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
• Fire Prevention
• SERIAL NUMBER LOCATIONS
• Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• LOADER IDENTIFICATION
• SAFETY & MAINTENANCE
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• 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 (AHC)
• LIFTING AND BLOCKING THE LOADER
• Procedure
• TRANSPORTING THE BOBCAT LOADER
• Procedure
• TOWING THE LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• Engaging The Lift Arm Support Device
• Disengaging The Lift Arm Support Device
• BOB-TACH
• Inspection and Maintenance
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
• Description
• Inspecting the Seat Bar
• Maintaining the Seat Bar
• SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)
• Description
• Inspecting the Seat Bar
• Maintaining the Seat Bar
• REMOTE START
• Procedure
• SERVICE SCHEDULE
• Chart
• FUEL SYSTEM
• Fuel Specifications
• Filling the Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• AIR CLEANER SERVICE
• Checking
• 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
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing Hydraulic/Hydrostatic Filter
• Replacing Hydraulic Fluid and Case Dain Filters
• Breather Cap
• TIRE MAINTENANCE
• Wheel Nuts
• Rotating
• Mounting
• LUBRICATION OF THE BOBCAT LOADER
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Tighten Procedures
• Troubleshooting Chart
• CYLINDER(S)
• Checking The Lift Cylinders
• Lift Cylinders Removal And Installation
• Checking The Tilt Cylinder
• Tilt Cylinder Removal And Installation
• Lift Cylinder Identification
• Tilt Cylinder Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking
• Adjustment
• Removal and Installation
• BICS™ VALVE
• Removal And Installation
• Lift Arm By-Pass Orifice Dissembly And Assembly
• Check Valve Dissembly And Assembly
• Lock Valve Dissembly And Assembly
• Solenoid Dissembly And Assembly
• Solenoid Testing
• HYDRAULIC CONTROL VALVE (FOOT CONTROL)
• Removal And Installation
• Identification Chart
• Load Check Valve
• Main Relief Valve
• Port Relief Valve
• Anti-Cavitation Valve
• Plug
• Rubber Boot
• Lift And Tilt Lock Block
• Lift Spool and Detent
• Tilt Spool Removal And Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Electric Solenoid Disassembly
• Port-Auxiliary Section Disassembly
• Cleaning And Inspection
• HYDRAULIC CONTROL VALVE (AHC)
• Removal And Installation
• Actuator Removal And Installation
• Identification Chart
• Lift Base End Restrictor
• Load Check Valve
• Main Relief Valve
• Port Relief Valve
• Anti-Cavitation Valve
• Plug
• Lift Spool Removal And Installation
• Tilt Spool Removal And Installation
• Lift and Tilt Spool Disassembly And Assembly
• Auxiliary Spool Removal And Installation
• Auxiliary Electric Solenoid Disassembly
• Port-Auxiliary Section Disassembly
• Cleaning And Inspection
• LIFT ARM BY-PASS CONTROL VALVE
• Inspecting
• Additional Inspection For Loaders With Advanced Hand Controls
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP (ALUMINUM)
• Checking The Output Of The Hydraulic Pump
• Removal And Installation
• 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
• BUCKET POSITION VALVE
• Solenoid Removal And Installation
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY PRESSURE RELIEF BLOCK
• Removal And Installation
• Disassembly And Assembly
• Solenoid Testing
• Solenoid Inspection
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• CONTROL PANEL
• Removal and Installation
• STEERING
• Shock Removal And Installation
• Steering Shaft Removal And Installation
• Shaft Disassembly And Assembly
• Lever Removal And Installation
• Rubber Boot Replacement
• Linkage Removal And Installation
• Linkage Adjustment
• Neutral Adjustment
• STEERING (ADVANCE HAND CONTROL) (AHC)
• Components Identification
• Handle Control Unit Removal And Installation
• Steering Handle Removal and Installation
• Steering Handle Disassembly and Assembly
• Lever Removal and Installation
• Steering Lever Boot
• STEERING (ADVANCED HAND CONTROL) (AHC) W/ PUSH BUTTON FLOAT
• Components Identification
• Handle Sensor Removal And Installation
• Control Handle Removal And Installation
• Control Handle Disassembly And Assembly
• Control Lever Removal And Installation
• Control Lever Boot
• HYDROSTATIC MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• Carrier Shaft Seal Replacement
• Carrier Removal And Installation
• HYDROSTATIC MOTOR
• Carrier Parts Identification
• Carrier Disassembly
• Carrier Assembly
• CHARGE PRESSURE
• Sender Removal And Installation
• Checking Charge Pressure
• Adjusting
• HYDROSTATIC PUMP
• Replenishing/High Pressure Relief Valve
• Removal And Installation
• Parts Identification (Right Half)
• Parts Identification (Left Half)
• Hydraulic Pump Removal And Installation
• Pump Separation
• Disassembly
• Assembly
• DRIVE BELT
• Shield Removal And Installation
• Adjusting
• Drive Belt Replacement
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Parts Identification
• Tensioner Pulley Disassembly
• Tensioner Pulley Assembly
• OIL COOLER
• Removal and Installation
• DRIVE SYSTEM
• BRAKE
• Pedal Removal And Installation
• Pedal Disassembly And Assembly
• Disc Removal And Installation
• DRIVE COMPONENTS
• Axle Seal Removal And Installation
• Axle Sprocket And Bearings Removal And Installation
• Chain Removal And Installation
• CHAINCASE
• Checking And Adding Oil
• Removing The Oil
• Front Cover Removal And Installation
• Center Cover Removal And Installation
• Rear Cover Removal And Installation
• MAIN FRAME
• SEAT BAR
• Removal And Installation
• Assembling Components
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation
• Gas Cylinder Disassembly
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Slide Rail Removal And Installation
• Cushion Removal And Installation
• Back Removal And Installation
• Shock Removal And Installation
• BOB-TACH
• Removal And Installation
• Bob-Tach Lever And Wedge
• Bob-Tach Stops
• LIFT ARM
• Removal And Installation
• REAR GRILL
• Gas Cylinder Removal And Installation
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Door Latch And Catch Adjustment
• Door Latch Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• WIRING SCHEMATICS
• Troubleshooting Chart
• Description
• Fuse Location
• Relay Switch Location
• Solenoid Test
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Adjusting The Alternator Belt
• Alternator Output Test
• Rectifier (Diode) Test
• Alternator Regulator Test
• Removal And Installation
• Disassembly
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Rectifier Continuity (Diode) Test
• Assembly
• STARTER
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection And Repair
• No Load Test
• Assembly
• INSTRUMENT PANEL
• Left Panel
• Right Panel – (Standard) (With Key Switch)
• Right Panel – (Deluxe) (With Keyless Start)
• Right Panel Setup Display Options (Deluxe)
• Passwords
• Option and Field Accessory Panels
• Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• BOBCAT CONTROLLER
• Identification Chart
• Removal And Installation
• DIAGNOSTICS
• Service Codes
• BICS™ SYSTEM
• 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 (AHC)
• Troubleshooting Chart
• Troubleshooting Guide.
• SEAT BAR SENSOR
• Troubleshooting Chart
• Test
• Removal And Installation
• BICS™ Circuit Test
• TRACTION LOCK
• Troubleshooting Chart
• Inspecting
• Solenoid Removal And Installation
• Guide Removal
• Guide Installation
• ADVANCED HAND CONTROL (AHC) SYSTEM
• Components Identification
• ADVANCED HAND CONTROL (AHC) SYSTEM
• Troubleshooting Guide
• Parts Identification
• AHC Controller Removal And Installation
• Handle Control Unit Connector
• Switch Handle Removal and Installation
• Actuators Disassembly and Assembly
• ADVANCED HAND CONTROL (AHC) SYSTEM
• (W/PUSH BUTTON FLOAT)
• Components Identification
• Troubleshooting Guide
• Controller Connector And Wire Identification
• AHC Controller Removal And Installation
• Handle Sensor Removal And Installation
• Handle Sensor Connector
• Switch Handle Removal And Installation
• Actuators Disassembly And Assembly
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
• Controls Identification Chart
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Removal And Installation
• Disassembly
• MUFFLER
• Removal And Installation
• Spark Arrestor Cleaning Procedure
• AIR CLEANER
• Replacing Filter Element(s)
• Removal And Installation
• RADIATOR
• Removal And Installation
• COOLING FAN
• Drive Tension Pulley Removal And Installation
• Gearbox/Blower Housing Removal And Installation
• Blower Housing Grill Removal And Installation
• Blower Disassembly And Assembly
• Gearbox Parts Identification
• Gearbox Disassembly
• Gearbox Assembly
• Gearbox Checking Backlash
• ENGINE COMPONENTS AND TESTING
• Compression Checking
• Glow Plugs Checking
• Glow Plugs Removal And Installation
• Fuel Shut-Off Solenoid, Checking
• Fuel Shut-Off Solenoid, Adjusting
• Fuel Shut-Off Solenoid Removal And Installation
• Checking
• Fuel Injection Pump Removal And Installation
• Timing The Injection Pump
• Fuel Injector Removal And Installation
• Fuel Injector Checking
• Fuel Injector Disassembly
• Fuel Injector Assembly
• Valve Clearance Adjustment
• Rocker Arm And Shaft Checking
• Valve Timing, Checking
• ENGINE
• Removal And Installation
• Engine Mount Replacement
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• RECONDITIONING THE ENGINE
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head Servicing
• Cylinder Head Top Clearance
• Checking The Valve Guide
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Rocker Arm And Shaft Checking
• Timing Gearcase Cover Removal And Installation
• Idler Gear And Camshaft Removal And Installation
• Servicing The Camshaft
• Servicing The Idler Gear And Shaft
• Timing Gears Checking Backlash
• Fuel Camshaft Removal And Installation
• Fuel Camshaft 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
• Checking The Cylinder Bore
• Water Pump Disassembly And Assembly
• HEATER
• COMPONENTS
• Identification
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• BASIC TROUBLESHOOTING
• Cleaning The Heater Coil
• Checking The Electrical System
• Engine Coolant By-Passing The Heater Valve
• Heater Valve Not Opening Or Closing
• SYSTEM TROUBLESHOOTING CHART
• Blower Motor Does Not Operate
• Blower motor operators normally, but air flow is insufficient
• HEATER UNIT
• Removal And Installation
• Disassembly And Assembly
• HEATER COIL
• Removal And Installation
• HEATER FAN
• Removal And Installation
• Disassembly And Assembly
• Wire Connector Removal and Installation
• HEATER VALVE
• Removal and Installation
• Disassembly And Assembly
• 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
• LOADER TORQUE
• Specifications
• 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
• O-ring Flare Fitting
• Port Seal Fitting
• HYDRAULIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion
• SMR
• Revision No: 751-1
• Revision No: 751-2