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
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Work Machine Serial Number
• Engine Serial Number
• DELIVERY REPORT
• BOBCAT UTILITY WORK MACHINE IDENTIFICAITON
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE MACHINE
• Procedure For Jackstand Placement On The Axle
• Procedure For Jackstand Placement On The Frame
• LIFT ARM SUPPORT DEVICE
• Installing The Lift Arm Support Device
• Removing the Lift Arm Support Device
• CARGO BOX SUPPORT DEVICE
• Installing The Cargo Box Support Device
• Removing the Cargo Box Support Device
• OPERATOR CAB
• Description
• TRANSPORTING THE TOOLCAT
• Loading Onto Transport Vehicle
• Fastening To Transport Vehicle
• TOWING THE MACHINE
• Procedure
• REMOTE START
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Elements
• ENGINE COOLING SYSTEM
• Checking The Coolant Level
• Cleaning The Cooling System
• Removing & Replacing Coolant
• 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 The Oil And Filter
• HYDRAULIC / HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing Hydraulic/Hydrostatic Filter
• Replacing Hydraulic Fluid
• Hydraulic Fluid Chart
• Reservoir Breather
• AXLE/DIFFERENTIAL (FRONT & REAR)
• Checking And Adding Lubricant
• Replacing Lubricant
• BOB-TACH
• Inspection And Maintenance
• LUBRICATION
• Lubrication Locations
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Rotation
• Mounting
• SPARK ARRESTOR MUFFLER
• Maintenance
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary
• Tighten Procedures
• Troubleshooting Chart
• CYLINDER (LIFT)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (CARGO BOX)
• Checking (Left Side Cylinder)
• Checking (Right Side Cylinder)
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking
• Adjustment
• Removal And Installation
• PORT RELIEFS
• Checking The Port Relief Valve (Lift)
• Checking The Port Relief Valves (Tilt)
• WORK VALVE
• Removal And Installation
• Disassembly and Assembly
• STEERING AND CARGO BOX VALVE
• Removal And Installation
• Disassembly and Assembly
• AUXILIARY HYDRAULIC VALVE
• Removal And Installation
• Disassembly And Assembly
• POWER STEERING PUMP
• Removal And Installation
• Disassembly And Assembly
• PILOT VALVE
• Removal And Installation
• Disassembly And Assembly
• LIFT ARM BY-PASS CONTROL VALVE
• Inspecting
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Checking The Auxiliary Section Of The Hydraulic Pump
• Checking The Work Group Section Of The Hydraulic Pump
• Checking The Steering And Cargo Box Section Of The Hydraulic Pump
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC/HYDROSTATIC FILTER
• Housing Removal And Installation
• CONTROL LEVER (JOYSTICK)
• Joystick Handle Removal And Installation
• Joystick Removal And Installation
• Joystick Disassembly and Assembly
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
• Removal And Installation
• Disassembly And Assembly
• REMOTE HYDRAULICS DIVERTER VALVE
• Removal And Installation
• Disassembly And Assembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• HYDROSTATIC MOTOR
• Removal and Installation (Front Axle)
• Removal and Installation (Rear Axle)
• Disassembly
• Assembly
• CHARGE PRESSURE
• Checking Charge Pressure
• HYDROSTATIC PUMP
• Removal and Installation
• Directional Control Valve Removal and Installation
• PWM Control Valve Removal and Installation
• Replenishing/High Pressure Relief Valve
• Charge Relief Valve
• Disassembly
• Inspection
• Assembly
• Hydrostatic Pump Start-Up
• Neutral Adjustment
• 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
• Disassembly & Assembly (Front Axle)
• Disassembly & Assembly (Rear Axle)
• AXLE
• Front Axle Brush Guard Removal And Installation (S/N 520511246 & Below)
• Front Axle Brush Guard Removal And Installation (S/N 520511247 & Above)
• Front Axle Removal And Installation
• Rear Axle Removal And Installation
• Disconnecting The Axle Housings
• Primary Housing Disassembly
• Steering Cylinder Disassembly
• Brake Disassembly
• Secondary Housing And Differential Lock Disassembly
• Secondary Housing And Differential Lock Assembly
• Steering Cylinder Assembly
• Primary Housing Assembly
• Brake Assembly
• Connecting The Axle Housings
• AXLE HUB WITH AXLE SHAFT
• Removal And Installation (Without Wheel Position Sensor)
• Removal (With Wheel Position Sensor)
• Inspection
• Installation (With Wheel Position Sensor)
• AXLE HUB WITHOUT AXLE SHAFT
• Removal And Installation (Without Wheel Position Sensor)
• Removal (With Wheel Position Sensor)
• Bearing Pivot Inspection
• Installation (With Wheel Position Sensor)
• Disassembly
• Axle Hub Inspection
• Assembly
• Torque Check Procedure
• TIE ROD
• Removal And Installation (Front Axle)
• Removal And Installation (Rear Axle)
• Adjusting
• AXLE SHAFT
• Removal and Installation
• MAIN FRAME
• OPERATOR CAB
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• Seat Pan Removal And Installation
• Slide Rail Removal And Installation
• Cushion Removal And Installation
• Back Removal And Installation
• Arm Rest Bracket Removal And Installation
• Arm Rest Removal And Installation
• Shock Removal And Installation
• PASSENGER SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• Seat Pan Removal And Installation
• Arm Rest Removal And Installation
• BOB-TACH
• Removal and Installation
• Bob-Tach Lever and Wedge
• LIFT ARM
• Removal and Installation
• CARGO BOX
• Removal and Installation
• STEERING COLUMN
• Removal And Installation
• FUEL TANK
• Removal and Installation
• TRAVEL AND BRAKE PEDALS
• Removal And Installation
• Travel Speed Pedal Disassembly and Assembly
• SHOCKS
• Removal And Installation
• TRAILING ARMS
• Removal And Installation (Upper Arm)
• Removal And Installation (Lower Arm)
• LEAF SPRINGS
• Removal And Installation (Left Side)
• Removal and Installation (Right Side)
• HITCH
• Removal And Installation
• FLOOR CONSOLE
• Removal And Installation
• CENTER CONSOLE
• Removal And Installation
• FENDER (FRONT LEFT)
• Removal And Installation
• FENDER (FRONT RIGHT)
• Removal And Installation
• FENDER (REAR LEFT)
• Removal And Installation
• FENDER (REAR RIGHT)
• Removal And Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Troubleshooting Chart
• Description
• Fuse Location
• Solenoid Test
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR (90 AMP)
• Adjusting The Alternator Belt
• Alternator Identification
• Charging System Check
• Alternator Voltage Test
• Low Voltage Test
• High Voltage Test
• Removal And Installation
• Rectifier Continuity (Diode) Test
• Alternator Regulator Test
• Disassembly
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Assembly
• STARTER
• Checking
• Removal And Installation
• Parts Identification
• Disassembly and Assembly
• Inspection And Repair
• No Load Test
• INSTRUMENT PANEL
• Display Controller Panel
• Switch Panel
• Center Console
• Display Controller Panel Removal And Installation
• Center Console Removal And Installation
• Light Bulb Removal And Installation
• LIGHTS
• Front Removal And Installation
• DISPLAY CONTROLLER
• Identification Chart
• Removal And Installation
• DRIVE CONTROLLER
• Identification Chart
• Removal And Installation
• DIAGNOSTICS
• Service Codes
• TICS SYSTEM
• Inspecting the TICS System (Engine STOPPED – Key ON)
• Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
• Inspecting The Arm Rest Sensor (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm By-Pass Control
• ARM REST SENSOR
• Removal And Installation
• WHEEL SPEED SENSOR
• Removal and Installation (Front Axle)
• Removal and Installation (Rear Axle)
• WHEEL POSITION SENSOR
• Removal and Installation (Front Axle)
• Removal and Installation (Rear Axle)
• CALIBRATION
• Travel Pedal
• Brake Pedal
• Calibration for the brake pedal is complete.
• Pump
• Wheel Alignment Calibration
• SERVICE PC (LAPTOP COMPUTER)
• Connecting The Service PC To Remote Start Tool
• TRAVEL DIRECTION CONTROL LEVER
• Removal And Installation
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Removal And Installation
• MUFFLER
• Removal and Installation
• AIR CLEANER
• Removal and Installation
• RADIATOR
• Removal And Installation
• COOLING FAN
• Removal And Installation
• Fan Motor Disassembly and Assembly
• 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
• RPM SENSOR
• Adjustment
• 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
• HEATING, VENTILATION, AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Principals
• Chart
• COMPONENTS
• Identification
• SAFETY
• Safety Equipment
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• Cleaning The Condenser
• GENERAL AIR CONDITIONING SERVICE GUIDELINES
• Compressor Oil
• Compressor Oil Check
• Component Replacement And Refrigeration Leaks
• SYSTEM TROUBLESHOOTING
• Checking A/C Performance
• Gauge Pressure Related Troubleshooting
• Troubleshooting Tree
• TEMPERATURE/PRESSURE
• Chart
• AIR CONDITIONING SERVICE
• Chart
• SYSTEM CHARGING AND RECLAMATION
• Reclamation Procedure
• Charging Procedure With A Manifold Gauge Set
• COMPRESSOR
• Removal And Installation
• Compressor Clutch Disassembly
• CONDENSER
• Removal And Installation
• RECEIVER/DRIER
• Removal And Installation
• Pressure Switch Removal And Installation
• Pressure Relief Valve Removal And Installation
• EVAPORATOR/HEATER UNIT
• Removal And Installation
• THERMOSTAT
• Removal And Installation
• EXPANSION VALVE
• Removal And Installation
• HEATER/AC FAN
• Removal And Installation
• HEATER VALVE
• Removal And Installation
• Disassembly And Assembly
• SPECIFICATIONS
• UTILITY WORK MACHINE SPECIFICATIONS
• Dimensional Specifications
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• 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 SPECIFICATIONS FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• Torque For Kubota 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
• Quick-Lok™ Fitting
• HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion
• SERVICE MANUAL REVISION
• Revision No: 5600 – 1
• Revision No: 5600 – 2
• Revision No: 5600 – 3
• Revision No: 5600 – 4
• Revision No: 5600 – 5
• Revision No: 5600 – 6
• Revision No: 5600 – 7
• Revision No: 5600 – 8