BOBCAT B100 SN 570011001 570111001 Service Manual PDF DOWNLOAD
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TABLE OF CONTENTS:
BOBCAT B100 SN 570011001 570111001 Service Manual PDF DOWNLOAD
MAINTENANCE SAFETY……………………………………… 3
ALPHABETICAL INDEX……………………………………… 5
CONTENTS………………………………………………. 7
FOREWORD…………………………………………… 8
SAFETY INSTRUCTIONS…………………………………. 11
Fire Prevention…………………………………. 13
SERIAL NUMBER LOCATIONS……………………………… 15
Loader Backhoe Serial Number……………………… 15
Engine Serial Number…………………………….. 15
DELIVERY REPORT…………………………………….. 15
BOBCAT LOADER IDENTIFICATION…………………………. 16
SAFETY & MAINTENANCE……………………………………. 17
LIFTING AND BLOCKING THE LOADER BACKHOE……………….. 19
Procedure………………………………………. 19
LIFT ARM SUPPORT DEVICE……………………………… 21
Installing The Lift Arm Support Device…………….. 21
Removing The Lift Arm Support Device………………. 22
ENGINE COVER……………………………………….. 23
TRANSPORTING THE LOADER BACKHOE………………………. 25
Procedure………………………………………. 25
TOWING THE LOADER BACKHOE……………………………. 27
Procedure………………………………………. 27
AXLE TOE-IN………………………………………… 29
Adjustment……………………………………… 29
SERVICE SCHEDULE……………………………………. 31
Chart………………………………………….. 31
AIR CLEANER SERVICE…………………………………. 33
Replacing Filter Element…………………………. 33
ENGINE COOLING SYSTEM……………………………….. 35
Coolant Replacement……………………………… 35
FUEL SYSTEM………………………………………… 37
Fuel Specifications……………………………… 37
Filling The Fuel Tank……………………………. 37
Fuel Filter…………………………………….. 38
Removing Air From The Fuel System…………………. 38
ENGINE LUBRICATION SYSTEM……………………………. 39
Checking Engine Oil……………………………… 39
Oil Chart………………………………………. 39
Replacing Oil And Filter…………………………. 40
HYDRAULIC/HYDROSTATIC SYSTEM…………………………. 43
Checking And Adding Fluid………………………… 43
Cleaning The Cooler……………………………… 43
Replacing Hydraulic/Hydrostatic Filter…………….. 44
Replacing Hydraulic Fluid………………………… 45
REAR AXLE………………………………………….. 47
Checking Oil Level………………………………. 47
Draining Oil……………………………………. 47
BACKHOE BOOM LOCK…………………………………… 49
Disengaging The Boom Lock………………………… 49
Engaging Boom Lock………………………………. 50
BOB-TACH HAND LEVER…………………………………. 51
Inspection And Maintenance……………………….. 51
ALTERNATOR BELT…………………………………….. 53
Adjusting The Alternator Belt…………………….. 53
LUBRICATING THE LOADER BACKHOE……………………….. 55
TIRE MAINTENANCE……………………………………. 61
Wheel Nuts……………………………………… 61
Mounting……………………………………….. 61
Tire Pressure…………………………………… 61
HYDRAULIC SYSTEM……………………………………….. 63
HYDRAULIC / HYDROSTATIC SCHEMATICS……………………. 67
HYDRAULIC SYSTEM INFORMATION…………………………. 69
Troubleshooting…………………………………. 73
Description…………………………………….. 74
ARM CYLINDER……………………………………….. 75
Checking……………………………………….. 75
Removal And Installation…………………………. 77
Parts Identification…………………………….. 79
Disassembly…………………………………….. 80
Assembly……………………………………….. 83
BOOM CYLINDER………………………………………. 87
Checking……………………………………….. 87
Removal And Installation…………………………. 88
Parts Identification…………………………….. 90
Disassembly…………………………………….. 91
Assembly……………………………………….. 94
SWING CYLINDER……………………………………… 97
Removal And Installation…………………………. 97
Bushing Removal And Installation………………….. 98
Parts Identification (Left Side)………………….. 99
Parts Identification (Right Side)………………….100
Disassembly……………………………………..101
Assembly………………………………………..104
BUCKET CYLINDER……………………………………..107
Checking………………………………………..107
Removal And Installation………………………….109
Parts Identification……………………………..111
Disassembly……………………………………..112
Assembly………………………………………..115
STABILIZER CYLINDER………………………………….119
Checking………………………………………..119
Removal And Installation………………………….121
Parts Identification……………………………..124
Disassembly……………………………………..125
Assembly………………………………………..128
TILT CYLINDER……………………………………….131
Checking………………………………………..131
Removal And Installation………………………….132
Parts Identification (Left Side)…………………..133
Parts Identification (Right Side)………………….134
Disassembly……………………………………..135
Assembly………………………………………..138
LIFT CYLINDER……………………………………….141
Checking………………………………………..141
Removal And Installation………………………….142
Parts Identification……………………………..143
Disassembly……………………………………..144
Assembly………………………………………..147
STEERING CYLINDER……………………………………151
Checking………………………………………..151
Removal And Installation………………………….152
Parts Identification……………………………..155
Disassembly……………………………………..156
Assembly………………………………………..159
MAIN RELIEF VALVE……………………………………165
Testing The Main Relief Valve……………………..165
Adjustment………………………………………166
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)………………167
Testing And Adjusting (Arm Control)………………..167
Testing And Adjusting (Boom Control)……………….169
Testing And Adjusting (Boom Swing Control)………….171
PORT RELIEF VALVE (LOADER CONTROL VALVE)……………….173
Testing And Adjusting (Bucket Tilt)………………..173
Testing And Adjusting (Front Auxiliary)…………….175
LOADER CONTROL VALVE…………………………………177
Removal And Installation………………………….177
Parts Identification……………………………..179
Disassembly And Assembly………………………….180
Inlet/Outlet Valve Section………………………..181
Lift Arm Valve Section……………………………183
Tilt Valve Section……………………………….186
Auxiliary Valve Section…………………………..190
BACKHOE CONTROL VALVE………………………………..195
Removal And Installation………………………….195
Parts Identification……………………………..197
Disassembly And Assembly………………………….198
Inlet/Outlet Valve Section………………………..200
Arm Valve Section………………………………..202
Tilt Valve Section……………………………….205
Right Stabilizer Valve Section…………………….208
Left Stabilizer Valve Section……………………..211
Boom Valve Section……………………………….215
Boom Swing Valve Section………………………….218
Outlet Valve Section……………………………..221
HYDRAULIC FLUID RESERVOIR…………………………….223
Removal And Installation………………………….223
Filter Removal And Installation……………………225
HYDRAULIC FILTER HOUSING……………………………..227
Removal And Installation………………………….227
Disassembly……………………………………..228
Assembly………………………………………..229
GEAR PUMP…………………………………………..231
Removal And Installation………………………….231
Parts Identification……………………………..232
Disassembly And Assembly………………………….233
Inspection………………………………………235
STEERING PUMP……………………………………….237
Removal And Installation………………………….237
Parts Identification……………………………..240
Disassembly……………………………………..241
Inspection………………………………………250
Assembly………………………………………..250
TRAVEL PEDAL………………………………………..259
Removal And Installation………………………….259
Parts Identification……………………………..260
Disassembly And Assembly………………………….261
HYDROSTATIC SYSTEM………………………………………267
HYDROSTATIC SYSTEM INFORMATION………………………..269
Troubleshooting Chart…………………………….269
Replenishing Valve Function……………………….270
OIL COOLER………………………………………….271
Removal And Installation………………………….271
Parts Identification……………………………..273
Disassembly……………………………………..274
Assembly………………………………………..276
HYDROSTATIC DRIVE MOTOR………………………………279
Removal And Installation………………………….279
Parts Identification……………………………..281
Disassembly……………………………………..282
Inspection………………………………………286
Assembly………………………………………..288
HYDROSTATIC PUMP…………………………………….293
Removal And Installation………………………….293
Parts Identification……………………………..295
Disassembly……………………………………..297
Inspection………………………………………313
Assembly………………………………………..315
HYDROSTATIC TESTING………………………………….331
Pump Adjustment………………………………….331
DRIVE SYSTEM……………………………………………335
PARKING BRAKE……………………………………….337
Lever Removal And Installation…………………….337
Cable Removal And Installation…………………….338
Adjustment………………………………………340
BRAKE CALIPER……………………………………….341
Removal And Installation………………………….341
Parts Identification……………………………..344
Disassembly And Assembly………………………….345
BRAKE CALIPER……………………………………….351
Removal And Installation………………………….351
Parts Identification……………………………..354
Disassembly And Assembly………………………….355
REAR AXLE…………………………………………..361
Removal And Installation………………………….361
AXLE AND DIFFERENTIAL………………………………..365
Troubleshooting Chart…………………………….365
General Information………………………………366
Wheel Hub/Axle Parts Identification………………..366
Wheel Hub/Axle Disassembly………………………..367
Differential Parts Identification………………….370
Differential Disassembly………………………….371
Differential Inspection…………………………..377
Pinion Group Parts Identification………………….378
Pinion Group Disassembly………………………….379
Pinion Group Inspection…………………………..382
Pinion Group Assembly…………………………….383
Differential Assembly…………………………….390
Wheel Hub/Axle Assembly…………………………..399
MAIN FRAME……………………………………………..403
OPERATOR CAB………………………………………..405
Removal And Installation………………………….405
Cab Mount Removal And Installation…………………412
OPERATOR SEAT……………………………………….413
Removal And Installation………………………….413
FLOOR PANELS………………………………………..415
Left Front Panel Removal And Installation…………..415
Right Front Panel Removal And Installation………….415
Rear Panel Removal And Installation………………..416
GRILL………………………………………………417
Removal And Installation………………………….417
GRILL FRAME…………………………………………419
Removal And Installation………………………….419
ENGINE SIDE COVERS…………………………………..421
Removal And Installation………………………….421
FENDER……………………………………………..423
Removal And Installation………………………….423
ENGINE COVER………………………………………..425
Removal And Installation………………………….425
FUEL TANK…………………………………………..427
Removal And Installation………………………….427
Fuel Fill Screen Removal And Installation…………..428
LIFT ARMS…………………………………………..429
Removal And Installation………………………….429
BOB-TACH……………………………………………433
Removal And Installation………………………….433
Bob-Tach Lever And Wedge………………………….435
Pivot Pin Bushing Removal And Installation………….437
FRONT AXLE………………………………………….439
Removal And Installation………………………….439
Pivot Bushing Removal And Installation……………..441
AXLE HUB (FRONT)…………………………………….443
Removal And Installation………………………….443
SPINDLE…………………………………………….447
Removal And Installation………………………….447
ARM………………………………………………..451
Removal And Installation………………………….451
Bushing Removal And Installation…………………..453
BOOM……………………………………………….455
Removal And Installation………………………….455
SWING FRAME…………………………………………459
Boom Pivot Bushing Removal And Installation…………459
Removal And Installation………………………….460
Boom Swing Bushing Removal And Installation…………464
X-CHANGE™…………………………………………..465
Removal And Installation………………………….465
BUCKET……………………………………………..467
Backhoe Bucket Teeth Removal And Installation……….467
Loader Bucket Teeth Removal And Installation………..467
STABILIZER………………………………………….469
Removal And Installation………………………….469
ELECTRICAL SYSTEM AND ANALYSIS……………………………473
ELECTRICAL SCHEMATICS………………………………..475
ELECTRICAL SYSTEM INFORMATION…………………………477
Troubleshooting Chart…………………………….477
Description……………………………………..478
Fuse Location……………………………………478
BATTERY…………………………………………….479
Removal And Installation………………………….479
Servicing The Electrical System……………………480
Using A Booster Battery (Jump Starting)…………….481
ALTERNATOR………………………………………….483
Adjusting The Alternator Belt……………………..483
Description……………………………………..483
Tests…………………………………………..484
Alternator Output Test……………………………484
Full Field Test………………………………….485
Alternator Regulator Test…………………………485
Alternator Regulator Test With Voltmeter……………486
Removal And Installation………………………….487
Parts Identification……………………………..488
Pulley Removal And Installation……………………489
Disassembly And Assembly………………………….490
Rotor Continuity Test…………………………….493
Stator Continuity Test……………………………493
Rectifier Continuity (Diode) Test………………….494
Brush Length…………………………………….494
STARTER…………………………………………….495
Removal And Installation………………………….495
Checking The Starter In The Loader…………………495
Parts Identification……………………………..497
Disassembly……………………………………..498
Inspection And Repair…………………………….503
No Load Test…………………………………….507
Assembly………………………………………..508
CAB LIGHTS………………………………………….515
Bulb Removal And Installation……………………..515
Housing Removal And Installation…………………..517
FUEL LEVEL SENDER……………………………………519
Removal And Installation………………………….519
INSTRUMENT PANEL…………………………………….521
Removal And Installation………………………….521
ENGINE SERVICE………………………………………….523
TROUBLESHOOTING……………………………………..527
Chart…………………………………………..527
ENGINE SPEED CONTROL…………………………………529
Removal And Installation………………………….529
Cable Removal And Installation…………………….530
MUFFLER…………………………………………….531
Removal And Installation………………………….531
AIR CLEANER…………………………………………533
Housing Removal And Installation…………………..533
RADIATOR……………………………………………535
Removal And Installation………………………….535
ENGINE COMPONENTS AND TESTING…………………………537
Checking Engine Compression……………………….537
Checking Glow Plugs………………………………538
Glow Plug Removal And Installation…………………539
Fuel Shut-Off Solenoid Removal And Installation……..540
Checking Fuel Injection Pump………………………541
Fuel Injection Pump Removal And Installation………..542
Fuel Injection Pump Timing………………………..544
Fuel Injector Nozzles Removal And Installation………545
Checking Fuel Injector, Nozzles……………………547
Thermostat Removal And Installation………………..548
Water Pump Removal And Installation………………..549
ENGINE……………………………………………..551
Removal And Installation………………………….551
Mount Replacement………………………………..555
RECONDITIONING THE ENGINE…………………………….557
Timing Gear Case Cover Removal And Installation……..557
Oil Pump Removal And Installation………………….559
Crankshaft Front Seal Removal And Installation………561
Engine Speed Control Plate Removal And Installation….562
Idle Limit And Fuel Limit Adjustment……………….563
Exhaust Manifold Removal And Installation…………..563
Valve Cover Removal And Installation……………….564
Rocker Arm Removal And Installation………………..565
Push Rod Removal And Installation………………….566
Tappet Removal And Installation……………………567
Water Flange Removal And Installation………………567
Cylinder Head Removal And Installation……………..568
Checking Piston Top Clearance……………………..569
Cylinder Head Disassembly And Assembly……………..570
Servicing The Cylinder Head……………………….571
Combustion Chamber Removal And Installation…………574
Idler Gear Removal And Installation………………..575
Camshaft Removal And Installation………………….576
Fuel Camshaft Removal And Installation……………..578
Oil Pan Removal And Installation…………………..580
Governor Shaft Removal And Installation…………….581
Governor Fork Lever Removal And Installation………..584
Piston Removal And Installation……………………586
Checking The Piston And Connecting Rod……………..586
Connecting Rod Alignment………………………….587
Piston Ring Gap………………………………….587
Piston Ring Installation………………………….588
Connecting Rod Installation……………………….589
Checking Engine Cylinder Bore……………………..589
Crankshaft Removal And Installation………………..590
Checking Crankshaft Journal And Block Bearing……….592
Checking Crankshaft Journal And Main Bearing………..593
Connecting Rod Journal……………………………594
Checking The End Play Of The Crankshaft…………….595
Crankshaft Alignment……………………………..595
Engine Timing Installation………………………..596
Timing Gear Backlash, Idler Gear And Crankshaft……..596
Idler Gear And Camshaft Gear………………………597
Idler Gear And Fuel Camshaft Gear………………….597
Fuel Camshaft Gear And Governor Shaft Gear………….597
FLYWHEEL HOUSING…………………………………….599
Removal And Installation………………………….599
FLYWHEEL……………………………………………601
Removal And Installation………………………….601
Ring Gear Removal And Installation…………………601
RUBBER DRIVE COUPLER…………………………………603
Removal And Installation………………………….603
Disassembly……………………………………..603
TURBOCHARGER………………………………………..605
SPECIFICATIONS………………………………………….607
LOADER BACKHOE SPECIFICATIONS…………………………609
Loader Backhoe Dimensions…………………………609
Performance……………………………………..610
Controls………………………………………..610
Engine………………………………………….610
Hydraulic System…………………………………611
Electrical………………………………………612
Drive System…………………………………….612
Capacities………………………………………612
Tires…………………………………………..612
ENGINE SPECIFICATIONS………………………………..613
Engine Compression……………………………….613
Fuel Injection Nozzles……………………………613
Fuel Injection Pump………………………………613
Cylinder Head……………………………………613
Valves………………………………………….613
Valve Springs……………………………………614
Rocker Arms……………………………………..614
Camshaft………………………………………..614
Cylinders……………………………………….614
Piston Rings…………………………………….615
Pistons…………………………………………615
Crankshaft………………………………………615
Oil Pump………………………………………..616
Thermostat………………………………………616
Grinding Specifications for the Crankshaft………….617
LOADER BACKHOE TORQUE………………………………..619
Specifications…………………………………..619
TORQUE SPECIFICATIONS FOR BOLTS……………………….621
Torque For General Metric Bolts……………………621
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS……………..623
Specifications…………………………………..623
CONVERSIONS…………………………………………625
Decimal And Millimeter Equivalents…………………625
U.S. To Metric Conversion…………………………625
SMR……………………………………………………627
B100-1……………………………………………..627
B100-2……………………………………………..629
B100-3……………………………………………..631
B100-4……………………………………………..633
B100-5……………………………………………..635
B100-6……………………………………………..637
B100-7……………………………………………..639
B100-8……………………………………………..641
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DESCRIPTION:
BOBCAT B100 Service Manual PDF DOWNLOAD
(S/N 570011001 & Above)
(S/N 570111001 & Above)
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
- Check that ROPS mounting hardware is tightened and is Bobcat approved.
- The seat belt must be correctly installed, functional and in good condition.
- Check lift arm support device, replace if damaged.
- Machine signs must be legible and in the correct location.
- Foot pedal must return to neutral.
- Check for correct function of the work lights.
- The parking brake must function correctly.
- Enclosure door latches must open and close freely.
- Bob-Tach wedges and linkages must function correctly and be in good condition.
- Safety treads must be in good condition.
- Check for correct function of indicator lamps (Optional on some models).
- Check hydraulic fluid level, engine oil level and fuel supply.
- Inspect for fuel, oil or hydraulic fluid leaks.
- Lubricate the loader backhoe.
- Check the condition of the battery and cables.
- Inspect the air cleaner for damage or leaks. Check the condition of the element.
- Check the electrical charging system.
- Check tires for wear and pressure.
- Inspect for loosen or broken parts or connections.
- Operate the loader and check all functions.
- Check for any field modification not completed.
- Recommend to the owner that all necessary corrections be made before the machine is returned to service.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P