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 LOCATION
• Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• 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
• TRANSPORTING THE BOBCAT LOADER
• Procedure
• REMOTE START
• Procedure For Loader W/O Attachments Control Harness
• Procedure For Loader With Attachments Control Harness
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Element
• ENGINE COOLING SYSTEM
• Cleaning Cooling System
• 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
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Hydraulic/Hydrostatic Filter Replacement
• Replacing Hydraulic Fluid And Case Drain Filters
• FAN GEARBOX
• Checking And Adding Oil
• BOB-TACH
• Inspection And Maintenance
• POWER BOB-TACH
• Inspection And Maintenance
• LUBRICATING THE LOADER
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Troubleshooting
• Tightening Procedure
• CYLINDER (LIFT)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Checking
• Removal And Installation
• Base Pin Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (POWER BOB-TACH)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE (FOOT CONTROL)
• Checking The Main Relief Valve At Front Aux. Hyd.
• Removal And Installation
• Adjustment
• MAIN RELIEF VALVE (ACS)
• Checking The Main Relief Valve At Front Aux. Hyd.
• Removal And Installation
• Adjustment
• HYDRAULIC CONTROL VALVE (FOOT CONTROL)
• Removal And Installation
• BICS™ Valve, Removal And Installation
• BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation
• BICS™ Valve, Check Valve Removal And Installation
• BICS™ Valve, Lock Valve Removal And Installation
• BICS™ Valve, Solenoid Removal And Installation
• BICS™ Valve, Solenoid Testing
• Identification Chart
• Load Check Valve
• Main Relief Valve
• Port Relief Valve, Tilt Spool
• Port Relief Valve, Lift Spool
• Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
• Anti-Cavitation Valve, Lift Spool
• Rubber Boot
• Lift And Tilt Lock Block
• Lift Spool And Detent Removal
• Tilt Spool Removal And Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Plug Removal And Installation
• Auxiliary Electric Solenoid Disassembly
• Port-Auxiliary Section Removal And Installation
• Cleaning And Inspection
• HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
• Actuator Removal And Installation (In Loader)
• Actuator Removal And Installation (Out Of Loader)
• Removal And Installation
• BICS™ Valve, Removal And Installation
• BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
• BICS™ Valve, Check Valve Disassembly And Assembly
• BICS™ Valve, Lock Valve Disassembly And Assembly
• BICS™ Valve, Solenoid Disassembly And Assembly
• BICS™ Valve, Solenoid Testing
• Identification Chart
• Lift Base End Restrictor
• Load Check Valve
• Main Relief Valve
• Port Relief Valve
• Anti-Cavitation Valve/Port Relief Valve
• Anti-Cavitation Valve
• Lift Spool Removal
• Lift 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 W/Advanced Hand Controls
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Check The Output Of The Hydraulic Pump
• Removal And Installation
• Identification
• Disassembly And Assembly
• HYDRAULIC PUMP (CHARGE)
• Check The Output Of The Hydraulic Pump
• Removal and Installation
• Disassembly and Assembly
• HYDRAULIC PUMP (HI FLOW)
• Hydraulic Pump Test
• Inline Hydraulic Pump Test (Standard)
• Inline Hydraulic Pump Test (High Flow)
• High Flow Relief Adjustment Procedure
• High Flow Relief Valve Removal and Installation
• Removal And Installation
• Identification
• Disassembly And Assembly
• HYDRAULIC/HYDROSTATIC FILTER
• Housing Removal And Installation
• Mount Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Fluid Removal
• Removal And Installation
• Hydraulic Fluid Screen
• BUCKET POSITION VALVE
• Solenoid Removal And Installation
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• REAR AUXILIARY DIVERTER
• Removal and Installation
• Disassembly And Assembly
• Solenoid Testing
• Inspection
• POWER BOB-TACH BLOCK (EARLY MODELS)
• Removal And Installation
• Disassembly And Assembly
• POWER BOB-TACH BLOCK
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
• Removal and Installation
• Disassembly And Assembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• HYDROSTATIC MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• Filling
• CHARGE PRESSURE SENDER
• Testing
• Removal and Installation
• Setting Charge Pressure
• HYDROSTATIC PUMP
• Removal And Installation
• Replenishing/High Pressure Relief Valve
• Parts Identification (Right Half)
• Parts Identification (Left Half)
• Hydraulic Pump Removal And Installation
• Pump Separation
• Disassembly
• Assembly
• DRIVE BELT
• Shield Removal And Installation
• Adjustment
• Replacement
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Tension Spring
• OIL COOLER (SEAL TO CONNECT) (STC)
• Hydraulic Oil Cooler Removal and Installation
• DRIVE SYSTEM
• BRAKE
• Switch Operated Parking Brake
• Block Removal And Installation
• Block Disassembly And Assembly
• DRIVE COMPONENTS
• Track Checking
• Track Adjustment
• Track Removal And Installation
• Track Idler (Front) End Play Specifications
• Track Idler (Front) Removal And Installation
• Track Idler (Front) Parts Identification
• Track Idler (Front) Disassembly
• Track Idler (Front) Assembly
• Track Idler (Rear) End Play Specifications
• Track Idler (Rear) Parts Identification
• Track Idler (Rear) Removal And Installation
• Track Idler (Rear) Disassembly
• Track Idler (Rear) Assembly
• Track Roller Assembly End Play Specifications
• Track Roller Parts Identification
• Track Roller Removal And Installation
• Track Roller Disassembly
• Track Roller Assembly
• Track Housing Removal And Installation
• Track Damage Identification
• MAIN FRAME
• SEAT BAR
• Removal And Installation
• Assembling Components
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation (Dual Gas Spring)
• Gas Cylinder Removal And Installation (3rd Gas Spring)
• Gas Cylinder Bracket Disassembly And Assembly
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• OPERATOR SEAT (SUSPENSION)
• Removal And Installation
• Slide Rail Removal And Installation
• Cushion Removal And Installation
• Back Removal And Installation
• Shock Removal And Installation
• 3-Point Seat Belt Removal And Installation
• BOB-TACH
• Removal And Installation
• Bob-Tach Lever And Wedge
• POWER BOB-TACH
• Removal And Installation
• Power Bob-Tach Lever And Wedge
• Pivot Pin Bushing And Seal Replacement
• LIFT ARMS
• Removal And Installation
• REAR GRILL
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Adjusting The Rear Door Latch
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• CONTROL PEDALS
• Removal And Installation
• Pedal Adjustment
• CONTROL PEDALS (ACS)
• Foot Sensor Removal And Installation
• Foot Pedal Removal And Installation
• Foot Pedal Linkage Disassembly And Assembly
• CONTROL PANEL
• Removal And Installation
• Shock Removal And Installation
• Shaft Removal And Installation
• Shaft Disassembly And Assembly
• Linkage Removal And Installation
• Linkage Neutral Adjustment
• CONTROL HANDLE
• Lever Removal And Installation
• Steering Lever Boot
• CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL
• 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
• INSIDE ACCESS PANEL
• Removal And Installation (Left)
• Removal And Installation (Right)
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Troubleshooting
• Description
• Fuse Location
• Relay Switch Location
• Solenoid Test
• BATTERY
• Removal And Installation
• Servicing The Electrical System
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• 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
• Removal And Installation
• Parts Identification
• Checking
• Disassembly And Assembly
• Inspection And Repair
• No Load Test
• INSTRUMENT PANEL
• Left Panel
• Right Panel (Standard) (With Key Switch)
• Right Panel (Deluxe) (With Keyless Start)
• Right Panel Setup Display Options (Deluxe)
• Deluxe Panel Setup
• Passwords (Deluxe)
• Option And Field Accessory Panels (If Equipped)
• Standard Panel Removal And Installation (Right Side)
• Deluxe Panel Removal And Installation (Right Side)
• Standard & Deluxe Panel Removal And Installation (Left Side)
• Front Accessory Panel Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• BOBCAT CONTROLLER
• Identification Chart
• Removal And Installation
• DIAGNOSTICS SERVICE CODES
• Display
• Number Codes List
• 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 Controls System (ACS) or Selectable Joystick Control (SJC)
• Troubleshooting
• Troubleshooting Guide
• SEAT BAR SENSOR
• Troubleshooting Chart
• Test
• Removal And Installation
• BICS™ Circuit Test
• TRACTION LOCK
• Troubleshooting Chart
• Description Of The Control System
• Inspecting The Control System
• Parking Brake Solenoid Removal And Installation
• ADVANCED CONTROL SYSTEM (ACS)
• Components Identification
• Troubleshooting Guide
• Controller, Connector And Wire Identification
• ACS Controller Removal And Installation
• Handle Sensor Connector
• Switch Handle Removal
• Switch Handle Installation
• Actuators Disassembly And Assembly
• Handle Lock Solenoid Removal And Installation
• Handle Lock Solenoid Disassembly And Assembly
• Handle Lock Solenoid Connector
• Calibration Of The ACS System
• Switchable Hand/Foot Controls Calibration Procedure
• Hand Controls Only Calibration Procedure
• Foot Sensor Disassembly And Assembly
• Foot Sensor Connector
• Foot Lock Solenoid Removal And Installation
• Foot Lock Solenoid Connector
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
• Controls Identification Chart
• FLYWHEEL RPM SENSOR
• Adjustment
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Removal And Installation
• Speed Control Cable
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• RADIATOR
• Removal And Installation
• Mount Removal
• COOLING FAN
• Drive Tension Pulley Removal And Installation
• Gearbox/Blower Housing Removal And Installation
• Gearbox Parts Identification
• Gearbox Disassembly
• Gearbox Assembly
• Gearbox, Checking Backlash
• ENGINE
• Removal And Installation
• Mount Replacement
• Removal And Installation Tools
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Flywheel Housing Removal And Installation
• RECONDITIONING THE ENGINE
• Engine Tools Identification Chart
• Compression Pressure
• Cylinder Head Clearance
• Valve Cover And Injector Nozzle Removal And Installation
• Rocker Arm And Push Rod Disassembly And Assembly
• Valve Clearance
• Cylinder Head And Tappet Disassembly And Assembly
• Selecting Cylinder Head Gasket Disassembly And Assembly
• Valve Disassembly And Assembly
• Engine Timing (TDC)
• Injection Pump Assembly Removal
• Injection Pump Assembly Installation
• Injection Pump Removal and Installation
• Injection Pump Timing
• Fan Drive Pulley Disassembly And Assembly
• Water Pump Disassembly And Assembly
• Gearcase Cover Disassembly And Assembly
• Idle Gear And Camshaft Disassembly And Assembly
• Gearcase Plate Disassembly And Assembly
• Oil Pan And Oil Strainer Disassembly And Assembly
• Connecting Rod Cap Disassembly And Assembly
• Piston Disassembly And Assembly
• Piston Ring And Connecting Rod Disassembly And Assembly
• Bearing Case Cover Disassembly And Assembly
• Flywheel Housing Disassembly And Assembly
• Crankcase No. 2 Disassembly And Assembly
• Crankcase No. 1 And No. 2 Disassembly And Assembly
• Crankshaft Disassembly And Assembly
• Cylinder Head Surface Flatness
• Cylinder Head Flaw
• Valve Recessing
• Valve Lapping
• Clearance Between Valve Stem And Valve Guide
• Replacing Valve Guide
• Correcting Valve And Valve Seat
• Free Length And Tilt Of Valve Spring
• Valve Spring Setting Load
• Oil Clearance Between Rocker Arm Shaft And Bearing
• Oil Clearance Between Tappet And Tappet Guide Bore
• Timing Gear Backlash
• Idler Gear Side Clearance
• Camshaft Side Clearance
• Camshaft Alignment
• Cam Height
• Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing
• Replacing Idler Gear Bushing
• Piston Pin Bore I.D.
• Oil Clearance Between Piston Pin And Small End Bushing
• Replacing Small End Bushing
• Clearance Between Piston Ring And Groove
• Piston Ring Gap
• Connecting Rod Alignment
• Crankshaft Side Clearance
• Crankshaft Alignment
• Oil Clearance Between Crankpin And Crankpin Bearing
• Oil Clearance Between Crankshaft Journal And Crankshaft Bearing
• Replacing Crankshaft Sleeve
• Cylinder Bore I.D.
• Correcting Cylinder (Oversize +0.5 mm)
• Engine Oil Pressure
• Rotor Lobe Clearance
• Clearance Between Outer Rotor And Pump Body
• Thermostat Valve Opening Temperature
• Radiator Water Leakage
• Radiator Cap Air Leakage
• Thermostat Assembly
• Intake Air Heater
• Checking the Turbo Charger
• Compressor Side
• Wheel Shaft
• Axial Clearance
• Radial Clearance
• Air Cleaner, Intake Pipe, Inlet Pipe And Muffler
• Oil Pipe
• HEATING, VENTILATION, AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Principals
• Chart
• COMPONENTS
• Identification
• SAFETY
• Safety Equipment
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• Compressor Drive Belt Inspection
• Cleaning The Condenser
• BASIC TROUBLESHOOTING
• Poor A/C Performance
• Cleaning The A/C Evaporator Coil & Heater Coil
• Compressor Drive Belt Inspection
• Checking The Electrical System
• Engine Coolant By-Passing The Heater Valve
• Heater Valve Not Opening Or Closing
• GENERAL AIR CONDITIONING SERVICE GUIDELINES
• Compressor Oil
• Compressor Oil Check
• Component Replacement And Refrigeration Leaks
• SYSTEM TROUBLESHOOTING CHART
• 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
• Charging Procedure
• COMPRESSOR
• Removal And Installation
• Compressor Clutch Disassembly
• CONDENSER
• Removal And Installation
• RECEIVER/DRIER
• Removal And Installation
• PRESSURE RELIEF VALVE
• Removal And Installation
• PRESSURE SWITCH
• Removal And Installation
• EVAPORATOR/HEATER UNIT
• Removal And Installation
• Disassembly And Assembly
• THERMOSTAT
• Removal And Installation
• EXPANSION VALVE
• Removal And Installation
• EVAPORATOR
• Removal And Installation
• HEATER COIL
• Removal And Installation With A/C
• Removal And Installation Without A/C
• BLOWER FAN
• Removal And Installation
• Disassembly And Assembly
• Wire Connector Removal and Installation
• HEATER VALVE
• Removal and Installation
• Disassembly And Assembly
• SPECIFICATIONS
• LOADER SPECIFICATIONS (T250)
• Machine Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tracks
• ENGINE SPECIFICATIONS
• General
• Fuel System
• Valve And Valve Timing
• Valve Spring
• Piston And Piston Ring
• Connecting Rod
• Cylinder Head
• Crankshaft
• Cylinder Bore
• Oil Pump
• Rocker Arm
• Tappet
• Camshaft
• Thermostat
• Timing Gear
• Intake Air Heater
• TORQUE SPECIFICATIONS FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• Torque For Kubota Metric Engine Bolts
• Tightening Torques For General Use Screws, Bolts And Nuts
• 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
• SMR
• T250-1
• T250-2