Bobcat S100 Skid-Steer Loader Service Manual 6987401 (2023) S/N AB6420001 A8ET20001 B4KH11001

Description

File Details

• Manual type: Service Manual
• Brand / model: Bobcat S100 Skid-Steer Loader
• Document number: 6987401enUS (06-23) (M)
• Copyright / imprint: ©2023 Bobcat Company, Printed in U.S.A., E2B EU S5
• Language: English
• Page count: 740
• File format: PDF
• Serial coverage printed on the cover: S/N AB6420001 & Above, S/N A8ET20001 & Above, S/N B4KH11001 & Above

Bobcat S100 Skid-Steer Loader Service Manual 6987401 (2023) S/N AB6420001 A8ET20001 B4KH11001

This Bobcat S100 Skid-Steer Loader Service Manual 6987401 (2023) S/N AB6420001 A8ET20001 B4KH11001 is written for the loader mechanic. It supplies servicing and adjustment procedures for the S100 and its component parts and systems. Daily operating instructions stay in the Operation & Maintenance Manual; this book is the shop companion used after the machine is parked, blocked, and prepared for repair.

The cover identifies three loader serial families: AB6420001 & Above, A8ET20001 & Above, and B4KH11001 & Above. Engine chapters split the same way. For S/N A8ET20001 & Above the engine service section describes a Kubota V1505-T4F diesel of 1,55 L (94.4 in³). For S/N B4KH11001 & Above it describes a Kubota V1505-E4B diesel of the same displacement. Loader specification tables also list Kubota V1505-E3B Interim Tier 4 (NA) and V1505-E2B Stage 2 (EU) combinations for S/N AB6420001 & Above and A8ET20001 & Above, plus a V1505-T4F Stage V rating table. Always match the loader serial plate inside the cab and the engine serial stamp on top of the engine before applying a torque, clearance, or pressure value.

Standard controls and Selectable Joystick Controls (SJC) are both documented. Rated operating capacity in the specification tables is 453 kg (1000 lb) on one performance page and 457–461 kg (1008–1017 lb) on the ISO 14397-1 page. Travel speed for a single-speed loader is given as 0–10,3 km/h (0–6.4 mph) or 0–8,2 km/h (0–5.1 mph) depending on the table; two-speed SJC high range is listed up to 14 km/h (8.7 mph) or 13,4 km/h (8.3 mph). Use the table that belongs to the serial family on the machine.

Chapters Covered

• Safety and Maintenance — lifting and blocking; lift arm support install and remove; operator cab raise/lower, cab door sensor, special applications kit; trailer transport and towing; remote start tool kits MEL1563 and 7217666; service schedule; air cleaner; engine cooling; fuel system and biodiesel notes; engine lubrication; hydraulic/hydrostatic fluid and filters; chaincase oil; hand-lever and power Bob-Tach; lubrication points; tires; spark arrester muffler; pivot pins; storage and return to service; stopping the engine; emergency exit; seat belt
• Hydraulic System — symbol glossary and troubleshooting; lift, tilt, and Bob-Tach cylinders (test, R&I, parts ID, disassembly); main relief valve (standard and SJC); control valve work; lift arm bypass; hydraulic pump test and R&I (standard and SJC); front auxiliary and related valves; power Bob-Tach block; hydraulic/hydrostatic schematics for the three serial families
• Hydrostatic System — system information; motors; hydrostatic pump (standard and SJC) including replenishing/high-pressure relief valves, disassembly, and neutral adjustment; drive belt and tensioner
• Drive System — final drive / chaincase, covers, sprockets, axles, and traction lock hardware
• Mainframe — frame, lift arms, operator cab structure, seats and belts, rear door and grille, fuel tank, steering linkages, lights, cab door and special applications kit door
• Electrical System and Analysis — system description and schematics; battery and jump starting; alternator and starter; instrument panels (earlier and later, key and keyless); service codes; Bobcat Interlock Control System (BICS™) inspection; seat bar sensor; traction lock; SJC calibration and compensation; flywheel rpm sensor; deluxe instrumentation; password lockout; back-up alarm
• Engine Service — separate information for S/N A8ET20001 & Above and S/N B4KH11001 & Above (description, specifications, torque values, troubleshooting, engine R&I, mounts, compression test); speed control (standard and SJC); muffler; air cleaner housing; radiator, fan, water pump, thermostat; oil pan and oil pump; fuel shutoff solenoid, injection pump timing, injectors; glow plugs, valve clearance, cylinder head, pistons, crankshaft, timing gears, flywheel housing
• Heater — system description, filter and coil maintenance, blower and valve troubleshooting, heater unit/coil/fan/valve R&I
• Specifications — machine dimensions; performance; engine; drive and controls; hydraulic system; electrical system; capacities; tires; environmental and temperature data; technical service guide values; SAE and metric bolt torques; hydraulic connection specs; hydraulic/hydrostatic fluid specs; conversion charts; service tools
• Alphabetical Index

Taken together, the S100 service manual walks a technician from safe lift-and-block setup through system diagnosis, component R&I, overhaul limits, and the specification pages used to confirm pressures, flows, clearances, and fill quantities. Hydraulic and hydrostatic schematics (V-1321, printed October 2018) sit in the hydraulic section for both standard and SJC machines across all three serial families.

Shop Safety, Cab Work, and Service Schedule

Safety pages require jackstands under the front axles and rear corners of the frame before the engine is run for service, and an approved lift arm support whenever arms stay raised. Cab nuts torque to 54–61 N·m (40–45 ft-lb). Remote start kits MEL1563 (tool MEL1563, harnesses MEL1565 / MEL1566) and 7217666 (tool 7022042, harnesses 6689747 / 6689746) are covered so hydraulics and traction can be exercised with the cab raised.

The service schedule starts every 10 hours with engine oil level, air filters and air system, cooling system cleaning, and related daily items. First 50 hours includes the engine/hydrostatic drive belt plus engine oil and filter. Later intervals add spark arrester cleaning, battery cables, fuel filters, drive belts, BICS™ lift-arm bypass check, and first-500-hour valve adjustment. Fuel pages specify ASTM B5 and EN590 B7 blends and warn against biodiesel above five percent. Hydraulic fluid notes ISO VG 46 or ISO VG 46 HVLP with minimum VI 155, and warn against starting when fluid is below -30°C (-20°F).

Hydraulics, Hydrostatics, and Final Drive

Gear-pump capacity in the loader specification table is 36,46 L/min (9.63 U.S. gpm) with standard controls and 37,42 L/min (9.88 U.S. gpm) with SJC. System relief is 20,7 MPa (207 bar) (3000 psi) standard and 19,0 MPa (190 bar) (2755 psi) SJC. Schematic callouts give main relief 20684 kPa (207 bar) (3000 psi) for S/N AB6420001 and A8ET20001, and 19400–20000 kPa (194–200 bar) (2800–2900 psi) for S/N B4KH11001. Charge pump flow on the schematic is 24,2 L/min (6.4 U.S. gpm) at high idle; high-pressure relief/replenishing valves are 29300 kPa (293 bar) (4000 psi). Lift cylinders are 50,8 mm (2.00 in) bore × 31,8 mm (1.25 in) rod × 653,5 mm (25.73 in) stroke; tilt cylinders are 57,2 mm (2.25 in) bore × 31,8 mm (1.25 in) rod × 307,1 mm (12.09 in) stroke.

The hydrostatic drive is fully hydrostatic 4-wheel drive with infinitely variable tandem piston pumps and two reversing motors. Final drive uses #80 HS endless roller chain (no master link), two chains per side, no idler sprocket, in a sealed oil-lubricated chaincase. Axles are 44,7 mm (1.76 in) heat treated. Pump-to-engine hardware torque is given as 88–95 N·m (65–70 ft-lb) in the SJC pump section. Neutral adjustment procedures for SJC pumps require the remote start tool, jackstands, and cold-engine screw settings.

Engine, Electrical, and Cab Heater Work

Engine service is the longest overhaul section. Both serial-family chapters include removal of the engine/hydrostatic pump package with a fabricated lifting tool, four-mount replacement at 95 N·m (70 ft-lb), compression testing with MEL10630 and MEL1352, valve clearance 0,145–0,185 mm (0.0057–0.0073 in) intake and exhaust (cold), firing order 1-3-4-2, and oil pressure targets of 48 kPa (7 psi) at low idle and 200–440 kPa (28.5–64 psi) at high idle. Cylinder bore standard is printed as 78,0–78,019 mm (3.0709–3.0716 in) with a wear limit of 78,5 mm (3.077 in). Glow plugs, injection-pump timing from the flywheel mark, injector service, cylinder head, pistons, connecting rods, crankshaft, camshaft, and flywheel housing are all stepwise procedures.

Electrical work covers a 12-volt system with a 90-ampere belt-driven alternator, 700 CCA battery, 3,2 kW (4.29 hp) starter, and a 100 amp master fuse. Charging tests use 13.5 V as the low-voltage branch point. Service-code tables list engine oil pressure, hydraulic charge, solenoid, and related faults. BICS™ inspection is written both engine-stopped and engine-running: seat bar, PRESS TO OPERATE LOADER, auxiliary lockout, and traction lock. SJC calibration, lift/tilt compensation, steering drift compensation, and drive response are included, along with flywheel rpm sensor air-gap adjustment above the starter.

The heater chapter treats the coolant-fed coil, blower motor, and heater valve, including diagnosis when coolant bypasses the valve or the blower runs with weak airflow.

Specification Data in the Back of the Book

SPEC-10 records machine dimensions (for example overall length 2800 mm / 110.2 in with the standard 50 in dirt bucket), operating weights around 1856–1936 kg (4091–4267 lb), fuel 45,0 L (11.9 U.S. gal), engine oil with filter 4,5 L (4.8 qt), coolant 11,0 L without heater or 12,0 L with heater, hydraulic/hydrostatic reservoir 13,0 L (3.4 U.S. gal), system 22,0 L (5.8 U.S. gal), and chaincase 22,0 L (5.8 U.S. gal). Standard tires are 27 × 8.50–15, 4 ply. Coolant mix is 47% water / 53% propylene glycol; radiator cap 97 kPa (14 psi); thermostat fully open at 85°C (185°F). Fuel-consumption guideline at full load is 9,5 L/h (2.5 U.S. gal/h). Maximum cylinder drift without a bucket is 33 mm (1.3 in) in 10 minutes.

Use This Manual on the Machine You Have

The Bobcat S100 Skid-Steer Loader Service Manual 6987401 (2023) S/N AB6420001 A8ET20001 B4KH11001 supports lift and tilt cylinder rebuilds, main-relief setting, gear-pump and charge-pump tests, hydrostatic pump overhaul and neutral set, chaincase and traction-lock service, engine R&I and internal measurements, charging and starting diagnosis, BICS™ and SJC calibration, heater component replacement, and scheduled fluid/filter work. Correct serial-matched pressures, torques, and clearances keep the interlock system, hydrostatic drive, and lift circuit behaving as designed after the repair.

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