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 SKID STEER LOADER IDENTIFICATION
• PREVENTIVE MAINTENANCE
• SERVICE SCHEDULE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• TOWING THE LOADER
• Procedure
• STOPPING THE BOBCAT LOADER
• LIFT ARM SUPPORT DEVICE
• Engaging The Lift Arm Support Device
• Disengaging The Lift Arm Support Device
• OPERATOR CAB
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• 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
• Oil Chart
• Replacing Oil And Filter
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Replacing The Coolant
• ALTERNATOR BELT
• Adjusting The Alternator Belt
• HYDRAULIC/HYDROSTATIC SYSTEM
• Description
• Checking And Adding Fluid
• Replacing The Hydraulic/Hydrostatic Filter
• Replacing Hydraulic Fluid
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Rotation
• Tire Mounting
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• LUBRICATING THE BOBCAT LOADER
• Procedure
• PIVOT PINS
• BOB–TACH
• Inspection And Maintenance
• AUXILIARY CONTROL LOCKBOLT
• Removal
• U–JOINT LUBRICATION
• Procedure
• REMOTE START SWITCH
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS
• TROUBLESHOOTING
• HYDRAULIC SYSTEM INFORMATION
• Tighten Procedures
• LIFT CYLINDERS
• Checking The Lift Cylinder(s)
• Removal And Installation
• TILT CYLINDER
• Checking The Tilt Cylinder
• Removal And Installation
• HYDRAULIC CYLINDER
• Lift Cylinder Identification
• Tilt Cylinder Identification
• Disassembly And Assembly
• MAIN RELIEF VALVE
• Checking The Main Relief Valve Without Auxiliaries
• Checking The Main Relief Valve With Auxiliaries
• Removal And Installation
• Adjustment
• HYDRAULIC CONTROL VALVE
• Removal And Installation
• Identification Chart
• Disassembly and Assembly
• Load Check Valve
• Main Relief Valve
• Anti–Cavitation Check Valve
• Rubber Boot
• Lift Spool Detent
• Tilt Centering Spring
• One Way Restrictors
• Inspection
• Spool Seal Installation
• HYDRAULIC PUMP
• Checking The Output Of The Hydraulic Pump
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Inspection
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• LIFT LOCK BY–PASS VALVE
• Removal And Installation
• Disassembly and Assembly
• TILT LOCK VALVE
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC FILTER HOUSING
• 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
• HYDROSTATIC MOTOR
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Inspection
• Timing The Hydrostatic Motor
• HYDROSTATIC 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 By–Pass Valve
• Hydraulic Oil Temperature Switch
• Charge Pressure By–Pass Valve
• OIL COOLER
• Removal and Installation
• DRIVE SYSTEM
• PARKING BRAKE
• Removal And Installation
• Disassembly And Assembly
• PARKING BRAKE DISC
• Removal and Installation
• TRACTION LOCK GUIDES
• 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
• 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
• REAR DOOR
• Removal And Installation
• Door Latch Adjustment
• Striker Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)
• Striker Disassembly And Assembly (S/N 516313551 & Above) & (S/N 516415035 & Above)
• Adjusting The Striker (S/N 516313551 & Above) & (S/N 516415035 & Above)
• Latch Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• BOB–TACH
• Removal And Installation
• Bob–Tach Lever And Wedge
• LIFT ARMS
• Removal and Installation
• REAR GRILL
• Removal And Installation
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• TROUBLESHOOTING
• ELECTRICAL SYSTEM INFORMATION
• Description
• Fuse Location
• Relay Switches Location
• BATTERY
• Removal And Installation
• USING A BOOSTER BATTERY (JUMP STARTING)
• Procedure
• ALTERNATOR
• Removal And Installation
• Adjusting The Alternator Belt
• Description
• Tests
• Alternator Output Test
• Full Field Test
• Alternator Regulator Test
• Alternator Regulator Test With Voltmeter
• Parts Identification
• Pulley Removal And Installation
• Disassembly And Assembly
• Rotor Continuity Test
• Stator Continuity Test
• Rectifier Continuity (Diode) Test
• Brush Length
• STARTER
• Removal And Installation
• Checking The Starter In The Loader
• Parts Identification
• Disassembly
• Inspection And Repair
• No Load Test
• Assembly
• 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
• ENGINE
• Removal And Installation
• U–JOINT COUPLER
• Removal And Installation
• Disassembly and Assembly
• RUBBER DRIVE COUPLER
• Removal And Installation
• Disassembly
• Assembly
• FLYWHEEL
• Removal And Installation
• FLYWHEEL HOUSING
• Flywheel Ring Gear
• Removal And Installation
• ENGINE MOUNTING BRACKETS
• Removal and Installation
• BLOWER FAN HOUSING
• Removal And Installation
• ENGINE COMPRESSION
• Checking
• GLOW PLUGS
• Checking
• Removal And Installation
• FUEL SHUT–OFF SOLENOID
• Removal And Installation
• FUEL LIFT PUMP
• Removal And Installation
• FUEL INJECTION PUMP
• Checking The Injection Pump
• Removal And Installation
• Timing The Injection Pump
• FUEL INJECTOR NOZZLES
• Removal and Installation
• Checking Fuel Injector Nozzles
• THERMOSTAT
• Removal And Installation
• WATER PUMP
• Removal And Installation
• TIMING GEAR CASE COVER
• Removal And Installation
• OIL PUMP
• Removal And Installation
• CRANKSHAFT FRONT SEAL
• Removal And Installation
• ENGINE SPEED CONTROL PLATE
• Removal And Installation
• Governor Spring Removal
• Start Spring Removal
• Idle Limit And Fuel Limit Adjustment
• EXHAUST MANIFOLD
• Removal And Installation
• VALVE COVER
• Removal And Installation
• ROCKER ARM
• Removal And Installation
• PUSH ROD
• Removal And Installation
• TAPPET
• Removal And Installation
• WATER FLANGE
• Removal And Installation
• CYLINDER HEAD
• Removal
• Installation
• Checking Piston Top Clearance
• Disassembly
• Assembly
• Servicing The Cylinder Head
• Combustion Chamber Removal And Installation
• IDLER GEAR
• Removal And Installation
• CAMSHAFT
• Removal And Installation
• FUEL CAMSHAFT
• Removal And Installation
• OIL PAN
• Removal And Installation
• GOVERNOR SHAFT
• Removal And Installation
• GOVERNOR FORK LEVER
• Removal And Installation
• PISTON
• Removal And Installation
• Checking The Piston And Connecting Rod
• Connecting Rod Alignment
• Piston Ring Gap
• Piston Ring Installation
• Connecting Rod Installation
• Checking Engine Cylinder Bore
• CRANKSHAFT
• Removal And Installation
• Checking Crankshaft Journal And Block Bearing
• Checking The Crankshaft Journal And Main Bearing
• Connecting Rod Journal
• Checking The End Play Of The Crankshaft
• Crankshaft Alignment
• ENGINE TIMING
• Installation
• TIMING GEAR BACKLASH
• Idler Gear And Crankshaft
• Idler Gear And Camshaft Gear
• Idler Gear And Fuel Camshaft Gear
• Fuel Camshaft Gear And Governor Shaft Gear
• 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)
• nspecting 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
• 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)
• nspecting 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
• SPECIFICATIONS
• LOADER SPECIFICATIONS
• Loader Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS
• Engine Compression
• 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
• 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
• SERVICE MANUAL REVISIONS
• 553-1
• 553-2
• 553-3