HEATER FAN (S/N A3W611001 - A3W613399 AND A3W711001 - A3W713235)....3429
Removal And Installation....3429
HEATER FAN (S/N A3W613400 & ABOVE AND A3W713236 & ABOVE)....3431
Removal And Installation....3431
HEATER VALVE (S/N A3W611001 - A3W613399 AND A3W711001 - A3W713235)....3433
Removal And Installation....3433
HEATER VALVE (S/N A3W613400 & ABOVE AND A3W713236 & ABOVE)....3435
Removal And Installation....3435
HEATER SWITCH (S/N A3W611001 - A3W613399 AND A3W711001 - A3W713235)....3437
Removal And Installation....3437
Checking....3438
HEATER SWITCH (S/N A3W613400 & ABOVE AND A3W713236 & ABOVE)....3439
Removal And Installation....3439
Checking....3440
SPECIFICATIONS....3441
(S70) LOADER SPECIFICATIONS....3443
Machine Dimensions....3443
Performance....3444
Engine....3444
Controls....3444
Drive System....3445
Hydraulic System....3445
Electrical....3446
Capacities....3446
Tires....3446
TORQUE SPECIFICATIONS FOR BOLTS....3447
Torque For General SAE Bolts....3447
Torque For General Metric Bolts....3448
HYDRAULIC CONNECTION SPECIFICATIONS....3449
O-ring Face Seal Connection....3449
Straight Thread O-ring Fitting....3450
Tubelines And Hoses....3450
Flare Fitting....3450
Port Seal Fitting....3451
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....3453
Specifications....3453
CONVERSIONS....3455
Decimal And Millimeter Equivalent Chart....3455
U.S. To Metric Conversion Chart....3455
SERVICE TOOLS REQUIRED....3457
Remote Start Tools....3457
Hydraulic Tools....3458
Mainframe And Drive Tools....3460
Electrical Tools....3461
Engine Tools....3461
HVAC Tools....3464
ALPHABETICAL INDEX....3465
SERVICE MANUAL REVISION....3467
Revision No: S70 - 1....3467
Revision No: S70 - 2....3469
Revision No: S70 - 3....3471
Revision No: S70 - 4....3473
Revision No: S70 - 5....3475
Revision No: S70 - 6....3477
6987130 (10-09) - S100 Skid-Steer Loader Operation & Maintenance Manual....3479
OPERATOR SAFETY WARNINGS....3481
CONTENTS....3483
FOREWORD....3485
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....3487
REGULAR MAINTENANCE ITEMS....3487
SERIAL NUMBER LOCATIONS....3488
Loader Serial Number....3488
Engine Serial Number....3488
LOADER IDENTIFICATION....3489
FEATURES, ACCESSORIES AND ATTACHMENTS....3490
Buckets Available....3491
Attachments....3491
Special Applications Kit....3492
SAFETY & TRAINING RESOURCES....3493
SAFETY INSTRUCTIONS....3495
Before Operation....3495
Safe Operation Is The Operator?s Responsibility....3496
Safe Operation Needs A Qualified Operator....3496
Avoid Silica Dust....3497
FIRE PREVENTION....3497
Maintenance....3497
Operation....3497
Electrical....3497
Hydraulic System....3498
Fueling....3498
Starting....3498
Spark Arrestor Exhaust System....3498
Welding And Grinding....3498
Fire Extinguishers....3498
MACHINE SIGNS (DECALS)....3500
PUBLICATIONS AND TRAINING RESOURCES....3502
OPERATING INSTRUCTIONS....3503
INSTRUMENT PANEL IDENTIFICATION....3507
Cab Light....3507
Left Panel....3508
Display Screen....3510
Standard Key Panel....3510
Deluxe Instrumentation Panel....3511
Side Panel....3512
Front Panel....3512
CONTROL IDENTIFICATION....3513
Standard Controls....3513
SEAT BAR RESTRAINT SYSTEM....3514
Operation....3514
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3515
Operation....3515
LIFT ARM BYPASS CONTROL....3516
Operation....3516
PARKING BRAKE....3516
Operation....3516
TRACTION LOCK OVERRIDE....3516
Operation....3516
EMERGENCY EXIT....3517
Rear Window....3517
Front Door....3517
BACK-UP ALARM SYSTEM....3518
Description....3518
Operation....3518
ENGINE SPEED CONTROL....3518
Operation....3518
DRIVING AND STEERING THE LOADER....3519
Operation....3519
Stopping The Loader....3519
Using The Control Levers....3519
HYDRAULIC CONTROLS....3520
Description....3520
Hydraulic Bucket Positioning....3520
Front Auxiliary Hydraulic Control Lockout....3520
FRONT Auxiliary Hydraulics Operation (Variable Flow)....3521
FRONT Auxiliary Hydraulics Operation (Continuous Flow)....3521
Quick Couplers....3522
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....3522
ATTACHMENT CONTROL DEVICE (ACD)....3523
Description....3523
DAILY INSPECTION....3524
Daily Inspection And Maintenance....3525
PRE-STARTING PROCEDURE....3526
Entering The Loader....3526
Operation & Maintenance Manual And Operator?s Handbook Locations....3526
Seat Adjustment....3527
Seat Belt Adjustment....3528
Seat Bar....3528
STARTING THE ENGINE....3529
Standard Key Panel....3529
Deluxe Instrumentation Panel....3531
Cold Temperature Starting....3533
Warming The Hydraulic / Hydrostatic System....3533
MONITORING THE DISPLAY PANELS....3534
Left Panel....3534
Warning And Shutdown....3534
STOPPING THE ENGINE AND LEAVING THE LOADER....3535
Procedure....3535
Counterweights....3536
Description....3536
Effect On The Loader And Loader Operation....3536
When To Consider Using Counterweights....3536
When To Consider Removing Counterweights....3536
Accessories That Affect Machine Weight....3536
ATTACHMENTS....3537
Choosing The Correct Bucket....3537
Pallet Forks....3537
Installing And Removing The Attachment....3538
OPERATING PROCEDURE....3541
Inspect The Work Area....3541
Operating With A Full Bucket....3541
Operating With An Empty Bucket....3542
Filling And Emptying The Bucket....3543
Leveling The Ground Using Float....3544
Digging And Filling A Hole....3544
TOWING THE LOADER....3546
Procedure....3546
LIFTING THE LOADER....3546
Single Point Lift....3546
TRANSPORTING THE LOADER ON A TRAILER....3547
Loading And Unloading....3547
Fastening....3547
PREVENTIVE MAINTENANCE....3549
MAINTENANCE SAFETY....3553
SERVICE SCHEDULE....3555
Chart....3555
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3556
Inspecting The BICS (Engine STOPPED - Key ON)....3556
Inspecting The Seat Bar Sensor (Engine RUNNING)....3556
Inspecting The Traction Lock (Engine RUNNING)....3556
Inspecting The Lift Arm Bypass Control....3556
SEAT BAR RESTRAINT SYSTEM....3557
Description....3557
Inspecting....3557
Maintaining....3557
SEAT BELT....3558
Inspection And Maintenance....3558
LIFT ARM SUPPORT DEVICE....3559
Installing....3559
Removing....3560
BACK-UP ALARM SYSTEM....3561
Description....3561
Inspecting....3561
Adjusting Switch Position....3561
OPERATOR CAB....3562
Description....3562
Raising....3562
Lowering....3563
Cab Door Sensor....3564
REAR DOOR....3565
Opening And Closing....3565
Adjusting....3565
REAR GRILL....3566
Removing....3566
Installing....3566
HEATING SYSTEM....3567
Cleaning And Maintenance....3567
Filters....3567
Heater Coil....3567
Troubleshooting....3567
AIR CLEANER SERVICE....3568
Replacing Filter Elements....3568
FUEL SYSTEM....3569
Fuel Specifications....3569
Biodiesel Blend Fuel....3569
Filling The Fuel Tank....3570
Fuel Filter....3571
Removing Air From The Fuel System....3571
ENGINE LUBRICATION SYSTEM....3572
Checking And Adding Engine Oil....3572
Engine Oil Chart....3572
Removing And Replacing Oil And Filter....3572
ENGINE COOLING SYSTEM....3573
Cleaning....3573
Checking Level....3573
Removing And Replacing Coolant....3574
ELECTRICAL SYSTEM....3575
Description....3575
Fuse And Relay Location / Identification....3575
Battery Maintenance....3576
Using A Booster Battery (Jump Starting)....3577
Removing And Installing Battery....3578
HYDRAULIC / HYDROSTATIC SYSTEM....3579
Checking And Adding Fluid....3579
Hydraulic / Hydrostatic Fluid Chart....3579
Removing And Replacing Hydraulic Fluid....3580
Removing And Replacing Hydraulic / Hydrostatic Filter....3581
Removing And Replacing Case Drain Filters....3582
Removing And Replacing Hydraulic Charge Filter....3583
Breather Cap....3583
SPARK ARRESTOR MUFFLER....3584
Cleaning Procedure....3584
TIRE MAINTENANCE....3585
Wheel Nuts....3585
Rotating....3585
Mounting....3585
FINAL DRIVE TRANSMISSION (CHAINCASE)....3586
Checking And Adding Oil....3586
Removing And Replacing Oil....3586
ALTERNATOR BELT....3587
Belt Adjustment....3587
Belt Replacement....3587
DRIVE BELT....3588
Belt Adjustment....3588
Belt Replacement....3588
LUBRICATING THE LOADER....3589
Lubrication Locations....3589
PIVOT PINS....3591
Inspection And Maintenance....3591
BOB-TACH....3592
Inspection And Maintenance....3592
LOADER STORAGE AND RETURN TO SERVICE....3593
Storage....3593
Return To Service....3593
SYSTEM SETUP & ANALYSIS....3595
DIAGNOSTIC SERVICE CODES....3597
Viewing Service Codes (Standard Key Panel)....3597
Viewing Service Codes (Deluxe Instrumentation Panel)....3597
Service Codes List....3598
CONTROL PANEL SETUP....3602
Right Panel Setup (Deluxe Instrumentation Panel)....3602
Attachment Control Information (Deluxe Instrumentation Panel)....3603
PASSWORD SETUP....3604
Password Description....3604
Changing The Owner Password....3604
Changing The User Passwords....3605
Password Lockout Feature....3605
MAINTENANCE CLOCK....3606
Description....3606
Setup....3606
Reset....3606
MACHINE SIGN TRANSLATIONS....3607
SERVICE SCHEDULE (6734534)....3609
DANGER (6702301)....3612
DANGER (6702302)....3612
DANGER (6717343)....3612
WARNING (6579528)....3612
WARNING (6577754)....3613
IMPORTANT (7139929)....3613
WARNING (6737189)....3613
WARNING (6728539)....3614
DANGER (6809511)....3615
WARNING (6704786)....3615
LIFT ARM SUPPORT DEVICE (6706558)....3616
WARNING (6733996)....3617
WARNING (6710358)....3617
WARNING (6725370)....3617
SPECIFICATIONS....3619
(S100) LOADER SPECIFICATIONS....3621
Machine Dimensions....3621
Performance....3622
Engine....3622
Controls....3622
Drive System....3623
Hydraulic System....3623
Electrical....3624
Capacities....3624
Tires....3624
WARRANTY....3625
ALPHABETICAL INDEX....3629
6987130 (9-12) - S100 Skid-Steer Loader Operation & Maintenance Manual....3631
OPERATOR SAFETY WARNINGS....3633
CONTENTS....3635
FOREWORD....3637
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....3639
REGULAR MAINTENANCE ITEMS....3639
SERIAL NUMBER LOCATIONS....3640
Loader Serial Number....3640
Engine Serial Number....3640
LOADER IDENTIFICATION....3641
FEATURES, ACCESSORIES AND ATTACHMENTS....3642
Buckets Available....3643
Attachments....3643
Special Applications Kit....3644
SAFETY & TRAINING RESOURCES....3645
SAFETY INSTRUCTIONS....3647
Before Operation....3647
Safe Operation Is The Operator?s Responsibility....3648
Safe Operation Needs A Qualified Operator....3648
Avoid Silica Dust....3649
FIRE PREVENTION....3649
Maintenance....3649
Operation....3649
Electrical....3649
Hydraulic System....3650
Fueling....3650
Starting....3650
Spark Arrestor Exhaust System....3650
Welding And Grinding....3650
Fire Extinguishers....3650
MACHINE SIGNS (DECALS)....3652
PUBLICATIONS AND TRAINING RESOURCES....3654
OPERATING INSTRUCTIONS....3655
INSTRUMENT PANEL IDENTIFICATION....3659
Cab Light....3659
Left Panel....3660
Display Screen....3662
Standard Key Panel....3662
Deluxe Instrumentation Panel....3663
Side Panel....3664
Front Panel....3664
CONTROL IDENTIFICATION....3665
Standard Controls....3665
SEAT BAR RESTRAINT SYSTEM....3666
Operation....3666
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3667
Operation....3667
LIFT ARM BYPASS CONTROL....3668
Operation....3668
PARKING BRAKE....3668
Operation....3668
TRACTION LOCK OVERRIDE....3668
Operation....3668
EMERGENCY EXIT....3669
Rear Window....3669
Front Door....3669
BACK-UP ALARM SYSTEM....3670
Description....3670
Operation....3670
ENGINE SPEED CONTROL....3670
Operation....3670
DRIVING AND STEERING THE LOADER....3671
Operation....3671
Stopping The Loader....3671
Using The Control Levers....3671
HYDRAULIC CONTROLS....3672
Description....3672
Hydraulic Bucket Positioning....3672
Front Auxiliary Hydraulic Control Lockout....3672
FRONT Auxiliary Hydraulics Operation (Variable Flow)....3673
FRONT Auxiliary Hydraulics Operation (Continuous Flow)....3673
Quick Couplers....3674
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....3674
ATTACHMENT CONTROL DEVICE (ACD)....3675
Description....3675
DAILY INSPECTION....3676
Daily Inspection And Maintenance....3677
PRE-STARTING PROCEDURE....3678
Entering The Loader....3678
Operation & Maintenance Manual And Operator?s Handbook Locations....3678
Seat Adjustment....3679
Seat Belt Adjustment....3680
Seat Bar....3680
STARTING THE ENGINE....3681
Standard Key Panel....3681
Deluxe Instrumentation Panel....3683
Cold Temperature Starting....3685
Warming The Hydraulic / Hydrostatic System....3685
MONITORING THE DISPLAY PANELS....3686
Left Panel....3686
Warning And Shutdown....3686
STOPPING THE ENGINE AND LEAVING THE LOADER....3687
Procedure....3687
COUNTERWEIGHTS....3688
Description....3688
Effect On The Loader And Loader Operation....3688
When To Consider Using Counterweights....3688
When To Consider Removing Counterweights....3688
Accessories That Affect Machine Weight....3688
ATTACHMENTS....3689
Choosing The Correct Bucket....3689
Pallet Forks....3689
Installing And Removing The Attachment....3690
OPERATING PROCEDURE....3693
Inspect The Work Area....3693
Operating With A Full Bucket....3693
Operating With An Empty Bucket....3694
Filling And Emptying The Bucket....3695
Leveling The Ground Using Float....3696
Digging And Filling A Hole....3696
TOWING THE LOADER....3698
Procedure....3698
LIFTING THE LOADER....3698
Single Point Lift....3698
TRANSPORTING THE LOADER ON A TRAILER....3699
Loading And Unloading....3699
Fastening....3699
PREVENTIVE MAINTENANCE....3701
MAINTENANCE SAFETY....3705
SERVICE SCHEDULE....3707
Chart....3707
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3708
Inspecting The BICS (Engine STOPPED - Key ON)....3708
Inspecting The Seat Bar Sensor (Engine RUNNING)....3708
Inspecting The Traction Lock (Engine RUNNING)....3708
Inspecting The Lift Arm Bypass Control....3708
SEAT BAR RESTRAINT SYSTEM....3709
Description....3709
Inspecting....3709
Maintaining....3709
SEAT BELT....3710
Inspection And Maintenance....3710
LIFT ARM SUPPORT DEVICE....3711
Installing....3711
Removing....3712
BACK-UP ALARM SYSTEM....3713
Description....3713
Inspecting....3713
Adjusting Switch Position....3713
OPERATOR CAB....3714
Description....3714
Raising....3714
Lowering....3715
Cab Door Sensor....3716
REAR DOOR....3717
Opening And Closing....3717
Adjusting....3717
REAR GRILL....3718
Removing....3718
Installing....3718
HEATING SYSTEM....3719
Cleaning And Maintenance....3719
Filters....3719
Heater Coil....3719
Troubleshooting....3719
AIR CLEANER SERVICE....3720
Replacing Filter Elements....3720
FUEL SYSTEM....3721
Fuel Specifications....3721
Biodiesel Blend Fuel....3721
Filling The Fuel Tank....3722
Fuel Filter....3723
Removing Air From The Fuel System....3723
ENGINE LUBRICATION SYSTEM....3724
Checking And Adding Engine Oil....3724
Engine Oil Chart....3724
Removing And Replacing Oil And Filter....3724
ENGINE COOLING SYSTEM....3725
Cleaning....3725
Checking Level....3725
Removing And Replacing Coolant....3726
ELECTRICAL SYSTEM....3727
Description....3727
Fuse And Relay Location / Identification....3727
Battery Maintenance....3728
Using A Booster Battery (Jump Starting)....3729
Removing And Installing Battery....3730
HYDRAULIC / HYDROSTATIC SYSTEM....3731
Checking And Adding Fluid....3731
Hydraulic / Hydrostatic Fluid Chart....3731
Removing And Replacing Hydraulic Fluid....3732
Removing And Replacing Hydraulic / Hydrostatic Filter....3733
Removing And Replacing Case Drain Filters....3734
Removing And Replacing Hydraulic Charge Filter....3735
Breather Cap....3735
SPARK ARRESTOR MUFFLER....3736
Cleaning Procedure....3736
TIRE MAINTENANCE....3737
Wheel Nuts....3737
Rotating....3737
Mounting....3737
FINAL DRIVE TRANSMISSION (CHAINCASE)....3738
Checking And Adding Oil....3738
Removing And Replacing Oil....3738
ALTERNATOR BELT....3739
Belt Adjustment....3739
Belt Replacement....3739
DRIVE BELT....3740
Belt Adjustment....3740
Belt Replacement....3740
LUBRICATING THE LOADER....3741
Lubrication Locations....3741
PIVOT PINS....3743
Inspection And Maintenance....3743
BOB-TACH....3744
Inspection And Maintenance....3744
LOADER STORAGE AND RETURN TO SERVICE....3745
Storage....3745
Return To Service....3745
SYSTEM SETUP & ANALYSIS....3747
DIAGNOSTIC SERVICE CODES....3749
Viewing Service Codes (Standard Key Panel)....3749
Viewing Service Codes (Deluxe Instrumentation Panel)....3749
Service Codes List....3750
CONTROL PANEL SETUP....3754
Right Panel Setup (Deluxe Instrumentation Panel)....3754
Attachment Control Information (Deluxe Instrumentation Panel)....3755
PASSWORD SETUP....3756
Password Description....3756
Changing The Owner Password....3756
Changing The User Passwords....3757
Password Lockout Feature....3757
MAINTENANCE CLOCK....3758
Description....3758
Setup....3758
Reset....3758
MACHINE SIGN TRANSLATIONS....3759
SERVICE SCHEDULE (6734534)....3761
DANGER (6702301)....3764
DANGER (6702302)....3764
DANGER (6717343)....3764
WARNING (6579528)....3764
WARNING (6577754)....3765
IMPORTANT (7139929)....3765
WARNING (6737189)....3765
WARNING (6728539)....3766
DANGER (6809511)....3767
WARNING (6704786)....3767
LIFT ARM SUPPORT DEVICE (6706558)....3768
WARNING (6733996)....3769
WARNING (6710358)....3769
WARNING (6725370)....3769
SPECIFICATIONS....3771
(S100) LOADER SPECIFICATIONS....3773
Machine Dimensions....3773
Performance....3774
Engine....3774
Controls....3774
Drive System....3775
Hydraulic System....3775
Electrical....3776
Capacities....3776
Tires....3776
WARRANTY....3777
ALPHABETICAL INDEX....3781
6987131 (10-12) - S100 Skid-Steer Loader Service Manual....3783
MAINTENANCE SAFETY....3785
CONTENTS....3787
FOREWORD....3789
FOREWORD....3791
SAFETY INSTRUCTIONS....3794
FIRE PREVENTION....3796
Maintenance....3796
Operation....3796
Electrical....3796
Hydraulic System....3796
Fueling....3796
Starting....3796
Spark Arrestor Exhaust System....3796
Welding And Grinding....3797
Fire Extinguishers....3797
SERIAL NUMBER LOCATIONS....3798
Loader Serial Number....3798
Engine Serial Number....3798
DELIVERY REPORT....3799
LOADER IDENTIFICATION....3800
SAFETY & MAINTENANCE....3801
LIFTING AND BLOCKING THE LOADER....3803
Procedure....3803
LIFT ARM SUPPORT DEVICE....3805
Installing....3805
Removing....3806
OPERATOR CAB....3807
Description....3807
Raising....3807
Lowering....3808
Cab Door Sensor....3809
TRANSPORTING THE LOADER ON A TRAILER....3811
Loading And Unloading....3811
Fastening....3811
TOWING THE LOADER....3813
Procedure....3813
REMOTE START TOOL KIT-MEL1563....3815
Remote Start Tool - MEL1563....3815
Service Tool Harness Control - MEL1565....3816
Service Tool Harness Communicator - MEL1566....3817
Remote Start Procedure....3818
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....3821
Description....3821
Remote Start Tool (Service Tool) - 7003030....3822
Loader Service Tool Harness - 6689747....3823
Computer Service Tool Harness - 6689746....3824
Remote Start Procedure....3825
SERVICE SCHEDULE....3829
Chart....3829
AIR CLEANER SERVICE....3831
Replacing Filter Elements....3831
ENGINE COOLING SYSTEM....3833
Cleaning....3833
Checking Level....3833
Removing And Replacing Coolant....3834
FUEL SYSTEM....3835
Fuel Specifications....3835
Biodiesel Blend Fuel....3835
Filling The Fuel Tank....3836
Fuel Filter....3837
Removing Air From The Fuel System....3837
ENGINE LUBRICATION SYSTEM....3839
Checking And Adding Engine Oil....3839
Engine Oil Chart....3839
Removing And Replacing Oil And Filter....3840
HYDRAULIC / HYDROSTATIC SYSTEM....3841
Checking And Adding Fluid....3841
Hydraulic / Hydrostatic Fluid Chart....3841
Removing And Replacing Hydraulic Fluid....3842
Removing And Replacing Hydraulic / Hydrostatic Filter....3843
Removing And Replacing Case Drain Filters....3844
Removing And Replacing Hydraulic Charge Filter....3845
Breather Cap....3845
FINAL DRIVE TRANSMISSION (CHAINCASE)....3847
Checking And Adding Oil....3847
Removing And Replacing Oil....3847
BOB-TACH (HAND LEVER)....3849
Inspection And Maintenance....3849
LUBRICATING THE LOADER....3851
Lubrication Locations....3851
TIRE MAINTENANCE....3853
Wheel Nuts....3853
Rotating....3853
Mounting....3853
SPARK ARRESTER MUFFLER....3855
Cleaning Procedure....3855
PIVOT PINS....3857
Inspection And Maintenance....3857
LOADER STORAGE AND RETURN TO SERVICE....3859
Storage....3859
Return To Service....3859
STOPPING THE ENGINE AND LEAVING THE LOADER....3861
Procedure....3861
Emergency Exit....3862
HYDRAULIC SYSTEM....3863
HYDRAULIC / HYDROSTATIC SCHEMATICS....3865
HYDRAULIC SYSTEM INFORMATION....3867
Glossary Of Hydraulic / Hydrostatic Symbols....3867
Troubleshooting....3871
CYLINDER (LIFT)....3873
Testing....3873
Removal And Installation....3874
Parts Identification....3875
Disassembly And Assembly....3876
CYLINDER (TILT)....3879
Testing....3879
Removal And Installation....3879
Parts Identification....3881
Disassembly And Assembly....3882
MAIN RELIEF VALVE....3885
Description....3885
Testing....3885
Adjusting....3886
Removal And Installation....3886
HYDRAULIC CONTROL VALVE....3887
Description....3887
Removal And Installation....3887
Identification Chart....3890
Load Check Valve Removal And Installation (Tilt And Auxiliary)....3891
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3892
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3893
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3893
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3894
Port Relief Valve Removal And Installation....3894
Rubber Boot Removal And Installation....3895
End Cap / Spool Lock Block Removal And Installation....3895
Lift Spool And Detent Removal And Installation....3896
Tilt Spool Removal And Installation....3905
Auxiliary Spool Removal And Installation....3907
Solenoid Removal And Installation....3915
Lock Valve Removal And Installation....3916
Main Relief Valve Removal And Installation....3918
LIFT ARM BYPASS CONTROL VALVE....3919
Description....3919
Testing....3919
Removal And Installation....3920
Disassembly And Assembly....3922
HYDRAULIC PUMP....3923
Description....3923
Pump Test At Quick Couplers....3923
Direct Pump Test....3924
Direct Pump Test (Charge Section)....3925
Removal And Installation....3928
Parts Identification....3931
Disassembly And Assembly....3932
Hydraulic Pump Start Up....3936
HYDRAULIC / HYDROSTATIC FILTERS....3937
Description....3937
Hydraulic / Hydrostatic Filter Housing Removal And Installation....3937
HYDRAULIC FLUID RESERVOIR....3939
Description....3939
Removal And Installation....3939
Hydraulic Fluid Screen....3940
OIL COOLER....3941
Description....3941
Removal And Installation....3941
BUCKET POSITION VALVE....3943
Description....3943
Solenoid Removal And Installation....3943
Solenoid Testing....3944
Removal And Installation....3944
Disassembly And Assembly....3947
FRONT AUXILIARY HYDRAULIC COUPLERS....3949
Description....3949
Removal And Installation....3949
HYDROSTATIC SYSTEM....3951
HYDROSTATIC SYSTEM INFORMATION....3953
Description....3953
Troubleshooting....3954
HYDROSTATIC MOTOR....3955
Description....3955
Removal And Installation....3955
Parts Identification....3957
Disassembly And Assembly....3958
CHARGE PRESSURE....3963
Description....3963
Testing....3963
Sender Removal And Installation....3964
Adjusting....3965
HYDROSTATIC PUMP....3967
Description....3967
Replenishing / High Pressure Relief Valve Removal And Installation....3967
Removal And Installation....3968
Hydrostatic Pump Startup....3970
Parts Identification....3971
Disassembly....3972
Assembly....3977
DRIVE BELT....3983
Description....3983
Shield Removal And Installation....3983
Adjusting....3983
Belt Removal And Installation....3984
Tensioner Pulley Removal And Installation....3984
Tensioner Pulley Disassembly And Assembly....3984
CASE DRAIN FILTER....3985
Description....3985
Disassembly And Assembly....3985
DRIVE SYSTEM....3987
BRAKE....3989
Description....3989
Disk Removal And Installation....3989
DRIVE COMPONENTS....3991
Description....3991
Axle Seal Removal And Installation....3992
Axle Sprocket And Bearings Removal And Installation....3994
Chain Removal And Installation....3998
CHAINCASE....4001
Description....4001
Front Cover Removal And Installation....4001
Center Cover Removal And Installation....4002
MAINFRAME....4005
SEAT BAR....4007
Description....4007
Removal And Installation....4007
Disassembly And Assembly....4009
Compression Spring Disassembly And Assembly....4010
OPERATOR CAB....4011
Gas Cylinder Removal And Installation....4011
Gas Cylinder Bracket Disassembly And Assembly....4013
Removal And Installation....4014
OPERATOR SEAT....4017
Removal And Installation....4017
Seat Belt Removal And Installation....4017
OPERATOR SEAT (SUSPENSION)....4019
Removal And Installation....4019
Slide Rail Removal And Installation....4020
Seat Belt Removal And Installation....4020
Lower Cushion Removal And Installation....4021
Back Cushion Removal And Installation....4021
Shock Removal And Installation....4022
3-Point Seat Belt Removal And Installation....4022
BOB-TACH HAND LEVER....4025
Description....4025
Removal And Installation....4025
Lever And Wedge Disassembly And Assembly....4027
Pivot Pin Bushing And Seal Removal And Installation....4028
LIFT ARMS....4029
Removal And Installation....4029
REAR GRILLE....4035
Removal And Installation....4035
REAR DOOR....4037
Removal And Installation....4037
Striker Removal And Installation....4038
Striker Disassembly And Assembly....4038
Striker (Adjusting)....4038
Latch Removal And Installation....4039
FUEL TANK....4041
Removal And Installation....4041
Fuel Level Sender Removal And Installation....4042
Fuel Fill Screen Removal And Installation....4042
Fuel Pickup Screen....4042
CONTROL PEDALS AND LINKAGES....4043
Description....4043
Pedal Removal And Installation....4043
Linkage Removal And Installation....4044
Pedal (Adjusting)....4044
CONTROL PANEL....4047
Description....4047
Removal And Installation....4048
Shaft Removal And Installation....4051
Shaft Disassembly And Assembly....4051
Linkage Removal And Installation....4052
Pintle Arm Removal And Installation....4053
Pintle Arm Disassembly And Assembly....4056
Linkage Neutral Adjusting....4057
Linkage Travel Adjusting....4060
CONTROL HANDLE / LEVER....4065
Description....4065
Lever Removal And Installation....4065
Boot Removal And Installation....4065
WINDOW (REAR)....4067
Removal....4067
Installation....4067
WINDOW (TOP)....4069
Removal And Installation....4069
WINDOW (SIDE)....4071
Removal And Installation....4071
WINDOW (FRONT DOOR)....4073
Removal (Standard Window)....4073
Installation (Standard Window)....4074
Removal And Installation (Special Applications Window)....4075
CAB DOOR....4077
Description....4077
Removal And Installation....4077
Aligning....4078
Adjusting....4079
Checking Operation....4079
ELECTRICAL SYSTEM & ANALYSIS....4081
ELECTRICAL SCHEMATICS....4085
ELECTRICAL SYSTEM INFORMATION....4089
Glossary Of Electrical Symbols....4089
Cab Harness Connectors....4092
Mainframe Harness Connectors....4093
Description....4094
Troubleshooting....4095
Fuse And Relay Location / Identification....4096
Solenoid Testing....4097
BATTERY....4099
Removal And Installation....4099
Servicing....4100
Using A Booster Battery (Jump Starting)....4101
ALTERNATOR....4103
Belt Adjustment....4103
Belt Replacement....4103
Charging System Inspection....4104
Alternator Voltage Testing....4105
Low Voltage Testing....4105
High Voltage Testing....4106
Removal And Installation....4107
Parts Identification....4109
STARTER....4111
Testing....4111
Removal And Installation....4112
Parts Identification....4113
INSTRUMENT PANELS....4115
Left Panel....4115
Display Screen....4117
Standard Key Panel....4117
Deluxe Instrumentation Panel....4118
Side Panel....4119
Front Panel....4119
Removal And Installation (Left And Right)....4120
Key Switch Removal And Installation....4121
Alarm Removal And Installation....4121
Front Accessory Panel Removal And Installation....4122
LIGHTS....4123
Front Removal And Installation....4123
Rear Removal And Installation....4123
Cab Light Removal And Installation....4124
BOBCAT CONTROLLER (MAIN)....4125
Description....4125
Connector Identification....4126
Removal And Installation....4128
DIAGNOSTIC SERVICE CODES....4129
Viewing Service Codes (Standard Key Panel)....4129
Viewing Service Codes (Deluxe Instrumentation Panel)....4129
Service Codes List....4130
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....4135
Description....4135
Inspecting The BICS? Controller (Engine STOPPED - Key ON)....4135
Inspecting The Seat Bar Sensor (Engine RUNNING)....4135
Inspecting The Traction Lock (Engine RUNNING)....4135
Inspecting The Lift Arm Bypass Control....4135
Troubleshooting....4136
Troubleshooting Chart....4137
SEAT BAR SENSOR....4139
Description....4139
Troubleshooting....4139
Testing....4140
Removal And Installation....4141
Bobcat Interlock Control System (BICS?) Circuit Test....4143
TRACTION LOCK....4145
Description....4145
Troubleshooting....4145
Removal And Installation....4146
Inspecting....4149
SERVICE PC (LAPTOP COMPUTER)....4151
Connecting To The Remote Start Tool....4151
Connecting Remote Start Tool (Service Tool)....4151
FLYWHEEL RPM SENSOR....4153
Description....4153
Adjusting....4153
CONTROL PANEL SETUP....4155
Right Panel Setup (Deluxe Instrumentation Panel)....4155
Attachment Control Information (Deluxe Instrumentation Panel)....4156
PASSWORD SETUP....4157
Password Description....4157
Changing The Owner Password....4157
Changing The User Passwords....4158
Password Lockout Feature....4158
MAINTENANCE CLOCK....4159
Description....4159
Setup....4160
Reset....4163
BACK-UP ALARM SYSTEM....4165
Description....4165
Inspecting....4165
Adjusting Switch Position....4166
Troubleshooting....4167
Alarm Removal And Installation....4168
Switch Removal And Installation....4168
ENGINE SERVICE....4171
ENGINE INFORMATION....4173
Description....4173
Specifications....4174
Torque Values....4178
Troubleshooting....4179
Engine Removal And Installation....4180
Engine Mount Replacement....4188
Compression - Checking....4188
ENGINE SPEED CONTROL....4189
Removal And Installation....4189
MUFFLER....4191
Removal And Installation....4191
AIR CLEANER....4193
Removal And Installation....4193
ENGINE COOLING SYSTEM....4195
Radiator Removal And Installation....4195
Fan Removal And Installation....4196
Water Pump Removal And Installation....4197
Water Pump Disassembly And Assembly....4197
Thermostat Housing Removal And Installation....4198
Testing The Thermostat....4198
LUBRICATION SYSTEM....4199
Oil Pan Removal And Installation....4199
Oil Pump Removal And Installation....4199
Oil Pump Inspection....4200
Engine Oil Pressure - Testing....4201
FUEL SYSTEM....4203
Fuel Camshaft Removal And Installation....4203
Fuel Camshaft Governor Disassembly And Assembly....4203
Fuel Shutoff Solenoid - Checking....4204
Fuel Shutoff Solenoid Removal And Installation....4205
Fuel Injection Pump Removal And Installation....4206
Timing The Injection Pump....4208
Fuel Injector Removal And Installation....4210
Fuel Injector Nozzles Pressure - Checking....4211
Nozzle Spray Condition....4212
Valve Seat Tightness....4213
CYLINDER HEAD....4215
Glow Plug - Testing....4215
Glow Plug Removal And Installation....4216
Valve Clearance Adjustment....4216
Valve Timing - Checking....4217
Cylinder Head Removal And Installation....4218
Cylinder Head Disassembly And Assembly....4220
Cylinder Head - Servicing....4220
Cylinder Head Top Clearance....4221
Valve Guide - Checking....4221
Reconditioning The Valve And Valve Seat....4222
Valve Spring....4224
Valve Tappets....4225
Rocker Arm And Shaft - Checking....4225
CRANKSHAFT AND PISTONS....4227
Piston And Connecting Rod Removal And Installation....4227
Piston And Connecting Rod - Servicing....4228
Cylinder Bore - Checking....4231
Connecting Rod Alignment....4231
Crankshaft And Bearings Removal And Installation....4232
Crankshaft And Bearings - Servicing....4234
CAMSHAFT AND TIMING GEARS....4239
Timing Gearcase Cover Removal And Installation....4239
Timing Gears Backlash - Checking....4241
Idler Gear And Shaft Removal And Installation....4241
Camshaft - Servicing....4242
Idler Gear And Shaft Servicing....4244
FLYWHEEL....4245
Flywheel Removal And Installation....4245
HEATING, VENTILATION, AIR CONDITIONING....4247
HEATER SYSTEM....4249
Description....4249
REGULAR MAINTENANCE....4251
Filter Elements Removal And Installation....4251
Cleaning The Heater Coil....4252
TROUBLESHOOTING....4253
Blower Motor Does Not Operate....4253
Blower Motor Operators Normally, But Air Flow Is Insufficient....4253
Electrical System....4254
Engine Coolant bypassing The Heater Valve....4258
Heater Valve Not Opening Or Closing....4258
HEATER UNIT....4261
Removal And Installation....4261
HEATER COIL....4263
Removal And Installation....4263
HEATER FAN....4265
Blower Removal And Installation....4265
Disassembly And Assembly....4266
Connector Identification....4268
HEATER VALVE....4269
Removal And Installation....4269
Disassembly And Assembly....4270
SPECIFICATIONS....4271
(S100) LOADER SPECIFICATIONS....4273
Machine Dimensions....4273
Performance....4274
Engine....4274
Controls....4274
Drive System....4275
Hydraulic System....4275
Electrical....4276
Capacities....4276
Tires....4276
TORQUE SPECIFICATIONS FOR BOLTS....4277
Torque For General SAE Bolts....4277
Torque For General Metric Bolts....4278
HYDRAULIC CONNECTION SPECIFICATIONS....4279
O-ring Face Seal Connection....4279
Straight Thread O-ring Fitting....4280
Tubelines And Hoses....4280
Flare Fitting....4280
Port Seal Fitting....4281
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....4283
Specifications....4283
CONVERSIONS....4285
Decimal And Millimeter Equivalent Chart....4285
U.S. To Metric Conversion Chart....4285
ALPHABETICAL INDEX....4287
SERVICE MANUAL REVISION....4289
Revision No: S100 - 1....4289
Revision No: S100 - 2....4291
Revision No: S100 - 3....4293
Revision No: S100 - 4....4295
6987131 (3-09) - S100 Skid-Steer Loader Service Manual....4297
MAINTENANCE SAFETY....4299
ALPHABETICAL INDEX....4301
CONTENTS....4303
FOREWORD....4304
SAFETY INSTRUCTIONS....4307
FIRE PREVENTION....4309
Maintenance....4309
Operation....4309
Electrical....4309
Hydraulic System....4309
Fueling....4309
Starting....4309
Spark Arrestor Exhaust System....4309
Welding And Grinding....4310
Fire Extinguishers....4310
SERIAL NUMBER LOCATIONS....4311
Loader Serial Number....4311
Engine Serial Number....4311
DELIVERY REPORT....4312
LOADER IDENTIFICATION....4313
SAFETY AND MAINTENANCE....4315
LIFTING AND BLOCKING THE LOADER....4319
Procedure....4319
LIFT ARM SUPPORT DEVICE....4321
Installing....4321
Removing....4322
OPERATOR CAB....4323
Description....4323
Raising....4323
Lowering....4324
Cab Door Sensor....4325
TRANSPORTING THE LOADER ON A TRAILER....4327
Loading And Unloading....4327
Fastening....4327
TOWING THE LOADER....4329
Procedure....4329
REMOTE START TOOL KIT-MEL1563....4331
Remote Start Tool - MEL1563....4331
Service Tool Harness Control - MEL1565....4332
Service Tool Harness Communicator - MEL1566....4333
Remote Start Procedure....4334
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....4337
Description....4337
Remote Start Tool (Service Tool) - 6689778....4338
Loader Service Tool Harness - 6689747....4339
Computer Service Tool Harness - 6689746....4340
Remote Start Procedure....4341
SERVICE SCHEDULE....4345
Chart....4345
AIR CLEANER SERVICE....4347
Replacing Filter Elements....4347
ENGINE COOLING SYSTEM....4349
Cleaning....4349
Checking Level....4349
Removing And Replacing Coolant....4350
FUEL SYSTEM....4351
Fuel Specifications....4351
Biodiesel Blend Fuel....4351
Filling The Fuel Tank....4352
Fuel Filter....4353
Removing Air From The Fuel System....4353
ENGINE LUBRICATION SYSTEM....4355
Checking And Adding Engine Oil....4355
Engine Oil Chart....4355
Removing And Replacing Oil And Filter....4355
HYDRAULIC / HYDROSTATIC SYSTEM....4357
Checking And Adding Fluid....4357
Hydraulic / Hydrostatic Fluid Chart....4357
Removing And Replacing Hydraulic Fluid....4358
Removing And Replacing Hydraulic / Hydrostatic Filter....4359
Removing And Replacing Case Drain Filters....4360
Removing And Replacing Hydraulic Charge Filter....4361
Breather Cap....4361
FINAL DRIVE TRANSMISSION (CHAINCASE)....4363
Checking And Adding Oil....4363
Removing And Replacing Oil....4363
BOB-TACH (HAND LEVER)....4365
Inspection And Maintenance....4365
LUBRICATING THE LOADER....4367
Lubrication Locations....4367
TIRE MAINTENANCE....4369
Wheel Nuts....4369
Rotating....4369
Mounting....4369
SPARK ARRESTOR MUFFLER....4371
Cleaning Procedure....4371
PIVOT PINS....4373
Inspection And Maintenance....4373
LOADER STORAGE AND RETURN TO SERVICE....4375
Storage....4375
Return To Service....4375
STOPPING THE ENGINE AND LEAVING THE LOADER....4377
Procedure....4377
Emergency Exit....4378
HYDRAULIC SYSTEM....4379
HYDRAULIC / HYDROSTATIC SCHEMATICS....4381
HYDRAULIC SYSTEM INFORMATION....4383
Glossary Of Hydraulic / Hydrostatic Symbols....4383
Troubleshooting....4387
CYLINDER (LIFT)....4389
Testing....4389
Removal And Installation....4390
Parts Identification....4391
Disassembly And Assembly....4392
CYLINDER (TILT)....4395
Testing....4395
Removal And Installation....4395
Parts Identification....4397
Disassembly And Assembly....4398
MAIN RELIEF VALVE....4401
Description....4401
Testing....4401
Adjusting....4402
Removal And Installation....4402
HYDRAULIC CONTROL VALVE....4403
Description....4403
Removal And Installation....4403
Identification Chart....4406
Load Check Valve Removal And Installation (Tilt and Auxiliary)....4407
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....4408
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....4409
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....4409
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....4410
Port Relief Valve Removal And Installation....4410
Rubber Boot Removal And Installation....4411
End Cap / Spool Lock Block Removal And Installation....4411
Lift Spool And Detent Removal And Installation....4412
Tilt Spool Removal And Installation....4421
Auxiliary Spool Removal And Installation....4423
Solenoid Removal And Installation....4431
Lock Valve Removal And Installation....4432
Main Relief Valve Removal And Installation....4434
LIFT ARM bypass CONTROL VALVE....4435
Description....4435
Testing....4435
Removal and Installation....4435
Disassembly And Assembly....4437
HYDRAULIC PUMP....4439
Description....4439
Pump Test at Quick Couplers....4439
Direct Pump Test....4440
Direct Pump Test (Charge Section)....4441
Removal And Installation....4444
Parts Identification....4447
Disassembly And Assembly....4448
Hydraulic Pump Start Up....4452
HYDRAULIC / HYDROSTATIC FILTERS....4453
Description....4453
Hydraulic / Hydrostatic Filter Housing Removal And Installation....4453
HYDRAULIC FLUID RESERVOIR....4455
Description....4455
Removal And Installation....4455
Hydraulic Fluid Screen....4456
OIL COOLER....4457
Description....4457
Removal And Installation....4457
BUCKET POSITION VALVE....4459
Description....4459
Solenoid Removal And Installation....4459
Solenoid Testing....4460
Removal And Installation....4460
Disassembly And Assembly....4463
FRONT AUXILIARY HYDRAULIC COUPLERS....4465
Description....4465
Removal And Installation....4465
HYDROSTATIC SYSTEM....4467
HYDROSTATIC SYSTEM INFORMATION....4469
Description....4469
Troubleshooting....4470
HYDROSTATIC MOTOR....4471
Description....4471
Removal And Installation....4471
Parts Identification....4473
Disassembly And Assembly....4474
CHARGE PRESSURE....4479
Description....4479
Testing....4479
Sender Removal And Installation....4480
Adjusting....4481
HYDROSTATIC PUMP....4483
Description....4483
Replenishing / High Pressure Relief Valve Removal And Installation....4483
Removal And Installation....4484
Hydrostatic Pump Startup....4486
Parts Identification....4487
Disassembly....4488
Assembly....4493
DRIVE BELT....4499
Description....4499
Shield Removal And Installation....4499
Adjusting....4499
Belt Removal And Installation....4500
Tensioner Pulley Removal And Installation....4500
Tensioner Pulley Disassembly And Assembly....4500
CASE DRAIN FILTER....4501
Description....4501
Disassembly And Assembly....4501
DRIVE SYSTEM....4503
BRAKE....4505
Description....4505
Disk Removal And Installation....4505
DRIVE COMPONENTS....4507
Description....4507
Axle Seal Removal And Installation....4508
Axle Sprocket And Bearings Removal And Installation....4510
Chain Removal And Installation....4514
CHAINCASE....4517
Description....4517
Front Cover Removal And Installation....4517
Center Cover Removal And Installation....4518
MAIN FRAME....4521
SEAT BAR....4525
Description....4525
Removal And Installation....4525
Disassembly And Assembly....4527
Compression Spring Disassembly And Assembly....4528
OPERATOR CAB....4529
Gas Cylinder Removal And Installation....4529
Gas Cylinder Bracket Disassembly And Assembly....4531
Removal And Installation....4532
OPERATOR SEAT....4535
Removal And Installation....4535
Seat Belt Removal And Installation....4535
OPERATOR SEAT (SUSPENSION)....4537
Removal And Installation....4537
Slide Rail Removal And Installation....4538
Seat Belt Removal and Installation....4538
Lower Cushion Removal And Installation....4539
Back Cushion Removal And Installation....4539
Shock Removal And Installation....4540
3-Point Seat Belt Removal And Installation....4540
BOB-TACH HAND LEVER....4543
Description....4543
Removal And Installation....4543
Lever And Wedge Disassembly And Assembly....4545
Pivot Pin Bushing And Seal Removal And Installation....4546
LIFT ARMS....4547
Removal And Installation....4547
REAR GRILL....4553
Removal And Installation....4553
REAR DOOR....4555
Removal And Installation....4555
Striker Removal and Installation....4556
Striker Disassembly and Assembly....4556
Striker (Adjusting)....4556
Latch Removal And Installation....4557
FUEL TANK....4559
Removal And Installation....4559
Fuel Level Sender Removal And Installation....4560
Fuel Fill Screen Removal And Installation....4560
Fuel Pickup Screen....4560
CONTROL PEDALS AND LINKAGES....4561
Description....4561
Pedal Removal And Installation....4561
Linkage Removal And Installation....4562
Pedal (Adjusting)....4562
CONTROL PANEL....4565
Description....4565
Removal and Installation....4566
Shaft Removal And Installation....4569
Shaft Disassembly And Assembly....4569
Linkage Removal And Installation....4570
Pintle Arm Removal And Installation....4571
Pintle Arm Disassembly and Assembly....4574
Linkage Neutral Adjusting....4575
Linkage Travel Adjusting....4578
CONTROL HANDLE / LEVER....4583
Description....4583
Lever Removal And Installation....4583
Boot Removal And Installation....4583
WINDOW (REAR)....4585
Removal....4585
Installation....4585
WINDOW (TOP)....4587
Removal And Installation....4587
WINDOW (SIDE)....4589
Removal And Installation....4589
WINDOW (FRONT DOOR)....4591
Removal (Standard Window)....4591
Installation (Standard Window)....4592
Removal And Installation (Special Applications Window)....4593
CAB DOOR....4595
Description....4595
Removal And Installation....4595
Aligning....4596
Adjusting....4597
Checking Operation....4597
ELECTRICAL SYSTEM & ANALYSIS....4599
ELECTRICAL SCHEMATICS....4603
ELECTRICAL SYSTEM INFORMATION....4605
Glossary Of Electrical Symbols....4605
Cab Harness Connectors....4608
Mainframe Harness Connectors....4609
Description....4610
Troubleshooting....4611
Fuse And Relay Location / Identification....4612
Solenoid Testing....4613
BATTERY....4615
Removal And Installation....4615
Servicing....4616
Using A Booster Battery (Jump Starting)....4617
ALTERNATOR....4619
Belt Adjustment....4619
Belt Replacement....4619
Charging System Inspection....4620
Alternator Voltage Testing....4621
Low Voltage Testing....4621
High Voltage Testing....4622
Removal And Installation....4623
Parts Identification....4625
STARTER....4627
Testing....4627
Removal And Installation....4628
Parts Identification....4629
INSTRUMENT PANELS....4631
Display Screen....4633
Standard Key Panel....4633
Deluxe Instrumentation Panel....4634
Side Panel....4635
Front Panel....4635
Removal And Installation (Left And Right)....4636
Key Switch Removal And Installation....4637
Alarm Removal And Installation....4637
Front Accessory Panel Removal And Installation....4638
LIGHTS....4639
Front Removal And Installation....4639
Rear Removal And Installation....4639
Cab Light Removal And Installation....4640
BOBCAT CONTROLLER (MAIN)....4641
Description....4641
Connector Identification....4642
Removal And Installation....4644
DIAGNOSTIC SERVICE CODES....4645
Viewing Service Codes (Standard Key Panel)....4645
Viewing Service Codes (Deluxe Instrumentation Panel)....4645
Service Codes List....4646
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....4651
Description....4651
Inspecting The BICS Controller (Engine STOPPED - Key ON)....4651
Inspecting The Seat Bar Sensor (Engine RUNNING)....4651
Inspecting The Traction Lock (Engine RUNNING)....4651
Inspecting The Lift Arm Bypass Control....4652
Troubleshooting....4653
Troubleshooting Chart....4654
SEAT BAR SENSOR....4655
Description....4655
Troubleshooting....4655
Testing....4656
Removal And Installation....4657
Bobcat Interlock Control System (BICS) Circuit Test....4659
TRACTION LOCK....4661
Description....4661
Troubleshooting....4661
Removal And Installation....4662
Inspecting....4665
SERVICE PC (LAPTOP COMPUTER)....4667
Connecting To The Remote Start Tool....4667
Connecting Remote Start Tool (Service Tool)....4667
FLYWHEEL RPM SENSOR....4669
Description....4669
Adjusting....4669
CONTROL PANEL SETUP....4671
Right Panel Setup (Deluxe Instrumentation Panel)....4671
Attachment Control Information (Deluxe Instrumentation Panel)....4672
PASSWORD SETUP....4673
Password Description....4673
Changing The Owner Password....4673
Changing The User Passwords....4674
Password Lockout Feature....4674
MAINTENANCE CLOCK....4675
Description....4675
Setup....4676
Reset....4679
BACK-UP ALARM SYSTEM....4681
Description....4681
Inspecting....4681
Adjusting Switch Position....4682
Troubleshooting....4683
Alarm Removal And Installation....4684
Switch Removal And Installation....4684
ENGINE SERVICE....4687
ENGINE INFORMATION....4689
Description....4689
Specifications....4690
Torque Values....4694
Troubleshooting....4695
Engine Removal And Installation....4696
Engine Mount Replacement....4704
Compression-Checking....4704
ENGINE SPEED CONTROL....4705
Removal And Installation....4705
MUFFLER....4707
Removal And Installation....4707
AIR CLEANER....4709
Removal And Installation....4709
ENGINE COOLING SYSTEM....4711
Radiator Removal And Installation....4711
Fan Removal And Installation....4712
Water Pump Removal And Installation....4713
Water Pump Disassembly And Assembly....4713
Thermostat Housing Removal And Installation....4714
Testing The Thermostat....4714
LUBRICATION SYSTEM....4715
Oil Pan Removal And Installation....4715
Oil Pump Removal And Installation....4715
Oil Pump Inspection....4716
Engine Oil Pressure - Testing....4717
FUEL SYSTEM....4719
Fuel Camshaft Removal And Installation....4719
Fuel Camshaft Governor Disassembly And Assembly....4719
Fuel Shutoff Solenoid - Checking....4720
Fuel Shutoff Solenoid Removal And Installation....4721
Fuel Injection Pump Removal And Installation....4722
Timing The Injection Pump....4724
Fuel Injector Removal And Installation....4726
Fuel Injector Nozzles Pressure - Checking....4727
Nozzle Spray Condition....4728
Valve Seat Tightness....4729
CYLINDER HEAD....4731
Glow Plug - Testing....4731
Glow Plug Removal And Installation....4732
Valve Clearance Adjustment....4732
Valve Timing - Checking....4733
Cylinder Head Removal And Installation....4734
Cylinder Head Disassembly and Assembly....4736
Cylinder Head - Servicing....4736
Cylinder Head Top Clearance....4737
Valve Guide - Checking....4737
Reconditioning The Valve And Valve Seat....4738
Valve Spring....4740
Valve Tappets....4741
Rocker Arm And Shaft - Checking....4741
CRANKSHAFT AND PISTONS....4743
Piston And Connecting Rod Removal And Installation....4743
Piston And Connecting Rod - Servicing....4744
Cylinder Bore Checking....4747
Connecting Rod Alignment....4747
Crankshaft And Bearings Removal And Installation....4748
Crankshaft And Bearings - Servicing....4750
CAMSHAFT AND TIMING GEARS....4755
Timing Gearcase Cover Removal And Installation....4755
Timing Gears Backlash - Checking....4757
Idler Gear And Shaft Removal And Installation....4757
Camshaft - Servicing....4758
Idler Gear And Shaft Servicing....4760
FLYWHEEL....4761
Flywheel Removal And Installation....4761
HEATER....4763
HEATER SYSTEM....4765
Description....4765
REGULAR MAINTENANCE....4767
Filter Elements Removal And Installation....4767
Cleaning The Heater Coil....4768
TROUBLESHOOTING....4769
Blower Motor Does Not Operate....4769
Blower Motor Operators Normally, But Air Flow Is Insufficient....4769
Electrical System....4770
Engine Coolant bypassing The Heater Valve....4774
Heater Valve Not Opening Or Closing....4774
HEATER UNIT....4777
Removal And Installation....4777
HEATER COIL....4779
Removal And Installation....4779
HEATER FAN....4781
Blower Removal And Installation....4781
Disassembly And Assembly....4782
Connector Identification....4784
HEATER VALVE....4785
Removal and Installation....4785
Disassembly And Assembly....4786
SPECIFICATIONS....4787
(S100) LOADER SPECIFICATIONS....4789
Machine Dimensions....4789
Performance....4790
Engine....4790
Controls....4790
Drive System....4791
Hydraulic System....4791
Electrical....4792
Capacities....4792
Tires....4792
TORQUE SPECIFICATIONS FOR BOLTS....4793
Torque For General SAE Bolts....4793
Torque For General Metric Bolts....4794
HYDRAULIC CONNECTION SPECIFICATIONS....4795
O-ring Face Seal Connection....4795
Straight Thread O-ring Fitting....4796
Tubelines And Hoses....4796
Flare Fitting....4796
Port Seal Fitting....4797
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....4799
Specifications....4799
CONVERSIONS....4801
Decimal And Millimeter Equivalent Chart....4801
U.S. To Metric Conversion Chart....4801
SERVICE MANUAL REVISION....4803
Revision No: S100 - 1....4803
6987131 (4-11) - S100 Skid-Steer Loader Service Manual....4805
MAINTENANCE SAFETY....4807
CONTENTS....4809
FOREWORD....4811
FOREWORD....4813
SAFETY INSTRUCTIONS....4816
FIRE PREVENTION....4818
Maintenance....4818
Operation....4818
Electrical....4818
Hydraulic System....4818
Fueling....4818
Starting....4818
Spark Arrestor Exhaust System....4818
Welding And Grinding....4819
Fire Extinguishers....4819
SERIAL NUMBER LOCATIONS....4820
Loader Serial Number....4820
Engine Serial Number....4820
DELIVERY REPORT....4821
LOADER IDENTIFICATION....4822
SAFETY & MAINTENANCE....4823
LIFTING AND BLOCKING THE LOADER....4825
Procedure....4825
LIFT ARM SUPPORT DEVICE....4827
Installing....4827
Removing....4828
OPERATOR CAB....4829
Description....4829
Raising....4829
Lowering....4830
Cab Door Sensor....4831
TRANSPORTING THE LOADER ON A TRAILER....4833
Loading And Unloading....4833
Fastening....4833
TOWING THE LOADER....4835
Procedure....4835
REMOTE START TOOL KIT-MEL1563....4837
Remote Start Tool - MEL1563....4837
Service Tool Harness Control - MEL1565....4838
Service Tool Harness Communicator - MEL1566....4839
Remote Start Procedure....4840
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....4843
Description....4843
Remote Start Tool (Service Tool) - 7003030....4844
Loader Service Tool Harness - 6689747....4845
Computer Service Tool Harness - 6689746....4846
Remote Start Procedure....4847
SERVICE SCHEDULE....4851
Chart....4851
AIR CLEANER SERVICE....4853
Replacing Filter Elements....4853
ENGINE COOLING SYSTEM....4855
Cleaning....4855
Checking Level....4855
Removing And Replacing Coolant....4856
FUEL SYSTEM....4857
Fuel Specifications....4857
Biodiesel Blend Fuel....4857
Filling The Fuel Tank....4858
Fuel Filter....4859
Removing Air From The Fuel System....4859
ENGINE LUBRICATION SYSTEM....4861
Checking And Adding Engine Oil....4861
Engine Oil Chart....4861
Removing And Replacing Oil And Filter....4862
HYDRAULIC / HYDROSTATIC SYSTEM....4863
Checking And Adding Fluid....4863
Hydraulic / Hydrostatic Fluid Chart....4863
Removing And Replacing Hydraulic Fluid....4864
Removing And Replacing Hydraulic / Hydrostatic Filter....4865
Removing And Replacing Case Drain Filters....4866
Removing And Replacing Hydraulic Charge Filter....4867
Breather Cap....4867
FINAL DRIVE TRANSMISSION (CHAINCASE)....4869
Checking And Adding Oil....4869
Removing And Replacing Oil....4869
BOB-TACH (HAND LEVER)....4871
Inspection And Maintenance....4871
LUBRICATING THE LOADER....4873
Lubrication Locations....4873
TIRE MAINTENANCE....4875
Wheel Nuts....4875
Rotating....4875
Mounting....4875
SPARK ARRESTER MUFFLER....4877
Cleaning Procedure....4877
PIVOT PINS....4879
Inspection And Maintenance....4879
LOADER STORAGE AND RETURN TO SERVICE....4881
Storage....4881
Return To Service....4881
STOPPING THE ENGINE AND LEAVING THE LOADER....4883
Procedure....4883
Emergency Exit....4884
HYDRAULIC SYSTEM....4885
HYDRAULIC / HYDROSTATIC SCHEMATICS....4887
HYDRAULIC SYSTEM INFORMATION....4889
Glossary Of Hydraulic / Hydrostatic Symbols....4889
Troubleshooting....4893
CYLINDER (LIFT)....4895
Testing....4895
Removal And Installation....4896
Parts Identification....4897
Disassembly And Assembly....4898
CYLINDER (TILT)....4901
Testing....4901
Removal And Installation....4901
Parts Identification....4903
Disassembly And Assembly....4904
MAIN RELIEF VALVE....4907
Description....4907
Testing....4907
Adjusting....4908
Removal And Installation....4908
HYDRAULIC CONTROL VALVE....4909
Description....4909
Removal And Installation....4909
Identification Chart....4912
Load Check Valve Removal And Installation (Tilt And Auxiliary)....4913
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....4914
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....4915
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....4915
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....4916
Port Relief Valve Removal And Installation....4916
Rubber Boot Removal And Installation....4917
End Cap / Spool Lock Block Removal And Installation....4917
Lift Spool And Detent Removal And Installation....4918
Tilt Spool Removal And Installation....4927
Auxiliary Spool Removal And Installation....4929
Solenoid Removal And Installation....4937
Lock Valve Removal And Installation....4938
Main Relief Valve Removal And Installation....4940
LIFT ARM BYPASS CONTROL VALVE....4941
Description....4941
Testing....4941
Removal And Installation....4942
Disassembly And Assembly....4944
HYDRAULIC PUMP....4945
Description....4945
Pump Test At Quick Couplers....4945
Direct Pump Test....4946
Direct Pump Test (Charge Section)....4947
Removal And Installation....4950
Parts Identification....4953
Disassembly And Assembly....4954
Hydraulic Pump Start Up....4958
HYDRAULIC / HYDROSTATIC FILTERS....4959
Description....4959
Hydraulic / Hydrostatic Filter Housing Removal And Installation....4959
HYDRAULIC FLUID RESERVOIR....4961
Description....4961
Removal And Installation....4961
Hydraulic Fluid Screen....4962
OIL COOLER....4963
Description....4963
Removal And Installation....4963
BUCKET POSITION VALVE....4965
Description....4965
Solenoid Removal And Installation....4965
Solenoid Testing....4966
Removal And Installation....4966
Disassembly And Assembly....4969
FRONT AUXILIARY HYDRAULIC COUPLERS....4971
Description....4971
Removal And Installation....4971
HYDROSTATIC SYSTEM....4973
HYDROSTATIC SYSTEM INFORMATION....4975
Description....4975
Troubleshooting....4976
HYDROSTATIC MOTOR....4977
Description....4977
Removal And Installation....4977
Parts Identification....4979
Disassembly And Assembly....4980
CHARGE PRESSURE....4985
Description....4985
Testing....4985
Sender Removal And Installation....4986
Adjusting....4987
HYDROSTATIC PUMP....4989
Description....4989
Replenishing / High Pressure Relief Valve Removal And Installation....4989
Removal And Installation....4990
Hydrostatic Pump Startup....4992
Parts Identification....4993
Disassembly....4994
Assembly....4999
DRIVE BELT....5005
Description....5005
Shield Removal And Installation....5005
Adjusting....5005
Belt Removal And Installation....5006
Tensioner Pulley Removal And Installation....5006
Tensioner Pulley Disassembly And Assembly....5006
CASE DRAIN FILTER....5007
Description....5007
Disassembly And Assembly....5007
DRIVE SYSTEM....5009
BRAKE....5011
Description....5011
Disk Removal And Installation....5011
DRIVE COMPONENTS....5013
Description....5013
Axle Seal Removal And Installation....5014
Axle Sprocket And Bearings Removal And Installation....5016
Chain Removal And Installation....5020
CHAINCASE....5023
Description....5023
Front Cover Removal And Installation....5023
Center Cover Removal And Installation....5024
MAINFRAME....5027
SEAT BAR....5029
Description....5029
Removal And Installation....5029
Disassembly And Assembly....5031
Compression Spring Disassembly And Assembly....5032
OPERATOR CAB....5033
Gas Cylinder Removal And Installation....5033
Gas Cylinder Bracket Disassembly And Assembly....5035
Removal And Installation....5036
OPERATOR SEAT....5039
Removal And Installation....5039
Seat Belt Removal And Installation....5039
OPERATOR SEAT (SUSPENSION)....5041
Removal And Installation....5041
Slide Rail Removal And Installation....5042
Seat Belt Removal And Installation....5042
Lower Cushion Removal And Installation....5043
Back Cushion Removal And Installation....5043
Shock Removal And Installation....5044
3-Point Seat Belt Removal And Installation....5044
BOB-TACH HAND LEVER....5047
Description....5047
Removal And Installation....5047
Lever And Wedge Disassembly And Assembly....5049
Pivot Pin Bushing And Seal Removal And Installation....5050
LIFT ARMS....5051
Removal And Installation....5051
REAR GRILLE....5057
Removal And Installation....5057
REAR DOOR....5059
Removal And Installation....5059
Striker Removal And Installation....5060
Striker Disassembly And Assembly....5060
Striker (Adjusting)....5060
Latch Removal And Installation....5061
FUEL TANK....5063
Removal And Installation....5063
Fuel Level Sender Removal And Installation....5064
Fuel Fill Screen Removal And Installation....5064
Fuel Pickup Screen....5064
CONTROL PEDALS AND LINKAGES....5065
Description....5065
Pedal Removal And Installation....5065
Linkage Removal And Installation....5066
Pedal (Adjusting)....5066
CONTROL PANEL....5069
Description....5069
Removal And Installation....5070
Shaft Removal And Installation....5073
Shaft Disassembly And Assembly....5073
Linkage Removal And Installation....5074
Pintle Arm Removal And Installation....5075
Pintle Arm Disassembly And Assembly....5078
Linkage Neutral Adjusting....5079
Linkage Travel Adjusting....5082
CONTROL HANDLE / LEVER....5087
Description....5087
Lever Removal And Installation....5087
Boot Removal And Installation....5087
WINDOW (REAR)....5089
Removal....5089
Installation....5089
WINDOW (TOP)....5091
Removal And Installation....5091
WINDOW (SIDE)....5093
Removal And Installation....5093
WINDOW (FRONT DOOR)....5095
Removal (Standard Window)....5095
Installation (Standard Window)....5096
Removal And Installation (Special Applications Window)....5097
CAB DOOR....5099
Description....5099
Removal And Installation....5099
Aligning....5100
Adjusting....5101
Checking Operation....5101
ELECTRICAL SYSTEM & ANALYSIS....5103
ELECTRICAL SCHEMATICS....5107
ELECTRICAL SYSTEM INFORMATION....5110
Glossary Of Electrical Symbols....5110
Cab Harness Connectors....5113
Mainframe Harness Connectors....5114
Description....5115
Troubleshooting....5116
Fuse And Relay Location / Identification....5117
Solenoid Testing....5118
BATTERY....5120
Removal And Installation....5120
Servicing....5121
Using A Booster Battery (Jump Starting)....5122
ALTERNATOR....5124
Belt Adjustment....5124
Belt Replacement....5124
Charging System Inspection....5125
Alternator Voltage Testing....5126
Low Voltage Testing....5126
High Voltage Testing....5127
Removal And Installation....5128
Parts Identification....5130
STARTER....5132
Testing....5132
Removal And Installation....5133
Parts Identification....5134
INSTRUMENT PANELS....5136
Left Panel....5136
Display Screen....5138
Standard Key Panel....5138
Deluxe Instrumentation Panel....5139
Side Panel....5140
Front Panel....5140
Removal And Installation (Left And Right)....5141
Key Switch Removal And Installation....5142
Alarm Removal And Installation....5142
Front Accessory Panel Removal And Installation....5143
LIGHTS....5144
Front Removal And Installation....5144
Rear Removal And Installation....5144
Cab Light Removal And Installation....5145
BOBCAT CONTROLLER (MAIN)....5146
Description....5146
Connector Identification....5147
Removal And Installation....5149
DIAGNOSTIC SERVICE CODES....5150
Viewing Service Codes (Standard Key Panel)....5150
Viewing Service Codes (Deluxe Instrumentation Panel)....5150
Service Codes List....5151
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....5156
Description....5156
Inspecting The BICS? Controller (Engine STOPPED - Key ON)....5156
Inspecting The Seat Bar Sensor (Engine RUNNING)....5156
Inspecting The Traction Lock (Engine RUNNING)....5156
Inspecting The Lift Arm Bypass Control....5156
Troubleshooting....5157
Troubleshooting Chart....5158
SEAT BAR SENSOR....5160
Description....5160
Troubleshooting....5160
Testing....5161
Removal And Installation....5162
Bobcat Interlock Control System (BICS?) Circuit Test....5164
TRACTION LOCK....5166
Description....5166
Troubleshooting....5166
Removal And Installation....5167
Inspecting....5170
SERVICE PC (LAPTOP COMPUTER)....5172
Connecting To The Remote Start Tool....5172
Connecting Remote Start Tool (Service Tool)....5172
FLYWHEEL RPM SENSOR....5174
Description....5174
Adjusting....5174
CONTROL PANEL SETUP....5176
Right Panel Setup (Deluxe Instrumentation Panel)....5176
Attachment Control Information (Deluxe Instrumentation Panel)....5177
PASSWORD SETUP....5178
Password Description....5178
Changing The Owner Password....5178
Changing The User Passwords....5179
Password Lockout Feature....5179
MAINTENANCE CLOCK....5180
Description....5180
Setup....5181
Reset....5184
BACK-UP ALARM SYSTEM....5186
Description....5186
Inspecting....5186
Adjusting Switch Position....5187
Troubleshooting....5188
Alarm Removal And Installation....5189
Switch Removal And Installation....5189
ENGINE SERVICE....5192
ENGINE INFORMATION....5194
Description....5194
Specifications....5195
Torque Values....5199
Troubleshooting....5200
Engine Removal And Installation....5201
Engine Mount Replacement....5209
Compression - Checking....5209
ENGINE SPEED CONTROL....5210
Removal And Installation....5210
MUFFLER....5212
Removal And Installation....5212
AIR CLEANER....5214
Removal And Installation....5214
ENGINE COOLING SYSTEM....5216
Radiator Removal And Installation....5216
Fan Removal And Installation....5217
Water Pump Removal And Installation....5218
Water Pump Disassembly And Assembly....5218
Thermostat Housing Removal And Installation....5219
Testing The Thermostat....5219
LUBRICATION SYSTEM....5220
Oil Pan Removal And Installation....5220
Oil Pump Removal And Installation....5220
Oil Pump Inspection....5221
Engine Oil Pressure - Testing....5222
FUEL SYSTEM....5224
Fuel Camshaft Removal And Installation....5224
Fuel Camshaft Governor Disassembly And Assembly....5224
Fuel Shutoff Solenoid - Checking....5225
Fuel Shutoff Solenoid Removal And Installation....5226
Fuel Injection Pump Removal And Installation....5227
Timing The Injection Pump....5229
Fuel Injector Removal And Installation....5231
Fuel Injector Nozzles Pressure - Checking....5232
Nozzle Spray Condition....5233
Valve Seat Tightness....5234
CYLINDER HEAD....5236
Glow Plug - Testing....5236
Glow Plug Removal And Installation....5237
Valve Clearance Adjustment....5237
Valve Timing - Checking....5238
Cylinder Head Removal And Installation....5239
Cylinder Head Disassembly And Assembly....5241
Cylinder Head - Servicing....5241
Cylinder Head Top Clearance....5242
Valve Guide - Checking....5242
Reconditioning The Valve And Valve Seat....5243
Valve Spring....5245
Valve Tappets....5246
Rocker Arm And Shaft - Checking....5246
CRANKSHAFT AND PISTONS....5248
Piston And Connecting Rod Removal And Installation....5248
Piston And Connecting Rod - Servicing....5249
Cylinder Bore - Checking....5252
Connecting Rod Alignment....5252
Crankshaft And Bearings Removal And Installation....5253
Crankshaft And Bearings - Servicing....5255
CAMSHAFT AND TIMING GEARS....5260
Timing Gearcase Cover Removal And Installation....5260
Timing Gears Backlash - Checking....5262
Idler Gear And Shaft Removal And Installation....5262
Camshaft - Servicing....5263
Idler Gear And Shaft Servicing....5265
FLYWHEEL....5266
Flywheel Removal And Installation....5266
HEATING, VENTILATION, AIR CONDITIONING....5268
HEATER SYSTEM....5270
Description....5270
REGULAR MAINTENANCE....5272
Filter Elements Removal And Installation....5272
Cleaning The Heater Coil....5273
TROUBLESHOOTING....5274
Blower Motor Does Not Operate....5274
Blower Motor Operators Normally, But Air Flow Is Insufficient....5274
Electrical System....5275
Engine Coolant bypassing The Heater Valve....5279
Heater Valve Not Opening Or Closing....5279
HEATER UNIT....5282
Removal And Installation....5282
HEATER COIL....5284
Removal And Installation....5284
HEATER FAN....5286
Blower Removal And Installation....5286
Disassembly And Assembly....5287
Connector Identification....5289
HEATER VALVE....5290
Removal And Installation....5290
Disassembly And Assembly....5291
SPECIFICATIONS....5292
(S100) LOADER SPECIFICATIONS....5294
Machine Dimensions....5294
Performance....5295
Engine....5295
Controls....5295
Drive System....5296
Hydraulic System....5296
Electrical....5297
Capacities....5297
Tires....5297
TORQUE SPECIFICATIONS FOR BOLTS....5298
Torque For General SAE Bolts....5298
Torque For General Metric Bolts....5299
HYDRAULIC CONNECTION SPECIFICATIONS....5300
O-ring Face Seal Connection....5300
Straight Thread O-ring Fitting....5301
Tubelines And Hoses....5301
Flare Fitting....5301
Port Seal Fitting....5302
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....5304
Specifications....5304
CONVERSIONS....5306
Decimal And Millimeter Equivalent Chart....5306
U.S. To Metric Conversion Chart....5306
ALPHABETICAL INDEX....5308
SERVICE MANUAL REVISION....5310
Revision No: S100 - 1....5310
Revision No: S100 - 2....5312
Revision No: S100 - 3....5314
6987370 (11-10) - S100 Skid-Steer Loader Operation & Maintenance Manual....5316
OPERATOR SAFETY WARNINGS....5318
CONTENTS....5320
FOREWORD....5322
BOBCAT COMPANY IS IS0 9001 CERTIFIED....5324
REGULAR MAINTENANCE ITEMS....5324
SERIAL NUMBER LOCATIONS....5325
Loader Serial Number....5325
Engine Serial Number....5325
LOADER IDENTIFICATION....5326
FEATURES, ACCESSORIES AND ATTACHMENTS....5327
Buckets Available....5328
Attachments....5328
Special Applications Kit....5329
SAFETY & TRAINING RESOURCES....5330
SAFETY INSTRUCTIONS....5332
Before Operation....5332
Safe Operation Is The Operator?s Responsibility....5333
Safe Operation Needs A Qualified Operator....5333
Avoid Silica Dust....5334
FIRE PREVENTION....5334
Maintenance....5334
Operation....5334
Electrical....5334
Hydraulic System....5335
Fueling....5335
Starting....5335
Spark Arrestor Exhaust System....5335
Welding And Grinding....5335
Fire Extinguishers....5335
MACHINE SIGNS (DECALS)....5337
PUBLICATIONS AND TRAINING RESOURCES....5339
OPERATING INSTRUCTIONS....5340
INSTRUMENT PANEL IDENTIFICATION....5344
Cab Light....5344
Left Panel....5345
Display Screen....5347
Standard Key Panel....5348
Keyless Start Panel....5348
Deluxe Instrumentation Panel....5349
Side Panel....5350
Front Panel....5350
CONTROL IDENTIFICATION....5351
Standard Controls....5351
Selectable Joystick Controls (SJC)....5352
SEAT BAR RESTRAINT SYSTEM....5353
Operation....5353
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5354
Operation....5354
LIFT ARM BYPASS CONTROL....5355
Operation....5355
PARKING BRAKE....5355
Operation....5355
TRACTION LOCK OVERRIDE....5355
Operation....5355
EMERGENCY EXIT....5356
Rear Window....5356
Front Door....5356
BACK-UP ALARM SYSTEM....5357
Description....5357
Operation....5357
ENGINE SPEED CONTROL....5358
Operation....5358
DRIVING AND STEERING THE LOADER....5359
Available Control Configurations....5359
Operation (Standard)....5359
Operation (SJC) In ?ISO? Control Pattern....5360
Operation (SJC) In ?H? Control Pattern....5361
STOPPING THE LOADER....5361
Using The Control Levers Or Joysticks....5361
TWO-SPEED CONTROL....5362
Description....5362
Operation (SJC)....5362
SPEED MANAGEMENT....5363
Operation....5363
Changing The Factory Default Setting....5364
DRIVE RESPONSE....5365
Description....5365
Operation....5365
STEERING DRIFT COMPENSATION....5367
Description....5367
Operation....5367
HYDRAULIC CONTROLS....5369
Description....5369
Standard Controls....5369
Selectable Joystick Controls (SJC) In ?ISO? Control Pattern....5369
Selectable Joystick Controls (SJC) In ?H? Control Pattern....5370
Hydraulic Bucket Positioning....5370
Front Auxiliary Hydraulic Control Lockout....5370
FRONT Auxiliary Hydraulics Operation (Variable Flow)....5371
FRONT Auxiliary Hydraulics Operation (Continuous Flow)....5372
Quick Couplers....5373
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....5374
ATTACHMENT CONTROL DEVICE (ACD)....5375
Description....5375
DAILY INSPECTION....5376
Daily Inspection And Maintenance....5377
PRE-STARTING PROCEDURE....5378
Entering The Loader....5378
Operation & Maintenance Manual And Operator?s Handbook Locations....5378
Seat Adjustment....5379
Seat Belt Adjustment....5380
Seat Bar....5380
STARTING THE ENGINE....5381
Standard Key Panel....5381
Keyless Start Panel....5383
Deluxe Instrumentation Panel....5385
Cold Temperature Starting....5387
Warming The Hydraulic / Hydrostatic System....5387
MONITORING THE DISPLAY PANELS....5388
Left Panel....5388
Warning And Shutdown....5388
STOPPING THE ENGINE AND LEAVING THE LOADER....5389
Procedure....5389
COUNTERWEIGHTS....5390
Description....5390
Effect On The Loader And Loader Operation....5390
When To Consider Using Counterweights....5390
When To Consider Removing Counterweights....5390
Accessories That Affect Machine Weight....5390
ATTACHMENTS....5391
Choosing The Correct Bucket....5391
Pallet Forks....5391
Installing And Removing The Attachment....5392
OPERATING PROCEDURE....5395
Inspect The Work Area....5395
Basic Operating Instructions....5395
Driving On Public Roads....5395
Operating With A Full Bucket....5396
Operating With An Empty Bucket....5396
Filling And Emptying The Bucket (Foot Pedals)....5397
Leveling The Ground Using Float (Foot Pedals)....5398
Digging And Filling A Hole (Foot Pedals)....5399
Filling And Emptying The Bucket (SJC - ?H? Pattern)....5400
Leveling The Ground Using Float (SJC - ?H? Pattern)....5401
Digging And Filling A Hole (SJC - ?H? Pattern)....5401
Filling And Emptying The Bucket (SJC - ?ISO? Pattern)....5402
Leveling The Ground Using Float (SJC - ?ISO? Pattern)....5403
Digging And Filling A Hole (SJC - ?ISO? Pattern)....5403
TOWING THE LOADER....5404
Procedure....5404
LIFTING THE LOADER....5404
Single-Point Lift....5404
TRANSPORTING THE LOADER ON A TRAILER....5405
Loading And Unloading....5405
Fastening....5405
PREVENTIVE MAINTENANCE....5406
MAINTENANCE SAFETY....5410
SERVICE SCHEDULE....5412
Chart....5412
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5413
Inspecting The BICS (Engine STOPPED - Key ON)....5413
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5413
Inspecting The Seat Bar Sensor (Engine RUNNING)....5413
Inspecting The Traction Lock (Engine RUNNING)....5413
Inspecting The Lift Arm Bypass Control....5413
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....5413
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine RUNNING)....5414
SEAT BAR RESTRAINT SYSTEM....5415
Description....5415
Inspecting....5415
Maintaining....5415
SEAT BELT....5416
Inspection And Maintenance....5416
LIFT ARM SUPPORT DEVICE....5417
Installing....5417
Removing....5418
BACK-UP ALARM SYSTEM....5419
Description....5419
Inspecting....5419
Adjusting Switch Position....5419
OPERATOR CAB....5420
Description....5420
Raising....5420
Lowering....5421
Cab Door Sensor....5422
REAR DOOR (TAILGATE)....5423
Opening And Closing....5423
Adjusting....5423
REAR GRILLE....5424
Removing....5424
Installing....5424
HEATING SYSTEM....5425
Cleaning And Maintenance....5425
Filters....5425
Heater Coil....5425
Troubleshooting....5425
AIR CLEANER SERVICE....5426
Replacing Filter Elements....5426
FUEL SYSTEM....5427
Fuel Specifications....5427
Biodiesel Blend Fuel....5427
Filling The Fuel Tank....5428
Fuel Filter....5429
Removing Air From The Fuel System....5429
ENGINE LUBRICATION SYSTEM....5430
Checking And Adding Engine Oil....5430
Engine Oil Chart....5430
Removing And Replacing Oil And Filter....5430
ENGINE COOLING SYSTEM....5431
Cleaning....5431
Checking Level....5431
Removing And Replacing Coolant....5432
ELECTRICAL SYSTEM....5433
Description....5433
Fuse And Relay Location / Identification....5433
Battery Maintenance....5434
Using A Booster Battery (Jump Starting)....5435
Removing And Installing Battery....5436
HYDRAULIC / HYDROSTATIC SYSTEM....5437
Checking And Adding Fluid....5437
Hydraulic / Hydrostatic Fluid Chart....5437
Removing And Replacing Hydraulic Fluid....5438
Removing And Replacing Hydraulic / Hydrostatic Filter....5439
Removing And Replacing Case Drain Filters....5440
Removing And Replacing Hydraulic Charge Filter....5441
Breather Cap....5441
SPARK ARRESTER MUFFLER....5442
Cleaning Procedure....5442
TIRE MAINTENANCE....5443
Wheel Nuts....5443
Rotating....5443
Mounting....5443
FINAL DRIVE TRANSMISSION (CHAINCASE)....5444
Checking And Adding Oil....5444
Removing And Replacing Oil....5444
ALTERNATOR BELT....5445
Belt Adjustment....5445
Belt Replacement....5445
DRIVE BELT....5446
Belt Adjustment....5446
Belt Replacement....5446
LUBRICATING THE LOADER....5447
Lubrication Locations....5447
PIVOT PINS....5449
Inspection And Maintenance....5449
BOB-TACH....5450
Inspection And Maintenance....5450
LOADER STORAGE AND RETURN TO SERVICE....5451
Storage....5451
Return To Service....5451
SYSTEM SETUP & ANALYSIS....5452
DIAGNOSTIC SERVICE CODES....5454
Viewing Service Codes....5454
Service Codes List....5455
CONTROL PANEL SETUP....5460
Right Panel Setup (Deluxe Instrumentation Panel)....5460
Attachment Control Information (Deluxe Instrumentation Panel)....5461
PASSWORD SETUP (KEYLESS START PANEL)....5462
Password Description....5462
Changing The Owner Password....5462
Password Lockout Feature....5462
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....5463
Password Description....5463
Changing The Owner Password....5463
Changing The User Passwords....5464
Password Lockout Feature....5464
MAINTENANCE CLOCK....5465
Description....5465
Setup....5465
Reset....5465
MACHINE SIGN TRANSLATIONS....5466
SERVICE SCHEDULE (6734534)....5468
DANGER (6702301)....5471
WARNING (6577754)....5471
DANGER (6702302)....5471
DANGER (6717343)....5471
WARNING (6579528)....5472
WARNING (6704786)....5472
WARNING (6728539)....5473
WARNING (6710358)....5474
DANGER (6809511)....5474
WARNING (6725370)....5475
WARNING (6737189)....5475
WARNING (6737248)....5475
LIFT ARM SUPPORT DEVICE (6706558)....5476
warning (7131518)....5477
IMPORTANT (6560573)....5481
SPECIFICATIONS....5482
(S100) LOADER SPECIFICATIONS....5484
Machine Dimensions....5484
Performance....5485
Engine....5485
Drive System....5485
Controls....5486
Hydraulic System....5486
Electrical....5487
Capacities....5487
Tires....5487
WARRANTY....5488
WARRANTY....5490
ALPHABETICAL INDEX....5492
6987370 (5-14) - S100 Skid-Steer Loader Operation & Maintenance Manual....5496
OPERATOR SAFETY WARNINGS....5498
CONTENTS....5500
FOREWORD....5502
BOBCAT COMPANY IS IS0 9001 CERTIFIED....5504
REGULAR MAINTENANCE ITEMS....5504
SERIAL NUMBER LOCATIONS....5505
Loader Serial Number....5505
Engine Serial Number....5505
LOADER IDENTIFICATION....5506
FEATURES, ACCESSORIES AND ATTACHMENTS....5507
Buckets Available....5508
Attachments....5508
SAFETY AND TRAINING RESOURCES....5510
SAFETY INSTRUCTIONS....5512
Before Operation....5512
Safe Operation Is The Operator?s Responsibility....5513
Safe Operation Needs A Qualified Operator....5513
Avoid Silica Dust....5514
FIRE PREVENTION....5514
Maintenance....5514
Operation....5514
Electrical....5514
Hydraulic System....5515
Fueling....5515
Starting....5515
Spark Arrester Exhaust System....5515
Welding And Grinding....5515
Fire Extinguishers....5515
MACHINE SIGNS (DECALS)....5517
PUBLICATIONS AND TRAINING RESOURCES....5519
OPERATING INSTRUCTIONS....5520
INSTRUMENT PANEL IDENTIFICATION....5524
Cab Light....5525
Left Panel....5526
Display Screen....5528
Standard Key Panel....5529
Keyless Start Panel....5529
Deluxe Instrumentation Panel....5530
Side Panel....5531
Front Panel....5531
CONTROL IDENTIFICATION....5532
Standard Controls....5532
Selectable Joystick Controls (SJC)....5533
SEAT BAR RESTRAINT SYSTEM....5534
Operation....5534
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....5535
Operation....5535
LIFT ARM BYPASS CONTROL....5536
Operation....5536
PARKING BRAKE....5536
Operation....5536
TRACTION LOCK OVERRIDE....5536
Operation....5536
EMERGENCY EXIT....5537
Rear Window....5537
Front Door....5537
BACK-UP ALARM SYSTEM....5538
Description....5538
Operation....5538
ENGINE SPEED CONTROL....5539
Operation....5539
DRIVING AND STEERING THE LOADER....5540
Available Control Configurations....5540
Operation (Standard)....5540
Operation (SJC) In ?ISO? Control Pattern....5541
Operation (SJC) In ?H? Control Pattern....5542
STOPPING THE LOADER....5542
Using The Control Levers Or Joysticks....5542
TWO-SPEED CONTROL....5543
Description....5543
Operation (SJC)....5543
SPEED MANAGEMENT....5544
Operation....5544
Changing The Factory Default Setting....5545
DRIVE RESPONSE....5546
Description....5546
Operation....5546
STEERING DRIFT COMPENSATION....5548
Description....5548
Operation....5548
LIFT AND TILT COMPENSATION....5550
Description....5550
Operation....5550
HYDRAULIC CONTROLS....5552
Description....5552
Standard Controls....5552
Selectable Joystick Controls (SJC) In ?ISO? Control Pattern....5552
Selectable Joystick Controls (SJC) In ?H? Control Pattern....5553
Hydraulic Bucket Positioning....5553
Front Auxiliary Hydraulic Control Lockout....5553
FRONT Auxiliary Hydraulics Operation (Variable Flow)....5554
FRONT Auxiliary Hydraulics Operation (Continuous Flow)....5555
Quick Couplers....5556
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....5557
ATTACHMENT CONTROL DEVICE (ACD)....5558
Description....5558
DAILY INSPECTION....5559
Daily Inspection And Maintenance....5560
PRE-STARTING PROCEDURE....5561
Entering The Loader....5561
Operation & Maintenance Manual And Operator?s Handbook Locations....5561
Seat Adjustment....5562
Seat Belt Adjustment....5563
Seat Bar....5563
STARTING THE ENGINE....5564
Standard Key Panel....5564
Keyless Start Panel....5566
Deluxe Instrumentation Panel....5568
Cold Temperature Starting....5570
Warming The Hydraulic / Hydrostatic System....5570
MONITORING THE DISPLAY PANELS....5571
Left Panel....5571
Warning And Shutdown....5571
STOPPING THE ENGINE AND LEAVING THE LOADER....5572
Procedure....5572
COUNTERWEIGHTS....5573
Description....5573
Effect On The Loader And Loader Operation....5573
When To Consider Using Counterweights....5573
When To Consider Removing Counterweights....5573
Accessories That Affect Machine Weight....5573
ATTACHMENTS....5574
Choosing The Correct Bucket....5574
Pallet Forks....5574
Installing And Removing The Attachment (Hand Lever Bob-Tach)....5575
Installing And Removing The Attachment (Power Bob-Tach)....5577
OPERATING PROCEDURE....5580
Inspect The Work Area....5580
Basic Operating Instructions....5580
Driving On Public Roads....5580
Operating With A Full Bucket....5581
Operating With An Empty Bucket....5581
Filling And Emptying The Bucket (Foot Pedals)....5582
Leveling The Ground Using Float (Foot Pedals)....5583
Digging And Filling A Hole (Foot Pedals)....5584
Filling And Emptying The Bucket (SJC - ?H? Pattern)....5585
Leveling The Ground Using Float (SJC - ?H? Pattern)....5586
Digging And Filling A Hole (SJC - ?H? Pattern)....5586
Filling And Emptying The Bucket (SJC - ?ISO? Pattern)....5587
Leveling The Ground Using Float (SJC - ?ISO? Pattern)....5588
Digging And Filling A Hole (SJC - ?ISO? Pattern)....5588
TOWING THE LOADER....5589
Procedure....5589
LIFTING THE LOADER....5589
Single-Point Lift....5589
TRANSPORTING THE LOADER ON A TRAILER....5590
Loading And Unloading....5590
Fastening....5590
PREVENTIVE MAINTENANCE....5592
MAINTENANCE SAFETY....5596
SERVICE SCHEDULE....5598
Chart....5598
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....5599
Inspecting The BICS? (Engine STOPPED - Key ON)....5599
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5599
Inspecting The Seat Bar Sensor (Engine RUNNING)....5599
Inspecting The Traction Lock (Engine RUNNING)....5599
Inspecting The Lift Arm Bypass Control....5599
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....5599
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine RUNNING)....5600
SEAT BAR RESTRAINT SYSTEM....5601
Description....5601
Inspecting....5601
Maintaining....5601
SEAT BELT....5602
Inspection And Maintenance....5602
LIFT ARM SUPPORT DEVICE....5603
Installing....5603
Removing....5604
BACK-UP ALARM SYSTEM....5605
Description....5605
Inspecting....5605
Adjusting Switch Position....5605
OPERATOR CAB....5606
Description....5606
Raising....5606
Lowering....5607
Cab Door Sensor....5609
REAR DOOR (TAILGATE)....5610
Opening And Closing....5610
Adjusting....5610
REAR GRILLE....5611
Removing....5611
Installing....5611
HEATING SYSTEM....5612
Cleaning And Maintenance....5612
Filters....5612
Heater Coil....5612
Troubleshooting....5612
AIR CLEANER SERVICE....5613
Replacing Filter Elements....5613
FUEL SYSTEM....5614
Fuel Specifications....5614
Biodiesel Blend Fuel....5614
Filling The Fuel Tank....5615
Fuel Filter....5616
Removing Air From The Fuel System....5616
ENGINE LUBRICATION SYSTEM....5617
Checking And Adding Engine Oil....5617
Engine Oil Chart....5617
Removing And Replacing Oil And Filter....5617
ENGINE COOLING SYSTEM....5618
Cleaning....5618
Checking Level....5618
Removing And Replacing Coolant....5619
ELECTRICAL SYSTEM....5620
Description....5620
Fuse And Relay Location / Identification....5620
Battery Maintenance....5621
Using A Booster Battery (Jump Starting)....5622
Removing And Installing Battery....5623
HYDRAULIC / HYDROSTATIC SYSTEM....5624
Checking And Adding Fluid....5624
Hydraulic / Hydrostatic Fluid Chart....5624
Removing And Replacing Hydraulic Fluid....5625
Removing And Replacing Hydraulic / Hydrostatic Filter....5626
Removing And Replacing Case Drain Filters....5627
Removing And Replacing Hydraulic Charge Filter....5628
Breather Cap....5628
SPARK ARRESTER MUFFLER....5629
Cleaning Procedure....5629
TIRE MAINTENANCE....5630
Wheel Nuts....5630
Rotating....5630
Mounting....5630
FINAL DRIVE TRANSMISSION (CHAINCASE)....5631
Checking And Adding Oil....5631
Removing And Replacing Oil....5631
ALTERNATOR BELT....5632
Belt Adjustment....5632
Belt Replacement....5632
DRIVE BELT....5633
Belt Adjustment....5633
Belt Replacement....5633
LUBRICATING THE LOADER....5634
Lubrication Locations....5634
PIVOT PINS....5636
Inspection And Maintenance....5636
BOB-TACH (HAND LEVER)....5637
Inspection And Maintenance....5637
BOB-TACH (POWER)....5638
Inspection And Maintenance....5638
LOADER STORAGE AND RETURN TO SERVICE....5639
Storage....5639
Return To Service....5639
SYSTEM SETUP AND ANALYSIS....5640
DIAGNOSTIC SERVICE CODES....5642
Viewing Service Codes....5642
Service Codes List....5643
CONTROL PANEL SETUP....5648
Right Panel Setup (Deluxe Instrumentation Panel)....5648
Attachment Control Information (Deluxe Instrumentation Panel)....5649
PASSWORD SETUP (KEYLESS START PANEL)....5650
Password Description....5650
Changing The Owner Password....5650
Password Lockout Feature....5650
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....5651
Password Description....5651
Changing The Owner Password....5651
Changing The User Passwords....5652
Password Lockout Feature....5652
MAINTENANCE CLOCK....5653
Description....5653
Setup....5653
Reset....5653
MACHINE SIGN TRANSLATIONS....5654
MACHINE SIGN TRANSLATIONS....5656
Service Schedule (6734534)....5656
Danger (6702301)....5659
Warning (6577754)....5659
Danger (6702302)....5659
Danger (6717343)....5659
Warning (6579528)....5660
Warning (6704786)....5660
Warning (6728539)....5661
Warning (6710358)....5662
Danger (7170355)....5662
Warning (6725370)....5663
Warning (6737189)....5663
Warning (6737248)....5663
Lift Arm Support Device (6706558)....5664
Warning (7131518)....5665
Warning (7131519)....5667
Important (6560573)....5669
SPECIFICATIONS....5670
(S100) LOADER SPECIFICATIONS....5672
Machine Dimensions....5672
Performance....5673
Engine....5673
Drive System....5673
Controls....5674
Hydraulic System....5674
Electrical....5675
Capacities....5675
Tires....5675
WARRANTY....5676
WARRANTY....5678
ALPHABETICAL INDEX....5680
6987401 (1-11) - S100 Skid-Steer Loader Service Manual....5682
MAINTENANCE SAFETY....5684
CONTENTS....5686
FOREWORD....5688
FOREWORD....5690
SAFETY INSTRUCTIONS....5693
FIRE PREVENTION....5695
Maintenance....5695
Operation....5695
Electrical....5695
Hydraulic System....5695
Fueling....5695
Starting....5695
Spark Arrester Exhaust System....5695
Welding And Grinding....5696
Fire Extinguishers....5696
SERIAL NUMBER LOCATIONS....5697
Loader Serial Number....5697
Engine Serial Number....5697
DELIVERY REPORT....5698
LOADER IDENTIFICATION....5699
SAFETY & MAINTENANCE....5700
LIFTING AND BLOCKING THE LOADER....5704
Procedure....5704
LIFT ARM SUPPORT DEVICE....5706
Installing....5706
Removing....5707
OPERATOR CAB....5708
Description....5708
Raising....5708
Lowering....5710
Cab Door Sensor....5711
Special Applications Kit....5711
Special Applications Kit Inspection And Maintenance....5711
TRANSPORTING THE LOADER ON A TRAILER....5712
Loading And Unloading....5712
Fastening....5712
TOWING THE LOADER....5714
Procedure....5714
REMOTE START TOOL KIT - MEL1563....5716
Remote Start Tool - MEL1563....5716
Service Tool Harness Control - MEL1565....5717
Service Tool Harness Communicator - MEL1566....5718
Remote Start Procedure....5719
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....5722
Description....5722
Remote Start Tool (Service Tool) - 7003030....5723
Loader Service Tool Harness - 6689747....5724
Computer Service Tool Harness - 6689746....5725
Remote Start Procedure....5726
SERVICE SCHEDULE....5730
Chart....5730
AIR CLEANER SERVICE....5732
Replacing Filter Elements....5732
ENGINE COOLING SYSTEM....5734
Cleaning....5734
Checking Level....5734
Removing And Replacing Coolant....5735
FUEL SYSTEM....5736
Fuel Specifications....5736
Biodiesel Blend Fuel....5736
Filling The Fuel Tank....5737
Fuel Filter....5738
Removing Air From The Fuel System....5738
ENGINE LUBRICATION SYSTEM....5740
Checking And Adding Engine Oil....5740
Engine Oil Chart....5740
Removing And Replacing Oil And Filter....5741
HYDRAULIC / HYDROSTATIC SYSTEM....5742
Checking And Adding Fluid....5742
Hydraulic / Hydrostatic Fluid Chart....5742
Removing And Replacing Hydraulic Fluid....5743
Removing And Replacing Hydraulic / Hydrostatic Filter....5744
Removing And Replacing Case Drain Filters....5745
Removing And Replacing Hydraulic Charge Filter....5746
Breather Cap....5746
FINAL DRIVE TRANSMISSION (CHAINCASE)....5748
Checking And Adding Oil....5748
Removing And Replacing Oil....5748
BOB-TACH....5750
Inspection And Maintenance....5750
LUBRICATING THE LOADER....5752
Lubrication Locations....5752
TIRE MAINTENANCE....5754
Wheel Nuts....5754
Rotating....5754
Mounting....5754
SPARK ARRESTER MUFFLER....5756
Cleaning Procedure....5756
PIVOT PINS....5758
Inspection And Maintenance....5758
LOADER STORAGE AND RETURN TO SERVICE....5760
Storage....5760
Return To Service....5760
STOPPING THE ENGINE AND LEAVING THE LOADER....5762
Procedure....5762
EMERGENCY EXIT....5764
Rear Window....5764
Front Door....5764
SEAT BELT....5766
Inspection And Maintenance....5766
HYDRAULIC SYSTEM....5768
HYDRAULIC / HYDROSTATIC SCHEMATICS....5772
HYDRAULIC SYSTEM INFORMATION....5776
Glossary Of Hydraulic / Hydrostatic Symbols....5776
Troubleshooting....5780
CYLINDER (LIFT)....5782
Testing....5782
Removal And Installation....5783
Parts Identification....5784
Disassembly And Assembly....5785
CYLINDER (TILT)....5788
Testing....5788
Removal And Installation....5788
Rod End Pivot Pin Bushing And Seal Removal And Installation....5790
Base End Pivot Pin Removal And Installation....5790
Parts Identification....5791
Disassembly And Assembly....5792
MAIN RELIEF VALVE....5796
Description....5796
Testing....5796
Adjusting....5797
Removal And Installation....5797
MAIN RELIEF VALVE (SJC)....5798
Description....5798
Testing....5798
Adjusting....5799
Removal And Installation....5800
HYDRAULIC CONTROL VALVE....5802
Description....5802
Removal And Installation....5802
Identification Chart....5805
BICS? Load Check Valve Removal And Installation....5806
Load Check Valve Removal And Installation (Tilt And Auxiliary)....5807
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....5808
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....5809
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....5809
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....5810
Port Relief / Anti-Cavitation Valve Removal And Installation....5810
Plug Removal And Installation....5811
Rubber Boot Removal And Installation....5811
End Cap / Spool Lock Block Removal And Installation....5812
Lift Spool And Detent Removal And Installation....5812
Tilt Spool Removal And Installation....5821
Auxiliary Spool Removal And Installation....5824
Solenoid Removal And Installation....5831
Lock Valve Removal And Installation....5832
Lift Arm Bypass Orifice Removal And Installation....5834
Main Relief Valve Removal And Installation....5835
HYDRAULIC CONTROL VALVE (SJC)....5836
Description....5836
Removal And Installation....5836
Actuator Removal And Installation....5840
Identification Chart....5843
BICS? Load Check Valve Removal And Installation....5844
Load Check Valve Removal And Installation (Tilt And Auxiliary)....5845
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....5846
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....5847
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....5847
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....5848
Port Relief / Anti-Cavitation Valve Removal And Installation....5848
Plug Removal And Installation....5849
End Cap Block Removal And Installation....5850
Lift Spool And Detent Removal And Installation....5851
Tilt Spool Removal And Installation....5855
Auxiliary Spool Removal And Installation....5857
Auxiliary Solenoid Removal And Installation....5859
Solenoid Removal And Installation....5860
Lock Valve Removal And Installation....5861
Lift Arm Bypass Orifice Removal And Installation....5862
Main Relief Valve Removal And Installation....5863
Check Valve Removal And Installation....5864
LIFT ARM BYPASS CONTROL VALVE....5866
Description....5866
Testing....5866
Removal And Installation....5866
Disassembly And Assembly....5868
HYDRAULIC PUMP....5870
Description....5870
Pump Test At Quick Couplers....5870
Direct Pump Test (Standard Section)....5871
Direct Pump Test (Charge Section)....5872
Removal And Installation....5875
Hydraulic Pump Startup....5877
Parts Identification....5878
Disassembly And Assembly....5879
HYDRAULIC PUMP (SJC)....5884
Description....5884
Pump Test At Quick Couplers....5884
Direct Pump Test (Standard Section)....5885
Removal And Installation....5887
Hydraulic Pump Startup....5887
Parts Identification....5888
Disassembly And Assembly....5889
HYDRAULIC / HYDROSTATIC FILTERS....5894
Description....5894
Housing Removal And Installation....5894
Charge Filter Housing Removal And Installation....5895
HYDRAULIC FLUID RESERVOIR....5896
Description....5896
Removal And Installation....5896
Hydraulic Fluid Screen....5898
OIL COOLER....5900
Description....5900
Removal And Installation....5900
BUCKET POSITION VALVE....5902
Description....5902
Solenoid Removal And Installation....5902
Solenoid Testing....5903
Removal And Installation....5903
Disassembly And Assembly....5906
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....5908
Description....5908
Removal And Installation....5908
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC)....5910
Description....5910
Removal And Installation....5910
Disassembly And Assembly....5910
AUXILIARY HYDRAULIC INTERLOCK VALVE....5912
Description....5912
Removal And Installation....5912
Disassembly And Assembly....5913
HYDROSTATIC SYSTEM....5914
HYDROSTATIC SYSTEM INFORMATION....5916
Description....5916
Troubleshooting....5917
HYDROSTATIC MOTOR....5918
Description....5918
Removing And Replacing Oil....5918
Removal And Installation....5918
Parts Identification....5920
Disassembly And Assembly....5921
CHARGE PRESSURE....5926
Description....5926
Testing....5926
Sender Removal And Installation....5927
Adjusting....5928
HYDROSTATIC PUMP....5930
Description....5930
Replenishing / High Pressure Relief Valve Removal And Installation....5930
Removal And Installation....5931
Hydrostatic Pump Startup....5933
Parts Identification....5934
Disassembly....5935
Assembly....5940
HYDROSTATIC PUMP (SJC)....5946
Description....5946
High Pressure Relief And Bypass Valve....5947
Removal And Installation....5948
Hydrostatic Pump Startup....5950
Hydraulic Controller Removal And Installation....5951
Parts Identification....5953
Disassembly And Assembly....5954
Mechanical Neutral Adjustment....5969
Hydraulic Controller Neutral Adjustment....5972
DRIVE BELT....5976
Description....5976
Shield Removal And Installation....5976
Adjusting....5976
Belt Removal And Installation....5977
Tensioner Pulley Removal And Installation....5977
Tensioner Pulley Disassembly And Assembly....5977
CASE DRAIN FILTER....5978
Description....5978
Disassembly And Assembly....5978
DRIVE SYSTEM....5980
BRAKE....5982
Description....5982
Disc Removal And Installation....5982
DRIVE COMPONENTS....5984
Description....5984
Axle Seal Removal And Installation....5985
Axle, Sprocket And Bearings Removal And Installation....5987
Chain Removal And Installation....5991
CHAINCASE....5994
Description....5994
Front Cover Removal And Installation....5994
Center Cover Removal And Installation....5995
MAINFRAME....5998
SEAT BAR....6002
Description....6002
Removal And Installation....6002
Disassembly And Assembly....6003
Compression Spring Disassembly And Assembly....6004
OPERATOR CAB....6006
Gas Cylinder Removal And Installation....6006
Gas Cylinder Bracket Disassembly And Assembly....6008
Removal And Installation....6009
OPERATOR SEAT....6012
Removal And Installation....6012
Seat Belt Removal And Installation....6012
OPERATOR SEAT (SUSPENSION)....6014
Removal And Installation....6014
Slide Rail Removal And Installation....6015
Seat Belt Removal And Installation....6015
Lower Cushion Removal And Installation....6016
Back Cushion Removal And Installation....6016
Shock Removal And Installation....6017
3-Point Seat Belt Removal And Installation....6017
BOB-TACH (HAND LEVER)....6020
Description....6020
Removal And Installation....6020
Lever And Wedge Disassembly And Assembly....6022
Bob-Tach Stops....6023
Pivot Pin Bushing And Seal Removal And Installation....6024
LIFT ARMS....6026
Removal And Installation....6026
REAR GRILLE....6032
Removal And Installation....6032
REAR DOOR....6034
Removal And Installation....6034
Striker Removal And Installation....6035
Striker Disassembly And Assembly....6035
Striker (Adjusting)....6036
Latch Removal And Installation....6037
FUEL TANK....6038
Removal And Installation....6038
Fuel Level Sender Removal And Installation....6039
Fuel Fill Screen Removal And Installation....6039
Fuel Pickup Screen....6039
CONTROL PEDALS AND LINKAGES....6040
Description....6040
Pedal Removal And Installation....6040
Linkage Removal And Installation....6041
Pedal (Adjusting)....6042
CONTROL PANEL....6044
Description....6044
Removal And Installation....6045
Shaft Removal And Installation....6048
Shaft Disassembly And Assembly....6048
Shock Removal And Installation....6049
Linkage Removal And Installation....6049
Pintle Arm Removal And Installation....6050
Pintle Arm Disassembly And Assembly....6053
Linkage Neutral (Adjusting)....6054
Linkage Travel (Adjusting)....6057
CONTROL PANEL (SJC)....6062
Description....6062
Removal And Installation....6062
CONTROL HANDLE / LEVER....6064
Description....6064
Lever Removal And Installation....6064
Boot Removal And Installation....6064
CONTROL HANDLE / LEVER (SJC)....6066
Description....6066
Joystick Testing....6066
Joystick Removal And Installation....6068
Joystick Mount Removal And Installation....6069
WINDOW (REAR)....6070
Removal....6070
Installation....6070
WINDOW (TOP)....6072
Removal And Installation....6072
WINDOW (SIDE)....6074
Removal And Installation....6074
WINDOW (CAB DOOR)....6076
Removal (Standard Window)....6076
Installation (Standard Window)....6077
Removal And Installation (Special Applications Window)....6078
CAB DOOR....6080
Description....6080
Removal And Installation....6080
Aligning....6081
Adjusting....6082
Checking Operation....6082
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR)....6084
Description....6084
Removal And Installation....6084
Aligning....6085
Adjusting....6086
Checking Operation....6086
ELECTRICAL SYSTEM & ANALYSIS....6088
ELECTRICAL SCHEMATICS....6092
ELECTRICAL SYSTEM INFORMATION....6096
Glossary Of Electrical Symbols....6096
Standard Cab Harness Connectors....6099
Deluxe Cab Harness Connectors....6100
Mainframe Harness Connectors....6101
Description....6102
Troubleshooting....6103
Fuse And Relay Location / Identification....6104
Solenoid Testing....6105
BATTERY....6106
Removal And Installation....6106
Servicing....6107
Using A Booster Battery (Jump Starting)....6108
ALTERNATOR....6110
Belt Adjustment....6110
Belt Replacement....6110
Charging System Inspection....6111
Alternator Voltage Testing....6112
Low Voltage Testing....6112
High Voltage Testing....6113
Removal And Installation....6114
Parts Identification....6116
STARTER....6118
Testing....6118
Removal And Installation....6119
Parts Identification....6120
INSTRUMENT PANELS....6122
Left Panel....6122
Standard Key Panel....6124
Keyless Start Panel....6124
Deluxe Instrumentation Panel....6125
Side Panel....6126
Front Panel....6126
Front Panel Removal And Installation....6127
Removal And Installation (Left And Right)....6128
Key Switch Removal And Installation....6129
Alarm Removal And Installation....6129
LIGHTS....6130
Front Removal And Installation....6130
Rear Removal And Installation....6130
Cab Light Removal And Installation....6131
BOBCAT CONTROLLER (GATEWAY)....6132
Description....6132
Connector Identification....6133
Removal And Installation....6136
BOBCAT CONTROLLER (AUXILIARY) (SJC)....6138
Description....6138
Connector Identification....6139
Removal And Installation....6142
BOBCAT CONTROLLER (ACS) (SJC)....6144
Description....6144
Connector And Wire Identification....6145
Removal And Installation....6146
BOBCAT CONTROLLER (DRIVE) (SJC)....6148
Description....6148
Connector Identification....6149
Removal And Installation....6151
DIAGNOSTIC SERVICE CODES....6154
Viewing Service Codes (Standard Key Panel And Keyless Start Panel)....6154
Viewing Service Codes (Deluxe Instrumentation Panel)....6154
Service Codes List....6155
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....6160
Description....6160
Inspecting The BICS? (Engine STOPPED - Key ON)....6161
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....6161
Inspecting The Seat Bar Sensor (Engine RUNNING)....6161
Inspecting The Traction Lock (Engine RUNNING)....6161
Inspecting The Lift Arm Bypass Control....6161
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....6161
Troubleshooting....6162
SEAT BAR SENSOR....6164
Description....6164
Troubleshooting....6164
Testing....6165
Removal And Installation....6166
Bobcat Interlock Control System (BICS?) Circuit Test....6169
TRACTION LOCK....6172
Description....6172
Troubleshooting....6172
Removal And Installation....6173
Inspecting....6176
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....6178
Identification Chart....6178
SERVICE PC (LAPTOP COMPUTER)....6182
Connecting Remote Start Tool....6182
Connecting Remote Start Tool (Service Tool)....6182
CALIBRATION....6184
Description....6184
Actuator Testing....6184
Lift And Tilt Calibration (SJC)....6186
Hydrostatic Pump Calibration (SJC)....6188
STEERING DRIFT COMPENSATION....6194
Description....6194
Operation....6194
FLYWHEEL RPM SENSOR....6196
Description....6196
Adjusting....6196
CONTROL PANEL SETUP....6198
Right Panel Setup (Deluxe Instrumentation Panel)....6198
Attachment Control Information (Deluxe Instrumentation Panel)....6199
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....6200
Password Description....6200
Changing The Owner Password....6200
Changing The User Passwords....6201
Password Lockout Feature....6201
PASSWORD SETUP (KEYLESS START PANEL)....6202
Password Description....6202
Changing The Owner Password....6202
Password Lockout Feature....6202
MAINTENANCE CLOCK....6204
Description....6204
Setup....6205
Reset....6208
BACK-UP ALARM SYSTEM....6210
Description....6210
Inspecting....6210
Adjusting Switch Position....6210
Troubleshooting (Standard)....6211
Troubleshooting (Joystick)....6212
Alarm Removal And Installation....6213
Switch Removal And Installation....6213
ENGINE SERVICE....6216
ENGINE INFORMATION....6218
Description....6218
Specifications....6219
Torque Values....6223
Troubleshooting....6224
Engine Removal And Installation....6225
Engine Mount Replacement....6237
Compression - Checking....6238
ENGINE SPEED CONTROL....6240
Removal And Installation....6240
ENGINE SPEED CONTROL (SJC)....6242
Removal And Installation....6242
Disassembly And Assembly....6244
MUFFLER....6246
Removal And Installation....6246
AIR CLEANER....6248
Housing Removal And Installation....6248
ENGINE COOLING SYSTEM....6250
Radiator Removal And Installation....6250
Fan Removal And Installation....6251
Water Pump Removal And Installation....6252
Water Pump Disassembly And Assembly....6252
Thermostat Housing Removal And Installation....6253
Thermostat - Checking....6253
LUBRICATION SYSTEM....6254
Oil Pan Removal And Installation....6254
Oil Pump Removal And Installation....6254
Oil Pump Inspection....6255
Engine Oil Pressure - Testing....6256
FUEL SYSTEM....6258
Fuel Shutoff Solenoid - Checking....6258
Fuel Shutoff Solenoid Removal And Installation....6258
Fuel Injection Pump - Checking....6259
Fuel Injection Pump Removal And Installation....6260
Governor Disassembly And Assembly....6262
Fuel Camshaft Removal And Installation....6263
Fuel Injection Pump - Timing....6264
Fuel Injector Removal And Installation....6266
Fuel Injector Nozzle Pressure - Checking....6267
Nozzle Spray Condition....6268
Valve Seat Tightness....6269
CYLINDER HEAD....6270
Glow Plug - Testing....6270
Glow Plug Removal And Installation....6271
Valve Clearance Adjustment....6271
Valve Timing - Checking....6272
Cylinder Head Removal And Installation....6273
Cylinder Head Disassembly And Assembly....6275
Cylinder Head - Servicing....6275
Cylinder Head Top Clearance....6276
Valve Guide - Checking....6276
Reconditioning The Valve And Valve Seat....6277
Valve Spring....6279
Valve Tappets....6280
Rocker Arm And Shaft - Checking....6280
Push Rod Alignment - Checking....6281
CRANKSHAFT AND PISTONS....6282
Piston And Connecting Rod Removal And Installation....6282
Piston And Connecting Rod - Servicing....6283
Cylinder Bore - Checking....6286
Connecting Rod Alignment....6286
Crankshaft And Bearings Removal And Installation....6287
Crankshaft And Bearings - Servicing....6289
CAMSHAFT AND TIMING GEARS....6294
Timing Gearcase Cover Removal And Installation....6294
Timing Gears Backlash - Checking....6296
Idler Gear And Shaft Removal And Installation....6296
Camshaft - Servicing....6297
Idler Gear And Shaft Servicing....6299
FLYWHEEL AND HOUSING....6300
Flywheel Removal And Installation....6300
Ring Gear Removal And Installation....6300
Housing Removal And Installation....6301
HEATER....6304
HEATER SYSTEM....6306
Description....6306
REGULAR MAINTENANCE....6308
Filters....6308
Heater Coil....6308
TROUBLESHOOTING....6310
Blower Motor Does Not Operate....6310
Blower Motor Operators Normally, But Air Flow Is Insufficient....6310
Electrical System....6311
Engine Coolant Bypassing The Heater Valve....6315
Heater Valve Not Opening Or Closing....6315
HEATER UNIT....6318
Removal And Installation....6318
HEATER COIL....6320
Removal And Installation....6320
BLOWER FAN....6322
Removal And Installation....6322
Disassembly And Assembly....6323
Connector Identification....6325
HEATER VALVE....6326
Removal And Installation....6326
Disassembly And Assembly....6327
SPECIFICATIONS....6328
(S100) LOADER SPECIFICATIONS....6330
Machine Dimensions....6330
Performance....6331
Engine....6331
Drive System....6331
Controls....6332
Hydraulic System....6332
Electrical....6333
Capacities....6333
Tires....6333
TORQUE SPECIFICATIONS FOR BOLTS....6334
Torque For General SAE Bolts....6334
Torque For General Metric Bolts....6335
HYDRAULIC CONNECTION SPECIFICATIONS....6336
O-ring Face Seal Connection....6336
Straight Thread O-ring Fitting....6337
Tubelines And Hoses....6337
Flare Fitting....6337
Port Seal Fitting....6338
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....6340
Specifications....6340
CONVERSIONS....6342
Decimal And Millimeter Equivalent Chart....6342
U.S. To Metric Conversion Chart....6342
ALPHABETICAL INDEX....6344
SERVICE MANUAL REVISION....6346
Revision No: S100 - 1....6346
Revision No: S100 - 2....6348
Revision No: S100 - 3....6350
Revision No: S100 - 4....6352
6987401 (10-12) - S100 Skid-Steer Loader Service Manual....6354
MAINTENANCE SAFETY....6356
CONTENTS....6358
FOREWORD....6360
FOREWORD....6362
SAFETY INSTRUCTIONS....6365
FIRE PREVENTION....6367
Maintenance....6367
Operation....6367
Electrical....6367
Hydraulic System....6367
Fueling....6367
Starting....6367
Spark Arrester Exhaust System....6367
Welding And Grinding....6368
Fire Extinguishers....6368
SERIAL NUMBER LOCATIONS....6369
Loader Serial Number....6369
Engine Serial Number....6369
DELIVERY REPORT....6370
LOADER IDENTIFICATION....6371
SAFETY AND MAINTENANCE....6372
LIFTING AND BLOCKING THE LOADER....6376
Procedure....6376
LIFT ARM SUPPORT DEVICE....6378
Installing....6378
Removing....6379
OPERATOR CAB....6380
Description....6380
Raising....6380
Lowering....6382
Cab Door Sensor....6383
Special Applications Kit....6384
Special Applications Kit Inspection And Maintenance....6384
TRANSPORTING THE LOADER ON A TRAILER....6386
Loading And Unloading....6386
Fastening....6386
TOWING THE LOADER....6388
Procedure....6388
REMOTE START TOOL KIT - MEL1563....6390
Remote Start Tool - MEL1563....6390
Service Tool Harness Control - MEL1565....6391
Service Tool Harness Communicator - MEL1566....6392
Remote Start Procedure....6393
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....6396
Description....6396
Remote Start Tool (Service Tool) - 7022042....6397
Loader Service Tool Harness - 6689747....6398
Computer Service Tool Harness - 6689746....6399
Remote Start Procedure....6400
SERVICE SCHEDULE....6404
Chart....6404
AIR CLEANER SERVICE....6406
Replacing Filter Elements....6406
ENGINE COOLING SYSTEM....6408
Cleaning....6408
Checking Level....6408
Removing And Replacing Coolant....6409
FUEL SYSTEM....6410
Fuel Specifications....6410
Biodiesel Blend Fuel....6410
Filling The Fuel Tank....6411
Fuel Filter....6412
Removing Air From The Fuel System....6412
ENGINE LUBRICATION SYSTEM....6414
Checking And Adding Engine Oil....6414
Engine Oil Chart....6414
Removing And Replacing Oil And Filter....6415
HYDRAULIC / HYDROSTATIC SYSTEM....6416
Checking And Adding Fluid....6416
Hydraulic / Hydrostatic Fluid Chart....6416
Removing And Replacing Hydraulic Fluid....6417
Removing And Replacing Hydraulic / Hydrostatic Filter....6418
Removing And Replacing Case Drain Filters....6419
Removing And Replacing Hydraulic Charge Filter....6420
Breather Cap....6420
FINAL DRIVE TRANSMISSION (CHAINCASE)....6422
Checking And Adding Oil....6422
Removing And Replacing Oil....6422
BOB-TACH (HAND LEVER)....6424
Inspection And Maintenance....6424
BOB-TACH (POWER)....6426
Inspection And Maintenance....6426
LUBRICATING THE LOADER....6428
Lubrication Locations....6428
TIRE MAINTENANCE....6430
Wheel Nuts....6430
Rotating....6430
Mounting....6430
SPARK ARRESTER MUFFLER....6432
Cleaning Procedure....6432
PIVOT PINS....6434
Inspection And Maintenance....6434
LOADER STORAGE AND RETURN TO SERVICE....6436
Storage....6436
Return To Service....6436
STOPPING THE ENGINE AND LEAVING THE LOADER....6438
Procedure....6438
EMERGENCY EXIT....6440
Rear Window....6440
Front Door....6440
SEAT BELT....6442
Inspection And Maintenance....6442
HYDRAULIC SYSTEM....6444
HYDRAULIC / HYDROSTATIC SCHEMATICS....6448
HYDRAULIC SYSTEM INFORMATION....6452
Glossary Of Hydraulic / Hydrostatic Symbols....6452
Troubleshooting....6456
CYLINDER (LIFT)....6458
Testing....6458
Removal And Installation....6459
Parts Identification....6460
Disassembly And Assembly....6461
CYLINDER (TILT)....6464
Testing....6464
Removal And Installation....6464
Rod End Pivot Pin Bushing And Seal Removal And Installation....6466
Base End Pivot Pin Removal And Installation....6466
Parts Identification....6467
Disassembly And Assembly....6468
CYLINDER (BOB-TACH)....6472
Testing....6472
Removal And Installation....6473
Parts Identification....6474
Disassembly And Assembly....6475
MAIN RELIEF VALVE....6478
Description....6478
Testing....6478
Adjusting....6479
Removal And Installation....6479
MAIN RELIEF VALVE (SJC)....6480
Description....6480
Testing....6480
Adjusting....6481
Removal And Installation....6482
HYDRAULIC CONTROL VALVE....6484
Description....6484
Removal And Installation....6484
Identification Chart....6486
BICS? Load Check Valve Removal And Installation....6487
Load Check Valve Removal And Installation (Tilt And Auxiliary)....6488
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6489
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6490
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6490
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6491
Port Relief / Anti-Cavitation Valve Removal And Installation....6491
Plug Removal And Installation....6492
Rubber Boot Removal And Installation....6492
End Cap / Spool Lock Block Removal And Installation....6493
Lift Spool And Detent Removal And Installation....6493
Tilt Spool Removal And Installation....6502
Auxiliary Spool Removal And Installation....6505
Solenoid Removal And Installation....6512
Lock Valve Removal And Installation....6513
Lift Arm Bypass Orifice Removal And Installation....6515
Main Relief Valve Removal And Installation....6516
HYDRAULIC CONTROL VALVE (SJC)....6518
Description....6518
Removal And Installation....6518
Actuator Removal And Installation....6521
Identification Chart....6524
BICS? Load Check Valve Removal And Installation....6525
Load Check Valve Removal And Installation (Tilt And Auxiliary)....6526
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6527
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6528
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6528
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6529
Port Relief / Anti-Cavitation Valve Removal And Installation....6529
Plug Removal And Installation....6530
End Cap Block Removal And Installation....6531
Lift Spool And Detent Removal And Installation....6531
Tilt Spool Removal And Installation....6535
Auxiliary Spool Removal And Installation....6537
Auxiliary Solenoid Removal And Installation....6539
Solenoid Removal And Installation....6540
Lock Valve Removal And Installation....6541
Lift Arm Bypass Orifice Removal And Installation....6542
Main Relief Valve Removal And Installation....6543
Check Valve Removal And Installation....6543
LIFT ARM BYPASS CONTROL VALVE....6546
Description....6546
Testing....6546
Removal And Installation....6546
Disassembly And Assembly....6548
HYDRAULIC PUMP....6550
Description....6550
Pump Test At Quick Couplers....6550
Direct Pump Test (Standard Section)....6551
Direct Pump Test (Charge Section)....6552
Removal And Installation....6555
Hydraulic Pump Startup....6557
Parts Identification....6558
Disassembly And Assembly....6559
HYDRAULIC PUMP (SJC)....6564
Description....6564
Pump Test At Quick Couplers....6564
Direct Pump Test (Standard Section)....6565
Removal And Installation....6566
Hydraulic Pump Startup....6567
Parts Identification....6568
Disassembly And Assembly....6569
HYDRAULIC / HYDROSTATIC FILTERS....6574
Description....6574
Housing Removal And Installation....6574
Charge Filter Housing Removal And Installation....6575
HYDRAULIC FLUID RESERVOIR....6576
Description....6576
Removal And Installation....6576
Hydraulic Fluid Screen....6578
OIL COOLER....6580
Description....6580
Removal And Installation....6580
BUCKET POSITION VALVE....6582
Description....6582
Solenoid Removal And Installation....6582
Solenoid Testing....6583
Removal And Installation....6583
Disassembly And Assembly....6586
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....6588
Description....6588
Removal And Installation....6588
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC)....6590
Description....6590
Removal And Installation....6590
Disassembly And Assembly....6590
AUXILIARY HYDRAULIC INTERLOCK VALVE....6592
Description....6592
Removal And Installation....6592
Disassembly And Assembly....6593
BOB-TACH (POWER) BLOCK....6594
Description....6594
Removal And Installation....6594
Disassembly And Assembly....6596
HYDROSTATIC SYSTEM....6600
HYDROSTATIC SYSTEM INFORMATION....6602
Description....6602
Troubleshooting....6603
HYDROSTATIC MOTOR....6604
Description....6604
Removing And Replacing Oil....6604
Removal And Installation....6604
Parts Identification....6606
Disassembly And Assembly....6607
CHARGE PRESSURE....6612
Description....6612
Testing....6612
Sender Removal And Installation....6613
Adjusting....6614
HYDROSTATIC PUMP....6616
Description....6616
Replenishing / High Pressure Relief Valve Removal And Installation....6616
Removal And Installation....6617
Hydrostatic Pump Startup....6619
Parts Identification....6620
Disassembly....6621
Assembly....6626
HYDROSTATIC PUMP (SJC)....6632
Description....6632
High Pressure Relief And Bypass Valve....6633
Removal And Installation....6634
Hydrostatic Pump Startup....6636
Hydraulic Controller Removal And Installation....6637
Parts Identification....6639
Disassembly And Assembly....6640
Mechanical Neutral Adjustment....6655
Hydraulic Controller Neutral Adjustment....6658
DRIVE BELT....6662
Description....6662
Shield Removal And Installation....6662
Adjusting....6662
Belt Removal And Installation....6663
Tensioner Pulley Removal And Installation....6663
Tensioner Pulley Disassembly And Assembly....6663
CASE DRAIN FILTER....6664
Description....6664
Disassembly And Assembly....6664
DRIVE SYSTEM....6666
BRAKE....6668
Description....6668
Disc Removal And Installation....6668
DRIVE COMPONENTS....6670
Description....6670
Axle Seal Removal And Installation....6671
Axle, Sprocket And Bearings Removal And Installation....6673
Chain Removal And Installation....6677
CHAINCASE....6680
Description....6680
Front Cover Removal And Installation....6680
Center Cover Removal And Installation....6681
MAINFRAME....6684
SEAT BAR....6688
Description....6688
Removal And Installation....6688
Disassembly And Assembly....6689
Compression Spring Disassembly And Assembly....6690
OPERATOR CAB....6692
Gas Cylinder Removal And Installation....6692
Gas Cylinder Bracket Disassembly And Assembly....6694
Removal And Installation....6695
OPERATOR SEAT....6698
Removal And Installation....6698
Seat Belt Removal And Installation....6698
OPERATOR SEAT (SUSPENSION)....6700
Removal And Installation....6700
Slide Rail Removal And Installation....6701
Seat Belt Removal And Installation....6701
Lower Cushion Removal And Installation....6702
Back Cushion Removal And Installation....6702
Shock Removal And Installation....6703
3-Point Seat Belt Removal And Installation....6703
BOB-TACH (HAND LEVER)....6706
Description....6706
Removal And Installation....6706
Lever And Wedge Disassembly And Assembly....6708
Bob-Tach Stops....6709
Pivot Pin Bushing And Seal Removal And Installation....6710
BOB-TACH (POWER)....6712
Description....6712
Removal And Installation....6712
Lever And Wedge Disassembly And Assembly....6714
Bob-Tach Stops....6715
Pivot Pin Bushing And Seal Removal And Installation....6716
LIFT ARMS....6718
Removal And Installation....6718
REAR GRILLE....6724
Removal And Installation....6724
REAR DOOR....6726
Removal And Installation....6726
Striker Removal And Installation....6727
Striker Disassembly And Assembly....6727
Striker (Adjusting)....6728
Latch Removal And Installation....6729
FUEL TANK....6730
Removal And Installation....6730
Fuel Level Sender Removal And Installation....6731
Fuel Fill Screen Removal And Installation....6731
Fuel Pickup Screen....6731
CONTROL PEDALS AND LINKAGES....6732
Description....6732
Pedal Removal And Installation....6732
Linkage Removal And Installation....6733
Pedal (Adjusting)....6733
CONTROL PANEL....6734
Description....6734
Removal And Installation....6735
Shaft Removal And Installation....6738
Shaft Disassembly And Assembly....6738
Shock Removal And Installation....6739
Linkage Removal And Installation....6739
Pintle Arm Removal And Installation....6740
Pintle Arm Disassembly And Assembly....6743
Linkage Neutral (Adjusting)....6744
Linkage Travel (Adjusting)....6747
CONTROL PANEL (SJC)....6752
Description....6752
Removal And Installation....6752
CONTROL HANDLE / LEVER....6754
Description....6754
Lever Removal And Installation....6754
Boot Removal And Installation....6754
CONTROL HANDLE / LEVER (SJC)....6756
Description....6756
Joystick Testing....6756
Joystick Removal And Installation....6757
Joystick Mount Removal And Installation....6758
WINDOW (REAR)....6760
Removal....6760
Installation....6760
WINDOW (TOP)....6762
Removal And Installation....6762
WINDOW (SIDE)....6764
Removal And Installation....6764
WINDOW (CAB DOOR)....6766
Removal (Standard Window)....6766
Installation (Standard Window)....6767
Removal And Installation (Special Applications Window)....6768
CAB DOOR....6770
Description....6770
Removal And Installation....6770
Aligning....6771
Adjusting....6772
Checking Operation....6772
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR)....6774
Description....6774
Removal And Installation....6774
Aligning....6775
Adjusting....6776
Checking Operation....6776
ELECTRICAL SYSTEM AND ANALYSIS....6778
ELECTRICAL SCHEMATICS....6782
ELECTRICAL SYSTEM INFORMATION....6786
Glossary Of Electrical Symbols....6786
Standard Cab Harness Connectors....6789
Deluxe Cab Harness Connectors....6790
Mainframe Harness Connectors....6791
Description....6792
Troubleshooting....6793
Fuse And Relay Location / Identification....6794
Solenoid Testing....6795
BATTERY....6796
Removal And Installation....6796
Servicing....6797
Using A Booster Battery (Jump Starting)....6798
ALTERNATOR....6800
Belt Adjustment....6800
Belt Replacement....6800
Charging System Inspection....6801
Alternator Voltage Testing....6802
Low Voltage Testing....6802
High Voltage Testing....6803
Removal And Installation....6803
Parts Identification....6805
STARTER....6806
Testing....6806
Removal And Installation....6807
Parts Identification....6808
INSTRUMENT PANELS....6810
Left Panel....6810
Standard Key Panel....6812
Keyless Start Panel....6812
Deluxe Instrumentation Panel....6813
Side Panel....6814
Front Panel....6814
Front Panel Removal And Installation....6815
Removal And Installation (Left And Right)....6816
Key Switch Removal And Installation....6816
Alarm Removal And Installation....6817
LIGHTS....6818
Front Removal And Installation....6818
Rear Removal And Installation....6818
Cab Light Removal And Installation....6819
BOBCAT CONTROLLER (GATEWAY)....6820
Description....6820
Connector Identification....6821
Removal And Installation....6824
BOBCAT CONTROLLER (AUXILIARY) (SJC)....6826
Description....6826
Connector Identification....6827
Removal And Installation....6830
BOBCAT CONTROLLER (ACS) (SJC)....6832
Description....6832
Connector And Wire Identification....6833
Removal And Installation....6834
BOBCAT CONTROLLER (DRIVE) (SJC)....6836
Description....6836
Connector Identification....6837
Removal And Installation....6839
DIAGNOSTIC SERVICE CODES....6842
Viewing Service Codes....6842
Service Codes List....6843
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....6848
Description....6848
Inspecting The BICS? (Engine STOPPED - Key ON)....6849
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....6849
Inspecting The Seat Bar Sensor (Engine RUNNING)....6849
Inspecting The Traction Lock (Engine RUNNING)....6849
Inspecting The Lift Arm Bypass Control....6849
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....6849
Troubleshooting....6850
SEAT BAR SENSOR....6852
Description....6852
Troubleshooting....6852
Testing....6853
Removal And Installation....6854
Bobcat Interlock Control System (BICS?) Circuit Test....6857
TRACTION LOCK....6858
Description....6858
Troubleshooting....6858
Removal And Installation....6859
Inspecting....6862
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....6864
Identification Chart....6864
SERVICE PC (LAPTOP COMPUTER)....6868
Connecting Remote Start Tool....6868
Connecting Remote Start Tool (Service Tool)....6868
CALIBRATION....6870
Description....6870
Actuator Testing....6870
Lift And Tilt Calibration (SJC)....6872
Hydrostatic Pump Calibration (SJC)....6874
STEERING DRIFT COMPENSATION....6880
Description....6880
Operation....6880
FLYWHEEL RPM SENSOR....6882
Description....6882
Adjusting....6882
CONTROL PANEL SETUP....6884
Right Panel Setup (Deluxe Instrumentation Panel)....6884
Attachment Control Information (Deluxe Instrumentation Panel)....6885
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....6886
Password Description....6886
Changing The Owner Password....6886
Changing The User Passwords....6887
Password Lockout Feature....6887
PASSWORD SETUP (KEYLESS START PANEL)....6888
Password Description....6888
Changing The Owner Password....6888
Password Lockout Feature....6888
MAINTENANCE CLOCK....6890
Description....6890
Setup....6891
Reset....6894
BACK-UP ALARM SYSTEM....6896
Description....6896
Inspecting....6896
Adjusting Switch Position....6896
Troubleshooting (Standard)....6897
Troubleshooting (Joystick)....6898
Alarm Removal And Installation....6899
Switch Removal And Installation....6899
ENGINE SERVICE....6902
ENGINE INFORMATION....6904
Description....6904
Specifications....6905
Torque Values....6909
Troubleshooting....6910
Engine Removal And Installation....6911
Engine Mount Replacement....6923
Compression - Checking....6924
ENGINE SPEED CONTROL....6926
Removal And Installation....6926
ENGINE SPEED CONTROL (SJC)....6928
Removal And Installation....6928
Disassembly And Assembly....6930
MUFFLER....6932
Removal And Installation....6932
AIR CLEANER....6934
Housing Removal And Installation....6934
ENGINE COOLING SYSTEM....6936
Radiator Removal And Installation....6936
Fan Removal And Installation....6937
Water Pump Removal And Installation....6938
Water Pump Disassembly And Assembly....6938
Thermostat Housing Removal And Installation....6939
Thermostat - Checking....6939
LUBRICATION SYSTEM....6940
Oil Pan Removal And Installation....6940
Oil Pump Removal And Installation....6940
Oil Pump Inspection....6941
Engine Oil Pressure - Testing....6942
FUEL SYSTEM....6944
Fuel Shutoff Solenoid - Checking....6944
Fuel Shutoff Solenoid Removal And Installation....6944
Fuel Injection Pump - Checking....6945
Fuel Injection Pump Removal And Installation....6946
Governor Disassembly And Assembly....6948
Fuel Camshaft Removal And Installation....6949
Fuel Injection Pump - Timing....6950
Fuel Injector Removal And Installation....6952
Fuel Injector Nozzle Pressure - Checking....6953
Nozzle Spray Condition....6954
Valve Seat Tightness....6955
CYLINDER HEAD....6956
Glow Plug - Testing....6956
Glow Plug Removal And Installation....6957
Valve Clearance Adjustment....6957
Valve Timing - Checking....6958
Cylinder Head Removal And Installation....6959
Cylinder Head Disassembly And Assembly....6961
Cylinder Head - Servicing....6961
Cylinder Head Top Clearance....6962
Valve Guide - Checking....6962
Reconditioning The Valve And Valve Seat....6963
Valve Spring....6965
Valve Tappets....6966
Rocker Arm And Shaft - Checking....6966
Push Rod Alignment - Checking....6967
CRANKSHAFT AND PISTONS....6968
Piston And Connecting Rod Removal And Installation....6968
Piston And Connecting Rod - Servicing....6969
Cylinder Bore - Checking....6972
Connecting Rod Alignment....6972
Crankshaft And Bearings Removal And Installation....6973
Crankshaft And Bearings - Servicing....6975
CAMSHAFT AND TIMING GEARS....6980
Timing Gearcase Cover Removal And Installation....6980
Timing Gears Backlash - Checking....6982
Idler Gear And Shaft Removal And Installation....6982
Camshaft - Servicing....6983
Idler Gear And Shaft Servicing....6985
FLYWHEEL AND HOUSING....6986
Flywheel Removal And Installation....6986
Ring Gear Removal And Installation....6986
Housing Removal And Installation....6987
HEATER....6990
HEATER SYSTEM....6992
Description....6992
REGULAR MAINTENANCE....6994
Filters....6994
Heater Coil....6994
TROUBLESHOOTING....6996
Blower Motor Does Not Operate....6996
Blower Motor Operators Normally, But Air Flow Is Insufficient....6996
Electrical System....6997
Engine Coolant Bypassing The Heater Valve....7001
Heater Valve Not Opening Or Closing....7001
HEATER UNIT....7004
Removal And Installation....7004
HEATER COIL....7006
Removal And Installation....7006
BLOWER FAN....7008
Removal And Installation....7008
Disassembly And Assembly....7009
Connector Identification....7011
HEATER VALVE....7012
Removal And Installation....7012
Disassembly And Assembly....7013
SPECIFICATIONS....7014
(S100) LOADER SPECIFICATIONS....7016
Machine Dimensions....7016
Performance....7017
Engine....7017
Drive System....7017
Controls....7018
Hydraulic System....7018
Electrical....7019
Capacities....7019
Tires....7019
TORQUE SPECIFICATIONS FOR BOLTS....7020
Torque For General SAE Bolts....7020
Torque For General Metric Bolts....7021
HYDRAULIC CONNECTION SPECIFICATIONS....7022
O-ring Face Seal Connection....7022
Straight Thread O-ring Fitting....7023
Tubelines And Hoses....7023
Flare Fitting....7023
Port Seal Fitting....7024
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....7026
Specifications....7026
CONVERSIONS....7028
Decimal And Millimeter Equivalent Chart....7028
U.S. To Metric Conversion Chart....7028
ALPHABETICAL INDEX....7030
SERVICE MANUAL REVISION....7032
Revision No: S100 - 1....7032
Revision No: S100 - 2....7034
Revision No: S100 - 3....7036
Revision No: S100 - 4....7038
Revision No: S100 - 5....7040
Revision No: S100 - 6....7042
Revision No: S100 - 7....7044
Revision No: S100 - 8....7046
6987401 (4-11) - S100 Skid-Steer Loader Service Manual....7048
MAINTENANCE SAFETY....7050
CONTENTS....7052
FOREWORD....7054
FOREWORD....7056
SAFETY INSTRUCTIONS....7059
FIRE PREVENTION....7061
Maintenance....7061
Operation....7061
Electrical....7061
Hydraulic System....7061
Fueling....7061
Starting....7061
Spark Arrestor Exhaust System....7061
Welding And Grinding....7062
Fire Extinguishers....7062
SERIAL NUMBER LOCATIONS....7063
Loader Serial Number....7063
Engine Serial Number....7063
DELIVERY REPORT....7064
LOADER IDENTIFICATION....7065
SAFETY & MAINTENANCE....7066
LIFTING AND BLOCKING THE LOADER....7070
Procedure....7070
LIFT ARM SUPPORT DEVICE....7072
Installing....7072
Removing....7073
OPERATOR CAB....7074
Description....7074
Raising....7074
Lowering....7076
Cab Door Sensor....7077
Special Applications Kit....7077
Special Applications Kit Inspection And Maintenance....7077
TRANSPORTING THE LOADER ON A TRAILER....7078
Loading And Unloading....7078
Fastening....7078
TOWING THE LOADER....7080
Procedure....7080
REMOTE START TOOL KIT - MEL1563....7082
Remote Start Tool - MEL1563....7082
Service Tool Harness Control - MEL1565....7083
Service Tool Harness Communicator - MEL1566....7084
Remote Start Procedure....7085
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....7088
Description....7088
Remote Start Tool (Service Tool) - 7003030....7089
Loader Service Tool Harness - 6689747....7090
Computer Service Tool Harness - 6689746....7091
Remote Start Procedure....7092
SERVICE SCHEDULE....7096
Chart....7096
AIR CLEANER SERVICE....7098
Replacing Filter Elements....7098
ENGINE COOLING SYSTEM....7100
Cleaning....7100
Checking Level....7100
Removing And Replacing Coolant....7101
FUEL SYSTEM....7102
Fuel Specifications....7102
Biodiesel Blend Fuel....7102
Filling The Fuel Tank....7103
Fuel Filter....7104
Removing Air From The Fuel System....7104
ENGINE LUBRICATION SYSTEM....7106
Checking And Adding Engine Oil....7106
Engine Oil Chart....7106
Removing And Replacing Oil And Filter....7107
HYDRAULIC / HYDROSTATIC SYSTEM....7108
Checking And Adding Fluid....7108
Hydraulic / Hydrostatic Fluid Chart....7108
Removing And Replacing Hydraulic Fluid....7109
Removing And Replacing Hydraulic / Hydrostatic Filter....7110
Removing And Replacing Case Drain Filters....7111
Removing And Replacing Hydraulic Charge Filter....7112
Breather Cap....7112
FINAL DRIVE TRANSMISSION (CHAINCASE)....7114
Checking And Adding Oil....7114
Removing And Replacing Oil....7114
BOB-TACH....7116
Inspection And Maintenance....7116
LUBRICATING THE LOADER....7118
Lubrication Locations....7118
TIRE MAINTENANCE....7120
Wheel Nuts....7120
Rotating....7120
Mounting....7120
SPARK ARRESTER MUFFLER....7122
Cleaning Procedure....7122
PIVOT PINS....7124
Inspection And Maintenance....7124
LOADER STORAGE AND RETURN TO SERVICE....7126
Storage....7126
Return To Service....7126
STOPPING THE ENGINE AND LEAVING THE LOADER....7128
Procedure....7128
EMERGENCY EXIT....7130
Rear Window....7130
Front Door....7130
SEAT BELT....7132
Inspection And Maintenance....7132
HYDRAULIC SYSTEM....7134
HYDRAULIC / HYDROSTATIC SCHEMATICS....7138
HYDRAULIC SYSTEM INFORMATION....7142
Glossary Of Hydraulic / Hydrostatic Symbols....7142
Troubleshooting....7146
CYLINDER (LIFT)....7148
Testing....7148
Removal And Installation....7149
Parts Identification....7150
Disassembly And Assembly....7151
CYLINDER (TILT)....7154
Testing....7154
Removal And Installation....7154
Rod End Pivot Pin Bushing And Seal Removal And Installation....7156
Base End Pivot Pin Removal And Installation....7156
Parts Identification....7157
Disassembly And Assembly....7158
MAIN RELIEF VALVE....7162
Description....7162
Testing....7162
Adjusting....7163
Removal And Installation....7163
MAIN RELIEF VALVE (SJC)....7164
Description....7164
Testing....7164
Adjusting....7165
Removal And Installation....7166
HYDRAULIC CONTROL VALVE....7168
Description....7168
Removal And Installation....7168
Identification Chart....7171
BICS? Load Check Valve Removal And Installation....7172
Load Check Valve Removal And Installation (Tilt And Auxiliary)....7173
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7174
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7175
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7175
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7176
Port Relief / Anti-Cavitation Valve Removal And Installation....7176
Plug Removal And Installation....7177
Rubber Boot Removal And Installation....7177
End Cap / Spool Lock Block Removal And Installation....7178
Lift Spool And Detent Removal And Installation....7178
Tilt Spool Removal And Installation....7187
Auxiliary Spool Removal And Installation....7190
Solenoid Removal And Installation....7197
Lock Valve Removal And Installation....7198
Lift Arm Bypass Orifice Removal And Installation....7200
Main Relief Valve Removal And Installation....7201
HYDRAULIC CONTROL VALVE (SJC)....7202
Description....7202
Removal And Installation....7202
Actuator Removal And Installation....7206
Identification Chart....7209
BICS? Load Check Valve Removal And Installation....7210
Load Check Valve Removal And Installation (Tilt And Auxiliary)....7211
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7212
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7213
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7213
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7214
Port Relief / Anti-Cavitation Valve Removal And Installation....7214
Plug Removal And Installation....7215
End Cap Block Removal And Installation....7216
Lift Spool And Detent Removal And Installation....7217
Tilt Spool Removal And Installation....7221
Auxiliary Spool Removal And Installation....7223
Auxiliary Solenoid Removal And Installation....7225
Solenoid Removal And Installation....7226
Lock Valve Removal And Installation....7227
Lift Arm Bypass Orifice Removal And Installation....7228
Main Relief Valve Removal And Installation....7229
Check Valve Removal And Installation....7230
LIFT ARM BYPASS CONTROL VALVE....7232
Description....7232
Testing....7232
Removal And Installation....7232
Disassembly And Assembly....7234
HYDRAULIC PUMP....7236
Description....7236
Pump Test At Quick Couplers....7236
Direct Pump Test (Standard Section)....7237
Direct Pump Test (Charge Section)....7238
Removal And Installation....7241
Hydraulic Pump Startup....7243
Parts Identification....7244
Disassembly And Assembly....7245
HYDRAULIC PUMP (SJC)....7250
Description....7250
Pump Test At Quick Couplers....7250
Direct Pump Test (Standard Section)....7251
Removal And Installation....7253
Hydraulic Pump Startup....7253
Parts Identification....7254
Disassembly And Assembly....7255
HYDRAULIC / HYDROSTATIC FILTERS....7260
Description....7260
Housing Removal And Installation....7260
Charge Filter Housing Removal And Installation....7261
HYDRAULIC FLUID RESERVOIR....7262
Description....7262
Removal And Installation....7262
Hydraulic Fluid Screen....7264
OIL COOLER....7266
Description....7266
Removal And Installation....7266
BUCKET POSITION VALVE....7268
Description....7268
Solenoid Removal And Installation....7268
Solenoid Testing....7269
Removal And Installation....7269
Disassembly And Assembly....7272
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....7274
Description....7274
Removal And Installation....7274
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC)....7276
Description....7276
Removal And Installation....7276
Disassembly And Assembly....7276
AUXILIARY HYDRAULIC INTERLOCK VALVE....7278
Description....7278
Removal And Installation....7278
Disassembly And Assembly....7279
HYDROSTATIC SYSTEM....7280
HYDROSTATIC SYSTEM INFORMATION....7282
Description....7282
Troubleshooting....7283
HYDROSTATIC MOTOR....7284
Description....7284
Removing And Replacing Oil....7284
Removal And Installation....7284
Parts Identification....7286
Disassembly And Assembly....7287
CHARGE PRESSURE....7292
Description....7292
Testing....7292
Sender Removal And Installation....7293
Adjusting....7294
HYDROSTATIC PUMP....7296
Description....7296
Replenishing / High Pressure Relief Valve Removal And Installation....7296
Removal And Installation....7297
Hydrostatic Pump Startup....7299
Parts Identification....7300
Disassembly....7301
Assembly....7306
HYDROSTATIC PUMP (SJC)....7312
Description....7312
High Pressure Relief And Bypass Valve....7313
Removal And Installation....7314
Hydrostatic Pump Startup....7316
Hydraulic Controller Removal And Installation....7317
Parts Identification....7319
Disassembly And Assembly....7320
Mechanical Neutral Adjustment....7335
Hydraulic Controller Neutral Adjustment....7338
DRIVE BELT....7342
Description....7342
Shield Removal And Installation....7342
Adjusting....7342
Belt Removal And Installation....7343
Tensioner Pulley Removal And Installation....7343
Tensioner Pulley Disassembly And Assembly....7343
CASE DRAIN FILTER....7344
Description....7344
Disassembly And Assembly....7344
DRIVE SYSTEM....7346
BRAKE....7348
Description....7348
Disc Removal And Installation....7348
DRIVE COMPONENTS....7350
Description....7350
Axle Seal Removal And Installation....7351
Axle, Sprocket And Bearings Removal And Installation....7353
Chain Removal And Installation....7357
CHAINCASE....7360
Description....7360
Front Cover Removal And Installation....7360
Center Cover Removal And Installation....7361
MAINFRAME....7364
SEAT BAR....7368
Description....7368
Removal And Installation....7368
Disassembly And Assembly....7369
Compression Spring Disassembly And Assembly....7370
OPERATOR CAB....7372
Gas Cylinder Removal And Installation....7372
Gas Cylinder Bracket Disassembly And Assembly....7374
Removal And Installation....7375
OPERATOR SEAT....7378
Removal And Installation....7378
Seat Belt Removal And Installation....7378
OPERATOR SEAT (SUSPENSION)....7380
Removal And Installation....7380
Slide Rail Removal And Installation....7381
Seat Belt Removal And Installation....7381
Lower Cushion Removal And Installation....7382
Back Cushion Removal And Installation....7382
Shock Removal And Installation....7383
3-Point Seat Belt Removal And Installation....7383
BOB-TACH (HAND LEVER)....7386
Description....7386
Removal And Installation....7386
Lever And Wedge Disassembly And Assembly....7388
Bob-Tach Stops....7389
Pivot Pin Bushing And Seal Removal And Installation....7390
LIFT ARMS....7392
Removal And Installation....7392
REAR GRILLE....7398
Removal And Installation....7398
REAR DOOR....7400
Removal And Installation....7400
Striker Removal And Installation....7401
Striker Disassembly And Assembly....7401
Striker (Adjusting)....7402
Latch Removal And Installation....7403
FUEL TANK....7404
Removal And Installation....7404
Fuel Level Sender Removal And Installation....7405
Fuel Fill Screen Removal And Installation....7405
Fuel Pickup Screen....7405
CONTROL PEDALS AND LINKAGES....7406
Description....7406
Pedal Removal And Installation....7406
Linkage Removal And Installation....7407
Pedal (Adjusting)....7408
CONTROL PANEL....7410
Description....7410
Removal And Installation....7411
Shaft Removal And Installation....7414
Shaft Disassembly And Assembly....7414
Shock Removal And Installation....7415
Linkage Removal And Installation....7415
Pintle Arm Removal And Installation....7416
Pintle Arm Disassembly And Assembly....7419
Linkage Neutral (Adjusting)....7420
Linkage Travel (Adjusting)....7423
CONTROL PANEL (SJC)....7428
Description....7428
Removal And Installation....7428
CONTROL HANDLE / LEVER....7430
Description....7430
Lever Removal And Installation....7430
Boot Removal And Installation....7430
CONTROL HANDLE / LEVER (SJC)....7432
Description....7432
Joystick Testing....7432
Joystick Removal And Installation....7434
Joystick Mount Removal And Installation....7435
WINDOW (REAR)....7436
Removal....7436
Installation....7436
WINDOW (TOP)....7438
Removal And Installation....7438
WINDOW (SIDE)....7440
Removal And Installation....7440
WINDOW (CAB DOOR)....7442
Removal (Standard Window)....7442
Installation (Standard Window)....7443
Removal And Installation (Special Applications Window)....7444
CAB DOOR....7446
Description....7446
Removal And Installation....7446
Aligning....7447
Adjusting....7448
Checking Operation....7448
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR)....7450
Description....7450
Removal And Installation....7450
Aligning....7451
Adjusting....7452
Checking Operation....7452
ELECTRICAL SYSTEM & ANALYSIS....7454
ELECTRICAL SCHEMATICS....7458
ELECTRICAL SYSTEM INFORMATION....7462
Glossary Of Electrical Symbols....7462
Standard Cab Harness Connectors....7465
Deluxe Cab Harness Connectors....7466
Mainframe Harness Connectors....7467
Description....7468
Troubleshooting....7469
Fuse And Relay Location / Identification....7470
Solenoid Testing....7471
BATTERY....7472
Removal And Installation....7472
Servicing....7473
Using A Booster Battery (Jump Starting)....7474
ALTERNATOR....7476
Belt Adjustment....7476
Belt Replacement....7476
Charging System Inspection....7477
Alternator Voltage Testing....7478
Low Voltage Testing....7478
High Voltage Testing....7479
Removal And Installation....7480
Parts Identification....7482
STARTER....7484
Testing....7484
Removal And Installation....7485
Parts Identification....7486
INSTRUMENT PANELS....7488
Left Panel....7488
Standard Key Panel....7490
Keyless Start Panel....7490
Deluxe Instrumentation Panel....7491
Side Panel....7492
Front Panel....7492
Front Panel Removal And Installation....7493
Removal And Installation (Left And Right)....7494
Key Switch Removal And Installation....7495
Alarm Removal And Installation....7495
LIGHTS....7496
Front Removal And Installation....7496
Rear Removal And Installation....7496
Cab Light Removal And Installation....7497
BOBCAT CONTROLLER (GATEWAY)....7498
Description....7498
Connector Identification....7499
Removal And Installation....7502
BOBCAT CONTROLLER (AUXILIARY) (SJC)....7504
Description....7504
Connector Identification....7505
Removal And Installation....7508
BOBCAT CONTROLLER (ACS) (SJC)....7510
Description....7510
Connector And Wire Identification....7511
Removal And Installation....7512
BOBCAT CONTROLLER (DRIVE) (SJC)....7514
Description....7514
Connector Identification....7515
Removal And Installation....7517
DIAGNOSTIC SERVICE CODES....7520
Viewing Service Codes....7520
Service Codes List....7521
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....7526
Description....7526
Inspecting The BICS? (Engine STOPPED - Key ON)....7527
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7527
Inspecting The Seat Bar Sensor (Engine RUNNING)....7527
Inspecting The Traction Lock (Engine RUNNING)....7527
Inspecting The Lift Arm Bypass Control....7527
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....7527
Troubleshooting....7528
SEAT BAR SENSOR....7530
Description....7530
Troubleshooting....7530
Testing....7531
Removal And Installation....7532
Bobcat Interlock Control System (BICS?) Circuit Test....7535
TRACTION LOCK....7538
Description....7538
Troubleshooting....7538
Removal And Installation....7539
Inspecting....7542
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....7544
Identification Chart....7544
SERVICE PC (LAPTOP COMPUTER)....7548
Connecting Remote Start Tool....7548
Connecting Remote Start Tool (Service Tool)....7548
CALIBRATION....7550
Description....7550
Actuator Testing....7550
Lift And Tilt Calibration (SJC)....7552
Hydrostatic Pump Calibration (SJC)....7554
STEERING DRIFT COMPENSATION....7560
Description....7560
Operation....7560
FLYWHEEL RPM SENSOR....7562
Description....7562
Adjusting....7562
CONTROL PANEL SETUP....7564
Right Panel Setup (Deluxe Instrumentation Panel)....7564
Attachment Control Information (Deluxe Instrumentation Panel)....7565
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7566
Password Description....7566
Changing The Owner Password....7566
Changing The User Passwords....7567
Password Lockout Feature....7567
PASSWORD SETUP (KEYLESS START PANEL)....7568
Password Description....7568
Changing The Owner Password....7568
Password Lockout Feature....7568
MAINTENANCE CLOCK....7570
Description....7570
Setup....7571
Reset....7574
BACK-UP ALARM SYSTEM....7576
Description....7576
Inspecting....7576
Adjusting Switch Position....7576
Troubleshooting (Standard)....7577
Troubleshooting (Joystick)....7578
Alarm Removal And Installation....7579
Switch Removal And Installation....7579
ENGINE SERVICE....7582
ENGINE INFORMATION....7584
Description....7584
Specifications....7585
Torque Values....7589
Troubleshooting....7590
Engine Removal And Installation....7591
Engine Mount Replacement....7603
Compression - Checking....7604
ENGINE SPEED CONTROL....7606
Removal And Installation....7606
ENGINE SPEED CONTROL (SJC)....7608
Removal And Installation....7608
Disassembly And Assembly....7610
MUFFLER....7612
Removal And Installation....7612
AIR CLEANER....7614
Housing Removal And Installation....7614
ENGINE COOLING SYSTEM....7616
Radiator Removal And Installation....7616
Fan Removal And Installation....7617
Water Pump Removal And Installation....7618
Water Pump Disassembly And Assembly....7618
Thermostat Housing Removal And Installation....7619
Thermostat - Checking....7619
LUBRICATION SYSTEM....7620
Oil Pan Removal And Installation....7620
Oil Pump Removal And Installation....7620
Oil Pump Inspection....7621
Engine Oil Pressure - Testing....7622
FUEL SYSTEM....7624
Fuel Shutoff Solenoid - Checking....7624
Fuel Shutoff Solenoid Removal And Installation....7624
Fuel Injection Pump - Checking....7625
Fuel Injection Pump Removal And Installation....7626
Governor Disassembly And Assembly....7628
Fuel Camshaft Removal And Installation....7629
Fuel Injection Pump - Timing....7630
Fuel Injector Removal And Installation....7632
Fuel Injector Nozzle Pressure - Checking....7633
Nozzle Spray Condition....7634
Valve Seat Tightness....7635
CYLINDER HEAD....7636
Glow Plug - Testing....7636
Glow Plug Removal And Installation....7637
Valve Clearance Adjustment....7637
Valve Timing - Checking....7638
Cylinder Head Removal And Installation....7639
Cylinder Head Disassembly And Assembly....7641
Cylinder Head - Servicing....7641
Cylinder Head Top Clearance....7642
Valve Guide - Checking....7642
Reconditioning The Valve And Valve Seat....7643
Valve Spring....7645
Valve Tappets....7646
Rocker Arm And Shaft - Checking....7646
Push Rod Alignment - Checking....7647
CRANKSHAFT AND PISTONS....7648
Piston And Connecting Rod Removal And Installation....7648
Piston And Connecting Rod - Servicing....7649
Cylinder Bore - Checking....7652
Connecting Rod Alignment....7652
Crankshaft And Bearings Removal And Installation....7653
Crankshaft And Bearings - Servicing....7655
CAMSHAFT AND TIMING GEARS....7660
Timing Gearcase Cover Removal And Installation....7660
Timing Gears Backlash - Checking....7662
Idler Gear And Shaft Removal And Installation....7662
Camshaft - Servicing....7663
Idler Gear And Shaft Servicing....7665
FLYWHEEL AND HOUSING....7666
Flywheel Removal And Installation....7666
Ring Gear Removal And Installation....7666
Housing Removal And Installation....7667
HEATER....7670
HEATER SYSTEM....7672
Description....7672
REGULAR MAINTENANCE....7674
Filters....7674
Heater Coil....7674
TROUBLESHOOTING....7676
Blower Motor Does Not Operate....7676
Blower Motor Operators Normally, But Air Flow Is Insufficient....7676
Electrical System....7677
Engine Coolant Bypassing The Heater Valve....7681
Heater Valve Not Opening Or Closing....7681
HEATER UNIT....7684
Removal And Installation....7684
HEATER COIL....7686
Removal And Installation....7686
BLOWER FAN....7688
Removal And Installation....7688
Disassembly And Assembly....7689
Connector Identification....7691
HEATER VALVE....7692
Removal And Installation....7692
Disassembly And Assembly....7693
SPECIFICATIONS....7694
(S100) LOADER SPECIFICATIONS....7696
Machine Dimensions....7696
Performance....7697
Engine....7697
Drive System....7697
Controls....7698
Hydraulic System....7698
Electrical....7699
Capacities....7699
Tires....7699
TORQUE SPECIFICATIONS FOR BOLTS....7700
Torque For General SAE Bolts....7700
Torque For General Metric Bolts....7701
HYDRAULIC CONNECTION SPECIFICATIONS....7702
O-ring Face Seal Connection....7702
Straight Thread O-ring Fitting....7703
Tubelines And Hoses....7703
Flare Fitting....7703
Port Seal Fitting....7704
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....7706
Specifications....7706
CONVERSIONS....7708
Decimal And Millimeter Equivalent Chart....7708
U.S. To Metric Conversion Chart....7708
ALPHABETICAL INDEX....7710
SERVICE MANUAL REVISION....7712
Revision No: S100 - 1....7712
Revision No: S100 - 2....7714
Revision No: S100 - 3....7716
Revision No: S100 - 4....7718
Revision No: S100 - 5....7720
Revision No: S100 - 6....7722
6987402 (5-14) - S100 Skid-Steer Loader Operation & Maintenance Manual....7724
OPERATOR SAFETY WARNINGS....7726
CONTENTS....7728
FOREWORD....7730
DECLARATION OF CONFORMITY....7732
BOBCAT COMPANY IS IS0 9001 CERTIFIED....7734
REGULAR MAINTENANCE ITEMS....7734
LUBRICANTS AND FLUIDS....7735
SERIAL NUMBER LOCATIONS....7736
Loader Serial Number....7736
Engine Serial Number....7736
LOADER IDENTIFICATION....7737
FEATURES, ACCESSORIES AND ATTACHMENTS....7738
Buckets Available....7739
Attachments....7739
SAFETY AND TRAINING RESOURCES....7742
SAFETY INSTRUCTIONS....7744
Before Operation....7744
Safe Operation Is The Operator?s Responsibility....7745
Safe Operation Needs A Qualified Operator....7745
Avoid Silica Dust....7746
FIRE PREVENTION....7746
Maintenance....7746
Operation....7746
Electrical....7746
Hydraulic System....7747
Fueling....7747
Starting....7747
Spark Arrester Exhaust System....7747
Welding And Grinding....7747
Fire Extinguishers....7747
PUBLICATIONS AND TRAINING RESOURCES....7748
MACHINE SIGNS (DECALS)....7749
No-Text Safety Signs....7751
OPERATING INSTRUCTIONS....7754
INSTRUMENT PANEL IDENTIFICATION....7758
Cab Light....7759
Left Panel....7760
Display Screen....7763
Standard Key Panel....7764
Keyless Start Panel....7764
Deluxe Instrumentation Panel....7765
Side Panel....7766
Front Panel....7766
CONTROL IDENTIFICATION....7767
Standard Controls....7767
Selectable Joystick Controls (SJC)....7768
SEAT BAR RESTRAINT SYSTEM....7769
Operation....7769
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....7770
Operation....7770
PARKING BRAKE....7771
Operation....7771
TRACTION LOCK OVERRIDE....7771
Operation....7771
ENGINE SPEED CONTROL....7772
Operation....7772
LIFT ARM BYPASS CONTROL....7772
Operation....7772
EMERGENCY EXIT....7773
Rear Window....7773
Front Door....7773
BACK-UP ALARM SYSTEM....7774
Description....7774
Operation....7774
DRIVING AND STEERING THE LOADER....7775
Available Control Configurations....7775
Operation (Standard)....7775
Operation (SJC) In ?ISO? Control Pattern....7776
Operation (SJC) In ?H? Control Pattern....7777
STOPPING THE LOADER....7777
Using The Control Levers Or Joysticks....7777
TWO-SPEED CONTROL....7778
Description....7778
Operation (SJC)....7778
SPEED MANAGEMENT....7779
Operation....7779
Changing The Factory Default Setting....7780
DRIVE RESPONSE....7781
Description....7781
Operation....7781
STEERING DRIFT COMPENSATION....7783
Description....7783
Operation....7783
LIFT AND TILT COMPENSATION....7785
Description....7785
Operation....7785
HYDRAULIC CONTROLS....7787
Description....7787
Standard Controls....7787
Selectable Joystick Controls (SJC) In ?ISO? Control Pattern....7787
Selectable Joystick Controls (SJC) In ?H? Control Pattern....7788
Hydraulic Bucket Positioning....7788
Front Auxiliary Hydraulic Control Lockout....7788
FRONT Auxiliary Hydraulics Operation (Variable Flow)....7789
FRONT Auxiliary Hydraulics Operation (Continuous Flow)....7790
Quick Couplers....7791
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....7792
ATTACHMENT CONTROL DEVICE (ACD)....7793
Description....7793
DAILY INSPECTION....7794
Daily Inspection And Maintenance....7795
PRE-STARTING PROCEDURE....7796
Entering The Loader....7796
Operation & Maintenance Manual And Operator?s Handbook Locations....7796
Seat Adjustment....7797
Seat Belt Adjustment....7798
Seat Bar....7798
STARTING THE ENGINE....7799
Standard Key Panel....7799
Keyless Start Panel....7801
Deluxe Instrumentation Panel....7803
Cold Temperature Starting....7805
Warming The Hydraulic / Hydrostatic System....7805
MONITORING THE DISPLAY PANELS....7806
Left Panel....7806
Warning And Shutdown....7806
STOPPING THE ENGINE AND LEAVING THE LOADER....7807
Procedure....7807
COUNTERWEIGHTS....7808
Description....7808
Effect On The Loader And Loader Operation....7808
When To Consider Using Counterweights....7808
When To Consider Removing Counterweights....7808
Accessories That Affect Machine Weight....7808
ATTACHMENTS....7809
Choosing The Correct Bucket....7809
Pallet Forks....7809
Installing And Removing The Attachment (Hand Lever Bob-Tach)....7810
Installing And Removing The Attachment (Power Bob-Tach)....7812
OPERATING PROCEDURE....7815
Inspect The Work Area....7815
Basic Operating Instructions....7815
Driving On Public Roads....7815
Operating With A Full Bucket....7816
Operating With An Empty Bucket....7816
Filling And Emptying The Bucket (Foot Pedals)....7817
Levelling The Ground Using Float (Foot Pedals)....7818
Digging And Filling A Hole (Foot Pedals)....7819
Filling And Emptying The Bucket (SJC - ?H? Pattern)....7820
Levelling The Ground Using Float (SJC - ?H? Pattern)....7821
Digging And Filling A Hole (SJC - ?H? Pattern)....7821
Filling And Emptying The Bucket (SJC - ?ISO? Pattern)....7822
Levelling The Ground Using Float (SJC - ?ISO? Pattern)....7823
Digging And Filling A Hole (SJC - ?ISO? Pattern)....7823
TOWING THE LOADER....7824
Procedure....7824
LIFTING THE LOADER....7824
Single-Point Lift....7824
TRANSPORTING THE LOADER ON A TRAILER....7825
Loading And Unloading....7825
Fastening....7825
PREVENTIVE MAINTENANCE....7826
MAINTENANCE SAFETY....7830
SERVICE SCHEDULE....7832
Chart....7832
Inspection Checkbook....7833
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....7833
Inspecting The BICS? (Engine STOPPED - Key ON)....7833
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7833
Inspecting The Seat Bar Sensor (Engine RUNNING)....7833
Inspecting The Traction Lock (Engine RUNNING)....7834
Inspecting The Lift Arm Bypass Control....7834
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....7834
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine RUNNING)....7835
SEAT BAR RESTRAINT SYSTEM....7836
Description....7836
Inspecting....7836
Maintaining....7836
SEAT BELT....7837
Inspection And Maintenance....7837
LIFT ARM SUPPORT DEVICE....7838
Installing....7838
Removing....7839
BACK-UP ALARM SYSTEM....7840
Description....7840
Inspecting....7840
Adjusting Switch Position....7840
OPERATOR CAB....7841
Description....7841
Raising....7841
Lowering....7842
Cab Door Sensor....7843
REAR DOOR (TAILGATE)....7844
Opening And Closing....7844
Adjusting....7844
REAR GRILLE....7845
Removing....7845
Installing....7845
HEATING SYSTEM....7846
Cleaning And Maintenance....7846
Filters....7846
Heater Coil....7846
Troubleshooting....7846
AIR CLEANER SERVICE....7847
Replacing Filter Elements....7847
FUEL SYSTEM....7848
Fuel Specifications....7848
Biodiesel Blend Fuel....7848
Filling The Fuel Tank....7849
Fuel Filter....7850
Removing Air From The Fuel System....7850
ENGINE LUBRICATION SYSTEM....7851
Checking And Adding Engine Oil....7851
Engine Oil Chart....7851
Removing And Replacing Oil And Filter....7851
ENGINE COOLING SYSTEM....7852
Cleaning....7852
Checking Level....7852
Removing And Replacing Coolant....7853
ELECTRICAL SYSTEM....7854
Description....7854
Fuse And Relay Location / Identification....7854
Battery Maintenance....7855
Using A Booster Battery (Jump Starting)....7856
Removing And Installing Battery....7857
HYDRAULIC / HYDROSTATIC SYSTEM....7858
Checking And Adding Fluid....7858
Hydraulic / Hydrostatic Fluid Chart....7858
Removing And Replacing Hydraulic Fluid....7859
Removing And Replacing Hydraulic / Hydrostatic Filter....7860
Removing And Replacing Case Drain Filters....7861
Removing And Replacing Hydraulic Charge Filter....7862
Breather Cap....7862
SPARK ARRESTER MUFFLER....7863
Cleaning Procedure....7863
TYRE MAINTENANCE....7864
Wheel Nuts....7864
Rotating....7864
Mounting....7864
FINAL DRIVE TRANSMISSION (CHAINCASE)....7865
Checking And Adding Oil....7865
Removing And Replacing Oil....7865
ALTERNATOR BELT....7866
Belt Adjustment....7866
Belt Replacement....7866
DRIVE BELT....7867
Belt Adjustment....7867
Belt Replacement....7867
LUBRICATING THE LOADER....7868
Lubrication Locations....7868
PIVOT PINS....7870
Inspection And Maintenance....7870
BOB-TACH (HAND LEVER)....7871
Inspection And Maintenance....7871
BOB-TACH (POWER)....7872
Inspection And Maintenance....7872
LOADER STORAGE AND RETURN TO SERVICE....7873
Storage....7873
Return To Service....7873
SYSTEM SETUP AND ANALYSIS....7874
DIAGNOSTIC SERVICE CODES....7876
Viewing Service Codes....7876
Service Codes List....7877
CONTROL PANEL SETUP....7882
Right Panel Setup (Deluxe Instrumentation Panel)....7882
Attachment Control Information (Deluxe Instrumentation Panel)....7883
PASSWORD SETUP (KEYLESS START PANEL)....7884
Password Description....7884
Changing The Owner Password....7884
Password Lockout Feature....7884
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7885
Password Description....7885
Changing The Owner Password....7885
Changing The User Passwords....7886
Password Lockout Feature....7886
MAINTENANCE CLOCK....7887
Description....7887
Setup....7887
Reset....7887
SPECIFICATIONS....7888
(S100) LOADER SPECIFICATIONS....7890
Machine Dimensions....7890
Performance....7891
Engine....7891
Drive System....7891
Controls....7892
Hydraulic System....7892
Electrical....7893
Capacities....7893
Tyres....7893
Fuel Consumption....7894
Environmental....7894
Temperature Range....7894
WARRANTY....7896
WARRANTY....7898
ALPHABETICAL INDEX....7900
6987403 (10-12) - S100 Skid-Steer Loader Service Manual....7902
MAINTENANCE SAFETY....7904
CONTENTS....7906
FOREWORD....7908
FOREWORD....7910
SAFETY INSTRUCTIONS....7913
Before Operation....7913
Safe Operation Is The Operator?s Responsibility....7914
Safe Operation Needs A Qualified Operator....7914
Avoid Silica Dust....7915
FIRE PREVENTION....7915
Maintenance....7915
Operation....7915
Electrical....7915
Hydraulic System....7916
Fueling....7916
Starting....7916
Spark Arrester Exhaust System....7916
Welding And Grinding....7916
Fire Extinguishers....7916
SERIAL NUMBER LOCATIONS....7917
Loader Serial Number....7917
Engine Serial Number....7917
DELIVERY REPORT....7918
LOADER IDENTIFICATION....7919
SAFETY AND MAINTENANCE....7920
LIFTING AND BLOCKING THE LOADER....7924
Procedure....7924
LIFT ARM SUPPORT DEVICE....7926
Installing....7926
Removing....7927
OPERATOR CAB....7928
Description....7928
Raising....7928
Lowering....7929
Cab Door Sensor....7930
Special Applications Kit....7931
Special Applications Kit Inspection And Maintenance....7931
TRANSPORTING THE LOADER ON A TRAILER....7932
Loading And Unloading....7932
Fastening....7932
TOWING THE LOADER....7934
Procedure....7934
REMOTE START TOOL KIT-MEL1563....7936
Remote Start Tool - MEL1563....7936
Service Tool Harness Control - MEL1565....7937
Service Tool Harness Communicator - MEL1566....7938
Remote Start Procedure....7939
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....7942
Description....7942
Remote Start Tool (Service Tool) - 7022042....7943
Loader Service Tool Harness - 6689747....7944
Computer Service Tool Harness - 6689746....7945
Remote Start Procedure....7946
SERVICE SCHEDULE....7950
Chart....7950
AIR CLEANER SERVICE....7952
Replacing Filter Elements....7952
ENGINE COOLING SYSTEM....7954
Cleaning....7954
Checking Level....7954
Removing And Replacing Coolant....7955
FUEL SYSTEM....7956
Fuel Specifications....7956
Biodiesel Blend Fuel....7956
Filling The Fuel Tank....7957
Fuel Filter....7958
Removing Air From The Fuel System....7958
ENGINE LUBRICATION SYSTEM....7960
Checking And Adding Engine Oil....7960
Engine Oil Chart....7960
Removing And Replacing Oil And Filter....7961
HYDRAULIC / HYDROSTATIC SYSTEM....7962
Checking And Adding Fluid....7962
Hydraulic / Hydrostatic Fluid Chart....7962
Removing And Replacing Hydraulic Fluid....7963
Removing And Replacing Hydraulic / Hydrostatic Filter....7964
Removing And Replacing Case Drain Filters....7965
Removing And Replacing Hydraulic Charge Filter....7966
Breather Cap....7966
FINAL DRIVE TRANSMISSION (CHAINCASE)....7968
Checking And Adding Oil....7968
Removing And Replacing Oil....7968
BOB-TACH (HAND LEVER)....7970
Inspection And Maintenance....7970
BOB-TACH (POWER)....7972
Inspection And Maintenance....7972
LUBRICATING THE LOADER....7974
Lubrication Locations....7974
TIRE MAINTENANCE....7976
Wheel Nuts....7976
Rotating....7976
Mounting....7976
SPARK ARRESTER MUFFLER....7978
Cleaning Procedure....7978
PIVOT PINS....7980
Inspection And Maintenance....7980
LOADER STORAGE AND RETURN TO SERVICE....7982
Storage....7982
Return To Service....7982
STOPPING THE ENGINE AND LEAVING THE LOADER....7984
Procedure....7984
EMERGENCY EXIT....7986
Rear Window....7986
Front Door....7986
SEAT BELT....7988
Inspection And Maintenance....7988
HYDRAULIC SYSTEM....7990
HYDRAULIC / HYDROSTATIC SCHEMATICS....7994
HYDRAULIC SYSTEM INFORMATION....7998
Glossary Of Hydraulic / Hydrostatic Symbols....7998
Troubleshooting....8002
CYLINDER (LIFT)....8004
Testing....8004
Removal And Installation....8005
Parts Identification....8006
Disassembly And Assembly....8007
CYLINDER (TILT)....8010
Testing....8010
Removal And Installation....8010
Rod End Pivot Pin Bushing And Seal Removal And Installation....8012
Base End Pivot Pin Removal And Installation....8012
Parts Identification....8013
Disassembly And Assembly....8014
CYLINDER (BOB-TACH)....8018
Testing....8018
Removal And Installation....8019
Parts Identification....8020
Disassembly And Assembly....8021
MAIN RELIEF VALVE....8024
Description....8024
Testing....8024
Adjusting....8025
Removal And Installation....8025
MAIN RELIEF VALVE (SJC)....8026
Description....8026
Testing....8026
Adjusting....8027
Removal And Installation....8028
HYDRAULIC CONTROL VALVE....8030
Description....8030
Removal And Installation....8030
Identification Chart....8032
BICS? Load Check Valve Removal And Installation....8033
Load Check Valve Removal And Installation (Tilt And Auxiliary)....8034
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8035
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8036
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8036
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8037
Port Relief Valve Removal And Installation....8037
Plug Removal And Installation....8038
Rubber Boot Removal And Installation....8038
End Cap / Spool Lock Block Removal And Installation....8039
Lift Spool And Detent Removal And Installation....8039
Tilt Spool Removal And Installation....8048
Auxiliary Spool Removal And Installation....8051
Solenoid Removal And Installation....8058
Lock Valve Removal And Installation....8059
Lift Arm Bypass Orifice Removal And Installation....8061
Main Relief Valve Removal And Installation....8062
HYDRAULIC CONTROL VALVE (SJC)....8064
Description....8064
Removal And Installation....8064
Actuator Removal And Installation....8067
Identification Chart....8070
BICS? Load Check Valve Removal And Installation....8071
Load Check Valve Removal And Installation (Tilt And Auxiliary)....8072
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8073
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8074
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8074
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8075
Port Relief / Anti-Cavitation Valve Removal And Installation....8075
Plug Removal And Installation....8076
End Cap Block Removal And Installation....8077
Lift Spool And Detent Removal And Installation....8077
Tilt Spool Removal And Installation....8081
Auxiliary Spool Removal And Installation....8083
Auxiliary Solenoid Removal And Installation....8085
Solenoid Removal And Installation....8086
Lock Valve Removal And Installation....8087
Lift Arm Bypass Orifice Removal And Installation....8088
Main Relief Valve Removal And Installation....8089
Check Valve Removal And Installation....8089
LIFT ARM BYPASS CONTROL VALVE....8092
Description....8092
Testing....8092
Removal And Installation....8092
Disassembly And Assembly....8094
HYDRAULIC PUMP....8096
Description....8096
Pump Test At Quick Couplers....8096
Direct Pump Test (Standard Section)....8097
Direct Pump Test (Charge Section)....8098
Removal And Installation....8101
Hydraulic Pump Start Up....8103
Parts Identification....8104
Disassembly And Assembly....8105
HYDRAULIC PUMP (SJC)....8110
Description....8110
Pump Test At Quick Couplers....8110
Direct Pump Test (Standard Section)....8111
Removal And Installation....8112
Hydraulic Pump Start Up....8113
Parts Identification....8114
Disassembly And Assembly....8115
HYDRAULIC / HYDROSTATIC FILTERS....8120
Description....8120
Housing Removal And Installation....8120
Charge Filter Housing Removal And Installation....8121
HYDRAULIC FLUID RESERVOIR....8122
Description....8122
Removal And Installation....8122
Hydraulic Fluid Screen....8124
OIL COOLER....8126
Description....8126
Removal And Installation....8126
BUCKET POSITION VALVE....8128
Description....8128
Solenoid Removal And Installation....8128
Solenoid Testing....8129
Removal And Installation....8129
Disassembly And Assembly....8132
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....8134
Description....8134
Removal And Installation....8134
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC)....8136
Description....8136
Removal And Installation....8136
Disassembly And Assembly....8136
AUXILIARY HYDRAULIC INTERLOCK VALVE....8138
Description....8138
Removal And Installation....8138
Disassembly And Assembly....8139
BOB-TACH (POWER) BLOCK....8140
Description....8140
Removal And Installation....8140
Disassembly And Assembly....8142
HYDROSTATIC SYSTEM....8146
HYDROSTATIC SYSTEM INFORMATION....8148
Description....8148
Troubleshooting....8149
HYDROSTATIC MOTOR....8150
Description....8150
Removing And Replacing Oil....8150
Removal And Installation....8150
Parts Identification....8152
Disassembly And Assembly....8153
CHARGE PRESSURE....8158
Description....8158
Testing....8158
Sender Removal And Installation....8159
Adjusting....8160
HYDROSTATIC PUMP....8162
Description....8162
Replenishing / High Pressure Relief Valve Removal And Installation....8162
Removal And Installation....8163
Hydrostatic Pump Startup....8165
Parts Identification....8166
Disassembly....8167
Assembly....8172
HYDROSTATIC PUMP (SJC)....8178
Description....8178
High Pressure Relief And Bypass Valve....8179
Removal And Installation....8180
Hydrostatic Pump Start Up....8182
Hydraulic Controller Removal And Installation....8183
Parts Identification....8185
Disassembly And Assembly....8186
Mechanical Neutral Adjustment....8201
Hydraulic Controller Neutral Adjustment....8204
DRIVE BELT....8208
Description....8208
Shield Removal And Installation....8208
Adjusting....8208
Belt Removal And Installation....8209
Tensioner Pulley Removal And Installation....8209
Tensioner Pulley Disassembly And Assembly....8209
CASE DRAIN FILTER....8210
Description....8210
Disassembly And Assembly....8210
DRIVE SYSTEM....8212
BRAKE....8214
Description....8214
Disc Removal And Installation....8214
DRIVE COMPONENTS....8216
Description....8216
Axle Seal Removal And Installation....8217
Axle, Sprocket And Bearings Removal And Installation....8219
Chain Removal And Installation....8223
CHAINCASE....8226
Description....8226
Front Cover Removal And Installation....8226
Center Cover Removal And Installation....8227
MAINFRAME....8230
SEAT BAR....8234
Description....8234
Removal And Installation....8234
Disassembly And Assembly....8235
Compression Spring Disassembly And Assembly....8236
OPERATOR CAB....8238
Gas Cylinder Removal And Installation....8238
Gas Cylinder Bracket Disassembly And Assembly....8240
Removal And Installation....8241
OPERATOR SEAT....8244
Removal And Installation....8244
Seat Belt Removal And Installation....8244
OPERATOR SEAT (SUSPENSION)....8246
Removal And Installation....8246
Slide Rail Removal And Installation....8247
Seat Belt Removal And Installation....8247
Lower Cushion Removal And Installation....8248
Back Cushion Removal And Installation....8248
Shock Removal And Installation....8249
3-Point Seat Belt Removal And Installation....8249
BOB-TACH (HAND LEVER)....8252
Description....8252
Removal And Installation....8252
Lever And Wedge Disassembly And Assembly....8254
Bob-Tach Stops....8256
Pivot Pin Bushing And Seal Removal And Installation....8256
BOB-TACH (POWER)....8258
Description....8258
Removal And Installation....8258
Lever And Wedge Disassembly And Assembly....8260
Bob-Tach Stops....8261
Pivot Pin Bushing And Seal Removal And Installation....8262
LIFT ARMS....8264
Removal And Installation....8264
REAR GRILLE....8270
Removal And Installation....8270
REAR DOOR....8272
Removal And Installation....8272
Striker Removal And Installation....8273
Striker Disassembly And Assembly....8273
Striker (Adjusting)....8274
Latch Removal And Installation....8275
FUEL TANK....8276
Removal And Installation....8276
Fuel Level Sender Removal And Installation....8277
Fuel Fill Screen Removal And Installation....8277
Fuel Pickup Screen....8277
CONTROL PEDALS AND LINKAGES....8278
Description....8278
Pedal Removal And Installation....8278
Linkage Removal And Installation....8279
Pedal (Adjusting)....8279
CONTROL PANEL....8280
Description....8280
Removal And Installation....8281
Shaft Removal And Installation....8284
Shaft Disassembly And Assembly....8284
Shock Removal And Installation....8285
Linkage Removal And Installation....8285
Pintle Arm Removal And Installation....8286
Pintle Arm Disassembly And Assembly....8289
Linkage Neutral (Adjusting)....8290
Linkage Travel (Adjusting)....8293
CONTROL PANEL (SJC)....8298
Description....8298
Removal And Installation....8298
CONTROL HANDLE / LEVER (STANDARD)....8300
Description....8300
Lever Removal And Installation....8300
Boot Removal And Installation....8300
CONTROL HANDLE / LEVER (SJC)....8302
Description....8302
Joystick Testing....8302
Joystick Removal And Installation....8303
Joystick Mount Removal And Installation....8304
WINDOWS (REAR)....8306
Removal....8306
Installation....8306
WINDOWS (TOP)....8308
Removal And Installation....8308
WINDOWS (SIDE)....8310
Removal And Installation....8310
WINDOWS (CAB DOOR)....8312
Removal (Standard Window)....8312
Installation (Standard Window)....8313
Removal And Installation (Special Applications Window)....8314
CAB DOOR....8316
Description....8316
Removal And Installation....8316
Aligning....8317
Adjusting....8318
Checking Operation....8318
CAB DOOR (SPECIAL APPLICATIONS KIT DOOR)....8320
Description....8320
Removal And Installation....8320
Aligning....8321
Adjusting....8322
Checking Operation....8322
ELECTRICAL SYSTEM AND ANALYSIS....8324
ELECTRICAL SCHEMATICS....8328
ELECTRICAL SYSTEM INFORMATION....8332
Glossary Of Electrical Symbols....8332
Standard Cab Harness Connectors....8335
Deluxe Cab Harness Connectors....8336
Mainframe Harness Connectors....8337
Description....8338
Troubleshooting....8339
Fuse And Relay Location / Identification....8340
Solenoid Testing....8341
BATTERY....8342
Removal And Installation....8342
Servicing....8343
Using A Booster Battery (Jump Starting)....8344
ALTERNATOR....8346
Belt Adjustment....8346
Belt Replacement....8346
Charging System Inspection....8347
Alternator Voltage Testing....8348
Low Voltage Testing....8348
High Voltage Testing....8349
Removal And Installation....8349
Parts Identification....8351
STARTER....8352
Testing....8352
Removal And Installation....8353
Parts Identification....8354
INSTRUMENT PANELS....8356
Left Panel....8356
Standard Key Panel....8358
Keyless Start Panel....8358
Deluxe Instrumentation Panel....8359
Side Panel....8360
Front Panel....8360
Front Panel Removal And Installation....8361
Removal And Installation (Left And Right)....8361
Key Switch Removal And Installation....8362
Alarm Removal And Installation....8363
LIGHTS....8364
Front Removal And Installation....8364
Rear Removal And Installation....8364
Cab Light Removal And Installation....8365
BOBCAT CONTROLLER (GATEWAY)....8366
Description....8366
Connector Identification....8367
Removal And Installation....8370
BOBCAT CONTROLLER (AUXILIARY) (SJC)....8372
Description....8372
Connector Identification....8373
Removal And Installation....8376
BOBCAT CONTROLLER (ACS) (SJC)....8378
Description....8378
Connector And Wire Identification....8379
Removal And Installation....8380
BOBCAT CONTROLLER (DRIVE) (SJC)....8382
Description....8382
Connector Identification....8383
Removal And Installation....8385
DIAGNOSTIC SERVICE CODES....8388
Viewing Service Codes....8388
Service Codes List....8389
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....8394
Description....8394
Inspecting The BICS? (Engine STOPPED - Key ON)....8395
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....8395
Inspecting The Seat Bar Sensor (Engine RUNNING)....8395
Inspecting The Traction Lock (Engine RUNNING)....8395
Inspecting The Lift Arm Bypass Control....8395
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....8395
Troubleshooting....8396
SEAT BAR SENSOR....8398
Description....8398
Troubleshooting....8398
Testing....8399
Removal And Installation....8400
Bobcat Interlock Control System (BICS?) Circuit Test....8403
TRACTION LOCK....8404
Description....8404
Troubleshooting....8404
Removal And Installation....8405
Inspecting....8408
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....8410
Identification Chart....8410
SERVICE PC (LAPTOP COMPUTER)....8414
Connecting Remote Start Tool....8414
Connecting Remote Start Tool (Service Tool)....8414
CALIBRATION....8416
Description....8416
Actuator Testing....8416
Lift And Tilt Calibration (SJC)....8418
Hydrostatic Pump Calibration (SJC)....8420
STEERING DRIFT COMPENSATION....8426
Description....8426
Operation....8426
FLYWHEEL RPM SENSOR....8428
Description....8428
Adjusting....8428
CONTROL PANEL SETUP....8430
Right Panel Setup (Deluxe Instrumentation Panel)....8430
Attachment Control Information (Deluxe Instrumentation Panel)....8431
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....8432
Password Description....8432
Changing The Owner Password....8432
Changing The User Passwords....8433
Password Lockout Feature....8433
PASSWORD SETUP (KEYLESS START PANEL)....8434
Password Description....8434
Changing The Owner Password....8434
Password Lockout Feature....8434
MAINTENANCE CLOCK....8436
Description....8436
Setup....8437
Reset....8440
BACK-UP ALARM SYSTEM....8442
Description....8442
Inspecting....8442
Adjusting Switch Position....8442
Troubleshooting (Standard)....8443
Troubleshooting (Joystick)....8444
Alarm Removal And Installation....8445
Switch Removal And Installation....8445
ENGINE SERVICE....8448
ENGINE INFORMATION....8450
Description....8450
Specifications....8451
Torque Values....8455
Troubleshooting....8456
Engine Removal And Installation....8457
Engine Mount Replacement....8469
Compression - Checking....8470
ENGINE SPEED CONTROL....8472
Removal And Installation....8472
ENGINE SPEED CONTROL (SJC)....8474
Removal And Installation....8474
Disassembly And Assembly....8476
MUFFLER....8478
Removal And Installation....8478
AIR CLEANER....8480
Housing Removal And Installation....8480
ENGINE COOLING SYSTEM....8482
Radiator Removal And Installation....8482
Fan Removal And Installation....8483
Water Pump Removal And Installation....8484
Water Pump Disassembly And Assembly....8484
Thermostat Housing Removal And Installation....8485
Thermostat - Checking....8485
LUBRICATION SYSTEM....8486
Oil Pan Removal And Installation....8486
Oil Pump Removal And Installation....8486
Oil Pump Inspection....8487
Engine Oil Pressure - Testing....8488
FUEL SYSTEM....8490
Fuel Shutoff Solenoid - Checking....8490
Fuel Shutoff Solenoid Removal And Installation....8490
Fuel Injection Pump - Checking....8491
Fuel Injection Pump Removal And Installation....8492
Governor Disassembly And Assembly....8494
Fuel Camshaft Removal And Installation....8495
Fuel Injection Pump - Timing....8496
Fuel Injector Removal And Installation....8498
Fuel Injector Nozzle Pressure - Checking....8499
Nozzle Spray Condition....8500
Valve Seat Tightness....8501
CYLINDER HEAD....8502
Glow Plug - Testing....8502
Glow Plug Removal And Installation....8503
Valve Clearance Adjustment....8503
Valve Timing - Checking....8504
Cylinder Head Removal And Installation....8505
Cylinder Head Disassembly And Assembly....8507
Cylinder Head - Servicing....8507
Cylinder Head Top Clearance....8508
Valve Guide - Checking....8508
Reconditioning The Valve And Valve Seat....8509
Valve Spring....8511
Valve Tappets....8512
Rocker Arm And Shaft - Checking....8512
Push Rod Alignment - Checking....8513
CRANKSHAFT AND PISTONS....8514
Piston And Connecting Rod Removal And Installation....8514
Piston And Connecting Rod - Servicing....8515
Cylinder Bore Checking....8518
Connecting Rod Alignment....8518
Crankshaft And Bearings Removal And Installation....8519
Crankshaft And Bearings - Servicing....8521
CAMSHAFT AND TIMING GEARS....8526
Timing Gearcase Cover Removal And Installation....8526
Timing Gears Backlash - Checking....8528
Idler Gear And Shaft Removal And Installation....8528
Camshaft - Servicing....8529
Idler Gear And Shaft Servicing....8531
FLYWHEEL AND HOUSING....8532
Flywheel Removal And Installation....8532
Ring Gear Removal And Installation....8532
Housing Removal And Installation....8533
HEATER....8536
HEATER SYSTEM....8538
Description....8538
REGULAR MAINTENANCE....8540
Filters....8540
Heater Coil....8540
TROUBLESHOOTING....8542
Blower Motor Does Not Operate....8542
Blower Motor Operates Normally, But Air Flow Is Insufficient....8542
Electrical System....8543
Engine Coolant Bypassing The Heater Valve....8547
Heater Valve Not Opening Or Closing....8547
HEATER UNIT....8550
Removal And Installation....8550
HEATER COIL....8552
Removal And Installation....8552
BLOWER FAN....8554
Removal And Installation....8554
Disassembly And Assembly....8555
Connector Identification....8557
HEATER VALVE....8558
Removal And Installation....8558
Disassembly And Assembly....8559
SPECIFICATIONS....8560
(S100) LOADER SPECIFICATIONS....8562
Machine Dimensions....8562
Performance....8563
Engine....8563
Drive System....8563
Controls....8564
Hydraulic System....8564
Electrical....8565
Capacities....8565
Tires....8565
TORQUE SPECIFICATIONS FOR BOLTS....8566
Torque for General SAE Bolts....8566
Torque For General Metric Bolts....8567
HYDRAULIC CONNECTION SPECIFICATIONS....8568
O-ring Face Seal Connection....8568
Straight Thread O-ring Fitting....8569
Tubelines And Hoses....8569
Flare Fitting....8569
Port Seal Fitting....8570
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....8572
Specifications....8572
CONVERSIONS....8574
Decimal And Millimeter Equivalent Chart....8574
U.S. To Metric Conversion Chart....8574
ALPHABETICAL INDEX....8576
SERVICE MANUAL REVISION....8578
Revision No: S100 - 1....8578
Revision No: S100 - 2....8580
Revision No: S100 - 3....8582
Revision No: S100 - 4....8584
Revision No: S100 - 5....8586
Revision No: S100 - 6....8588
Revision No: S100 - 7....8590
Revision No: S100 - 8....8592
Bobcat Skid-Steer Loaders S70, S100 Repair Service Manuals + Operation & Maintenance Manuals
