A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• SAFETY INSTRUCTIONS
• SERIAL NUMBER LOCATIONS
• LOADER SERIAL NUMBER
• ENGINE SERIAL NUMBER
• DELIVERY REPORT
• 553 BOBCAT LOADER IDENTIFICATION
• OPTIONS AND ACCESSORIES
• PREVENTIVE MAINTENANCE
• SERVICE SCHEDULE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• TRANSPORTING THE LOADER
• Procedure
• LIFTING THE LOADER
• Single Point Lift
• TOWING THE LOADER
• Procedure
• STOPPING THE BOBCAT LOADER
• LIFT ARM SUPPORT DEVICE
• Installing And Removing Lift Arm Support Device
• OPERATOR CAB
• Description
• Emergency Exit
• Raising The Operator Cab
• Lowering The Operator Cab
• SEAT BAR RESTRAINT SYSTEM
• Description
• Seat Bar Inspection
• Seat Bar Maintenance
• AIR CLEANER SERVICE
• Replacing Filter Element
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Replacing Oil And Filter
• ENGINE COOLING SYSTEM
• Checking The Coolant Level
• Propylene Glycol
• Cleaning The Cooling System
• Removing Coolant From The Cooling System
• ALTERNATOR BELT
• Adjusting The Alternator Belt
• USING A BOOSTER BATTERY (Jump Starting)
• Procedure
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing Hydraulic/Hydrostatic Filter
• Replacing The Hydraulic Fluid
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Rotation
• Tire Mounting
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• Removing Oil From The Chaincase
• LUBRICATION OF THE LOADER
• Procedure
• REMOTE START SWITCH
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• TROUBLESHOOTING
• HYDRAULIC SYSTEM INFORMATION
• Flare Connections
• O–ring Face Seal Connection
• Straight Thread O–ring Fitting
• Tubelines and Hoses
• LIFT CYLINDER(S)
• Removal and Installation
• Checking The Lift Cylinder(s) For Internal Leakage
• TILT CYLINDER
• Removal And Installation
• Checking The Tilt Cylinder For Internal Leakage
• HYDRAULIC CYLINDER IDENTIFICATION
• Lift Cylinder Components
• Tilt Cylinder Components
• HYDRAULIC CYLINDER
• Disassembly
• Assembly
• HYDRAULIC CONTROL VALVE
• Removal And Installation
• Checking The Main Relief Valve
• Main Relief Valve Removal And Installation
• Main Relief Valve Adjustment
• Identification Chart
• Disassembly And Assembly
• Load Check Valve
• Main Relief Valve
• Anti–Cavitation Valve
• Rubber Boot
• Lift Spool Detent
• Tilt Centering Spring
• Auxiliary Spool Detent
• One Way Restrictors
• Inspection
• Spool Seal Installation
• HYDRAULIC PUMP
• Removal And Installation
• Checking The Output Of The Hydraulic Pump
• Main Relief Valve Adjustment
• Parts Identification
• Disassembly and Assembly
• Inspection
• HYDRAULIC FILTER HOUSING
• Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• CONTROL PEDALS
• Removal And Installation
• Pedal Adjustment
• PEDAL INTERLOCK LINKAGE
• Removal And Installation
• Adjustment
• CROSSMEMBER LINKAGE
• Removal And Installation
• HYDROSTATIC SYSTEM
• TROUBLESHOOTING
• HYDROSTATIC SYSTEM INFORMATION
• Replenishing Valve Function
• CONTROL PANEL
• Removal And Installation
• STEERING LEVERS
• Removal And Installation
• Disassembly And Assembly
• STEERING LINKAGE
• Removal And Installation
• Pintle Lever Disassembly And Assembly
• Steering Neutral Adjustment
• HYDR0STATIC PUMP
• Checking Charge Pressure
• Removal And Installation
• Drive Coupler Removal And Installation
• Parts Identification
• Disassembly and Assembly
• Inspection
• PORT BLOCK
• Removal And Installation
• Oil Cooler Bypass Valve
• Hydraulic Oil Temperature Switch
• Charge Pressure Bypass Valve
• HYDROSTATIC DRIVE MOTOR
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Inspection
• Timing The Hydrostatic Motor
• DRIVE SYSTEM
• PARKING BRAKE
• Removal And Installation
• Disassembly And Assembly
• PARKING BRAKE DISC
• Removal And Installation
• Brake Disc Guide Removal And Installation
• CHAINCASE FLUID
• Removing Oil From The Chaincase
• CHAINCASE COVERS
• Front Cover Removal And Installation
• Rear Cover Removal And Installation
• AXLE SEAL
• Removal And Installation
• AXLE, BEARINGS, AND SPROCKET
• Removal And Installation
• DRIVE CHAIN
• Removal
• MAIN FRAME
• SEAT BAR
• Removal And Installation
• Assembly
• Compressing The Gas Cylinder
• OPERATOR CAB GAS CYLINDER
• Removal And Installation
• Disassembly And Assembly
• OPERATOR CAB
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• BOB–TACH
• Removal And Installation
• Bob–Tach Lever And Wedge
• LIFT ARMS
• Removal And Installation
• REAR GRILL
• Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• REAR DOOR
• Removal And Installation
• Door Handle Adjustment
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• TROUBLESHOOTING
• ELECTRICAL SYSTEM INFORMATION
• Description
• Fuse Location
• Relay Switches Location
• Removing And Installing The Battery
• ALTERNATOR
• Alternator Belt Shield Removal And Installation
• Removal And Installation
• Adjusting The Alternator Belt
• Alternator Output Test
• Rectifier (Diode) Test
• Alternator Regulator Test
• Disassembly And Inspection – Parts Identification
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Rectifier Continuity (Diode) Test
• Assembly
• STARTER
• Removal And Installation
• Checking The Starter
• Disassembly And Assembly
• Parts Identification
• Cleaning And Inspection
• Replacing The Brushes
• INSTRUMENT PANEL
• Removal And Installation
• FRONT LIGHTS
• Removal And Installation
• ENGINE SERVICE
• TROUBLESHOOTING
• ENGINE SPEED CONTROL
• Removal And Installation
• Disassembly
• Linkage Bar Removal And Installation
• RADIATOR
• Removal And Installation
• ENGINE MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• FUEL FILTER
• Removal And Installation
• ENGINE
• Removal And Installation
• U–JOINT COUPLER
• Removal And Installation
• Disassemly And Assembly
• FLYWHEEL
• Removal And Installation
• Flywheel Ring Gear
• BLOWER FAN HOUSING
• Removal And Installation
• ENGINE COMPRESSION
• Checking
• GLOW PLUGS
• Checking
• Removal And Installation
• FUEL INJECTION PUMP
• Checking The Injection Pump
• Removal And Installation
• Timing The Injection Pump
• FUEL INJECTOR NOZZLES
• Removal
• Installation
• Checking Fuel Injector Nozzles
• CYLINDER HEAD
• Removal
• Installation
• Disassembly
• Assembly
• Servicing The Cylinder Head
• TIMING GEARCASE COVER
• Removal
• Installation
• TIMING GEARS AND CAMSHAFT
• Removal
• Installation
• Servicing The Timing Gear And The Camshaft
• OIL PUMP
• Removal And Installation
• Servicing The Oil Pump
• WATER PUMP
• Removal And Installation
• PISTONS AND CRANKSHAFT
• Piston And Camshaft Removal
• Piston Installation
• Servicing The Pistons And Connecting Rods
• Crankshaft Installation
• Servicing The Crankshaft
• Servicing The Cylinder Liners
• BICS™ SYSTEM
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• Inspecting The BICS System Controller (Engine STOPPED – Key ON)
• Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm By–Pass Control
• Maintenance
• Troubleshooting Chart
• TROUBLESHOOTING GUIDE
• BICS CONTROLLER
• TRACTION LOCK
• SEAT SENSOR
• SEAT BAR SENSOR
• LIFT LOCK BYPASS VALVE
• BICS™ SYSTEM CONTROLLER
• Removal And Installation
• Controller Test
• SEAT BAR SENSOR
• Removal And Installation
• Seat Bar Sensor Test
• SEAT SENSOR
• Removal And Installation
• Seat Sensor Test
• TRACTION LOCK
• Removal And Installation
• LIFT LOCK BYPASS VALVE
• Removal And Installation
• Disassembly And Assembly
• TILT LOCK VALVE
• Removal And Installation
• Disassembly And Assembly
• SPECIFICATIONS
• LOADER SPECIFICATIONS
• LOADER DIMENSIONS
• OPERATIONS & PERFORMANCE
• ENGINE
• HYDRAULIC SYSTEM
• ELECTRICAL
• DRIVE SYSTEM
• CAPACITIES
• TIRES
• VIBRATION DATA
• ENGINE SPECIFICATIONS
• Fuel Injection Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Rocker Arms
• Camshaft
• Cylinders
• Piston Rings
• Pistons
• Crankshaft
• Oil Pump
• Thermostat
• Grinding Specifications for the Crankshaft
• TORQUE SPECIFICATIONS FOR LOADER
• Specifications
• HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• METRIC TORQUE SPECIFICATIONS FOR BOLTS
• STANDARD TORQUE SPECIFICATIONS FOR BOLTS
• DECIMAL AND MILLIMETER EQUIVALENTS
• U.S. TO METRIC CONVERSION
• SERVICE MANUAL REVISIONS
• 553-1