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Bobcat S100 Loader Service Manual (SN A8ET11001-A8ET19999)

Format: PDF (Printable Document)

File Language: English

File Pages: 521

File Size: 16.44 MB (Speed Download Link)

Brand: Bobcat

Model: S100 Loader

Book No: 6904926

Serial No: SN A8ET11001-A8ET19999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat S100 Loader Service Manual (SN A8ET11001-A8ET19999)

The S100 is a small skid-steer that ends up in tight back yards, barns, and rental yards, doing fork work, light dirt work, and snow. The people who reach for this service manual are the ones actually turning wrenches: shop mechanics, mobile techs like me, and owners who are past warranty and sick of guessing. They want correct teardown order, hydraulic test points, wiring paths, and torque specs so the machine goes back to work without a comeback.

What this manual helps you do

  • Diagnose hydraulic issues by checking test ports, reliefs, and drive and loader functions in a logical order
  • Trace and repair electrical faults using wiring diagrams and connector callouts instead of chasing wires blindly
  • Follow step-by-step removal and installation for pumps, drive motors, cylinders, axles, and Bob-Tach components
  • Rebuild and adjust key assemblies like the hydrostatic system, chaincases, control linkages, and brake components
  • Verify adjustments and clearances after a repair so you're not tearing back into it after the next job

Who this is for

This is for anyone responsible for repairing an S100 in the A8ET11001-A8ET19999 serial range: small contractors, rental fleets, owner-operators, and field techs with a truck full of tools. If you only want basic controls, safety, and daily checks, you want the operator's handbook instead, not this manual.

FAQ

Q: Is this a searchable PDF and are the wiring diagrams readable?

A: These manuals are normally supplied as searchable PDFs, and the wiring diagrams are designed to be zoomed in clearly on a laptop or tablet.

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

A: Check your serial plate. If your S100 serial number falls between A8ET11001 and A8ET19999, this is the right manual.

Q: Is this what I need for real repairs, not just maintenance?

A: Yes. This is the workshop service manual, meant for full diagnostics and repair work, not just fluid changes.

Bottom line, if you're repairing an S100 in that A8ET serial range, this is the manual you want in the truck or shop. If your serial is outside that range, keep looking.

📘 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 (If Equipped)
    • 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 – 6689779
      • Description
      • Remote Start Tool (Service Tool) – 6689778
      • 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
      • 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 / Hydrostatic Filter
      • Removing And Replacing Hydraulic Fluid and Case Drain Filters
      • Removing And Replacing Charge Filter
    • FINAL DRIVE TRANSMISSION (CHAINCASE)
      • Checking And Adding Oil
      • Removing And Replacing Oil
    • BOB-TACH (HAND LEVER)
      • Inspection And Maintenance
    • BOB-TACH (POWER OPTION)
      • 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
    • BACK-UP ALARM SYSTEM
      • Description
      • Operation
  • 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
    • CYLINDER (BOB-TACH)
      • 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
    • BOB-TACH (POWER) BLOCK
      • Description
      • 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
      • 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
      • Parts Identification
      • Disassembly
      • Assembly
      • Hydrostatic Pump Start Up
    • DRIVE BELT
      • Description
      • Shield Removal And Installation
      • Adjusting
      • Belt Removal And Installation
      • Tensioner Pulley Removal And Installation
      • Tensioner Pulley Disassembly And Assembly
    • CASE DRAIN FILTER
      • Description
      • 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
    • BOB-TACH (POWER OPTION)
      • 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)
    • CAB DOOR
      • Description
      • Removal And Installation
      • Aligning
      • Adjusting
      • Checking Operation
  • ELECTRICAL SYSTEM & ANALYSIS
    • ELECTRICAL SCHEMATIC
    • 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
      • LCD Screen Functions
      • Standard Key Panel
      • Deluxe Instrumentation 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)
      • Viewing Service Codes (Deluxe Instrumentation 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)
      • Connecting To The Remote Start Tool
      • Connecting Remote Start Tool (Service Tool)
    • FLYWHEEL RPM SENSOR
      • Description
      • Adjusting
    • CONTROL PANEL SETUP
      • Right Panel Setup (Deluxe Instrumentation Panel)
      • Attachment Control Information (Deluxe Instrumentation Panel)
    • PASSWORD SETUP
      • Password Description
      • Changing The Owner Password
      • Changing The User Passwords
      • Password Lockout Feature
    • 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
      • Oil Pump Inspection (Cont’d)
      • 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
    • LOADER SPECIFICATIONS
      • Machine Dimensions
      • Machine Rating
      • Function Time
      • Weights
      • Engine
      • Electrical
      • Hydraulic System
      • Hydraulic Cylinders
      • Drive System
      • Traction
      • Environmental
      • Fluid Capacities
      • Fluid Specifications
      • Controls
      • Instrumentation
    • 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

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