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
• Removing
• OPERATOR CAB
• Description
• Raising
• Lowering
• TRANSPORTING LOADER ON A TRAILER
• Loading And Unloading
• Fastening
• TOWING THE LOADER
• Procedure
• REMOTE START
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Elements
• ENGINE COOLING SYSTEM
• Cleaning
• Checking
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Oil Chart
• Removing And Replacing Oil And Filter
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Removing And Replacing The Hydraulic/Hydrostatic Filter
• Removing And Replacing The Hydraulic/Hydrostatic Fluid
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• Removing Oil From Chaincase
• AUXILIARY CONTROL LOCKBOLT
• Procedure
• BOB-TACH
• Inspection And Maintenance
• LUBRICATING THE BOBCAT
• Lubrication Locations
• TIRE MAINTENANCE
• Wheel Nuts
• Rotating
• Mounting
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• PIVOT PINS
• Inspection And Maintenance
• SEAT BAR RESTRAINT SYSTEM
• Inspection And Maintenance
• RUBBER COUPLER LUBRICATION
• Procedure
• LOADER STORAGE AND RETURN TO SERVICE
• Storage
• Return to Service
• STOPPING THE ENGINE AND LEAVING THE LOADER
• Procedure
• Emergency Exit
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting Chart
• CYLINDER (LIFT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CYLINDER (TILT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• MAIN RELIEF VALVE
• Description
• Testing With Auxiliaries
• Testing Without Auxiliaries
• Removal and Installation
• HYDRAULIC CONTROL VALVE
• Description
• BICS Valve Removal And Installation
• Identification Chart
• Disassembly And Assembly
• Load Check Valve Removal And Installation
• Main Relief Valve Removal And Installation
• Anti-Cavitation Check Valve Removal And Installation
• Port Relief Valve Removal And Installation
• Rubber Boot (Lift) Removal And Installation
• Rubber Boot (Tilt) Removal And Installation
• Rubber Boot (Auxiliary) Removal And Installation
• Lift Spool And Detent Removal And Installation
• Tilt Spool Removal And Installation
• Auxiliary Spool And Detent Removal And Installation
• One Way Restrictors Removal And Installation
• Spool Seal Installation
• LIFT ARM BY-PASS CONTROL VALVE
• Description
• Testing
• Removal And Installation
• Disassembly And Assembly
• TILT LOCK VALVE
• Description
• Testing
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Description
• Direct Pump Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC/HYDROSTATIC FILTER
• Description
• Housing Removal And Installation
• Housing Disassembly And Assembly
• HYDRAULIC FLUID RESERVOIR
• Description
• Removal And Installation
• Hydrauilc Fluid Screen
• OIL COOLER
• Description
• Removal And Installation
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting
• Description
• HYDROSTATIC MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Timing
• PORT BLOCK
• Description
• Removal And Installation
• Oil Cooler By-Pass Valve Removal And Installation
• Hydraulic Oil Temperature Switch Removal And Installation
• Charge Pressure By-Pass Valve Removal And Installation
• HYDROSTATIC PUMP
• Description
• Checking Charge Pressure
• Removal And Installation
• Drive Coupler Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Inspection
• DRIVE SYSTEM
• PARKING BRAKE
• Description
• Disk Removal And Installation
• Traction Lock Guides Removal And Installation
• DRIVE COMPONENTS
• Description
• Axle Seal Removal And Installation
• Chain Removal And Installation
• CHAINCASE
• Description
• Front Cover Removal And Installation
• Rear Cover Removal And Installation
• MAIN FRAME
• SEAT BAR
• Description
• Removal And Installation
• Disassembly And Assembly
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation
• Gas Cylinder Disassembly And Assembly
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• BOB-TACH
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• LIFT ARM
• Removal And Installation
• REAR GRILL
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Striker Removal And Installation
• Striker Disassembly And Assembly
• Striker Adjustment
• Latch Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender Removal And Installation
• CONTROL PEDALS AND LINKAGES
• Description
• Removal And Installation
• Pedal Adjustment
• Pedal Interlock Linkage Removal And Installation
• Pedal Interlock Linkage Adjustment
• Crossbar Linkage Removal And Installation
• CONTROL PANEL
• Description
• Removal And Installation
• CONTROL LEVER
• Description
• Lever Removal And Installation
• Lever Disassembly And Assembly
• Linkage Removal And Installation
• Pintle Lever Removal And Installation
• Pintle Lever Disassemby And Assembly
• WINDOW (REAR)
• Removal
• Installation
• WINDOW (TOP)
• Removal
• Installation
• WINDOW (SIDE)
• Removal And Installation
• WINDOW (FRONT DOOR)
• Removal (Standard Window)
• Installation (Standard Window)
• Removal And Installation (Special Applications Window)
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Description
• Troubleshooting
• Fuse And Relay Location And Identification
• BATTERY
• Removal And Installation
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Belt Adjustment
• Charging System Inspection
• Alternator Voltage Testing
• Low Voltage Testing
• High Voltage Testing
• Removal And Installation
• Parts Identification
• STARTER
• Testing
• Removal And Installation
• Parts Identification
• INSTRUMENT PANELS
• Left And Right Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• Cab Light Removal And Installation
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
• Description
• Inspecting The BICS 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
• Removal And Installation
• SEAT BAR SENSOR
• Description
• Troubleshooting
• Testing
• Removal And Installation
• Bobcat Interlock Control System (BICS) Circuit Test
• TRACTION LOCK
• Description
• Troubleshooting
• Removal And Installation
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Torque Values
• Troubleshooting
• Engine Removal And Installation
• Engine Mount Replacement
• Compression – Checking
• ENGINE SPEED CONTROL
• Removal And Installation
• Linkage Bar Removal And Installation
• ENGINE SPEED CONTROL PLATE
• Removal And Installation
• Governor Spring Removal
• Start Spring Removal
• Idle Limit And Fuel Limit Adjustment
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• ENGINE COOLING SYSTEM
• Cooling Fan Removal And Installation
• Radiator Removal And Installation
• Water Pump Removal And Installation
• Thermostat Housing Removal And Installation
• Thermostat Testing
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump Inspection
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Fuel Camshaft Removal And Installation
• Fuel Camshaft Governor Disassembly And Assembly
• Fuel Shutoff Solenoid, Removal And Installation
• Fuel Lift Pump Removal And Installation
• Fuel Injection Pump, Checking
• Fuel Injection Pump Removal And Installation
• Injection Pump – Timing
• Fuel Injector Removal And Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spray Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Glow Plugs – Testing
• Glow Plugs Removal And Installation
• Closed Breather System – Checking
• Valve Clearance Adjustment
• Valve Timing – Checking
• Exhaust Manifold Removal And Installation
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head – Servicing
• Cylinder Head Top Clearance
• Valve Guide And Valve Checking
• Reconditioning The Valve And Valve Seat
• Valve Springs
• Valve Tappets
• Rocker Arm And Shaft Removal And Installation
• Rocker Arm And Shaft Disassembly And Assembly
• Rocker Arm And Shaft – Checking
• CRANKSHAFT AND PISTONS
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod – Servicing
• Cylinder Bore Checking
• Connecting Rod Alignment
• Crankshaft And Bearing Removal And Installation
• Crankshaft And Bearing – Servicing
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal And Installation
• Timing Gears Backlash – Checking
• Idler Gear And Shaft Removal And Installation
• Idler Gear And Shaft Servicing
• Camshaft Removal And Installation
• Camshaft Servicing
• Camshaft Gear Removal And Installation
• Engine Timing Gear Alignment
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• RUBBER DRIVE COUPLER
• Removal And Installation
• Disassembly And Assembly
• WATER FLANGE
• Removal And Installation
• HEATER
• HEATER SYSTEM
• Description
• REGULAR MAINTENANCE
• Filter Element Removal And Installation
• Heater Coil
• TROUBLESHOOTING
• Electric System
• Heater Valve Not Opening Or Closing
• Blower Motor Does Not Operate
• Blower Motor Operates Normally, But Air Flow Is Insufficient
• HEATER UNIT
• Removal And Installation
• HEATER COIL
• Removal And Installation
• HEATER FAN
• Blower Removal And Installation
• Disassembly And Assembly
• HEATER MOTOR
• Removal And Installation
• RESISTOR
• Removal And Installation
• Checking
• HEATER VALVE
• Removal And Installation
• HEATER SWITCH
• Removal And Installation
• Checking The Switch
• SPECIFICATIONS
• 553 LOADER SPECIFICATIONS
• Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• 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/HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion Chart
• SMR
• 553-1