PDF Operation & Maintenance Manual Bobcat S100 Skid Steer Loader - 3 MB
This is the complete Operation & Maintenance Manual for the Bobcat S100 Skid Steer Loader.
Inside you will find crucial information on safe operation, daily checks, and scheduled maintenance intervals.
Adhering to the procedures in this guide will help you keep your S100 running smoothly and prevent unexpected downtime.
It's a must-have for any owner or operator.
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--- Page 1 ---
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
--- Page 3 ---
LOADER IDENTIFICATION
OPERATION &
FRONT LIGHTS MAINTENANCE
MANUAL AND
OPERATOR’S
OPERATOR SEAT HANDBOOK
with SEAT BELT
& SEAT BAR
GRAB
HANDLES
TILT
CYLINDER FRONT AUXILIARY
QUICK COUPLERS
STEPS
BUCKET † BUCKET S0183
STEPS
● OPERATOR CAB
(ROPS/FOPS) LIFT ARM
SUPPORT
DEVICE
LIFT ARM
REAR
GRILL
LIFT
CYLINDER
REAR
DOOR
REAR
LIGHT
TAIL
LIGHT
S0184
* TIRES
* TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
● ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO 3449, Level I.
Level II is available.
† Bucket - Many Buckets and other Attachments are available.
VII S100 Operation & Maintenance Manual
--- Page 4 ---
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
6733996 7139929
Under Rear Grill
6577754
6578368
6706558
6809511 (4)
6717343 (2)
(Under Cab)
6727595 (Ref.)
6734534
Inside Rear Door
S0184
XVII S100 Operation & Maintenance Manual
--- Page 5 ---
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 Move the lever forward to increase engine speed. Move
located on the inside of the rear door. 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 Press the bottom of the switch (Item 2) [Figure OI-16] to
both steering levers in the reverse position [Figure OI- disengage the parking brake. The traction drive system
14]. Slight movement of the steering levers in the reverse will be unlocked.
position is required with hydrostatic transmissions, before
the back-up alarm will sound. NOTE: The PARKING BRAKE light on the left
instrument panel will remain ON until the
If alarm does not sound or for adjustment instructions, engine is started, the PRESS TO OPERATE
see inspection and maintenance instructions for the LOADER button is pressed and the parking
back-up alarm system in the preventive maintenance brake is disengaged.
section of this manual. (See BACK-UP ALARM SYSTEM
on Page PM-13.)
OI-9 S100 Operation & Maintenance Manual
--- Page 6 ---
STARTING THE ENGINE (CONT’D) Cold Temperature Starting
Warming The Hydraulic / Hydrostatic System
WARNING
Do not use ether with glow plug (preheat) systems.
IMPORTANT Explosion can result which can cause injury, death,
or severe engine damage.
When the temperature is below -20°F (-30°C), W-2071-0903
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 If the temperature is below freezing perform the following
(-18°C) if possible. to make starting the engine easier:
I-2007-1285
• Replace the engine oil with the correct type and
Let the engine run for a minimum of 5 minutes to warm viscosity for the anticipated starting temperature
the engine and hydrostatic transmission fluid before (See ENGINE LUBRICATION SYSTEM on Page PM-
operating the loader. 22.)
Figure OI-37 • Make sure the battery is fully charged.
• Install an engine heater, available from your local
Bobcat dealer.
NOTE: The display screen of the left instrument
1 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.
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
--- Page 7 ---
OPERATING PROCEDURE (CONT’D) Digging And Filling A Hole
Leveling The Ground Using Float Digging
Figure OI-63 Figure OI-64
1 2 1 2
3 3
B-15598 B-15584
B-15973 B-15973
Put the lift arms in float position by pushing the toe of the Lower the lift arms all the way by pushing the toe of the
left pedal (Item 1) [Figure OI-63] until it is locked in the left pedal (Item 1) [Figure OI-64]. Put the cutting edge of
forward position. the bucket on the ground by pushing the toe of the right
Tilt the bucket forward by pushing the toe of the right pedal (Item 2) [Figure OI-64].
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
Drive backward to level loose material [Figure OI-63]. traction and keep an even digging depth. Continue to
drive forward until the bucket is full. When the ground is
Push the heel of the left pedal (Item 3) [Figure OI-63] to hard, raise and lower the cutting edge of the bucket
unlock the float position.
(Items 2 & 3) [Figure OI-64] while driving forward slowly.
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
--- Page 8 ---
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS
■ ■ ■
ITEM SERVICE REQUIRED 8-10 50 100
250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check condition indicator, replace element when required (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
--- Page 9 ---
REAR DOOR
Opening And Closing
WARNING
Keep the rear door closed when operating the
WARNING machine. Failure to do so could seriously injure a
bystander.
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
Reach into the slot in the rear door and pull the latch mechanism.
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
--- Page 10 ---
ELECTRICAL SYSTEM (CONT’D) end of the same cable (Item 4) [Figure PM-44] to the
engine.
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
AVOID INJURY OR DEATH (Item 4) [Figure PM-44] first.
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and Remove the cable from the positive terminal (Item 2)
rubber gloves to keep acid off body. [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 Damage to the alternator can occur if:
of water or milk! DO NOT induce vomiting. Get • Engine is operated with battery cables
prompt medical attention. disconnected.
W-2065-0807
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
Figure PM-44 both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
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
--- Page 11 ---
LUBRICATING THE LOADER (CONT’D) Figure PM-65
Lubrication Locations (Cont’d)
Figure PM-63 4
2
S4037
4. Base End Tilt Cylinder (Both Sides) (Item 4) [Figure
S4085 PM-61] & [Figure PM-65].
Figure PM-66
2. Base End Lift Cylinder (Both Sides) (Item 2) [Figure
PM-61] & [Figure PM-63].
Figure PM-64 6 7
5
3
S4139
S4086
5. Rod End Tilt Cylinder (Both Sides) (Item 5) [Figure
3. Lift Arm Pivot Pin (Both Sides) (Item 3) [Figure PM- PM-66].
61] & [Figure PM-64].
6. Bob-Tach Pivot Pin (Both Sides) (Item 6) [Figure PM-
66].
7. Bob-Tach Wedge (Both Sides) (Item 7) [Figure PM-
66].
PM-37 S100 Operation & Maintenance Manual
--- Page 12 ---
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
--- Page 13 ---
WARNING (6577754) IMPORTANT (7139929)
WARNING (6733996)
MST-7 S100 Operation & Maintenance Manual
--- Page 14 ---
(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 Double acting; Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter: Lift Cylinder (2) 2.00 (50.8)
Tilt Cylinder (1) 2.25 (57.2)
Rod Diameter: Lift Cylinder (2) 1.25 (31.8)
Tilt Cylinder (1) 1.25 (31.8)
Stroke: Lift Cylinder (2) 25.73 (653.54)
Tilt Cylinder (1) 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 2.8 Seconds
Lower Lift Arms 1.8 Seconds
Bucket Dump 1.6 Seconds
Bucket Rollback 1.2 Seconds
SPEC-5 S100 Operation & Maintenance Manual
--- Page 15 ---
OPERATOR SAFETY WARNINGS
CORRECT
Operator must have instructions
WARNING before operating the machine.
Untrained operators can cause
injury or death.
W-2001-0502
Safety Alert Symbol: This symbol with a warning statement, P-90216
means: “Warning, be alert! Your safety
Never use the loader without