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 AND MAINTENANCE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• Installing Lift Arm Support Device
• Removing The Lift Arm Support Device
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• TRANSPORTING THE BOBCAT LOADER
• Procedure
• TOWING THE LOADER
• Procedure
• REMOTE START
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Checking
• Replacing Filter Element(s)
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing The 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 Oil And Filter
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing Hydraulic/Hydrostatic Filter
• Replacing Hydrostatic Motor Case Drain Filter(s)
• Replacing Hydraulic Fluid
• Breather Cap
• FAN GEARBOX
• Checking And Maintaining
• BOB-TACH™
• Inspection And Maintenance
• POWER BOB-TACH™
• Inspection And Maintenance
• LUBRICATION OF THE BOBCAT LOADER
• Procedure
• SPARK ARRESTOR MUFFLER
• Servicing
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic/Hydrostatic Symbols
• Tighten Procedures
• Troubleshooting Chart
• CYLINDER (LIFT)
• Checking
• Removal And Installation
• Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Checking
• Removal And Installation
• Rod End Pivot Pin Bushing And Seal Replacement
• Identification
• Disassembly
• Assembly
• CYLINDER (POWER BOB-TACH™)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking
• Adjustment
• HYDRAULIC CONTROL VALVE (FOOT CONTROL)
• Removal And Installation
• Identification Chart
• BICS Valve, Lift Load Check Valve Removal And Installation
• Load Check Valve Removal And Installation (Tilt & Auxiliary)
• Anti-Cavitation Valve (Lift, Rod End)
• Port Relief/Anti-Cavitation Valve (Lift, Base End)
• Port Relief/Anti-Cavitation Valve (Tilt, Base End)
• Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
• Port Relief Valve
• Plug Removal
• Rubber Boot Removal and Installation
• End Cap/Spool Lock Block Removal and Installation
• Lift Spool and Detent Removal and Installation
• Tilt Spool Removal and Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Solenoid Disassembly and Assembly
• BICS Valve Solenoid Disassembly And Assembly
• BICS Valve, Lock Valve Removal And Installation
• BICS Valve, Check Valve Removal And Installation
• BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
• Main Relief Valve
• HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
• Removal And Installation
• Actuator Removal And Installation (Out of Loader)
• Identification Chart (ACS)
• BICS Valve, Load Check Valve Removal And Installation (Lift)
• Load Check Valve Removal And Installation (Tilt & Auxiliary)
• Anti-Cavitation Valve (Lift, Rod End)
• Port Relief/Anti-Cavitation Valve (Lift, Base End)
• Port Relief/Anti-Cavitation Valve (Tilt, Base End)
• Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
• Port Relief Valve
• Plug Removal
• End Cap Block Removal and Installation
• Lift Spool Removal and Installation
• Tilt Spool Removal and Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Solenoid Disassembly and Assembly
• BICS Valve Solenoid Disassembly And Assembly
• BICS Valve, Lock Valve Removal And Installation
• BICS Valve, Check Valve Removal And Installation
• BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
• Main Relief Valve
• LIFT ARM BY-PASS CONTROL VALVE
• Inspecting
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Check The Output Of The Hydraulic Pump Without Rear Auxiliary
• Removal And Installation
• Identification
• Disassembly And Assembly
• HYDRAULIC/HYDROSTATIC FILTER
• Housing Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• BUCKET POSITION VALVE
• Solenoid Removal And Installation
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• REAR AUXILIARY DIVERTER VALVE
• Removal And Installation
• Disassembly And Assembly
• Inspection
• 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
• Replacing the Motor Oil
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• 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
• Pressure Relief Valve Test
• Right Motor Brake Test
• Left Motor Brake Test
• Block Removal And Installation
• Block Disassembly And Assembly
• DRIVE COMPONENTS
• Track Tension
• Track Tension Adjusting
• Track Removal And Installation
• Track Idler (Front) Removal And Installation
• Track Idler (Front) Disassembly and Assembly
• Track Idler (Rear) End Play Specifications
• Track Idler (Rear) Removal And Installation
• Track Idler (Rear) Disassembly and Assembly
• Track Roller Assembly End Play Specifications
• Track Roller Removal And Installation
• Track Roller Disassembly and 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
• Gas Cylinder Disassembly
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Slide Rail Removal And Installation
• Seat Belt 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
• Bob-Tach Stops
• POWER BOB-TACH™
• Removal And Installation
• Power Bob-Tach Lever And Wedge
• LIFT ARM
• Removal And Installation
• REAR GRILL
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Striker Removal and Installation
• Striker Disassembly and Assembly
• Door Latch and Catch Adjustment
• Latch Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• Fuel Fill Screen
• Fuel Pickup Screen
• CONTROL PEDALS
• Removal And Installation
• Pedal Adjustment
• Crossbar Linkage Removal And Installation
• Lift Foot Pedal Linkage Removal And Installation
• Tilt Foot Pedal Linkage Removal And Installation
• CONTROL PEDALS (ACS)
• Foot Sensor Removal And Installation
• Foot Pedal Removal And Installation
• Foot Pedal Linkage Disassembly And Assembly
• CONTROL PANEL
• Description
• Removal and Installation
• Shock Removal And Installation
• Shaft Removal And Installation
• Shaft Disassembly And Assembly
• Linkage Removal And Installation
• Pintle Arm Disassembly and Assembly
• Linkage Neutral Adjustment
• Linkage Travel Adjustment
• CONTROL HANDLE
• Control Lever Removal And Installation
• Rubber Boot Replacement
• 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
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Troubleshooting Chart
• Description
• Relay Switch Location
• Fuse Location
• BATTERY
• Removal And Installation
• Servicing
• 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
• Checking
• Removal And Installation
• Parts Identification
• 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)
• Option And Field Accessory Panels (If Equipped)
• Removal And Installation
• Front Accessory Panel Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• BOBCAT CONTROLLER
• Identification Chart
• Removal And Installation
• DIAGNOSTIC 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
• Troubleshooting Chart
• 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
• ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL
• 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
• 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
• Disassembly
• MUFFLER
• Removal And Installation
• AIR CLEANER
• 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 Shutoff Solenoid, Checking
• Fuel Shutoff Solenoid Removal And Installation
• Fuel Injection Pump Removal And Installation
• Timing The Injection Pump
• Fuel Injector Removal And Installation
• Checking Nozzle Injection Pressure
• Nozzle Spraying Condition
• Valve Seat Tightness
• Valve Clearance Adjustment
• 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
• Valve Guide Checking
• 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
• Camshaft Servicing
• Idler Gear And Shaft Servicing
• 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
• Valve Tappets
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod Servicing
• Connecting Rod Alignment
• Crankshaft And Bearings Removal And Installation
• Crankshaft And Bearings, Servicing
• Cylinder Bore, Checking
• Water Pump Removal And Installation
• 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 (T140)
• Machine Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tracks
• Ground 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
• 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
• HYDRAULIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion
• SMR
• T140-1