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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