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Bobcat S100 Troubleshooting

The Bobcat S100 skid steer loader driveline system components: a 91.4 cu.in (1.5L) Kubota V1505-E2B 4-cylinder indirect injection diesel engine with a rated power of 24.5 hp (18.2 kW), and 1-speed or 2-speed transmission. The hydraulic system has a pump with a rated capacity of 13.2 gal/min (50 l/min). The system relief pressure is 3000 psi (207 bar). The Bobcat S100 is equipped with a radial-lift loader boom, 80 HSOC roller chains, and 27-8.50x15 tires. The skid steer loader has a boom lifting force of 1855 lbs (843 kg) and bucket breakout force of 1950 lbs (886 kg). The rated operating capacity is 1000 lbs (457 kg), and tipping load is 2000 lbs (914 kg).

Engine Troubleshooting

Engine starts up hard or will not start
Air in fuel tank - Bleed fuel tank.
Fuel filter plugging - Clean or change the filter.
Damaged or dirty injection nozzles - Clean or replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is not adjusted - Adjust valve clearance.
Fuel injection pump malfunctioning - Repair or change injection pump.

Diesel starts but stalls suddenly
Air filter is plugged - Change or service air filter element.
Fuel filter element is clogged - Install new filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Fuel injection pump failure - Rebuild or install a new injection pump.

Engine stalls during operation
Engine has not warmed up to recommended temperature - Warm up the engine.
Clogged fuel filter - Change filter element.
Air in the fuel lines - Bleed the fuel lines.
Clogged or burnt injection nozzle - Check and replace nozzles if required.
Fuel injection pump timing is not adjusted - Adjust as recommended.

Engine stops when idling
Low idle speed setting is not correct - Adjust low idling as recommended.
Fuel injection pump malfunction - Repair or change injection pump.
Fuel injector fault - Replace fuel injectors.
The valve clearance is not adjusted - Adjust valve clearance.

Engine power loss
Air filter is plugged - Clean or change.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Incorrect fuel injection pressure - Adjust to proper pressure.
The valve clearance is not adjusted - Adjust valve clearance.
Low idle speed setting is not correct - Correct the settings.
Dirt in the fuel hoses or lines - Service fuel hoses and lines.
Blown cylinder head gasket - Replace the gasket as required.
Worn or damaged piston rings - Piston rings replacement required.

Engine overheats
Engine coolant is insufficient - Add coolant fluid and inspect the cooling system for leaks.
Engine oil level is low - Fill up the engine oil.
Dirty radiator core or defective radiator cap - Change cap or clean radiator.
Fan belt is broken or worn - Change as required.
Engine overload - Load reducing required.

Low oil pressure
Oil level is insufficient - Need to add oil.
Oil filter element clogged - Change or clean engine oil filter element.
Wrong oil viscosity - Drain crankcase and refill with correct oil.
Incorrect crankshaft bearing oil clearance - Install new bearings.
Oil pump is defective - Repair or replace.

Engine noises or knocks
Insufficient engine oil - Fill the crankcase with engine oil.
Engine is not preheated - Warm up the engine.
Fuel injection pump timing is not adjusted - Set it up as required.
Low idle speed setting is not correct - Normalize low idle speed.
Damaged or clogged injectors - Clean fuel injectors or change it.
Connecting rod is not aligned or defective - Connecting rod needs to be replaced or aligned.
Worn or broken pistons - Replace the pistons.

Drive System Troubleshooting

Drive system does not work in either direction
Insufficient hydraulic fluid - Fill up the hydraulic fluid.
Drive chain is worn - Check drive chain and change faulty parts.
Input drive shaft is not working properly - Repair or install a new drive shaft.
Relief valve is worn or damaged - Repair or replace.
Suction line or hydraulic filter is plugged - Service suction line or change hydraulic filter.
Defective foot or hand controls - Check and repair as required.
Drive motor or pump is worn - Inspect and replace as necessary.

Loss of power
Plugged hydraulic oil filter - Replace or service hydraulic filter.
Worn or open relief valve - Change or close relief valve.
Transmission components are damaged or faulty - Check and change defective components.
Input drive shaft is damaged - Rebuild or change the shaft.
Air in the hydraulic system - Bleed air from system.

Overheated drive system
Hydraulic oil level is low - Fill the system to proper hydraulic oil level.
Hydraulic fluid filter is plugged - Change or service hydraulic filter.
Stuck relief valve - Repair or replace relief valve.
Drive pump or hydraulic motor malfunction - Inspect and replace as necessary.
Plugged hydraulic oil cooler - Clean cooling fins as required.
Transmission overloading - Load needs to be reduced.

Drive system is noisy
Oil viscosity is too heavy - Use the specified type of oil.
Air in the hydraulic system - Air bleeding is required.
Worn hydraulic motor or drive pump - Change or repair faulty component.
Worn or defective mechanical components of drive system - Check the components for defect or damage and change if necessary.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is not correct - Correct setting is required.
Main relief valve is damaged or adjusted improperly - Adjust relief valve or change if required.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Hydraulic oil level is insufficient - Fill up the hydraulic oil.
Hydraulic pump is faulty - Change or repair hydraulic pump if required.

Boom cannot be lowered or raised
Lift controls are faulty - Change or repair.
Damaged hydraulic oil pump - Install new pump or repair it.
Defective hydraulic control valve - Change or repair hydraulic valve.
Hydraulic cylinder is broken - Repair or install a new lift cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.

Bucket does not tilt
Bucket tilt controls are damaged - Replace or repair.
Damaged hydraulic oil pump - Repair or change pump if required.
Hydraulic control valve malfunction - Repair or change the valve.
Hydraulic bucket cylinder is broken - Replace or repair cylinder.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.

Boom or bucket runs slowly
Defective hydraulic pump - Test the pump flow rate and install new pump if required.
Hydraulic cylinder leaking - Change cylinder piston seals.
Low hydraulic fluid level - Fill up the hydraulic fluid.
Hydraulic control valve is faulty or out of adjustment - Set correctly or repair.
Hydraulic pressure is low - Correct adjustment is required.

Bucket or boom is jerky
Air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter clogging - Service or change the hydraulic filter.
Hydraulic oil contamination - Change hydraulic oil.
Scratched cylinder rod or tube - Replace failed component.

Hydraulic pump is excessively noisy
Lack of oil or hydraulic leakage - Refill hydraulic oil or repair leaks in system.
Dirty hydraulic filter - Service or replace hydraulic filter.
Clogged suction line - Need to clean the suction line.
Air enters the pump - Need to bleed air.
Worn pump components - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Loose or corroded electrical wiring connections - Clean or tighten wiring connections.
Battery terminal clamps are defective - Terminal clamps should be changed.
Battery bad cell - Replace the battery.
Worn or loose belt - Adjust belt tension or install a new belt.

Starter cranks slowly
Battery capacity is low - Battery is drained, recharge it.
Battery is not holding charge - Service battery or change it.
Faulty battery terminals or disconnected cables - Connect wiring properly or install new terminals.

Starter motor won't turn
Battery is drained or defective - Charge or replace the battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Low battery output - Low battery charging, charge as required.
Damaged starter motor - Repair or install a new starter.