Bobcat S100 Skid-Steer Loader Operation & Maintenance Manual 6904925 (8-07) - PDF DOWNLOAD

Operation & Maintenance Manual S100 Skid-Steer Loader S/N A2G711001 & Above

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 6904925 (5-07) Revised (8-07) (2)

Printed in U.S.A.

© Bobcat Company 2007

OPERATOR SAFETY WARNINGS CORRECT

WARNING

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W-2001-1285

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

Never use the loader without instructions. See machine signs (decals), Operation & Maintenance Manual, and Operator’s Handbook.

CORRECT

CORRECT

WRONG

B-15570

B-15572

B-15571

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the foot pedals or footrests when operating loader.

Never use loader without operator cab with ROPS and FOPS approval.

Fasten your seat belt.

Never use loader as man lift or elevating device for personnel.

WRONG

WRONG

WRONG

B-15573

B-15574

B-15575A

Do not use loader in atmosphere with explosive dust, explosive gas, or where exhaust can contact flammable material.

Never exceed Capacity.

B-10731a

Never carry riders.

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload, and turn on flat level ground.

WRONG

WRONG

WRONG

B-15576

B-15577 B-16102

B-15578

Rated

Operating

Never leave loader with engine running or with lift arms up.

To park, engage parking brake and put attachment flat on the ground.

Never modify equipment.

Use only attachments approved by Bobcat Company for this model loader.

SAFETY EQUIPMENT The Bobcat Loader must be equipped with safety items necessary for each job. Ask your dealer for information on the safe use of attachments and accessories.

1. SEAT BELT: Check belt fasteners and check for damaged webbing or buckle.

2. SEAT BAR: When up, it must lock the loader controls.

3. OPERATOR CAB (ROPS and FOPS): It must be on the loader with all fasteners tight.

4. HANDBOOK: Must be in the cab.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICS) OSW09-0805

FOREWORD

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY & TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . XI OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . PM-1 SYSTEM SETUP & ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . SA-1 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . MST-1 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-1 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY-1 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX-1

REFERENCE INFORMATION Write the correct information for YOUR Bobcat Loader in the spaces below. Always use these numbers when referring to your Bobcat Loader.

SAFETY & TRAINING RESOURCES OPERATING INSTRUCTIONS (OI) PREVENTIVE MAINTENANCE (PM) SYSTEM SETUP & ANALYSIS (SA) MACHINE SIGN TRANSLATIONS (MST) SPECIFICATIONS (SPEC)

Loader Serial Number Engine Serial Number

WARRANTY NOTES:

ALPHABETICAL INDEX YOUR BOBCAT DEALER: ADDRESS: PHONE:

Bobcat Company P.O. Box 128 Gwinner, ND 58040-0128

Bobcat Company Europe Drève Richelle 167 B-1410 WATERLOO Belgium

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S100 Operation & Maintenance Manual

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S100 Operation & Maintenance Manual

FOREWORD

FOREWORD This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat Loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR BOBCAT LOADER. If you have any questions, see your Bobcat dealer. This manual may illustrate options and accessories not installed on your loader.

BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED . . . . . . . . . . . . V DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . VIII Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Buckets Available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Special Applications Kit Inspection And Maintenance . . . . . . . . . X Standard Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

SYSTEM SETUP & ANALYSIS

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . V

TRANSLATIONS

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

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S100 Operation & Maintenance Manual

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S100 Operation & Maintenance Manual

BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED

ISO 9001:2000 is an international standard that controls the processes and procedures which we use to design, develop, manufacture and distribute Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001:2000 standard. The BSI registration certifies that Bobcat's manufacturing facilities in Gwinner and Bismarck, North Dakota (North America), Pontchateau (France), Dobris (Czech Republic) and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 9001:2000. Only certified assessors, like BSI, can grant registrations.

ISO 9001:2000 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

REGULAR MAINTENANCE ITEMS

MOTOR OIL 6903105 . . . . . .

6903106 . . . . . .

6903113 . . . . . .

6903107 . . . . . .

6903108 . . . . . .

6903112 . . . . . .

6903109 . . . . . .

6903110 . . . . . .

6903111 . . . . . .

ENGINE OIL FILTER (6 Pack) 6657635

HYDRAULIC FILTER 6661248

FUEL FILTER 6667352

CASE DRAIN FILTER, In-Line 6661022

AIR FILTER, Outer 6690907

BATTERY 6673865

AIR FILTER, Inner 6690908

COOLANT PRESSURE CAP 6733429 FLUID, Hydraulic / Hydrostatic 6903117 - (Two -2.5 Gal. containers) 6903118 - (5 Gal.) 6903119 - (55 Gal.)

SAE 15W/40 CE/SG (12 qt.)

SAE 15W/40 CE/SG (1 Gal.) SAE 15W/40 CE/SG (2.5 Gal.) SAE 10W/30 CE/SG (12 qt.)

SAE 10W/30 CE/SG (1 Gal.) SAE 10W/30 CE/SG (2.5 Gal.) SAE 30W CE/SG (12 qt.)

SAE 30W CE/SG (1 Gal.) SAE 30W CE/SG (2.5 Gal.)

Propylene Glycol Premixed - 6724094 Concentrate - 6724354

NOTE: Always verify Part Numbers with your Bobcat dealer.

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S100 Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

Engine Serial Number

Always use the serial number of the loader when 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 2

Figure 1

1

S4043

1 The engine serial number is located on top of the engine (Item 1) [Figure 2].

DELIVERY REPORT S4464

Figure 3

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 B-16315

1. The four digit Model / Engine Combination Module number identifies the model number and engine combination.

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].

2. The five digit Production Sequence Number identifies the order which the loader is produced.

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S100 Operation & Maintenance Manual

LOADER IDENTIFICATION OPERATION & MAINTENANCE MANUAL AND OPERATOR’S HANDBOOK

FRONT LIGHTS

OPERATOR SEAT with SEAT BELT & SEAT BAR GRAB HANDLES TILT CYLINDER

FRONT AUXILIARY QUICK COUPLERS

STEPS

BUCKET †

BUCKET STEPS

S0183

● OPERATOR CAB

(ROPS/FOPS)

LIFT ARM SUPPORT DEVICE

LIFT ARM REAR GRILL LIFT CYLINDER REAR DOOR

REAR LIGHT TAIL LIGHT

* TIRES

S0184

* 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 - Many Buckets and other Attachments are available.

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S100 Operation & Maintenance Manual

FEATURES, ACCESSORIES AND ATTACHMENTS Standard Items

Options and Accessories

Model S100 Bobcat Loaders are equipped with the following standard items:

Below is a list of some equipment available from your Bobcat Loader dealer as Dealer and / or Factory Installed Accessories and Factory Installed Options. See your Bobcat dealer for other available options, accessories and attachments.

• • • • • •

• • • • • • • • •

Adjustable Cushion Seat Automatically Activated Glow Plugs Auxiliary Hydraulics, Front Bobcat Interlock Control System (BICS) Bob-Tach™ Deluxe Cab (includes: interior insulation, top & rear windows, accessory harness, dome light and 12 volt power port (ROPS & FOPS Approved) Engine / Hydraulic Systems Shutdown Instrumentation: Hourmeter, Engine Temperature and Fuel Gauges, Warning Lights Lift Arm Support Device Lights, Front & Rear Parking Brake Seat Bar Seat Belt Spark Arrestor Exhaust System Tires (27x8.50-15 6PR) (Heavy Duty)

• • • • • • • • • • • • • • • • • • • • • • • •

Access Cover (Foot Pedal Area) Adjustable Suspension Seat Attachment Control Kit Back-up Alarm & Horn Cab Door Cab Enclosure Cab Enclosure (Vinyl) Cab Heater Catalytic Exhaust Purifier Engine Heater Fire Extinguisher Falling Object Protective Structure (FOPS) (Level II) Hydraulic Bucket Positioning (Includes On/Off Selection) Lift Kit(s) (For lifting entire loader) Locking Fuel Cap Rear Window Wiper Seat Belt with 3-Point Restraint Seat Belt - 3 Inch Wide Sound Cab (Reduces noise at operator ear) Special Applications Kit Tailgate Lock Tires: Flotation Warning Lights: Four-Way Flasher (Includes Direction Signals), Rotating Beacon, Strobe Light Windows Top and Rear Windows Side Windows Polycarbonate Top Window Externally Removable Rear Window

Specifications subject to change without notice.

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S100 Operation & Maintenance Manual

Buckets Available

FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D) These and other attachments are approved for use on this model loader. Do not use unapproved attachments.

Attachments not manufactured by Bobcat may not be approved.

The versatile Bobcat Loader quickly turns into a multi-job machine with a tight-fit attachment hook-up: from bucket to grapple to pallet fork to backhoe and a variety of other attachments.

BUCKET

See your Bobcat dealer for more details on these and other attachments and field accessories.

Many bucket styles, widths and different capacities are available for a variety of different applications. They include Construction & Industry, Low profile, Fertilizer and Snow, to name a few. See your Bobcat dealer for the correct bucket for your Bobcat Loader and application.

Increase the versatility of your Bobcat Loader with a variety of bucket styles and sizes.

Attachments • • • • •

• • • • •

• • • • • • • • • • •

Angle Broom Attachment Control Kit Auger Backhoe Blades Snow Blade V-Blade Brush Saw Buckets Digger Dumping Hopper Hydraulic Breaker

IX

Landplane Pallet Fork Scraper Soil Conditioner Three-Point Hitch Tiller Tree Fork Trencher Utility Fork Utility Frame X-Change Frame

S100 Operation & Maintenance Manual

Special Applications Kit Inspection And Maintenance

FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D)

• • •

Special Applications Kit

• • •

Inspect for cracks or damage. Replace if required.

Pre-rinse with water to remove gritty materials.

Wash with a mild household detergent and warm water.

Use a sponge or soft cloth. Rinse well with water and dry with a clean soft cloth or rubber squeegee.

Do not use abrasive or highly alkaline cleaners.

Do not clean with metal blades or scrapers.

B-25286A

Available for special applications to restrict material from entering cab openings. Kit includes 1/2 inch Polycarbonate front door, top and rear windows.

See your Bobcat dealer for availability.

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S100 Operation & Maintenance Manual

SAFETY & TRAINING RESOURCES MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . .XVIII SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Safe Operation Is The Operator’s Responsibility. . . . . . . . . . . .XIV Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . .XIV

XI

SAFETY & TRAINING RESOURCES

S100 Operation & Maintenance Manual

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SAFETY INSTRUCTIONS

•

An Operator’s Handbook is fastened to the operator cab of the Loader. It’s brief instructions are convenient to the operator. 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.

•

The AEM Safety Manual delivered with the machine gives general safety information.

•

The Skid-Steer Loader Operating Training Course is available through your Bobcat dealer. This course is intended to provide rules and practices of correct operation of the Bobcat Loader. The course is available in English and Spanish versions.

•

Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

•

See the PUBLICATIONS AND TRAINING RESOURCES Page in this manual or your Bobcat dealer for Service and Parts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web sites www.training.bobcat.com or www.bobcat.com

Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

The Bobcat Loader is highly maneuverable and compact.

It is rugged and useful under a wide variety of conditions.

This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat Loader usage.

The Bobcat Loader has an internal combustion engine with resultant heat and exhaust. All exhaust gasses can kill or cause illness so use the Loader with adequate ventilation.

The dealer explains the capabilities and restrictions of the Bobcat Loader and attachment for each application.

The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for a Rated Operating Capacity (some have restricted lift heights).

They are designed for secure fastening to the Bobcat Loader. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the machine - attachment combination.

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.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat machine and attachments: •

The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine and attachment is in safe operating condition.

•

The Operation & Maintenance Manual delivered with the machine or attachment gives operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine.

Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

•

Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

Call Before You Dig 1-888-258-0808 When you call, you will be directed to a location in your state/city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0307

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S100 Operation & Maintenance Manual

SAFETY INSTRUCTIONS (CONT’D)

A Qualified Operator Must Do The Following:

Safe Operation Is The Operator’s Responsibility

Understand the Written Instructions, Rules and Regulations

Safety Alert Symbol

•

The written instructions from Bobcat Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, Safety Manual and machine signs (decals).

•

Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. Regulations may apply to local driving requirements or use of a Slow Moving Vehicle (SMV) emblem. Regulations may identify a hazard such as a utility line.

This symbol with a warning statement means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

WARNING Operator must have instructions before running the machine. Untrained operators can cause injury or death.

Have Training with Actual Operation •

Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered.

•

The new operator must start in an area without bystanders and use all the controls until he or she can operate the machine and attachment safely under all conditions of the work area. Always fasten seat belt before operating.

•

Operator Training Courses are available from your Bobcat dealer in English and Spanish. They provide information for safe and efficient equipment operation. Safety videos are also available.

•

Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

W-2001-1285

IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine.

I-2019-0284

WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

Know the Work Conditions

W-2044-1285

•

Know the weight of the materials being handled.

Avoid exceeding the Rated Operating Capacity (R.O.C.) of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of the load if handling dense material.

•

The operator must know any prohibited uses or work areas, for example, he or she needs to know about excessive slopes.

•

Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the Before Operation Section of this manual.

•

Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing protection or Special Applications Kits are required for some work. See your Bobcat dealer about Bobcat Safety Equipment for your model.

The Bobcat Loader and attachment must be in good operating condition before use.

Check all of the items on the Bobcat Service Schedule Decal under the 8-10 hour column or as shown in the Operation & Maintenance Manual.

Safe Operation Needs A Qualified Operator For an operator to be qualified, he or she must not use drugs or alcoholic drinks which impair alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.

SI SSL-0307 XIV

S100 Operation & Maintenance Manual

SAFETY INSTRUCTIONS (CONT’D)

•

Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

•

Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Fire Prevention The machines and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Figure 1

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.

The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

•

Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

•

The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

•

Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight.

Repair or replace any damaged part.

•

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

•

Do not use ether or starting fluids on any engine that has glow plugs or an air intake heater. These starting aids can cause explosion and injure you or bystanders.

•

Always clean the machine, 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.

•

Stop the engine and let it cool before adding fuel. No smoking!

•

Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].

Sl SSL-0307

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S100 Operation & Maintenance Manual

MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Loader dealer.

7136754

Shoulder Belt Opt. - 6725370

6735140 6904923 6728539

Door Opt. 6707852

Door Opt. 7110316

7136749

BU Alarm Opt. 6737189

6718579 Inside Cab

7135574 (Inside Fuse Cover)

6579528 (Crossmember Center)

6561383 (Behind Bob-Tach)

6727595 (5)

6702301

6710358 6702302

S0183

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S100 Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (CONT’D) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Loader dealer.

6708929

6565990 Under Rear Grill

6733996

7139929

6577754 6578368

6706558

6809511 (4)

6717343 (2) (Under Cab)

6727595 (Ref.)

Inside Rear Door

6734534

S0184

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S100 Operation & Maintenance Manual

PUBLICATIONS AND TRAINING RESOURCES The following publications are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

OPERATOR’S HANDBOOK

For the latest information on Bobcat products and the Bobcat Company, visit our web site at www.training.bobcat.com or www.bobcat.com

6904923

Gives basic operation instructions and safety warnings

OPERATION & MAINTENANCE MANUAL 6904925 SKID-STEER LOADER OPERATOR TRAINING COURSE 6901726

Complete instructions on the correct operation and the routine maintenance of the Bobcat Loader.

Introduces operator to step-by-step basics of Skid-Steer Loader operation. Also available in Spanish P/N 6724036 OPERATOR VIDEO

SAFETY

SERVICE MANUAL 6902176

6904926 OPERATOR SAFETY DVD (English & Spanish) 6904762

Complete maintenance instructions for your Bobcat Loader.

Provides basic safety instructions contained in all Bobcat Safety Videos in both English and Spanish

SAFETY MANUAL

SKID-STEER LOADER SERVICE SAFETY TRAINING COURSE

6556500

6900641

Introduces Service Technicians to step-by-step basics of proper and safe Skid-Steer Loader maintenance and servicing procedures

Provide basic safety procedures and warnings for your Bobcat Loader. Also available in Spanish P/N 6724451

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OPERATING INSTRUCTIONS ATTACHMENTS ..................................................................................... OI-23 Choosing The Correct Bucket........................................................... OI-23 Installing And Removing The Attachment......................................... OI-24 Pallet Forks ....................................................................................... OI-23 BACK-UP ALARM SYSTEM .................................................................... OI-9 Operation ............................................................................................ OI-9 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ............................... OI-7 Operation ............................................................................................ OI-7

OPERATING INSTRUCTIONS (OI)

DAILY INSPECTION .............................................................................. OI-13 Daily Inspection And Maintenance.................................................... OI-14 DRIVING AND STEERING THE LOADER ............................................ OI-10 Operation .......................................................................................... OI-10 Stopping The Loader ........................................................................ OI-10 ENGINE SPEED CONTROL.................................................................... OI-9 Operation ............................................................................................ OI-9 HORN (OPTION)...................................................................................... OI-6 Operation ............................................................................................ OI-6 HYDRAULIC CONTROLS...................................................................... OI-11 Auxiliary Control Lockout .................................................................. OI-11 Auxiliary Hydraulics........................................................................... OI-12 Bucket Position Valve Operation (If Equipped) ................................. OI-11 Description ........................................................................................ OI-11 Quick Couplers ................................................................................. OI-12 Relieving Hydraulic Pressure (Loader and Attachment) ................... OI-12 INSTRUMENT PANEL IDENTIFICATION ................................................ OI-3 Cab Light............................................................................................. OI-4 Display Screen Functions ................................................................... OI-4 Left Panel............................................................................................ OI-3 Option And Field Accessory Panels.................................................... OI-5 Right Instrument Panel (Key Switch) .................................................. OI-4 LIFT ARM BYPASS CONTROL ............................................................... OI-8 Operation ............................................................................................ OI-8 LIFTING THE LOADER.......................................................................... OI-31 Single Point Lift ................................................................................. OI-31 Continued On Next Page

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S100 Operation & Maintenance Manual

OPERATING INSTRUCTIONS (CONT’D) MONITORING THE DISPLAY PANELS ...................................................... OI-20 Left Panel............................................................................................... OI-20 Warning And Shutdown ......................................................................... OI-20 OPERATING PROCEDURE ....................................................................... OI-26 Digging And Filling A Hole ..................................................................... OI-29 Filling And Emptying The Bucket ........................................................... OI-28 Inspecting The Work Area ..................................................................... OI-26 Leveling The Ground Using Float .......................................................... OI-29 Operating With An Empty Bucket .......................................................... OI-27 Operating With A Full Bucket................................................................. OI-26 PARKING BRAKE ......................................................................................... OI-9 Operation ................................................................................................. OI-9 PRE-STARTING PROCEDURE .................................................................. OI-15 Entering The Loader .............................................................................. OI-15 Seat Adjustment..................................................................................... OI-15 Seat Bar ................................................................................................. OI-17 Seat Belt Adjustment ............................................................................. OI-16 Operation & Maintenance Manual and Operator’s Handbook LocationsOI-15 SEAT BAR RESTRAINT SYSTEM................................................................ OI-6 Operation ................................................................................................. OI-6 STARTING THE ENGINE............................................................................ OI-17 Cold Temperature Starting ..................................................................... OI-19 Key Switch ............................................................................................. OI-17 Warming The Hydraulic / Hydrostatic System........................................ OI-19 STOPPING THE ENGINE AND LEAVING THE LOADER .......................... OI-21 Emergency Exit...................................................................................... OI-22 Procedure .............................................................................................. OI-21 TOWING THE LOADER.............................................................................. OI-30 Procedure .............................................................................................. OI-30 TRACTION LOCK OVERRIDE ..................................................................... OI-8 Operation ................................................................................................. OI-8 TRANSPORTING THE LOADER ON A TRAILER ...................................... OI-32 Fastening ............................................................................................... OI-32 Loading And Unloading.......................................................................... OI-32

OI-2

S100 Operation & Maintenance Manual

INSTRUMENT PANEL IDENTIFICATION Left Panel Figure OI-1

2

12

3

1

13 14

11

4

6

9

8

7

10

5

18

15 17

16

19 20

S0150 S0150 REF.

DESCRIPTION

FUNCTION/OPERATION

REF.

DESCRIPTION

FUNCTION/OPERATION

1

Engine Shows engine coolant temperature.

Temperature Gauge

11

Hydraulic Oil Pressure

Not Used

2

Direction Indicator Left

Green when active: left direction indicators are on.

12

Hydraulic Oil Temperature

Not Used

3

General Warning

Amber when active: problem with one or more engine or hydraulic functions.

13

Direction Indicator Right

Green when active: right direction indicators are on.

4

Engine Oil Pressure Not Used

14

Fuel Gauge

Shows the amount of fuel in the tank.

5

Engine Failure Or Malfunction

Amber when active: one or more engine malfunctions.

15

Work Lights And Road Lights

Left LED green when active (button pressed once): work lights and front road lights are on.

Left and right LED green when active (button pressed twice): work lights, front and rear road lights are on.

Press the button a third time to switch all lights off.

6

Seat Belt

Red light comes ON when the key switch is turned on and stays on for 45 seconds to remind the operator to fasten the seat belt.

16

Auxiliary High Flow Not Used

7

Seat Bar

Red light comes ON when the seat bar is raised.

17

Auxiliary

Not Used

8

Lift & Tilt Valve

Red light comes ON: the lift and tilt functions cannot be operated. To operate these functions, the seat bar must be lowered and the PRESS TO OPERATE LOADER button must be pressed.

18

Display Mode (For display screen)

Cycles through (after each button press): • On start up - engine hours • Engine RPM • Battery voltage • Maintenance clock • Service codes From engine hours, press and hold for 2 seconds to jump to service codes.

Press and hold for 7 seconds to reset the maintenance clock when maintenance clock screen is displayed.

9

Parking Brake

Red light comes ON when the Parking Brake is engaged.

19

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 for service. (See TRACTION LOCK OVERRIDE on Page OI-8.) Press a second time to lock the brakes.

10

Hydraulic System Failure Or Malfunction

Amber when active: one or more hydraulic system malfunctions.

20

Press To Operate Loader

Green when pressed. (Functions only when the seat bar is down and the engine is running) Press to activate the BICS system when the Seat Bar is down and the operator is seated in operating position.

OI-3

S100 Operation & Maintenance Manual

INSTRUMENT PANEL IDENTIFICATION (CONT’D)

Right Instrument Panel (Key Switch)

Display Screen Functions

Figure OI-3

Figure OI-2

1 2 1

2 3

S4002 S4498

6

5

4

3 S4001A

The functions of the key switch [Figure OI-3] are: The display screen is shown in [Figure OI-2]:

1. ENGINE STOP

1. DATA DISPLAY

2. ENGINE RUN / PREHEAT

2. HOUR METER

3. ENGINE START

3. SERVICE INDICATOR (in combination with (1): maintenance clock)

Cab Light Figure OI-4

If not active, OFF will be displayed.

Indicates the number of hours until the maintenance interval will expire. When the service interval has expired, it will alternate between SRVCE and the hours it was set to.

4. BATTERY voltage)

CHARGING

CONDITION

(battery

5. ENGINE REVOLUTIONS PER MINUTE (RPM)

1

S4003

6. ENGINE PREHEAT The cab light is located on the right-hand side in the back of the cab. Push the button (Item 1) [Figure OI-4] to turn the light ON. Push the button again to turn it OFF.

OI-4

S100 Operation & Maintenance Manual

INSTRUMENT PANEL IDENTIFICATION (CONT’D)

The side accessory panel is shown in [Figure OI-6]:

Option And Field Accessory Panels

Figure OI-6

The front accessory panel is shown in [Figure OI-5]:

1

2

3

4

5

6

7

8

9

Figure OI-5

S1076

1

2

3

4

5

6

8

7

REF. NO.

S4113

REF. NO.

DESC.

FUNCTION/OPERATION

1

NOT USED

----

2

BUCKET POSITION (Option)

Press the top of the switch to retain the bucket fixed in its relative position to the ground.Press the bottom of the switch toreturn to normal operation.

3

NOT USED

----

4

PARKING BRAKE Press the top of the switch to engage the parking brake.

Press the bottom of the switch 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 of the switch to turn the hazard lights OFF.

DESC.

FUNCTION/OPERATION

1

POWER PLUG

2 3

NOT USED FRONT WIPER

4

REAR WIPER (OPTION)

5 6 7

NOT USED NOT USED FAN MOTOR

8 9

NOT USED TEMPERATURE CONTROL

----

7

ROTATING Press the top of the switch to turn BEACON (Option) the rotating beacon ON. Press the bottom of the switch to turn the rotating beacon OFF.

8

NOT USED

Provides a 12 V receptacle for accessories.

--Press the bottom of the switch to start the front wiper (press and hold for washer fluid).

Press the top of the switch to stop the wiper.

Press the bottom of the switch to start the wiper.

Press the top of the switch to stop the wiper.

------Turn the knob clockwise to increase fan speed.

Turn counterclockwise to decrease the fan speed.

There are four positions; OFF-1-2-3.

---Turn the knob clockwise to increase the temperature.

Turn counterclockwise to decrease the temperature.

----

OI-5

S100 Operation & Maintenance Manual

HORN (OPTION)

SEAT BAR RESTRAINT SYSTEM

Operation

Operation

Figure OI-7

Figure OI-8

1

1

S4419 S4040

The seat bar restraint system has a pivoting seat bar with arm rests (Item 1) [Figure OI-8].

Press the button (Item 1) [Figure OI-7] on top of the left steering lever to activate the horn.

WARNING AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W-2046-0595

When the seat bar is down, the PRESS TO OPERATE LOADER button is activated, and the brake is released, the lift, tilt and traction drive functions can be operated.

(Traction drive will operate only when the engine is running.)

When the seat bar is up, the lift, tilt and traction drive functions are deactivated and both foot pedals will be locked.

WARNING Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move pedals until both lock.

• Move auxiliary control out of detent position.

W-2164-1294

OI-6

S100 Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

Figure OI-10

Operation

WARNING

1

2

3

AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.

S3999

W-2151-0394

There are three display lights (Items 1-3) [Figure OI-10] located on the left instrument panel that must be OFF to operate the machine.

Figure OI-9

When the seat bar is down, the PRESS TO OPERATE LOADER button is activated, and the parking brake is released, the lift, tilt and traction drive functions can be operated.

When the seat bar is up, the lift, tilt and traction drive functions are deactivated.

1

WARNING S2867

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move pedals until both lock.

• Move auxiliary control out of detent position.

The Bobcat Interlock Control System (BICS) has a pivoting seat bar with arm rests (Item 1) [Figure OI-9].

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

W-2164-1294

The BICS requires the operator to be seated in the operating position with the seat bar (Item 1) [Figure OI-9] fully lowered before the lift, tilt, and traction functions can be operated. The seat belt must be fastened any time you operate the machine.

WARNING AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W-2046-0595

OI-7

S100 Operation & Maintenance Manual

LIFT ARM BYPASS CONTROL

TRACTION LOCK OVERRIDE

Operation

Operation

Figure OI-11

Figure OI-12

2 1

1

1

P54406 S4402

The lift arm bypass control (Item 1) [Figure OI-11] is used to lower the lift arms if the lift arms cannot be lowered during normal operations.

• • • •

(Functions only when the seat bar is raised and the engine is running.) There is a TRACTION LOCK OVERRIDE button (Item 1) [Figure OI-12] on the left instrument panel which will allow you to use the steering levers to move the loader forward and backward when using the backhoe attachment or for service.

Sit in the operator seat.

Fasten the seat belt and lower the seat bar.

Turn the lift arm bypass knob (Item 1) [Figure OI-11] clockwise 1/4 turn.

Pull up and hold the knob until the lift arms slowly lower.

OI-8

•

Press the TRACTION LOCK OVERRIDE button once to unlock the brakes. The PARKING BRAKE light (Item 2) [Figure OI-12] will be OFF.

•

Press the button a second time to lock the brakes.

The PARKING BRAKE light (Item 2) [Figure OI-12] will be ON.

S100 Operation & Maintenance Manual

BACK-UP ALARM SYSTEM

ENGINE SPEED CONTROL

Operation

Operation

Figure OI-13

Figure OI-15

1

1

S4006

P-76101

The speed control lever is to the right of the operator seat (Item 1) [Figure OI-15].

This machine may be equipped with a back-up alarm system. The back-up alarm (Item 1) [Figure OI-13] is located on the inside of the rear door.

Move the lever forward to increase engine speed. Move backward to decrease engine speed.

Figure OI-14

PARKING BRAKE Operation Figure OI-16 1 2 S4113

Press the top of the switch (Item 1) [Figure OI-16] to engage the parking brake. The traction drive system will be locked.

The back-up alarm will sound when the operator moves both steering levers in the reverse position [Figure OI14]. Slight movement of the steering levers in the reverse position is required with hydrostatic transmissions, before the back-up alarm will sound.

Press the bottom of the switch (Item 2) [Figure OI-16] to disengage the parking brake. The traction drive system will be unlocked.

NOTE: The PARKING BRAKE light on the left instrument panel will remain ON until the engine is started, the PRESS TO OPERATE LOADER button is pressed and the parking brake is disengaged.

If alarm does not sound or for adjustment instructions, see inspection and maintenance instructions for the back-up alarm system in the preventive maintenance section of this manual. (See BACK-UP ALARM SYSTEM on Page PM-13.)

OI-9

S100 Operation & Maintenance Manual

Figure OI-18

DRIVING AND STEERING THE LOADER Operation Figure OI-17

1

1

S2867

The control levers (Item 1) [Figure OI-17] are on the leftand right-hand side in front of the seat.

Move the levers smoothly. Avoid sudden starting and stopping.

WARNING PI-1849A

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

Stopping The Loader When the steering levers are moved to the neutral position, the hydrostatic transmission will act as a service brake to stop the loader.

W-2046-0595

The levers control forward and reverse travel and turning the loader [Figure OI-18].

Forward Travel - Push both levers forward.

Reverse Travel - Pull both levers backward.

Normal Turning - Move one lever farther forward than the other.

Fast Turning - Push one lever forward and pull the other lever backward.

OI-10

S100 Operation & Maintenance Manual

HYDRAULIC CONTROLS

Bucket Position Valve Operation (If Equipped)

Description

The function of the bucket position valve is to keep the bucket in the same relative position to the ground while raising the lift arms.

Two foot pedals control the hydraulic cylinders for the lift and tilt functions.

Figure OI-21 Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

1

Figure OI-19 S4113

2 Press the top of the BUCKET POSITION switch (Item 1) [Figure OI-21] to engage the bucket position function.

Press the bottom of the switch to disengage this function.

1 P15579

S4065

Bucket positioning functions only during upward lift cycle.

Auxiliary Control Lockout

Lift Arm Operation (Left Pedal)

Figure OI-22

Push the heel (Item 1) [Figure OI-19] of the pedal to raise the lift arms.

Push the toe (Item 2) [Figure OI-19] of the pedal to lower the lift arms.

Lift Arm Float Position Operation (Left Pedal) Push the toe (Item 2) [Figure OI-19] of the pedal all the way forward until it locks into the float position.

1 Use the float position of the lift arms to level loose material while driving backward.

Raise the lift arms to disengage the float position.

S0186

Figure OI-20 Remove the auxiliary control lockout bolt and nut (Item 1) [Figure OI-22] before using the auxiliary control for the first time.

2

1 P15581A

S4065

Tilt Operation - (Right Pedal) Push the heel (Item 1) [Figure OI-20] of the pedal to tilt the bucket backward.

Push the toe (Item 2) [Figure OI-20] of the pedal to tilt the bucket forward.

OI-11

S100 Operation & Maintenance Manual

Quick Couplers

HYDRAULIC CONTROLS (CONT’D) Auxiliary Hydraulics

WARNING

Figure OI-23

AVOID BURNS

1

Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments.

Be careful when connecting and disconnecting quick couplers.

W-2220-0396

WARNING S0186A

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 from a physician familiar with this injury.

The handle of the right steering lever (Item 1) [Figure OI23] is also the control lever for the front auxiliary hydraulics.

Move the handle to the right or to the left to activate the auxiliary hydraulics and operate an attachment (Example: To open or close grapple teeth). Moving the lever in the opposite direction will reverse the action of the attachment.

W-2072-0807

Figure OI-24

Move the handle all the way to the right, to put the control valve in the locked position for a constant flow of hydraulic fluid under pressure to the quick couplers.

Move the handle out of the locked position before leaving the operator cab.

Relieving Hydraulic Pressure (Loader and Attachment) With the engine stopped and the attachment flat on the ground, move the right steering lever to the left and to the right several times. This relieves pressure that can be trapped in the auxiliary circuit which would make it difficult to engage quick couplers from an attachment.

S4044

To Connect: Remove dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage or excessive wear. If any of these conditions exist, the coupler(s) [Figure OI-24] must be replaced.

Install the male coupler into the female coupler. Full connection is made when the ball release sleeve slides forward on the female coupler.

To Disconnect: Hold the male coupler. Retract the sleeve on the female coupler until the couplers disconnect.

OI-12

S100 Operation & Maintenance Manual

DAILY INSPECTION Figure OI-25

6734534_C-V

OI-13

S100 Operation & Maintenance Manual

DAILY INSPECTION (CONT’D) Daily Inspection And Maintenance

WARNING

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule [Figure OI-25] is a guide for correct maintenance of the Bobcat Loader. It is located inside the rear door of the loader. (See SERVICE SCHEDULE (6734534) on Page MST-3.)

•

Engine oil level.

•

Engine coolant system, check system for damage or leaks.

•

Clean engine area of flammable materials.

•

Engine air filter, check system for damage or leaks.

•

Fuel filter, remove trapped water.

•

Heater filter.

•

Hydraulic / hydrostatic fluid level.

Operator must have instructions before operating the machine. Untrained operators can cause injury or death.

W-2001-0502

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.

IMPORTANT •

•

Lift arm support device, replace if damaged.

•

Tires, check for wear, damage, correct air pressure.

•

Operator cab and cab mounting hardware.

•

Loose or broken parts, repair or replace as necessary.

•

Safety signs and safety treads, check for damage.

•

Lubricate pivot pins (lift arms, Bob-Tach, cylinders, Bob-Tach wedges).

•

Check seat belt, seat bar and control interlocks for wear or damage.

•

Check seat bar. When seat bar is raised, both pedals must be deactivated.

•

Bobcat Interlock Control System (BICS).

•

Indicators and lights.

•

Clean foot pedal area.

•

Monitor instrument panel for fuel level, coolant temperature and air cleaner condition.

•

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 12 inches (300 mm) from the decal. Wash from the center of the decal toward the edges.

I-2226-0104

OI-14

S100 Operation & Maintenance Manual

PRE-STARTING PROCEDURE Entering The Loader

WARNING

Figure OI-26

AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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 S0515

Seat Adjustment Adjustable Cushion Seat

Use the bucket or attachment steps, grab handles and safety treads (on the loader lift arms and frame) to get on and off the loader [Figure OI-26]. DO NOT JUMP.

Figure OI-28

Safety treads are installed on the Bobcat Loader to provide a slip resistant surface for getting on and off the loader.

1

Keep the safety treads clean and replace them when damaged. Replacement treads are available from your Bobcat dealer.

Operation & Maintenance Manual and Operator’s Handbook Locations 2

Figure OI-27

3

S4727

Use the lever (Item 1) and knob (Item 2) [Figure OI-28] to adjust the position of the seat for comfortable operation of the loader controls.

1

2 The lever (Item 1) sets the seat cushion for the weight of the operator. The knob (Item 2) [Figure OI-28] sets the angle of the seat back.

The lever (Item 3) [Figure OI-28] adjusts the fore / aft position of the seat.

S4010

Read and understand the Operation Manual and the Operator’s Handbook (Item 1) [Figure OI-27] before operating the loader.

The Operation Manual and other manuals can be kept in a container (Item 2) [Figure OI-27] provided behind the operator seat.

OI-15

S100 Operation & Maintenance Manual

PRE-STARTING PROCEDURE (CONT’D)

Figure OI-30 1

Seat Adjustment (Cont’d) Adjustable Suspension Seat (Option)

P16041

Figure OI-29

2

P16038

Squeeze both seat belt adjusters to release and lengthen each half of the seat belt (Item 1) [Figure OI-30].

S4009

Fasten the seat belt.

Pull the ends of the belt through the belt adjusters so that the seat belt is snug and the buckle is centered between your hips [Figure OI-30].

1 3

Figure OI-31 2 S4008

N21774A

Adjust the position of the seat for comfortable operation of the loader controls: •

Release the lever (Item 1) [Figure OI-29] to move the seat forward or backward.

•

Release the lever (Item 2) [Figure OI-29] to adjust the angle of the seat back.

•

Turn the lever (Item 3) [Figure OI-29] to adjust the seat cushion for weight of the operator.

1 N21773A

N21773

3-Point Restraint (Option) - Connect the shoulder belt to the lap belt (Item 1). Pull the lap belt across to the left side of the seat (Item 2) [Figure OI-31] and fasten.

Seat Belt Adjustment

The shoulder belt must be positioned over your right shoulder and the lap belt must be snug over your lower hips.

IMPORTANT Check the seat belt and shoulder belt retractors for correct operation.

Adjustment is continuously maintained with the seat belt retractors.

Keep retractors clean and replace as necessary.

I-2199-0200

OI-16

S100 Operation & Maintenance Manual

PRE-STARTING PROCEDURE (CONT’D)

STARTING THE ENGINE

Seat Bar

Key Switch

Figure OI-32

WARNING

1 • •

AVOID INJURY OR DEATH Engines can have hot parts and hot exhaust gas.

Keep flammable material away.

Do not use machines in atmosphere containing explosive gas.

W-2051-1086

Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page OI-15.)

S4465

Figure OI-33

Lower the seat bar (Item 1) [Figure OI-32].

Put the foot pedals and steering levers in neutral position.

1 NOTE: Keep your hands on the steering levers and your feet on the foot pedals while operating the loader.

WARNING AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

S4006

Move the speed control lever (Item 1) [Figure OI-33] to the mid position.

W-2046-0595

OI-17

S100 Operation & Maintenance Manual

STARTING THE ENGINE (CONT’D) Key Switch (Cont’d)

WARNING

Figure OI-34 1

•

2

• 3

AVOID INJURY OR DEATH Fasten seat belt, start and operate only from the operator seat.

Never wear loose clothing when working near machine.

W-2135-1188

Figure OI-36

S4002 S4498

Turn the key switch from STOP (Item 1) [Figure OI-34] to RUN (Item 2). The Instrument Panel / Monitoring System will do a self test.

1

Figure OI-35 2

S0150

Lower the seat bar and press the PRESS TO OPERATE LOADER button (Item 1) [Figure OI-36] to activate the BICS system and to perform hydraulic and loader functions. The PRESS TO OPERATE LOADER light (Item 1) will be ON when the BICS system is active.

1

WARNING

S4001A

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

If the temperature is cold, the glow plugs will automatically cycle. The ENGINE PREHEAT light (Item 1) [Figure OI-35] on the display screen will be ON and the cycle time remaining will show in the hour meter (Item 2).

W-2050-0807

When the ENGINE PREHEAT light goes OFF, turn the key switch to START (Item 3) [Figure OI-34].

Release the key when the engine starts. It will return to the RUN position.

OI-18

S100 Operation & Maintenance Manual

Cold Temperature Starting

STARTING THE ENGINE (CONT’D) Warming The Hydraulic / Hydrostatic System

WARNING Do not use ether with glow plug (preheat) systems.

Explosion can result which can cause injury, death, or severe engine damage.

IMPORTANT

W-2071-0903

When the temperature is below -20°F (-30°C), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F (-18°C) if possible.

If the temperature is below freezing perform the following to make starting the engine easier:

I-2007-1285

•

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature (See ENGINE LUBRICATION SYSTEM on Page PM22.)

•

Make sure the battery is fully charged.

•

Install an engine heater, available from your local Bobcat dealer.

Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader.

Figure OI-37

NOTE: The display screen of the left instrument panel may not be immediately visible when the temperature is below -15°F (-26°C). It may take 30 seconds to several minutes for the panel to warm up. All systems remain monitored even when the display is off.

1

S0150

If the Hydraulic Error icon (Item 1) [Figure OI-37] comes ON when operating the loader (cold), more warm up time is needed.

OI-19

S100 Operation & Maintenance Manual

The SHUTDOWN feature is associated with the following icons:

MONITORING THE DISPLAY PANELS Left Panel

• • • • •

Figure OI-38

General Warning Engine Oil Pressure Engine Coolant Temperature Hydraulic Oil Temperature Hydraulic Charge Pressure

Whenever STOP appears on the display screen, lower the lift arms all the way, put the attachment flat on the ground and stop the engine to prevent damage to the engine or loader systems.

1 S3999

Frequently monitor the temperature and fuel gauges and BICS lights [Figure OI-38]. All BICS lights must be off to operate the loader. (See BOBCAT INTERLOCK CONTROL SYSTEM (BICS) on Page SA-3.)

After the engine is running, frequently monitor the left instrument panel [Figure OI-38] for error conditions.

(See DIAGNOSTIC SERVICE CODES on Page SA-4.)

The associated icon will be ON if there is an error condition.

EXAMPLE: Engine Coolant Temperature is High: The Engine Temperature icon will be ON. The corresponding service code can be consulted by means of the “i” button (Item 1) [Figure OI-38] (DISPLAY MODE).

NOTE: Find the cause of the error code and correct before operating the loader again.

Warning And Shutdown When a WARNING condition exists, the associated icon light will come ON and there will be 3 beeps from the alarm.

NOTE: Be aware that, if this condition is allowed to continue, there may be damage to the engine or loader hydraulic systems.

When a SHUTDOWN condition exists, the associated icon light will come ON and there will be a continuous beep from the alarm and the monitoring system will automatically stop the engine in 15 seconds. The engine can be restarted to move or relocate the loader.

OI-20

S100 Operation & Maintenance Manual

Unbuckle the seat belt.

STOPPING THE ENGINE AND LEAVING THE LOADER Procedure

Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

Stop the Bobcat Loader on level ground.

Figure OI-41

Lower the lift arms fully and put the attachment flat on the ground.

Figure OI-39

1

S4006 P66668A S0597

Pull the engine speed control lever (Item 1) [Figure OI39] fully backward to decrease the engine speed.

Exit the loader [Figure OI-41].

Figure OI-40 1

WARNING Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move pedals until both lock.

• Move auxiliary control out of detent position.

W-2164-1294

S4002 S4498

Turn the key switch to the STOP position (Item 1) [Figure OI-40].

Engage the parking brake.

Lift the seat bar and make sure the lift and tilt functions are deactivated. Move the pedals until they both lock and traction drive is also deactivated.

Move auxiliary control out of detent position.

OI-21

S100 Operation & Maintenance Manual

Front Door (If Equipped)

STOPPING THE ENGINE AND LEAVING THE LOADER (CONT’D)

NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit [Figure OI-44].

Emergency Exit The front opening on the operator cab and rear window provide exits.

Rear Window (If Equipped)

NOTE: If the loader has a Special Application Door Kit installed, the window of the front door is NOT an emergency exit.

Figure OI-42

Figure OI-44

1

S4046

N20171

S4045

Pull the tag on the top of the rear window [Figure OI-42] to remove the rubber cord.

Pull the plastic loop (Item 1) [Figure OI-44] at the top 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 OI-45

Figure OI-43

1

1

1 1

6707852

S0363

Push the window out with your foot at any corner of the window (Item 1) [Figure OI-45].

P45260A

Exit through the front door.

Exit through the rear of the operator cab [Figure OI-43].

OI-22

S100 Operation & Maintenance Manual

Use the correct bucket size for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the ROC for the loader. Partial loads make steering more difficult.

ATTACHMENTS Choosing The Correct Bucket

WARNING

Pallet Forks

Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

Figure OI-47

1

W-2052-0500

Maximum load varies with model of pallet fork being used.

NOTE: Warranty is void if non-approved attachments are used on the Bobcat Loader.

The dealer can identify, for each model loader, the attachments and buckets approved by Bobcat. The buckets and attachments are approved for Rated Operating Capacity (ROC) and for secure fastening to the Bob-Tach.

B17255

The ROC for this loader is shown on a decal in the operator cab. (See (S100) LOADER SPECIFICATIONS on Page SPEC-3.)

The maximum load to be carried when using a pallet fork is shown on a decal located on the pallet fork frame (Item 1) [Figure OI-47].

The ROC is determined by using a standard bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used, the load center moves forward and reduces the ROC. If very dense material is loaded, the volume must be reduced to prevent overloading.

See your Bobcat dealer for more information about pallet fork inspection, maintenance and replacement. See your Bobcat Loader dealer for ROC when using a pallet fork and for other available attachments.

Figure OI-46 WRONG

WARNING AVOID INJURY OR DEATH Do not exceed Rated Operating Capacity (ROC).

Excessive load can cause tipping or loss of control.

W-2053-0903

B15576

Exceeding the ROC [Figure OI-46] can cause the following problems: • • • •

Steering the loader may be difficult.

Tires will wear faster.

There will be a loss of stability.

The life of the Bobcat Loader will be reduced.

OI-23

S100 Operation & Maintenance Manual

Figure OI-50

ATTACHMENTS (CONT’D) Installing And Removing The Attachment The Bob-Tach is used for fast changing of buckets and attachments. See the appropriate Attachment Operation & Maintenance Manual to install other attachments.

Installing Figure OI-48

S3982

Tilt the Bob-Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [Figure OI-50]. This will cause the bucket frame to fit up against the front of the Bob-Tach.

S3980

WARNING

Pull the Bob-Tach levers all the way up [Figure OI-48].

Enter the loader and perform the PRE-STARTING PROCEDURE. (See PRE-STARTING PROCEDURE on Page OI-15.) Start the engine.

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move pedals until both lock.

• Move auxiliary control out of detent position.

Lower the lift arms and tilt the Bob-Tach slightly forward.

Figure OI-49

W-2164-1294

Stop the engine, engage the parking brake, raise the seat bar, unfasten the seat belt and exit the loader.

Figure OI-51

S3981

Disengage the parking brake and drive the loader forward until the top edge of the Bob-Tach is completely under the top flange of the bucket [Figure OI-49] (or other attachment).

S3983

Push down on the Bob-Tach levers until they are fully engaged in the locked position [Figure OI-51].

NOTE: Make sure the Bob-Tach levers do not hit the bucket (or other attachment).

OI-24

S100 Operation & Maintenance Manual

ATTACHMENTS (CONT’D)

If the attachment is hydraulically controlled, connect the hydraulic hoses of the attachment to the loader (See Quick Couplers on Page OI-12.) You may need to release hydraulic pressure before connecting the quick couplers (See Relieving Hydraulic Pressure (Loader and Attachment) on Page OI-12.).

Installing And Removing The Attachment (Cont’d) Installing (Cont’d) Figure OI-52

Removing

1

•

Lower the lift arms, put the attachment flat on the ground and lower or close the hydraulic equipment.

•

If the attachment is hydraulically controlled (Combination bucket, backhoe, etc.): stop the engine and relieve hydraulic pressure in the auxiliary circuit (See Relieving Hydraulic Pressure (Loader and Attachment) on Page OI-12.)

•

Stop the engine, engage the parking brake, raise the seat bar, unfasten the seat belt and exit the loader.

•

Disconnect the hydraulic hoses from the attachment.

S2869

The levers must contact the frame at the shaded areas (Item 1) [Figure OI-52] (wedges fully extended).

WARNING

If the levers do not engage in the locked position, contact your Bobcat dealer for maintenance.

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move pedals until both lock.

• Move auxiliary control out of detent position.

Figure OI-53

W-2164-1294

Figure OI-54 S0163

The wedges must extend through the holes in the mounting frame of the bucket (or attachment) and touch the lower edge of these holes, securely fastening the bucket to the Bob-Tach [Figure OI-53].

WARNING

S3980

Pull the Bob-Tach levers all the way up [Figure OI-54].

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.

WARNING

W-2102-0497

Bob-Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

W-2054-1285

OI-25

S100 Operation & Maintenance Manual

ATTACHMENTS (CONT’D)

OPERATING PROCEDURE

Installing And Removing The Attachment (Cont’d)

Inspecting The Work Area

Removing (Cont’d)

Before beginning operation, inspect the work area for unsafe conditions.

Enter the loader and perform the PRE-STARTING PROCEDURE. (See PRE-STARTING PROCEDURE on Page OI-15.) Start the engine and disengage the parking brake.

Look for sharp drop-offs or rough terrain. Have underground utility lines (gas, water, sewer, irrigation, etc.) located and marked.

Remove objects or other construction material that could cause personal injury or damage the loader.

Figure OI-55

Operating With A Full Bucket

WARNING AVOID INJURY OR DEATH • Keep the lift arms as low as possible.

• Do not travel or turn with the lift arms up.

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

S3988

Tilt the Bob-Tach forward while backing the loader away from the bucket or attachment [Figure OI-55].

W-2018-1187

NOTE: In muddy conditions or to prevent the attachment from freezing to the ground, put the attachment on planks or blocks before removing it from the machine.

IMPORTANT Machines warmed up with moderate engine speed and light load have longer life.

I-2015-0284

When operating on a public road or highway, always follow local regulations. For example: Slow Moving Vehicle Sign or direction signals may be required.

Always warm the engine and hydrostatic system before operating the loader.

Keep the lift arms as low as possible and do not travel or turn with the lift arms up. Turn only on level ground and go up and down slopes, not across them.

Do not overload the machine and keep the heavy end of the machine uphill.

OI-26

S100 Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Operating With An Empty Bucket

Operating With A Full Bucket (Cont’d)

Figure OI-58

Operate the loader with the engine at full speed for maximum horsepower. Move the steering levers only a small amount to operate the loader slowly.

WITH BUCKET EMPTY

New operators must operate the loader in an open area without bystanders. Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

Figure OI-56 WITH BUCKET FULL

Going Up Slope

B15588

Figure OI-59 WITH BUCKET EMPTY

Going Up Slope

B15582

Figure OI-57 WITH BUCKET FULL

Going Down Slope B15587

With an empty bucket, go up or down the slope with the back of the loader (heavy end) toward the top of the slope [Figure OI-58] & [Figure OI-59].

Raise the bucket only high enough to avoid obstructions on rough ground.

Going Down Slope

B15583

With a full bucket, go up or down the slope with the bucket (heavy end) toward the top of the slope [Figure OI-56] & [Figure OI-57].

OI-27

S100 Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D) Filling And Emptying The Bucket

WARNING

Filling

Load, unload and turn on flat level ground. Do not exceed Rated Operating Capacity (ROC) shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

Figure OI-60 1

2

W-2056-0903

Emptying Figure OI-62 1 B-15585 B-15973

2

Figure OI-61

1 B-15595 B-15973

Keep the bucket low when moving to the area where you want to empty the bucket.

Level the bucket by pushing the toe of the right pedal (Item 1) while raising the lift arms (or use the BUCKET POSITION button if equipped) to help prevent material from falling off the back of the bucket. Raise the lift arms by pushing the heel of the left pedal (Item 2) [Figure OI-62].

B-15586 B-15973

Lower the lift arms all the way by pushing the toe of the left pedal (Item 1) [Figure OI-60]. Tilt the bucket forward by pushing the toe of the right pedal (Item 2) [Figure OI60] until the cutting edge of the bucket is on the ground.

Drive forward slowly until the bucket is over the top of the truck box or bin [Figure OI-62].

Drive slowly forward into the material. Tilt the bucket backward all the way by pushing the heel of the right pedal (Item 1) [Figure OI-61] when the bucket is full.

Empty the bucket by pushing the toe of the right pedal (Item 1) [Figure OI-62]. If all the material is near the side of the truck or bin, use the bucket tilt to move it to the other side.

Drive backward away from the material.

WARNING Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W-2057-0694

OI-28

S100 Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Digging And Filling A Hole

Leveling The Ground Using Float

Digging

Figure OI-63

Figure OI-64 1

2

2

1

3

3

B-15598 B-15973

B-15584 B-15973

Put the lift arms in float position by pushing the toe of the left pedal (Item 1) [Figure OI-63] until it is locked in the forward position.

Lower the lift arms all the way by pushing the toe of the left pedal (Item 1) [Figure OI-64]. Put the cutting edge of the bucket on the ground by pushing the toe of the right pedal (Item 2) [Figure OI-64].

Tilt the bucket forward by pushing the toe of the right pedal (Item 2) [Figure OI-63] to change the position of the cutting edge of the bucket.

Drive forward slowly and continue to tilt the bucket down (Item 2) [Figure OI-64] until it enters the ground.

With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

Raise the cutting edge a small amount by pushing the heel of the right pedal (Item 3) [Figure OI-64] to increase traction and keep an even digging depth. Continue to drive forward until the bucket is full. When the ground is hard, raise and lower the cutting edge of the bucket (Items 2 & 3) [Figure OI-64] while driving forward slowly.

Drive backward to level loose material [Figure OI-63].

Push the heel of the left pedal (Item 3) [Figure OI-63] to unlock the float position.

Figure OI-65

IMPORTANT Never drive forward when the hydraulic control for lift arms is in float position.

1

I-2005-1285

B-15596 B-15973

Tilt the bucket backward by pushing the heel of the right pedal (Item 1) [Figure OI-65] as far as it will go when the bucket is full.

OI-29

S100 Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

TOWING THE LOADER

Digging And FIlling (Cont’d)

Procedure

Filling

Because of the design of the loader, there is not a recommended towing procedure.

Figure OI-66 2

1

•

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 tires when the loader is skidded.

The towing chain (or cable) must be rated at 1 & 1/2 times the weight of the loader. (See Performance on Page SPEC-4.)

B-15597 B-15973

Lower the lift arms by pushing the toe of the left pedal (Item 1) [Figure OI-66]. Put the cutting edge of the bucket on the ground by pushing the toe of the right pedal (Item 2) [Figure OI-66]. Drive forward to the edge of the hole to push the material into the hole.

Tilt the bucket farther forward (Item 2) [Figure OI-66] as soon as it is past the edge of the hole.

If necessary, raise the lift arms to empty the bucket.

OI-30

S100 Operation & Maintenance Manual

LIFTING THE LOADER Single Point Lift

WARNING • • •

AVOID INJURY OR DEATH Before lifting, check fasteners on single point lift and operator cab.

Assemble front cab fasteners as shown in this manual.

Never allow riders in the cab or bystanders within 15 feet (5 meters) while lifting the machine.

W-2007-0497

Lift the loader with the single point lift which is available as a kit from your Bobcat Loader dealer.

Figure OI-67 1

TS1959

Attach cables or chains to the single point lift as shown (Item 1) [Figure OI-67].

The single point lift, supplied by Bobcat, is designed to lift and support the Bobcat Loader without affecting roll over (ROPS) and falling object protection (FOPS) features of the operator cab.

OI-31

S100 Operation & Maintenance Manual

TRANSPORTING THE LOADER ON A TRAILER

Fastening

Loading And Unloading

Figure OI-69

WARNING AVOID SERIOUS INJURY OR DEATH Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

S4759

S4758

W-2058-0807

Be sure the transport and towing vehicles are of adequate size and capacity for the weight of the loader.

(See Performance on Page SPEC-4.)

Figure OI-68 Alternate Front Tie Down

S1075

S1848

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 OI-69].

•

Lower the bucket or attachment to the floor.

•

Stop the engine.

•

Engage the parking brake.

•

Install chains at the front and rear loader tie down positions [Figure OI-69].

•

Fasten each end of the chain to the transport vehicle.

S1077

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure OI68].

The rear of the trailer must be blocked or supported [Figure OI-68] when loading or unloading the loader to prevent the front end of the trailer from raising up.

OI-32

S100 Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-19 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-19 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-35 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-35 Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-35 BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PM-13 PM-13 PM-13 PM-13

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-39 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-39 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . .

Inspecting The BICS Controller (Engine STOPPED - Key ON). . .

Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . .

Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . .

Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . .

Maintaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREVENTIVE MAINTENANCE (PM)

PM-8 PM-8 PM-8 PM-8 PM-8 PM-9

CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-36 Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-36 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . .

Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . .

Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . .

PM-25 PM-26 PM-25 PM-25 PM-28 PM-26

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . .

PM-23 PM-23 PM-23 PM-24

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . . . . .

PM-22 PM-22 PM-22 PM-22

Continued On Next Page

PM-1

S100 Operation & Maintenance Manual

PREVENTIVE MAINTENANCE (CONT’D) FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . PM-34 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-34 Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-34 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . .

PM-20 PM-20 PM-21 PM-20 PM-21

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . PM-29 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-29 Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-29 Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . PM-29 Removing And Replacing Hydraulic Fluid and Case Drain Filters. . . . PM-30 Removing And Replacing Charge Filter. . . . . . . . . . . . . . . . . . . . . . . . PM-31 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-12 LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . PM-41 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-41 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-41 LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-36 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-36 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Door Sensor (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PM-14 PM-16 PM-14 PM-15 PM-14

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-38 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-38 REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Continued On Next Page

PM-2

S100 Operation & Maintenance Manual

PREVENTIVE MAINTENANCE (CONT’D) REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PM-9 PM-9 PM-9 PM-9

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-32 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-32 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PM-3

PM-33 PM-33 PM-33 PM-33

S100 Operation & Maintenance Manual

PM-4

S100 Operation & Maintenance Manual

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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 W-2003-0903 instructions can cause injury or death.

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

B10731a

B15590

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

CORRECT

B15591

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B15592

B15593

B15599

Have good ventilation when welding or grinding painted parts.

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

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device.

Replace it if damaged.

WRONG

WRONG

B15600

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

B15601 B-16102 Keep body, jewelry and clothing

away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

WRONG

B6589 B-16102

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

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

PM-5

S100 Operation & Maintenance Manual

PM-6

S100 Operation & Maintenance Manual

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.

WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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-2003-0903 SERVICE SCHEDULE

ITEM

HOURS

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 (See AIR CLEANER SERVICE on Page PM-19.) Check for leaks and damaged components.

Empty dust cup as needed.

Engine Cooling System Clean debris from oil cooler, radiator & 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, Control Interlocks needed. Clean dirt and debris from moving parts. Check the seat bar and control interlocks for correct operation.

Bobcat Interlock Control Check that three BICS indicator lights and functions are activated. See details Systems (BICS) in this Manual.

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. (See TIRE ❏ MAINTENANCE on Page PM-33.)

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.

PM-7

S100 Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

Inspecting The Traction Lock (Engine RUNNING)

Inspecting The BICS Controller (Engine STOPPED Key ON)

5. Lower the seat bar, disengage the parking brake and 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.

Figure PM-1

1

2

6. Lower the seat bar and press the PRESS TO OPERATE LOADER button. Engage the parking brake and move the steering levers slowly forward and backward. The traction drive system will be locked.

3

NOTE: The PARKING BRAKE light on the left instrument panel will remain ON until the engine is started, the PRESS TO OPERATE LOADER button is pressed and the parking brake is disengaged.

S3999

Inspecting The Lift Arm Bypass Control 7. Raise the lift arms 6 feet (2 meters) off the ground.

Stop the engine. Turn the lift arm bypass control knob clockwise 1/4 turn. Pull up and hold the knob until the lift arms slowly lower.

4

S2870

1. Sit in the operator seat, turn the key ON, lower the seat bar and disengage the parking brake. Press the PRESS TO OPERATE LOADER button. Three BICS lights (Items 1-3) on the left instrument panel should be OFF (SEAT BAR, LIFT & TILT VALVE and PARKING BRAKE) and the PRESS TO OPERATE LOADER button will light up green (Item 4) [Figure PM-1].

WARNING AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.

2. Raise the seat bar fully. Three BICS lights (Items 1-3) [Figure PM-1] on the left instrument panel should be ON (SEAT BAR, LIFT & TILT VALVE and PARKING BRAKE).

W-2151-0394

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.

PM-8

S100 Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

Maintaining

Description

See the service schedule for correct service interval.

(See SERVICE SCHEDULE on Page PM-7.)

The seat bar restraint system has a pivoting seat bar with arm rests.

Figure PM-2

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The foot pedals have hydraulic valve spool interlocks for the lift and tilt functions. The spool interlocks require the operator to lower the seat bar in order to operate the foot pedal controls.

When the seat bar is down, the PRESS TO OPERATE LOADER button is activated and the engine is running, the lift, tilt and traction drive functions can be operated.

1

1

When the seat bar is up, the lift and tilt control pedals are locked when returned to the NEUTRAL position.

S4010

Inspecting Use compressed air to clean any debris or dirt from the pivot parts (Item 1) [Figure PM-2]. Do not lubricate.

Inspect all mounting hardware. The correct bolt torque is 26 ft.-lb. (35 N•m).

Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the PRESS TO OPERATE LOADER button.

If the seat bar system does not function correctly, replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

Operate the hydraulic controls to check that both the lift and tilt functions operate correctly. Raise the lift arms until the attachment is about 2 feet (600 mm) off the ground.

Raise the seat bar. Move the hydraulic controls. Pedals must be firmly locked in the NEUTRAL position. There must be no motion of the lift arms or tilt (attachment) when the controls are moved.

WARNING The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hydraulic controls do not deactivate.

Lower the seat bar, press the PRESS TO OPERATE LOADER button, lower the lift arms. Operate the lift control. While the lift arms are going up, raise the seat bar. The lift arms must stop.

W-2465-0703

Lower the seat bar, press the PRESS TO OPERATE LOADER button, lower the lift arms and put the attachment flat on the ground. Stop the engine. Raise the seat bar. Operate the foot pedals to be sure they are firmly locked in the NEUTRAL position.

PM-9

S100 Operation & Maintenance Manual

Figure PM-3

SEAT BELT Inspection And Maintenance

1

3

WARNING Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death.

W-2466-0703

2

Check the seat belt daily for correct function.

4

Inspect the seat belt system thoroughly yearly or more often if the machine is exposed to severe environmental conditions or applications.

The seat belt system should be repaired or replaced if it shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet (UV) rays from the sun, dusty/dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), or hardware.

B22283

The items below are referenced in [Figure PM-3].

1. Check the seat belt webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. Look for cuts, wear, fraying, dirt and stiffness.

2. Check the buckle and latch for proper function. Make sure latch plate is not excessively worn, deformed or buckle is not damaged.

3. Check the retractor web storage device (if equipped) by extending the seat belt webbing to determine if it extends and retracts the webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have weakened.

See your Bobcat dealer for approved seat belt system replacement parts for your machine.

PM-10

S100 Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

Figure PM-4

Installing Maintenance and service work can be done with the lift arms lowered. If the lift arms are raised, use the following procedures to engage and disengage an approved lift arm support device.

WARNING 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 P43747

Install jackstands (Item 1) [Figure PM-4] under the rear corners of the loader frame.

W-2059-0598

Figure PM-5

WARNING 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.

3

W-2271-1197

2

1 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 PM-5].

PM-11

S100 Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE (CONT’D)

Removing

Installing (Cont’d)

Remove the retaining pin (Item 1) [Figure PM-7] from the lift arm support device.

Figure PM-6 Figure PM-8

1 1

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 PM-6] to the lift arm support device so the spring does not interfere with the support device engagement.

Connect the spring (Item 1) [Figure PM-8] from the lift arm support device to the bracket below the lift arms.

Sit in the operator’s seat, fasten the seat belt and lower the seat bar. Start the engine.

Sit in the operator seat, fasten the seat belt and lower the seat bar. Start the engine.

Figure PM-9 Figure PM-7

1

2 1

P54468 P54470

N20524

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod (Item 1) [Figure PM-7].

Raise the lift arms a small amount. The spring will lift the support device off the lift cylinder rod. Lower the lift arms.

Stop the engine.

Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine.

Raise the seat bar and move the pedals until both lock.

Raise the seat bar, unbuckle the seat belt, move the pedals until both lock and exit the cab.

Disconnect the spring from the bracket.

Install the retaining pin (Item 2) [Figure PM-7] 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 PM-9] through the lift arm support device and through the bracket. Connect the spring to the retaining pin.

Remove the jackstands.

PM-12

S100 Operation & Maintenance Manual

Figure PM-11

BACK-UP ALARM SYSTEM Description This machine may be equipped with a back-up alarm system. The back-up alarm will sound when the operator moves both steering levers in the reverse position. Slight movement of the steering levers in the reverse position is required with hydrostatic transmissions, before the backup alarm will sound.

1

Inspecting 2

Figure PM-10

P-69346

Inspect the back-up alarm electrical connections (Item 1) [Figure PM-11], wire harness (Item 2) [Figure PM-11] and back-up alarm switches (if equipped) (Item 2) [Figure PM-12] for tightness and damage. Repair or replace any damaged components.

1

If the back-up alarm switches require adjustment, (See Adjusting Switch Position on Page PM-13.)

Adjusting Switch Position Stop the engine and raise the operator cab. (See Raising on Page PM-14.)

P-76108

Inspect for damaged or missing back-up alarm decal (Item 1) [Figure PM-10]. Replace if required.

Figure PM-12 1

Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the PRESS TO OPERATE LOADER button. Disengage the parking brake.

1

Move both steering levers in the reverse position. The back-up alarm must sound when all wheels or both tracks are moving in reverse.

Switch Rollers contacting Bellcranks

The back-up alarm is located on the inside of the rear door.

S4877

Place the steering levers in the neutral position.

Loosen the screws (Item 1) [Figure PM-12] securing the back-up alarm switches.

Position the back-up alarm switch rollers so that they just make contact with bellcranks without compressing the switch springs [Figure PM-12]. Torque the screws (Item 1) [Figure PM-12] securing the switches to the bracket to 14-19 in.-lb. (1,6-2,1 N•m).

Lower the operator cab (See Lowering on Page PM-15.) and inspect back-up alarm system for proper function.

(See Inspecting on Page PM-13.)

PM-13

S100 Operation & Maintenance Manual

OPERATOR CAB

Raising

Description

Always stop the engine before raising or lowering the cab.

The Bobcat Loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for rollover protection.

Stop the loader on a level surface and lower the lift arms.

If the lift arms must be up while raising the operator cab, install the lift arm support device. (See LIFT ARM SUPPORT DEVICE on Page PM-11.)

ROPS/FOPS - Roll Over Protective Structure per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I. Level II is available.

Figure PM-13

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

Install jackstands (Item 1) [Figure PM-13] under the rear corners of the loader frame.

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

Figure PM-14

W-2069-0200

2

1

1

2 S4011

S4012

Remove the nut and plate (Items 1&2) [Figure PM-14] on the inside front corner of the cab (Both sides).

PM-14

S100 Operation & Maintenance Manual

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.

OPERATOR CAB (CONT’D) Raising (Cont’d) Figure PM-15

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 PM-16]. 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.

S4078

NOTE: Always use the grab handles (once you can reach them) to lower the 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 PM-15].

Figure PM-17

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

2

1 Figure PM-16 2

1 S4012 SXXXX

S4011 SXXXX

Install the plates and nuts (Items 1&2) [Figure PM-17] (both sides).

Tighten the nuts to 40-45 ft.-lb. (54-61 N•m) torque.

N20120

S4013

Pull down on the bottom of the operator cab until it stops at the latching mechanism [Figure PM-16].

PM-15

S100 Operation & Maintenance Manual

OPERATOR CAB (CONT’D) Cab Door Sensor (If Equipped) Figure PM-18

1

P68116

P68115

The cab door (option) has a sensor (Item 1) [Figure PM18] installed which deactivates the lift and tilt valves when the door is open.

CLOSE DOOR TO OPERATE lift and tilt valves.

Figure PM-19

1

S3999

The LIFT / TILT LOCK light (Item 1) [Figure PM-19] will be ON until the door is closed, the key switch is turned to ON, the seat bar is lowered and the PRESS TO OPERATE LOADER button is pressed.

PM-16

S100 Operation & Maintenance Manual

REAR DOOR Opening And Closing

WARNING Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

WARNING

W-2020-1285

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

Adjusting

W-2012-0497

Figure PM-22 Figure PM-20

1

S4466 P30806

P45012

The door latch catch (Item 1) [Figure PM-22] can be adjusted left and right for alignment with the door latch mechanism.

Reach into the slot in the rear door and pull the latch handle [Figure PM-20].

Close the rear door before operating the loader.

Pull the rear door open.

Figure PM-21 1

2

P16366

P16367

Move the door stop into the engaged position (Item 1) to hold the door open. Move the door stop up (Item 2) [Figure PM-21] and close the rear door.

PM-17

S100 Operation & Maintenance Manual

REAR GRILL

CAB FILTERS

Removing

Cleaning And Maintenance

Open the rear door.

The heating system requires regular inspection and maintenance. (See SERVICE SCHEDULE on Page PM7.)

Figure PM-23

Filters Figure PM-24 1

2

1 S4082

Raise the rear grill (Item 1) [Figure PM-23] and remove it from the loader.

P48012

Installing

The fresh air filter is located below the rear window of the cab (Item 1) [Figure PM-24].

Align the two tabs of the rear grill into the two slots in the loader frame (Inset) [Figure PM-23].

Remove the knobs, the filter housing and the filter.

Lower the rear grill.

Shake the filter or use low air pressure to remove dirt.

The filter can be cleaned several times in this manner before it must be replaced.

Install the filter housing.

The recirculation filter is located in front of the rear window inside the cab (Item 2) [Figure PM-24].

Remove the clamping knobs, grill and filter.

Shake the filter or use low air pressure to remove dirt.

The filter can be cleaned several times in this manner before it must be replaced.

Install the filter housing.

Troubleshooting If the fan does not run, check the fuse. (See ELECTRICAL SYSTEM on Page PM-25.)

PM-18

S100 Operation & Maintenance Manual

Figure PM-27

AIR CLEANER SERVICE Replacing Filter Elements Figure PM-25

1

S4020

2

1

Pull the element straight out (Item 1) [Figure PM-27].

Install a new outer element.

S4051

Install the dust cover (Item 2) [Figure PM-26].

Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator (Item 1) [Figure PM-25].

Check the air intake hose and the air cleaner housing for damage. Make sure all connections are tight.

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [Figure PM-25]. Start the engine. If the red ring does not show, do not replace the filter element.

Inner Filter

Outer Filter

Figure PM-28

Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

Figure PM-26

2

1 1 S4019 S4021

Remove the inner filter (Item 1) [Figure PM-28].

S4014

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Open the evacuator valve (Item 1) [Figure PM-26] to get rid of large particles of dust and dirt.

Install a new inner element.

Install the outer element.

Remove the dust cover by lifting the lever (Item 2) [Figure PM-26].

Install the dust cover [Figure PM-26].

PM-19

S100 Operation & Maintenance Manual

Figure PM-30

FUEL SYSTEM 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 correct specification. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [Figure PM-30].

Filling The Fuel Tank

Install and tighten the fuel fill cap (Inset) [Figure PM-29].

WARNING 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 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 which can result in injury or death.

Figure PM-29

W-2103-0807

S4014

Open the rear door.

Remove the fuel fill cap (Inset) [Figure PM-29].

PM-20

S100 Operation & Maintenance Manual

FUEL SYSTEM (CONT’D)

After replacing the filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

Fuel Filter For the service interval for removing water from, or replacing the fuel filter (See SERVICE SCHEDULE on Page PM-7.)

Figure PM-32

Removing Water Figure PM-31

S4018 S4014

3

4 1

S4017

S4014

Open the vent (Item 3) [Figure PM-31] on the fuel filter housing.

2

Squeeze the hand pump (priming bulb) (Inset) [Figure PM-32] until air bubbles do not come up any more.

S4014

Loosen the drain (Item 1) [Figure PM-31] at the bottom of the filter element to remove water from the filter.

Close the vent (Item 3) [Figure PM-31] on the fuel filter housing.

Replacing Element

Open the vent (Item 4) [Figure PM-31] on the fuel injection pump.

Remove the filter element (Item 2) [Figure PM-31].

Squeeze the hand pump (priming bulb) (Inset) [Figure PM-32] until air bubbles do not come up any more.

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.

Close the vent (Item 4) [Figure PM-31] on the fuel injection pump.

Remove air from the fuel system. (See Removing Air From The Fuel System below.)

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.

Removing Air From The Fuel System

WARNING 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 from a physician familiar with this injury.

W-2072-0807

PM-21

S100 Operation & Maintenance 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 PM-7.)

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 PM-33

Figure PM-35

2 S4023

1

1 S4024

2

S4014

Open the rear door.

Open the rear door and remove the dipstick (Item 1) [Figure PM-33].

Remove the drain hose from its storage position (Item 2).

Remove the drain plug (Item 1) [Figure PM-35].

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 PM-35].

Figure PM-34

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 and return the drain hose to the stored position.

Add engine oil. (See Checking And Adding Engine Oil on Page PM-22.)

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 which can result in injury or death.

B16320

Use a good quality motor oil that meets API Service Classification of CD or better. (See Engine Oil Chart [Figure PM-34].)

W-2103-0807

PM-22

S100 Operation & Maintenance Manual

ENGINE COOLING SYSTEM

Figure PM-37

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Cleaning 1

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 PM-36

S4757

Remove the coolant fill cap (Item 1) [Figure PM-37].

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 glycol in your cooling system.

1

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 PM-36].

IMPORTANT

Check the cooling system for leaks.

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

Lower the rear grill and close the rear door.

Checking Level

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

Open the rear door and remove the rear grill. (See REAR GRILL on Page PM-18.)

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 engine damage.

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.

I-2124-0497

W-2019-1285

PM-23

S100 Operation & Maintenance Manual

Use a refractometer to check the condition of propylene glycol in your cooling system.

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant Open the rear door and remove the rear grill (See REAR GRILL on Page PM-18.)

Run the engine until it is at operating temperature. After stopping the engine, let it cool down and check the coolant level again. Add coolant as needed.

Figure PM-38

Install the rear grill and close the rear door.

IMPORTANT 1 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.

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

S4757

Remove the coolant fill cap (Item 1) [Figure PM-38].

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

Connect a hose to the engine block drain valve. Open the drain valve and drain the coolant into 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 Capacities on Page SPEC-7.) 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 -34°F (-37°C) 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 PM-38].

PM-24

S100 Operation & Maintenance Manual

Figure PM-41

ELECTRICAL SYSTEM Description

1 2

The loader has a 12 V, negative ground alternator charging system. The electrical system is protected by fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

Fuse And Relay Location / Identification

3 4

Figure PM-39

13

11

9

5

15

17

6

18

7

19

8

10

12

14

16

20 7135574

The location and sizes are shown below and in [Figure PM-41]: REF DESCRIPTION

AMP

REF DESCRIPTION

AMP

1

Traction

30

11 Front & Marker R Lights

2

Fuel Shutoff

30

12 Fuel Shutoff

R

3

Power Plug

15

13 Rear Lights

R

4

Switched Cab

15

14 Traction

R

5

Heater

25

15 Switch Power

R

6

Front & Marker 15 Lights

16 Starter

R

The electrical system is protected from overload by fuses and relays under the fuse panel cover (Inset) [Figure PM-39]. A decal is inside the cover to show location and amp ratings.

7

Rear Lights

15

17 Remote Start / 25 Cab Lights

8

Bobcat Controller 25

18 Instrument Power 15

9

Heater

R

19 Alternator Accessories

Figure PM-40

10 Glow Plugs

R

20 Attachments Plug 25

S0188

S4014

& 25

R - Relay

S4016

Remove the cover to check or replace the fuses [Figure PM-40].

PM-25

S100 Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Using A Booster Battery (Jump Starting)

Battery Maintenance

If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

Figure PM-42

Figure PM-43 1

P09590

P09589

The battery cables must be clean and tight [Figure PM42]. Check electrolyte level in the battery. Add distilled water as needed. Remove acid or corrosion from battery and cables with sodium bicarbonate (baking soda) and water solution.

S4498

The key switch must be in the STOP position (Item 1) [Figure PM-43]. The booster battery must be 12 V.

Put Battery Saver (6664458) or grease on the battery terminals and cable ends to prevent corrosion.

WARNING 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.

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.

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F (16°C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

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.

Battery gas can explode and cause serious injury.

W-2066-0705

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W-2065-0807

PM-26

S100 Operation & Maintenance Manual

end of the same cable (Item 4) [Figure PM-44] to the engine.

ELECTRICAL SYSTEM (CONT’D) Using A Booster Battery (Jump Starting) (Cont’d)

NOTE: Keep cables away from moving parts.

Start the engine. (See STARTING THE ENGINE on Page OI-17.)

WARNING

After the engine has started, remove the ground (-) cable (Item 4) [Figure PM-44] first.

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.

Remove the cable from the positive terminal (Item 2) [Figure PM-44].

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.

IMPORTANT

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

Damage to the alternator can occur if: • Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.)

• Extra battery cables (booster cables) are connected wrong.

W-2065-0807

Figure PM-44

I-2023-1285

4 3

S4025

2

1

P31860

Connect the end of the first cable to the positive (+) terminal (Item 1) of the booster battery. Connect the other end of the same cable to the positive terminal (Item 3) [Figure PM-44] on the loader starter.

Connect the end of the second cable to the negative (-) terminal (Item 2) of the booster battery. Connect the other

PM-27

S100 Operation & Maintenance Manual

Figure PM-46

ELECTRICAL SYSTEM (CONT’D) Removing And Installing Battery

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 and wash eye with clean, cool water for at least 15 minutes.

P09589

P09590

Always clean the battery terminals and cable ends when installing a new or used battery [Figure PM-46].

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

NOTE: Always connect the negative (-) cable last and remove it first to prevent sparks.

W-2065-0807

Install and tighten the battery hold down clamp.

Open the rear door.

Connect and tighten the battery cables.

Figure PM-45 Close the rear door before operating the loader.

3

2 1 S4027

S4014

Disconnect the negative (-) battery cable (Item 1) [Figure PM-45].

Remove the battery hold down clamp (Item 2) [Figure PM-45].

Disconnect the positive (+) cable (Item 3) [Figure PM-45] from the battery.

Remove the battery from the loader.

NOTE: When removing or installing the battery in the loader, do not touch any metal parts with the battery terminals.

PM-28

S100 Operation & Maintenance Manual

HYDRAULIC / HYDROSTATIC SYSTEM

Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid

Figure PM-48

Use only recommended fluid in the hydraulic system.

(See Hydraulic System on Page SPEC-5.)

Stop the loader on a level surface.

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

Stop the engine.

Figure PM-47

P64023A

Use the correct hydraulic / hydrostatic fluid shown in chart [Figure PM-48].

1 S4028

Removing And Replacing Hydraulic / Hydrostatic Filter For the correct service interval SCHEDULE on Page PM-7.)

S4031

(See

SERVICE

Stop the engine and open the rear door.

Figure PM-49

2

3 S4029

S4030

Remove the fill cap (Item 1) [Figure PM-47].

Add oil until it is at the center of the sight gauge (Item 2) [Figure PM-47]. Do not overfill.

S4080

Remove the screen (Item 3) [Figure PM-47] and clean with solvent as needed.

Install the fill cap (Item 1) [Figure PM-47].

S4014

Remove the filter (Inset) [Figure PM-49].

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.

PM-29

S100 Operation & Maintenance Manual

Figure PM-50

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic / Hydrostatic Filter (Cont’d)

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.

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.

S4031

Raise the operator cab. (See Raising on Page PM-14.)

Remove the fill cap (Item 1) [Figure PM-50].

W-2072-0807

Figure PM-51

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.

1

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 which can result in injury or death.

S4033

S4032

Disconnect the hose (Item 1) [Figure PM-51] from the hydraulic reservoir and drain the fluid into a container.

W-2103-0807

Reconnect the hose when the reservoir is empty.

Removing And Replacing Hydraulic Fluid and Case Drain Filters For the correct service interval SCHEDULE on Page PM-7.)

(See

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.

SERVICE

Replace the fluid if it becomes contaminated or after major repair.

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 PM-29.)

PM-30

S100 Operation & Maintenance Manual

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

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Fluid and Case Drain Filters (Cont’d)

WARNING

Figure PM-52

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately.

1

S4034

W-2145-0290

Removing And Replacing Charge Filter Figure PM-53

S4032

The case drain filters are located under the cab, next to the transmission, one on each side (Item 1) [Figure PM52].

1 2

Disconnect the fittings at the end of the case drain filters and remove both filters.

1

S4254

WARNING Remove the hydraulic connections (Item 1) and remove the charge filter (Item 2) [Figure PM-53]. 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 which can result in injury or death.

W-2103-0807

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 PM-15.)

Replace the hydraulic / hydrostatic filter. (See Removing And Replacing Hydraulic / Hydrostatic Filter on Page PM-29.)

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.

PM-31

S100 Operation & Maintenance Manual

SPARK ARRESTOR MUFFLER

WARNING

Cleaning Procedure See the SERVICE SCHEDULE for service interval for cleaning the spark arrestor muffler. (See SERVICE SCHEDULE on Page PM-7.)

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

Do not operate the loader with a defective exhaust system.

W-2050-0807

Stop the engine and open the rear door.

Figure PM-54

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 material. Failure to obey warnings can cause injury or death.

Remove the plug (Item 1) [Figure PM-54] from the bottom of the muffler.

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.

PM-32

S100 Operation & Maintenance Manual

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.

TIRE MAINTENANCE Wheel Nuts Figure PM-55

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.

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.

S4503

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.

See the SERVICE SCHEDULE for the service interval to check the wheel nuts [Figure PM-55]. (See SERVICE SCHEDULE on Page PM-7.)

Avoid excessive pressure which can rupture the tire and cause serious injury or death.

When installing wheel nuts, tighten to 160 ft.-lb. (217 N•m) torque.

During inflation of the tire, check the tire pressure frequently to avoid over inflation.

When checking wheel nut torque, set the torque wrench to 140 ft.-lb. (190 N•m) to prevent over-tightening.

Rotating

WARNING

Check the tires regularly for wear, damage and pressure.

Inflate tires to the maximum pressure shown on the sidewall of the tire.

AVOID SERIOUS INJURY OR DEATH Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

Figure PM-56

W-2078-0807

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 PM-56].

PM-33

S100 Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

Removing And Replacing Oil

Checking And Adding Oil

Remove the check plug (Item 1) [Figure PM-57] 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 / hydrostatic system.

(See (S100) LOADER SPECIFICATIONS on Page SPEC-3.)

Figure PM-58

Stop the loader on a level surface.

Stop the engine.

Figure PM-57

1 P31287A

Use a pump to suction the oil from the chaincase [Figure PM-58].

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 PM-57] 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.

PM-34

S100 Operation & Maintenance Manual

ALTERNATOR BELT

Belt Replacement

Belt Adjustment

Stop the engine and open the rear door.

Stop the engine and raise the operator cab. (See Raising on Page PM-14.)

Loosen the alternator mounting and adjustment bolts (Items 1 & 2) [Figure PM-59] and loosen the belt all the way.

Figure PM-59

Remove the belt and install a new belt.

Move the alternator until the belt has 2.3 mm movement at the middle of the belt span with, for a new belt, 2.57 2.69 lbf. (11.2 - 12.0 N) of force.

Tighten the adjustment bolt and mounting bolts.

Lower the operator cab. (See Lowering on Page PM-15.)

S4014

1

1 S4022

Loosen the alternator mounting bolt (Item 1) [Figure PM59].

Loosen the adjustment bolt (Item 2) [Figure PM-59].

Move the alternator until the belt has 2.3 mm movement at the middle of the belt span with 2.16 - 2.33 lbf. (9.63 10.4 N) of force.

Tighten the adjustment bolt and mounting bolts.

Lower the operator cab. (See Lowering on Page PM-15.)

PM-35

S100 Operation & Maintenance Manual

DRIVE BELT

LUBRICATING THE LOADER

Belt Replacement

Lubrication Locations

Stop the engine.

Lubricate the loader as specified for the best performance of the loader. (See SERVICE SCHEDULE on Page PM-7.)

Open the rear door and disconnect the negative (-) cable from the battery.

Record the operating hours each time you lubricate the Bobcat Loader.

Figure PM-60

Always use a good quality lithium based multi-purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows.

Lubricate the following locations on the loader: Figure PM-61

1

3 2

4

S4014

2

1

3 S4137

Figure PM-62

S4083

1

Remove the belt shield fasteners (Item 1) [Figure PM60] and remove the belt shield.

Use a socket wrench (without socket) to move the spring loaded belt tensioner (Item 2) [Figure PM-60] upward.

While holding the spring loaded belt tensioner up, you can remove the drive belt (Item 3) [Figure PM-60].

Carefully lower the spring loaded belt tensioner to its stop.

S1080

1. Rod End Lift Cylinder (Both Sides) (Item 1) [Figure PM-61] & [Figure PM-62].

Install a new drive belt by reversing the above procedure.

PM-36

S100 Operation & Maintenance Manual

Figure PM-65

LUBRICATING THE LOADER (CONT’D) Lubrication Locations (Cont’d)

4

Figure PM-63

2

S4037

4. Base End Tilt Cylinder (Both Sides) (Item 4) [Figure PM-61] & [Figure PM-65].

S4085

Figure PM-66

2. Base End Lift Cylinder (Both Sides) (Item 2) [Figure PM-61] & [Figure PM-63].

6

Figure PM-64

7

5

3

S4139 S4086

5. Rod End Tilt Cylinder (Both Sides) (Item 5) [Figure PM-66].

3. Lift Arm Pivot Pin (Both Sides) (Item 3) [Figure PM61] & [Figure PM-64].

6. Bob-Tach Pivot Pin (Both Sides) (Item 6) [Figure PM66].

7. Bob-Tach Wedge (Both Sides) (Item 7) [Figure PM66].

PM-37

S100 Operation & Maintenance Manual

LUBRICATING THE LOADER (CONT’D)

PIVOT PINS

Lubrication Locations (Cont’d)

Inspection And Maintenance

Figure PM-67

Figure PM-68

1

8

8 N20575A

S4039

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [Figure PM-68].

8. 250 Hours: Steering Lever Shaft (two) under the cab (Item 8) [Figure PM-67].

Check that the lock nuts are tightened to 35-40 ft.-lb. (4854 N•m) torque.

PM-38

S100 Operation & Maintenance Manual

PIVOT PINS (CONT’D)

BOB-TACH

Inspection And Maintenance (Cont’d)

Inspection And Maintenance

Figure PM-69

Figure PM-71

3 1

4

2

5

N17027 S4137

Move the Bob-Tach levers down to engage the wedges [Figure PM-71].

Figure PM-70

The levers and wedges must move freely.

6

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 S4139

Figure PM-72 Check the following pivot pins (Items 1-6) [Figure PM69] & [Figure PM-70].

1

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 PM-72].

PM-39

S100 Operation & Maintenance Manual

BOB-TACH (CONT’D) Inspection And Maintenance (Cont’d) The spring loaded wedge (Item 1) [Figure PM-72] must contact the lower edge of the hole in the attachment (Item 2).

If the wedge does not contact the lower edge of the hole [Figure PM-72], the attachment will be loose and can come off the Bob-Tach.

Figure PM-73

B17460

Inspect the mounting frame on the attachment and BobTach, linkages and wedges for excessive wear or damage [Figure PM-73]. 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 PM-7.) (See also LUBRICATING THE LOADER on Page PM-36.)

PM-40

S100 Operation & Maintenance 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 service.

Sometimes it may be necessary to store your Bobcat Loader for an extend period of time. Below is a list of items to perform before storage.

•

Thoroughly clean the loader including the engine compartment.

Check the engine and hydraulic oil levels; check coolant level.

•

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 on the ground.

•

Lubricate the loader.

•

Put blocks under the frame to remove weight from the tires.

•

Check tire inflation and remove blocks from under frame.

•

Put grease on any exposed cylinder rods.

•

Remove cover from exhaust pipe opening.

•

Put fuel stabilizer in the fuel tank and run the engine a few minutes to circulate the stabilizer to the pump and fuel injectors.

•

Start the engine and let run for a few minutes while observing the instrument panels and systems for correct operation.

•

Drain and flush the cooling system. Refill with premixed coolant.

•

Operate machine, check for correct function.

•

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.

PM-41

S100 Operation & Maintenance Manual

PM-42

S100 Operation & Maintenance Manual

SYSTEM SETUP & ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . SA-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-3 DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . SA-4 Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-5 Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-4

SYSTEM SETUP & ANALYSIS (SA)

SA-1

S100 Operation & Maintenance Manual

SA-2

S100 Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Troubleshooting The following list shows the probable causes when the BICS system lights are off or flashing and the associated service codes. (See DIAGNOSTIC SERVICE CODES on Page SA-4.)

Indicator Light

Light OFF

PRESS TO OPERATE LOADER button is NOT pressed.

Light ON

PRESS TO OPERATE LOADER button IS pressed.

Effect on Operation of Loader when Light is ON

Flashes

Service Code

Lift and tilt functions will operate. Continuous Flashing M-52-02 Loader can be moved forward Continuous Flashing M-52-21 and backward.

Continuous Flashing M-52-22

1 Seat Bar is down. Seat Bar is up. Lift and tilt functions will not operate.

Continuous Flashing M-11-21 Continuous Flashing M-11-22

2 Control valve can Control valve be used. cannot be used.

3

Loader can be moved forward and backward 4

Lift and tilt functions will not operate.

Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Solid (battery) Icon Solid (battery) Icon Solid (battery) Icon Solid (battery) Icon Solid (battery) Icon Loader cannot Loader cannot be moved forward Continuous Flashing and backward. be moved Continuous Flashing forward and Continuous Flashing backward.

Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Continuous Flashing Solid (battery) Icon Solid (battery) Icon Solid (battery) Icon Solid (battery) Icon Solid (battery) Icon

SA-3

M-17-05 M-17-06 M-17-07 M-18-05 M-18-06 M-18-07 M-54-05 M-54-06 M-54-07 M-79-74 M-03-09 M-03-10 M-03-11 M-03-14 M-03-22 M-15-02 M-15-03 M-16-05 M-16-06 M-16-07 M-25-02 M-25-03 M-25-07 M-03-09 M-03-10 M-03-11 M-03-14 M-03-22

S100 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES Viewing Service Codes Figure SA-1

1 S3999

Press and hold the “i” button (Item 1) [Figure SA-1] for 2 seconds to display the service codes. (See INSTRUMENT PANEL IDENTIFICATION on Page OI-3.)

The service codes will show up as Mxxxx, with M being the controller the error is coming from and xxxx being the actual service code.

If more than one service 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 sounding, headlights and taillights flashing, 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.

SA-4

S100 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES (CONT'D) Service Codes List CODE

FUNCTION

FAILURES

ICON

BUZZER

M-02-17 Hydraulic Implement Filter

Plugged

Service manual icon

none

M-03-09 Battery Voltage

Low

solid battery icon

3 beeps

M-03-10 Battery Voltage

High

solid battery icon

3 beeps

M-03-11 Battery Voltage

Extremely High

solid battery icon

none

M-03-14 Battery Voltage

Extremely Low

solid battery icon

none

M-03-22 Battery Voltage

Out of Range Low

solid battery icon

none

M-04-14 Engine Oil Pressure

Extremely Low

flashing eop icon

continuous

M-04-15 Engine Oil Pressure

Shutdown

flashing eop icon

none

M-05-09 Hydraulic Charge Pressure

Low

solid hyd icon

3 beeps

M-05-10 Hydraulic Charge Pressure

High

solid hyd icon

3 beeps

M-05-11 Hydraulic Charge Pressure

Extremely High

flashing hyd icon

continuous

M-05-14 Hydraulic Charge Pressure

Extremely Low

flashing hyd icon

continuous

M-05-15 Hydraulic Charge Pressure

Shutdown

flashing hyd icon

none

M-05-21 Hydraulic Charge Pressure

Out of Range High

solid hyd icon

none

M-05-22 Hydraulic Charge Pressure

Out of Range Low

solid hyd icon

none

M-06-10 Engine Speed

High

solid rpm icon

3 beeps

M-06-11 Engine Speed

Extremely High

flashing rpm icon

continuous

M-06-13 Engine Speed

No Signal

solid rpm icon

none

M-06-15 Engine Speed

Shutdown

flashing rpm icon

none

M-06-18 Engine Speed

Out of Range

solid rpm icon

none

M-07-10 Hydraulic Oil Temperature

High

solid hyd icon

3 beeps

M-07-11 Hydraulic Oil Temperature

Extremely High

flashing hyd icon

continuous

M-07-15 Hydraulic Oil Temperature

Shutdown

flashing hyd icon

none

M-07-21 Hydraulic Oil Temperature

Out of Range High

solid hyd icon

none

M-07-22 Hydraulic Oil Temperature

Out of Range Low

solid hyd icon

none

M-08-10 Engine Coolant Temperature

High

solid ect icon

3 beeps

M-08-11 Engine Coolant Temperature

Extremely High

flashing ect icon

continuous

M-08-15 Engine Coolant Temperature

In Shutdown

flashing ect icon

none

M-09-09 Fuel Level

Low

solid fuel icon

1 beep

M-09-21 Fuel Level

Out of Range High

solid fuel icon

none

M-09-22 Fuel Level

Out of Range Low

solid fuel icon

none

M-11-21 Seatbar Sensor

Out of Range High

flashing seatbar icon

3 beeps

M-11-22 Seatbar Sensor

Out of Range Low

flashing seatbar icon

3 beeps

M-13-05 Fuel Hold Solenoid

Short to Battery

flashing engine icon

3 beeps

M-13-06 Fuel Hold Solenoid

Short to Ground

flashing engine icon

3 beeps

M-13-07 Fuel Hold Solenoid

Open Circuit

flashing engine icon

3 beeps

M-14-02 Fuel Pull Output

Error On

flashing engine icon

3 beeps

M-14-03 Fuel Pull Output

Error Off

flashing engine icon

3 beeps

SA-5

S100 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES (CONT'D) Service Codes List (Cont’d) CODE

FUNCTION

FAILURES

ICON

BUZZER

M-15-02 Traction Lock Pull Output

Error On

flashing traction icon

3 beeps

M-15-03 Traction Lock Pull Output

Error Off

flashing traction icon

3 beeps

M-16-05 Traction Lock Hold Solenoid

Short to Battery

flashing traction icon

3 beeps

M-16-06 Traction Lock Hold Solenoid

Short to Ground

flashing traction icon

3 beeps

M-16-07 Traction Lock Hold Solenoid

Open Circuit

flashing traction icon

3 beeps

M-17-05 Hydraulic Lock Valve Solenoid

Short to Battery

flashing workgroup icon

3 beeps

M-17-06 Hydraulic Lock Valve Solenoid

Short to Ground

flashing workgroup icon

3 beeps

M-17-07 Hydraulic Lock Valve Solenoid

Open Circuit

flashing workgroup icon

3 beeps

M-18-05 Lift Spool Lock

Short to Battery

flashing workgroup icon

3 beeps

M-18-06 Lift Spool Lock

Short to Ground

flashing workgroup icon

3 beeps

M-18-07 Lift Spool Lock

Open Circuit

flashing workgroup icon

3 beeps

M-21-02 Glow Plug Output

Error On

flashing glow plug icon

none

M-21-03 Glow Plug Output

Error Off

flashing low plug icon

none

M-22-02 Starter Output

Error On

-

-

M-22-03 Starter Output

Error Off

-

-

M-23-02 Starter Relay

Error On

-

-

M-23-03 Starter Relay

Error Off

-

-

M-23-07 Starter Output

Open Circuit

-

-

M-24-02 Fuel Pull Relay

Error On

flashing engine icon

3 beeps

M-24-03 Fuel Pull Relay

Error Off

flashing engine icon

3 beeps

M-24-07 Fuel Pull Output

Open Circuit

flashing engine icon

3 beeps

M-25-02 Traction Pull Relay

Error On

flashing traction icon

3 beeps

M-25-03 Traction Pull Relay

Error Off

flashing traction icon

3 beeps

M-25-07 Traction Pull Output

Open Circuit

flashing traction icon

3 beeps

M-26-02 Glow Plug Relay

Error on

flashing glow plug icon

none

M-26-03 Glow Plug Relay

Error off

flashing glow plug icon

none

M-26-07 Glow Plug Output

Open Circuit

flashing glow plug icon

none

M-30-28 Controller Memory

Failure

M-31-28 Interrupted Power (also occurs after software updates)

Failure

M-41-09 Alternator

Low

flashing battery icon

3 beeps

M-41-10 Alternator

High

flashing battery icon

continuous

M-41-11 Alternator

Extremely High

M-46-21 5 Volt Sensor Supply

Out of Range High

solid general warning

3 beeps

M-46-22 5 Volt Sensor Supply

Out of Range Low

solid general warning

3 beeps

M-47-21 8 Volt Sensor Supply

Out of Range High

solid general warning

3 beeps

M-47-22 8 Volt Sensor Supply

Out of Range Low

solid general warning

3 beeps

M-48-02 Front Light Relay

Error On

flash light 1 indicator

none

SA-6

S100 Operation & Maintenance Manual

DIAGNOSTIC SERVICE CODES (CONT'D) Service Codes List (Cont’d) CODE

FUNCTION

FAILURES

ICON

BUZZER

M-48-03 Front Light Relay

Error Off

flash light 1 indicator

none

M-48-07 Front Light Output

Open Circuit

flash light 1 indicator

none

M-49-02 Rear Light Relay

Error On

flash light 2 indicator

none

M-49-03 Rear Light Relay

Error Off

flash light 2 indicator

none

M-49-07 Rear Light Output

Open Circuit

flash light 2 indicator

none

M-50-02 Front Light Output

Error On

flash light 1 indicator

none

M-50-03 Front Light Output

Error Off

flash light 1 indicator

none

M-51-02 Rear Light Output

Error On

flash light 2 indicator

none

M-51-03 Rear Light Output

Error Off

flash light 2 indicator

none

M-52-02 PTOL Switch

Error On

flash PTOL LED

none

M-52-21 PTOL Switch

Out of Range High

flash PTOL LED

none

M-52-22 PTOL Switch

Out of Range Low

flash PTOL LED

none

M-53-05 PTOL LED

Short to Battery

3 beeps

M-53-06 PTOL LED

Short to Ground

3 beeps

M-54-05 Tilt Spool Lock

Short to Battery

flashing workgroup icon

3 beeps

M-54-06 Tilt Spool Lock

Short to Ground

flashing workgroup icon

3 beeps

M-54-07 Tilt Spool Lock

Open Circuit

flashing workgroup icon

3 beeps

M-64-02 Switched Power Relay

Error On

solid general warning

none

M-64-03 Switched Power Relay

Error Off

solid general warning

none

M-70-02 Switched Power Output

Error On

solid general warning

none

M-70-03 Switched Power Output

Error Off

solid general warning

none

M-74-23 Main Controller (Bobcat Controller)

Not Programmed

solid general warning

3 beeps

M-74-72 Main Controller (Bobcat Controller)

In Boot Code

solid general warning

none

M-76-04 Left Display Panel

No communication

M-77-48 Key Switch

Multiple

flash general warning

3 beeps

M-79-74 Door

Open

flash workgroup icon

1 beep

SA-7

S100 Operation & Maintenance Manual

SA-8

S100 Operation & Maintenance Manual

MACHINE SIGN TRANSLATIONS DANGER (6702301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 DANGER (6702302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 DANGER (6717343) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 IMPORTANT (7139929) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 LIFT ARM SUPPORT DEVICE (6706558) . . . . . . . . . . . . . . . MST-12 SERVICE SCHEDULE (6734534). . . . . . . . . . . . . . . . . . . . . . . MST-3 WARNING (6577754) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 WARNING (6579528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 WARNING (6704786) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9 WARNING (6710358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-11 WARNING (6725370) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-11

MACHINE SIGN TRANSLATIONS (MST)

WARNING (6726423) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9 WARNING (6733996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 WARNING (6737189) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-12 WARNING (6809511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-11 WARNING (7136754) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-10 WARNING (6728539) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8

MST-1

S100 Operation & Maintenance Manual

MST-2

S100 Operation & Maintenance Manual

SERVICE SCHEDULE (6734534)

MST-3

S100 Operation & Maintenance Manual

SERVICE SCHEDULE (6734534) (CONT’D)

MST-4

S100 Operation & Maintenance Manual

SERVICE SCHEDULE (6734534) (CONT’D)

MST-5

S100 Operation & Maintenance Manual

DANGER (6702301)

DANGER (6717343)

DANGER (6702302)

WARNING (6579528)

MST-6

S100 Operation & Maintenance Manual

WARNING (6577754)

IMPORTANT (7139929)

WARNING (6733996)

MST-7

S100 Operation & Maintenance Manual

WARNING (6728539)

MST-8

S100 Operation & Maintenance Manual

WARNING (6704786)

WARNING (6726423)

MST-9

S100 Operation & Maintenance Manual

WARNING (7136754)

MST-10

S100 Operation & Maintenance Manual

WARNING (6710358)

WARNING (6809511)

WARNING (6725370)

MST-11

S100 Operation & Maintenance Manual

WARNING (6737189)

LIFT ARM SUPPORT DEVICE (6706558)

MST-12

S100 Operation & Maintenance Manual

SPECIFICATIONS (S100) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . SPEC-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6

SPECIFICATIONS (SPEC)

SPEC-1

S100 Operation & Maintenance Manual

SPEC-2

S100 Operation & Maintenance Manual

(S100) LOADER SPECIFICATIONS Machine Dimensions • •

Dimensions are given for loader equipped with standard tires and C/I bucket and may vary with other bucket types.

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

S0129 S0114 Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

SPEC-3

S100 Operation & Maintenance Manual

(S100) LOADER SPECIFICATIONS (CONT’D) Performance Rated Operating Capacity (ISO)

1000 lb. (453 kg)

Tipping Load (ISO)

2039 lb. (925 kg)

Operating Weight

4110 lb. (1864 kg)

SAE Breakout Force - Lift - Tilt

1877 lb. (8350 N) 1866 lb. (8300 N)

Travel Speed

0-6.5 mph (10.4 km/hr.)

Push Force

2967 lb. (1346 kg)

Vehicle Steering

Direction and speed controlled by two hand levers.

Loader Hydraulics - Lift and Tilt

Controlled by separate foot pedals.

- Front Auxiliary (Std.)

Controlled by lateral movement of the right hand steering lever.

Engine

Hand lever engine speed, key type start switch, function error shutdown.

Starting Aid

Glow Plug-Automatically activated by Key Switch or Keyless instrumentation.

Service Brake

Two independent hydrostatic systems controlled by two hand operated steering levers.

Secondary Brake

One of the hydrostatic transmissions.

Parking Brake

Mechanical disc, hand operated rocker switch on front instrument panel

Controls

SPEC-4

S100 Operation & Maintenance Manual

(S100) LOADER SPECIFICATIONS (CONT’D) Engine Make/Model

KUBOTA V1505-E2B-BCZ-1

Fuel/Cooling

Diesel/Liquid

Horsepower @ 3000 RPM (SAE)

Net: 33.5 HP (25 kW) Gross: 35.5 HP (26.5 kW)

Torque @ 1700 RPM (SAE)

Net: 67 ft.-lb. (91 N•m) Gross: 68 ft.-lb. (92 N•m)

Number of Cylinders

Four

Displacement

91.41 cu. in. (1498 cu. cm.)

Bore/Stroke

3.07 / 3.09 (78.0 / 78.4)

Lubrication

Gear Pump Pressure System W/Filter

Crankcase Ventilation

Closed-Breathing

Air Cleaner

Dry replaceable paper cartridge w/separate safety element

Ignition

Diesel-Compression

Low Idle

1100 RPM

High Idle

3200 RPM

Hydraulic System Pumps

Engine driven, Gear type

Pump Capacity

13.1 GPM (49.6 L/min.) @ 3270 Pump RPM @ 91% efficiency

Filters

Full flow replaceable, 3 micron synthetic media element

System Relief Valve Setting

3000 PSI (20.7 MPa)

Hydraulic Cylinders Bore Diameter: Lift Cylinder (2) Tilt Cylinder (1) Rod Diameter: Lift Cylinder (2) Tilt Cylinder (1) Stroke: Lift Cylinder (2) Tilt Cylinder (1)

Double acting; Tilt cylinder has cushioning feature on dump & rollback 2.00 (50.8) 2.25 (57.2) 1.25 (31.8) 1.25 (31.8) 25.73 (653.54) 12.09 (307.1)

Control Valve

3-spool, open center type w/float detent on lift and electrically controlled auxiliary spool.

Fluid Lines

SAE standard tubelines, hoses and fittings.

Fluid Type

BOBCAT FLUID, Hydraulic / Hydrostatic 6903117 - (2.5 Gal.) 6903118 - (5 Gal.) 6903119 - (55 Gal.)

Hydraulic Function Time: Raise Lift Arms Lower Lift Arms Bucket Dump Bucket Rollback

2.8 Seconds 1.8 Seconds 1.6 Seconds 1.2 Seconds

SPEC-5

S100 Operation & Maintenance Manual

(S100) LOADER SPECIFICATIONS (CONT’D) Electrical Alternator

Belt driven, 90 amps ventilated

Battery

12 volts, 600 cold cranking amps @ 0°F. (-18°C); 115 minute reserve capacity at 25 amps

Starter

12 volts; Gear Reduction Type; 2.68 HP (2.0 kW)

Instrumentation

Standard Instrumentation: Gauges: Hourmeter, Fuel, Engine Temperature Warning Lights: Engine Coolant Temperature, Engine Oil Pressure, Hydraulic Oil Temperature & Charge Pressure, Hydraulic Filter, Engine Air Filter, Seat Belt, Fuel Level, General Warning, System Voltage Indicators: BICS Functions, glow plugs, Headlights, Bucket Positioning

Drive System Main Drive

Hydrostatic 4 wheel drive

Transmission

Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors.

Final Drive

#80 HS endless roller chain & sprockets in sealed chaincase with oil lubrication.

Total Engine to Wheel Reduction

40:1

Axle Size

1.76 (44.70)

Wheel Bolts

0.5625-18 in.

Cooling System Without Heater With Heater

3.0 Gal. (11.6 L) 3.3 Gal. (12.3 L)

Fuel

11.9 Gal. (45 L)

Engine Oil W/Filter

1.2 Gal. (4.5 L)

Hydraulic Reservoir

3.4 Gal. (13 L)

Hydraulic / Hydrostatic System (Including Reservoir)

5.8 Gal. (22 L)

Chaincase Reservoir

5.8 Gal. (22 L)

Coolant Recovery Bottle

1.1 Gal. (4 L)

Standard Duty Heavy Duty

27 x 8.50 - 15, 6 ply rating 27 x 8.50 - 15, 6 ply rating

Recommended Pressure

Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

Capacities

Tires

SPEC-6

S100 Operation & Maintenance Manual

WARRANTY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY-3

WARRANTY

WARRANTY

WARRANTY-1

S100 Operation & Maintenance Manual

WARRANTY-2

S100 Operation & Maintenance Manual

WARRANTY Bobcat Loaders Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Loader will be free from proven defects in material and workmanship with respect to (i) all components of the product except as otherwise specified herein for twelve (12) months, (ii) the drive belt from the hydrostatic pump to the engine, for thirty six (36) months, provided that after the initial twelve month warranty period, such warranty shall be limited to parts only and does not include labor, (iii) tracks and Bobcat brand tires, for twelve (12) months on a prorated basis based on the remaining depth of the track or tire at the time any defect is discovered, and (iv) Bobcat brand batteries, for an additional twelve (12) months after the initial twelve month warranty period, provided that Bobcat Company shall only reimburse a fixed portion of the cost of replacing the battery during such additional twelve months. The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company's option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement.

Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to diesel engine fuel injection pumps and injectors or tires (except Bobcat brand tires). The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. This warranty does not cover replacement of scheduled service items such as oil, filters, tune-up parts, and other high-wear items. This warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any accessory or attachment not approved by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

6570162 (8-02)

Printed in U.S.A.

WARRANTY-3

S100 Operation And Maintenance Manual

WARRANTY-4

ALPHABETICAL INDEX AIR CLEANER SERVICE................................................................ PM-19 ALTERNATOR BELT ....................................................................... PM-35 ATTACHMENTS ................................................................................ OI-23 BACK-UP ALARM SYSTEM ............................................................... OI-9 BACK-UP ALARM SYSTEM ........................................................... PM-13 BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED ..............................V BOBCAT INTERLOCK CONTROL SYSTEM (BICS) .......................... OI-7 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ........................ PM-8 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ......................... SA-3 BOB-TACH ...................................................................................... PM-39 CAB FILTERS ................................................................................. PM-18 DAILY INSPECTION ......................................................................... OI-13 DELIVERY REPORT...............................................................................VI DIAGNOSTIC SERVICE CODES ...................................................... SA-4 DRIVE BELT.................................................................................... PM-36 DRIVING AND STEERING THE LOADER ....................................... OI-10 ELECTRICAL SYSTEM .................................................................. PM-25 ENGINE COOLING SYSTEM ......................................................... PM-23 ENGINE LUBRICATION SYSTEM.................................................. PM-22 ENGINE SPEED CONTROL............................................................... OI-9 FEATURES, ACCESSORIES AND ATTACHMENTS ...........................VIII FINAL DRIVE TRANSMISSION (CHAINCASE) ............................. PM-34

ALPHABETICAL INDEX

FUEL SYSTEM ............................................................................... PM-20 HORN (OPTION)................................................................................. OI-6 HYDRAULIC CONTROLS................................................................. OI-11 HYDRAULIC / HYDROSTATIC SYSTEM ....................................... PM-29 INSTRUMENT PANEL IDENTIFICATION ........................................... OI-3 LIFT ARM BYPASS CONTROL .......................................................... OI-8 LIFT ARM SUPPORT DEVICE ........................................................PM-11 LIFTING THE LOADER..................................................................... OI-31 Continued On Next Page

INDEX-1

S100 Operation & Maintenance Manual

ALPHABETICAL INDEX (CONT’D) LOADER IDENTIFICATION .................................................................. VII LOADER SERIAL NUMBER .................................................................. VI (S100) LOADER SPECIFICATIONS ............................................. SPEC-3 LOADER STORAGE AND RETURN TO SERVICE ........................ PM-41 LUBRICATING THE LOADER ........................................................ PM-36 MACHINE SIGNS (DECALS)............................................................... XVI MAINTENANCE SAFETY ................................................................. PM-5 MONITORING THE DISPLAY PANELS ............................................ OI-20 OPERATING PROCEDURE ............................................................. OI-26 OPERATOR CAB ............................................................................ PM-14 PARKING BRAKE ............................................................................... OI-9 PIVOT PINS .................................................................................... PM-38 PRE-STARTING PROCEDURE ........................................................ OI-15 REAR DOOR................................................................................... PM-17 REAR GRILL ................................................................................... PM-18 REGULAR MAINTENANCE ITEMS........................................................ V SAFETY INSTRUCTIONS ................................................................... XIII SEAT BAR RESTRAINT SYSTEM...................................................... OI-6 SEAT BELT...................................................................................... PM-10 SERIAL NUMBER LOCATIONS ............................................................ VI SERVICE SCHEDULE ...................................................................... PM-7 STARTING THE ENGINE.................................................................. OI-17 SPARK ARRESTOR MUFFLER...................................................... PM-32 STOPPING THE ENGINE AND LEAVING THE LOADER ................ OI-21 STARTING THE ENGINE.................................................................. OI-17 TIRE MAINTENANCE ..................................................................... PM-33 TOWING THE LOADER.................................................................... OI-30 TRACTION LOCK OVERRIDE ........................................................... OI-8 TRANSPORTING THE LOADER ON A TRAILER ............................ OI-32 WARRANTY ........................................................................WARRANTY-3

INDEX-2

S100 Operation & Maintenance Manual