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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