Bobcat X100 Excavator Repair Service Manual – 6570483

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This workshop repair service manual PDF download for the X-100 Bobcat Mini Hydraulic Excavator 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 Excavator X 100

TABLE OF CONTENTS :

10 ENGINE
11 STRUCTURE AND FUNCTION
12 TESTING AND ADJUSTING
13 DISASSEMBLY AND ASSEMBLY

20 POWER TRAIN
21 STRUCTURE AND FUNCTION
23 DISASSEMBLY AND ASSEMBLY .
24 MAINTENANCE STANDARD

30 UNDERCARRIAGE
31 STRUCTURE AND FUNCTION
33 DISASSEMBLY AND ASSEMBLY
34 MAINTENANCE STANDARD

60 HYDRAULIC SYSTEM
61 STRUCTURE AND FUNCTION
62 TESTING AND ADJUSTING
63 DISASSEMBLY AND ASSEMBLY
64 MAINTENANCE STANDARD

70 WORK EQUIPMENT
71 STRUCTURE AND FUNCTION
73 DISASSEMBLY AND ASSEMBLY
74 MAINTENANCE STANDARD

80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION

90 OTHERS
93 DISASSEMBLY AND ASSEMBLY

SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6570483 (3-87)
Total Pages : 227

This 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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CONTENTS
SAFETY
FOREWORD
SYMBOLS

STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
TIGHTENING TORQUE FOR NUTS OF FLARED

COATING MATERIALS

ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE

WEIGHT TABLE

CAPACITY TABLE OF FUEL, COOLANT AND LUBRICANTS (S/N 11999 & Below)
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

TABLE OF OIL AND COOLANT QUANTITIES (S/N 12001 & Above)
PROPER SELECTION OF FULE, COOLANT AND LUBRICANTS

ENGINE STRUCTURE AND FUNCTION
ENGINE MOUNT
RADIATOR
POWER TAKE-OFF SYSTEM
FUEL TANK AND PIPING
ENGINE CONTROL

ENGINE TESTING AND ADJUSTING
STANDARDS FOR TESTING AND ADJUSTING (100)
TESTING AND ADJUSTING TOOL LIST
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
FAN BELT TENSION
BLEEDING AIR FROM FUEL LINE
MEASURING ENGINE OIL PRESSURE
MEASURING OIL AND COOLANT TEMPERATURES

ENGINE DISASSEMBLY AND ASSEMBLY
REMOVAL OF STARTING MOTOR ASSEMBLY
INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL OF ALTERNATOR ASSEMBLY
INSTALLATION OF ALTERNATOR ASSEMBLY
REMOVAL OF WATER PUMP ASSEMBLY
INSTALLATION OF WATER PUMP ASSEMBLY
REMOVAL OF NOZZLE HOLDER ASSEMBLY
INSTALLATION OF NOZZLE HOLDER ASSEMBLY
REMOVAL OF CYLINDER HEAD ASSEMBLY
INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL OF RADIATOR ASSEMBLY
INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL OF ENGING ASSEMBLY
INSTALLATION OF ENGINE ASSEMBLY

POWER TRAIN STRUCTURE AND FUNCTION
POWER TRAIN (S/N 12001 & Above)
SWING CIRCLE (S/N 11999 & Below)
SWING CIRCLE (S/N 12001 & Above)
SWING MACHINERY (S/N 11999 & Below)
SWING MACHINERY (S/N 12001 & Above)
SPROCKET (S/N 11999 & Below)
SPROCKET (S/n 12001 & Above)

POWER TRAIN DISASSEMBLY AND ASSEMBLY
REMOVAL OF SWING CIRCLE ASSEMBLY
INSTALLATION OF SWING CIRCLE ASSEMBLY
REMOVAL OF SWING MACHINERY ASSEMBLY
INSTALLATION OF SWING MACHINERY ASSEMBLY
DISASSEMBLY OF SWING MACHINERY ASSEMBLY
ASSEMBLY OF SWING MACHINERY ASSEMBLY

POWER TRAIN MAINTENANCE STANDARD
SWING CIRCLE (S/N 11999 & Below)
SWING CIRCLE (S/N 12001 & Above)
SWING MACHINERY (S/N 11999 & Below)
SWING MACHINERY (S/N 12001 & Above)
SPROCKET (S/N 11999 & Below)
SPROCKET (S/n 12001 & Above)

UNDERCARRIAGE STRUCTURE AND FUNCTION
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER
TRACK SHOE

UNDERCARRIAGE DISASSEMBLY AND ASSEMBLY
REMOVAL OF RECOIL SPRING ASSEMBLY
INSTALLATION OF RECOIL SPRING ASSEMBLY
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
ASSEMBLY OF RECOIL SPRING ASSEMBLY
REMOVAL OF IDLER ASSEMBLY
INSTALLATION OF IDLER ASSEMBLY
REMOVAL OF TRACK ROLLER ASSEMBLY
INSTALLATION OF TRACK ROLLER ASSEMBLY
REMOVAL OF TRACK SHOE ASSEMBLY
INSTALLATION OF TRACK SHOE ASSEMBLY

UNDERCARRIAGE MAINTENANCE STANDARD
TRACK FRAME AND RECOIL SPRING (S/N 11999 & Below)
TRACK FRAME AND RECOIL SPRING (S/N 12001 & Above)
TRACK FRAME AND RECOIL SPRING (S/N 12001 & Above)
IDLER (S/N 11999 & Below)
IDLER (S/N 12001 & Above)
IDLER (S/N 12001 & Above)
TRACK ROLLER (S/N 12001 & Above)
TRACK ROLLER (S/N 11999 & Below)
TRACK ROLLER (S/N 12001 & Above)
TRACK SHOE (S/N 11999 & Below)
TRACK SHOE (S/N 12001 & Above)
TRACK SHOE (S/N 12001 & Above)

HYDRAULIC SYSTEM STRUCTURE AND FUNCTION
HYDRAULIC PIPING (S/N 11999 & Below)
HYDRAULIC PIPING (S/N 12001 & Above)
HYDRAULIC CIRCUIT DIAGRAM (S/N 11001 – 11999)
HYDRAULIC CIRCUIT DIAGRAM (S/N 12001 & Above)
HYDRAULIC CIRCUIT SCHEMATICS (S/N 11001 – 11999)
HYDRAULIC CIRCUIT SCHEMATICS (S/N 12001 & Above)
HYDRAULIC TANK AND FILTER (S/N 11999 & Below)
HYDRAULIC TANK (S/N 12001 & Above)
HYDRAULIC PUMP (S/N 11999 & Below)
1-SPOOL CONTROL VALVE (Auxilliary) (S/N 12001 & Above)
2-SPOOL CONTROL VALVE (S/N 11999 & Below)
3-SPOOL CONTROL VALVE (S/N 11999 & Below)
3-SPOOL CONTROL VALVE (S/N 12001 & Above)
4-SPOOL CONTROL VALVE (S/N 11999 & Below)
4-SPOOL CONTROL VALVE (S/N 11999 & Below)
6-SPOOL CONTROL VALVE
CENTER SWIVEL JOINT (S/N 11999 & Below)
CENTER SWIVEL JOINT (S/N 12001 & Above)
WORK EQUIPMENT SWIVEL JOINT (S/N 11999 & Below)
SWING MOTOR (S/N 11999 & Below)
SWING MOTOR (S/N 12001 & Above)
TRAVEL MOTOR AND FINAL DRIVE (S/N 11999 & Below)
TRAVEL MOTOR (With Reduction Gear) (S/N 12001 & Above)
HYDRAULIC CYLINDERS
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
SWING CYLINDER
BLADE CYLINDER
VALVE CONTROL (S/N 11999 & Below)
VALVE CONTROL (S/N 12001 & Above)

HYDRAULIC SYSTEM TESTING AND ADJUSTING
MEASURING DELIVERY OF HYDRAULIC PUMP
MEASURING TEMPERATURE OF HYDRAULIC OIL
TESTING AND ADJUSTING HYDRAULIC PRESSURE
MEASURING TEMPERATURE OF HYDRAULIC OIL
100 HYDRAULIC PUMP CHECK
Checking the Output of the Hydraulic Pump at the Boom Cylinder
Adjusting the Main Relief Valve
Checking the Output of the Hydraulic Pump at the Arm Cylinder
Adjusting the Main Releif Valve
Checking the Output of the Hydraulic Pump at the Blade Cylinder
Adjusting the Main Relief Valve
Checking the Port Relief Valve
STANDARDS FOR TESTING AND ADJUSTING

HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
REMOVAL OF 4-SPOOL CONTROL VALVE ASSEMBLY (FOR RIGHT TRAVEL, BOOM, BUCKET, SWING)
INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY
REMOVAL OF 2-SPOOL CONTROL VALVE ASSEMBLY (FOR LEFT TRAVEL, ARM)
INSTALLATION OF 2-SPOOL CONTROL VALVE ASSEMBLY
DISASSEMBLY OF 2-SPOOL CONTROL VALVE ASSEMBLY
ASSEMBLY OF 2-SPOOL CONTROL VALVE ASSEMBLY
REMOVAL OF 3-SPOOL CONTROL VALVE ASSEMBLY (FOR SWING, TRAVAL ACCELERATION, BLADE)
INSTALLATION OF 3-SPOOL CONTROL VALVE ASSEMBLY
DISASSEMBLY OF 3-SPOOL CONTROL VALVE ASSEMBLY
ASSEMBLY OF 3-SPOOL CONTROL VALVE ASSEMBLY
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL OF SWING MOTOR ASSEMBLY
INSTALLATION OF SWING MOTOR ASSEMBLY
REMOVAL OF TRAVEL MOTOR ASSEMBLY
INSTALLATION OF TRAVEL MOTOR ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY
INSTALLATION OF BOOM CYLINDER ASSEMBLY
REMOVAL OF ARM CYLINDER ASSEMBLY
INSTALLATION OF ARM CYLINDER ASSEMBLY
REMOVAL OF BUCKET CYLINDER ASSEMBLY
INSTALLATION OF BUCKET CYLINDER ASSEMBLY
REMOVAL OF BLADE CYLINDER ASSEMBLY
INSTALLATION OF BLADE CYLINDER ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY
INSTALLATION OF BOOM CYLINDER ASSEMBLY
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
REMOVAL OF SWIVEL JOINT ASSEMBLY FOR WORK EQUIPMENT
INSTALLATION OF SWIVEL JOINT ASSEMBLY FOR WORK EQUIPMENT

HYDRAULIC SYSTEM MAINTENANCE STANDARD
HYDRAULIC PUMP (S/N 11999 & Below)
TRIPLE GEAR PUMP (SBR-10 + 10 + 8) (S/N 12001 & Above)
SWING MOTOR (S/N 11999 & Below)
SWING MOTOR (S/N 12001 & Above)
1-SPOOL CONTROL VALVE (S/N 12001 & Above)
2-SPOOL CONTROL VALVE (S/N 11999 & Above)
3-SPOOL CONTROL VALVE (S/N 11999 & Below)
3-SPOOL CONTROL VALVE (S/N 12001 & Above)
4-SPOOL CONTROL VALVE (S/N 11999 & Below)
6-SPOOL CONTROL VALVE (S/N 12001 & Above)
HYDRAULIC CYLINDER (S/N 11999 & Below)
HYDRAULIC CYLINDER (S/N 12001 & Above)

WORK EQUIPMENT STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUPMENT (S/N 12001 & Above)

WORK EQUPMENT DISASSEMBLY AND ASSEMBLY
REMOVAL OF WORK EQUIPMENT ASSEMBLY
INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL OF BLADE ASSEMBLY
INSTALLATION OF BLADE ASSEMBLY
DISASSEMBLY OF WORK EQUIPMENT ASSEMBLY
REMOVAL OF BUCKET ASSEMBLY
REMOVAL OF ARM ASSEMBLY
REMOVAL OF BOOM ASSEMBLY
ASSEMBLY OF WORK EQUIPMENT ASSEMBLY
INSTALLATION OF BOOM ASSEMBLY
INSTALLATION OF ARM ASSEMBLY
INSTALLATION OF BUCKET ASSEMBLY

WORK EQUIPMENT MAINTENANCE STANDARD
WORK EQUIPMENT

WORK EQUIPMENT STRUCTURE AND FUNCTION
ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM (S/N 12001 & Above)

OTHERS DISASSEMBLY AND ASSEMBLY
REMOVAL OF FLOOR FRAME ASSEMBLY
INSTALLATION OF FLOOR FRAME ASSEMBLY

SERVICE MANUAL REVISION
100-1
100-2

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