PDF Service Manual Bobcat B100 Backhoe Loader - 4 MB
This service manual provides comprehensive instructions for the maintenance and repair of the Bobcat B100 Backhoe Loader.
It is designed for technicians and contains detailed information on troubleshooting, disassembly, and assembly of all major systems.
Use this guide to perform accurate diagnostics and repairs, ensuring your B100 operates at peak performance.
This manual is essential for keeping your backhoe loader reliable and productive.
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--- Page 1 ---
B100
Service
Manual
(S/N 570011001 & Above)
(S/N 570111001 & Above)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
6901844 (6-12) Printed in U.S.A. © Bobcat Company 2011
--- Page 3 ---
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 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.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Loader Backhoe Operator Training Course is
available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Loader Backhoe.
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284
• The Loader Backhoe Safety Video is available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI LB-0206 SM
B100 Bobcat Loader Backhoe
V Service Manual
--- Page 4 ---
LIFT ARM SUPPORT DEVICE Figure 10-20-2
Maintenance and service work can be do ne with the lift
arms lowered. If the lift arms are raised, use the following
procedures to install and remove the approved lift arm
support device:
Installing The 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
P-33316
support device. Failure to us e an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. Install the lift arm support device (Item 1) [Figure 10-20-
W-2059-0598
2] over the lift cylinder rod.
Figure 10-20-3
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.
W-2271-1197
Figure 10-20-1
P-32752
1
Start the engine and lower the lift ams slowly until the
support device is held securely [Figure 10-20-3].
Stop the engine.
P-32750
Remove the approved lift arm support device (Item 1)
[Figure 10-20-1] from the storage position.
With the operator in the seat, fasten seat belt and engage
the parking brake. Start the engine and raise the lift arms.
After the lift arms are raised fully, stop the engine.
B250 Bobcat Loader Backhoe
10-20-1 Service Manual
--- Page 5 ---
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 backhoe.
Instructions are necessary before operating or servicing machine. Read
and understand the Operation & Maintenance Manual and signs (decals) on
WARNING machine. Follow wa rnings 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-2003-1285
SERVICE SCHEDULE HOURS
■
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the engine oil level and add as needed.
Engine Air Filter and Air Check display panel. Service only when required. Check for
System leakes and damaged components.
Engine Cooling System Clean debris from oil cooler radiator & grill.
Lift Arms, Cyl., Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins, Wedges
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Belt Reactors Check the condition of seat belt. Clean or replace seat belt
retractors as needed.
Stabilizers Check the pins and operating parts.
Safety Signs and Safety Check for damaged signs (decals) and safety treads. Replace
Treads 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.
Indicators and Lights Check for correct operation of all indicators and lights.
Parking Brake Check operation, adjust as required.
Hydraulic Fluid, Hoses and Check fluid level & add as needed. check for damage & leaks.
Tubelines Repair or replace as needed.
Rear Differential Check oil level. Add oil as needed.
Wheel Nuts Check for loose wheel nuts and tighten to 140 ft.-lb.
(190 N•m) torque.
Hydraulic Filter Check filter.
Battery Check cables, connnections and electrolyte level. Add distilled
water as needed.
Engine Cooling System Check engine cooling system. *
Alternator Belt Check tension and adjust as needed.
Fuel Injectors Check fuel injector nozzles.
Fuel Filter Replace the filter element.
Steering King Pins Lubricate with multi-purpose lithium based grease.
Hyd./Hydro. Filter Replace the filter element
Engine Oil and Filter Replace oil & filter. Use CD or better grade oil and Bobcat filter.
Hyd. Res. Breather Cap Replace the reservoir breather cap.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves. #
Wheel Bearings Repack the wheel bearings.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace gydraulic/hydrostatic filter element when the transmission warning light comes ON.
† First oil and filter change must occur at 50 hours: 250 hours thereafter.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. (See Service Manual for procedure.)
■ Or every 12 months.
▼ Or every five years
B100 Bobcat Loader Backhoe
10-70-1 Service Manual
--- Page 6 ---
ENGINE LUBRICATION SYSTEM (CONT'D)
Replacing Oil And Filter (Cont’d)
Figure 10-110-5
1
P-32743
Remove the dipstick (Item 2) [Figure 10-110-4 on Page
10-110-2] and check the oil level. Add oil as needed if it is
not at the top mark on the dipstick (Item 1) [Figure 10-
110-5].
Install the dipstick and close the engine cover.
B100 Bobcat Loader Backhoe
10-110-3 Service Manual
--- Page 7 ---
BOB-TACH HAND LEVER Figure 10-150-3
Inspection And Maintenance
Figure 10-150-1 Bob-Tach
Wedge
1
Wedge Must Contact
Lower Edge Of Hole
In The Attachment
B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]
P-32760 must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
Move the Bob-tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-150-1]. The levers and wedges must move freely. [Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
The wedges must extend through the holes in th e
attachment mounting frame (Item 1) [Figure 10-150-1]. Figure 10-150-4
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-2
TS-1062A
Inspect the mounting frame on th e attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. 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.
1
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.)
P-32757
B100 Bobcat Loader Backhoe
10-150-1 Service Manual
--- Page 8 ---
TIRE MAINTENANCE Tire Pressure
Wheel Nuts
Figure 10-180-1
WARNING
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.
W-2078-1285
Front tire pressure - 36 PSI (250 kPa)
Rear tire pressure - 58 PSI (400 kPa)
Always replace the tires with the same size tires.
P-32762
See SERVICE SCHEDULE on Page 10-70-1 for the
service interval to check the wheel nuts. The correct
torque is 140 ft.-lb. (190 N•m) torque [Figure 10-180-1].
Mounting
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
Check the tires regularly for wear, damage and pressure.
Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment.
Tires and rims must always be checked for correct size
before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and
cause serious injury or death.
During inflation of th e tire, check the ti re pressure
frequently to avoid over inflation.
B100 Bobcat Loader Backhoe
10-180-1 Service Manual
--- Page 9 ---
HYDRAULIC SYSTEM INFORMATION (CONT'D)
B100 Bobcat Loader Backhoe
20-10-3 Service Manual
--- Page 10 ---
ARM CYLINDER (CONT’D) Figure 20-20-16
Disassembly (Cont’d)
Figure 20-20-14 1
P-38035
Remove the ex pander band (Item 1) [Figure 20-20-16]
P-36893 from the piston.
Apply moderate heat to the piston/rod to break the loctite
Support the cylinder rod on a wood block [Figure 20-20- bond. Do not overheat.
14].
Figure 20-20-17
Figure 20-20-15
2
1
1
P-38033
P-36894
Use a gla nd nut wrench (MEL1075) and remove the
Remove the two wear rings (Item 1) [Figure 20-20-15] piston assembly (Item 1) [Figure 20-20-17] from the rod.
and seal (Item 2) [Figure 20-20-15] from the piston.
B100 Bobcat Loader Backhoe
20-20-7 Service Manual
--- Page 11 ---
BOOM CYLINDER (CONT’D) Figure 20-21-10
Disassembly
1
Use the following tool to disassemble the cylinder:
MEL1075
Figure 20-21-8
P-36891
Remove the rod assembly (Item 1) [Figure 20-21-10]
from the housing.
Figure 20-21-11
P-36889
Put the base end of the cylinder in a vise [Figure 20-21-
8].
Figure 20-21-9
1
P-36892
Put the rod end of the cylinder in a vise [Figure 20-21-
11].
P-36890
Use a gland nut wrench (MEL 1075) and remove the
head gland (Item 1) [Figure 20-21-9].
B100 Bobcat Loader Backhoe
20-21-5 Service Manual
--- Page 12 ---
SWING CYLINDER (CONT’D) Figure 20-22-8
Disassembly
1
Use the following tool to disassemble the cylinder:
MEL1075
Figure 20-22-6
P-36891
Remove the rod assembly (Item 1) [Figure 20-22-8] from
the housing.
Figure 20-22-9
P-36946
Put the cylinder in a vise [Figure 20-22-6].
Figure 20-22-7
1 P-36892
Put the rod end of the cylinder in a vise [Figure 20-22-9].
P-36947
Use a gland nut wrench (MEL 1075) and remove the
head gland (Item 1) [Figure 20-22-7].
B100 Bobcat Loader Backhoe
20-22-5 Service Manual
--- Page 13 ---
BUCKET CYLINDER (CONT’D)
Parts Identification
1. Bushing
2. Grease fitting
3. Cover
4. Bolt
5. Seal
6. Back-up Ring
7. Head
8. Piston
9. O-ring
10. Wiper
11. Rod
12. Washer
4
12
3
2 5
1
7
6 10
1 7 5
9
9 1
9
5 2
11
8
B-16970
B100 Bobcat Loader Backhoe
20-23-5 Service Manual
--- Page 14 ---
STABILIZER CYLINDER (CONT’D) Figure 20-24-9
Removal And Installation
The procedure is the same for both stabilizer cylinders.
The right stabilizer is shown. 1
Figure 20-24-8
P-33756
Remove the retainer bolt (Item 1) [Figure 20-24-9].
Installation: Tighten the bolt to 18-19 ft.-lb. (24-26 N•m)
torque.
P-33755
Figure 20-24-10
Lower the stabilizer to the work surface [Figure 20-24-8].
Stop the engine and engage the parking brake.
1
Relieve hydraulic pressure.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
P-33757
damage the system.
I-2003-0888
Remove the pivot pin (Item 1) [Figure 20-24-10].
B100 Bobcat Loader Backhoe
20-24-3 Service Manual
--- Page 15 ---
TILT CYLINDER Figure 20-30-2
Checking
Remove attachment from the Bob-Tach.
Lower the l ift arms to the g round, fully retract the tilt
cylinders.
Stop the engine, engage the parking brake. 2
Operate the control lever to relieve hydraulic pressure.
1
WARNING P-36974
Hydraulic fluid escaping under pressure can have Install a p lug (Item 1) [Figure 20-30-2] in the hose and
sufficient force to enter a person’s body by tighten.
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a With the parking brake engaged, start the engine and
physician familiar with this injury is not received retract the cylinder.
immediately.
W-2145-0290
Stop the engine and engage the parking brake.
Figure 20-30-1 If there is any leakage from the base end fitting (Item 2)
[Figure 20-30-2], remove the cylinder for repair or
replacement.
1
P-36973
Check only one cylinder at a t ime. Disconnect the hose
(Item 1) [Figure 20-30-1] from the b ase end of the tilt
cylinder.
B100 Bobcat Loader Backhoe
20-30-1 Service Manual
--- Page 16 ---
LIFT CYLINDER Figure 20-31-2
Checking
Lower the lift arms. Stop the engine.
Engage the parking brake and exit the machine.
WARNING 1
Diesel fuel or hydraulic fluid unde r pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
P-33545
Use a piece of cardboard or wood to find le aks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention Install a p lug (Item 1) [Figure 20-31-2] in the hose and
from a physician familiar with this injury. tighten.
W-2072-0496
Engage the parking brake. Start the engine and retract
Figure 20-31-1 the lift cylinder.
If there is any leakage from the fitt ing, remove the
cylinder for repair or replacement.
1
P-33544
Check only one cylinder at a t ime. Disconnect the hose
(Item 1) [Figure 20-31-1] which goes to the base end of
the lift cylinder.
B100 Bobcat Loader Backhoe
20-31-1 Service Manual
--- Page 17 ---
STEERING CYLINDER Figure 20-32-2
Checking
Remove the grill. (See GRILL on Page 50-40-1.)
1
Remove the grill guard. (See GRILL FRAME on Page 50-
50-1.)
Figure 20-32-1
2 1
P-33566
Install a plug (Item 1) [Figure 20-32-2] on the hose and
tighten.
Start the engine and turn the steering wheel in the same
direction it was originally turned.
P-33565 If there is any leakage from the open port, remove the
cylinder for repair or replacement.
The steering cylinder can be checked by fully turning the
steering wheel in either direction.
Start the engine and turn the steering wheel fully in either
direction. Stop the engine.
If the steering wheel was turned to th e left remove the
hose (Item 1) [Figure 20-32-1] from the steering cylinder.
If the steering wheel was turned to the right remove the
hose (Item 2) [Figure 20-32-1] from the steering cylinder.
B100 Bobcat Loader Backhoe
20-32-1 Service Manual
--- Page 18 ---
STEERING CYLINDER (CONT’D) Figure 20-32-30
Assembly (Cont’d)
Figure 20-32-28
1
P-33605
Install the wiper (Item 1) [Figure 20-32-30] in the heads.
P7427
Figure 20-32-31
Install the rod seal on the rod seal tool [Figure 20-32-28].
NOTE: During installation, the spring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to co llapse the r od seal [Figure 20-
32-28].
Figure 20-32-29
P-33614
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-32-31].
P-23758
Install the rod seal in the head [Figure 20-32-29].
B100 Bobcat Loader Backhoe
20-32-11 Service Manual
--- Page 19 ---
PORT RELIEF VALVE (BACKHOE CONTROL VALVE) The correct reading should be:
(CONT’D)
Rod End 2320-2900 PSI (17500 kPa)