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
• ALPHABETICAL INDEX
• CONTENTS
• FOREWORD
• SAFETY INSTRUCTIONS
• SERIAL NUMBER LOCATIONS
• LOADER SERIAL NUMBER
• ENGINE SERIAL NUMBER
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• PREVENTIVE MAINTENANCE
• SERVICE SCHEDULE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• TRANSPORTING THE LOADER
• Procedure
• TOWING THE LOADER
• Procedure
• STOPPING THE BOBCAT LOADER
• LIFTING THE LOADER
• Four Point Lift
• Single Point Lift
• LIFT ARM SUPPORT DEVICE
• Engaging The Lift Arm Support Device
• Disengaging The Lift Arm Support Device
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• SEAT BAR RESTRAINT SYSTEM (Foot Pedals)
• Description
• Seat Bar Inspection
• Seat Bar Maintenance
• SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)
• Description
• Seat Bar Inspection
• Seat Bar Maintenance
• SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)
• 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
• Oil Chart
• Replacing Oil And Filter
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing The Coolant
• ALTERNATOR BELT
• Adjusting
• FAN GEARBOX
• Checking And Maintaining
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing Hydraulic/Hydrostatic Filter
• Replacing Hydraulic Fluid
• Breather Cap
• 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
• DRIVE BELT
• Adjusting the Drive Belt
• Replacing The Drive Belt
• LUBRICATION OF THE BOBCAT LOADER
• Procedure
• PIVOT PINS
• BOB–TACH
• Inspection and Maintenance
• REMOTE START SWITCH
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• GLOSSARY OF HYDRAULIC/HYDROSTATIC SYMBOLS FOR LOADERS
• TROUBLESHOOTING
• HYDRAULIC SYSTEM INFORMATION
• Tightening Procedures
• LIFT CYLINDER(S)
• Checking The Lift Cylinders
• Removal And Installation
• TILT CYLINDER
• Checking The Tilt Cylinder
• Removal And Installation
• Rod End Seal Replacement
• HYDRAULIC CYLINDER IDENTIFICATION
• Lift Cylinder Components
• Tilt Cylinder Components
• HYDRAULIC CYLINDERS
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking
• Adjustment
• Removal And Installation
• BICS™ VALVE
• Lift Arm By–Pass Orifice
• Lock Valve
• Check Valve
• BICS™ Valve Solenoid
• Removal
• Installation
• HYDRAULIC CONTROL VALVE
• Removal And Installation
• Identification Chart
• Disassembly
• Load Check Valve
• Lift Base End Restrictor
• Main Relief Valve
• Port Relief Valve (Lift)
• Anti–Cavitation
• Rubber Boot
• Lift Spool And Detent
• Tilt Spool And Centering Spring
• Inspection
• Auxiliary Spool
• Auxiliary Electric Solenoid
• Port–Auxiliary Section
• Cleaning and Inspection
• Spool Seal Installation
• HYDRAULIC PUMP
• Checking The Output Of The Hydraulic Pump
• Removal And Installation
• Disassembly And Assembly
• Inspection
• Identification
• HYDRAULIC FILTER HOUSING
• Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• CONTROL PEDALS
• Removal And Installation
• Pedal Adjustment
• CONTROL INTERLOCK LINKAGE (Pedal or Mechanical Hand)
• Adjustment
• Removal And Installation
• LIFT LOCK BY–PASS VALVE
• Removal And Installation
• Disassembly And Assembly
• HYDROSTATIC SYSTEM
• TROUBLESHOOTING
• HYDROSTATIC SYSTEM INFORMATION
• Replenishing Valve Function
• Checking Charge Pressure
• CONTROL PANEL
• Removal And Installation
• Steering Shaft Removal And Installation
• Steering Shaft Disassembly And Assembly
• Steering Lever Removal And Installation
• Rubber Boot Replacement
• STEERING LINKAGE
• Removal And Installation
• Steering Linkage Adjustment
• HYDROSTATIC DRIVE MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• HYDROSTATIC PUMP
• Removal And Installation
• Identification
• Disassembly And Assembly
• Inspection
• DRIVE BELT HOUSING
• Removal And Installation
• SPRING LOADED DRIVE BELT TENSIONER PULLEY
• Removal And Installation
• Identification
• Disassembly
• Assembly
• OIL COOLER
• Removal And Installation
• DRIVE SYSTEM
• PARKING BRAKE
• Removal And Installation
• Disassembly And Assembly
• PARKING BRAKE DISC
• Removal And Installation
• TRACTION LOCK GUIDES
• Disassembly
• Assembly
• CHAINCASE FLUID
• Removing Oil From The Chaincase
• CHAINCASE COVERS
• Center Chaincase Cover Removal And Installation
• Front Chaincase Cover Removal And Installation
• Rear Chaincase Cover Removal And Installation
• MOTOR CARRIER
• Shaft Seal Replacement
• Removal And Installation
• Disassembly
• Assembly
• AXLE SEAL
• Removal and Installation
• AXLE, SPROCKET AND BEARINGS
• Removal And Installation
• DRIVE CHAIN
• Removal And Installation
• MAIN FRAME
• SEAT BAR (W/COMPRESSION SPRINGS)
• Removal And Installation
• Assembling Components
• Compression Spring Disassembly And Assembly
• OPERATOR CAB GAS CYLINDER
• Removal And Installation
• Disassembly And Assembly
• OPERATOR CAB
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• BOB–TACH
• Bob–Tach Lever And Wedge
• Removal And Installation
• Bob–Tach Stops
• LIFT ARMS
• Removal And Installation
• REAR GRILL
• Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• REAR DOOR
• Removal And Installation
• Door Latch Removal And Installation
• Door Latch And Catch Adjustment
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• TROUBLESHOOTING
• ELECTRICAL SYSTEM INFORMATION
• Description
• Fuse Location
• BATTERY
• Removal And Installation
• Servicing The Battery
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Alternator Output Test
• Rectifier (Diode) Test
• Alternator Regulator Test
• Removal And Installation
• Adjusting The Alternator Belt
• Disassembly And Inspection
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Rectifier Continuity (Diode) Test
• Assembly
• STARTER
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection And Repair
• No Load Test
• Assembly
• STANDARD INSTRUMENT PANEL
• Removal And Installation
• FRONT LIGHTS
• Removal And Installation
• RELAY SWITCHES
• Location
• ENGINE SERVICE
• TROUBLESHOOTING
• ENGINE SPEED CONTROL
• Removal And Installation
• Disassembly
• RADIATOR
• Removal And Installation
• ENGINE MUFFLER
• Removal And Installation
• BLOWER HOUSING/FAN GEARBOX
• Removal And Installation
• Tension Pulley Removal And Installation
• Blower Fan Disassembly And Assembly
• FAN GEARBOX
• Identification
• Disassembly
• Assembly
• Checking Backlash
• AIR CLEANER
• Removal And Installation
• ENGINE
• Removal And Installation
• Engine Mount Replacement
• FLYWHEEL
• Removal And Installation
• Flywheel Ring Gear
• ENGINE COMPRESSION
• Checking
• GLOW PLUGS
• Checking The Glow Plugs
• Removal And Installation
• FUEL INJECTION PUMP
• Checking The Injection Pump
• Adjusting Shut–Off Linkage
• Removal And Installation
• Timing The Injection Pump
• FUEL INJECTION NOZZLES
• Removal And Installation
• Checking The Injector Nozzle
• CYLINDER HEAD
• Removal And Installation
• Disassembly And Assembly
• Servicing The Cylinder Head
• Top Clearance
• VALVE, VALVE SEAT AND GUIDE
• Checking The Valve Guide
• Valve Spring
• VALVE CLEARANCE
• Adjustment
• ROCKER ARM AND SHAFT
• Checking
• TIMING GEARCASE COVER
• Removal And Installation
• IDLER GEAR AND CAMSHAFT
• Servicing The Camshaft
• Removal And Installation
• Servicing The Idler Gear And Shaft
• TIMING GEARS
• Checking Backlash
• FUEL CAMSHAFT
• Removal And Installation
• Governor
• CRANKSHAFT GEAR
• Removal And Installation
• OIL PUMP
• Removal And Installation
• Oil Pump Service
• Checking Engine Oil Pressure
• Relief Valve
• PISTON AND CONNECTING ROD
• Removal And Installation
• Servicing The Piston And Connecting Rod
• Connecting Rod Alignment
• CRANKSHAFT AND BEARINGS
• Removal And Installation
• Servicing the Crankshaft and Bearings
• CYLINDER BORE
• Checking The Cylinder Bore
• WATER PUMP
• Disassembly And Assembly
• SYSTEMS ANALYSIS
• BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM
• BICS™ (With Press To Operate Button)
• Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
• Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
• Inspecting The Seat Bar Sensor (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm By–Pass Control
• Additional Inspection For Loaders With Advanced Hand Controls
• Troubleshooting Chart
• ADVANCED HAND CONTROLS (AHC)
• Troubleshooting Chart
• BICS™ (Without Press To Operate Button)
• Inspecting The BICS Controller (Engine STOPPED –Key ON)
• Inspecting Deactivation Of The Auxiliary Hydraulics System (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
• BICS™ SYSTEM CONTROLLER
• Troubleshooting Guide
• Removal And Installation
• SEAT BAR SENSOR
• Troubleshooting Guide
• Seat Bar Sensor Test
• Removal And Installation
• BICS™ Controller Seat Bar Sensor Circuit Test
• SEAT SENSOR
• Troubleshooting Guide
• Seat Sensor Test
• Removal And Installation
• BICS™ Controller Seat Sensor Circuit Test
• TRACTION LOCK
• Troubleshooting Guide
• Removal And Installation
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
• Controls Identification Chart
• SPECIFICATIONS
• LOADER SPECIFICATIONS
• SPECIFICATIONS
• PERFORMANCE
• CONTROLS
• ENGINE
• HYDRAULIC SYSTEM
• ELECTRICAL
• DRIVE SYSTEM
• CAPACITIES
• TIRES
• FLOOR PRESSURE
• ENGINE SPECIFICATIONS
• Fuel Injection Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Valve Timing
• Rocker Arms
• Camshaft
• Tappet
• Cylinders
• Piston Rings
• Pistons
• Connecting Rod
• Oil Pump
• Crankshaft
• Timing Gear
• Thermostat
• Crankshaft Re–Grind Data
• Torque For General Metric Bolts
• HYDRAULIC CONNECTION SPECIFICATIONS
• O–Ring Face Seal Connection
• Straight Thread O–ring Fitting
• Tubelines And Hoses
• Flare Fitting
• O–Ring Flare Fitting
• Port Seal Fitting
• TORQUE SPECIFICATIONS FOR LOADER
• HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
• STANDARD TORQUE SPECIFICATIONS FOR BOLTS
• DECIMAL AND MILLIMETER EQUIVALENTS
• U.S. TO METRIC CONVERSION
• ADVANCE HAND CONTROL SYSTEM (AHC)
• ELECTRICAL SCHEMATICS W/ADVANCED HAND CONTROL OPTIONS
• AHC COMPONENTS
• Identification
• TROUBLESHOOTING (AHC)
• Chart
• ACTUATOR VOLTAGE TEST
• Procedure
• HANDLE CONTROL UNIT TEST
• Procedure
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• Troubleshooting Chart
• ADVANCED HAND CONTROLS (AHC)
• Troubleshooting Chart
• AHC/PWM CONTROLLER
• Removal And Installation
• Description
• Conditions
• Troubleshooting Chart
• Handle Testing
• Solenoid Coil Testing
• CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
• Control Handle Unit Removal And Installation
• Control Unit Connector
• Switch Handle Removal And Installation
• AHC Handle Removal And Installation
• AHC Handle Disassembly And Assembly
• AHC Steering Lever Removal And Installation
• AHC Steering Lever Boot
• Actuators Removal And Installation
• Actuators Disassembly And Assembly
• CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)
• Components Identification
• Controller Connector And Wire Identification
• AHC/PWM Controller Removal And Installation
• Handle Sensor Removal And Installation
• Handle Sensor Connector
• Switch Handle Removal And Installation
• Control Handle Removal And Installation
• Control Handle Disassembly And Assembly
• Control Lever Removal And Installation
• Control Lever Boot
• Actuators Disassembly And Assembly
• Components Identification
• BICS™ VALVE
• Lift Arm By–Pass Orifice
• Check Valve
• Lock Valve
• BICS™ Valve Solenoid
• Removal And Installation
• HYDRAULIC CONTROL VALVE
• Removal And Installation
• Identification Chart
• Disassembly And Assembly
• Load Check Valve
• Lift Base End Restrictor
• Main Relief Valve
• Port Relief Valve (Lift)
• Anti–Cavitation/Port Relief Valve
• Port Relief Valve (Tilt)
• Anti–Cavitation Valve
• Rubber Boot
• Lift And Tilt Spool
• Inspection
• Auxiliary Spool
• Auxiliary Electrical Solenoid
• Spool Seal Installation
• H–Port Auxiliary Section
• SERVICE MANUAL REVISIONS
• 751–1
• 751–2
• 751–3
• 751–4