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Bobcat S100 Loader Service Manual (SN A2G711001-A2G799999)

Format: PDF (Printable Document)

File Language: English

File Pages: 504

File Size: 14.84 MB (Speed Download Link)

Brand: Bobcat

Model: S100 Loader

Book No: 6904926

Serial No: SN A2G711001-A2G799999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat S100 Loader Service Manual (SN A2G711001-A2G799999)

The S100 is a small skid-steer loader you'll see on tight residential jobs, barns, and inside plants where a full-size machine won't fit. Around my shop, the service manual is what we grab when an S100 comes in with a hydrostatic issue, an electrical fault, or a leak that isn't obvious. Buyers for this manual are usually trying to get hard data: test ports, sequences, and what lives under each cover so the machine goes back out clean and on schedule.

What this manual helps you do

  • Diagnose hydraulic and hydrostatic problems, then check pressures and flows in the right order
  • Trace electrical faults using wiring diagrams and connector callouts
  • Follow step-by-step teardown and reassembly for major components like drive motors, cylinders, and the Bob-Tach system
  • Set and verify adjustments after repairs, like control linkages and chain case service work
  • Replace engine and chassis parts correctly with torque sequences and standard workshop procedures

Who this is for

This manual is for anyone maintaining or repairing a Bobcat S100 loader in the A2G711001 to A2G799999 serial range: small contractors, owner-operators, shop mechanics, and rental fleets. If you only need basic controls, daily checks, or safety info, you want the operator's handbook instead, not this service manual.

FAQ

Q: Is this a searchable PDF with readable wiring diagrams?

A: Yes, these manuals are normally PDF, text searchable, and the wiring diagrams are sized so you can zoom in to read wire colors and pin numbers.

Q: How do I know if it fits my exact S100?

A: Check your serial plate. If your S100 serial number falls between A2G711001 and A2G799999, this is the right service manual range.

Q: Is this the right document if I'm doing a full hydraulic or engine repair?

A: Yes, this is the workshop-level service manual, meant for full diagnostics and component rebuilds, not just routine greasing and fluid checks.

Bottom line, if your S100 is in that A2G711001-A2G799999 range and you're doing real repair work, this is the manual you want. If you're just learning to run the machine, it's the wrong book.

📘 Show Index

Table of Contents:

  • 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
  • SMR
    • S100-1
    • S100-2
    • S100-3

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