Bobcat S100 Skid-Steer Loader Repair Service Manual – 6904926

(S/N: A2G711001 & Above – S/N: A89L11001 & Above)
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This workshop repair service manual PDF download for the Bobcat S100 Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader S100
S/N: A2G711001 & Above
S/N: A89L11001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6904926 (4-11)
Total Pages : 502

This Bobcat Skid-Steer Loader Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing
Removing
OPERATOR CAB
Description
Raising
Lowering
Cab Door Sensor
TRANSPORTING THE LOADER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE LOADER
Procedure
REMOTE START TOOL KIT-MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Control – MEL1565
Service Tool Harness Communicator – MEL1566
Remote Start Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
Description
Remote Start Tool (Service Tool) – 7003030
Loader Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Removing And Replacing Case Drain Filters
Removing And Replacing Hydraulic Charge Filter
Breather Cap
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing And Replacing Oil
BOB-TACH (HAND LEVER)
Inspection And Maintenance
LUBRICATING THE LOADER
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
Inspection And Maintenance
LOADER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
Emergency Exit

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATIC
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
MAIN RELIEF VALVE
Description
Testing
Adjusting
Removal And Installation
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Identification Chart
Load Check Valve Removal And Installation (Tilt and Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Rubber Boot Removal And Installation
End Cap / Spool Lock Block Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Main Relief Valve Removal And Installation
LIFT ARM bypass CONTROL VALVE
Description
Testing
Removal and Installation
Disassembly And Assembly
HYDRAULIC PUMP
Description
Pump Test at Quick Couplers
Direct Pump Test
Direct Pump Test (Charge Section)
Removal And Installation
Parts Identification
Disassembly And Assembly
Hydraulic Pump Start Up
HYDRAULIC / HYDROSTATIC FILTERS
Description
Hydraulic / Hydrostatic Filter Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Description
Removal And Installation
BUCKET POSITION VALVE
Description
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLERS
Description
Removal And Installation

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Description
Troubleshooting
HYDROSTATIC MOTOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
CHARGE PRESSURE
Description
Testing
Sender Removal And Installation
Adjusting
HYDROSTATIC PUMP
Description
Replenishing / High Pressure Relief Valve Removal And Installation
Removal And Installation
Hydrostatic Pump Start Up
Parts Identification
Disassembly
Assembly
DRIVE BELT
Description
Shield Removal And Installation
Adjusting
Belt Removal And Installation
Tensioner Pulley Removal And Installation
Tensioner Pulley Disassembly And Assembly

DRIVE SYSTEM
BRAKE
Description
Disk Removal And Installation
DRIVE COMPONENTS
Description
Axle Seal Removal And Installation
Axle Sprocket And Bearings Removal And Installation
Chain Removal And Installation
CHAINCASE
Description
Front Cover Removal And Installation
Center Cover Removal And Installation

MAIN FRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal and Installation
Lower Cushion Removal And Installation
Back Cushion Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Striker Removal and Installation
Striker Disassembly and Assembly
Striker (Adjusting)
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
Fuel Fill Screen Removal And Installation
Fuel Pickup Screen
CONTROL PEDALS AND LINKAGES
Description
Pedal Removal And Installation
Linkage Removal And Installation
Pedal (Adjusting)
CONTROL PANEL
Description
Removal and Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Pintle Arm Removal And Installation
Pintle Arm Disassembly and Assembly
Linkage Neutral Adjusting
Linkage Travel Adjusting
CONTROL HANDLE / LEVER
Description
Lever Removal And Installation
Boot Removal And Installation
WINDOW (REAR)
Removal
Installation
WINDOW (TOP)
Removal And Installation
WINDOW (SIDE)
Removal And Installation
WINDOW (FRONT DOOR)
Removal (Standard Window)
Installation (Standard Window)
Removal And Installation (Special Applications Window)

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Harness Connectors
Mainframe Harness Connectors
Description
Troubleshooting
Fuse And Relay Location / Identification
Solenoid Testing
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANELS
Left Panel
Display Screen
Standard Key Panel
Option And Field Accessory Panels
Removal And Installation (Left And Right)
Key Switch Removal And Installation
Alarm Removal And Installation
Front Accessory Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
BOBCAT CONTROLLER (MAIN)
Description
Connector Identification
Removal And Installation
DIAGNOSTIC SERVICE CODES
Viewing Service Codes (Standard Key Panel)
Service Codes List
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Inspecting The BICS Controller (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm Bypass Control
Troubleshooting
Troubleshooting Chart
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal And Installation
Bobcat Interlock Control System (BICS) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Removal And Installation
Inspecting
SERVICE PC (LAPTOP COMPUTER)
Connecting To The Remote Start Tool
Connecting Remote Start Tool (Service Tool)
FLYWHEEL RPM SENSOR
Description
Adjusting
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM
Description
Inspecting
Adjusting Switch Position
Troubleshooting
Alarm Removal And Installation
Switch Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression-Checking
ENGINE SPEED CONTROL
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Fan Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
Testing The Thermostat
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor Disassembly And Assembly
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Removal And Installation
Timing The Injection Pump
Fuel Injector Removal And Installation
Fuel Injector Nozzles Pressure – Checking
Nozzle Spray Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plug – Testing
Glow Plug Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly and Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore Checking
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Idler Gear And Shaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft Servicing
FLYWHEEL
Flywheel Removal And Installation

HEATER
HEATER SYSTEM
Description
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Cleaning The Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operators Normally, But Air Flow Is Insufficient
Electrical System
Engine Coolant bypassing The Heater Valve
Heater Valve Not Opening Or Closing
HEATER UNIT
Removal And Installation
HEATER COIL
Removal And Installation
HEATER FAN
Blower Removal And Installation
Disassembly And Assembly
Connector Identification
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
(S100) LOADER SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart

SERVICE MANUAL REVISIONS
S100-1
S100-2

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