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EN

Service Manual
S100 Skid-Steer Loader

S/N A2G811001 & Above


S/N A8ET11001 - A8ET19999

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)

6904926enGB (01-09) (B) Printed in Europe Bobcat Company 2009

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MAINTENANCE SAFETY

Instructions are necessary before operating or servicing machine. Read and


understand the Operation & Maintenance Manual, Operators Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-15590 B-15591


Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.

WRONG WRONG WRONG

B-15592 B-15593 B-15599


Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

B-15600 B-15601 B-6589


Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner /
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW08-0805

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ALPHABETICAL INDEX

AIR CLEANER ........................................................70-01 HYDRAULIC / HYDROSTATIC SYSTEM ................ 10-01


AIR CLEANER SERVICE........................................10-01 HYDRAULIC PUMP ................................................ 20-01
ALTERNATOR ......................................................... 60-01 HYDRAULIC SYSTEM INFORMATION .................. 20-01
HYDROSTATIC MOTOR ......................................... 30-01
BACK-UP ALARM SYSTEM ........................ 10-01, 60-01 HYDROSTATIC PUMP ............................................ 30-01
BATTERY..................................................................60-01 HYDROSTATIC SYSTEM INFORMATION .............. 30-01
BLOWER FAN......................................................... 20-01
BOBCAT CONTROLLER (MAIN) ............................ 60-01 INSTRUMENT PANELS ......................................... 60-01
BOBCAT INTERLOCK CONTROL
SYSTEM (BICS)...................................................... 60-01 LIFT ARM BYPASS CONTROL VALVE .................. 20-01
BOB-TACH (HAND LEVER)......................... 10-01, 50-01 LIFT ARMS...............................................................50-01
BOB-TACH (POWER) BLOCK ................................ 20-01 LIFT ARM SUPPORT DEVICE ............................... 10-01
BOB-TACH (POWER-OPTION).....................10-01, 50-01 LIFTING AND BLOCKING THE LOADER .............. 10-01
BRAKE .................................................................... 40-01 LIGHTS ................................................................... 60-01
BUCKET POSITION VALVE.................................... 20-01 LOADER SPECIFICATIONS ............................. SPEC-01
LOADER STORAGE AND RETURN TO SERVICE .10-01
CAB DOOR ............................................................. 50-01 LUBRICATING THE LOADER................................. 10-01
CAMSHAFT AND TIMING GEARS..........................70-01 LUBRICATION SYSTEM......................................... 70-01
CASE DRAIN FILTER ............................................. 30-01
CHAINCASE ........................................................... 40-01 MAINTENANCE CLOCK......................................... 60-01
CHARGE PRESSURE ........................................... 30-01 MAIN RELIEF VALVE...............................................20-01
CONTROL HANDLE / LEVER ................................ 50-01 MUFFLER ............................................................... 70-01
CONTROL PANEL .................................................. 50-01
CONTROL PANEL SETUP ..................................... 60-01 OIL COOLER .......................................................... 20-01
CONTROL PEDALS AND LINKAGE....................... 50-01 OPERATOR CAB ......................................... 10-01, 50-01
CONVERSIONS.................................................SPEC-01 OPERATOR SEAT................................................... 50-01
CRANKSHAFT AND PISTONS............................... 70-01 OPERATOR SEAT (SUSPENSION)........................ 50-01
CYLINDER (BOB-TACH)......................................... 20-01
CYLINDER HEAD ................................................... 70-01 PASSWORD SETUP............................................... 60-01
CYLINDER (LIFT) ................................................... 20-01 PIVOT PINS..............................................................10-01
CYLINDER (TILT).................................................... 20-01
REAR DOOR ..........................................................50-01
DIAGNOSTICS SERVICE CODES ......................... 60-01 REAR GRILL ..........................................................50-01
DRIVE BELT............................................................ 30-01 REGULAR MAINTENANCE.................................... 80-01
DRIVE COMPONENETS ........................................ 40-01 REMOTE START TOOL .......................................... 10-01

ELECTRICAL SYSTEM INFORMATION ................ 60-01 SEAT BAR ............................................................... 50-01


ENGINE COOLING SYSTEM ...................... 10-01, 70-01 SEAT BAR SENSOR............................................... 60-01
ENGINE INFORMATION......................................... 70-01 SERVICE PC (LAPTOP COMPUTER).................... 60-01
ENGINE LUBRICATION SYSTEM ...........................10-01 SERVICE SCHEDULE.............................................10-01
ENGINE SPEED CONTROL................................... 70-01 SPARK ARRESTOR MUFFLER.............................. 10-01
STARTER ................................................................ 60-01
FINAL DRIVE TRANSMISSION (CHAINCASE) ..... 10-01 STOPPING THE ENGINE AND
FLYWHEEL AND HOUSING ................................... 70-01 LEAVING THE LOADER ......................................... 10-01
FLYWHEEL RPM SENSOR......................................60-01
FRONT AUXILIARY HYDRAULIC COUPLER TIRE MAINTENANCE ............................................. 10-01
BLOCK......................................................................20-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
FUEL SYSTEM..............................................10-01, 70-01 TOWING THE LOADER.......................................... 10-01
FUEL TANK...............................................................50-01 TRACTION LOCK ................................................... 60-01
TRANSPORTING THE BOBCAT LOADER............. 10-01
HEATER COIL......................................................... 80-01 TROUBLESHOOTING ............................................ 80-01
HEATER FAN .......................................................... 80-01
HEATER SYSTEM .................................................. 80-01 WINDOW (FRONT DOOR) ..................................... 50-01
HEATER UNIT......................................................... 80-01 WINDOW (REAR) ................................................... 50-01
HEATER VALVE ...................................................... 80-01 WINDOW (SIDE)..................................................... 50-01
HYDRAULIC CONNECTION SPECS ................SPEC-01 WINDOW (TOP) ...................................................... 50-01
HYDRAULIC CONTROL VALVE ..............................20-01
HYDRAULIC FLUID RESERVOIR .......................... 20-01
HYDRAULIC / HYDROSTATIC FILTERS..................20-01
HYDRAULIC / HYDROSTATIC
FLUID SPECIFICATIONS ..................................SPEC-01

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CONTENTS
SAFETY &
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V
HYDRAULIC
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII SYSTEM

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX


HYDROSTATIC
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X SYSTEM

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
DRIVE
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 SYSTEM

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 MAIN FRAME

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01


ELECTRICAL
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 SYSTEM &
ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 ENGINE


SERVICE
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HEATER

SPECIFICATIONS

SPECIFICATION

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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must


hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and


correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.

4. The seat bar must be 12. Safety treads must be in good


correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.

6. Machine signs (decals) must 14. Check hydraulic fluid level,


be legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers, hand controls 15. Inspect for fuel, oil or


and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).

8. Check for correct function of 16. Lubricate the loader.


the work lights.

FW SSL-0308 SM

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17. Check the condition of the 22. Check for any field
battery and cables. modification not completed.

18. Inspect the air cleaner for 23. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.

19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: back-
approved tires or tracks. up alarm, fire extinguisher,
rotating beacon, lift kits, etc.).
21. Inspect for loose or broken 26. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.

FW SSL-0308 SM

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FW SSL-0308 SM

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SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
Warning, be alert! Your safety is involved! that the machine is in safe operating condition.
Carefully read the message that follows.
The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operators and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation &
warnings and instructions in the manuals when Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions An Operators Handbook fastened to the operator cab.
can cause injury or death. Its brief instructions are convenient to the operator.
W-2003-0903
The handbook is available from your dealer in an
English edition or one of many other languages. See
your Bobcat dealer for more information on translated
versions.
IMPORTANT
The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-type
service and repair work.

The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at


www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

WARNING The Skid-Steer Loader Safety Video is available from


your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI SSL-0308 SM

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SAFETY INSTRUCTIONS (CONTD)

The dealer and owner / operator review the recommended


uses of the product when delivered. If the owner / operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.

Cutting or drilling concrete containing sand or rock


containing quartz may result in exposure to silica dust. Do
not exceed Permissible Exposure Limits (PEL) to silica
dust as determined by OSHA or other job site Rules and
Regulations. Use a respirator, water spray or other means
to control dust. Silica dust can cause lung disease and is
known to the state of California to cause cancer.

SI SSL-0308 SM

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FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage and


leakage. Never use open flame or bare skin to check for
leaks. Hydraulic tubes and hoses must be properly routed
and have adequate support and secure clamps. Tighten
or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed


regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operators area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or


hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still hot.

Check the spark arrestor exhaust system regularly to


make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).

Check all electrical wiring and connections for damage.


Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.

Battery gas can explode and cause serious injury. Use the
procedure in the Operation & Maintenance Manual for
connecting the battery and for jump starting. Do not jump
start or charge a frozen or damaged battery. Keep any
open flames or sparks away from batteries. Do not smoke
in battery charging area.
SI SSL-0308 SM

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FIRE PREVENTION (CONTD)

Welding And Grinding

Always clean the machine and attachment, disconnect


the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted


parts. Wear dust mask when grinding painted parts. Toxic
dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as


hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits are located
and how to use them. Inspect the fire extinguisher and
service the fire extinguisher regularly. Obey the
recommendations on the instructions plate.

SI SSL-0308 SM

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SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the loader when Figure 2


requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

Figure 1

S4043
1

The engine serial number is located on top of the engine


(Item 1) [Figure 2].

S4464

Loader Serial Number

The loader serial number plate (Item 1) [Figure 1] is


located inside the cab on the right-hand side.

Explanation of loader Serial Number:


XXXX XXXXX

Module 2. - Production
Sequence (Series)

Module 1. - Model / Engine


Combination

1. The four digit Model / Engine Combination Module


number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies


the order which the loader is produced.

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DELIVERY REPORT

Figure 3

B-16315

The delivery report must be filled out by the dealer and


signed by the owner or operator when the Bobcat Loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure 3].

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LOADER IDENTIFICATION

FRONT LIGHTS

OPERATOR SEAT
with SEAT BELT
& SEAT BAR

GRAB
HANDLES

FRONT AUXILIARY
TILT QUICK COUPLERS
CYLINDER

STEPS
BUCKET S0183
BUCKET STEP
OPERATOR CAB
(ROPS / FOPS) LIFT ARM
SUPPORT
DEVICE

LIFT ARM

REAR
GRILL
LIFT
BACK-UP CYLINDER
ALARM

REAR
DOOR

REAR
LIGHT
TAIL
LIGHT
S0184
* TIRES

* TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.
Level II is available.
Bucket - Several different Buckets and other Attachments are available.

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SAFETY AND MAINTENANCE
SAFETY AND
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 MAINTENANCE
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

BACK-UP ALARM SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

BOB-TACH (POWER OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

ENGINE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1


Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1


Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . 10-110-1

FINAL DRIVE TRANSMISSION (CHAINCASE). . . . . . . . . . . . . . . . . . 10-130-1


Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1


Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . 10-100-2

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 10-120-1


Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid and Case Drain Filters . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . 10-120-1

LIFT ARM SUPPORT DEVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1


Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-10-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . 10-190-1


Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Continued On Next Page

19 of 521 10-01 S100 Service Manual


SAFETY AND MAINTENANCE (CONTD)

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1


Lubrication Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1


Cab Door Sensor (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

REMOTE START TOOL KIT-MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1


Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . 10-60-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . 10-60-2

REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . . . . . . . . . 10-61-1


Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . 10-61-4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . 10-61-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5
Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . . . . . . . . . 10-61-2

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1


Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1


Cleaning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . 10-200-1


Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

TIRE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1


Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . . . . . . . . . 10-40-1


Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD


TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.

20 of 521 10-02 S100 Service Manual


LIFTING AND BLOCKING THE LOADER Figure 10-10-2

Procedure

Figure 10-10-1

S6030

Put the floor jack under the rear of the loader.


B-7023A
Lift the rear of the loader and install jack stands [Figure
10-10-2].

Figure 10-10-3

WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operators
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
S6031

Always park the loader on a level surface.


Put the floor jack under the front of the loader [Figure 10-
10-3].

WARNING Lift the front of the loader and put jack stands under the
axle tubes [Figure 10-10-3].

Put jackstands under the front axles and rear corners NOTE: Make sure the jack stands do not touch the
of the frame before running the engine for service. tires. Make sure tires clear floor or any
Failure to use jackstands can allow the machine to fall obstacles.
or move and cause injury or death.
W-2017-0286

21 of 521 10-10-1 S100 Service Manual


22 of 521 10-10-2 S100 Service Manual
LIFT ARM SUPPORT DEVICE Figure 10-20-1

Installing

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment 1
to fall and cause injury or death. 1
W-2059-0598
P43747

Install jackstands (Item 1) [Figure 10-20-1] under the rear

WARNING corners of the loader frame.

Figure 10-20-2
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or with
missing parts can cause lift arms to drop causing
injury or death.
W-2271-1197

P54468

Disconnect the spring (Item 1) from the lift arm support


device retaining pin. Support the lift arm support device
(Item 2) with your hand and remove the retaining pin (Item
3) [Figure 10-20-2].

23 of 521 10-20-1 S100 Service Manual


LIFT ARM SUPPORT DEVICE (CONTD) Removing

Installing (Contd) Remove the retaining pin (Item 1) [Figure 10-20-4] from
the lift arm support device.
Figure 10-20-3
Figure 10-20-5

P54469

P54472

Lower the lift arm support device to the top of the lift
cylinder. Hook the free end of the spring (Item 1) [Figure Connect the spring (Item 1) [Figure 10-20-5] from the lift
10-20-3] to the lift arm support device so the spring does arm support device to the bracket below the lift arms.
not interfere with the support device engagement.
Sit in the operators seat, fasten the seat belt and lower
Sit in the operator seat, fasten the seat belt and lower the the seat bar. Start the engine.
seat bar. Start the engine.
Figure 10-20-6
Figure 10-20-4

P54468
P54470 N20524

Raise the lift arms a small amount. The spring will lift the
Raise the lift arms until the lift arm support device drops support device off the lift cylinder rod. Lower the lift arms.
onto the lift cylinder rod [Figure 10-20-4]. Stop the engine.

Lower the lift arms slowly until the support device is held Raise the seat bar, unbuckle the seat belt, move the
between the lift arm and the lift cylinder. Stop the engine. pedals until both lock and exit the cab.
Raise the seat bar and move the pedals until both lock.
Disconnect the spring from the bracket.
Install the retaining pin (Item 1) [Figure 10-20-4] into the
rear of the lift arm support device below the cylinder rod. Raise the support device into storage position and insert
the retaining pin (Item 1) [Figure 10-20-6] through the lift
arm support device and through the bracket. Connect the
spring to the retaining pin.

Remove the jackstands.

24 of 521 10-20-2 S100 Service Manual


OPERATOR CAB Raising

Description Always stop the engine before raising or lowering the cab.

The Bobcat loader has an operator cab (ROPS and Stop the loader on a level surface and lower the lift arms.
FOPS) as standard equipment to protect the operator If the lift arms must be up while raising the operator cab,
from rollover and falling objects. Check with your dealer if install the lift arm support device. (See LIFT ARM
the operator cab has been damaged. The seat belt must SUPPORT DEVICE on Page 10-20-1.)
be worn for rollover protection.
Figure 10-30-1
ROPS / FOPS - Roll Over Protective Structure per ISO
3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.

Level I - Protection from falling bricks, small concrete


blocks, and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II - Protection from falling trees, rocks: for machines


involved in site clearing, overhead demolition or forestry.
1
1

WARNING P43747

Never modify operator cab by welding, grinding, Install jackstands (Item 1) [Figure 10-30-1] under the rear
drilling holes or adding attachments unless corners of the loader frame.
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from Figure 10-30-2
rollover and falling objects, and result in injury or
death.
W-2069-0200

2
1

S4011 S4012

Remove the nut and plate (Items 1 and 2) [Figure 10-30-


2] on the inside front corner of the cab (Both sides).

25 of 521 10-30-1 S100 Service Manual


OPERATOR CAB (CONTD)

Raising (Contd)

Figure 10-30-3
WARNING
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803

Support the cab and release the latching mechanism


(Inset) [Figure 10-30-4]. Remove your hand from the
latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way.

NOTE: Always use the grab handles (once you can


reach them) to lower the cab.

Figure 10-30-5

S4078

Lift on the grab handle and bottom of the operator cab 2


slowly until the cab is all the way up and the latching 1
mechanism engages [Figure 10-30-3].

Lowering 2

Always stop the engine before raising or lowering the cab. 1

Figure 10-30-4 S4012 S4011


SXXXX SXXXX

Install the plates and nuts (Items 1 and 2) [Figure 10-30-


5] (both sides).

Tighten the nuts to 40-50 ft.-lb. (54-68 Nm) torque.

N20120 S4013

Pull down on the bottom of the operator cab until it stops


at the latching mechanism [Figure 10-30-4].

NOTE: The weight of the cab increases when


equipped with options and accessories such
as cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised
slightly from the latch to be able to release the
latch.

26 of 521 10-30-2 S100 Service Manual


OPERATOR CAB (CONTD) Figure 10-30-7

Cab Door Sensor (If Equipped)

This machine may be equipped with a Cab Door Sensor.

Figure 10-30-6

S3999A
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] will
be ON when the door is open, the key switch is turned to
RUN or the RUN / ENTER button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER button
1
2 is pressed.

[DOOR] will appear in the data display [Figure 10-30-7].


P-68116
P-68115

The cab door (option) has a sensor (Item 1) [Figure 10-


30-6] installed which deactivates the lift and tilt valves
when the door is open.

A decal is located on the latch mechanism (Item 2)


[Figure 10-30-6].

The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] will
be OFF when the door is closed, the key switch is turned
to RUN or the RUN / ENTER button is pressed, the seat
bar is lowered and the PRESS TO OPERATE LOADER
button is pressed.

27 of 521 10-30-3 S100 Service Manual


28 of 521 10-30-4 S100 Service Manual
TRANSPORTING THE LOADER ON A TRAILER Fastening

Loading And Unloading Figure 10-40-2

WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when S4759 S4758

loading onto a transport vehicle. Wood ramps can


break and cause personal injury.
W-2058-0807

Be sure the transport and towing vehicles are of adequate


size and capacity for the weight of the loader. (See
Weights on Page SPEC-10-2.)

Figure 10-40-1 Alternate Front


Tie Down

S1848 S1075

Use the following procedure to fasten the Bobcat Loader


to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].

Lower the bucket or attachment to the floor.


S1077
Stop the engine.

A loader with an empty bucket or no attachment must be Engage the parking brake.
loaded backward onto the transport vehicle [Figure 10-
40-1]. Install chains at the front and rear loader tie down
positions [Figure 10-40-2].
The rear of the trailer must be blocked or supported
[Figure 10-40-1] when loading or unloading the loader to Fasten each end of the chain to the transport vehicle.
prevent the front end of the trailer from raising up.

29 of 521 10-40-1 S100 Service Manual


30 of 521 10-40-2 S100 Service Manual
TOWING THE LOADER

Procedure

Because of the design of the loader, there is not a


recommended towing procedure.

The loader can be lifted onto a transport vehicle.

The loader can be skidded a short distance to move for


service (EXAMPLE: Move onto a transport vehicle.)
without damage to the hydrostatic system. (The
wheels will not turn.) There might be slight wear to the
wheels when the loader is skidded.

The towing chain (or cable) must be rated at 1 and 1/


2 times the weight of the loader. (See Weights on
Page SPEC-10-2.)

31 of 521 10-50-1 S100 Service Manual


32 of 521 10-50-2 S100 Service Manual
REMOTE START TOOL KIT-MEL1563 Figure 10-60-2

Tools that will be needed to complete the following steps


are:

MEL1563 - Remote Start Tool


MEL1565 - Service Tool Harness Control 2
MEL1566 - Service Tool Harness Communicator 3
(Computer Interface) 1

Remote Start Tool - MEL1563

Figure 10-60-1

P16117
1

The traction lock switch (Item 1) [Figure 10-60-2] is used


to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow/variable flow switch (Item 2) [Figure


10-60-2] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate maximum flow.
P16114 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF. The
The remote start tool (Item 1) [Figure 10-60-1] is required switch is used when checking pressures and flow rate.
when the service technician is checking the hydraulic/
hydrostatic system or adjusting the steering linkage. The auxiliary pressure release (Item 3) [Figure 10-60-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.

NOTE: With the engine running; pushing and holding


the pressure release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.

10-60-1 S100 Service Manual


33 of 521
REMOTE START TOOL KIT-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565

Remote Start Tool - MEL1563 (Contd) Figure 10-60-5

Figure 10-60-3
2

1 1

P16114

P16116
The service tool harness control (Item 1) is used to
connect the remote start tool (Item 2) [Figure 10-60-5] to
Figure 10-60-4 the electrical system on the loader.

1 Figure 10-60-6

P16120

S6014
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the cap (Item 1) [Figure 10-60-6] from the loader
harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.

The panel must be removed from inside the operator cab


and plugged into this connector [Figure 10-60-4].

10-60-2 S100 Service Manual


34 of 521
REMOTE START TOOL KIT-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566

Service Tool Harness Control - MEL1565 (Contd) Figure 10-60-8

Figure 10-60-7 2

2
1 1

P16119

EM1024
The service tool harness communicator (Item 1) is
required to connect remote start tool to the Service PC
Loaders equipped with an attachment harness (Item 1) (Item 2) [Figure 10-60-8].
must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-7].

Connect the service tool harness to the ACD connector


and the loader harness connector.

NOTE: To monitor, diagnose or load new software the


Service PC must be connected to the Remote
Start Tool Switch.

10-60-3 S100 Service Manual


35 of 521
REMOTE START TOOL KIT-MEL1563 (CONTD) Figure 10-60-11

Remote Start Procedure

The tool listed will be needed to do the following


procedure:
1
MEL1563: Remote Start Tool Kit

Figure 10-60-9

EM1024

Remove the cap (Item 1) [Figure 10-60-10] or disconnect


the attachment control harness (Item 1) [Figure 10-60-
11] if connected.

Figure 10-60-12

P16115

The remote start tool (Item 1) [Figure 10-60-9] is required


when the operator cab is in the raised position for service
and the service technician needs to turn the key switch on
or start the engine. Example: adjusting the steering
linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) and


install an approved lift arm support device.

Raise the operator cab (if required by the procedure).


S6035
Open the rear door of the loader.
Connect the remote start tool to the loader harness
Figure 10-60-10 connector [Figure 10-60-12].

NOTE: The key switch on the right-hand side operator


panel must be in the off position or the Remote
Start Kit will not operate.

1
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
S6014 start tool in the run position disconnects the operator
panel key switch from the start circuit. If the service
technician will be working in the engine area it is
important to remove the operator panel keys.
W-2357-0899

10-60-4 S100 Service Manual


36 of 521
REMOTE START TOOL KIT-MEL1563 (CONT'D) The auxiliary pressure release (Item 3) [Figure 10-60-14]
is used to release hydraulic pressure to the front and/or
Remote Start Procedure (Cont'd) rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
Figure 10-60-13
NOTE: With the engine running; pushing and holding
the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

P16116

The remote start tool (Item 1) [Figure 10-60-13] has three


rocker switches.

Figure 10-60-14
NOTE: With the engine running; pushing and holding
the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.

2 Figure 10-60-15
3 1

P16118

The traction lock switch (Item 1) [Figure 10-60-14] is


used to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.
P-34661

The maximum flow/variable flow switch (Item 2) [Figure


10-60-14] is used to activate the auxiliary hydraulics. Push the couplers on the front auxiliary block toward the
Pressing the switch once will activate variable flow. block and hold for five seconds to release the front
Pressing the switch again will activate maximum flow. The auxiliary pressure [Figure 10-60-15].
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF. The
switch is used when checking pressures and flow rate.

10-60-5 S100 Service Manual


37 of 521
10-60-6 S100 Service Manual
38 of 521
REMOTE START TOOL (SERVICE TOOL) KIT -
6689779

Description

The Remote Start Tool (Service Tool) Kit is a replacement


tool for MEL 1563 Remote Start Tool and MEL 1400B -
BOSS Diagnostic Tool.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,


can be used to service older loaders with the BOSS
system using the supplied BOSS Service Tool Harness
P/N 6689745.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,


can be used to service newer loaders using the supplied
harness P/N 6689747.

A computer can be connected to the Remote Start Tool


(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.

10-61-1 S100 Service Manual


39 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
6689779 (CONT'D)
2
Tools that will be needed to complete the following steps
are:
5 3
Order from Bobcat Parts P/N: 6689779 - Remote Start
Tool (Service Tool) Kit
6 4
Kit Includes:
6689778 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness 1
6689745 - BOSS Service Tool Harness

Remote Start Tool (Service Tool) - 6689778


P-76439
Figure 10-61-1
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-2] has five buttons.

The STOP button (Item 2) [Figure 10-61-2] is used to


stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-2] is used to turn


the Remote Start Tool (Service Tool) on and activates the
1 loader ignition power. The button will illuminate to indicate
the service tool is active.

The START button (Item 4) [Figure 10-61-2] is used to


start the loader engine.
P-76678

The traction lock button (Item 5) [Figure 10-61-2] is used


to turn traction lock ON or OFF. Push the button and the
The remote start tool (Item 1) [Figure 10-61-1] is required button will illuminate indicating the traction lock is disabled
when the service technician is checking the hydraulic / in which the wheels or tracks are able to turn.
hydrostatic system or adjusting the steering linkage.
The auxiliary button (Item 6) [Figure 10-61-2] is used to
activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing the
button a second time will turn the flow OFF. The button is
used when checking pressures and flow rate.

10-61-2 S100 Service Manual


40 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-5
6689779 (CONT'D)
2
Loader Service Tool Harness - 6689747

Figure 10-61-3
1

EM1024
2

Loaders with an attachment control harness (7 pin or 14


pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].

The loader service tool harness (Item 1) is used to When the remote start procedure is completed, replace
connect the remote start tool (service tool) (Item 2) the loader connector cap (Item 1) [Figure 10-61-4] or
[Figure 10-61-3] to the electrical system on the loader. reconnect the attachment control harness to the loader
harness [Figure 10-61-5].
Figure 10-61-4

S6014

Loaders without an attachment control harness, remove


the loader harness cap (Item 1) [Figure 10-61-4] and
connect the Loader Service Tool Harness, from the
Remote Start Tool (Service Tool), to the loader harness
connector.

10-61-3 S100 Service Manual


41 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
6689779 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Contd)

Figure 10-61-6

3 1

2
P-76450
1

S6035 The computer service tool harness (Item 1) is required to


connect remote start tool (service tool) to the Service PC
(Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.

The second connector (Item 3) [Figure 10-61-6]


is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use. This
connector is not used on the S100.

Connect the Remote Start Tool (Service Tool) connector


(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].

NOTE: The right instrument panel (Standard Key


Panel or Deluxe Instrumentation Panel) must
be in the off position or the Remote Start Tool
(Service Tool) will not operate.

P-76454

10-61-4 S100 Service Manual


42 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-9
6689779 (CONT'D)

Remote Start Procedure

WARNING 1

AVOID INJURY OR DEATH


With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
S6014
Pressing the RUN button on the Remote Start Tool
disconnects the operator panel from the start circuit.
If the service technician will be working in the engine Loaders without an attachment control harness, remove
area it is important to remove the operator panel key the loader harness cap (Item 1) [Figure 10-61-9] and
or lock the keypad with a unique password. connect the Loader Service Tool Harness, from the
W-2647-0707 Remote Start Tool (Service Tool), to the loader harness
connector.
The tool listed will be needed to do the following
Figure 10-61-10
procedure:

6689779: Remote Start Tool (Service Tool) Kit

Figure 10-61-8 2
1

EM1024

Loaders with an attachment control harness (7 pin or 14


pin), the attachment harness (Item 1) must be
P-76450 disconnected from the loader harness (Item 2) [Figure
10-61-10].
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-8] is required when the operator cab is in the raised When the remote start procedure is completed, replace
position for service and the service technician needs to the loader connector cap (Item 1) [Figure 10-61-10] or
turn on the loader or start the engine. Example: adjusting reconnect the attachment control harness to the loader
the steering linkage. harness [Figure 10-61-10].

Lift and block the loader.

Raise the lift arms (if required by the procedure) and


install an approved lift arm support device.

Raise the operator cab (if required by the procedure).

Open the rear door of the loader.

10-61-5 S100 Service Manual


43 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-12
6689779 (CONT'D)
2
Remote Start Procedure (Cont'd)

Figure 10-61-11
5 3
3
6 4

2
P-76439

1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-


61-12] has five buttons.
S6035
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item
1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to turn
[Figure 10-61-11] is always used for the Remote Start Tool (Service Tool) on and activates the
connection to the loader harness. loader ignition power. The button will illuminate to indicate
the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The right instrument panel (Standard Key to indicate the auxiliary hydraulics are active. Pressing the
Panel or Deluxe Instrumentation Panel) must
button a second time will turn the flow OFF. The button is
be in the off position or the Remote Start Tool
(Service Tool) will not operate. used when checking pressures and flow rate.

P-76454

10-61-6 S100 Service Manual


44 of 521
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-14
6689779 (CONT'D)

Remote Start Procedure (Cont'd)

Figure 10-61-13

1 2

P-34661

Push the couplers on the front auxiliary block toward the


block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].

The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.

The computer icon with the right facing arrows (Item 2)


[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.

NOTE: To relieve the pressure at the rear or


secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
the remote start tool and move the AUXILIARY
Hydraulic Switch to the right and left several
times.

10-61-7 S100 Service Manual


45 of 521
10-61-8 S100 Service Manual
46 of 521
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

SERVICE SCHEDULE HOURS



ITEM SERVICE REQUIRED 8-10 50 100
250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check condition indicator, replace element when required. Check for leaks and
damaged components. Empty dust cup as needed.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Seat Belt, Seat Belt Retractors, Check the condition of seat belt. Clean or replace seat belt retractors as
Seat Bar needed. Clean dirt and debris from moving parts. Check the seat bar and
control interlocks for correct operation.
Bobcat Interlock Control Check that four BICS indicator lights and functions are activated. See details in
Systems (BICS) this Manual.
Front Horn / Back-up Alarm Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on sidewall of tire.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater Filter (If equipped) Clean or replace filter as needed.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level and add oil as needed. Check for correct operation. Repair or
Foot Pedals, Steering Levers adjust as needed.
Parking Brake Check operation.
Wheel Nuts Check for loose wheel nuts and tighten to correct torque.
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage.
Alternator Belt Check condition and tension. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. Use CF/CG4 or better grade oil and Bobcat filter.
Hydrostatic Filter, Charge Filter Replace the hydrostatic filter and the charge filter.
Engine Valves Adjust the engine valves.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Coolant Replace the coolant. Every 2 years.
Or every 12 months.
Check every 8-10 hours for the first 50 hours, then 50 hour intervals thereafter.
Inspect new belt after first 50 hours.
Replace the hydraulic / hydrostatic filter element after the first 50 hours; and thereafter when the transmission warning light
comes ON while operating or at the 500 hour interval.
First oil and filter change must occur at 50 hours; every 250 hours thereafter.

47 of 521 10-70-1 S100 Service Manual


48 of 521 10-70-2 S100 Service Manual
AIR CLEANER SERVICE Figure 10-80-3

Replacing Filter Elements

Figure 10-80-1

S4020
1 2
Pull the element straight out (Item 1) [Figure 10-80-3].

Install a new outer element.


S4051
Install the dust cover (Item 2) [Figure 10-80-2].
Replace the large (outer) filter element only when the red
Check the air intake hose and the air cleaner housing for
ring shows in the window of the condition indicator (Item
damage. Make sure all connections are tight.
1) [Figure 10-80-1].
Inner Filter
NOTE: Before replacing the filter element, push the
button on the condition indicator (Item 2)
Replace the inner filter every third time the outer filter is
[Figure 10-80-1]. Start the engine. If the red
replaced or when the red ring still shows in the indicator
ring does not show, do not replace the filter
window after the outer filter has been replaced.
element.
Figure 10-80-4
Outer Filter

Figure 10-80-2

1
S4019
S4021

Remove the inner filter (Item 1) [Figure 10-80-4].

S4014 NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Open the evacuator valve (Item 1) [Figure 10-80-2] to get
rid of large particles of dust and dirt. Install a new inner element.

Remove the dust cover by lifting the lever (Item 2) [Figure Install the outer element.
10-80-2].
Install the dust cover [Figure 10-80-2].

49 of 521 10-80-1 S100 Service Manual


50 of 521 10-80-2 S100 Service Manual
ENGINE COOLING SYSTEM Figure 10-90-2

Check the cooling system every day to prevent over-


heating, loss of performance or engine damage. 1

Cleaning

Open the rear door and raise the rear grill.

NOTE: Be careful when raising and lowering the rear


grill so that it does not fall on the radiator and
damage the fins.

Figure 10-90-1

S0297

Remove the coolant fill cap (Item 1) [Figure 10-90-2].


Check the coolant level. The level markers are on the
tank. Coolant must be at the bottom marker when the
engine is cold and on the top marker when hot.

Use a refractometer to check the condition of propylene


1 glycol in your cooling system.

Close the rear door before operating the loader.


S4082

Use low air pressure or water pressure to clean the top of


the radiator (Item 1) [Figure 10-90-1].
IMPORTANT
Check the cooling system for leaks.
AVOID ENGINE DAMAGE
Lower the rear grill and close the rear door. Always use the correct ratio of water to antifreeze.

Checking Level Too much antifreeze reduces cooling system


efficiency and may cause serious premature engine
Open the rear door and remove the rear grill (See REAR damage.
GRILL on Page 50-60-1).
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.

WARNING Always add a premixed solution. Adding full strength


concentrated coolant can cause serious premature
AVOID INJURY OR DEATH engine damage.
I-2124-0497
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W-2019-0907

51 of 521 10-90-1 S100 Service Manual


ENGINE COOLING SYSTEM (CONTD) Use a refractometer to check the condition of propylene
glycol in your cooling system.
Removing And Replacing Coolant
Run the engine until it is at operating temperature. After
Open the rear door and remove the rear grill. stopping the engine, let it cool down and check the
coolant level again. Add coolant as needed.
Figure 10-90-3
Install the rear grill and close the rear door.

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system


efficiency and may cause serious premature engine
damage.

S0297
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Remove the coolant fill cap (Item 1) [Figure 10-90-3].
Always add a premixed solution. Adding full strength
Connect a hose to the engine block drain valve. Open the concentrated coolant can cause serious premature
drain valve, connect a hose to it and drain the coolant into engine damage.
a container. I-2124-0497

After all the coolant is removed, close the drain valve and
remove the hose.

NOTE: Fluids such as engine oil, hydraulic fluid,


coolant, etc. must be disposed of in an
environmentally safe manner. Some
regulations require that certain spills and
leaks on the ground must be cleaned in a
specific manner. See local, state and federal
regulations for correct disposal.

Mix the coolant in a separate container. (See Fluid


Specifications on Page SPEC-10-5.) Use 53% propylene
glycol and 47% water.

1 gallon and one pint of propylene glycol mixed with 1


gallon of water is the correct ratio (53% / 47%) to
provide -34F (-37C) freeze protection.

NOTE: The loader is factory filled with propylene


glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

Fill the recovery tank with premixed coolant until it is at the


lower marker on the tank. Install the coolant fill cap (Item
1) [Figure 10-90-3].

52 of 521 10-90-2 S100 Service Manual


FUEL SYSTEM Figure 10-100-2

Fuel Specifications WRONG

Use only clean, high quality diesel fuel, Grade No. 2 or


Grade No. 1.

The following is one suggested blending guideline which


should prevent fuel gelling during cold temperatures:

TEMPERATURE F (C) NO. 2 NO. 1


+15 (9) 100% 0%
Down to -20 (-29) 50% 50%
Below -20 (-29) 0% 100%
B15650

Contact your fuel supplier for local recommendations.


Use a clean, approved safety container to add fuel of the
Filling The Fuel Tank correct specification. Add fuel only in an area that has free
movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].

Install and tighten the fuel fill cap (Inset) [Figure 10-100-
WARNING 1].

AVOID INJURY OR DEATH


Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire. WARNING
W-2063-0807
AVOID INJURY OR DEATH
Figure 10-100-1 Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

S4014

Open the rear door.

Remove the fuel fill cap (Inset) [Figure 10-100-1].

53 of 521 10-100-1 S100 Service Manual


FUEL SYSTEM (CONTD) Removing Air From The Fuel System

Fuel Filter

For the service interval for removing water from, or


replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.).
WARNING
AVOID INJURY OR DEATH
Removing Water
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Figure 10-100-3
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
S4014
3
After replacing the filter element or when the fuel tank has
run out of fuel, the air must be removed from the fuel
4 system before starting the engine.
1
S4017
2 Figure 10-100-4

S4014

Loosen the drain (Item 1) [Figure 10-100-3] at the bottom


of the filter element to remove water from the filter.

Replacing Element
S4018
Remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten. S4014

Remove air from the fuel system. (See Removing Air


From The Fuel System below.) Open the vent (Item 3) [Figure 10-100-3] on the fuel filter
housing.

Squeeze the hand pump (priming bulb) (Inset) [Figure


10-100-4] until air bubbles do not come up any more.

Close the vent (Item 3) [Figure 10-100-3] on the fuel filter


housing.

Open the vent (Item 4) [Figure 10-100-3] on the fuel


injection pump.

Squeeze the hand pump (priming bulb) (Inset) [Figure


10-100-4] until air bubbles do not come up any more.

Close the vent (Item 4) [Figure 10-100-3] on the fuel


injection pump.

Start the engine.

It may be necessary to open the vent plug briefly while the


engine is running. Close the vent when the engine runs
smoothly.

54 of 521 10-100-2 S100 Service Manual


ENGINE LUBRICATION SYSTEM Removing And Replacing Oil And Filter

Checking And Adding Engine Oil For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.)
Check the engine oil level every day before starting the
engine for the work shift. Run the engine until it is at operating temperature. Stop
the engine.
Figure 10-110-1
Figure 10-110-3

2
S4023
1

S4024

2 S4014
Open the rear door.

Open the rear door and remove the dipstick (Item 1) Remove the drain hose from its storage position. Remove
[Figure 10-110-1]. the drain plug (Item 1) [Figure 10-110-3].

Keep the oil level between the marks on the dipstick. Drain the oil into a container and dispose of used oil in an
environmentally safe manner.
Engine Oil Chart Remove the oil filter (Item 2) [Figure 10-110-3].

Figure 10-110-2 Clean the filter housing surface.


Put clean oil on the new oil filter gasket.
Install the filter and hand tighten.
Install and tighten the drain plug.
Add engine oil.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
B16320 Failure to use care around combustibles can cause
explosion or fire.
Use a good quality motor oil that meets API Service W-2103-0508
Classification of CD or better. (See Engine Oil Chart
[Figure 10-110-2].)

55 of 521 10-110-1 S100 Service Manual


56 of 521 10-110-2 S100 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid Figure 10-120-2

Use only recommended fluid in the hydraulic system. (See


Specifications on Page SPEC-40-1.)

Stop the loader on a level surface.

Lower the lift arms and tilt the Bob-Tach fully back.

Stop the engine.


Figure 10-120-1

P64023A

Use the correct hydraulic / hydrostatic fluid shown in chart


[Figure 10-120-2].
1
S4028
Removing And Replacing Hydraulic / Hydrostatic
Filter

For the correct service interval (See SERVICE


S4031 SCHEDULE on Page 10-70-1.)

Stop the engine and open the rear door.

Figure 10-120-3

2
3
S4029 S4030

Remove the fill cap (Item 1) [Figure 10-120-1].

Add oil until it is at the center of the sight gauge (Item 2) S4080
[Figure 10-120-1]. Do not overfill.

Remove the screen (Item 3) [Figure 10-120-1] and clean


with solvent as needed.

Install the fill cap (Item 1) [Figure 10-120-1].


S4014

Remove the filter (Inset) [Figure 10-120-3].

Clean the surface of the filter housing where the filter seal
contacts the housing.

Put clean oil on the seal of the new filter. Install and hand
tighten the new filter.

57 of 521 10-120-1 S100 Service Manual


HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Figure 10-120-4

Removing And Replacing Hydraulic / Hydrostatic


Filter (Contd)

WARNING 1
S4028
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
S4031
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention Raise the operator cab. (See Raising on Page 10-30-1.)
from a physician familiar with this injury.
W-2072-0807 Remove the fill cap (Item 1) [Figure 10-120-4].

Figure 10-120-5
Start the engine and operate the loader hydraulic controls.

Stop the engine and check for leaks at the filter.

Check the fluid level in the reservoir and add as needed.

Close the rear door.

WARNING 1

AVOID INJURY OR DEATH


Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. S4033 S4032

Failure to use care around combustibles can cause


explosion or fire. Disconnect the hose (Item 1) [Figure 10-120-5] from the
W-2103-0508
hydraulic reservoir and drain the fluid into a container.

Removing And Replacing Hydraulic Fluid and Case Reconnect the hose when the reservoir is empty.
Drain Filters
NOTE: Fluids such as engine oil, hydraulic fluid,
For the correct service interval (See SERVICE coolant, etc. must be disposed of in an
SCHEDULE on Page 10-70-1.) environmentally safe manner. Some
regulations require that certain spills and
Replace the fluid if it becomes contaminated or after leaks on the ground must be cleaned in a
major repair. specific manner. See local, state and federal
regulations for correct disposal.
Always replace the hydraulic / hydrostatic filter and the
case drain filters whenever the hydraulic fluid is replaced.
(See Removing And Replacing Hydraulic / Hydrostatic
Filter on Page 10-120-1)

58 of 521 10-120-2 S100 Service Manual


HYDRAULIC / HYDROSTATIC SYSTEM (CONTD)

Removing And Replacing Hydraulic Fluid and Case


Drain Filters (Contd) WARNING
Figure 10-120-6
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
1 physician familiar with this injury is not received
immediately.
W-2145-0290
S4034

Removing And Replacing Charge Filter

Figure 10-120-7

S4032

1
The case drain filters are located under the cab, next to 2
the transmission, one on each side (Item 1) [Figure 10-
120-6].
1
Disconnect the fittings at the end of the case drain filters
and remove both filters.
S4254

Remove the hydraulic connections (Item 1) and remove


WARNING the charge filter (Item 2) [Figure 10-120-7]. Replace the
entire filter.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Disassemble the case drain filters and discard the filter


elements. Thoroughly clean the filter housings with
solvent. Install new filter elements and reassemble. Install
the filters into the loader and reconnect the fittings. Lower
the cab. (See Lowering on Page 10-30-2.)

Replace the hydraulic / hydrostatic filter. (See Removing


And Replacing Hydraulic / Hydrostatic Filter on Page 10-
120-1)

Add the correct fluid to the reservoir until it is at the center


of the sight gauge. Do not overfill.

Start the engine and operate the loader hydraulic controls.


Stop the engine and check for leaks.

Check the fluid level in the reservoir and add as needed.

59 of 521 10-120-3 S100 Service Manual


60 of 521 10-120-4 S100 Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil

Checking And Adding Oil Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing.
The chaincase contains the final drive sprockets and
chains. Use the same type of oil as the hydraulic / Figure 10-130-2
hydrostatic system. (See Fluid Specifications on Page
SPEC-10-5.)

Stop the loader on a level surface.

Stop the engine.

Figure 10-130-1

P31287A

Use a pump to suction the oil from the chaincase [Figure


10-130-2].

Recycle or dispose of the used oil in an environmentally


safe manner.
P31287
Add new oil until you can reach the oil with the tip of your
finger through the hole.
Remove the check plug (Item 1) [Figure 10-130-1] from
the front of the chaincase housing. Install and tighten the plug.

If oil can be reached with the tip of your finger through the
hole, the oil level is correct.

If the level is low, add lubricant through the check plug


hole until it reaches the desired level.

Install and tighten the plug.

61 of 521 10-130-1 S100 Service Manual


62 of 521 10-130-2 S100 Service Manual
BOB-TACH (HAND LEVER) Figure 10-140-2

Inspection And Maintenance


1
Figure 10-140-1

Wedge must contact


lower edge of hole in
the attachment.
S4087 B15177

The wedges (Item 1) must extend through the holes in the


attachment mounting frame (Item 2) [Figure 10-140-2].
N17027
The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
Move the Bob-Tach levers down to engage the wedges 140-2].
[Figure 10-140-1].
If the wedge does not contact the lower edge of the hole
The levers and wedges must move freely. [Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.

Figure 10-140-3

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497

B17460

Inspect the mounting frame on the attachment and Bob-


Tach, linkages and wedges for excessive wear or damage
[Figure 10-140-3]. Replace any parts that are damaged,
bent or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for


repair or replacement parts.

Lubricate the wedges (See SERVICE SCHEDULE on


Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)

63 of 521 10-140-1 S100 Service Manual


64 of 521 10-140-2 S100 Service Manual
BOB-TACH (POWER OPTION) Figure 10-141-3

Inspection And Maintenance

Figure 10-141-1

S2849 S4050

Push and hold the top of the BOB-TACH WEDGES UP / B17460


DOWN switch [Figure 10-141-1] until wedges are fully
raised. Push and hold the bottom of the BOB-TACH Inspect the mounting frame on the attachment and the
WEDGES UP / DOWN switch until the wedges are fully Bob-Tach, linkages and wedges for excessive wear or
down. damage [Figure 10-141-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
The levers and wedges must move freely.
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.

WARNING Lubricate the wedges (See SERVICE SCHEDULE on


Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497

Figure 10-141-2

Wedge must contact


lower edge of hole in the
attachment.
S4087 B15177

The wedges (Item 1) must extend through the holes in the


attachment mounting frame (Item 2) [Figure 10-141-2].

The spring loaded wedge (Item 1) must contact the lower


edge of the hole in the attachment (Item 2) [Figure 10-
141-2].

If the wedge does not contact the lower edge of the hole
[Figure 10-141-2], the attachment will be loose and can
come off the Bob-Tach.

65 of 521 10-141-1 S100 Service Manual


66 of 521 10-141-2 S100 Service Manual
LUBRICATING THE LOADER Figure 10-150-3

Lubrication Locations

Lubricate the loader as specified for the best performance


of the loader. (See SERVICE SCHEDULE on Page 10-70-
1.) 2

Record the operating hours each time you lubricate the


Bobcat Loader.

Always use a good quality lithium based multi-purpose


grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
S4085
Lubricate the following locations on the loader:

Figure 10-150-1 2. Base End Lift Cylinder (Both Sides) (Item 2) [Figure
10-150-2] and [Figure 10-150-3].

Figure 10-150-4
3
2
4

1 3

S4036
S4086

Figure 10-150-2 3. Lift Arm Pivot Pin (Both Sides) (Item 3) [Figure 10-
150-1] and [Figure 10-150-4].

S1080

1. Rod End Lift Cylinder (Both Sides) (Item 1) [Figure 10-


150-1] and [Figure 10-150-2].

67 of 521 10-150-1 S100 Service Manual


LUBRICATING THE LOADER (CONTD) Figure 10-150-7

Lubrication Locations (Contd)

Figure 10-150-5

4 8

8
S4039

8. 250 Hours: Steering Lever Shaft (two) under the cab


S4037 (Item 8) [Figure 10-150-7].

4. Base End Tilt Cylinder (Both Sides) (Item 4) [Figure Figure 10-150-8
10-150-1] and [Figure 10-150-5].

Figure 10-150-6 9

7 9
5

P43829 P43830

9. Power Bob-Tach Pivot Pins (If Equipped) [Figure 10-


150-8].

S4038

5. Rod End Tilt Cylinder (Both Sides) (Item 5) [Figure 10-


150-6].

6. Bob-Tach Pivot Pin (Both Sides) (Item 6) [Figure 10-


150-6].

7. Bob-Tach Wedge (Both Sides) (Item 7) [Figure 10-


150-6].

68 of 521 10-150-2 S100 Service Manual


TIRE MAINTENANCE Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
Wheel Nuts capability. Check for the correct pressure before operating
the loader.
Figure 10-160-1
Mounting

Tires are to be repaired only by an authorized person


using the proper procedures and safe equipment.

Tires and rims must always be checked for correct size


before mounting. Check rim and tire bead for damage.

The rim flange must be cleaned and free of rust.

The tire bead and rim flange must be lubricated with a


rubber lubricant before mounting the tire.

S4503 Avoid excessive pressure which can rupture the tire and
cause serious injury or death.
See the SERVICE SCHEDULE for the service interval to
During inflation of the tire, check the tire pressure
check the wheel nuts [Figure 10-160-1]. (See SERVICE
frequently to avoid overinflation.
SCHEDULE on Page 10-70-1.)

When installing wheel nuts, tighten to 160 ft.-lb. (217 Nm)


torque.

When checking wheel nut torque, set the torque wrench to WARNING
140 ft.-lb. (190 Nm) to prevent over-tightening.
AVOID INJURY OR DEATH
Rotating Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
Check the tires regularly for wear, damage and pressure. explosion which can result in injury or death.
Inflate tires to the maximum pressure shown on the W-2078-1007
sidewall of the tire.

Figure 10-160-2

IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794

B9976

Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires to
the front [Figure 10-160-2].

It is important to keep all tires the same size. If different


sizes are used, each tire will be turning at a different rate
and cause excessive wear. The tread bars of all the tires
must face the same direction.

69 of 521 10-160-1 S100 Service Manual


70 of 521 10-160-2 S100 Service Manual
SPARK ARRESTOR MUFFLER

Cleaning Procedure

See the SERVICE SCHEDULE for service interval for


WARNING
cleaning the spark arrestor muffler. (See SERVICE
AVOID INJURY OR DEATH
SCHEDULE on Page 10-70-1.)
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
Do not operate the loader with a defective exhaust
fumes. If the engine is stationary, vent the exhaust
system.
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Stop the engine and open the rear door. W-2050-0807

Figure 10-170-1

WARNING
1
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285

WARNING
S4014
Never use machine in atmosphere with explosive dust
or gases or where exhaust can contact flammable
Remove the plug (Item 1) [Figure 10-170-1] from the
material. Failure to obey warnings can cause injury or
bottom of the muffler.
death.
W-2068-1285

WARNING
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284

Start the engine and run for about 10 seconds while a


second person, wearing safety goggles, holds a piece of
wood over the outlet of the muffler. This will force
contaminants out through the cleanout hole.

Stop the engine.

Install and tighten the plug.

Close the rear door.

71 of 521 10-170-1 S100 Service Manual


72 of 521 10-170-2 S100 Service Manual
PIVOT PINS Figure 10-180-2

Inspection And Maintenance

Figure 10-180-1
3
1 4

1 2

5
S4036

Figure 10-180-3
N20575A

All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-180-1].
6
Check that the lock nuts are tightened to 25-28 ft.-lb. (34-
38 Nm) torque.

S4038

Check the following pivot pins (Items 1-6) [Figure 10-180-


2] and [Figure 10-180-3].

73 of 521 10-180-1 S100 Service Manual


74 of 521 10-180-2 S100 Service Manual
LOADER STORAGE AND RETURN TO SERVICE Return To Service

Storage After the Bobcat Loader has been in storage, it is


necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
Loader for an extend period of time. Below is a list of
items to perform before storage. Check the engine and hydraulic oil levels; check
coolant level.
Thoroughly clean the loader including the engine
compartment. Install a fully charged battery.

Lubricate the loader. Remove grease from exposed cylinder rods.

Replace worn or damaged parts. Check all belt tensions.

Park the loader in a dry protected shelter. Be sure all shields and guards are in place.

Lower the lift arms all the way and put the bucket flat Lubricate the loader.
on the ground.
Check tire inflation and remove blocks from under
Put blocks under the frame to remove weight from the frame.
tires.
Remove cover from exhaust pipe opening.
Put grease on any exposed cylinder rods.
Start the engine and let run for a few minutes while
Put fuel stabilizer in the fuel tank and run the engine a observing the instrument panels and systems for
few minutes to circulate the stabilizer to the pump and correct operation.
fuel injectors.
Operate machine, check for correct function.
Drain and flush the cooling system. Refill with
premixed coolant. Stop the engine and check for leaks. Repair as
needed.
Replace all fluids and filters (engine, hyd. / hydro.).

Replace air cleaner, heater and air conditioning filters.

Put all controls in neutral position.

Remove the battery. Be sure the electrolyte level is


correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.

Cover the exhaust pipe opening.

Tag the machine to indicate that it is in storage


condition.

75 of 521 10-190-1 S100 Service Manual


76 of 521 10-190-2 S100 Service Manual
STOPPING THE ENGINE AND LEAVING THE LOADER Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
Procedure personnel.

Stop the Bobcat Loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Deluxe Instrumentation
Lower the lift arms fully and put the attachment flat on the Panel allows operation of the loader without
ground. using a password.

Figure 10-200-1 Figure 10-200-3

S4006

Pull the engine speed control lever (Item 1) [Figure 10-


200-1] fully backward to decrease the engine speed.

Engage the parking brake.


P66668A
S0597

Figure 10-200-2
Exit the loader [Figure 10-200-3].

WARNING
Before you leave the operators seat:
2 Lower the lift arms, put the attachment flat on the
ground.
Stop the engine.
P-76603 B-15553L
Engage the parking brake.
Raise the seat bar, move pedals until both lock.
Turn the key switch to the STOP position (Item 1) [Figure Move auxiliary hydraulic control lever out of
10-200-2]. detent position.
W-2164-0108
Turn the key switch to the STOP position (Item 1)
(Standard Key Panel) or press the STOP button (Item 2)
(Deluxe Instrumentation Panel) [Figure 10-200-2].

NOTE: The loader lights will remain ON for


approximately 90 seconds after turning the
loader OFF.

Move auxiliary control out of detent position.

Raise the seat bar and make sure the lift and tilt functions
are deactivated.

Unbuckle the seat belt.

77 of 521 10-200-1 S100 Service Manual


STOPPING THE ENGINE AND LEAVING THE LOADER Front Door (If Equipped)
(CONTD)
NOTE: When an Operator Cab Enclosure Kit is
Emergency Exit installed, the window of the front door can be
used as an emergency exit [Figure 10-200-6].
The front opening on the operator cab and rear window
provide exits. NOTE: If the loader has a Special Application Door Kit
installed, the window of the front door is NOT
Rear Window (If Equipped) an emergency exit.

Figure 10-200-4 Figure 10-200-6

S4046 S4045 N20171

Pull the tag on the top of the rear window [Figure 10-200- Pull the plastic loop (Item 1) [Figure 10-200-6] at the top
4] to remove the rubber cord. of the window in the front door to remove the rubber cord.

Push the rear window out of the rear of the operator cab. Figure 10-200-7

Figure 10-200-5

1 1

1
1

6707852 S0363

Push the window out with your foot at any corner of the
P45260A window (Item 1) [Figure 10-200-7].

Exit through the front door.


Exit through the rear of the operator cab [Figure 10-200-
5].

78 of 521 10-200-2 S100 Service Manual


BACK-UP ALARM SYSTEM Operation

Description Figure 10-210-2

Figure 10-210-1

S4006

The back-up alarm (Item 1) [Figure 10-210-1] is located


The back-up alarm will sound when the operator moves
on the inside of the rear door.
both steering levers into the reverse position [Figure 10-
210-2]. Slight movement of the steering levers into the
A back-up alarm is not a substitute for looking to the
reverse position is required with hydrostatic
rear when operating the loader in reverse, or for
transmissions, before the back-up alarm will sound.
keeping bystanders away from the work area.
Operators must always look in the direction of travel,
If alarm does not sound or for adjustment instructions
including reverse, and must also keep bystanders away
(See Adjusting Switch Position on page 60-170-2.)
from the work area, even though the loader is equiooed
with a back-up alarm.

Operators must be trained to always look in the direction


of travel, including when operating the loader in
reverse and to keep bystanders away from the work area.
Other workers should be trained to always keep away
from the operators work area and travel path.

10-210-1 S100 Service Manual


79 of 521
10-210-2 S100 Service Manual
80 of 521
HYDRAULIC SYSTEM

BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1 HYDRAULIC
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3 SYSTEM
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2

CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1


Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

CYLINDER (LIFT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1


Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1


Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

FRONT AUXILIARY HYDRAULIC COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Continued On Next Page

81 of 521 20-01 S100 Service Manual


HYDRAULIC SYSTEM (CONTD)

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1


Anti-Cavitation Valve Removal And Installation (Lift, Rod End). . . . . . . . . . . 20-40-6
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-21
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . . 20-40-9
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-40-10
Load Check Valve Removal And Installation (Tilt and Auxiliary) . . . . . . . . . . 20-40-5
Lock Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 20-40-7
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)20-40-7
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 20-40-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1


Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1


Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Hydraulic / Hydrostatic Filter Housing Removal And Installation. . . . . . . . . . 20-70-1

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1


Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Direct Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-14
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Pump Test at Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1


Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

Continued On Next Page

82 of 521 20-02 S100 Service Manual


HYDRAULIC SYSTEM (CONTD)

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1


Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01)
UNLESS OTHERWISE SPECIFIED.

83 of 521 20-03 S100 Service Manual


84 of 521 20-04 S100 Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
S100 (S/N A2G811001 AND ABOVE)
(S/N A8ET11001 A8ET19999)

(PRINTED JANUARY 2009)


V-0887 legend
LEGEND
1 VARIABLE DISPLACEMENT BIDIRECTIONAL 17 RELIEF VALVE MAIN: 34 INLET SCREEN / FILTER: Inside of Inlet
HYDROSTATIC PUMP: 17.5 GPM (66,4 L/min) 3000 PSI (206,84 bar) Fitting
2 HYDRAULIC PUMP.............Gear Type: 18 RELIEF / ANTICAVITATION VALVE 35 PULL BUTTON ACTIVATED
13.1 GPM (49,6 L/min) @ 3270 Pump RPM PORT: 4000 PSI (275,79 bar) DIRECTIONAL CONTROL VALVE:
3 CHARGE PUMP: Lift Arm Bypass Valve
19 ANTICAVITATION VALVE
6.4GPM (24,2 L/min) @ 3270 Pump RPM
36 FILTER BOB-TACH: 100 Mesh
4 RELIEF / REPLENISHING VALVE HIGH 20 LOAD CHECK VALVE
PRESSURE: 4250 PSI (293 bar)
21 QUICKCOUPLER MALE 37 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE
5 RELIEF VALVE CHARGE INLET: HYDRAULIC POWERED BOB-TACH VALVE: 30 PSI (2 bar)
290 PSI (20 bar) 22 QUICKCOUPLER FEMALE 38 RESTRICTION:
6 BIDIRECTIONAL HYDROSTATIC DRIVE MOTOR: 0.089 Inch (2,26 mm)
211.6 GPM (801,2 L/min) @ 3270 Pump RPM 23 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE: Bucket Positioning 39 RESTRICTION: 0.025 Inch (0,6 mm)
7 DRIVE MOTOR SHUTTLE VALVE On / Off
40 SOLENOID ACTIVATED DIRECTIONAL
24 FLOW DIVIDER ADJUSTMENT VALVE Dealer Copy -- Not for Resale
8 SHUTTLE RELIEF VALVE: CONTROL VALVE
220 PSI (15,2 bar) 25 PILOT ACTIVATED DIRECTIONAL CONTROL 41 RELIEF VALVE: 1200 PSI (85 bar)
VALVE: FLOW CONTROL SPOOL
9 FILTER - CASE DRAIN: 90 micron
42 PILOT OPEREATED CHECK VALVE:
26 CHECK VALVE BUCKET POSITION VALVE
85 PSI (5,5 bar)
10 FILTER CHARGE: 20 micron Nom,
40 micron Abs 27 43
PILOT ACTIVATED DIRECTIONAL RELIEF VALVE: 2000 PSI (137 bar)
CONTROL VALVE: UNLOADING SPOOL
11 FILTER BYPASS VALVE: 40 PSI (2,76 bar)
28 TILT CYLINDER 44 CHECK VALVE: 300 PSI (20,7 bar)
12 ATMOSPHERIC RESERVOIR
29 LIFT CYLINDER
45 RESTRICTION:
13 FILTER HYDRAULIC: 11 micron 0.016 Inch (0,4 mm)
30 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE: BICS Cartridge
46 POWER BOB-TACH CYLINDER: Optional
14 FILTER BYPASS VALVE: 50 PSI (3,45 bar)
31 SOLENOID AVTIVATED DIRECTIONAL
15 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE BICS Control
40 PSI (2,76 bar) 32 INLET SCREEN / FILTER

16 OIL COOLER 33 CHECK VALVE: Inside of Inlet Fitting


NOTE: Unless otherwise specified, springs have
NO significant pressure value.

V-0887 legend (01-01-09)


Printed in Europe

85 of 521
HYDRAULIC/HYDROSTATIC SCHEMATIC
S100 (S/N A2G811001 AND ABOVE)
(S/N A8ET11001 A8ET19999)
(PRINTED JANUARY 2009)
(V-0887)
QUICK COUPLERS
(FRONT AUXILIARY LEFT SIDE LIFT ARM)

MALE
HYDRAULIC FILTER
16
13
21
OIL
DRIVE MOTOR 12 14 COOLER

FEMALE

22
7 8 15

BUCKET POSITION VALVE (OPTIONAL)

D
26
6

B A HYDRAULIC
46 24
POWERED
BOB-TACH
HYDRAULIC AND (OPTIONAL)
HYDROSTATIC PUMPS
42 43 A
1 HYDRAULIC CONTROL VALVE
4 4 23 C
25
44
5 41
39 27
45
40 38
AUXILIARY
36 SPOOL B
B A

CHARGE 37
INLET
Dealer Copy -- Not for Resale
1
TILT CYLINDERS
19 20 BICS CONTROL VALVE

4 4
28
D C

2 TILT CYLINDER
B A SPOOL 30

3 OUTLET
INLET

19 20 28
18

LIFT CYLINDERS
6 18
30
LIFT CYLINDER
B A SPOOL

29

9
20
7 8 IN-LINE FILTER
10 34 33
17 32 31

DRIVE MOTOR LIFT ARM BY PASS VALVE

11 35

V-0887 (01-01-09)

86 of 521
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols


SYMBOL DESCRIPTION SYMBOL DESCRIPTION

FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS

WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed


Solid Line - Working (Main) Line, Restriction - Affected by Viscosity
Return Line (line conducting fluid (property of resistance to flowing
from working devices to the reservoir) fluid).
and Feed line (main line conductor).
VARIABLE ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
PILOT PRESSURE - Dashed Line -
Pilot Line (Line which conducts TEMPERATURE CONTROL -
control fluid). (Indication of temperature).

DRAIN CIRCUITS - Dotted Line -


TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.
FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).

OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies


Connected). electric signal with pressure.

DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting fitting SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.

PRESSURE SWITCH - Switch


activates when pressure reaches
specified level.

MUFFLER (silencer) - Reduces


noise.

87 of 521 20-10-1 S100 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONTD)

Glossary Of Hydraulic / Hydrostatic Symbols (Contd)


SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS


linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward CONTROL VALVE WITH DETENT
strokes). (Holds Valve in Position) - device for
maintaining a given position
DOUBLE ACTING HYDRAULIC (mechanical).
CYLINDER, UNEQUAL
DISPLACEMENT - With single piston CONTROL VALVE ACTIVATED BY A
rod. PULL BUTTON (manual).

DOUBLE ACTING HYDRAULIC


CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY A
DISPLACEMENT and CUSHION ON PUSH-PULL BUTTON (manual).
ONE END - With single piston rod.

CONTROL VALVE ACTIVATED BY A


LEVER (manual).
PUMP: To convert mechanical energy into hydraulic
energy.
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
CONTROL VALVE WITH SPRING
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).

MOTOR: To convert hydraulic energy into rotary CONTROL VALVE ACTIVATED BY A


mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).

FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY


BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).

88 of 521 20-10-2 S100 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONTD)

Glossary Of Hydraulic / Hydrostatic Symbols (Contd)


SYMBOL DESCRIPTION SYMBOL DESCRIPTION

NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for the
allows free flow in one direction only. opening (fully or restricted) or the closing of one or more
flow paths (represented by several squares).

NON-RETURN VALVE (Check Valve) TWO PORTS and CLOSED FLOW


OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-
RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST

O
IS
D

FRONT

BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).

STEERING CONTROL VALVE


(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.

89 of 521 20-10-3 S100 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONTD)

Glossary Of Hydraulic / Hydrostatic Symbols (Contd)


SYMBOL DESCRIPTION SYMBOL DESCRIPTION

PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS


control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.

RELIEF / REPLENISHING VALVE or


RELIEF / ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.

DUAL PRESSURE RELIEF VALVE -


When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.

LOCK VALVE - hydraulic pressure is


applied to open the valve to allow the
hydraulic cylinder to move.

FLOW CONTROL VALVE: Valve controlling the flow in


one or both directions.

ONE WAY RESTRICTOR VALVE


(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.

TOW VALVE - Normally in closed


position.

LOAD SENSE BLEED VALVE -


Regulates small amount of fluid flow
(leakage).

90 of 521 20-10-4 S100 Service Manual


HYDRAULIC SYSTEM INFORMATION (CONTD)

Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285

If the service code appears in the left instrument panel,


refer to the Electrical Service Manual for the probable
cause.

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
bypass valve stuck. 12
bypass valve stem bent or broke. 13

KEY TO CORRECT THE CAUSE


1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid.
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.

91 of 521 20-10-5 S100 Service Manual


92 of 521 20-10-6 S100 Service Manual
CYLINDER (LIFT) Figure 20-20-2

Testing

2
WARNING
1
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention P-45266
from a physician familiar with this injury.
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.
Figure 20-20-1
Connect the negative ground cable to the battery.

Engage the parking brake. Lower the seat bar. Start the
engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.

Repeat the procedure to check the other lift cylinder.

P-45265

WARNING
Lower the lift arms. Stop the engine. Pull up the lift arm
bypass control to release the hydraulic pressure. AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Check only one cylinder at a time. Open the rear door. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Disconnect the negative ground cable from the battery. explosion or fire.
W-2103-0508

Disconnect the hose (Item 1) [Figure 20-20-1] from the lift


cylinder base end port.

93 of 521 20-20-1 S100 Service Manual


CYLINDER (LIFT) (CONTD) Figure 20-20-4

Removal And Installation

The removal procedure will be explained for the right lift


cylinder. The removal of the other cylinder is similar.
1
Figure 20-20-3

S3467

Remove the retainer bolt (Item 1) and nut (Item 2) [Figure


20-20-4] from the lift arm pins (both rod and base end).

Installation: Tighten the bolt and nut to 25-28 ft.-lb. (35-


S4344 38 Nm) torque.

NOTE: Remove the air cleaner (See Removal And


Stop the engine. Pull up the lift arm bypass control to Installation on Page 20-110-2) to remove the
release the hydraulic pressure. right rear pivot pin. The pin must be driven out
from the engine compartment.
Open the rear door and disconnect the negative ground
cable from the battery. Figure 20-20-5

Disconnect and plug the hoses (Item 1) [Figure 20-20-3]


from the lift cylinder.

S4324

To remove the lift cylinder rod end pivot pin use a pin
puller (Item 1) [Figure 20-20-5].

94 of 521 20-20-2 S100 Service Manual


CYLINDER (LIFT) (CONTD)

Parts Identification

1. Rod 9. Tube Line Assy


2. Wiper Seal 10. Plug
3. Rod Seal 11. O-ring
4. Head 12. Nut
5. O-ring 13. O-ring
6. Bacup ring 14. Spacer
7. O-ring
8. Cylinder

S4379

95 of 521 20-20-3 S100 Service Manual


CYLINDER (LIFT) (CONTD) Figure 20-20-7

Disassembly And Assembly


4
Use the following tools to service the cylinder:
3
2
MEL1074 - O-ring Seal Hook.
1
Spanner Wrench.

MEL1033 - Rod Seal Installation Tool.

MEL1396 - Seal Installation Tool.

Piston Ring Compressor.


P-48036
Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
damage. Replace any damaged parts. and head (Item 4) [Figure 20-20-7].

Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-20-7] to
600 ft.-lb. (814 Nm) torque.
Lubricate all O-rings and seals with hydraulic oil during
installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit. Use
Hold the hydraulic cylinder over a drain pan and move the locktite while tightening the nut.
rod in and out slowly to remove the fluid from the cylinder.
Figure 20-20-8
Put the base end of the cylinder in a vise.

Figure 20-20-6 2

2
1 1

P-48038

P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
20-8] from the piston.

Use a spanner wrench to loosen the head (Item 1) NOTE: If the fiber surface (Item 3) [Figure 20-20-8] on
[Figure 20-20-6] from the cylinder case. the piston head, becomes damaged, the
complete piston head must be replaced.
Assembly: Tighten the head with a spanner wrench until
the head is seated all the way into the cylinder (Item 1)
[Figure 20-20-6].

96 of 521 20-20-4 S100 Service Manual


CYLINDER (LIFT) (CONTD) Figure 20-20-11

Disassembly And Assembly (Contd)

Figure 20-20-9
1

P-48040

Remove the wiper seal (Item 1) [Figure 20-20-11] from


P7424 the cylinder head.

Figure 20-20-12
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-9]. Allow the
seal to stretch for 30 seconds before installing it on the
piston. 2

Once the seal is installed on the piston, a piston ring


compressor can be used on the piston for 3 minutes to
compress the seal into place.
1
Figure 20-20-10

P-48041A P-48042

Assembly: Install the wiper seal, with the wiper side of


the seal (Item 1), toward the outside of the head (Item 2)
2 [Figure 20-20-12].

P-48039

Remove the two O-rings (Item 1) and the back-up washer


(Item 2) [Figure 20-20-10] from the cylinder head.

97 of 521 20-20-5 S100 Service Manual


CYLINDER (LIFT) (CONTD) Figure 20-20-15

Disassembly And Assembly (Contd)

Figure 20-20-13

P7425

Assembly: Install the rod seal in the head. Rotate the


P-48042 handles to collapse the rod seal.

Reverse the disassembly procedure to assemble the lift


Remove the rod seal (Item 1) [Figure 20-20-13] from the cylinder.
cylinder head.

Figure 20-20-14

P-48043A P7427

Assembly: Install the rod seal on the rod seal tool


[Figure 20-20-14].

NOTE: During installation the spring side of the seal


(Item 1) [Figure 20-20-14] must be installed
toward the inside of the cylinder.

98 of 521 20-20-6 S100 Service Manual


CYLINDER (TILT) Removal And Installation

Testing

Remove the attachment. Roll the Bob-Tach fully back.


Stop the engine. Raise the seat bar. WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
WARNING sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
Hydraulic fluid escaping under pressure can have W-2103-0508
sufficient force to enter a persons body by
penetrating the skin. This can cause serious injury
Removal procedure will be explained for the right tilt
and possible death if proper medical treatment by a
cylinder. Removal procedure for the left cylinder is similar.
physician familiar with this injury is not received
immediately.
Figure 20-21-2
W-2145-0290

Figure 20-21-1

S4300

S4220 Remove the attachment. Roll the Bob-Tach forward and


lower the lift arms.
Disconnect the hose which goes to the base end of the tilt
Place the Bob-Tach flat on a pallet to allow the tilt cylinder
cylinder (Item 1) [Figure 20-21-1].
base end pin enough clearance to be removed [Figure
20-21-2].
Install a cap on the hose fitting and tighten.
Stop the engine. Move the tilt pedal to release the
Engage the parking brake. Lower the seat bar.
hydraulic pressure. Raise the seat bar.
Start the engine and push the Press to Operate button.
Push the bottom (heel) of the tilt pedal.

If there is leakage from the open port, remove the tilt


cylinder for repair.

99 of 521 20-21-1 S100 Service Manual


CYLINDER (TILT) (CONTD) Figure 20-21-5

Removal And Installation (Contd)


2
Figure 20-21-3

1
2

S4321

Remove the retainer bolt (Item 2) and nut (Item 1) [Figure


S4220 20-21-5] from the rod end pivot pin.

Remove the rod end pivot pin.


Disconnect both hydraulic hoses (Items 1 and 2) [Figure
20-21-3]. Remove the cylinder.

Figure 20-21-4

WARNING
1
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
2
explosion or fire.
W-2103-0508

S4309

Remove the retainer nut (Item 1) and bolt (Item 2) [Figure


20-21-4] from the cylinder rod end pivot pin. Drive the pin
through with a punch.

Installation: Tighten the retainer nut to 25-28 ft.-lb. (34-


38 Nm) torque.

100 of 521 20-21-2 S100 Service Manual


CYLINDER (TILT) (CONTD)

Parts Identification

1. Piston 9. Back-up ring


2. O-ring 10
. O-ring
3. Seal 11. Head
4. Nut 12. Wiper Seal
5. Plug 13. Rod Seal
6. O-ring 14. Rod
7. Cylinder
8. O-ring

S4378

101 of 521 20-21-3 S100 Service Manual


CYLINDER (TILT) (CONTD) Figure 20-21-7

Disassembly And Assembly


3
Use the following tools to service the cylinder: 2

MEL1074 - O-ring Seal Hook.


1
Spanner Wrench.

MEL1033 - Rod Seal Installation Tool.

MEL1396 - Seal Installation Tool.

Piston Ring Compressor.


P-48071
Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other Remove the nut (Item 1), piston (Item 2) and head (Item
damage. Replace any damaged parts. 3) [Figure 20-21-7].

Always install new O-rings and seals during assembly. Assembly: Tighten the nut (Item 1) [Figure 20-21-7] to
100 ft.-lb. (136 Nm) torque.
Lubricate all O-rings and seals with hydraulic oil during
installation. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. Figure 20-21-8

Put the base end of the cylinder in a vise.

Figure 20-21-6

P-48088 P-48089

Assembly: Mark the end of the shaft and nut. Tighten the
P-48034
nut an additional 135 degrees or 2-1/4 flats [Figure 20-
21-8]. Use locktite while tightening the nut.

Use a spanner wrench to loosen the head (Item 1)


[Figure 20-21-6] from the cylinder case.

Assembly: Tighten the head with a spanner wrench until


the head is seated all of the way into the cylinder (Item 2)
[Figure 20-21-6].

102 of 521 20-21-4 S100 Service Manual


CYLINDER (TILT) (CONTD) Figure 20-21-11

Disassembly And Assembly (Contd)


1
Figure 20-21-9

2
2

P-48039

Remove the two O-rings (Item 1) and the back-up washer


P-48073 (Item 2) [Figure 20-21-11] from the cylinder head.

Figure 20-21-12
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
21-9] from the piston.

Figure 20-21-10
1

P-48040

Remove the wiper seal (Item 1) [Figure 20-21-12] from


P7424 the cylinder head.

Assembly: Install the new seal on the tool and slowly


stretch it until it fits the piston [Figure 20-21-10]. Allow the
seal to stretch for 30 seconds before installing it on the
piston.

Once the seal is installed on the piston, a piston ring


compressor can be used on the piston for 3 minutes to
compress the seal into place.

103 of 521 20-21-5 S100 Service Manual


CYLINDER (TILT) (CONTD) Figure 20-21-15

Disassembly And Assembly (Contd)

Figure 20-21-13
1

P-48043 P7427

Assembly: Install the rod seal on the rod seal tool


P-48041 P-48042 [Figure 20-21-15].

NOTE: During installation the spring side of the seal


Install the wiper seal, with the wiper side of the seal (Item (Item 1) [Figure 20-21-15] must be installed
1) toward the outside of the head (Item 2) [Figure 20-21- toward the inside of the cylinder.
13].
Figure 20-21-16
Figure 20-21-14

P7425
P-48042

Assembly: Install the rod seal in the head. Rotate the


Remove the rod seal (Item 1) [Figure 20-21-14] from the handles to collapse the rod seal [Figure 20-21-16].
cylinder head.

104 of 521 20-21-6 S100 Service Manual


CYLINDER (BOB-TACH) Figure 20-22-1

Testing

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire. 1
W-2103-0508
S5919

Tilt the Bob-Tach forward, so it is parallel to the floor

WARNING [Figure 20-22-1].

Disconnect the hose (Item 1) [Figure 20-22-1] from the


AVOID INJURY OR DEATH power Bob-Tach cylinder base end port.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or Install a plug in the hose (Item 1) [Figure 20-22-1] and
death. Fluid leaks under pressure may not be visible. tighten.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid Engage the parking brake. Lower the seat bar. Start the
enters skin or eyes, get immediate medical attention engine.
from a physician familiar with this injury.
W-2072-0807 Push and hold the BOB-TACH WEDGES UP Switch
(Front Accessory Panel).

If there is any leakage from the base end cylinder port


(Item 2) [Figure 20-22-1], remove the Bob-Tach cylinder
for repair.

The verification of the rod end side of the cylinder is


similar.

105 of 521 20-22-1 S100 Service Manual


CYLINDER (BOB-TACH) (CONTD) Figure 20-22-3

Removal And Installation

Figure 20-22-2

1 1

S5918

2
1 Remove the bolts (Item 1) [Figure 20-22-3].
S5919
Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm)
torque.
Disconnect and cap the hoses (Items 1 and 2) [Figure 20-
22-2] from the cylinder fittings. Remove the washers and cylinder from the lever pivots.

Cap the fittings. Remove the cylinder.

106 of 521 20-22-2 S100 Service Manual


CYLINDER (BOB-TACH) (CONTD)

Parts Identification

1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod

3
2
14
13 12
11
10
9
8 7 6
5
4

15

PE1064

107 of 521 20-22-3 S100 Service Manual


CYLINDER (BOB-TACH) (CONTD) Figure 20-22-5

Disassembly and Assembly


4 3 2
Use the following tools to service the cylinder:
1
MEL1074 - O-ring Seal Hook
Spanner Wrench
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.
P16294

Always install new O-rings and seals during assembly.


Remove the head and rod assembly from the cylinder
Lubricate all O-rings and seals with hydraulic oil during [Figure 20-22-5]. Put the rod end in a vise.
installation.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Hold the hydraulic cylinder over a drain pan and move the and head (Item 4) [Figure 20-22-5] from the rod.
rod in and out slowly to remove the fluid from the cylinder.
Assembly: Grease the piston where the nut contacts the
Put the base end of the cylinder in a vise. piston. Do not get grease on the threads. Install the new
nut (Item 1) [Figure 20-22-5]. Use locktite while tightening
Figure 20-22-4 the nut.

2 Assembly: Tighten the nut to 90 ft.-lb. (122 Nm) torque.

Figure 20-22-6

3
2
1
1
4

P-43212

Use a spanner wrench to loosen the head (Item 1)


[Figure 20-22-4].
P16295

Assembly: Tighten the head with a spanner wrench until


the head is seated all of the way into the cylinder (Item 2) Remove the O-ring (Item 1), and seal (Item 2) from the
[Figure 20-22-4]. piston (Item 3) [Figure 20-22-6].

NOTE: The piston center hole (Item 4) [Figure 20-22-6]


has a bevel on one end. The bevel goes toward
the rod when assembling.

108 of 521 20-22-4 S100 Service Manual


CYLINDER (BOB-TACH) (CONTD) Figure 20-22-9

Disassembly And Assembly (Contd)

Figure 20-22-7
1

P-48040

Remove the wiper seal (Item 1) [Figure 20-22-9] from the


P7424 cylinder head.

Figure 20-22-10
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-22-7]. Allow the
seal to stretch for 30 seconds before installing it on the
piston. 2

Once the seal is installed on the piston, a piston ring


compressor can be used on the piston for 3 minutes to
compress the seal into place.
1
Figure 20-22-8

P-48041A P-48042

Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2 10].

P-48039

Remove the two O-rings (Item 1) and the back-up washer


(Item 2) [Figure 20-22-8] from the cylinder head.

109 of 521 20-22-5 S100 Service Manual


CYLINDER (BOB-TACH) (CONTD) Figure 20-22-13

Disassembly And Assembly (Contd)

Figure 20-22-11

P7425

Assembly: Install the rod seal in the head. Rotate the


P-48042 handles to collapse the rod seal [Figure 20-22-13].

Reverse the disassembly procedure to assemble the Bob-


Remove the rod seal (Item 1) [Figure 20-22-11] from the Tach cylinder.
cylinder head.

Figure 20-22-12

P-48043A P7427

Assembly: Install the rod seal on the rod seal tool


[Figure 20-22-12].

NOTE: During installation the spring side of the seal


(Item 1) [Figure 20-22-12] must be installed
toward the inside of the cylinder.

110 of 521 20-22-6 S100 Service Manual


MAIN RELIEF VALVE Figure 20-30-1

Description

The main relief valve limits the hydraulic system pressure


by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
2 1
The main relief valve is adjustable and is located on the
hydraulic control valve near the bottom, facing the front of
the loader.

Testing

S2851

IMPORTANT Connect the IN port (Item 1) [Figure 20-30-1] of the


hydraulic tester to the bottom (female) quick coupler on
The hydraulic tester must be in the fully open position the loader.
before you start the engine.
I-2024-0284 Connect the OUT port (Item 2) [Figure 20-30-1] of the
hydraulic tester to the top (male) quick coupler on the
loader.

Figure 20-30-2
WARNING
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284

WARNING
Put jackstands under the front axles and rear corners S0186

of the frame before running the engine for service.


Failure to use jackstands can allow the machine to fall
Move the handle all the way to the right, to put the control
or move and cause injury or death.
valve in the locked position for a constant flow of hydraulic
W-2017-0286
fluid under pressure to the quick couplers [Figure 20-30-
2].
The tools listed will be needed to do the following
procedure: Move the handle out of the locked position before leaving
the operator cab.
MEL10003 - Hydraulic Tester

MEL10006 - Hydraulic Test Kit

Turn the key switch to the OFF position. To release the


hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for three
seconds.

Lift and block the loader (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

111 of 521 20-30-1 S100 Service Manual


MAIN RELIEF VALVE (CONTD) Removal And Installation

Testing (Contd) Raise the operator cab (See Raising on Page 10-30-1.)

Watch the flow meter on the hydraulic tester to make sure Figure 20-30-4
the flow is correct. Increase the engine speed to full RPM.

Refer to Specifications, for both flow and pressure


specifications of the hydraulic system (See Hydraulic
System on Page SPEC-10-3.).

Check the free flow specification.

Turn the restrictor control, on the tester, until the main


relief valve opens. Check the relief pressure.
1
If the relief pressure is not correct, stop the engine and
adjust the main relief valve.

Adjusting
S4268

Figure 20-30-3
Clean the area around the control valve. Loosen and
remove the main relief valve (Item 1) [Figure 20-30-4].

Remove the O-rings and back-up washers [Figure 20-30-


O-ring 3].

Clean the main relief valve in clean solvent. Use air


pressure to dry the valve.
1
Install new O-rings and back-up washers. Install the main
relief valve (Item 1) [Figure 20-30-4] and tighten. Check
Back-up the pressure again.

Installation: Tighten the main relief valve to 35-40 ft.-lb.


B-6764 (47-54 Nm) torque.

If the pressure is not correct, adjust the main relief valve.


Remove the end cap (Item 1) [Figure 20-30-3].
WARNING
Turn the adjusting screw in or out until the pressure is
correct. AVOID INJURY OR DEATH
Instructions are necessary before operating or
NOTE: If the correct pressure can not be reached, servicing machine. Read and understand the
replace the main relief valve. Check the Operation & Maintenance Manual, Operators
pressure setting of the new relief valve. Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807

112 of 521 20-30-2 S100 Service Manual


HYDRAULIC CONTROL VALVE Lift and block the loader .

Description Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
The hydraulic control valve is located inside the main 20-1).
frame, below the operator cab.
Raise the operator cab (See Raising on Page 10-30-1).
The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the Clean the area around the control valve.
lift, tilt and auxiliary functions.
Drain the hydraulic reservoir (See Removing And
The lift and tilt functions are operated using mechanical Replacing Hydraulic Fluid and Case Drain Filters on Page
linkages to connect the foot pedals to the lift and tilt 10-120-2).
spools.
Open the rear door of the loader.
The auxiliary functions are operated using mechanical
linkages to connect the right steering lever to the auxiliary NOTE: Before disconnecting the tubelines, first mark
spool. Move the lever to the right or left to activate the the tubelines and the fittings to make sure the
auxiliary hydraulics. tubelines are on the right fitting when
reconnecting.
The hydraulic control valve contains a main relief valve
which is adjustable. Remove the bucket position valve (See Removal And
Installation on Page 20-110-1).
Removal And Installation
Figure 20-40-1

WARNING
Never work on a machine with the lift arms up unless
S4268
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the right and left steering linkage (Item 1)
to fall and cause injury or death. [Figure 20-40-1] by removing the bolts and nuts on both
W-2059-0598 ends of the steering linkage.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

113 of 521 20-40-1 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) Figure 20-40-4

Removal And Installation (Contd)

Figure 20-40-2

1
1 1 2 2

1
S4183

Remove the bar (Item 1) that connects the control valve


S4180 with the lever. Also remove the two chain links (Item 2)
[Figure 20-40-4].

Disconnect the three plugs (Item 1) [Figure 20-40-2] from Figure 20-40-5
the hydraulic control valve.

Figure 20-40-3 1

6 11 7
12 1
9
10

5 1
4

3 2
S2906

8
S4181 Remove the two screws (Item 1) [Figure 20-40-5].

Installation: Tighten the bolts to 40-50 ft.-lb. (54-68 Nm)


Disconnect the 12 hydraulic tubelines (Items 1 to 12) torque.
[Figure 20-40-3] from the hydraulic control valve.

Upon disconnection, cap the tubeline and the fitting on the


hydraulic control valve.

114 of 521 20-40-2 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD)

Removal And Installation (Contd)

Figure 20-40-6

S4184

Remove the hydraulic control valve from the loader by


means of a hoist [Figure 20-40-6].

NOTE: Make sure the hydraulic control valve is well


supported when putting it down.

115 of 521 20-40-3 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD)

Identification Chart

Figure 20-40-7

G1 E2 C1
J1 F4
F5
J3 B1 MR
E3 F3
A1
H1
H2

E1
B2
A2

A3
B3 D1 F1
E1 D5
C3 C2
D3 F2 D4
D2 J4 J5
J2

S5948

ITEM S100 LOADER ITEM S100 LOADER


A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool / Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Lift Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function F5 Auxiliary Spool
C3 Load Check Valve Auxiliary Function G1 BICS Valve Solenoid
D1 Anti-Cavitation Valve
Lift (Rod End) H1 BICS Lock Valve (Tilt)
D2 Port Relief / Anti-Cavitation Valve 3500 PSI H2 BICS Lock Valve (Lift)
Lift (Base End)
J1 Inlet Fluid Flow (From Pump)
D3 Port Relief / Anti-Cavitation Valve 3500 PSI
Tilt (Base End) J2 Outlet Fluid Flow (Return to Tank)
D4 Port Relief / Anti-Cavitation Valve 3500 PSI J3 Lift Arm bypass Orifice
Tilt (Rod End) J4 Hydraulic Reservoir
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) J5 Lift Arm bypass Valve (Drain)
3500 PSI (Optional)
MR Main Relief Valve 2700 PSI

116 of 521 20-40-4 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) NOTE: The tilt and auxiliary load check valves are
interchangeable.
Load Check Valve Removal And Installation (Tilt and
Auxiliary) Figure 20-40-9

Figure 20-40-8
2 1 3

1
2
2
1

S4188

S4185

Pull the springs (Item 1) and poppets (Item 2) [Figure 20-


40-9] out of the hydraulic control valve.
Locate the tilt section load check valve (Item 1) [Figure
20-40-8] on the hydraulic control valve. Check the orifice in the poppet to be sure it is not plugged.
Locate the auxiliary section load check valve (Item 2) Installation: Install a new O-ring (Item 3) [Figure 20-40-
[Figure 20-40-8] on the hydraulic control valve. 9] on the plug and lightly lubricate with oil before installing
and tighten the plug to 38-45 ft.-lb. (52-61 Nm) torque.

117 of 521 20-40-5 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) Figure 20-40-11

Anti-Cavitation Valve Removal And Installation (Lift,


Rod End)
3
Figure 20-40-10
2
1

1 S4203

Remove the spring (Item 1) and poppet (Item 2) [Figure


20-40-11].
S4201

Check the orifice in the poppet to be sure it is not plugged.


Remove the lift section anti-cavitation valve (Item 1)
Installation: Install a new O-ring (Item 3) [Figure 20-40-
[Figure 20-40-10] from the control valve.
11] on the plug and lightly lubricate with oil before
installing. Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

118 of 521 20-40-6 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End) Figure 20-40-14

Figure 20-40-12

1
S5922

S5922
Loosen the tilt circuit port relief / anti-cavitation valve (Item
1) [Figure 20-40-14] from the control valve.
Loosen the lift circuit port relief / anti-cavitation valve (Item
1) [Figure 20-40-10] from the control valve. Figure 20-40-15

Figure 20-40-13

S4202

S4202
Replace the O-ring (Item 1) [Figure 20-40-17] before
installation.
Replace the O-ring (Item 1) [Figure 20-40-17] before
installation. Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

119 of 521 20-40-7 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) Port Relief Valve Removal And Installation

Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-18


Installation (Tilt, Rod End)

Figure 20-40-16

S4201

S4201 Remove the port relief plug (Item 1) [Figure 20-40-18]


from the control valve.

Remove the tilt port relief / anti-cavitation valve (Item 1) Figure 20-40-19
[Figure 20-40-16] from the control valve.

Figure 20-40-17

1
S4204

S4202 Installation: Always use new O-rings (Item 1) [Figure 20-


40-19].Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

Replace the O-ring (Item 1) [Figure 20-40-17] before


installation.

Installation: Tighten to 38-45 ft.-lb. (52-61 Nm) torque.

120 of 521 20-40-8 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) End Cap / Spool Lock Block Removal And Installation

Rubber Boot Removal And Installation Figure 20-40-21

Figure 20-40-20
1
2
3
1

S4189

S4189
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-21] from the
Remove the four screws (Item 1) [Figure 20-40-20] on the end cap / spool lock block.
rubber boot retainer plate.
Remove the four end cap / spool lock block mount screws
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3 (Item 3) [Figure 20-40-21].
Nm) torque.
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Remove the rubber boots (Item 2) [Figure 20-40-20] from Nm) torque.
the retainer plate.
Remove the rubber boots and retainer plate from the lift
and tilt spools.

Figure 20-40-22

S4200

Remove the end cap / spool lock block (Item 1) [Figure


20-40-22] from the control valve.

121 of 521 20-40-9 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONTD) Figure 20-40-25

Lift Spool And Detent Removal And Installation

The tool listed will be needed to do the following


procedure:

MEL 1278 - Detent Tool

MEL 1285 - Detent Spring Tool


1
Remove the end cap / spool lock block from the control 2
valve (See End Cap / Spool Lock Block Removal And
Installation on Page 20-40-9).

Figure 20-40-23 S5925

Use a screwdriver to remove the snap ring (Item 1)


[Figure 20-40-25].

Remove the washer (Item 2) [Figure 20-40-25].


2
1 Figure 20-40-26

S5923

1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-23] from the lift spool.

Figure 20-40-24
1 2
S5926

1
Remove the screws (Item 1) [Figure 20-40-26] from the
detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-40-26].

Installation: Lubricate the screws and tighten to 90-100


in.-lb. (10-11,3 Nm) torque.

S5924
IMPORTANT
Remove the end cap (Item 1) [Figure 20-40-24].
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284

122 of 521 20-40-10 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-29

Lift Spool And Detent Removal And Installation


(Cont'd)

Figure 20-40-27

S5929

Remove the lift spool assembly and seal (Item 1) [Figure


20-40-29] from the control valve.
S5927
Figure 20-40-30

Put a rag around the detent assembly [Figure 20-40-27].


This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.

Figure 20-40-28

S5930
3 2 1

Remove the lift spool seal (Item 1) [Figure 20-40-30] from


the linkage end of the valve.

2 S5928

Remove the detent sleeve (Item 1), detent balls (Item 2)


and spring (Item 3) [Figure 20-40-28].

123 of 521 20-40-11 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-33

Lift Spool And Detent Removal And Installation


(Cont'd)

Figure 20-40-31

1
2
N-18916

Put a rag around the detent assembly [Figure 20-40-33].


This will prevent the detent balls and spring from being
P-8988 lost when the detent adapter is removed.

Remove the detent adapter with an Alan wrench.


Clamp the linkage end of the spool in a vise [Figure 20-
40-31]. Remove the back-up washer (Item 1) and spool seal (Item
2) [Figure 20-40-33].
NOTE: Protect spool before clamping in vise.
Figure 20-40-34
Figure 20-40-32

2 1

1
3

N-19004
N-18915

Remove the detent adapter (Item 1) [Figure 20-40-34]


Install the spring tool (Item 1) [Figure 20-40-32] over the from the spring assembly.
centering spring.

NOTE: Be careful when removing the detent adapter


(Item 2) [Figure 20-40-32] from the centering
spring, as it is under spring pressure.

NOTE: The centering spring (Item 3) [Figure 20-40-32]


is white on all 700 series loaders.

124 of 521 20-40-12 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-37

Lift Spool And Detent Removal And Installation


(Cont'd)

Figure 20-40-35

N-18918

Remove the stud from the end of the spool [Figure 20-40-
37].
N-19009
Figure 20-40-38

Remove spring tool (Item 1) [Figure 20-40-35] from the


spring assembly.

Figure 20-40-36

1
2
3

N-18920

Removal of the plastic plug:

N-18919A Make a center point in the plug using a 1/16 inch drill.

Drill a hole all the way through the plug using a 7/64 inch
Inspect the adapter (Item 1), collar (Item 2), spring (Item tap drill
3) and washer (Item 4) [Figure 20-40-36].
Turn a 6-32 tap (Item 1) [Figure 20-40-38] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE LOCTITE ON THE STUD


THREADS.

125 of 521 20-40-13 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-41

Lift Spool And Detent Removal And Installation


(Cont'd) O-Ring

Figure 20-40-39

2
Plastic
1 Plug
0.60 inch
(15,2 mm)

B-14712

Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
N-18961 20-40-41].

Figure 20-40-42
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-40-39].

NOTE: Check the O-ring for damage. The lift spool will
have an internal leak if there is damage to this
O-ring. Always replace the o-ring and recheck 1
the lift spool before the control valve is
replaced.

Figure 20-40-40

N-18967

Clamp the collar (Item 1) [Figure 20-40-42] in a vise.

N-18963

Install the plastic plug and O-ring in the spool [Figure 20-
40-40].

126 of 521 20-40-14 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-45

Lift Spool And Detent Removal And Installation


(Cont'd)

Figure 20-40-43
1

N-19004
1 3
2 Install the spring tool (Item 1) [Figure 20-40-45] over the
washer, spring, collar and detent adapter.
N-18958
Figure 20-40-46

Apply grease on all the detent component surfaces before


assembly [Figure 20-40-43].

Install the spring (Item 1) and detent balls (Item 2) into the 2
adapter (Item 3) [Figure 20-40-43] and compress with the
detent pliers (Item 1) [Figure 20-40-44].

Figure 20-40-44

N-18917

Install the spool seal (Item 1) and back-up washer (Item 2)


[Figure 20-40-46].
1

N-18968

Install the detent adapter to the collar [Figure 20-40-44].

NOTE: The collar and the detent adapter are held


together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

127 of 521 20-40-15 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-49

Lift Spool And Detent Removal And Installation


(Cont'd)

Figure 20-40-47

N-19007

Hold the detent balls in place with the detent pliers


[Figure 20-40-49].
N-19005
Figure 20-40-50

Install the spring assembly to the lift spool hand tight


[Figure 20-40-47].

Remove the spring tool.

Check the alignment of the detent adapter and the


washer.
1
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 Nm).

NOTE: The adapter must fit in the center of the washer


(Item 1) [Figure 20-40-47].

Figure 20-40-48 N-19008

Install the detent sleeve (Item 1) [Figure 20-40-50] to the


detent adapter.

CD-15051

Install the detent balls and spring [Figure 20-40-48].

128 of 521 20-40-16 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-53

Lift Spool And Detent Removal And Installation


(Cont'd)
1
Figure 20-40-51

1
S5924

Install the end cap (Item 1) [Figure 20-40-53].


1 2
S5926 Figure 20-40-54

Install the lift spool assembly in the spool bore [Figure 20-
40-51].

Install the detent bonnet (Item 1) [Figure 20-40-51].

Install the mounting screws (Item 2) [Figure 20-40-51].

Installation: Lubricate the screws and tighten to 90-100


in.-lb. (10-11,3 Nm) torque.
1
Figure 20-40-52

S5930

Install the spool seal (Item 1) [Figure 20-40-54] on the


linkage end of the valve.

1
2

S5925

Install the washer (Item 1) and snap ring (Item 2) [Figure


20-40-52].

129 of 521 20-40-17 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-57

Lift Spool And Detent Removal And Installation


(Cont'd)

Figure 20-40-55

2 2
1

3
S5932

Install the end cap / spool lock block (Item 1) [Figure 20-
40-57].
S5923
Install the lift and tilt spool rubber boots and mount plate
(Item 2) and install the four mounting screws (Item 3)
Install the O-ring (Item 1) and bushing (Item 2) [Figure [Figure 20-40-57].
20-40-55] on the lift spool.
Installation: Tighten the screws to 90-100 in.-lb. (10-11,3
Figure 20-40-56 Nm) torque.

Figure 20-40-58

1
2

S5931

S5933
Install the O-ring (Item 1) [Figure 20-40-56] on the control
valve.
Use an Ohm meter to measure the lock solenoid coils
resistance.

The correct resistance for the coil is 5.5 0.28 Ohms.

Installation: Install the lift spool (Item 1) and tilt spool


(Item 2) [Figure 20-40-58] lock solenoids and tighten to
35-45 ft.-lb. (52-61 Nm) torque.

130 of 521 20-40-18 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-61

Tilt Spool Removal And Installation

Remove the lift and tilt end cap / spool lock block. (See
End Cap / Spool Lock Block Removal And Installation on
Page 20-40-9.)

Figure 20-40-59

1
2

S5936

1 2 Use a screwdriver to remove the snap ring (Item 1)


[Figure 20-40-61].

Remove the washer (Item 2) [Figure 20-40-61].

S5934 Figure 20-40-62

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-40-59] from the tilt spool.

Figure 20-40-60

S5937

Remove the three bolts (Item 1) [Figure 20-40-62] from


the spool centering block and remove the spool centering
block.
S5935
Installation: Tighten the bolts to 90-100 in.-lb. (10-11,3
Nm) torque.
Remove the end cap (Item 1) [Figure 20-40-60].

131 of 521 20-40-19 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-65

Tilt Spool Removal And Installation (Cont'd)

Figure 20-40-63 1

N-18942

Put the linkage end of the spool in the vise [Figure 20-40-
S5938 65].

Install the spool tool (Item 1) [Figure 20-40-65] over the


Check and replace the O-ring (Item 1) [Figure 20-40-63] centering spring.
before replacing the spool centering block.
Figure 20-40-66
Figure 20-40-64

N-19014
S5939

Remove the bolt (Item 1) [Figure 20-40-66] holding the


Remove the tilt spool, centering spring, back-up washer centering spring to the spool.
and spool seal [Figure 20-40-64].
Installation: Tighten the bolt to 90-100 in.-lb. (10,2-11,3
Installation: Always use a new spool seal. Nm) torque.

Remove spring tool from the spring assembly.

132 of 521 20-40-20 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Auxiliary Spool Removal And Installation

Tilt Spool Removal And Installation (Cont'd) The tool listed will be needed to do the following
procedure:
Figure 20-40-67
MEL 1278 - Detent Tool

1 MEL 1285 - Detent Spring Tool


2
3 Remove the end cap / spool lock block from the control
valve (See End Cap / Spool Lock Block Removal And
Installation on Page 20-40-9).
4
Figure 20-40-69

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item 1
3) and washer (Item 4) [Figure 20-40-67].

Figure 20-40-68

2
1 S5941

Remove the spacer (Item 1) [Figure 20-40-69] from the


auxiliary spool.

Figure 20-40-70

S5940 N-18943
1

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-40-68].

Installation: Always use a new spool seal.

S5935

Remove the end cap (Item 1) [Figure 20-40-70].

133 of 521 20-40-21 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-73

Auxiliary Spool Removal And Installation (Cont'd)

Figure 20-40-71

1
2
S5938

Check and replace the O-ring (Item 1) [Figure 20-40-73]


S5936 before replacing the spool centering block.

Figure 20-40-74
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-71].

Remove the washer (Item 2) [Figure 20-40-71].

Figure 20-40-72

1 S5942

Put a rag around the detent assembly [Figure 20-40-74].


This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
S5937

Remove the three bolts (Item 1) [Figure 20-40-72] from


the spool centering block and remove the spool centering
block.

Installation: Tighten the bolts to 90-100 in.-lb. (10-11,3


Nm) torque.

134 of 521 20-40-22 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-77

Auxiliary Spool Removal And Installation (Cont'd)

Figure 20-40-75

3 2
1 1

S5945
2

Remove the auxiliary spool seal (Item 1) [Figure 20-40-


S5943 77] from the linkage end of the valve.

Figure 20-40-78
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-75].

Figure 20-40-76

1
P-8988

Clamp the linkage end of the spool in a vise [Figure 20-


S5944 40-78].

NOTE: Protect spool before clamping in vise.


Remove the auxiliary spool assembly and seal (Item 1)
[Figure 20-40-76] from the control valve.

135 of 521 20-40-23 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-81

Auxiliary Spool Removal And Installation (Cont'd)


1
Figure 20-40-79

1
3

N-19004

Remove the detent adapter (Item 1) [Figure 20-40-81]


N-18915 from the spring assembly.

Figure 20-40-82
Install the spring tool (Item 1) [Figure 20-40-79] over the
centering spring.
1
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-79] from the centering
spring, as it is under spring pressure.

NOTE: The centering spring (Item 3) [Figure 20-40-79]


is white on all 700 series loaders.

Figure 20-40-80

N-19009

Remove spring tool (Item 1) [Figure 20-40-82] from the


spring assembly.

1
2
N-18916

Put a rag around the detent assembly [Figure 20-40-80].


This will prevent the detent balls and spring from being
lost when the detent adapter is removed.

Remove the detent adapter with an Alan wrench.

Remove the back-up washer (Item 1) and spool seal (Item


2) [Figure 20-40-80].

136 of 521 20-40-24 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-85

Auxiliary Spool Removal And Installation (Cont'd)

Figure 20-40-83

1
2
3

1
4

N-18920

Removal of the plastic plug:


N-18919A
Make a center point in the plug using a 1/16 inch drill.

Inspect the adapter (Item 1), collar (Item 2), spring (Item Drill a hole all the way through the plug using a 7/64 inch
3) and washer (Item 4) [Figure 20-40-83]. tap drill

Figure 20-40-84 Turn a 6-32 tap (Item 1) [Figure 20-40-85] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
break the tap.

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE LOCTITE ON THE STUD


THREADS.

Figure 20-40-86

2
1
N-18918

Remove the stud from the end of the spool [Figure 20-40-
84].

N-18961

Install the O-ring (Item 1) over the nipple on the plastic


plug (Item 2) [Figure 20-40-86].

NOTE: Check the O-ring for damage. The auxiliary


spool will have an internal leak if there is
damage to this O-ring. Always replace the o-
ring and recheck the auxiliary spool before the
control valve is replaced.

137 of 521 20-40-25 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-89

Auxiliary Spool Removal And Installation (Cont'd)

Figure 20-40-87

N-18967

Clamp the collar (Item 1) [Figure 20-40-89] in a vise.


N-18963
Figure 20-40-90

Install the plastic plug and O-ring in the spool [Figure 20-
40-87].

Figure 20-40-88 2

O-Ring

1 3
2

Plastic N-18958
Plug
0.60 inch
(15,2 mm) Apply grease on all the detent component surfaces before
assembly [Figure 20-40-90].
B-14712
Install the spring (Item 1) and detent balls (Item 2) into the
adapter (Item 3) [Figure 20-40-90] and compress with the
Install the stud and tighten until the other end of the stud detent pliers (Item 1) [Figure 20-40-91].
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-88].

138 of 521 20-40-26 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-93

Auxiliary Spool Removal And Installation (Cont'd)

Figure 20-40-91
2

1 N-18917

Install the spool seal (Item 1) and back-up washer (Item 2)


N-18968 [Figure 20-40-93].

Figure 20-40-94
Install the detent adapter to the collar [Figure 20-40-91].

NOTE: The collar and the detent adapter are held


together by spring pressure when assembled
to the auxiliary spool not the detent balls. Hold
the detent adapter and collar together to
prevent the detent balls and spring from falling
1
out.

Figure 20-40-92

N-19005
1
Install the spring assembly to the auxiliary spool hand
tight [Figure 20-40-94].

Remove the spring tool.

Check the alignment of the detent adapter and the


washer.
N-19004
Tighten the adapter to 90-100 in.-lb. (10,2-11,3 Nm).

Install the spring tool (Item 1) [Figure 20-40-92] over the NOTE: The adapter must fit in the center of the washer
washer, spring, collar and detent adapter. (Item 1) [Figure 20-40-94].

139 of 521 20-40-27 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-97

Auxiliary Spool Removal And Installation (Cont'd)

Figure 20-40-95

N-19008

Install the detent sleeve (Item 1) [Figure 20-40-97] to the


CD-15051 detent adapter.

Install the detent balls and spring [Figure 20-40-95].

Figure 20-40-96

N-19007

Hold the detent balls in place with the detent pliers


[Figure 20-40-96].

140 of 521 20-40-28 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-100

Solenoid Removal And Installation

Figure 20-40-98
1
1

S4186

Remove the solenoid stem (Item 1) [Figure 20-40-100].


S4185
Installation: Lubricate the O-rings and tighten the stem to
20-24 ft.-lb. (27-33 Nm) torque.
Remove the nut (Item 1) [Figure 20-40-98] from the
solenoid stem. Figure 20-40-101

Installation: Tighten the nut to 53 in.-lb. (6 Nm) torque.

Remove the solenoid coil (Item 2) [Figure 20-40-98].


1 1 1
Figure 20-40-99

1
2 2

S4187

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-40-101] from the cartridge.

N-18693A
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any showing


Remove the O-rings (Item 1) [Figure 20-40-99] from both excessive wear.
ends of the solenoid coil.
NOTE: The screen (Item 3) [Figure 20-40-101] may be
Use an Ohm meter to measure the solenoid coil cleaned with solvent. If it is torn or worn it
resistance. needs to be replaced.

The correct resistance for the coil is 9.79 0.29 Ohms. Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-40-99] and


[Figure 20-40-101] and new back-up rings (Item 2)
[Figure 20-40-101] on the solenoid stem.

141 of 521 20-40-29 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-104

Lock Valve Removal And Installation


1
Figure 20-40-102 1
1 1

2
1

2 2 2

S4194

Remove the O-rings (Item 1) and back-up rings (Item 2)


S4185 [Figure 20-40-104] from the lift lock valve, and replace
with new.

Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-102] is for the lift circuit.

Figure 20-40-103

S4193

Remove the lift lock valve (Item 1) [Figure 20-40-103]


from the back of the control valve.

Installation: Lightly lubricate the lock valve O-rings and


tighten to 20-24 ft.-lb. (27-33 Nm) torque.

142 of 521 20-40-30 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D) Figure 20-40-107

Lock Valve Removal And Installation (Contd)

Figure 20-40-105

S5946

Remove the tilt lock valve (Item 1) [Figure 20-40-107]


S4189 from the front of the control valve.

Installation: Lightly lubricate the lock valve O-rings and


Locate the tilt circuit lock valve (Item 1) [Figure 20-40- tighten to 20-24 ft.-lb. (27-33 Nm) torque.
105].
Figure 20-40-108
Figure 20-40-106

1
1
1 1

1
2 2 2

S4194
S4191

Remove the O-rings (Item 1) and back-up rings (Item 2)


Remove the lift spool lock solenoid (Item 1) [Figure 20- [Figure 20-40-108] from the tilt lock valve, and replace
40-106]. with new.

Remove the tilt spool lock solenoid (Item 2) [Figure 20-


40-106].

Installation: Lubricate the O-rings and tighten the spool


lock solenoids to 38-45 ft.-lb. (52-61 Nm) torque.

143 of 521 20-40-31 S100 Service Manual


HYDRAULIC CONTROL VALVE (CONT'D)

Main Relief Valve Removal And Installation

Figure 20-40-109

S4191

Remove the main relief valve (Item 1) [Figure 20-40-109].

Figure 20-40-110

S4192

Remove the O-rings (Item 1) [Figure 20-40-110] from the


main relief valve.

Installation: Always use new O-rings. Tighten main relief


valve to 38-45 ft.-lb. (52-61 Nm) torque.

144 of 521 20-40-32 S100 Service Manual


LIFT ARM BYPASS CONTROL VALVE Removal and Installation

Description

The lift arm bypass control valve is located on the right


side of the machine close to the engine speed control.

The lift arm bypass control valve is manually operated by


pulling up on the Control Knob (Item 1) [Figure 20-50-1]
and turning the knob clockwise a 1/4 turn. The valve
releases the hydraulic fluid from the base end of the lift
cylinder(s) which allows the lift arm to slowly lower to the
transport position.

Testing
WARNING
Figure 20-50-1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1 W-2059-0598

Install jack stands under the rear corners of the loader.

Start the engine. Raise the lift arms and install an


approved lift arm support device (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.)

Raise the operator cab (See Raising on Page 10-30-1.)


S4225

Figure 20-50-2
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm bypass Control Knob (Item 1)
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm bypass Control Knob until the lift arms
slowly lower. 1

The knob should return to its initial position.

S4225

Hold the Lift Arm bypass Control knob (Item 1) [Figure


20-50-2] and loosen the jam nut on the Lift Arm bypass
valve shaft.

145 of 521 20-50-1 S100 Service Manual


LIFT ARM BYPASS CONTROL VALVE (CONTD) Figure 20-50-5

Removal And Installation (Contd)

Figure 20-50-3

1
1 2

S4228

Remove the two mounting bolts / nuts (Item 1) [Figure 20-


S4226 50-5].

Installation: Tighten the mounting bolts to 180-200 in.-lb.


Remove the Lift Arm bypass Control knob (Item 1) and (21-23 Nm) torque.
the jam nut (Item 2) [Figure 20-50-3] from the Lift Arm
bypass valve shaft. Figure 20-50-6

Figure 20-50-4

2 3
1

S4229

S2910
Remove the lift arm bypass control valve (Item 1) [Figure
20-50-6].
Disconnect the base end lift tubeline (Item 1) [Figure 20-
50-4] from the Lift Arm bypass valve. Remove the rubber washer (Item 2) [Figure 20-50-6].

Disconnect the motor case drain hose (Item 2) [Figure


20-50-4].

146 of 521 20-50-2 S100 Service Manual


LIFT ARM BYPASS CONTROL VALVE (CONTD)

Disassembly And Assembly

Figure 20-50-7

2 3
1

S4229

Remove the bypass valve (Item 1) from the valve block


(Item 3) [Figure 20-50-7]. Inspect the bypass valve for
damage and replace if necessary.

Installation: Tighten the valve to 33-37 ft.-lb. (45-50 Nm)


torque.

Inspect the hydraulic fittings on the valve block for


damage and replace if necessary.

147 of 521 20-50-3 S100 Service Manual


148 of 521 20-50-4 S100 Service Manual
HYDRAULIC PUMP This procedure will require one operator in the cab and
one operator running the tester.
Description
Start the engine and run at low idle. Press the Front
The hydraulic gear pump is attached to the end of the Auxiliary button. Engage the front auxiliary with the trigger
hydrostatic pumps and is located on the right side of the on the right handle. Make sure the tester is connected
loader between the hydraulic control valve and the engine. correctly. If no flow is indicated on the tester, the hoses
are connected wrong. With the hoses connected correctly,
The hydraulic gear pump is a combination of gear pumps increase the engine speed to full RPM.
that provide hydraulic flow to several hydraulic systems.
Warm the fluid to 140F (60C) by turning the restrictor
The hydraulic gear pump has a dedicated charge pump. control clockwise on the tester so it reads about a 1000
This supplies charge pressure to the hydrostatic pump. PSI (69 bar).

A seal kit is available to service the hydraulic pump. If any NOTE: DO NOT EXCEED 3300 PSI.
of the main components of the pump are damaged, the
entire pump must be replaced. Turn the restrictor control (Item 2) [Figure 20-60-1] on the
tester counterclockwise to obtain free flow, the flow should
Pump Test at Quick Couplers be approximately 16-17 GPM (60,6-64,5 L/min).

The tools listed will be needed to do the following Start turning the restrictor clockwise, causing more
procedure: restriction on the flow. The GPM should drop off slightly
until the pressure reaches approximately 2400 PSI (165
MEL10103 - Hydraulic Tester bar). At approximately 2400 PSI (165 bar) the flow should
MEL10106 - Hydraulic Test Kit start decreasing rapidly until the pressure reaches 2650-
2750 PSI (183-190 bar). At 2650-2750 PSI (183-190 bar)
Figure 20-60-1 the flow should be at 0 GPM (0 L/min). Turn the restrictor
(Item 2) [Figure 20-60-1] counterclockwise to free flow.
Shut the front auxiliary hydraulics off.
1
If flow and pressure specs are not obtained, go to Direct
Pump Testing. (See Direct Pump Test on Page 20-60-2.)

P-16903 S6029

NOTE: When testing the hydraulic flow of a machine,


hoses must be at least 3/4 inch (19 mm) in
diameter and connected directly to the
hydraulic tester without using any type of
quick coupler on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 50 GPM (189 L/min).

Install a hydraulic tester (Item 1) [Figure 20-60-1] onto


the front auxiliary quick couplers.

149 of 521 20-60-1 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-2

Direct Pump Test

The tools listed will be needed to do the following


procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

1
WARNING
S4268
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286 tubeline on the control valve.

Figure 20-60-3
Lift and block the loader (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)

Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) 2 1

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm S5999
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Connect the INLET hose from the tester to the OUTLET
hose (Item 1) [Figure 20-60-2] and [Figure 20-60-3] of
Raise the operator cab (See Raising on Page 10-30-1.) the pump.

Open the rear door of the loader. Connect the OUTLET hose (Item 2) [Figure 20-60-2] and
[Figure 20-60-3] from the tester to the tubeline on the
Connect the remote start tool (See Remote Start control valve.
Procedure on Page 10-60-4.)

150 of 521 20-60-2 S100 Service Manual


HYDRAULIC PUMP (CONTD) flow (GPM). The high pressure flow must be at least 80%
of free flow.
Direct Pump Test (Contd)
HIGH PRESSURE FLOW (GPM)
%= X 100
FREE FLOW (GPM)

IMPORTANT A low percentage may indicate a failed pump.

*Refer to (See Hydraulic System on Page SPEC-10-3.) for


The hydraulic tester must be in the fully open position
system relief pressure and full RPM.
before you start the engine.
I-2024-0284
Direct Pump Test (Charge Section)

Figure 20-60-4 The tools listed will be needed to do the following


EXAMPLE: TESTER procedure:
CONNECTION
MEL1563 - Remote Start Tool
Reservoir MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
6661247 - Filter Assembly
17 KB 1212 - Elbow Fitting
15 KB 1212 - Straight Fitting
15 KB 0812 - Reducer Fitting

Hydraulic Pump
Out In Hydraulic Control
Valve
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
1 Failure to use jackstands can allow the machine to fall
or move and cause injury or death.
W-2017-0286
BH-196

Lift and block the loader (See LIFTING AND BLOCKING


Sample tester connection shown [Figure 20-60-4]. THE LOADER on Page 10-10-1.)

Start the engine and run at low idle RPM. Make sure the Raise the lift arms and install an approved lift arm support
tester is connected correctly. If no flow is indicated on the device (See LIFT ARM SUPPORT DEVICE on Page 10-
tester, the hoses are connected wrong. With the hoses 20-1.)
connected correctly, increase the engine speed to full
RPM*.

Warm the fluid to 140F (60C) by turning the restrictor


control (Item 1) [Figure 20-60-4] on the tester to about
1000 PSI (68,95 bar).
WARNING
Never work on a machine with the lift arms up unless
DO NOT exceed system relief pressure. Open the the lift arms are secured by an approved lift arm
restrictor control and record the free flow (GPM) at full support device. Failure to use an approved lift arm
RPM*. support device can allow the lift arms or attachment
to fall and cause injury or death.
Push the maximum / variable flow switch (on the remote W-2059-0598
start tool) to engage the front auxiliary hydraulics, the light
will come ON. Push the button (on the right control lever)
for fluid flow to the quick coupler (fluid pressure will go
over main relief). Record the highest pressure (PSI) and

151 of 521 20-60-3 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-7

Direct Pump Test (Charge Section) (Contd)

NOTE: The fluid from the charge pump must be filtered


after it passes through the Hydraulic Tester, to
1
prevent any contamination to the Hydrostatic
Pumps.

Raise the operator cab (See Raising on Page 10-30-1.)

Open the rear door of the loader.


3
Connect the remote start tool (See Remote Start 2
Procedure on Page 10-60-4.)
P-39248
Figure 20-60-5

Install the fitting (15KB 1212-Straight Fitting) (Item 2)


2 [Figure 20-60-7] in the filter housing inlet.

Install the fitting (15KB 0812-Reducer Fitting) (Item 3)


3 4 [Figure 20-60-7] in the filter housing outlet.

1 Figure 20-60-8

P-39250 1

Assemble the filter assembly (Item 1), elbow fitting (Item


2), straight fitting (Item 3) and the reducer fitting (Item 4)
[Figure 20-60-5].

Figure 20-60-6
S4269

Disconnect the OUTLET hose (Item 1) [Figure 20-60-8]


from the charge pump.

1
1

P-39247

Determine the proper direction of oil flow through the filter


housing (Item 1) [Figure 20-60-6] and [Figure 20-60-7].

152 of 521 20-60-4 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-10

Direct Pump Test (Charge Section) (Contd)

Figure 20-60-9

P-39255A

Be sure all connections are tight and that the hoses are
S4270 not touching any moving parts before starting the loader
[Figure 20-60-10].

Connect the inlet hose from the hydraulic tester to the Start the engine and run at low idle RPM. Make sure the
outlet fitting (Item 1) [Figure 20-60-9] of the charge pump. tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
Connect the outlet fitting on the hydraulic filter to the hose connected correctly, increase the engine speed to full
that was removed from the charge pump. RPM*.

Connect the outlet hose on the hydraulic tester to the inlet Warm the fluid to 140F. (60C.) by turning the restrictor
fitting on the hydraulic filter assembly. control (Item 1) [Figure 20-60-10] on the tester to about
1000 PSI (68,95 bar). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM*.

Turn the restrictor down to system operating pressure. DO


NOT EXCEED SYSTEM RELIEF PRESSURE. Refer to
Hydraulic Schematics for pressure. The high pressure
flow must be at least 80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X 100
FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to (See Hydraulic System on Page SPEC-10-3.) for


system relief pressure and full RPM.

**Refer to the Hydraulic Schematics for pump flow and


RPM.

153 of 521 20-60-5 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-11

Removal And Installation 1

1
S4205

IMPORTANT
Remove the hydraulic reservoir bracket by removing the
When repairing hydrostatic and hydraulic systems, two screws (Item 1) [Figure 20-60-11].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Figure 20-60-12
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Lift and block the loader (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Raise the lift arms and install an approved lift arm support 1
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

Raise the operator cab (See Raising on Page 10-30-1.)


S4206
Open the rear door of the loader.

Remove the hydraulic reservoir (See Removal And


Disconnect the two outlet tubelines from the hydraulic
Installation on Page 20-90-1).
pump by loosening the nuts (Item 1) [Figure 20-60-12].

154 of 521 20-60-6 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-15

Removal And Installation (Contd) 11

Figure 20-60-13 2.5


1-1/2 I.S. Dia.
2-1/2 O.S. Dia.

2.5

1-1/2 Square Tubing 1/4 (4)


1 1/4 Wall Thickness Thick Gusset

1
16

1 9
S4207 45

Disconnect the inlet tubeline (Item 1) [Figure 20-60-13]


between the engine and the pump assembly from the 4
hydraulic pump. 1
0.5
1
Figure 20-60-14
0.375
Use two 3/8x1 Bolts for Drilled and Tapered Holes S5906

A tool needs to be fabricated to use in the removal


procedure. This tool allows the engine / hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
dimensions shown in [Figure 20-60-15] to make the
engine removal tool. (See Engine Removal And
Installation on Page 70-10-9.)

Figure 20-60-16
1 1

S4744

Remove the four engine mounts (Item 1) [Figure 20-60-


14].

Installation: Tighten the engine mount bolts to 70 ft.-lb.


(95 Nm) torque.

S2903

Install the chain on the engine as shown in [Figure 20-60-


16].

NOTE: You may need to adjust the chain which


fastens to the engine a couple of times to
reach the correct lifting position.

155 of 521 20-60-7 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-19

Removal And Installation (Contd)

Figure 20-60-17
1

S4207

Remove the hydraulic pump from the loader by removing


S2904 the two screws (Item 1) [Figure 20-60-19].

Installation: Tighten to 55-60 ft.-lb. (75-85 Nm) torque.


Lift the engine / hydrostatic pump assembly over a height
of approximately 1/5 in. (0,5 mm) [Figure 20-60-17].

Push the engine / hydrostatic pump assembly to the side


to make sure there is enough space to remove the
hydraulic pump from the assembly.

Figure 20-60-18

S4745

Put a wooden block between the engine mount socket


(Item 1) [Figure 20-60-18] pump assembly and the side
of the frame to make sure the engine / hydrostatic pump
assembly will stay in its place.

156 of 521 20-60-8 S100 Service Manual


HYDRAULIC PUMP (CONTD)

Parts Identification

1. Bolt (8)
2. Washer
3. Shaft seal
4. Washer
5. Pump Flange Section
6. Plug
7. O-ring
8. Pre-Load Seal
9. Load Seal
10. Wear plate
11. Drive Gear
12. Key
13. Idler Gear
14. Hydraulic Pump Section
15. O-ring
16. Pump Center Section
17. O-ring
18. Drive Gear NOT AVAILABLE AT TIME
19. Idler Gear OF PRINTING
20. Pre-Load Seal
21. Load Seal
22. Wear plate
23. Charge Pump Section
24. O-ring
25. Pump End Section

S4746

157 of 521 20-60-9 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-21

Disassembly And Assembly

Figure 20-60-20 1

1 3
1

S4209

Remove the pump flange section (Item 1) and the


S4208 hydraulic pump section (Item 2) from the pump center
section (Item 3) [Figure 20-60-21].
Mark the pump sections for correct assembly [Figure 20-
Remove both intermediate O-rings.
60-20].
Figure 20-60-22
Loosen the eight pump housing bolts (Item 1) [Figure 20-
60-20].

Installation: Tighten to 34 to 38 ft.-lb. (25 to 28 Nm)


torque.
1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly S4749
damage the system.
I-2003-0888
Remove the shaft seal (Item 1) [Figure 20-60-23] from
the pump flange section.

158 of 521 20-60-10 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-25

Disassembly And Assembly (Contd)


1
Figure 20-60-23

2
S4212

Figure 20-60-26
S6033

Remove the wear plate (Item 1) and the bushings (Item 2)


1
[Figure 20-60-23] from the pump end section and check
for wear. Replace if needed.

Figure 20-60-24

S4213

Remove the gear and axle (Item 1) [Figure 20-60-25] and


[Figure 20-60-26] from the pump center section.

Inspect the gear and axle (Item 1) [Figure 20-60-26].


Replace if needed.
S4748

Remove the load and preload seals (Item 1) [Figure 20-


60-23] from the wear plate.

159 of 521 20-60-11 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-29

Disassembly And Assembly (Contd)

Figure 20-60-27
1

S4216

Remove the bushings (Item 1) [Figure 20-60-29] from the


S4214 pump center section and check for wear. Replace if
needed.

Remove the pump center section (Item 1) [Figure 20-60- Figure 20-60-30
27] with drive gear and drive shaft by lifting it up.

Figure 20-60-28

1
1

S4217

3
Inspect the drive gear and drive shaft (Item 1) [Figure 20-
S4215
60-30] for wear. Replace if needed.

Remove the section seal (Item 1) [Figure 20-60-28] from


the pump center section.

Remove the pin (Item 2) from the drive shaft (Item 3)


[Figure 20-60-28] and remove the drive shaft by pulling it
out of the bushing.

160 of 521 20-60-12 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-33

Disassembly And Assembly (Contd)


1
Figure 20-60-31

S4219

Figure 20-60-34
S4218

Remove the wear plate (Item 1) [Figure 20-60-31] from 1


the pump lower section.

Figure 20-60-32

S4213

Remove the gear and axle (Item 1) [Figure 20-60-33] and


[Figure 20-60-34] from the pump lower section.

Inspect the gear and axle (Item 1) [Figure 20-60-34] for


S4748 wear. Replace if needed.

Remove the load and preload seals (Item 1) [Figure 20-


60-23] onto the wear plate.

161 of 521 20-60-13 S100 Service Manual


HYDRAULIC PUMP (CONTD) Figure 20-60-37

Disassembly And Assembly (Contd)

Figure 20-60-35
1

S4223

Remove the section seal (Item 1) [Figure 20-60-37] from


S4221 the pump end section

Figure 20-60-38
Remove the drive gear (Item 1) [Figure 20-60-35] from
the charge pump section.

Inspect the drive gear for wear and replace if needed.

Figure 20-60-36

S4224

Remove the bushings and check for wear. Replace if


needed [Figure 20-60-38].

S4222 Hydraulic Pump Start Up

Ensure the hydraulic reservoir is filled to the correct level


Remove the charge pump section (Item 1) [Figure 20-60- before starting the engine. (See Checking And Adding
36] from the pump lower section by lifting it up Fluid on Page 10-120-1.)

162 of 521 20-60-14 S100 Service Manual


HYDRAULIC / HYDROSTATIC FILTERS Hydraulic / Hydrostatic Filter Housing Removal And
Installation
Description
Drain the hydraulic fluid reservoir.
The hydraulic / hydrostatic filters help to remove
contaminants from the hydraulic fluid when the hydraulic / Open the rear door of the loader.
hydrostatic systems are operating.
Figure 20-70-1
The hydraulic / hydrostatic filter system consists of one
hydraulic / hydrostatic filter, one fan / charge pressure
filter and two case drain filters.

The hydraulic / hydrostatic filter removes contaminants


after the oil cooler. 1

The charge pressure filter removes contaminants before


the oil enters the hydrostatic pump. 1

IMPORTANT S5973

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all
Disconnect the sensor wires (Item 1) [Figure 20-70-1]
parts clean. Always use caps and plugs on hoses,
from the hydraulic / hydrostatic filter.
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-70-2

1 2

S4105

Disconnect the tubeline (Item 1) and the hose (Item 2)


[Figure 20-70-2] from the hydraulic / hydrostatic filter.

163 of 521 20-70-1 S100 Service Manual


HYDRAULIC / HYDROSTATIC FILTERS (CONTD)

Hydraulic / Hydrostatic Filter Housing Removal And


Installation (Contd)

Figure 20-70-3

1
1

S2905

Remove the hydraulic / hydrostatic filter housing by


removing the two screws (Item 1) [Figure 20-70-3].

164 of 521 20-70-2 S100 Service Manual


HYDRAULIC FLUID RESERVOIR Stop the engine.

Description Raise the operator cab (See Raising on Page 10-30-1.)

The hydraulic fluid reservoir is a storage container for the Figure 20-80-1
loaders hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid.

The hydraulic fluid reservoir is secured to the main frame


behind the operators cab.
1
Removal And Installation

Lift and block the loader (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Start the engine. Raise the lift arms and install an


approved lift arm support device (See LIFT ARM S4131
SUPPORT DEVICE on Page 10-20-1.)

Drain the hydraulic reservoir (Item 1) [Figure 20-80-1] by


means of a hose. Make sure the reservoir is as empty as
possible.

Figure 20-80-2

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 S4132

Disconnect the hose (Item 1) [Figure 20-80-2] from the


hydraulic reservoir by loosening the strap.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

165 of 521 20-80-1 S100 Service Manual


HYDRAULIC FLUID RESERVOIR (CONTD) Hydraulic Fluid Screen

Removal And Installation (Contd) Figure 20-80-5

Figure 20-80-3

1 1

S5916

S4133
Remove the fill cap (Item 1) [Figure 20-80-5] from the
hydraulic reservoir.
Disconnect the three hydraulic tubelines (Item 1) [Figure
20-80-3] from the hydraulic reservoir. Cap the tubelines. Figure 20-80-6

Figure 20-80-4

1
1
2

S5917

S4134
Remove the hydraulic fluid screen (Item 1) [Figure 20-80-
6] from the reservoir.
Remove the bracket (Item 1) by removing the two screws
(Item 2) [Figure 20-80-4]. Wash the screen in clean solvent and air dry, before
installing.
Installation: Tighten the screws to 15-20 ft.-lb. (20-27
Nm) torque.

Remove the hydraulic reservoir.

166 of 521 20-80-2 S100 Service Manual


OIL COOLER Figure 20-90-1

Description

The oil cooler is used to cool the loaders hydraulic and


hydrostatic oil. Oil passages are coiled into a heat
exchanger. The cooling fan forces air around the
passages cooling the oil. 1

The oil cooler is located underneath the rear grill.

Removal And Installation

S4134
IMPORTANT
Disconnect the two plugs (Item 1) [Figure 20-90-1].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-90-2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2
Open the rear door of the loader.

Remove the rear grill (See Removal And Installation on


Page 50-60-1).
1 1

S4252

Disconnect the two hydraulic tubelines (Item 1) [Figure


20-90-2] from the oil cooler.

Remove the oil cooler (and frame) by removing the five


screws (Item 2) [Figure 20-90-2].

167 of 521 20-90-1 S100 Service Manual


OIL COOLER (CONTD)

Removal And Installation (Contd)

Figure 20-90-3

1 2
3

S4253

Figure 20-90-4

S6032

Remove the ventilators from the oil cooler frame by


removing the eight screws (Item 1) [Figure 20-90-3].

Remove the nuts (Item 2) [Figure 20-90-3]from the two oil


cooler fittings.

Remove the oil cooler [Figure 20-90-4] from the frame by


removing the bolts (Item 3) [Figure 20-90-3].

168 of 521 20-90-2 S100 Service Manual


BUCKET POSITION VALVE Figure 20-100-2

Description

The Bucket Position Valve is an option that allows the


loader to meter the lift and tilt circuits. The metering of the
lift and tilt circuits allows the operator to hold the
attachment in the same relative position to the ground to
maximum lift height without using the tilt function.
1
The bucket position valve is located below the operator
cab below the left side of the control panel.

See Hydraulic Schematic for more circuit information.

Solenoid Removal And Installation S4171

Figure 20-100-1
Remove the solenoid stem (Item 1) [Figure 20-100-2]
from the bucket position valve.

1 Installation: Put oil on O-rings and back-up washers and


tighten the solenoid stem to 30-35 ft.-lb. (40,8-47,6 Nm)
torque.
2
Figure 20-100-3

S4294

Raise the operator cab (See Raising on Page 10-30-1).


1
Disconnect the wire harness connector (Item 1) [Figure
20-100-1] from the bucket position shutoff solenoid.
2
Remove the solenoid nut (Item 2) [Figure 20-100-1]. S5910

Installation: Tighten the solenoid nut to 60 in.-lb. (6,78 Inspect the solenoid stem and replace the O-rings (Item
Nm) torque. 1) and back-up washers (Item 2) [Figure 20-100-3].

169 of 521 20-100-1 S100 Service Manual


BUCKET POSITION VALVE (CONTD) Start the engine.

Solenoid Testing Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
Figure 20-100-4 20-1)

Stop the engine.

Raise the operator cab (See Raising on Page 10-30-1)

Figure 20-100-5

P9175

Use a test meter to measure coil resistance [Figure 20-


100-4]. Coil wires do not have polarity. Correct resistance
for the coil is 9.7 ohms 1 ohm @ 78 F (25,5 C).
S4294
Removal And Installation
Remove the solenoid (Item 1) [Figure 20-100-5] from the
hydraulic control valve by removing the nut.

Installation: Tighten the solenoid nut to 60 in.-lb. (6,78


Nm) torque.

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

170 of 521 20-100-2 S100 Service Manual


BUCKET POSITION VALVE (CONTD) Figure 20-100-8

Removal And Installation (Contd)

Figure 20-100-6

1
S4172

Remove the hydraulic tubeline (Item 1) by loosening the


S4268 nuts (Item 2) [Figure 20-100-8]. Cap the tubeline and the
fittings after disconnection.

Remove the left steering linkage by removing the bolts Figure 20-100-9
and nuts on both ends of the steering linkage [Figure 20-
100-6].

NOTE: Before disconnecting the hydraulic tubelines


from the bucket position valve, first mark the
tubelines and the fittings of the bucket
position valve to make sure the tubelines will
be put on the right fitting while reconnecting
the tubelines. 2 1

Figure 20-100-7

S4173

Disconnect the hydraulic tubeline (Item 1) by loosening


2 the nut (Item 2) [Figure 20-100-9]. Cap the tubline and
the fitting after disconnection.
2

S4171

Remove the hydraulic tubeline (Item 1) by loosening the


nuts (Item 2) [Figure 20-100-7]. Cap the fittings and
tubeline after disconnection.

171 of 521 20-100-3 S100 Service Manual


BUCKET POSITION VALVE (CONTD) Figure 20-100-12

Removal And Installation (Contd)

Figure 20-100-10

1
1

S4176

Remove the bucket position valve with its support plate by


S4174 removing the two screws (Item 1) [Figure 20-100-12].

Figure 20-100-13
Disconnect the two hydraulic tubelines by loosening the
nuts (Item 1) [Figure 20-100-10]. Cap the tubelines and
the fittings after disconnection. 1
1
Figure 20-100-11

S4177

Remove the bucket position valve from its support plate by


removing the two screws (Item 1) [Figure 20-100-13].
S4175

Disconnect the hydraulic tubeline (Item 1) [Figure 20-


100-11] from the bucket position valve by loosening the
nut. After disconnection, cap the fitting and the tubeline.

172 of 521 20-100-4 S100 Service Manual


BUCKET POSITION VALVE (CONTD) Figure 20-100-16

Disassembly And Assembly


3
Figure 20-100-14
2

1 1

S5913

Remove the tilt cylinder check valve (Item 1), spring (Item
S5911 2) and plug (Item 3) [Figure 20-100-16]. Check for wear,
check O-ring and replace as needed.

Remove the solenoid stem (Item 1) [Figure 20-100-14]. Figure 20-100-17

Assembly: Tighten the solenoid stem to 30-35 ft.-lb.


(40,8-47,6 Nm) torque.

Figure 20-100-15

2
1

1
S5914

Remove the plug (Item 1) and the flow control spool (Item
2) [Figure 20-100-17].
S5912
Check the flow control spool for wear, check the O-ring on
the plug and replace if needed.
Remove the plug and O-ring (Item 1) [Figure 20-100-15].

NOTE: Always install new O-rings before any parts are


installed into the valve. Check the parts for
wear or damage and replace as needed.

173 of 521 20-100-5 S100 Service Manual


BUCKET POSITION VALVE (CONTD)

Disassembly And Assembly (Contd)

Figure 20-100-18

S5915

Remove the plug (Item 1), spring (Item 2) and unloading


spool (Item 3) [Figure 20-100-18].

Check all parts and replace as needed. Install a new O-


ring on the plug before installing.

174 of 521 20-100-6 S100 Service Manual


BOB-TACH (POWER) BLOCK Lift and block the loader (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1).
Description
Raise the lift arms and install an approved lift arm support
The Power Bob-Tach block is an option that allows the device (See LIFT ARM SUPPORT DEVICE on Page 10-
operator to hydraulically control the Bob-Tach levers for 20-1).
mounting and dismounting the attachments.
Raise the operator cab (See Raising on Page 10-30-1).
The Power Bob-Tach block is operated by a switch on the
front console. Drain the hydraulic reservoir.

The Power Bob-Tach block is mounted on the front right Remove the steering linkages.
side of the machine.
Figure 20-110-1
Removal And Installation

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment 1
to fall and cause injury or death.
W-2059-0598

S4390

Disconnect the Power Bob-Tach harness from the


solenoid connectors (Item 1) [Figure 20-110-1].

Figure 20-110-2

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S4391

Disconnect the hydraulic tubeline (Item 1) [Figure 20-


110-2] from the Power Bob-Tach block.

175 of 521 20-110-1 S100 Service Manual


BOB-TACH (POWER) BLOCK (CONTD) Figure 20-110-5

Removal And Installation (Contd)

Figure 20-110-3

3 S4393

Disconnect the two hoses (Item 1) [Figure 20-110-3] and


1 S4398 (Item 2) [Figure 20-110-5] from the Power Bob-Tach
block.

Figure 20-110-4 Figure 20-110-6

1
3

S2853 1 S4398

Disconnect the hose (Item 1) [Figure 20-110-3] and Remove the four mounting bolts (Item 3) [Figure 20-110-
[Figure 20-110-4] from the Power Bob-Tach block. 6].

Installation: Tighten the mounting bolts to 25-28 ft.-lb.


(34-38 Nm) torque.

Remove the Power Bob-Tach block.

176 of 521 20-110-2 S100 Service Manual


BOB-TACH (POWER) BLOCK (CONTD) Figure 20-110-8

Disassembly And Assembly

Figure 20-110-7

1
3

2
2 1 S5900

Remove the spring guide (Item 1), spring (Item 2) and the
S4399 spool (Item 3) [Figure 20-110-8].

Check the O-ring (Item 4) [Figure 20-110-8] on the plug


Clean the block (Item 1) [Figure 20-110-7] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct
assembly. Figure 20-110-9

Remove the plug (Item 2) [Figure 20-110-7].

Installation: Tighten the plug to 25-30 ft.-lb. (34-40,6


Nm) torque.

1
IMPORTANT
1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly S5901

damage the system.


I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.

Do not remove the plug (Item 1) [Figure 20-110-9].

Installation: Tighten the plug to 12-14 ft.-lb. (16,3-19


Nm) torque.

177 of 521 20-110-3 S100 Service Manual


BOB-TACH (POWER) BLOCK (CONTD) Figure 20-110-12

Disassembly And Assembly (Contd)

Figure 20-110-10

1 3
S5903

Do not remove the plugs (Item 1) [Figure 20-110-12].


S2852
NOTE: Do not remove the plugs. If the plugs are
removed the internal pressure relieving spring
Remove the check valve (Item 1) [Figure 20-110-10]. setting will be altered.

Installation: Oil the check valve and O-rings and tighten Figure 20-110-13
the check valve to 20-25 ft.-lb. (27,1-34 Nm) torque.

Figure 20-110-11

1
2 1

P-48384

3
S5902 Remove the plug (Item 1) [Figure 20-110-13], inspect the
O-ring and replace as needed.

Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-110-13]
(Item 2) [Figure 20-110-11]. to 12-14 ft.-lb. (16,3-19 Nm) torque.

Check the O-rings and back up washers (Item 3) [Figure


20-110-11] on the check valve and piston assembly and
replace as needed.

178 of 521 20-110-4 S100 Service Manual


BOB-TACH (POWER) BLOCK (CONTD) Figure 20-110-16

Disassembly And Assembly (Contd)

Figure 20-110-14

1 1 2
2
S5904

Remove the first solenoid coil (Item 1) and the second


P-48664 solenoid coil (Item 2) [Figure 20-110-16].

NOTE: Remember the solenoid coil orientation for


Remove the orifice screw (Item 1) located behind the plug ease of installation.
(Item 2) [Figure 20-110-14].
Figure 20-110-17
Installation: Tighten the orifice screw (Item 2) [Figure
20-110-14] to 6-8 ft.-lb. (8,1-10,8 Nm) torque.

Figure 20-110-15

1
1
2
P-48386

Remove the solenoid stem (Item 1) [Figure 20-110-17].


P-48127
Installation: Tighten the solenoid stem to 20-25 ft.-lb.
(27,1-34 Nm) torque.
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.

Do not remove the plug (Item 1) [Figure 20-110-15].

Remove the solenoid nut (Item 2) [Figure 20-110-15].

Installation: Tighten the solenoid valve stem nut to 15-45


in.-lb. (1,7-5,1 Nm) torque.

179 of 521 20-110-5 S100 Service Manual


BOB-TACH (POWER) BLOCK (CONTD) Figure 20-110-20

Disassembly And Assembly (Contd)

Figure 20-110-18

S5905
1

Remove the screened orifice plug (Item 1) [Figure 20-


P-48175 110-20].

Installation: Tighten the screened orifice plug to 11-12


Remove the armature rod assembly (Item 1) [Figure 20- ft.-lb. (14,9-16,3 Nm) torque.
110-18].
Figure 20-110-21
Figure 20-110-19

2
2
1
1
S4394
P-48173

Inspect the screened orifice plug (Item 1) [Figure 20-110-


Inspect the solenoid stem (Item 1), armature assembly 21] for damage and replace if needed. If the screened
(Item 2) and the spool (Item 3) [Figure 20-110-19] for orifice plug is blocked replace with a new plug.
damage.
Check the O-ring (Item 2) [Figure 20-110-21] and replace
NOTE: If the solenoid stem is damaged (Item 1) check if needed.
the armature assembly (Item 2) for damage.
The armature assembly and spool (Item 3)
[Figure 20-110-19] are non-serviceable parts. If
they are damaged, order a new power Bob-
Tach block assembly from Bobcat parts.

180 of 521 20-110-6 S100 Service Manual


FRONT AUXILIARY HYDRAULIC COUPLERS

Description

The front auxiliary hydraulic couplers supply hydraulic


flow for various attachments.

The front auxiliary hydraulic couplers are located at the


front of the machine on the left side arm.

Removal And Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-120-1

1 2

S4044

Disconnect the auxiliary tubelines (Item 1) [Figure 20-


120-1] from the coupler frame.

Remove the mounting bolt (Item 2) [Figure 20-120-1].

181 of 521 20-120-1 S100 Service Manual


182 of 521 20-120-2 S100 Service Manual
HYDROSTATIC SYSTEM

CASE DRAIN FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1


Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
HYDROSTATIC
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
SYSTEM
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1


Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Disassembly And Assembly. . . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-2

HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1


Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Hydrostatic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Replenishing / High Pressure Relief Valve Removal And Installation 30-40-1

HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 30-10-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC 01)
UNLESS OTHERWISE SPECIFIED.

183 of 521 30-01 S100 Service Manual


184 of 521 30-02 S100 Service Manual
HYDROSTATIC SYSTEM INFORMATION

Description

The hydrostatic system consists of a tandem hydrostatic


pump and two hydrostatic motors. The hydrostatic system
allows forward and reverse motion of the loader.

The hydrostatic pump is connected to the engine by a


drive belt and provides fluid to the hydrostatic motors. The
charge pressure system assists in replenishing the fluid
that is lost due to internal leakage in the components of
the hydrostatic system.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

185 of 521 30-10-1 S100 Service Manual


HYDROSTATIC SYSTEM INFORMATION (CONTD)

Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285

If the service code appears in the left instrument panel,


refer to the Electrical Service Manual for the probable
cause.

PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side, in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9

KEY TO CORRECT THE CAUSE


1. The hydrostatic pump replenishing valves are not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump is damaged.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.

186 of 521 30-10-2 S100 Service Manual


HYDROSTATIC MOTOR Figure 30-20-1

Description

The hydrostatic motors are driven by high pressure from


the hydrostatic pumps.

In this system there is a case drain filter for each motor to


filter the excess low pressure oil before the oil enters the 1
hydraulic reservoir.

The hydrostatic motors do not have an internal brake.

Removal And Installation

S4499

Remove the back wheel / tire assemblies by removing the


eight bolts (Item 1) [Figure 30-20-1].

Figure 30-20-2

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. 1
W-2059-0598

S4372

Remove the cover by removing the four bolts (Item 1)


WARNING [Figure 30-20-2].

AVOID INJURY OR DEATH


Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Lift and block the loader (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

Stop the engine.

Raise the operator cab (See Raising on Page 10-30-1.)

187 of 521 30-20-1 S100 Service Manual


HYDROSTATIC MOTOR (CONTD) Disassembly And Assembly

Removal And Installation (Contd) Figure 30-20-5

Figure 30-20-3

1
1

S4257

S4230

Remove the end cap (Item 1) from the hydrostatic motor


by removing the four bolts (Item 2) [Figure 30-20-5].
Disconnect the three hydraulic tubelines (Item 1) [Figure
30-20-3] from the hydrostatic motor. Installation: Tighten the bolts to 45-55 ft.-lb. (61-75 Nm).

Figure 30-20-4 Figure 30-20-6

1
S4231 S4258

Remove the hydrostatic motor from the loader by Remove the O-rings (Item 1) [Figure 30-20-6] from the
removing the four mounting bolts (Item 1) [Figure 30-20- end cap and check for wear. Replace if needed
4] and pulling it out of the loader.

Installation: Tighten the four hydrostatic motor mounting


bolts 90-100 ft.-lb. (122-136 Nm).

188 of 521 30-20-2 S100 Service Manual


HYDROSTATIC MOTOR (CONTD) Figure 30-20-9

Disassembly And Assembly (Contd)

Figure 30-20-7

2 S4495

Installation: The motor needs proper timing when


S4259 reassembling. The timing alignment should be as shown
above [Figure 30-20-9]. Wrong timing results in reverse
rotation of the motor.
Remove the valve (Item 1) and valve plate (Item 2)
[Figure 30-20-7] from the hydrostatic motor. Figure 30-20-10

Figure 30-20-8

2
1 1
2

S4261

S4260
Remove both inner and outer seals (Items 1 and 2) and
the two springs (Item 3) [Figure 30-20-10] from the cone.
Remove the valve (Item 1) and check the O-ring (Item 2)
[Figure 30-20-8] for wear. Replace if needed.

189 of 521 30-20-3 S100 Service Manual


HYDROSTATIC MOTOR (CONTD) Figure 30-20-13

Disassembly And Assembly (Contd)


1
Figure 30-20-11

S4271

Remove the drive shaft (Item 1) [Figure 30-20-13] from


S4497 the hydrostatic motor.

Remove the gerotor section (Item 2) [Figure 30-20-13]


Installation: Install the inner and outer seals as shown in from the hydrostatic motor.
[Figure 30-20-9]. Apply grease on the inner and outer
seals. Figure 30-20-14

NOTE:
2
Figure 30-20-12 1

S4272

1
2 NOTE: Do not disassemble the gerotor section (Item
S4262 1) [Figure 30-20-14]

Installation: Align the drain hole (Item 2)[Figure 30-20-


Remove the balance ring (Item 1) from the valve (Item 2) 14] with other sections on hydrostatic motor.
[Figure 30-20-9]. Apply grease on all seals.

190 of 521 30-20-4 S100 Service Manual


HYDROSTATIC MOTOR (CONTD) Figure 30-20-17

Disassembly And Assembly (Contd)

Figure 30-20-15

S4277

Installation: Use a hydraulic press to install the drive


S4274 shaft in the housing [Figure 30-20-17].

Figure 30-20-18
Remove the drive shaft (Item 1) [Figure 30-20-15] from
the hydrostatic motor by pulling it out.
1
Turn the hydrostatic motor upside down.
2
3
Figure 30-20-16

S4278
1
Remove the seal (Item 1) [Figure 30-20-18] from the
drive shaft and inspect for wear. Replace if needed.

2 Remove the snap ring (Item 2) [Figure 30-20-18] from the


S4275
drive shaft.

Remove the plate from the drive shaft by removing the Remove the upper bearing (Item 3) [Figure 30-20-18]
eight bolts (Item 1) [Figure 30-20-16]. from the drive shaft by pulling it back.

Remove the O-ring (Item 2) [Figure 30-20-16] and


inspect for wear. Replace if needed.

Installation: Pretighten the eight bolts to 50 ft.-lb. (6


Nm), then torque screws to 300 ft.-lb.(34 Nm).

191 of 521 30-20-5 S100 Service Manual


HYDROSTATIC MOTOR (CONTD) Figure 30-20-20

Disassembly And Assembly (Contd)

Figure 30-20-19

2
S4280

Installation: Use a hydraulic press to install the two


S4279 bearings and the ring on the drive shaft [Figure 30-20-
20].

Remove the spacer (Item 1) [Figure 30-20-19] that is


situated between the two bearings.

Remove the lower bearing (Item 2) [Figure 30-20-19]


from the drive shaft by pulling it back.

192 of 521 30-20-6 S100 Service Manual


CHARGE PRESSURE

Description

Charge pressure is a supply of oil to the hydrostatic


WARNING
pumps. Charge pressure is regulated by a charge relief
Never work on a machine with the lift arms up unless
valve located inside the hydrostatic pump. Charge
the lift arms are secured by an approved lift arm
pressure is used to replenish hydrostatic fluid removed
support device. Failure to use an approved lift arm
from the drive circuit, pump and motor internal leakage
support device can allow the lift arms or attachment
and from the hydrostatic motors shuttle (flushing) valve.
to fall and cause injury or death.
W-2059-0598
Charge pressure is obtained from the standard section on
the hydraulic gear pump.
Figure 30-30-2
Charge pressure is also used to operate other hydraulic
functions, such as shifting the auxiliary spool in the main
1
hydraulic control valve.

The charge pressure sender is located on the charge filter


housing mounted next to the blower housing. Charge
pressure alarm settings are pre-programmed into the
main controller and are based on loader type and options
installed.
3
2
Testing

Figure 30-30-1

P-43197

Connect the gauge (Item 1), to the adapter fitting (P/N


93F5) (Item 2) [Figure 30-30-2].

Connect the hydraulic hose (Item 3) [Figure 30-30-2] to


the adapter fitting. Tighten all connections.
2
Raise the loader lift arms and install an approved lift arm
3 support device. (See LIFT ARM SUPPORT DEVICE on
1
Page 10-20-1.)

Place the loader on jackstands. (See LIFTING AND


P-43196A
BLOCKING THE LOADER on Page 10-10-1.)

The tools needed to check charge pressure, hydraulic Raise the operator cab. (See Raising on Page 10-30-1.)
hose (Item 1), Hydraulic gauge 1000 PSI (68,95 bar)
(Item 2) and adapter fitting (P/N 93F-5) (Item 3) [Figure
30-30-1].

193 of 521 30-30-1 S100 Service Manual


CHARGE PRESSURE (CONTD) Sender Removal And Installation

Testing (Contd) Figure 30-30-4

Figure 30-30-3

1
1
2
S5907

S5907
Disconnect the charge pressure sender connector (Item
1) [Figure 30-30-4] from the sender.
Remove the cap (Item 1) [Figure 30-30-3] from the fitting.
Remove the sender (Item 2) [Figure 30-30-4] from the
Install the hose that is attached to the pressure gauge, to adapter fitting.
the fitting, where the cap was removed.
Installation: Tighten the charge pressure sender to 7.4-
Tighten the hydraulic fittings. 8.1 ft.-lb. (10-11 Nm) torque.

Start the loader and warm the hydraulic fluid to 140 F


(60 C).

The charge pressure at high idle, with the fluid


temperature of 140 F (60 C) is 270 PSI (20 bar) with the
pump in neutral.

194 of 521 30-30-2 S100 Service Manual


CHARGE PRESSURE (CONTD)

Adjusting

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 30-30-5

S4376

The charge pressure valve is located inside the left hand


machine side hydrostatic pump (Item 1) [Figure 30-30-5].
See page 30-40-7 for disassembly of the charge inlet
relief valve.

The charge inlet relief valve can not be adjusted.

195 of 521 30-30-3 S100 Service Manual


196 of 521 30-30-4 S100 Service Manual
HYDROSTATIC PUMP Figure 30-40-2

Description

The hydrostatic pump is composed of two hydrostatic 1


piston pumps connected together. The pumps provide bi-
directional flow to two separate hydrostatic drive motors.
The pump flow and direction are controlled by two hand
levers, one for each pump.

The hydrostatic pump contains replenishing valves. The


function of these valves is to give replacement fluid to the 2
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure S4152
fluid out of the low pressure side of the hydrostatic circuit.

The hydrostatic pump contains the charge pressure relief. Remove the replenishing / high pressure relief valve (Item
The charge pressure relief is adjustable with shims. 1) [Figure 30-40-2] from the pump.

The hydrostatic pump is located in the center of the Assembly: Tighten the plug to 30-50 ft.-lb. (41-68 Nm)
mainframe mounted to the engine flywheel housing. torque.

Replenishing / High Pressure Relief Valve Removal Check for damage and replace as needed.
And Installation
Check O-ring (Item 2) [Figure 30-40-2] for damage and
Figure 30-40-1 replace as needed.

If the replenishing / high pressure relief valve must be


replaced, it must be replaced as a complete unit.

The pressure setting for a new replenishing / high


1 pressure relief valve is 4250 PSI (293 bar).

S4147

There are four replenishing / high pressure relief valves


(Item 1) [Figure 30-40-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and
two are located at the bottom of the pumps.

NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the
forward drive loop.

197 of 521 30-40-1 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-4

Removal And Installation

IMPORTANT 2

When repairing hydrostatic and hydraulic systems,


clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S4142

Remove the engine / hydrostatic pump assembly from the


loader. (See Removal And Installation on Page 70-10-2.) Loosen the drive belt (Item 1) by pulling the tension wheel
(Item 2) [Figure 30-40-4] upwards with a handle.
Figure 30-40-3
Remove the drive belt by pulling it back from the pulleys.

Figure 30-40-5

1
S4109
1

Remove the cover on the left side of the engine by S4143


removing the two brackets (Item 1) [Figure 30-40-3].

Remove the nut and washer (Item 1) [Figure 30-40-5] by


screwing them loose.

Installation: Tighten to 175-200 ft.lb. (237-271 Nm)


torque.

198 of 521 30-40-2 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-8

Removal And Installation (Contd)

Figure 30-40-6 1
2
2
2
1

1
1

S4146
1

Remove the black cover from the pump assembly by


S4144 removing the six screws (Item 1) and loosening the two
bolts (Item 2) [Figure 30-40-8].

Install the puller (Item 1) on the hydrostatic pump drive Figure 30-40-9
pulley. Remove the drive pulley (Item 2) [Figure 30-40-6]
from the pump shaft.

Installation: Install the key in the hydrostatic pump shaft


before installing the pump drive pulley.
1
Figure 30-40-7

1 S4147

1 Remove the hydraulic pump from the pump assembly by


removing the two screws (Item 1) [Figure 30-40-9].

Installation: Tighten to 90-100 ft.lb. (125-135 Nm)


S4145 torque.

Remove the three hydrostatic pump mounting bolts (Item


1) [Figure 30-40-7] from the pump and drive belt housing.
The pump assembly (one hydraulic and two hydrostatic) is
now loose from the drive belt housing.

Installation: Tighten to 90-100 ft.lb. (125-135 Nm)


torque.

199 of 521 30-40-3 S100 Service Manual


HYDROSTATIC PUMP (CONTD)

Removal And Installation (Contd)

Figure 30-40-10

S4148

Separate the two hydrostatic pumps by removing the two


screws (Item 1) [Figure 30-40-10].

Installation: Tighten to 90-100 ft.lb. (125-135 Nm)


torque.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

200 of 521 30-40-4 S100 Service Manual


HYDROSTATIC PUMP (CONTD)

Parts Identification

1. Bolt (2)
2. Washer
3. O-ring
4. Coupler
5. O-ring
6. Replenishing/High Pressure Relief Valve
7. Pin
8. Bearing
9. Valve Plate
10. Gasket
11. Block
12. Wear Plate
13. Swash plate
14. Tapered Roller Bearing
15. Plug
16. O-ring
17. Housing
18. O-ring
19. Bearing Race
20. Cover
21. Washer
22. Bolt (6)
23. Bearing
24. Crush Ring
25. Seal
26. Cover
27. Shaft (For Left Pump)
28. Key
29. Retainer Ring
30. Bearing Thrust
31. Bearing
32. Washer
33. Seal
34. Retainer Ring
35. Shaft (For Right Pump)
36. O-ring
37. Charge Pressure Relief Valve Housing
38. Piston
39. Spring
40. Washer
41. Retainer Ring
42. Pin
43. End Cap

S4747

201 of 521 30-40-5 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-13

Disassembly
1
Figure 30-40-11

1
S4151

1
Screw the two replenishing/high pressure valves (Item 1)
1 S4149 [Figure 30-40-13] out of the end cap.

NOTE: While removing the valves, oil can be spilled.


Remove the four bolts (Item 1) [Figure 30-40-11] from the
pump housing to separate the hydrostatic pump into left Figure 30-40-14
and right.

Figure 30-40-12
1

3
1

2 S4152

S4150 Remove the spring washer (Item 1) [Figure 30-40-14] to


disassemble the valve.

Remove the valve plate (Item 1) [Figure 30-40-12] and


gasket from the smallest hydrostatic pump part. Check
the valve plate for wear (both sides).

Check the valve plate locating pin (Item 2) [Figure 30-40-


12] for wear and replace if needed.

Check the needle bearing (Item 3) [Figure 30-40-12] for


wear and replace if needed.

202 of 521 30-40-6 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-17

Disassembly (Contd)

Figure 30-40-15

S4157

Remove the block and piston assembly (Item 1) [Figure


S4155 30-40-17] from the pump by pulling it back.

Figure 30-40-18
Remove the charge inlet relief valve (Item 1) [Figure 30-
40-15].

Figure 30-40-16
1

2
2
6 5 4 3 1

S4158

Pull the ring (Item 1) and pistons (Item 2) [Figure 30-40-


S4156 18] out of the cylinder block.

Check all the pistons for wear and replace if needed.


Remove the retaining ring (Item 1) [Figure 30-40-16].

NOTE: Remove the retaining ring very carefully


because of the expanding spring.

Successively pull the washer (Item 3), spring (Item 4) and


piston (Item 5) out of the valve housing (Item 2) [Figure
30-40-16].

Remove the O-ring (Item 6) [Figure 30-40-16].

203 of 521 30-40-7 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-20

Disassembly (Contd)

Figure 30-40-19

1
2 7

5 6
1 3 4

8 S4160

S4159 Remove the retaining ring (Item 1) [Figure 30-40-20] from


the back of the pump to remove the pump shaft out of the
pump housing.
Pull the retaining ring (Item 1) out of the cylinder block
(Item 2) [Figure 30-40-19]. Figure 30-40-21

NOTE: Remove the retaining ring carefully because of


the expanding spring.

Pull the two washers (Items 3 and 4) and the spring (Item 1 2 3 4 5 4
5) [Figure 30-40-19] out of the cylinder block. 6

Remove the ball guide retainer (Item 6) [Figure 30-40-19]


from the cylinder block.

Check the ball guide retainer for wear and replace if


needed.

Pull the retainer (Item 7) out of the cylinder block and


S4161
remove the three pins (Item 8) [Figure 30-40-19].

Check the cylinder block for wear and replace if needed.


Remove the seal ring (Item 1) and the washer (Item 2)
Check the three pins to see if they are all the same length. [Figure 30-40-21] from the pump shaft.

Remove the retaining ring (Item 3) [Figure 30-40-21] from


the pump shaft.

Remove the two bearing thrusts (Items 4) and the bearing


(Item 5) from the pump shaft. Also remove the retaining
ring (Item 6) [Figure 30-40-21].

204 of 521 30-40-8 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-24

Disassembly (Contd)

Figure 30-40-22
2
1 3

S4164

Remove the O-ring (Item 1), the crush ring (Item 2) and
S4162
the bearing race (Item 3) [Figure 30-40-24] from the
cover. Inspect them and replace if needed.
Remove the bearing (Item 1) [Figure 30-40-22] from the
Figure 30-40-25
pump housing.

Figure 30-40-23

1
1

1
1

S4165

S4163
Remove the lower cover from the pump housing by
removing the three bolts (Item 1) [Figure 30-40-25].
Remove the cover from the pump housing by removing
the three bolts (Item 1) [Figure 30-40-23].

205 of 521 30-40-9 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-28

Disassembly (Contd)

Figure 30-40-26

1
1

S4168

Remove the wear plate (Item 1) [Figure 30-40-28] from


S4166 the swash plate.

Slide the swash plate from side to side and remove the
lower tapered roller bearing (Item 1) [Figure 30-40-26]
from the swash plate shaft.

Figure 30-40-27

S4167

Tilt the swash plate (Item 1) [Figure 30-40-27] and


remove the swash plate with upper tapered roller bearing
from the pump housing.

206 of 521 30-40-10 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-31

Assembly

Figure 30-40-29

1
S4165

Install the lower cover on the pump housing and tighten


S4168 the bolts (Item 1) [Figure 30-40-31] to 29 ft.-lb. (39,3
Nm).

Install the wear plate (Item 1) [Figure 30-40-29] onto the Figure 30-40-32
swash plate.

Figure 30-40-30
2
1 3

S4164

S4166
Install the O-ring (Item 1), the crush ring (Item 2) and the
bearing race (Item 3) [Figure 30-40-32] on the cover.
Install the swash plate and the upper tapered roller
bearing into the pump housing [Figure 30-40-30].

207 of 521 30-40-11 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-35

Assembly (Contd)

Figure 30-40-33
1 2 3 4 5 4 6
1
1

1
S4161

Install the retaining ring (Item 1), the two metal rings (Item
S4163 4) and the bearing (Item 5) [Figure 30-40-35] onto the
pump shaft.

Install the cover on the pump housing and tighten the Install the retaining ring (Item 3) [Figure 30-40-35] onto
bolts (Item 1) [Figure 30-40-33] to 29 ft.-lb. (39,3 Nm). the pump shaft.

Figure 30-40-34 Install the big metal ring (Item 2) and the seal ring (Item 1)
[Figure 30-40-35] onto the pump shaft.

Figure 30-40-36

1
1

S4162

Install the bearing (Item 1) [Figure 30-40-34] into the


pump housing. S4160

Install the pump shaft into the pump housing and install
the retaining ring (Item 1) [Figure 30-40-36].

208 of 521 30-40-12 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-39

Assembly (Contd)

Figure 30-40-37

2 7

5 6
1 3 4

S4157
8

Install the rotating group into the pump as shown in


S4159 [Figure 30-40-39].

Figure 30-40-40
Install the two rings (Items 3 and 4) and the spring (Item
5) [Figure 30-40-37] into the cylinder block.

Install the retaining ring (Item 1) [Figure 30-40-37] into


the cylinder block.
2
Install the three pins (Item 8) into the cylinder block and 6 5 4 3 1
put the tension ring (Item 7) [Figure 30-40-37] in its place.

Install the ball guide retainer (Item 6) [Figure 30-40-37]


into the cylinder block.

Figure 30-40-38

S4156

Install the cylindric part (Item 5), the spring (Item 4), the
the ring (Item 3) and the retaining ring (Item 1) into the
valve housing (Item 2) [Figure 30-40-40].

S4158

Install the ring and pistons into the cylinder block [Figure
30-40-38].

209 of 521 30-40-13 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-43

Assembly (Contd)

Figure 30-40-41

S4152

Assemble the parts shown in [Figure 30-40-42] to


S4155 become the part shown in [Figure 30-40-43].

Figure 30-40-44
Screw the cylinder (Item 1) [Figure 30-40-41] into the end
cap after first installing the O-ring (Item 6) [Figure 30-40-
40]. 1

Figure 30-40-42

1
S4151

Install the two valves (Item 1) [Figure 30-40-44] into the


end cap and tighten to 95-105 ft.-lb. (128,8-142,4 Nm).
S4153

210 of 521 30-40-14 S100 Service Manual


HYDROSTATIC PUMP (CONTD) Figure 30-40-47

Assembly (Contd)

Figure 30-40-45 1

1 1

1 S4149

Assemble the two pump parts by means of the four bolts


S4150
(Item 1) [Figure 30-40-47].

Tighten the bolts to 19 ft.-lb. (25 Nm) torque.


Coat the backside of the valve plate (Item 1) [Figure 30-
40-45] with petroleum jelly to hold it in position and install Hydrostatic Pump Start Up
the valve plate onto the end cap.
Follow the hydraulic pump start up procedure (See
Figure 30-40-46 Hydraulic Pump Start Up on Page 20-60-14).

S6017

Install the two pins (Items 5) and gasket (Item 3) [Figure


30-40-46] onto the pump part.

211 of 521 30-40-15 S100 Service Manual


212 of 521 30-40-16 S100 Service Manual
DRIVE BELT Adjusting

Description Figure 30-50-2

The drive belt makes the mechanical connection from the


engine flywheel to the hydrostatic pump pulley.

The belt is a cord-reinforced rubber design. 1

Constant tension is applied to the drive belt by the use of


a spring-loaded belt tensioner.

The drive belt is protected by a plastic shield fastened to


the flywheel housing by metal clips. The shield is also in
place to protect the operator.

Shield Removal And Installation


S4232
Figure 30-50-1

The adjustment of the drive belt is done automatically by


means of a spring loaded tensioner pulley (Item 1)
[Figure 30-50-2].
1

S4232

Remove the two drive belt shield mounting clips (Item 1)


[Figure 30-50-1].

Remove the belt shield.

213 of 521 30-50-1 S100 Service Manual


DRIVE BELT (CONTD) Tensioner Pulley Removal And Installation

Belt Removal And Installation Remove the drive belt from the engine (See Belt Removal
And Installation on Page 30-50-2).
Open the rear door of the loader.
Figure 30-50-4
Remove the negative (-) cable from the battery. The
battery may be removed for additional working clearance
(See Removal And Installation on Page 60-20-1.) 1

Remove the belt shield (See Shield Removal And


Installation on Page 30-50-1).

Figure 30-50-3

S4233
1

Remove the tensioner pulley from the engine by removing


the screw (Item 1) [Figure 30-50-4].

Tensioner Pulley Disassembly And Assembly

S4233 Figure 30-50-5

Loosen the drive belt (Item 1) by pulling the tension wheel


(Item 2) [Figure 30-50-3] upwards with a socket wrench.

Remove the drive belt by pulling it back from the pulleys.

Install a new drive belt.


1
Reinstall the belt shield and connect the negative (-) cable
to the battery.

S4234

Remove the bolt (Item 1) [Figure 30-50-5] from the


tensioner pulley and remove the black cover.

214 of 521 30-50-2 S100 Service Manual


CASE DRAIN FILTER Figure 30-60-3

Description

The case drain filter is an external filter assembly in the


case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete 1
assembly or disassembled to replace the element with an
element kit and/or the spring kit purchased from Bobcat
Parts.

Disassembly And Assembly

Remove the case drain filter(s) from the machine. (See


Removing And Replacing Case Drain Filter on Page 10-
120-3.)
P-76218
Figure 30-60-1
Remove the filter element and spring assembly (Item 1)
[Figure 30-60-3]

NOTE: Remember the orientation of the filter element


and spring assembly for correct assembly.

Figure 30-60-4

1
3
P-76212

1
Remove the filter housing nut (Item 1) from the filter
housing (Item 2) [Figure 30-60-1].
2
Figure 30-60-2

P-76216

The larger taper spring (Item 1) slides over the end of the
2
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-60-4] slides into the filter element.

P-76214

Remove the packing (Item 1) and O-ring (Item 2) [Figure


30-60-2] from the filter housing nut.

30-60-1 S100 Service Manual


215 of 521
30-60-2 S100 Service Manual
216 of 521
DRIVE SYSTEM

BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disk Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

CHAINCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-30-2
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-30-2
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1


Axle Seal Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2 DRIVE
Axle Sprocket And Bearings Removal And Installation . . . . . . . . . . 40-20-4 SYSTEM
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD


TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.

217 of 521 40-01 S100 Service Manual


218 of 521 40-02 S100 Service Manual
BRAKE Disk Removal And Installation

Description Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
Figure 40-10-1 20-1.)

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
1 W-2059-0598

S2849
Raise the operator cab (See Raising on Page 10-30-1.)

Disconnect and remove the engine speed control (See


Removal And Installation on Page 70-20-1.)
The brake is used to hold the machine in place. The brake
is operated by a switch (Item 1) [Figure 40-10-1] located
Remove the control panel.
on the front accessory panel.
Remove the center chaincase cover (See Center Cover
The brake is applied by a spring-loaded wedge that drops
Removal And Installation on Page 40-30-2.)
into two notched brake discs. An electric solenoid is
getting power from a relay to pull the wedge away from the
Remove the traction lock assembly (See Removal And
discs. A signal from the main Bobcat controller holds the
Installation on Page 60-110-2.)
wedge away from the discs.
Figure 40-10-2
The hold signal will be interrupted and the wedge will drop
if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.

For more information on the brake (See TRACTION


LOCK on Page 60-110-1.)
1

1 S0364

The parking brake discs (Item 1) [Figure 40-10-2] are


located beneath the center chaincase cover.

219 of 521 40-10-1 S100 Service Manual


BRAKE (CONTD) Figure 40-10-4

Disk Removal And Installation (Contd)

Figure 40-10-3

3
P-54222

1
Snap ring pliers with 90 tips is necessary for removing
N-19105 the parking brake discs.

Remove the snap ring (Item 1) from the end of the


Inspect the traction lock guides (Item 1) [Figure 40-10-3] sprocket (Item 2) [Figure 40-10-4].
and the brake discs for damage or wear and replace if
necessary. Slide the disc (Item 3) [Figure 40-10-4] off the sprocket
and remove the disc.

Reverse the removal procedure to install the disc in the


loader.

220 of 521 40-10-2 S100 Service Manual


DRIVE COMPONENTS

Description

S4265

The drive components consist of a chaincase, drive


chains, sprockets, axleshafts, hubs and a brake.

The chaincase is partially filled with hydraulic fluid to


lubricate the chains and bearings.

On the bottom of the chaincase, these is a cover for


access to the fuel tank drain plug.

221 of 521 40-20-1 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-2

Axle Seal Removal And Installation

Figure 40-20-1

1
1
P-4159

2
Install the puller tool (Item 1) [Figure 40-20-2] on the axle
P-4157 hub.

A driver tool (Item 2) [Figure 40-20-2] can be used for


The tools listed are needed for the following procedure: centering the threaded rod of the puller.

Axle Hub Puller Tool


MEL1399 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)
WARNING
To loosen the axle hub mounting bolt (Item 1) [Figure 40-
20-1], use the following procedure. NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
Before lifting and blocking the loader, loosen the hub tapered fit on the axle end and can come off the axle
mounting bolt (Item 1) [Figure 40-20-1]. with great force and cause serious injury.
W-2186-0395
NOTE: If the axle and bearings are being replaced,
also loosen the sprocket mounting bolt inside
Use a wrench with the puller and remove the axle hub
the chaincase before lifting and blocking the
from the axle tube. A spacer and a power ram MEL 1242
loader. (See Axle Sprocket And Bearings
can be used between the axle and the tool if available,
Removal And Installation on Page 40-20-4.)
instead of the wrench, threaded rod and driver tool.
Lift and block the loader (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)

Remove the front tire / wheel assembly.

Remove the hub mounting bolt (Item 1) [Figure 40-20-1]


and washer from the axle.

Installation: Tighten the hub mounting bolt to 725-800 ft.-


lb. (983-1085 Nm) torque.

Remove two of the wheel mounting studs (Item 2) [Figure


40-20-1].

Use a wheel mounting nut on both studs and remove the


two studs with a hammer.

Installation: Support the flange of the axle hub and install


the two studs with a hammer. A hydraulic press can also
be used to install the studs.

222 of 521 40-20-2 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-5

Axle Seal Removal And Installation (Contd)

Figure 40-20-3

P-4160

1
Installation: MEL1399 seal driver tool is necessary for
P-4161 the following procedure:

Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair
Figure 40-20-4 sleeve kit is available from Bobcat Parts.

Place the new axle seal over the axle and into the axle
tube.

Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].

Hit the seal driver tool with a hammer until the tool is flush
with the edge of the axle tube [Figure 40-20-5].

1 Reverse removal procedure to install the axle hub and


wheel assembly.

P-4181

Drill a small hole in the axle seal.

Install a slide hammer (Item 1) [Figure 40-20-4] with a


screw tip end in the axle seal.

Remove the axle seal.

223 of 521 40-20-3 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-6

Axle Sprocket And Bearings Removal And Installation

The tools listed are needed for the following procedure:


1
MEL1242 - Power Ram
MEL1202B - Axle Bearing Service Set
2
NOTE: The procedure shown is for removing the front
axle, bearings and sprocket. This procedure
can also be used for the rear axle, bearings 1
and sprocket.

Use jackstands to support the rear of the loader. (The


loader wheels should remain on the ground.) S2912

Remove the 12 front cover mounting bolts (Item 1) and


the front cover (Item 2) [Figure 40-20-6] from the
WARNING chaincase (See Front Cover Removal And Installation on
Page 40-30-1.)
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Figure 40-20-7
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Raise the lift arms and install an approved lift arm support
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

Raise the operator cab (See Raising on Page 10-30-1.)

Remove the control panel. 1

P-4147A

Loosen the axle sprocket mounting bolt (Item 1) [Figure


40-20-7].

Lift and block the loader (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Remove the fluid from the chaincase.

Remove the axle hub. (See Axle Seal Removal And


Installation on Page 40-20-2.)

Remove the sprocket mounting bolt (Item 1) [Figure 40-


20-7].

Installation: Tighten the sprocket mounting bolt to 300-


330 ft.-lb. (407-447 Nm) torque.

224 of 521 40-20-4 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-10

Axle Sprocket And Bearings Removal And Installation


(Contd)

Figure 40-20-8 1

P-4170

A bearing puller (Item 1) [Figure 40-20-10] is needed for


1 the following procedure.
P-4158A
Put the axle / outer bearing assembly in the bearing puller
as shown and put in the hydraulic press [Figure 40-20-
Install the MEL1242 power ram (Item 1) [Figure 40-20-8] 10].
between the two sprockets.
Figure 40-20-11
Put a spacer between the power ram and axle. Push the
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure
until the axle is free from the sprocket and inner bearing.

Figure 40-20-9

P-4171

2 Be sure the bearing puller makes good contact with the


1 inner race of the bearing and press the bearing off the
mounting surface of the axle.
P-4162A
Be sure to hold on to the axle during removal as it will
slide freely along the axle shaft after removal from the
Remove the drive chain from the sprocket (Item 1) bearing mounting surface and until the bearing contacts
[Figure 40-20-9] and remove the sprocket from the the spline on the shaft.
chaincase.
Press the splined end of the axle free from the bearing
Remove the inner bearing (Item 2) [Figure 40-20-9] and [Figure 40-20-11].
remove the axle from the axle tube (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20-4.)

Installation: Pack both axle bearings with grease before


installing them.

225 of 521 40-20-5 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-13

Axle Sprocket And Bearings Removal And Installation


(Contd)

Figure 40-20-12

4
3

P-4175

2
When the bearing reaches the bearing mounting surface,
continue the installation until the bearing is fully seated
P-4169 [Figure 40-20-13].

Figure 40-20-14
Installation: A piece of round tubing (Item 1) [Figure 40-
20-12] is needed to install the bearing on the axle shaft.

The tubing needs to measure approximately 0.500 inch


(12,7 mm) to 1.0 inch (25,4 mm) in length. The inside
diameter of the tubing should not be under 2.100 inches
(53,3 mm) and the outside diameter should not be over
2.400 inches (60 mm).

A bearing puller (Item 2) [Figure 40-20-12] is also needed


to install the bearing on the axle.

Put the tubing (Item 1) on the bearing puller (Item 2)


[Figure 40-20-12].
P-4172
Put the bearing (Item 3) [Figure 40-20-12] on the tube as
shown.
Use the tools provided in the MEL1202B Axle Bearing
Put the spline end of the axle shaft (Item 4) [Figure 40- Service Set for bearing cup removal and installation. A
20-12] in the bearing and press the bearing onto the axle. slide hammer is also necessary for this procedure.

Be sure to hold on to the axle during installation, as it will Use the long rod and the bearing cup tool to remove the
slide freely along the axle shaft after the spline end has inner bearing cup [Figure 40-20-14].
passed through the bearing and until it reaches the
bearing mounting surface on the axle. Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-14].

226 of 521 40-20-6 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-17

Axle Sprocket And Bearings Removal And Installation


(Contd) 1
2
Figure 40-20-15

P-4174A
2
1
Figure 40-20-18

P-4179
1

To remove the outer bearing cup, place the bearing cup


tool (Item 1) [Figure 40-20-15] on the slide hammer.

Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-15].

After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-15] on the tool. 2

Figure 40-20-16 P-4164

Use the bearing cup installation tools (Item 1) and the


long threaded rod (Item 2) [Figure 40-20-18] from the
service set to install the inner and outer bearing cups.

Put the inner bearing cup in the axle tube (Item 2) [Figure
40-20-17].

Put the installation tool (Item 1) [Figure 40-20-17] in the


axle tube.

Install the long threaded rod into the axle tube and
through the installation tool (Item 1) [Figure 40-20-17].
P-4180
Secure the tool to the threaded rod with a nut (Item 3)
[Figure 40-20-17].
Use the slide hammer and remove the bearing cup from
the axle tube [Figure 40-20-16]. Put the installation tool (Item 1) [Figure 40-20-18] in the
axle tube with the threaded rod through the hole in the
tool.

227 of 521 40-20-7 S100 Service Manual


DRIVE COMPONENTS (CONTD) Chain Removal And Installation

Axle Sprocket And Bearings Removal And Installation


(Contd)

Secure the tool to the threaded rod with a nut [Figure 40-
20-18].
WARNING
Never work on a machine with the lift arms up unless
Hold the inside nut with a wrench and tighten the outside
the lift arms are secured by an approved lift arm
nut as shown in photo [Figure 40-20-18].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
Tighten the nut until the bearing cup is seated.
to fall and cause injury or death.
W-2059-0598
Figure 40-20-19

Raise the loader lift arms and install an approved lift arm
support device (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1.)

Lift and block the loader (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Raise the loader operator cab (See Raising on Page 10-


30-1.)

Drain the fluid from the chaincase.

Remove the engine speed control (See Removal And


P-4173
Installation on Page 70-20-1.)

Remove the control panel.


To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups. Remove the traction lock assembly (See Removal And
Installation on Page 60-110-2.)
Put the bearing cup tool on the short rod.
Remove the center chaincase cover (See Center Cover
Put the bearing cup in the axle tube and put the tool into Removal And Installation on Page 40-30-2.)
the tube over the bearing cup [Figure 40-20-19].
Remove the front chaincase cover (See Front Cover
Hit the short rod with a hammer until the bearing cup is Removal And Installation on Page 40-30-1.)
seated inside the axle tube.
Remove the front axle and sprocket (See Axle Sprocket
And Bearings Removal And Installation on Page 40-20-4.)

228 of 521 40-20-8 S100 Service Manual


DRIVE COMPONENTS (CONTD) Figure 40-20-22

Chain Removal And Installation (Contd)

Figure 40-20-20

1 B-13504A

The tool listed is needed for the following procedure:


S0463
MEL1037 - Chain Link Tool

Remove the parking brake disc (Item 1) [Figure 40-20- Installation: If a new chain is installed, a connector link
20]. (See Disk Removal And Installation on Page 40-10- must be used to connect the chain together.
1.)
Use MEL1037 Chain Link Tool and #80 chain adapter.
Remove the six mounting bolts (Item 2) [Figure 40-20-20]
from inside the chaincase. Secure the tool and place the connector link in the tool as
shown [Figure 40-20-22].
Installation: Tighten the mounting bolts to 125-140 ft.-lb.
(170-190 Nm) torque. Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-22].
Figure 40-20-21
Tighten the threaded rod of the chain link tool to 130 ft.-lb.
(176 Nm) torque.

1
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

P-54226

Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain from the sprocket.

NOTE: It may be necessary to tie the front drive chain


up as shown in [Figure 40-20-21], so the motor
assembly can be moved enough to free the
rear drive chain (Item 1) [Figure 40-20-21] from
the sprocket.

Remove the front drive chain from the chaincase.

229 of 521 40-20-9 S100 Service Manual


230 of 521 40-20-10 S100 Service Manual
CHAINCASE Figure 40-30-1

Description

The chaincase contains the drive components.


1
Front Cover Removal And Installation

Raise the loader lift arms and install an approved lift arm
support device (See LIFT ARM SUPPORT DEVICE on
Page 10-20-1)
1
Raise the operator cab (See Raising on Page 10-30-1)

S2912

Remove the 12 front chaincase cover mounting screws


(Item 1) [Figure 40-30-1].

Remove the front chaincase cover from the loader.

Installation: Apply polyurethane sealant to mating


surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

231 of 521 40-30-1 S100 Service Manual


CHAINCASE (CONTD) Figure 40-30-3

Center Cover Removal And Installation 3

1 2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
S4237

Raise the loader lift arms and install an approved lift arm
support device (See LIFT ARM SUPPORT DEVICE on
Disconnect the two electrical connectors (Item 1) and
Page 10-20-1)
remove the nut (Item 2) [Figure 40-30-3].
Raise the operator cab (See Raising on Page 10-30-1)
Remove the two solenoid coils (Item 3) [Figure 40-30-3]
from the solenoid stem.
Remove the remote control panel (See Removal and
Installation on Page 50-100-2).
Figure 40-30-4
Remove the hydraulic control valve (See Removal And
Installation on Page 20-40-1).

Figure 40-30-2 1

S4238

Remove the solenoid stem (Item 1) [Figure 40-30-4] from


S4236
the Bob-Tach block.

Disconnect the electrical connector (Item 1) [Figure 40-


30-2] from the traction lock solenoid.

232 of 521 40-30-2 S100 Service Manual


CHAINCASE (CONTD) Figure 40-30-7

Center Cover Removal And Installation (Contd)

Figure 40-30-5

2 S4241

Remove the center chaincase cover by removing the


S4239 chaincase cover mounting screws (Item 1) [Figure 40-30-
7].

Remove the side bracket (Item 1) by removing the screw Figure 40-30-8
(Item 2) [Figure 40-30-5].

Figure 40-30-6

3 1
1 2

3
2
2

S4242

S4240 Remove the traction lock assembly (Item 1) [Figure 40-


30-8] from the center chaincase cover.

Remove the side bracket (Item 1) by removing the screw Remove the traction lock solenoid by removing the two
(Item 2) [Figure 40-30-6]. screws (Item 2) [Figure 40-30-8].

Remove the traction lock guides (Item 3) [Figure 40-30-8]


from the center chaincase cover by removing the four
screws.

Thoroughly clean the polyurethane from the chaincase


cover, screws and traction lock guides and dry.

233 of 521 40-30-3 S100 Service Manual


CHAINCASE (CONTD) Figure 40-30-10

Center Cover Removal And Installation (Contd)

Figure 40-30-9
1
INCORRECT CORRECT

2
3
2

P11337

1
Installation: Install the traction wedge assembly (Item 1)
N-19106 N-19105 into the solenoid traction lock guides (Item 2) [Figure 40-
30-10]. Tighten the four bolts and check to make sure the
shaft assembly is moving freely in the guides.
Installation: Install the traction lock guides (Item 1)
[Figure 40-30-9] to the chaincase cover using the four Installation: Apply polyurethane sealant to mating
screws. Do not tighten at this time. surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage.

234 of 521 40-30-4 S100 Service Manual


MAIN FRAME

BOB-TACH HAND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . 50-40-4
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

BOB-TACH (POWER OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . . . . 50-41-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . 50-41-4
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

CAB DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1


Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
MAIN
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
FRAME
Checking Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1


Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Neutral Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-11
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Linkage Travel Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
Pintle Arm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-100-7
Pintle Arm Disassembly and Assembly. . . . . . . . . . . . . . . . . . . 50-100-10
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2
Shaft Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5

CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1


Fuel Fill Screen Removal And Installation. . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Level Sender Removal And Installation. . . . . . . . . . . . . . . . . 50-80-2
Fuel Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1


Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Continued On Next Page

235 of 521 50-01 S100 Service Manual


MAIN FRAME (CONTD)

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1


Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . . . 50-20-3
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1


Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-31-3
Lower Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-31-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Seat Belt Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-31-4

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1


Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2

REAR GRILL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1


Compression Spring Disassembly And Assembly. . . . . . . . . . . . . 50-10-4
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Continued On Next Page

236 of 521 50-02 S100 Service Manual


MAIN FRAME (CONTD)

WINDOW (FRONT DOOR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123-1


Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123-2
Removal (Standard Window). . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123-1
Removal And Installation (Special Applications Window) . . . . . . 50-123-3

WINDOW (REAR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1


Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1


Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-122-1

WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1


Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR
BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.

237 of 521 50-03 S100 Service Manual


238 of 521 50-04 S100 Service Manual
SEAT BAR Removal And Installation

Description Figure 50-10-1

The seat bar is the secondary restraint system that has a


sensor that automatically stops the loader functions until
the seat bar is lowered.

The seat bar is located in the operator cab.

P-43383

Raise the seat bar (Item 1) [Figure 50-10-1].

Figure 50-10-2

N-18463

Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]


from the cab harness.

Lower the seat bar.

239 of 521 50-10-1 S100 Service Manual


SEAT BAR (CONTD) Figure 50-10-5

Removal And Installation (Contd)

Figure 50-10-3

N-18572

Remove the seat bar mounting nuts (Item 1) [Figure 50-


P10564 P10563 10-5] (both sides).

Installation: Tighten the nuts to 28 ft.-lb. (38 Nm) torque.


Loosen the nut (both sides) at the front corners of the
operator cab [Figure 50-10-3]. Lower the operator cab (See Lowering on Page 10-30-2.)

Remove the nuts and plates (both sides) [Figure 50-10- Figure 50-10-6
3].

Installation: Tighten the nuts to 40-50 ft.-lb. (54-68 Nm)


torque.
1
Figure 50-10-4

S4010

Remove the seat bar (Item 1) [Figure 50-10-6] from the


operator cab.

S4078 Reverse the above procedure to install the seat bar into
the operator cab.
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].

240 of 521 50-10-2 S100 Service Manual


SEAT BAR (CONTD) Figure 50-10-9

Disassembly And Assembly


5
Figure 50-10-7 4 6

4 3
6
5
7
2 7
3

2 9 8
10 1
1 N-19340

Figure 50-10-10
N-19383

4
5
Figure 50-10-8
3 6
2
4
5 7
9 8
1
3 6
2 10

7
1
N-19220

Assemble the parts as shown for the right side of the seat
N-19219 bar pivot assembly [Figure 50-10-9] and [Figure 50-10-
10].

Assemble the parts as shown for the left side of the seat Seat Bar Mount (Item 1)
bar pivot assembly [Figure 50-10-7] and [Figure 50-10- Mounting Nut (Item 2)
8]. Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar Mount (Item 1) Seat Bar (Item 5)
Mounting Bolt (Item 2) Keyed Plastic Bushing (Item 6)
Keyed Plastic Bushing (Item 3) Mounting Bolt (Item 7)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5) Installation: Tighten the mounting bolt (Item 7) [Figure
Pivot Bushing (Item 6) 50-10-9] and [Figure 50-10-10] to 50-70 in.-lb. (5,6-7,9
Sensor Bracket (Item 7) Nm) torque.
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)

Installation: Tighten the mounting bolt (Item 2) [Figure


50-10-7] and [Figure 50-10-8] to 50-70 in.-lb. (5,6-7,9
Nm) torque.

241 of 521 50-10-3 S100 Service Manual


SEAT BAR (CONTD) NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
Compression Spring Disassembly And Assembly affected parts before the application of
LOCTITE #518.
Figure 50-10-11
Disassemble and assemble the seat bar compression
6 7 spring and parts as shown in Fig. [Figure 50-10-11].

Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
5
Pin (Item 6)
4 6
Bushing (Item 7)
3
2
1
N-19384

Figure 50-10-12

N-19222

Turn the bolt (Item 1) [Figure 50-10-11] and [Figure 50-


10-12] out of the clevis.

Assembly: Apply LOCTITE #518 adhesive to the bolt


threads. Adjust the compression spring by turning the bolt
in past the end of the clevis three turns.

242 of 521 50-10-4 S100 Service Manual


OPERATOR CAB Figure 50-20-2

Gas Cylinder Removal And Installation

WARNING 1

Cylinder contains high pressure gas. Do not open.


Opening cylinder can release rod and cause injury or
death.
W-2113-0288

P1518 P1528

WARNING Remove the cab nut and holddown plate (Item 1) [Figure
50-20-2] (both sides).
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Installation: Tighten the nut to 40-50 ft.-lb. (54-68 Nm)
support device. Failure to use an approved lift arm torque.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 50-20-3
W-2059-0598
1
Figure 50-20-1

N-20617D

P-54018
Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.

Remove the operator cab stop (Item 1) (both sides) Raise the operator cab. (See Raising on Page 10-30-1.) to
[Figure 50-20-1]. release the tension on the gas cylinder.

243 of 521 50-20-1 S100 Service Manual


OPERATOR CAB (CONTD) Figure 50-20-6

Gas Cylinder Removal And Installation (Contd)

Figure 50-20-4

SINGLE GAS CYLINDER

2 1

P-48587

Rotate the mounting bracket forward to relieve any


N-20631 remaining tension on the gas cylinder(s) [Figure 50-20-
6].

Figure 50-20-5 Remove the front screw (Item 1) [Figure 50-20-6] from
the gas cylinder mounting bracket.
DUAL GAS CYLINDER
Installation: Tighten the screws to 100-130 in.-lb. (11,3-
14,7 Nm) torque.

1 2

P-43354

Loosen the front screw (Item 1) and remove the rear


screw (Item 2) [Figure 50-20-4] and [Figure 50-20-5]
from the gas cylinder mounting bracket.

244 of 521 50-20-2 S100 Service Manual


OPERATOR CAB (CONTD) Gas Cylinder Bracket Disassembly And Assembly

Gas Cylinder Removal And Installation (Contd) Figure 50-20-9

Figure 50-20-7

SINGLE GAS CYLINDER

2
1
1

P1008

P-66830
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.
DUAL GAS CYLINDER
Assembly: Install a replacement cylinder inside the
cylinder housing.

Figure 50-20-10
1

P-68819

Remove the retaining pin(s) (Item 1) [Figure 50-20-7] and


[Figure 50-20-8] from the top pivot pin(s).

Remove the gas cylinder(s) (Item 2) [Figure 50-20-7] and


P1006
[Figure 50-20-8] from the operator cab.

Reverse the above procedure to install the gas


Apply a small amount of Loctite #242 on the threads of
cylinder(s).
the cylinder rod [Figure 50-20-10].

Reinstall the washer and clevis on the cylinder rod.

245 of 521 50-20-3 S100 Service Manual


OPERATOR CAB (CONTD) Figure 50-20-12

Removal And Installation

1
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796 S0365

Figure 50-20-11
Disconnect the cab harness connector (Item 1) [Figure
50-20-12].
1
Installation: Tighten connector screw to 30-35 in.-lb.
(3,4-4 Nm) torque.

Lower the cab (See Lowering on Page 10-30-2.)

Figure 50-20-13

N-20617D

1 2
Remove the operator cab gas cylinder(s) (See Gas
Cylinder Removal And Installation on Page 50-20-1.)

Remove the heater unit from the cab (if equipped).

Use the hoist connected to the operator cab grab handles


to lower or (raise) the operator cab when the gas cylinders P-54021

are disconnected [Figure 50-20-11].


Remove the rear mounting bolts (Item 1) and nuts (Item 2)
[Figure 50-20-13] (both sides) from the operator cab.

Installation: Tighten the bolt and nut to 25-35 ft.-lb. (34-


47 Nm) torque.

246 of 521 50-20-4 S100 Service Manual


OPERATOR CAB (CONTD)

Removal And Installation (Contd)

Figure 50-20-14

N-20627A S4299

Connect the slings (Items 1, 2, and 3) [Figure 50-20-14]


to a chain hoist.

Remove the operator cab from the loader.

Reverse the above procedure to install the operator cab.

247 of 521 50-20-5 S100 Service Manual


248 of 521 50-20-6 S100 Service Manual
OPERATOR SEAT Seat Belt Removal And Installation

Removal And Installation Figure 50-30-3

Figure 50-30-1

1 1
1

2
1 1

N-20729A

N-20729
Raise the operator cab. (See Raising on Page 10-30-1.)

Raise the operator cab (See Raising on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation (Items
1 and 2) [Figure 50-30-3] and peel back or cut insulation
Remove the four seat mounting nuts (Item 1) [Figure 50- to gain access to the head.
30-1] and washers from the operator seat mounting studs.
Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lb. (27
Nm) torque.

NOTE: Ensure the washers are installed.

Figure 50-30-2

2 N-20655

Remove the two nuts (Items 1 and 2) [Figure 50-30-4].

Installation: Tighten nut (Item 1) to 54 ft.-lb. (73 Nm)


P10564 P10563 torque. Tighten nut (Item 2) [Figure 50-30-4] to 34 ft.-lb.
(46 Nm) torque.

Lower the cab and install one of the plates and nuts Repeat for other half of seat belt and guide.
[Figure 50-30-2].

NOTE: With the seat removed the cab will raise.

Reverse the removal procedure to install the operator


seat.

249 of 521 50-30-1 S100 Service Manual


250 of 521 50-30-2 S100 Service Manual
OPERATOR SEAT (SUSPENSION) Figure 50-31-3

Removal And Installation

Figure 50-31-1

1 1

1
1 1
S4352

Figure 50-31-4
S4355

Raise the operator cab. (See Raising on Page 10-30-1.)


2
Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting studs.

Installation: Tighten the mounting nuts to 20 ft.-lb. (27


Nm) torque.
1
Figure 50-31-2

S4351

NOTE: Assure seat tethers are securely fastened to


the seatbelt studs (Item 1) [Figure 50-31-3] and
the seat rail studs (Item 2) [Figure 50-31-4].

NOTE: Verify the front two seat rail studs have


washers attached (Item 1) [Figure 50-31-4].

P10564 P10563

Lower the cab and install one of the mounting washers


and a nut [Figure 50-31-2].

NOTE: With the seat removed, the cab will raise.

Reverse the removal procedure to install the operator


seat.

251 of 521 50-31-1 S100 Service Manual


OPERATOR SEAT (SUSPENSION) (CONTD) Seat Belt Removal and Installation

Slide Rail Removal And Installation Figure 50-31-6

Figure 50-31-5

1
1

2
2

1
1
1
S4352

S4351
Remove the operator seat (See Removal And Installation
on Page 50-31-1.)
Remove the operator seat (See Removal And Installation
on Page 50-31-1.) Remove the nut (Item 1) [Figure 50-31-6] from the seat
belt mount.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5]. Remove the seat belt.

Remove the slide rail (Item 2) [Figure 50-31-5] from the Installation: Tighten the mounting nuts to 58 to 62 ft.-lb.
bottom of the seat frame. (78,6 to 84 Nm) torque.

Reverse the removal procedure to install the operator seat


slide rail.

252 of 521 50-31-2 S100 Service Manual


OPERATOR SEAT (SUSPENSION) (CONTD) Back Cushion Removal And Installation

Lower Cushion Removal And Installation Figure 50-31-9

Figure 50-31-7
1

N-18583

S4353
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-9] and tilt the seat back all the way forward.
Remove the retainer clips (Item 1) [Figure 50-31-7] and
lift the seat cushion. Figure 50-31-10

Figure 50-31-8

1 1

N-18578

S4354
Remove the two mounting screws (Item 1) [Figure 50-31-
10] from the seat back and remove the back.
Inspect the seat ride adjustment [Figure 50-31-8].
Reverse the removal procedure to install the operator
Reverse the removal procedure to install the operator seat.
seat.

253 of 521 50-31-3 S100 Service Manual


OPERATOR SEAT (SUSPENSION) (CONTD) 3-Point Seat Belt Removal And Installation

Shock Removal And Installation Raise the operator cab (See Raising on Page 10-30-1.)

Figure 50-31-11 Remove the operator seat (See Removal And Installation
on Page 50-31-1.)

Figure 50-31-12

2
1

2
1

1
P-43118
3

Raise the operator cab (See Raising on Page 10-30-1.) P16285

Remove the operator seat (See Removal And


Remove the mounting nut (Item 1) [Figure 50-31-12].
Installation on page 1.)
Remove the end release buckle (Item 2) [Figure 50-31-
Remove the seat shock mounting bolts (Item 1) (Both
12].
ends) [Figure 50-31-11].
Installation: Be sure the tether strap (Item 3) [Figure 50-
Remove the seat shock (Item 2) [Figure 50-31-11].
31-12] is on the seat belt stud behind the end release
buckle.
Reverse the removal procedure to install the operator seat
shock.
Figure 50-31-13

P16284

Remove the mounting nut (Item 1) [Figure 50-31-13].

Remove the seat belt retractor (Item 2) [Figure 50-31-13].

Installation: Be sure the tether strap (Item 3) [Figure 50-


31-13] is on the seat belt stud behind the seat belt
retractor.

254 of 521 50-31-4 S100 Service Manual


OPERATOR SEAT (SUSPENSION) (CONTD) Figure 50-31-15

3-Point Seat Belt Removal And Installation (Contd)

Figure 50-31-14 1 2

P16126

1
INSIDE OF CAB
P16128

OUTSIDE OF CAB Remove the shoulder harness retractor (Item 1) [Figure


P16131 50-31-15].

Installation: Line up the bolt (Item 1) [Figure 50-31-14]


Remove the mounting bolt (Item 1) [Figure 50-31-14]. with the mounting bracket (Item 2) [Figure 50-31-15] on
the inside of the cab.

255 of 521 50-31-5 S100 Service Manual


256 of 521 50-31-6 S100 Service Manual
BOB-TACH HAND LEVER Figure 50-40-2

Description

The Bob-Tach is the section of the loader lift arm that


attachments mount to. The Bob-Tach uses two manually
operated, spring assisted, locking wedge and lever
assemblies to secure the attachment to the Bob-tach.
1
The Bob-Tach is located on the front of the loader and is
connected to the lift arms. 3

Removal And Installation 2

Figure 50-40-1
S4309

Remove the retainer nut (Item 1) and bolt (Item 2) [Figure


50-40-2] from the pivot pin.

Installation: Tighten the retainer bolt to 25-28 ft.-lb. (34-


38 Nm) torque.

Remove the rod end pivot pin (Item 3) [Figure 50-40-2].

Remove the tilt cylinder rod end.

S4304

Tilt the Bob-Tach forward, so it is parallel to the floor. Put


blocks [Figure 50-40-1] approximately 3 inches thick
under each side of the Bob-Tach. Lower the Bob-Tach
onto the blocks.

257 of 521 50-40-1 S100 Service Manual


BOB-TACH HAND LEVER (CONTD) Figure 50-40-4

Removal And Installation (Contd)

Figure 50-40-3
2

1
1 S4316

2 Remove the seal dust cup (Item 1) [Figure 50-40-4].


S4313
Remove the rubber seal (Item 2) [Figure 50-40-4].
NOTE: Removal procedure is shown for the right side. Remove the pivot pin (Item 3) [Figure 50-40-4] from the
Left side procedure is the same. Bob-Tach frame.
Remove the grease fitting (Item 1) [Figure 50-40-3] from Check for wear and damage. Replace the pivot pins as
the Bob-Tach frame for the pivot pin (Both sides). needed.
NOTE: The grease fitting (Item 1) [Figure 50-40-3] must Installation: Push the pivot pin (Item 3) [Figure 50-40-4]
be removed to prevent the pivot pin from being into the Bob-Tach frame. Position the end of the pin flush
locked in the Bob-Tach frame. with the end of the Bob-Tach bushing.
Loosen the bolt (Item 2) [Figure 50-40-3] at the Bob-Tach Reverse the removal procedure to install the Bob-Tach.
pivot pin.

Strike the head of the bolt (Item 2) [Figure 50-40-3] to


push the pivot pin into the Bob-Tach frame.

Remove the bolt (Item 2) [Figure 50-40-3] and use a


punch to push the pivot pin all the way into the Bob-Tach
frame.

Installation: A longer bolt will be needed to temporarily


reach through the lift arms into the pins to seat them into
the lift arms. Once seated, reinstall the original bolts.
Tighten the bolts to 190 ft.-lb. (258 Nm) torque.

NOTE: Use tapered ream MEL 1233 to clean the


tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.

Slowly back the loader away to remove the Bob-Tach


frame.

258 of 521 50-40-2 S100 Service Manual


BOB-TACH HAND LEVER (CONTD) Figure 50-40-7

Lever And Wedge Disassembly And Assembly

Figure 50-40-5

S5991

1
Remove the Bob-Tach lever (Item 1) [Figure 50-40-7].
S5989
Figure 50-40-8

Use the following procedure to remove and install the


Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.
1
Figure 50-40-6

S5992

Use a punch and hammer, remove the roll pin (Item 1)


[Figure 50-40-8] from the Bob-Tach wedge and spring,
2 1
bolt and clevis assembly.
S5990

Remove the lever mounting bolt and nut (Item 1) and


spring (Item 2) [Figure 50-40-6].

259 of 521 50-40-3 S100 Service Manual


BOB-TACH HAND LEVER (CONTD) Pivot Pin Bushing And Seal Removal And Installation

Lever And Wedge Disassembly And Assembly Figure 50-40-11


(Contd)

Figure 50-40-9

1
2

S4316
1

S5993 Remove the Bob-Tach (See Removal And Installation on


Page 50-40-1).

Remove the spring, bolt and clevis assembly (Item 1) Remove the rubber seal (Item 1) [Figure 50-40-11].
[Figure 50-40-9].
Installation: Use a new seal when assembling.
Remove the wedge (Item 2) [Figure 50-40-9] from the
Bob-Tach frame. Figure 50-40-12

Always replace bent or broken wedges.

Figure 50-40-10

2
1 1

S5995
4
3
Remove the bushing (Item 1) [Figure 50-40-12] with a
S5994
slide hammer.

Installation: Install the bushing with a driver tool and


If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) or
hammer.
clevis (Item 4) are damaged, put the assembly in the vise.
Loosen and remove the bolt (Item 1) [Figure 50-40-10]
with a 5/16 inch allen wrench.

Replace the worn or damaged parts as needed.

Reverse the removal procedure to install the Bob-Tach


Lever and Wedge.

260 of 521 50-40-4 S100 Service Manual


BOB-TACH (POWER OPTION) Figure 50-41-2

Description

The Bob-tach is the section of the loader lift arm that


attachments mount to. The Power Bob-tach option uses
two hydraulically operated, spring assisted, locking wedge
and lever assemblies to secure the attachment to the Bob-
tach.
1
The hydraulically operated Power Bob-tach has a
hydraulic cylinder that opens and closes both wedge and 3
lever assemblies by pressing a switch on the front
accessory panel. The switch activates the Power Bob- 2
tach block to allow flow into or out of the hydraulic cylinder 4
connected to the levers on the Bob-tach. S4309

The Power Bob-tach block is located under the cab, on the


front left side, below the Bucket Positioning Valve (if Remove the retainer bolt (Item 1) and nut (Item 2) [Figure
equipped). 50-41-2] from the tilt cylinder rod end pin.

The Bob-tach is located on the front of the loader Installation: Tighten the retainer bolt and nut to 25-28 ft.-
connected to the loader lift arms. lb. (34-38 Nm) torque.

Removal And Installation Remove the pivot pin (Item 3) [Figure 50-41-2] from the
tilt cylinder rod end.
Figure 50-41-1
Remove the tilt cylinder rod end (Item 4) [Figure 50-41-2]
from the Bob-Tach.

S5919

Tilt the Bob-Tach forward, so it is parallel to the floor. Put


blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-41-1].

Lower the Bob-Tach onto the blocks.

Remove the hoses on the cylinder fittings (Item 1) [Figure


50-41-1].

Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the Bob-Tach lever to secure
the clamp.

261 of 521 50-41-1 S100 Service Manual


BOB-TACH (POWER OPTION) (CONTD) Figure 50-41-4

Removal And Installation (Contd)

Figure 50-41-3
2

1
1 S4316

2 Remove the dust cup (Item 1) [Figure 50-41-4] (Both


S4313 sides) when the Bob-Tach is free from the loader.

Remove the rubber seal (Item 2) [Figure 50-41-4] (Both


Remove the grease fitting (Item 1) [Figure 50-41-3] (Both sides).
sides). This allows grease to come out in the next step.
Not letting grease escape will prevent the pin from going Installation: Use a new seal when assembling.
into the Bob-Tach far enough to remove the Bob-Tach
from the lift arms. Remove the Bob-Tach pivot pin (Item 3) [Figure 50-41-4]
(Both sides).
Loosen the bolt (Item 2) [Figure 50-41-3] at the Bob-Tach
pivot pin. (Both sides) Check for wear and damage on the pins and the Bob-Tach
bushings. Replace as needed.
Strike the head of the bolt (Item 2) [Figure 50-41-3] to
push the pivot pin into the Bob-Tach frame. (Both sides) Reverse the removal procedure to install the Bob-Tach.

Remove the bolt. (Both sides)

Installation: A longer bolt will be needed to temporarily


reach through the lift arms into the pins to seat them into
the lift arms. Once seated, reinstall the original bolts.
Tighten the bolts to 190 ft.-lb. (258 Nm) torque.

Use a punch to push the pivot pins all the way inside the
Bob-Tach frame.

Remove the Bob-Tach from the lift arms.

262 of 521 50-41-2 S100 Service Manual


BOB-TACH (POWER OPTION) (CONTD) Figure 50-41-7

Lever And Wedge Disassembly And Assembly

Remove the Power Bob-Tach cylinder (See Removal And


Installation on Page 50-41-1.)
1
Figure 50-41-5

S5997

Remove the wedge (Item 1) [Figure 50-41-7].

1 Always replace bent or broken wedges.

S5919 Figure 50-41-8

Use the following procedure to remove and install the


Bob-Tach lever (Item 1) [Figure 50-41-5], spring and 2
wedge. 1
3
Figure 50-41-6

1
5

S5998

Remove the washer and bolt (Item 1) [Figure 50-41-8].

Installation: Tighten the bolts to 25-28 ft.-lb. (34-38 Nm)


torque.
S5996
Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the bottom
Use a punch and hammer, remove the roll pin (Item 1) [Figure 50-41-8].
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis. Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].

Installation: Tighten the nut to 25-28 ft.-lb. (34-38 Nm)


torque.

263 of 521 50-41-3 S100 Service Manual


BOB-TACH (POWER OPTION) (CONTD) Pivot Pin Bushing And Seal Removal And Installation

Lever And Wedge Disassembly And Assembly Figure 50-41-11


(Contd)

Figure 50-41-9

4
1

3 2 S4316

N-20625 Remove the Bob-Tach (See Removal And Installation on


Page 50-41-1.)

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) or Remove the rubber seal (Item 1) [Figure 50-41-11].
clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise. Installation: Use a new seal when assembling.

Remove the bolt and replace the damaged parts as Figure 50-41-12
needed.

Figure 50-41-10

S5995

N-18563 Remove the bushing (Item 1) [Figure 50-41-12] with a


slide hammer.

Use a punch and hammer to drive the roll pin (Item 1) Installation: Install the bushing with a driver tool and
[Figure 50-41-10] flush with the face of the Bob-Tach. hammer.

Reverse the removal procedure to install the Power Bob-


Tach lever and wedge.

264 of 521 50-41-4 S100 Service Manual


LIFT ARMS Figure 50-50-3

Removal And Installation

Figure 50-50-1

1
2
1
S5954

Remove the tubeline clamps (Item 1) [Figure 50-50-3]


S4297 under the lift arms.

Pull the tubelines (Item 2) [Figure 50-50-3] down.


Roll the Bob-Tach fully forward. Stop the engine.

Remove the Bob-Tach frame from the lift arms. (See


Removal And Installation on Page 50-40-1.)

Install jackstands under the rear of the loader [Figure 50-


50-1].

Left Side

Figure 50-50-2

S4044

Remove the front auxiliary block mounting bolts (Item 1)


[Figure 50-50-2].

265 of 521 50-50-1 S100 Service Manual


LIFT ARMS (CONTD) Figure 50-50-6

Removal And Installation (Contd)

Right Side

Figure 50-50-4

1
1

S5955

Remove the tubeline clamps (Item 1) [Figure 50-50-6]


1 under the lift arms.

S4325 Figure 50-50-7

Remove the mounting bolt (Item 1) [Figure 50-50-4] from


the tilt tubeline clamp.

Figure 50-50-5

1
2 S4312
1
1
Remove the lift arm support device mounting bolt (Item 1)
[Figure 50-50-7] spacer and nut.

S5982
Installation: Tighten the mounting bolt and nut to 25-28
ft.-lb. (34-38 Nm) torque.

Remove the lift arm support device (Item 1) [Figure 50- Remove the retainer bolt (Item 2) [Figure 50-50-7] and
50-5]. nut from the lift cylinder rod end pivot pin.

Installation: Tighten the mounting bolt and nut to 25-28


ft.-lb. (34-38 Nm) torque.

266 of 521 50-50-2 S100 Service Manual


LIFT ARMS (CONTD) Figure 50-50-10

Removal And Installation (Contd)

Figure 50-50-8

1 2

1
S5986

Wrap one of the 7 ft. lifting straps around the lift arm
S5983 crossmember as shown [Figure 50-50-10].

Both loops of the lifting strap should be supported by the


Raise the operator cab (See Raising on Page 10-30-1.) chain hoist [Figure 50-50-10].

Remove the right side lift cylinder pivot pin (Item 1) Use a chain hoist and lifting strap to raise the lift arms
[Figure 50-50-8]. enough to remove the tilt cylinder base end pivot pin
[Figure 50-50-10].
NOTE: Put a piece of cardboard under the rod end of
the lift cylinders to protect the fender from Figure 50-50-11
scratches.

Remove the lift arm support device (Item 2) [Figure 50-


50-8].

Figure 50-50-9

1 S5985

Remove the two tilt cylinders (Item 1) from the lift arm
crossmember by removing the bolts and nuts (Item 2)
[Figure 50-50-11] and removing the pivot pins.
S5984

Remove the left side lift cylinder pivot pin (Item 1) [Figure
50-50-9].

267 of 521 50-50-3 S100 Service Manual


LIFT ARMS (CONTD) Figure 50-50-14

Removal And Installation (Contd)

Figure 50-50-12

1 3

1
S4323

2
Remove the upright pivot pin mounting bolt (Item 1) and
S5987 nut (Item 2) [Figure 50-50-14] (Both sides.)

Tighten the pivot pin mounting bolt and nut to 25-28 ft.-lb.
Put the middle of the second lifting strap (Item 1) [Figure (34-38 Nm) torque.
50-50-12] up into the lift arm as shown.
Remove the upright pivot pin (Item 3) [Figure 50-50-14].
Install the lift cylinder pivot pin (Item 2) [Figure 50-50-12] (Both sides.)
and secure the pin with the mounting bolt and nut.
Figure 50-50-15
Wrap both ends of the strap around the top of the lift arm
and down the back of the lift arm [Figure 50-50-12].

Figure 50-50-13

S5956

S5987
Raise the lift arms with the chain hoist so the lift arms are
free from the loader [Figure 50-50-15].
Continue to wrap the lifting strap around the lift arm a
second time [Figure 50-50-13].

Fasten both loops of the lifting strap to a second chain


attached to the chain hoist.

Use the wrapping procedure on the third strap which


would be installed on the right side lift arm.

Use the chain hoist and lower the lift arms so they rest on
the blocking.

268 of 521 50-50-4 S100 Service Manual


LIFT ARMS (CONTD)

Removal And Installation (Contd)

Figure 50-50-16

S5953

Pull the lift arms away from the loader [Figure 50-50-16].

Lower the lift arms slowly and put on the floor.

Reverse the removal procedure to install the lift arms on


the loader.

269 of 521 50-50-5 S100 Service Manual


270 of 521 50-50-6 S100 Service Manual
REAR GRILL Figure 50-60-3

Removal And Installation

Figure 50-60-1

P-48130

Installation: Line up the tab (Item 1) on the grill with the


S4331 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.

Open the rear door. Reverse the removal procedure to install the grill.

Figure 50-60-2

S4082

Lift up on the rear grill (Item 1) [Figure 50-60-1] and


[Figure 50-60-2].

Lift the grill away from the loader.

271 of 521 50-60-1 S100 Service Manual


272 of 521 50-60-2 S100 Service Manual
REAR DOOR Figure 50-70-3

Removal And Installation


1
Figure 50-70-1

P-43360

1 Remove the top and bottom door hinge mounting bolts


P-68817 (Item 1) [Figure 50-70-3] and nuts.

NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the engine harness. hinge as shown.

Remove both rear lights from the door (See Rear Installation: Tighten the mounting bolts and nuts to 25-28
Removal And Installation on Page 60-60-1.) ft.-lb. (34-38 Nm) torque.

Figure 50-70-2 Lift the door away from the loader frame and put the door
flat on the floor.

Reverse the removal procedure to install the rear door.


2

P-34588

Secure the chain hooks (Item 1) [Figure 50-70-2] to the


door as shown.

Connect a chain hoist (Item 2) [Figure 50-70-2] to the


lifting chain.

273 of 521 50-70-1 S100 Service Manual


REAR DOOR (CONTD) Striker (Adjusting)

Striker Removal and Installation

Figure 50-70-4
WARNING
AVOID INJURY OR DEATH
1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497

Figure 50-70-6

1 1

P-31126

Remove the two striker mount bolts (Item 1) [Figure 50-


70-4].

Remove the striker assembly from the loader. 1


Striker Disassembly and Assembly
P-31126

Figure 50-70-5

Loosen the striker assembly mount bolts (Item 1) [Figure


2 2 50-70-6].
3
Align the striker assembly in the center of the mounting
holes.

NOTE: Tighten the striker assembly, top mount bolt


only, until it will hold the striker assembly in
the center of the mounting slots.
4
1
Close the rear door (This will align the striker assembly to
the correct position.)

Open the door.


P-31320

Installation: Tighten the mounting bolts (Item 1) [Figure


Remove the lock nut (Item 1) [Figure 50-70-5]. 50-70-6] to 90-100 ft.-lb. (125-135 Nm) torque.

Remove the rollers (Item 2) and the spacer (Item 3) from Close the rear door.
the bost (Item 4) [Figure 50-70-5].

Check the parts for wear and replace as needed.

274 of 521 50-70-2 S100 Service Manual


REAR DOOR (CONTD) Figure 50-70-9

Latch Removal And Installation

Figure 50-70-7
1

P-31128

1 Remove the door handle (Item 1) [Figure 50-70-9] from


P-31125 the rear door.

Disconnect the spring (Item 1) [Figure 50-70-7] from the


rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-7] from


the latch.

Figure 50-70-8

P-31127

Remove the spring (Item 1) [Figure 50-70-8] from the


door handle.

Remove the spring (Item 2) [Figure 50-70-8] from the


door latch.

Remove the door latch (Item 3) [Figure 50-70-8] from the


door handle.

275 of 521 50-70-3 S100 Service Manual


276 of 521 50-70-4 S100 Service Manual
FUEL TANK Figure 50-80-3

Removal And Installation


4
Figure 50-80-1

1
2
3

3 5

S4243

Disconnect the fuel fill hose (Item 1) and the vent hose
P1616 (Item 2) [Figure 50-80-3] from the fuel tank.

Remove the fuel supply and return hoses (Item 3) [Figure


Remove the cover (Item 1) [Figure 50-80-1] which is 50-80-3].
installed over the fuel drain.
Disconnect the fuel sender connector (Item 4) [Figure 50-
Installation: Tighten the cover mounting bolts to 15-20 80-3] from the fuel tank.
ft.-lb. (20-27 Nm) torque.
Lift the fuel tank (Item 5) [Figure 50-80-3] and remove it
Figure 50-80-2 from the loader.

P1619A

Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].

Open the rear door of the loader.

Remove the engine / hydrostatic pump assembly from the


loader (See Engine Removal And Installation on Page 70-
10-9.).

277 of 521 50-80-1 S100 Service Manual


FUEL TANK (CONTD) Fuel Fill Screen Removal And Installation

Fuel Level Sender Removal And Installation Figure 50-80-5

Raise the loader operator cab (See Raising on Page 10-


30-1.)

Figure 50-80-4

S5981

1
Disconnect the fuel fill hose (Item 1) [Figure 50-80-5]
2 from the fuel tank.
S5980
Figure 50-80-6

Disconnect the harness (Item 1) and loosen the fuel level


sender (Item 2) [Figure 50-80-4] with a wrench.

Pull the fuel level sender (Item 2) [Figure 50-80-4] out


and remove it from the fuel tank. Check the fuel level
sender for damage and replace if necessary.

Installation: Tighten the fuel level sender to 50-60 in.-lb.


(5,7-6,8 Nm) torque.
1

S5959

Remove the fuel inlet screen (Item 1) [Figure 50-80-6].


Clean and dry the screen. Check the screen for damage
and replace if necessary.

278 of 521 50-80-2 S100 Service Manual


FUEL TANK (CONTD)

Fuel Pickup Screen

Figure 50-80-7

1
S5981

Disconnect the fuel hose (Item 1) [Figure 50-80-7] from


the fitting.

Remove the fitting and grommet from the fuel tank.

Remove the fuel supply hose assembly from the fuel tank.

Remove the fuel supply screen from the hose and check
the screen for damage. Replace if needed.

279 of 521 50-80-3 S100 Service Manual


280 of 521 50-80-4 S100 Service Manual
CONTROL PEDALS AND LINKAGES Figure 50-90-1

Description

The control pedals and linkages are connected to the 1


control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.

The control pedals and linkages are located on the lower


mainframe at the operators feet.

Pedal Removal And Installation

WARNING S2907

Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Installation: Tighten the bolt and nut to 25-28 ft.-lb. (34-
to fall and cause injury or death. 38 Nm) torque.
W-2059-0598
Check the rubber bushing in the pedal for wear and
Raise the lift arms and install an approved lift arm support replace as needed.
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) Figure 50-90-2

Raise the operator cab (See Raising on Page 10-30-1.)

P-28909

Remove the two mounting bolts (Item 1) [Figure 50-90-2]


from the pedal mounting bracket.

Remove the pedal assembly from the loader.

281 of 521 50-90-1 S100 Service Manual


CONTROL PEDALS AND LINKAGES (CONTD) Pedal (Adjusting)

Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-3 spool must travel full stroke without the pedal hitting the
floor panel.

1 The pedals should be positioned at a comfortable angle


so full movement of the pedal can be reached easily while
properly sitting in the loader seat.

Figure 50-90-5

S2907

Disconnect the linkage from the pedal by removing the


bolt and nut (Item 1) [Figure 50-90-3].

Figure 50-90-4
P-28909

1 Loosen the two mounting bolts (Item 1) [Figure 50-90-5]


from the pedal mounting bracket.

Figure 50-90-6

1 2

S2908

Disconnect the linkage from the hydraulic control valve by


removing the bolt and nut (Item 1) [Figure 50-90-4].

Remove the linkage.


S2907

Loosen the bolt (Item 2) [Figure 50-90-6] and nut on the


pedal linkage.

Check the rubber bushing in the pedal for wear and


replace as needed.

Tilt the pedal back and forth until an acceptable neutral


angle is achieved on the pedal.

Tighten the two mounting bolts (Item 1) and pivot bolt


(Item 2) [Figure 50-90-6] on the pedal assembly to
standard torque.

282 of 521 50-90-2 S100 Service Manual


CONTROL PANEL

Description

Figure 50-100-1

S5947

The steering system [Figure 50-100-1] consists of The steering system returns the levers to their starting
independent steering levers the operator uses to provide position by means of the centering spring and the
steering input to the loader. returning force of the torsion bushings.

The steering levers are attached to pivoting bellcranks NOTE: Torsion bushings need to be replaced if torn or
that pivot on a steering shaft and plastic bushings. The
rotating in the housing. Loosen torsion
bellcranks have grease fittings.
bushing bolts slightly before adjustments are
The forward travel is adjusted by drift adjustment bolts. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
The bellcranks are attached to steering linkage bars with been made first.
rubber torsion bushings pressed into the bellcranks.
Bellcranks mount to the control panel. Sequence of steering adjustments:

Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, creep
linkage bars are adjustable in length for full travel 2. Set linkage travel at steering linkage bars
adjustment. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a
rubber torsion bushing is pressed into the pintle arms.

Pintle arms are of a two-piece design that allow easy


adjustment of the neutral or creep.

283 of 521 50-100-1 S100 Service Manual


CONTROL PANEL (CONT'D) Figure 50-100-2

Removal and Installation

S4225

WARNING Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
Never work on a machine with the lift arms up unless 20-1.)
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Raise the operator cab. (See Raising on Page 10-30-1.)
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the engine speed control. (See Removal And
W-2059-0598 Installation on Page 70-20-1.)

Loosen the jam nut from the bypass control knob (Item 1)
[Figure 50-100-2].

WARNING Figure 50-100-3

Put jackstands under the front axles and rear corners


of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall 1
or move and cause injury or death. 2
W-2017-0286 3

S6040

Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-3].

284 of 521 50-100-2 S100 Service Manual


CONTROL PANEL (CONT'D) Figure 50-100-6

Removal and Installation (Cont'd)

Figure 50-100-4

1
1
1
S4381

Scribe a mark across the top of the steering linkage bars


S2862 which are connected to the steering shaft on the control
panel.

Disconnect the control harness connector (Item 1) Remove the four steering linkage mounting bolts (Item 1)
[Figure 50-100-4] from the control levers. [Figure 50-100-6].

Figure 50-100-5 Installation: Align the marks on the steering linkage bars.
Tighten the steering linkage mounting bolts to 35-40 ft.-lb.
(47,5-54,2 Nm) torque.

S2855

Remove the linkage (Item 1) [Figure 50-100-5] by


disconnecting it from the control valve and the shaft.

285 of 521 50-100-3 S100 Service Manual


CONTROL PANEL (CONT'D) Figure 50-100-9

Removal and Installation (Cont'd)

Figure 50-100-7

1
1
1
P-
263
29

1 1

S4387 S2858

Remove the control panel mounting bolts (Item 1) [Figure


S2856 50-100-9] from both sides of the control panel.

Installation: Tighten the control panel mounting bolts to


Figure 50-100-8 15-20 ft.-lb. (20-27 Nm) torque.

Remove the control panel from the loader.

Reverse the removal procedure to install the control


panel.

1
S2857

Remove the control panel mounting bolts (Item 1) [Figure


50-100-7] and [Figure 50-100-8] from both sides of the
control panel.

Installation: Tighten the control panel mounting bolts to


15-20 ft.-lb. (20-27 Nm) torque.

286 of 521 50-100-4 S100 Service Manual


CONTROL PANEL (CONT'D) Shaft Disassembly And Assembly

Shaft Removal And Installation Figure 50-100-12

NOTE: The steering shaft can be removed without


removing the control panel from the loader.
1
Figure 50-100-10

2
2

P-4154

1 Disassemble the right and left steering bellcranks (Item


1) [Figure 50-100-12] from the cross shaft assembly.
S2855
Assembly: Install new nylon bushings (Item 2) [Figure
50-100-12] as needed when assembling the steering
Remove the linkage (Item 1) [Figure 50-100-10] by shaft. Be sure to apply grease on the cross shaft before
disconnecting it from the control valve and the shaft. installing the right and left bellcranks.

Remove the steering linkages (See Linkage Removal And NOTE: The bellcranks should pivot freely on the cross
Installation on Page 50-100-6.). shaft when assembled correctly.

Figure 50-100-11 Figure 50-100-13

1
1
1

S4227
S2857

Remove Control Handle Lever (See Lever Removal And To remove the steering shaft mounting bracket, remove
Installation on Page 50-100-1.) the three mounting bolts (Item 1) [Figure 50-100-13] from
the front of the control panel.
Remove the steering shaft pivot bolt (Item 1) [Figure 50-
100-11] from both sides of the control panel. Remove the steering shaft mounting bracket.
Installation: Tighten the pivot bolts to 25-28 ft.-lb. (34-38 Installation: Tighten the mounting bolts to 15-20 ft.-lb.
Nm) torque. (20-27 Nm) torque.

Remove the steering shaft from the control panel.

287 of 521 50-100-5 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-14

Linkage Removal And Installation

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
S2855

Remove the steering linkage mounting bolt and nut (Item

WARNING 1) [Figure 50-100-14]. Do this for both steering linkages.

Installation: Tighten the steering linkage mounting bolts


Put jackstands under the front axles and rear corners to 35-40 ft.-lb. (47,5-54,2 Nm) torque.
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall Figure 50-100-15
or move and cause injury or death.
W-2017-0286

Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

Lift and block the loader. (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Raise the operator cab (See Raising on Page 10-30-1.) 1

S2860

Remove the steering linkage mounting bolt (Item 1)


[Figure 50-100-15]. Do this for both steering linkages.

Installation: Tighten the steering linkage mounting bolts


to 35-40 ft.-lb. (47,5-54,2 Nm) torque.

Remove the steering linkages from the loader.

NOTE: After removal and installation of the linkage,


the linkage neutral adjustment procedure
must be performed.

288 of 521 50-100-6 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-18

Pintle Arm Removal And Installation


7
Figure 50-100-16 6 8
3 1 4
1

2
5
2
P-48630

The centering plate / centering spring assembly consists


2 of the following parts [Figure 50-100-18]:
P-48631

ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-16]. 1 Bolt
2 Bushings
Remove the bolt / spring assembly.
3 Washer
Installation: Tighten the centering spring bolt and a NEW 4 Bushing Spacer
lock nut to 25-28 ft.-lb. (34-38 Nm) torque.
5 Spring
Figure 50-100-17 6 Lock Nut
7 Centering Plate
8 Guide Bushings
1

P-48632

Slide the centering plate (Item 1) [Figure 50-100-17] to


the right to remove it from the hydrostatic pumps.

NOTE: Directions are shown and stated as if you were


sitting in the operators seat.

289 of 521 50-100-7 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-20

Pintle Arm Removal And Installation (Contd)

Figure 50-100-19
2
1

3
2 3
6

5
1
1 4
2
1
P-48627
2

If the surface of any of the four solid pintle cams (Item 1)


P-48629 are worn, loosen the bolt (Item 2) [Figure 50-100-20] and
rotate the cams 1/4 turn.

Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-19]. 20] from the pintle.

If the centering blocks need replacement, remove the Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2
bolts (Item 2) [Figure 50-100-19]. Remove the centering Nm) torque.
blocks.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Installation: Tighten the centering block bolts to 35-40 ft.- 100-20].
lb. (47,5-54,2 Nm) torque.
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-20].
centering plate.

NOTE: If the centering blocks are worn, they can be


removed and rotated 180 degrees and
reinstalled. If the solid cams are worn, they can
be loosened and rotated 90 degrees and
reinstalled.

290 of 521 50-100-8 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-23

Pintle Arm Removal And Installation (Contd)

Figure 50-100-21

2
2
3
4
3 1

P-48659
2

1 NOTE: When installing the pintle base (Item 1) onto


P-48624 the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure 50-
100-23].
Remove the bolt and nut (Item 1) [Figure 50-100-21].
Installation: Install the pintle base (Item 1) onto the pump
Inspect the washers (Item 2), pintle arm (Item 3) and the shaft (Item 2) [Figure 50-100-23]. The top of the pintle
steering linkage bar (Item 4) [Figure 50-100-21] for base should be level with the top of the pump shaft.
damage and replace as needed. Tighten the bolt to 35-40 ft.-lb. (47,5-54,2 Nm) torque.

NOTE: The washers (Item 2) [Figure 50-100-21] are NOTE: After installing the linkage onto the
hardened, and should only be replaced hydrostatic pumps the linkage neutral
through Bobcat Parts. adjustment procedure must be performed.

Figure 50-100-22 Figure 50-100-24

1
1
P-54615 P-54625

Loosen the bolt (Item 1) and remove the pintle base (Item Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-22]. 2) [Figure 50-100-24] and inspect the pintle solid cams
for damage or excessive wear.

Installation: Tighten the bolts to 35-40 ft.-lb. (47,5-54,2


Nm) torque.

291 of 521 50-100-9 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-26

Pintle Arm Disassembly and Assembly

Figure 50-100-25

4 1 3
2
2

P-48619
3

Using a bushing driver (Item 1) remove the torsion


P-54626 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) [Figure 50-
100-26] to catch the torsion bushing.
Remove the base pintle (Item 1) [Figure 50-100-25] from
the pump shaft. Installation: Install the torsion bushing (Item 2) [Figure
50-100-26] into the pintle arm using the same procedure
Remove the retaining bolt (Item 2), adjusting screw (Item as the removal.
3) and neoprene dampener (Item 4) [Figure 50-100-25]
from the base pintle. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Inspect parts for wear and damage, replace as needed. arm should be the same.

NOTE: Anti-sieze should be used on the adjusting


screw to prevent corrosion and allow free
movement while adjusting.

292 of 521 50-100-10 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-28

Linkage Neutral Adjusting

The following tool listed will be needed to do the following


procedure:

MEL1563 - Remote Start Tool Kit

Connect the remote start tool to the engine harness. (See


Remote Start Procedure on Page 10-60-4.) 1

Lift and block the loader. (See LIFTING AND BLOCKING


THE LOADER on Page 10-10-1.)

Figure 50-100-27 S2855

3
Loosen the bolt / nut (Item 1) [Figure 50-100-28] only
until the tension is released from the torsion bushing.

Figure 50-100-29
2
1
1

P-48450 2

Tool that may assist in the neutral adjustment [Figure 50-


100-27].

To make this tool use a locking grip C-Clamp and grind P-54613
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-27] to a small rounded edge.
Loosen the nut (Item 1) only until the tension is released
A steering centering block (Item 3) [Figure 50-100-27] is from the torsion bushing (Item 2) [Figure 50-100-29].
also needed. The centering block can be placed as shown
and welded to the C-clamp if desired. NOTE: The bolt must be loose enough to allow the
torsion bushing (Item 2) [Figure 50-100-29] to
turn freely between the torsion bushing and
the steering linkage bar.

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall
or move and cause injury or death.
W-2017-0286

293 of 521 50-100-11 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-32

Linkage Neutral Adjusting (Contd)

Figure 50-100-30
2

2 P16121

Using the remote start tool, turn the key (Item 1) [Figure
S5974 50-100-32] to the run position.

Move the traction lock override switch (Item 2) [Figure 50-


Loosen the two bolts (Item 1) holding the right centering 100-32] so the traction function is unlocked. (The traction
block. Move the right hand centering block (Item 2) lock override switch light will be ON.) On a standard
[Figure 50-100-30] until both pintle cams contact the loader the wedge brake will unlock.
centering block.
NOTE: When the engine is started, the wheels/tracks
NOTE: The left centering block is not adjustable. By may begin to move.
adjusting the right centering block the left
centering block will also become aligned NOTE: In loaders equipped with manual steering and
properly. hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-31 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key (Item 1) [Figure
50-100-32] and start the engine and run at low idle.

Tighten bolts (Item 3) [Figure 50-100-31] to 35-40 ft.-lb.


(47,5-54,2 Nm).
1
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-30] and [Figure 50-
2 100-31].
S5975

A modified locking grip C-Clamp and steering block


shown in [Figure 50-100-27] may be used to help in
aligning the centering blocks.

Install the centering block (Item 1) on the inside of the


pintle cams and the C-Clamp (Item 2) [Figure 50-100-31]
around both centering blocks.

Lock the C-Clamp in place.

294 of 521 50-100-12 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-34

Linkage Neutral Adjusting (Contd)

Start the neutral adjustment procedure with the left


pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.

Figure 50-100-33

2 1
1

P-54610

Move the engine speed control to high idle.

NOTE: The neutral range (dead-band) will vary


between the hydrostatic pumps.

NOTE: This procedure is shown for neutral


P-48632
adjustment on the left side of the loader. The
procedure is the same for the right side neutral
adjustment.
Loosen the left pump pintle adjustment lock bolts (Item
1). (The right pump pintle adjustment lock bolts are (Item Turn the adjustment screw (Item 1) [Figure 50-100-34]
2) [Figure 50-100-33].) Loosen the bolts enough to allow counterclockwise until forward creep is seen.
free movement between the pintle arm and the pintle
base. Turn the adjustment screw (Item 1) [Figure 50-100-34]
counterclockwise to a point between forward and reverse
NOTE: If the bolts are too loose or too tight, the where there is zero creep.
neutral adjustment may be affected.
Stroke the left steering lever to forward and allow the lever
to return to neutral. Stroke the left steering lever to reverse
and allow the lever to return to neutral. Check that there is
zero creep when the lever returns from either direction, on
the left side. Turn the adjustment screw (if necessary) until
zero creep is obtained.

295 of 521 50-100-13 S100 Service Manual


CONTROL PANEL (CONTD) Linkage Travel Adjusting

Linkage Neutral Adjusting (Contd) NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
Figure 50-100-35 adjustment procedure, check the torsion
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.

1
2 2 1

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
P-48632 W-2059-0598

Torque the left pump pintle adjustment lock bolts (Item 1) Raise the lift arms and install an approved lift arm support
[Figure 50-100-35] to 35-40 ft.-lb. (47,5-54,2 Nm). device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)
Repeat the adjustment procedure for the right pump.

Torque the right pump pintle adjustment lock bolts (Item 2)


[Figure 50-100-35] to 35-40 ft.-lb. (47,5-54,2 Nm).

Test both levers by moving them backward and forward


WARNING
and letting them return to neutral by the return spring
Put jackstands under the front axles and rear corners
force.
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall
If the levers do not return to neutral and the wheels do not
come to a complete stop, repeat the adjustment or move and cause injury or death.
procedure again. W-2017-0286

Stop the engine.


Lift and block the loader. (See LIFTING AND BLOCKING
Remove one pintle adjustment bolt (Item 1) [Figure 50- THE LOADER on Page 10-10-1.)
100-35] at a time and apply loctite 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the Raise the operator cab. (See Raising on Page 10-30-1.)
bolt to 35-40 ft.-lb. (47,5-54,2 Nm). Repeat for the three
remaining pintle adjustment lock bolts. Pre-load tension in the torsion bushings must be removed
before adjusting the steering linkage.
NOTE: To maintain proper adjustment setting,
remove and reinstall only one bolt at a time.
New bolts can be installed with pre applied
loctite.

Remove the loader remote start tool.

NOTE: After the neutral adjustment is completed on


both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
Adjusting on Page 50-100-14.)

296 of 521 50-100-14 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-38

Linkage Travel Adjusting (Contd)

Figure 50-100-36
1

1
S2861

Remove access plug from the top of the control panel.


S2855
Turn the control lever drift adjustment bolts (Item 1)
[Figure 50-100-38] (one on each control lever) out until it
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt is flush with the bottom of the nut.
(Item 2). The bolt (Item 2) [Figure 50-100-36] must be
loosened enough to allow the torsion bushing to turn Figure 50-100-39
freely between the steering bellcrank and the linkage bar.

Figure 50-100-37

3 2

4
1
P-51173

P-54613 Move the right side steering lever to the rear and install a
3/8 inch (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) [Figure
Loosen the nut (Item 1) only until the tension is released 50-100-39].
from the torsion bushing (Item 2) [Figure 50-100-37].

The bolt must be loose enough to allow the torsion


bushing (Item 2) [Figure 50-100-37] to turn freely
between the torsion bushing and the linkage bar.

297 of 521 50-100-15 S100 Service Manual


CONTROL PANEL (CONTD) Figure 50-100-41

Linkage Travel Adjusting (Contd)

Figure 50-100-40

2
2

1
P-51133

1 3 4
Before adjusting the linkage, check that the base pintle
P-51174 arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-41] and tighten to
35-40 ft.-lb. (48-54 Nm) torque. There should be no play
Move the right side steering lever forward and install a 15/ between the pintle arm and the square pump shaft.
16 inch (24 mm) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50- Also check that the cam mounting nuts or bolts (Item 4)
100-40]. [Figure 50-100-39] are tight, 35-40 ft.-lb. (48-54 Nm)
torque.
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel speed.

Remove the 3/8 inch (10 mm) thick spacer (Item 4)


[Figure 50-100-40].

298 of 521 50-100-16 S100 Service Manual


CONTROL PANEL (CONT'D) Figure 50-100-43

Linkage Travel Adjusting (Cont'd)

Figure 50-100-42

P-51175
1
1
S4381
Remove the spacer (Item 1) [Figure 50-100-43].

Disconnect the remote start tool. (See Remote Start


Loosen the two bolts and nuts (Item 1) [Figure 50-100- Procedure on Page 10-60-4.)
42] on each steering linkage bar.
Figure 50-100-44
Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm 2
is rotated to the front as far as possible. Use a locking
plier, clamp the two linkage bars together.

Installation: Tighten the nuts and bolts to 35-40 ft.-lb.


(47,5-54,2 Nm) torque.

Check the lever movement to make sure that the pintle


arm and the control lever are both at full stroke at the
1
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the
right side linkage.

P-54613

Tighten the two bolts (Item 1) and nuts (Item 2) [Figure


50-100-44] to 35-40 ft.-lb. (47,5-54,2 Nm).

299 of 521 50-100-17 S100 Service Manual


CONTROL PANEL (CONT'D) Figure 50-100-46

Linkage Travel Adjusting (Cont'd)

Figure 50-100-45
1

1
S2861

Push the control lever to full stroke and turn drift


S2855 adjustment bolt (Item 1) [Figure 50-100-46] in until it
touches the U-bolt holding the control lever.

Tighten the two bolts and nuts (Item 1) [Figure 50-100- Repeat steps on the other control lever.
45] to 35-40 ft.-lb. (47,5-54,2 Nm) torque at the steering
bell cranks. Drive the loader forward and check for drift.

The traditional benchmark for drift is less than 10 ft. (3048


mm) of drift in 100 ft. (30480 mm) of travel distance.

If the drift is excessive to the left, turn the right adjustment


bolt (Item 1) [Figure 50-100-46] in.

If the drift is excessive to the right, turn the left adjustment


bolt in.

NOTE: When using the drift adjustment bolts, only


adjust one bolt for each test drive.

In addition, only move each bolt a maximum of


one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.

Drift adjustment is for forward travel only.

Adjust the drift to an acceptable level.

Re-install the plug in the drift bolt access hole after


adjustment.

300 of 521 50-100-18 S100 Service Manual


CONTROL HANDLE / LEVER Boot Removal And Installation

Description Figure 50-110-2

The control handles / levers are used to control the


forward and reverse travel.

The control handles / levers are mounted onto the control


panel.

Lever Removal And Installation 2

Figure 50-110-1

1
1
P-28845

To replace the rubber boot (Item 1) [Figure 50-110-2] on


the control panel, remove the control lever (See Lever
Removal And Installation on Page 50-110-1)

Drill out the four rivets (Item 2) [Figure 50-110-2] located


on the flange of the rubber boot and remove the old boot.

S2863 Install the new boot and reinstall the control lever.

Remove the nuts from the two U-bolts (Item 1) [Figure


50-110-1] used to mount the control lever.

Remove the U-bolts from the control lever mount.

Remove the control lever (Item 2) [Figure 50-110-1] by


sliding the lever through the rubber boot (Item 1) [Figure
50-110-2] on the front of the control panel.

Installation: Tighten the U-bolts so the lever can not be


moved right or left when seated in the operator seat. Be
sure the control lever does not interfere with the operator
cab when lowering or raising the cab.

301 of 521 50-110-1 S100 Service Manual


302 of 521 50-110-2 S100 Service Manual
WINDOW (REAR) Figure 50-120-3

Removal

Figure 50-120-1

P16015A

Apply liquid soap on the rubber cord to make installation


P-64994 easier. Install the rubber cord (Item 1) [Figure 50-120-3]
into the molding on the inside of the operator cab.
Pull on the tag (Item 1) [Figure 50-120-1] on the rear
window to remove the rubber cord. Install the safety tag in the top center of the cord.

Using gloves, push the rear window out the rear of the Figure 50-120-4
operator cab.

NOTE: If rear window was broken, remove all glass


fragments from the rubber molding before
installing a new window.

Installation

Clean the area before installing the rubber molding.


1
Figure 50-120-2

P-64997

Apply liquid soap in the rubber molding (Item 1) [Figure


50-120-4] to make installation easier.

Install the window from the outside of the operator cab.

1 Install a lower corner of the rear window into the corner of


the molding. [Figure 50-120-4].

Align the other lower corner of the window in the molding.


P16014

Work the window downward until the window is fully


Install the rubber molding (Item 1) [Figure 50-120-2] seated in the lower portion of the molding.
around the edge of the rear opening in the operator cab.

If replacing the rubber molding (Item 1) [Figure 50-120-2]


cut off the excess molding.

303 of 521 50-120-1 S100 Service Manual


WINDOW (REAR) (CONTD) Figure 50-120-6

Installation (Contd)

Figure 50-120-5

1
P16013

Use the plastic stick (Item 1) [Figure 50-120-6] to position


P-64998 the locking tab into the groove to secure the window in the
molding.

Use a plastic stick (Item 1) [Figure 50-120-5] under the Tapping the window corners will help seat the window in
molding lip to guide the window into the molding groove. the molding.

304 of 521 50-120-2 S100 Service Manual


WINDOW (TOP) Figure 50-121-2

Removal And Installation

Figure 50-121-1

1 1

1
1

P-24378
1
1
Remove the bolts (item 1) [Figure 50-121-2], lift the
N-20950 window and remove the bushings.

install the bolts (Item 1) [Figure 50-121-2] through the


Loosen the knobs (Item 1) [Figure 50-121-1]. window grommels, the nylon bushings and through the
cab holes.
Installation: do not overtighten the knobs. This may
damage the window.

305 of 521 50-121-1 S100 Service Manual


306 of 521 50-121-2 S100 Service Manual
WINDOW (SIDE) Figure 50-122-3

Removal And Installation

Figure 50-122-1
2

N-20814

From inside the operator cab, loosen the knobs (Item 1)


P-66024 [Figure 50-122-2] and [Figure 50-122-3] on the window
slide rail bolts.

Release the latch (Item 1) [Figure 50-122-1] and slide the Move the window slide rail using the two thumb pads
front window back towards the rear of the operator cab. (Item 2) [Figure 50-122-2] and [Figure 50-122-3] towards
the rear of the operator cab and then down towards the
Figure 50-122-2 bottom of the operator cab.

NOTE: The top of the window should come out of the


top slide rail at this time. Make sure the
window is secure and does not fall. Make sure
the slide rails are in alignment and the window
1 1 is positioned in the top track during
installation.

Remove the front side window from the operator cab.

2 2 Figure 50-122-4

P-66019

2
1

P-66021

Installation: When installing the window make sure the


slide rail (Item 1) adjoins the front stationary slide rail
(Item 2) [Figure 50-122-4].

307 of 521 50-122-1 S100 Service Manual


WINDOW (SIDE) (CONTD)

Removal And Installation (Contd)

Figure 50-122-5

P-66020

The rear side window sets in a recessed groove.

NOTE: The window should be secured to prevent


damage when the bolt (Item 1) [Figure 50-122-
5] is loosened.

Loosen the bolt (Item 1) [Figure 50-122-5] on the rear


side window.

Remove the rear side window.

308 of 521 50-122-2 S100 Service Manual


WINDOW (FRONT DOOR) Figure 50-123-3

Removal (Standard Window)

Figure 50-123-1

3 1
2
1
1

1 S0366

Push the window out at any corner of the window (Item 1)


P-66051 [Figure 50-123-3].

NOTE: The window may fall when pushing on the


Remove the wiper arm assembly (Item 1) [Figure 50-123- corners. Have a second technician assist you
1]. during the removal of the window.

Remove the two screws (Item 2) and the nut (Item 3)


[Figure 50-123-1].

Secure the wiper motor inside the cab.

Figure 50-123-2

N-20171

Pull the plastic loop (Item 1) [Figure 50-123-2] at the top


of the window to remove the rubber cord.

309 of 521 50-123-1 S100 Service Manual


WINDOW (FRONT DOOR) (CONTD) Figure 50-123-6

Installation (Standard Window)

Clean the area before installing the rubber molding.

Figure 50-123-4
1

P-66059

Apply liquid soap in the rubber molding to make


installation easier.

P-66058 Install the window from the outside of the door frame.

Install a lower corner of the rear window (Item 1) [Figure


Install the rubber molding (Item 1) [Figure 50-123-4] 50-123-6] into the corner of the molding.
around the edge of the front door frame starting at the
bottom of the door frame. Align the other lower corner of the window in the molding.

If replacing the rubber molding (Item 1) [Figure 50-123-4] Work the window downward until the window is fully
cut off the excess molding. seated in the lower portion of the molding.

Figure 50-123-5 Figure 50-123-7

1
1

P-66651 P-66050

Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-123-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-123-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.

310 of 521 50-123-2 S100 Service Manual


WINDOW (FRONT DOOR) (CONTD) Removal And Installation (Special Applications
Window)
Installation (Standard Window) (Contd)
Replace the Lexan glazing under the following conditions:
Figure 50-123-8
When the glazing is four years old;
When the glazing becomes yellow or hazed;
Is scratched on either side with scratches that can be
felt with the fingernail;
Has cracks coming from the edges or mounting holes.
or fine cracks on the surface area;
Has contacted any fluids that have caused cloudiness.
Figure 50-123-10
1

1
P-66049A

Use the plastic stick (Item 1) [Figure 50-123-8] to position


the locking tab into the groove to secure the window in the
molding.

Tapping the window corners will help seat the window in


the molding.
P-66101
Figure 50-123-9

Remove window from loader.

1 NOTE: The Special Applications window is held on by


the brackets only, it does not sit in the rubber
molding. During Removal the window may fall
as the mounting bolts are loosened.

Remove the five mounting brackets and bolts (Item 1)


[Figure 50-123-10].
2

P-66051

Install the wiper motor (Item 1) and wiper arm assembly


(Item 2) [Figure 50-123-9].

311 of 521 50-123-3 S100 Service Manual


312 of 521 50-123-4 S100 Service Manual
CAB DOOR Figure 50-130-2

Description

The standard cab door is available as an option or dealer


installed kit. The Special Application Kit Door or Forestry
Door kit are available for use with certain attachments.

Removal And Installation

Figure 50-130-1

3
2

P-76520

1
P-76526
Open the cab door.

Remove the gas spring (Item 1) [Figure 50-130-1] from Lift the door (Item 1) [Figure 50-130-2] off the hinges.
the threshold.

Disconnect the electrical harnesses (Items 2 and 3)


[Figure 50-130-1].

Disconnect the washer bottle hose (Item 4) [Figure 50-


130-1].

50-130-1 S100 Service Manual


313 of 521
CAB DOOR (CONTD) Aligning

Removal And Installation (Contd) Figure 50-130-4

Figure 50-130-3 WRONG WRONG

2 1

P-76523A P-76524A

Figure 50-130-5

CORRECT CORRECT

1
2

N-20132
1
1
Remove the four bolts and nuts (Item 2) [Figure 50-130-
3] from the cab. P-76522A P-76525A

Remove the hinges (Item 1) [Figure 50-130-3] from the


cab. When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-130-4] between the door
Installation: Install the hinges (Item 1) on the cab and and the cab or the striker and the latch.
use the bolts and nuts (Item 2) [Figure 50-130-3] to
secure the hinges. Tighten to 7-7.9 ft.-lb. (9,6-10,7 Nm) If adjustment is needed. (See Adjusting on Page 50-140-
torque. 3.)

When the striker or latch is adjusted properly there will be


no gap (Item 1) [Figure 50-130-5] between the door and
the cab or the striker and the latch.

After verifying alignment check for proper operation. (See


Checking Operation on Page 50-130-3.)

50-130-2 S100 Service Manual


314 of 521
CAB DOOR (CONTD) Checking Operation

Adjusting Figure 50-130-8

Figure 50-130-6

1
1
EM1026

P-76521
Sit in operators seat. Turn key ON. (Standard Key Panel),
press RUN / ENTER button (Deluxe Instrumentation
Loosen the two bolts (Item 1) [Figure 50-130-6] and Panel), lower seat bar and close the door. Press the
adjust the latch as needed. PRESS TO OPERATE LOADER button (Item 1) [Figure
50-130-8].
NOTE: For the initial adjustment, position the latch
towards the bottom of the door. Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-130-8] will flash, an audible tone will sound,
Figure 50-130-7 and the message [door] will appear in the display.

Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-130-8] will go out and the display will return to
machine hours.

P-76516

Loosen the striker and adjust as needed (Item 1) [Figure


50-130-7].

NOTE: For the initial adjustment, position the striker


towards the front of the machine.

After adjusting the striker and latch recheck the alignment


of the door sensor (See Aligning on Page 50-130-2.)

50-130-3 S100 Service Manual


315 of 521
50-130-4 S100 Service Manual
316 of 521
ELECTRICAL SYSTEM & ANALYSIS

ALTERNATOR 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4

BACK-UP ALARM SYSTEM 60-170-1


Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-3

BATTERY 60-20-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2 ELECTRICAL
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . 60-20-3 SYSTEM &
ANALYSIS
BOBCAT CONTROLLER (MAIN) 60-70-1
Connector Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4

BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 60-90-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS Controller (Engine STOPPED - Key ON). . . 60-90-1
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . 60-90-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . 60-90-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4

CONTROL PANEL SETUP 60-140-1


Attachment Control Information (Deluxe Instrumentation Panel) 60-140-2
Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . 60-140-1

DIAGNOSTIC SERVICE CODES 60-80-1


Viewing Service Codes (Deluxe Instrumentation Panel) . . . . . . . . 60-80-1
Viewing Service Codes (Standard Key Panel) . . . . . . . . . . . . . . . 60-80-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2

Continued On Next Page

317 of 521 60-01 S100 Service Manual


ELECTRICAL SYSTEM & ANALYSIS (CONTD)

ELECTRICAL SYSTEM INFORMATION 60-10-1


Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . 60-10-8
Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7

FLYWHEEL RPM SENSOR 60-130-1


Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

INSTRUMENT PANELS 60-50-1


Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Deluxe Instrumentation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Front Accessory Panel Removal And Installation . . . . . . . . . . . . . 60-50-8
Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-50-7
LCD Screen Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option And Field Accessory Panels . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Removal And Installation (Left And Right). . . . . . . . . . . . . . . . . . . 60-50-6
Standard Key Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3

LIGHTS 60-60-1
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

MAINTENANCE CLOCK 60-160-1


Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-2

PASSWORD SETUP 60-150-1


Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-2
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-2

SEAT BAR SENSOR 60-100-1


Bobcat Interlock Control System (BICS) Circuit Test. . . . . . . . . . 60-100-5
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Continued On Next Page

318 of 521 60-02 S100 Service Manual


ELECTRICAL SYSTEM & ANALYSIS (CONTD)

SERVICE PC (LAPTOP) 60-120-1


Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . 60-120-1
Connecting To The Remote Start Tool . . . . . . . . . . . . . . . . . . . . 60-120-1

STARTER 60-40-1
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

TRACTION LOCK 60-110-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE


STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION
SPEC-01) UNLESS OTHERWISE SPECIFIED.

319 of 521 60-03 S100 Service Manual


320 of 521 60-04 S100 Service Manual
ELECTRICAL SCHEMATIC
S100 (S/N A2G811001 AND ABOVE)
(S/N A8ET11001 - A8ET19999)
(printed JANUARY 2009)
7136959

3600
3800

3200

8250 1010

2370

2380

3110
2410
8200

1020

3410
1800

2015
4370

3420
3400
4410
4380

2510

3200
2500

3100
8800
4200

8060 8040 2900


9350 9350
2860
2410 9360
2380 9210 9220 9200 9200
2370 9380
8250 9110 9120 9100 9100
3600 9370
1450
8020 8010
1710

9600
9500
2820

3010 3910
1210
3920 3920
3900 3900
2810 8080 8080

2810 7020 7022 7022


2750 2751 2751 2730

2790

3300 2780
3310
7000 7000
2760 7010
9800
2775 2775 2745
3430 7010
1440
2770 2765

1430
6100
3520
6010

6330

9360
9380
4110

3000
8000

6320

9370
8210

6230
8110

6210
8550

8510

4150
8150

6415
6515

2200 2200 1400


4200 4200 1410
4100 1370
1770
1700

6500
6400

6510
6410
1720
2720
8100 8100
8150 8800
2800 2800

6410
6510
6200

6310

6600
1410

8550

8500

8510
1440
1430

8100

8150
8110

3000
8000

2000

6230

6000
4150

1400

6200

6330
6210

6310
6320
8200
1370
4110

8210
4100

2600
7100
2010
1050

8000

Dealer Copy -- Not for Resale


1350

1360

1330
1070

1060

1030

1320
1140

1520

2040 2050 2060 1500 2020


2070 2070 2030 2030
8090
1300
1310
1410

1800
1700
1720
1730
1390
1770
2730
1710

1340

2900
7200
1080 1450 2510 1720
2500 2110 2720

2765
1070 2745
1040 2790 2090 1740
2710

1730
1390
1730

9600
9500
9800

1015 1060 2780


2740
1310 2730
1030
1050 2600
1110 1300 2800 2390
1340 2775 2015
1080
2710 2300 2100
2751
2000
2810
2720
2120
2200

3800
3910
3310 3010
3410
3110

printed in Europe 713695 (01-01-09)

321 of 521
ELECTRICAL SYSTEM INFORMATION

Glossary Of Electrical Symbols


SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting two harnesses together or represent an component that is
C107

3520 C C 3520
3510 B B 3510
a harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example:
three pin connectors shown). The
LIGHT -
C107 connector pins can be numbered
3500
A A
3500 alphabetical (shown) or numerical (1,
C C
3520
B B
3520 2, 3 etc.). The harness wires numbers
3510 3510
are called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.

COMPONENTS

- + BATTERY - Used for supplying and SWITCH - Single Pole - Double


storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.

GROUND - Used to represent an


external ground connection.

322 of 521 60-10-1 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD)

Glossary Of Electrical Symbols (Contd)


SYMBOL DESCRIPTION SYMBOL DESCRIPTION

COMPONENTS SOLENOID - Fuel and Traction Lock -

HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.

START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch to
warn personnel.

BUZZER - Audible alarm. Sounds at a


1
SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to


ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD

87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
GRD
control a high amp component. PARK V speed motor.
30 85 M
HIGH

FUSE - Used to protect the wire MOTOR - Washer - Single speed.


M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL

3700 3710 SPLICE () - Used to show when


3110
multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.

SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates


A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

323 of 521 60-10-2 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD)

Glossary Of Electrical Symbols (Contd)


SYMBOL DESCRIPTION

SENDERS AND SENSORS

+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
C
-
B pressure. (Sender voltage rating is
B
0.5 - 7.5 V listed to show volts at high and low
setting.)

B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)

to TEMPERATURE SENDER - Provides


B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000 ohm
ohm rating is listed to show ohms at
high and low setting.)

A TEMPERATURE SWITCH - The


B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)

FUEL SENDER - Provides a variable


B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)

C HALL EFFECT SENSOR - Detects


B linear or rotary position and provides
A a proportional variable voltage.

A
SPEED SENSOR - magnetic pickup -
detects RPM.
B

324 of 521 60-10-3 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD)

Cab Harness Connectors

Figure 60-10-1

C490

C480
C479

S1
S2

C260

C635
C408

C611

S6038

325 of 521 60-10-4 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD)

Mainframe Harness Connectors

Figure 60-10-2

S5950

326 of 521 60-10-5 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD)

Description

Figure 60-10-3

S6015

The electrical system is protected by fuses and relays


under the fuse panel cover (Item 1) [Figure 60-10-3]
located at the back of the loader.

The fuse panel cover (Item 1) [Figure 60-10-3] has a


decal inside to show the location and amp ratings.

IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397

327 of 521 60-10-6 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD)

Troubleshooting

The following troubleshooting chart is provided for


WARNING
assistance in locating and correcting BICS system AVOID INJURY OR DEATH
problems. It is recommended that these procedures be Instructions are necessary before operating or
done by authorized Bobcat Service Personnel only. servicing machine. Read and understand the
Operation & Maintenance Manual, Operators
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807

PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The cable and wire connection are not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

328 of 521 60-10-7 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD) Figure 60-10-6

Fuse And Relay Location / Identification 9 11 13 15


1 5 17
Figure 60-10-4 2 6 18

3 7 19
S0188 4 8 16 20
10 12 14

7135574

The location and sizes are shown below and in [Figure


S4014 60-10-6]:

REF DESCRIPTION AMP REF DESCRIPTION AMP


The electrical system is protected from overload by fuses
and relays under the fuse panel cover (Inset) [Figure 60- 1 Traction 30 11 Front and Marker R
Lights
10-4]. A decal is inside the cover to show location and
amp ratings. 2 Fuel Shutoff 30 12 Fuel Shutoff R
3 Power Plug 15 13 Rear Lights R
Figure 60-10-5 4 Switched Cab 15 14 Traction R
5 Heater 25 15 Switch Power R
6 Front and Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Remote Start / 25
Cab Lights
8 Bobcat Controller 25 18 Instrument 15
Power
9 Heater R 19 Alternator and 25
Accessories
10 Glow Plugs R 20 Attachments Plug 25

R - Relay
S4016

Remove the cover to check or replace the fuses [Figure


60-10-5].

329 of 521 60-10-8 S100 Service Manual


ELECTRICAL SYSTEM INFORMATION (CONTD) Solenoid Testing

Fuse And Relay Location / Identification (Contd) Figure 60-10-9

Figure 60-10-7

P9175

S6036

Use a test meter to measure coil resistance [Figure 60-


10-9]. Coil wires do not have polarity. Correct resistance
Figure 60-10-8 for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

S6037

The fans are protected by fan relays (Item 1) [Figure 60-


10-7] and two 50 amp fuses (Item 1) [Figure 60-10-8] that
are located next to the hydraulic reservoir.

330 of 521 60-10-9 S100 Service Manual


331 of 521 60-10-10 S100 Service Manual
BATTERY Figure 60-20-2

Removal And Installation

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get prompt
medical attention. When installing the battery in the loader, do not touch any
W-2065-0807 metal parts with the battery terminals.

Connect the negative (-) cable last to prevent sparks.


Open the rear door of the loader.
Connect and tighten the battery cables.
Figure 60-20-1
Close the rear door before operating the loader.

3
3
2

S4114

Disconnect the negative cable (Item 1) [Figure 60-20-1]


from the battery.

Remove the bracket (Item 2) by removing the screws


(Item 3) [Figure 60-20-1].

Disconnect the positive battery cable (Item 4) [Figure 60-


20-1].

Lift the battery out of the loader.

332 of 521 60-20-1 S100 Service Manual


BATTERY (CONTD) Figure 60-20-3

Servicing

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
The battery cables must be clean and tight. Check the
If electrolyte is taken internally drink large quantities electrolyte level in the battery. Add distilled water as
of water or milk! DO NOT induce vomiting. Get prompt needed. Remove acid or corrosion from the battery and
medical attention. cables with a sodium bicarbonate and water solution
W-2065-0807 [Figure 60-20-3].

Put Battery Saver (6988074) or grease on the battery


terminals and cable ends to prevent corrosion.

333 of 521 60-20-2 S100 Service Manual


BATTERY (CONTD) Figure 60-20-4

Using A Booster Battery (Jump Starting)

If it is necessary to use a booster battery to start the


engine, BE CAREFUL! There must be one person in the 2
operator's seat and one person to connect and disconnect 4
the battery cables.

The key switch must be OFF (Standard Key Panel) OR


the STOP Button must be pressed (Deluxe
Instrumentation Panel). The booster battery must be 12
volt.

3 1

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on P-31860
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.
Connect the end of the first cable (Item 1) to the positive
In case of acid contact, wash immediately with water. (+) terminal of the booster battery. Connect the other end
In case of eye contact get prompt medical attention of the same cable (Item 2) [Figure 60-20-4] to the positive
and wash eye with clean, cool water for at least 15 terminal on the loader starter.
minutes.
Connect the end of the second cable (Item 3) to the
If electrolyte is taken internally drink large quantities negative (-) terminal of the booster battery. Connect the
of water or milk! DO NOT induce vomiting. Get prompt other end of the same cable (Item 4) [Figure 60-20-4] to
medical attention. the engine.
W-2065-0807
Keep cables away from moving parts. Start the engine.

After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first.
WARNING Remove the cable from the positive terminal (Item 2)
[Figure 60-20-4].
AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
IMPORTANT
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F (16C) before Damage to the alternator can occur if:
connecting to a charger. Unplug charger before Engine is operated with battery cables
connecting or disconnecting cables to battery. Never disconnected.
lean over battery while boosting, testing or charging. Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
Battery gas can explode and cause serious injury. both cables from the battery.)
W-2066-0705 Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

334 of 521 60-20-3 S100 Service Manual


335 of 521 60-20-4 S100 Service Manual
ALTERNATOR Charging System Inspection

Belt Adjustment

Stop the engine and raise the operator cab (See Raising
on Page 10-30-1.) WARNING
Figure 60-30-1
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.

In case of acid contact, wash immediately with water.


In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities


of water or milk! DO NOT induce vomiting. Get prompt
medical attention.
W-2065-0807

S4014

2 WARNING
AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.

Do not jump start or charge a frozen or damaged


battery. Warm battery to 60F (16C) before
1 connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
S4022
Battery gas can explode and cause serious injury.
W-2066-0705
Loosen the alternator mounting bolt (Item 1) [Figure 60-
30-1].

Loosen the adjustment bolt (Item 2) [Figure 60-30-1].

Move the alternator until the belt has 2.3 mm movement at


IMPORTANT
the middle of the belt span with 2.16 - 2.33 lbf. (9.63 - 10.4
N) of force. Damage to the alternator can occur if:
Engine is operated with battery cables
Tighten the adjustment bolt and mounting bolts. disconnected.
Battery cables are connected when using a fast
Lower the operator cab (See Lowering on Page 10-30-2.) charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

336 of 521 60-30-1 S100 Service Manual


ALTERNATOR (CONTD) 1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test. (See Below.)
Charging System Inspection (Contd)
2. If the test light lights up, there is a short (drain) in the
Figure 60-30-2 electrical system of the loader. The short must be
repaired before the charging system can be checked.

3. Disconnect the red cables (Item 1) and L&S-terminal


connector (Item 2) [Figure 60-30-2]. If the test light
2
goes out, the alternator is faulty. If the test light stays
on, find the short in the system and repair it.
1
Alternator Voltage Testing

Figure 60-30-3

2
S5960

1
If the charging system malfunctions:

Check the condition and tension of the alternator belt


(See Belt Adjustment on Page 60-30-1.) Replace the
belt if it is worn.

Inspect the alternator wiring harness and the


connectors at alternator. The harness and connectors S5961
must be clean and tight.

Check the fuse for the alternator in the fuse panel. If Open the rear door.
the fuse is burnt, find the cause and repair / replace. If
the fuse is in doubt, remove it and check for continuity. Connect the remote start tool to the loader (See Remote
Start Procedure on Page 10-60-4.)
Check the electrolyte level in the battery. Add distilled
water as needed. (Does not apply to maintenance free Turn the engine on with the remote start tool and run at
batteries.) idle. With a voltmeter, check the voltage between the B+-
terminal (Item 1) and ground (Item 2) [Figure 60-30-3] at
Verify the charge of the battery. Make sure the battery the starter.
is fully charged.
The voltage must be higher than 13.5 volts but lower than
Disconnect the battery cables (negative first, then 14.7 volts at 70F (21 C) (Alternator temperature).
positive). Inspect the cable clamps and battery posts
for corrosion. Remove acid or corrosion from the If the voltage is higher than 14.7 volts, proceed to the
battery and cables with a sodium bicarbonate and following high voltage test.
water solution. Put grease on the cable ends and
battery terminals to prevent corrosion. Reconnect the If the voltage is lower than 13.5 volts, run the engine at
cable to the positive terminal. With the key off, connect high idle and recheck the voltage. If the voltage is still
a test light between the negative battery post and the below 13.5 volts, proceed with the following low voltage
disconnected negative cable clamp test.

337 of 521 60-30-2 S100 Service Manual


ALTERNATOR (CONTD) High Voltage Testing

Low Voltage Testing Figure 60-30-6

Figure 60-30-4

1 S4249

S4249
Turn engine OFF and remove the L&S-terminal connector
(Item 1) [Figure 60-30-6] from the alternator.
Turn engine OFF and remove the L&S-terminal connector
(Item 1) [Figure 60-30-4] from the alternator. NOTE: Check the continuity between the "S" terminal
and the positive (+) terminal on the battery or
Turn the remote start tool key to the ON position. starter. There should be continuity. If no
continuity, replace wire harness.
Figure 60-30-5
If the voltage is still above 14.7 volts at 70F (21 C)
(Alternator Temperature), then remove alternator for
replacement or repair. To repair, (See Alternator Voltage
Testing on Page 60-30-2.). for further component testing.

2 S5971

Check the voltage across the L&S-terminal (Item 1) and a


good ground source (Item 2) [Figure 60-30-5]. The
voltage should be what the battery voltage is. If not, check
wire harness, relay and fuses.

If the wire harness, relay and fuses are good then remove
the alternator for replacement or repair. To repair, (See
Alternator Voltage Testing on Page 60-30-2.) for further
component testing.

338 of 521 60-30-3 S100 Service Manual


ALTERNATOR (CONTD) Figure 60-30-7

Removal And Installation

Place jackstands under the rear corners of the loader.

S5972

WARNING Disconnect the both red cables (Item 1) [Figure 60-30-7]


from the alternator.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Disconnect the wiring harness connector (Item 2) [Figure
support device. Failure to use an approved lift arm 60-30-7] from the alternator.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 60-30-8
W-2059-0598

IMPORTANT 1

Damage to the alternator can occur if:


Engine is operated with battery cables
disconnected.
Battery cables are connected when using a fast
2
charger or when welding on the loader. (Remove
both cables from the battery.)
Extra battery cables (booster cables) are
S4248
connected wrong.
I-2023-1285

Remove the adjustment bolt (Item 1) [Figure 60-30-8]


Raise the lift arms and install an approved lift arm support from the mounting bracket.
device (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.) Remove the alternator belt (Item 2) [Figure 60-30-8] from
the alternator pulley.
Raise the operator cab (See Raising on Page 10-30-1.)

Disconnect the negative (-) cable from the battery.

339 of 521 60-30-4 S100 Service Manual


ALTERNATOR (CONTD)

Removal And Installation (Contd)

Figure 60-30-9

S4022

Remove the mounting bolt (Item 1) [Figure 60-30-9].

340 of 521 60-30-5 S100 Service Manual


ALTERNATOR (CONTD)

Parts Identification

1. Alternator 11. Bearing


2. Nut 12. Stator
3. Pulley 13. Housing 7
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Housing 16. Rectifier 1
7. Bolt 17. Cover
8. Bearing 18. Spacer 6
9. Retainer 19. Nut
10. Rotor

14
13
4 7
3
12 5
2

11
10

9
8

19

18

17

15 16 C-3529B

341 of 521 60-30-6 S100 Service Manual


STARTER Figure 60-40-3

Testing

Figure 60-40-1 2

Bat 1
S
M

Cranking
Motor
S2864

Disconnect the negative cable from the battery. (See


A-1992 Removal And Installation on Page 60-20-1.)

The key switch must be in the OFF position. Disconnect the S-terminal on the starter (Item 1) [Figure
60-40-3].
The battery must be fully charged.
Hold-In Test: Use circuit tester, attach one probe to the
The cable connections on the battery must be clean and L&S-terminal (Item 1) and one probe to the mounting bolt
tight. (Item 2) [Figure 60-40-3] on the magnetic switch
(solenoid). If there is no continuity replace the magnetic
Connect a jumper wire between L&S-terminal and BAT- switch (solenoid).
terminal [Figure 60-40-1].
Figure 60-40-4
If the starter turns but the engine does not turn, the starter
drive has a defect. 2

Figure 60-40-2
1
P-34675
Bat 1
S
M

2
Cranking
Motor
P-34674

Disconnect the negative (-) cable from the battery. (See


A-1991 Removal And Installation on Page 60-20-1.)

Connect a jumper wire (of at least four gauge in size) Disconnect the L&S-terminal on the starter (Item 1)
between the M terminal and the BAT terminal [Figure 60- [Figure 60-40-4].
40-2].
Pull-In Test: Use circuit tester, touch one probe to the
If the starter turns, the defect is in the solenoid. L&S-terminal (Item 1) and one probe to the starter motor
terminal (Item 2) [Figure 60-40-4]. If there is no continuity
If the starter does not turn, the starter is defective. replace the magnetic switch (solenoid).

342 of 521 60-40-1 S100 Service Manual


STARTER (CONTD) Figure 60-40-6

Removal And Installation

Stop the engine and open the rear door.

Remove the negative (-) and then the positive (+) cable
from the battery.
1
Figure 60-40-5

3 S5962

Remove the starter from the engine by removing the two


bolts (Item 1) [Figure 60-40-6].
3 2
1 Installation: Tighten the mounting bolts to 25-28 ft.-lb.
(34-38 Nm) torque.

S4121

Remove the red and black covering (Item 1) [Figure 60-


40-5] and loosen the nuts.

Disconnect the brown wire (Item 2) [Figure 60-40-5] from


the starter.

Disconnect the engine harness power wire and positive


(+) battery cable from the starter solenoid terminal (Item
3) [Figure 60-40-5].

343 of 521 60-40-2 S100 Service Manual


STARTER (CONTD)

Parts Identification

1. Starter
2. Frame
3. Brush
4. Armature
5. Yoke
6. Housing 1
7. Pinion
8. Clutch
9. Housing 2
10. Plunger

4 3

10

B-19162

344 of 521 60-40-3 S100 Service Manual


345 of 521 60-40-4 S100 Service Manual
INSTRUMENT PANELS
Left Panel

Figure 60-50-1

3 12
2

7 16
1
13
4

8 10 11 15
6 9

14
5

17 20

18 19

21 22

23

EM1026

The left instrument panel [Figure 60-50-1] is the same for


both Standard Key Panel and Deluxe Instrumentation
Panel equipped machines.

The table on the next page shows the DESCRIPTION and


FUNCTION / OPERATION for each of the components of
the left panel.

346 of 521 60-50-1 S100 Service Manual


INSTRUMENT PANELS (CONTD)

Left Panel (Contd)

REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 ENGINE OIL PRESSURE Engine oil pressure low or sensor error.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information.
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right turn signals are ON.
13 HYDRAULIC OIL PRESSURE Hydraulic oil pressure low or sensor error.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)
15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED
will light.) Press a second time to add REAR work lights. (Left and right
green LEDs will light.) Press a third time to turn all lights off. (Left and
right green LEDs will be off.)
Press and hold five seconds to display software version in display
screen.
18 HIGH-FLOW Not used.
19 AUXILIARY HYDRAULICS Not used.
20 INFORMATION Cycles through (after each button press):
Hourmeter (On start up)
Engine RPM
Battery voltage
Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running.
Press once to unlock the brakes. Allows you to use the steering levers
to move the loader forward or backward when using the backhoe
attachment or for service. (See TRACTION LOCK OVERRIDE in this
manual.) Press a second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS System when the seat bar is down and
operator is seated in operating position. Button will light.
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.

* For further description on Service Codes (See DIAGNOSTIC SERVICE CODES on PAGE 60-80-1.)

347 of 521 60-50-2 S100 Service Manual


INSTRUMENT PANELS (CONTD) Standard Key Panel

LCD Screen Functions Figure 60-50-3

Figure 60-50-2 1
2
1
6
3

S4002
S4498
5 4 3 2 S4001A

The functions of the key switch [Figure 60-50-3] are:


The LCD display is shown in [Figure 60-50-2]:
1. ENGINE STOP
1. DATA DISPLAY
2. ENGINE RUN / PREHEAT
2. SERVICE INDICATOR (in combination with (1):
3. ENGINE START
service clock)

If not active, OFF will be displayed.

Indicates the number of hours until the service interval


will expire. When the service interval has expired, it will
alternate between SRVCE and the hours it was set to.

3. BATTERY CHARGING CONDITION (battery voltage)

4. ENGINE REVOLUTIONS PER MINUTE (RPM)

5. ENGINE PREHEAT

6. HOURMETER

348 of 521 60-50-3 S100 Service Manual


INSTRUMENT PANELS (CONTD) 9. Keypad: The numeric keypad has two functions:
- To enter a number code (password) to allow starting
Deluxe Instrumentation Panel
the engine.
Figure 60-50-4 - To enter a number as directed for further use of the
Display Screen.
10. Start Button: Used to start the engine.
11. Run / Enter Button: Used to turn on the loaders
electrical system.

1 7 Figure 60-50-5
4
5
2 3 6

ENTER PASSWORD

8 LANGUAGES

B-16165

The first screen you will see on your new loader will be as
10 11 B-15553N shown in [Figure 60-50-5].

When this screen is on the display you can enter the


The machine may be equipped with a Deluxe
password and start the engine or change the Display
Instrumentation Panel [Figure 60-50-4].
Screen setup features.
1. Display Screen: The Display Screen is where all
NOTE: Your new loader (with Deluxe Instrumentation
system setup, monitoring, troubleshooting and error
Panel) will have an Owner Password. Your
conditions are displayed.
dealer will provide you with this password.
2. Bobcat Main Controller Error: Indicates Change the password to one that you will
communication error between Bobcat Main Controller easily remember to prevent unauthorized use
and Deluxe Instrumentation Panel. (See of your loader. (See Changing The Owner
DIAGNOSTIC SERVICE CODES on Page 60-80-1.) Password on Page 60-150-1.) Keep your
3. Display Error: Indicates communication error password in a safe place for future needs.
between instrument panel and Bobcat controller. (See
DIAGNOSTIC SERVICE CODES on Page 60-80-1.) Change Language: Press the Selection Button at the end
4. BobCARE PM SM
Icon: Indicates planned of the arrow [Figure 60-50-5] to go to the next screen.
maintenance is due. Use the Keypad to select the number of the language.
5. Engine Air Filter Icon: Indicates engine air filter
Press EXIT. The screen will return to [Figure 60-50-5].
requires service.
You can then enter the password and start the engine.
6. Hydraulic Filter Icon: Indicates hydraulic filter
requires service. See CONTROL PANEL SETUP for further description of
7. Selection Buttons: The four Selection Buttons allow screens to setup the system for your use. (See CONTROL
you to select items from the Display Screen and scroll PANEL SETUP on Page 60-140-1.)
through screens.
8. Stop Button: Used to stop the engine and shut down NOTE: Pressing the EXIT key will go to the previous
the loaders electrical system. screen and you can continue pressing until
you get to the initial (home) screen.
SHORTCUT: Press the 0 (zero) key to get to
the home screen immediately.

349 of 521 60-50-4 S100 Service Manual


INSTRUMENT PANELS (CONTD) The side accessory panel is shown in [Figure 60-50-7]:

Option And Field Accessory Panels Figure 60-50-7

The front accessory panel is shown in [Figure 60-50-6]: 1 2 3 4 5 6 7 8 9

Figure 60-50-6

S4005

1 2 3 4 5 6 7 8 REF.
DESC. FUNCTION / OPERATION
NO.
S2849
1 POWER PLUG Provides a 12 V receptacle for
accessories.
REF. 2 NOT USED ----
DESC. FUNCTION / OPERATION
NO. 3 FRONT WIPER Press the top of the switch to start
the front wiper (press and hold for
1 NOT USED ----
washer fluid).
2 BUCKET Press the top of the switch to retain Press the bottom to stop the wiper.
POSITION the bucket fixed in its relative 4 NOT USED ----
position to the ground. 5 NOT USED ----
Press the bottom to return to normal
6 NOT USED ----
operation.
7 FAN MOTOR Turn the knob clockwise to increase
3 BOB-TACH Press the top of the switch to move fan speed.
WEDGES UP/ the Bob-Tach wedges up (Power Turn counterclockwise to decrease.
DOWN Bob-Tach option). There are four positions; OFF-1-2-3.
Press the bottom to move the Bob-
8 NOT USED ----
Tach wedges down.
9 TEMPERATURE Turn the knob clockwise to increase
4 PARKING BRAKE Press the top of the switch to engage CONTROL the temperature.
the parking brake. Turn counterclockwise to decrease.
Press the bottom to disengage the
parking brake.
5 NOT USED ----
6 HAZARD LIGHTS Press the top of the switch to turn
(Option) the hazard lights ON.
Press the bottom to turn the hazard
lights OFF.
7 ROTATING Press the top of the switch to turn
BEACON (Option) the rotating beacon ON.
Press the bottom to turn the rotating
beacon OFF.
8 NOT USED ----

350 of 521 60-50-5 S100 Service Manual


INSTRUMENT PANELS (CONTD) Figure 60-50-10

Removal And Installation (Left And Right)

Figure 60-50-8
1

1
1

EM1026
1

Remove the three mounting bolts (Item 1) [Figure 60-50-


S4369 10].

Installation: Be careful to not overtighten the instrument


Remove the three mounting bolts (Item 1) [Figure 60-50- panel mounting bolts to prevent stripping of the threaded
8]. holes in the panels.

Installation: Be careful to not overtighten the instrument Figure 60-50-11


panel mounting bolts to prevent stripping of the threaded
holes in the panels.

Figure 60-50-9

3
2

1
S5976

Pull the left instrument panel down and disconnect the


S4334 two connectors (Item 1) [Figure 60-50-11] from the loader
alarm.

Pull the right instrument panel down and disconnect the Disconnect the two wire harness connectors (Item 2)
key switch wiring harness connector (Item 1) [Figure 60- [Figure 60-50-11] from the loader instrument panel.
50-9] from the panel.
Disconnect the connector (Item 3) [Figure 60-50-11] from
Remove the panel from the loader cab. the loader instrument panel.

Remove the instrument panel from the loader.

351 of 521 60-50-6 S100 Service Manual


INSTRUMENT PANELS (CONTD) Alarm Removal And Installation

Key Switch Removal And Installation Figure 60-50-14

Remove the right instrument panel from the loader (See


Removal And Installation (Left And Right) on Page 60-50-
6.)

Figure 60-50-12

S5978

1
2 Remove the left side instrument panel (See Removal And
Installation (Left And Right) on Page 60-50-6.)

S4498 Remove the retaining nut (Item 1) [Figure 60-50-14] from


the loader alarm.

Remove the ignition key (Item 1) from the switch. Remove Remove the alarm from the loader instrument panel.
the ignition switch retaining nut (Item 2) [Figure 60-50-12]
from the switch.

Figure 60-50-13

S5977

Remove the ignition switch (Item 1) [Figure 60-50-13]


from the control panel.

352 of 521 60-50-7 S100 Service Manual


INSTRUMENT PANELS (CONTD) Figure 60-50-16

Front Accessory Panel Removal And Installation

Figure 60-50-15

3
2 1

1 1

S5979

Pull the front accessory panel down and disconnect the


S0366 wire harness connector(s) (Items 1, 2, and 3) [Figure 60-
50-16] from the switches.

Remove the two mounting bolts (Item 1) [Figure 60-50- Remove the panel.
15].
Reverse the procedure to install the front accessory
Installation: Be careful to not overtighten the front panel.
accessory panel mounting bolts to prevent damage to the
plastic panel.

353 of 521 60-50-8 S100 Service Manual


LIGHTS Rear Removal And Installation

Front Removal And Installation Figure 60-60-2

Figure 60-60-1

S4326

S4339
Gently press the rear light through the light housing
[Figure 60-60-2].
Open the rear door.
Figure 60-60-3
Disconnect the negative (-) cable from the battery. (See
Removal And Installation on Page 60-20-1.)

Remove the light housing (Item 1) [Figure 60-60-1] from


the operator cab.

Remove the bulb assembly (Item 2) [Figure 60-60-1] from


the light housing by turning bulb assembly 1/4 turn.

Remove the bulb from the socket.

Reverse the above procedure to install the light.

S4327

With 1/3 of a turn, twist the light bulb out [Figure 60-60-3].

Reverse this procedure for installation.

354 of 521 60-60-1 S100 Service Manual


LIGHTS (CONTD) Figure 60-60-5

Cab Light Removal And Installation

Figure 60-60-4 1

1
1

P-66222

Remove and the bulb (Item 1) [Figure 60-60-5] from the


P-66221
light housing. Replace the bulb.

Remove the screws (Items 1) [Figure 60-60-4] from the


light cover.

NOTE: The wires for the switch will hold the light
cover. Do not pull the light cover too far away
from the light housing to prevent damage to
the wires.

Move the light cover to allow access to the bulb.

355 of 521 60-60-2 S100 Service Manual


BOBCAT CONTROLLER (MAIN)

Description

The main controller provides information to all other controllers. All loaders have a main controller.

The main controller is located behind the rear door, in the engine compartment, on the left side.

356 of 521 60-70-1 S100 Service Manual


BOBCAT CONTROLLER (MAIN) (CONTD)

Connector Identification

Controller

Harness Connector View Harness Connector View

S6041 / S6042

357 of 521 60-70-2 S100 Service Manual


BOBCAT CONTROLLER (MAIN) (CONTD)

Connector Identification (Contd)

Harness Connector View

6330 3300 x 3430 x x x x x x

3000 8250 x 9360 3520 x x 6230 x 8150

x x 4150 8550 3800 x 8210 x 9370 9380

2410 2380 8110 8000 8510 8210 4110 8080 2370


6320

Harness Connector View

9800 9350 3400 3900 x x x x x x

3920 3100 4410 x 2500 2510 3010 3200 x x

3420 1440 1430 8800 4380 4200 4370 9210 9110 x

S6043

358 of 521 60-70-3 S100 Service Manual


BOBCAT CONTROLLER (MAIN) (CONTD)

Removal And Installation

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Open the rear door.

Figure 60-70-1

1
P-67074

Remove the connectors (Item 1) [Figure 60-70-1].

NOTE: The connectors are keyed and will only plug in


one direction.

Loosen the mounting bolts (Item 2) [Figure 60-70-1] from


the Bobcat controller.

Installation: Tighten the bolts to 12-14 ft.-lb. (16,3-19


Nm) torque.

Reverse the above procedure to install the main


controller.

359 of 521 60-70-4 S100 Service Manual


DIAGNOSTIC SERVICE CODES Viewing Service Codes (Deluxe Instrumentation
Panel)
Viewing Service Codes (Standard Key Panel)
The Service Codes will aid your dealer in diagnosing
Figure 60-80-1 conditions which can damage your machine.

Figure 60-80-2
3 4

Press
TOOL / SETUP
2

Press
OWNER UTILITIES

1 EM1028

Press the INFORMATION button (Item 1) to cycle the Enter PASSWORD (owner
DATA DISPLAY (Item 2) [Figure 60-80-1] until the service or master) on Keypad
then press ENTER
code screen is displayed. If more than one SERVICE to Continue
CODE is present, the codes will scroll on the DATA
DISPLAY.

NOTE: Corroded or loose grounds can cause multiple


service codes and / or abnormal symptoms. All
instrument panel lights flashing, alarm Press
sounding, headlights and taillights flashing, SERVICE CODES
could indicate a bad ground. The same
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If
you observe these symptoms, check grounds
and positive leads first.
Press
Service Codes may be either a word (Item 3) or a number NEXT to view the next 8
(Item 4) [Figure 60-80-1]. (See following pages for Service Codes. (A total of 40
Codes can be stored.)
service codes.)

The following word errors may be displayed:


B-16163/B-24288/B-24290/B-24291/B-24298

[REPLY] One or both instrument panel(s) not


communicating with the controller. The Display Panel will list the Code Number, (CODE)
hourmeter reading when the error occurred (HOUR), and
[CODE] The controller is asking for a password. the User (USER) who was logged in to operate the
(Deluxe Instrumentation Panel only.) machine when the error occurred [Figure 60-80-2].
[ERROR] The wrong password was entered. (Deluxe A total of 40 Codes can be stored. When more than 40
Instrumentation Panel only.) codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.
[SHTDN] A shutdown condition exists.

[DOOR] Operator cab door is open. (Lift and Tilt


functions will not operate.)

360 of 521 60-80-1 S100 Service Manual


DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List

CODE DESCRIPTION CODE DESCRIPTION


A3623 ACD not programmed D3907 Left joystick Y-axis not in neutral
A8002 ACD output A error ON D4007 Right joystick Y-axis not in neutral
A8003 ACD output A error OFF D7501 CAN joystick communication error
A8005 ACD output A short to battery D7509 Operating mode switch short to ground or battery
A8006 ACD output A short to ground D7513 Right front wheel angle sensor unresponsive
A8007 ACD output A open circuit D7514 Left front wheel angle sensor unresponsive
A8032 ACD output A overcurrent D7515 Right rear wheel angle sensor unresponsive
A8102 ACD output B error ON D7516 Left rear wheel angle sensor unresponsive
A8103 ACD output B error OFF D7517 Left swash plate not in neutral
A8105 ACD output B short to battery D7518 Right swash plate not in neutral
A8106 ACD output B short to ground D7523 Right front wheel angle sensor out of range high
A8107 ACD output B open circuit D7524 Left front wheel angle sensor out of range high
A8132 ACD output B overcurrent D7525 Right rear wheel angle sensor out of range high
A8202 ACD output C error ON D7526 Left rear wheel angle sensor out of range high
A8203 ACD output C error OFF D7527 Left swash plate out of position
A8205 ACD output C short to battery D7528 Right swash plate out of position
A8206 ACD output C short to ground D7533 Right front wheel angle sensor out of range low
A8207 ACD output C open circuit D7534 Left front wheel angle sensor out of range low
A8232 ACD output C overcurrent D7535 Right rear wheel angle sensor out of range low
A8302 ACD output D error ON D7536 Left rear wheel angle sensor out of range low
A8303 ACD output D error OFF D7537 Sensor supply 1 out of range low
A8305 ACD output D short to battery D7538 Sensor supply 2 out of range low
A8306 ACD output D short to ground D7539 Left swash plate sensor out of range high
A8307 ACD output D open circuit D7540 Left swash plate sensor out of range low
A8332 ACD output D overcurrent D7541 Right swash plate sensor out of range high
A8402 ACD output E error ON D7542 Right swash plate sensor out of range low
A8403 ACD output E error OFF D7543 Left forward drive short to battery
A8405 ACD output E short to battery D7544 Left reverse drive short to battery
A8406 ACD output E short to ground D7545 Right forward drive short to battery
A8407 ACD output E open circuit D7546 Right reverse drive short to battery
A8432 ACD output E overcurrent D7547 Right front steer extend short to battery
A8502 ACD output F error ON D7548 Left front steer extend short to battery
A8503 ACD output F error OFF D7549 Right rear steer extend short to battery
A8505 ACD output F short to battery D7550 Left rear steer extend short to battery
A8506 ACD output F short to ground D7551 Steer pressure short to battery
A8507 ACD output F open circuit D7552 Back-up alarm error ON
A8532 ACD output F overcurrent D7553 Left forward drive short to ground
A8602 ACD output G error ON D7554 Left reverse drive short to ground
A8603 ACD output G error OFF D7555 Right forward drive short to ground
A8605 ACD output G short to battery D7556 Right reverse drive short to ground
A8606 ACD output G short to ground D7557 Right front steer extend short to ground
A8607 ACD output G open circuit D7558 Right front steer retract short to ground
A8702 ACD output H error ON D7559 Left front steer extend short to ground
A8703 ACD output H error OFF D7560 Left front steer retract short to ground
A8705 ACD output H short to battery D7561 Right rear steer extend short to ground
A8706 ACD output H short to ground D7562 Right rear steer retract short to ground
A8707 ACD output H open circuit D7563 Left rear steer extend short to ground
D7564 Left rear steer retract short to ground
D3905 Left joystick X-axis not in neutral D7565 Steer pressure short to ground

361 of 521 60-80-2 S100 Service Manual


DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Contd)

CODE DESCRIPTION CODE DESCRIPTION


D7566 Back-up alarm error OFF H2606 Front base solenoid short to ground
D7567 No communication from Gateway controller H2607 Front base solenoid open circuit
D7568 Angle sensors not calibrated H2632 Front base solenoid overcurrent
D7569 Battery voltage out of range high H2705 Front rod solenoid short to battery
D7570 Interrupted power H2706 Front rod solenoid short to ground
D7571 Battery voltage out of range low H2707 Front rod solenoid open circuit
D7572 Drive pump not calibrated H2732 Front rod solenoid overcurrent
D7573 Operating mode switch flipped while operating H2805 Diverter rod solenoid short to battery
D7574 Right speed uncommanded motion H2806 Diverter rod solenoid short to ground
D7575 Left speed uncommanded motion H2807 Diverter rod solenoid open circuit
D7577 Left speed sensor out of range high H2905 High-flow solenoid short to battery
D7578 Right speed sensor out of range high H2906 High-flow solenoid short to ground
D7579 Left speed sensor out of range low H2907 High-flow solenoid open circuit
D7580 Right speed sensor out of range low H2932 High-flow solenoid overcurrent
D7581 Right front steer retract short to battery H3128 Interrupted power failure
D7582 Left front steer retract short to battery H3648 ACD multiple
D7583 Right rear steer retract short to battery H3913 Left joystick grip no communication
D7584 Left rear steer retract short to battery H3916 Left joystick not connected
D7585 Sensor supply 1 out of range high H3928 Left joystick failure
D7586 Sensor supply 2 out of range high H3948 Left joystick multiple
D7587 Software update required H4013 Right joystick grip no communication
D7588 Switched power stuck ON H4016 Right joystick not connected
D7591 Left Swash Sensor Reversed H4028 Right joystick failure
D7592 Right Swash Sensor Reversed H4048 Right joystick multiple
D7593 Right speed sensor unresponsive H4423 Auxiliary not programmed
D7594 Left speed sensor unresponsive H4721 Sensor supply 1 out of range high
D7595 Left speed sensor reversed H4722 Sensor supply 1 out of range low
D7596 Right speed sensor reversed H7314 Remote control failure
D7597 Controller programmed H7328 Remote control no signal
D7598 In drive calibration mode H7404 Main controller no communication
D7599 In angle calibration mode H7604 Left hand panel no communication

H1221 Right Primary out of range high L0102 Left panel button 1 error ON
H1222 Right Primary out of range low L0202 Left panel button 2 error ON
H1224 Right Primary not in neutral L0302 Left panel button 3 error ON
H1321 Left Primary out of range high L0402 Left panel button 4 error ON
H1322 Left Primary out of range low L7404 Left panel main controller no communication
H1324 Left Primary not in neutral L7672 Left panel programming error
H2305 Rear base solenoid short to battery
H2306 Rear base solenoid short to ground M0116 Air filter not connected
H2307 Rear base solenoid open circuit M0117 Air filter plugged
H2332 Rear base solenoid overcurrent M0216 Hydraulic/Hydrostatic filter not connected
H2405 Rear rod solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2406 Rear rod solenoid short to ground M0309 Battery voltage low
H2407 Rear rod solenoid open circuit M0310 Battery voltage high
H2432 Rear rod solenoid overcurrent M0311 Battery voltage extremely high
H2505 Rear aux relief short to battery M0314 Battery voltage extremely low
H2506 Rear aux relief short to ground M0322 Battery voltage out of range low
H2605 Front base solenoid short to battery M0409 Engine oil pressure low

362 of 521 60-80-3 S100 Service Manual


DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Contd)

CODE DESCRIPTION CODE DESCRIPTION


M0414 Engine oil pressure extremely low M1707 Hydraulic lock valve solenoid open circuit
M0415 Engine oil pressure shutdown M1732 Hydraulic lock valve solenoid overcurrent
M0421 Engine oil pressure out of range high M1805 Lift spool lock short to battery
M0422 Engine oil pressure out of range low M1806 Lift spool lock short to ground
M0509 Hydraulic charge pressure low M1807 Lift spool lock open circuit
M0510 Hydraulic charge pressure high M1832 Lift spool lock overcurrent
M0511 Hydraulic charge pressure extremely high M2005 Two-speed primary short to battery
M0514 Hydraulic charge pressure extremely low M2006 Two-speed primary short to ground
M0515 Hydraulic charge pressure shutdown M2007 Two-speed primary open circuit
M0521 Hydraulic charge pressure out of range high M2032 Two-speed primary overcurrent
M0522 Hydraulic charge pressure out of range low M2102 Glow plug output error ON
M0610 Engine speed high M2103 Glow plug output error OFF
M0611 Engine speed extremely high M2107 Glow plug output open circuit
M0613 Engine speed no signal M2128 Glow plug output failure
M0615 Engine speed shutdown M2202 Starter output error ON
M0618 Engine speed out of range M2203 Starter output error OFF
M0710 Hydraulic oil temperature high M2207 Starter output open circuit
M0711 Hydraulic oil temperature extremely high M2228 Starter output error failure
M0715 Hydraulic oil temperature shutdown M2302 Starter relay error ON
M0721 Hydraulic oil temperature out of range high M2303 Starter relay error OFF
M0722 Hydraulic oil temperature out of range low M2402 Fuel pull relay error ON
M0810 Engine coolant temperature high M2403 Fuel pull relay error OFF
M0811 Engine coolant temperature extremely high M2502 Traction pull relay error ON
M0815 Engine coolant temperature shutdown M2503 Traction pull relay error OFF
M0821 Engine coolant temperature out of range high M2602 Glow plug relay error ON
M0822 Engine coolant temperature out of range low M2603 Glow plug relay error OFF
M0909 Fuel level low M3128 Interrupted power failure
M0921 Fuel level out of range high M3204 Workgroup no communication
M0922 Fuel level out of range low M3505 Hydraulic fan short to battery
M1016 Hydraulic charge filter not connected M3506 Hydraulic fan short to ground
M1017 Hydraulic charge filter plugged M3507 Hydraulic fan open circuit
M1121 Seat bar sensor out of range high M3532 Hydraulic fan overcurrent
M1122 Seat bar sensor out of range low M3705 Two-speed secondary short to battery
M1305 Fuel hold solenoid short to battery M3706 Two-speed secondary short to ground
M1306 Fuel hold solenoid short to ground M3707 Two-speed secondary open circuit
M1307 Fuel hold solenoid open circuit M3732 Two-speed secondary overcurrent
M1402 Fuel pull output error ON M4109 Alternator low
M1403 Fuel pull output error OFF M4110 Alternator high
M1407 Fuel pull output open circuit M4404 Auxiliary no communication
M1428 Fuel pull output failure M4621 5 volt sensor supply out of range high
M1502 Traction lock pull output error ON M4622 5 volt sensor supply out of range low
M1503 Traction lock pull output error OFF M4721 8 volt sensor supply out of range high
M1507 Traction lock pull output open circuit M4722 8 volt sensor supply out of range low
M1528 Traction lock pull output failure M4802 Front light relay error ON
M1605 Traction lock hold solenoid short to battery M4803 Front light relay error OFF
M1606 Traction lock hold solenoid short to ground M4807 Front light relay open circuit
M1607 Traction lock hold solenoid open circuit M4902 Rear light relay error ON
M1705 Hydraulic lock valve solenoid short to battery M4903 Rear light relay error OFF
M1706 Hydraulic lock valve solenoid short to ground M4907 Rear light relay open circuit

363 of 521 60-80-4 S100 Service Manual


DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Contd)

CODE DESCRIPTION CODE DESCRIPTION


M5002 Front light output error ON W3231 Tilt actuator fault
M5003 Front light output error OFF W3234 Tilt actuator not in neutral
M5007 Front light output open circuit W3235 Tilt handle / pedal not in neutral
M5028 Front light output failure W3236 Lift actuator fault
M5102 Rear light output error ON W3239 Lift actuator not in neutral
M5103 Rear light output error OFF W3240 Lift handle / pedal not in neutral
M5107 Rear light output open circuit W3249 Lift actuator short to ground
M5128 Rear light output failure W3250 Tilt actuator short to ground
M5202 PTOL switch error ON W3251 Lift actuator short to battery
M5221 PTOL switch out of range high W3252 Tilt actuator short to battery
M5222 PTOL switch out of range low W3253 Lift handle / pedal short to ground
M5305 PTOL LED short to battery W3254 Tilt handle / pedal short to ground
M5306 PTOL LED short to ground W3255 Lift handle / pedal short to battery
M5405 Tilt spool lock short to battery W3256 Tilt handle / pedal short to battery
M5406 Tilt spool lock short to ground W3257 Lift actuator reduced performance
M5407 Tilt spool lock open circuit W3258 Tilt actuator reduced performance
M5432 Tilt spool lock overcurrent W3259 Lift actuator wrong direction
M6402 Switched power relay error ON W3260 Tilt actuator wrong direction
M6403 Switched power relay error OFF W3261 Handle lock short to ground
M7002 Switched power output error ON W3262 Handle lock short to battery
M7003 Switched power output error OFF W3263 Pedal lock short to ground
M7007 Switched power output open circuit W3264 Pedal lock short to battery
M7028 Switched power output failure W3265 Sensor supply out of range
M7304 Remote control no communication W3266 Battery voltage out of range
M7423 Main controller unprogrammed W3267 Handle/pedal switch flipped while operating
M7504 Drive no communication W3275 Recovery mode error
M7604 Left display panel no communication W3276 CAN joystick information error
M7748 Key switch multiple W3277 Remote control information error
M7974 Door open W3905 Left joystick X-axis not in neutral
W4005 Right joystick X-axis not in neutral
W3223 ACS calibration required W4007 Right joystick Y-axis not in neutral
W3224 ACS calibration performed

364 of 521 60-80-5 S100 Service Manual


365 of 521 60-80-6 S100 Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The BICS Controller (Engine STOPPED -
Key ON)
Description
Figure 60-90-2
Figure 60-90-1

1 2 3 4

EM1027
EM1026

1. Sit in the operator seat, turn the key to RUN (Standard


The Bobcat Interlock Control System is an electronic Key Panel) or press RUN / ENTER button (Deluxe
system that is used to protect the operator. The system Instrumentation Panel), lower the seat bar and
consists of the traction lock, seat bar sensor and the lift disengage the parking brake. Press the PRESS TO
and tilt lockouts solenoid. OPERATE LOADER button. Three BICS lights (Items
2-4) [Figure 60-90-2] on the left instrument panel
These all have indicator lights on the left panel [Figure should be OFF (SEAT BAR, LIFT and TILT VALVE
60-90-1] of the loader cab. and PARKING BRAKE).
The Press To Operate button activates the system and 2. Raise the seat bar fully. Three BICS lights (Items 2-4)
allows the operator to function the loader. [Figure 60-90-2] on the left instrument panel should
be ON (SEAT BAR, LIFT and TILT VALVE and
If any of these indicator lights illuminates (except the PARKING BRAKE).
Press To Operate button) the loader will not function.
NOTE: Record what lights are blinking (if any) and the
number of light flashes.

Inspecting The Seat Bar Sensor (Engine RUNNING)

3. Fasten the seat belt, lower the seat bar and make sure
the parking brake is engaged.

4. Start the engine and operate at low idle. Press the


PRESS TO OPERATE LOADER button. While raising
the lift arms, raise the seat bar fully. The lift arms
should stop. Repeat using the tilt function.

366 of 521 60-90-1 S100 Service Manual


BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The Lift Arm Bypass Control
(CONTD)
7. Raise the lift arms 6 feet (2 meters) off the ground.
Inspecting The Traction Lock (Engine RUNNING) Stop the engine. Turn the lift arm bypass control knob
clockwise 1/4 turn. Pull up and hold the knob until the
5. Lower the seat bar, disengage the parking brake and lift arms slowly lower.
press the PRESS TO OPERATE LOADER button.
Raise the seat bar fully and move the steering levers
slowly forward and backward. The traction drive
system will be locked.

6. Lower the seat bar and press the PRESS TO


WARNING
OPERATE LOADER button. Engage the parking brake
and move the steering levers slowly forward and AVOID INJURY OR DEATH
backward. The traction drive system will be locked. The Bobcat Interlock Control System (BICS) must
deactivate the lift, tilt and traction drive functions. If it
NOTE: The PARKING BRAKE light on the left does not, contact your dealer for service. DO NOT
instrument panel will remain ON until the modify the system.
W-2151-0394
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
brake is disengaged.

367 of 521 60-90-2 S100 Service Manual


BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
(CONTD)

Troubleshooting WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285

PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4