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
• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• LOADER IDENTIFICATION
• SAFETY & MAINTENANCE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• Installing
• Removing
• OPERATOR CAB
• Description
• Raising
• Lowering
• Cab Door Sensor
• TRANSPORTING THE LOADER ON A TRAILER
• Loading And Unloading
• Fastening
• TOWING THE LOADER
• Procedure
• REMOTE START TOOL KIT-MEL1563
• Remote Start Tool – MEL1563
• Service Tool Harness Control – MEL1565
• Service Tool Harness Communicator – MEL1566
• Remote Start Procedure
• REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
• Description
• Remote Start Tool (Service Tool) – 7003030
• Loader Service Tool Harness – 6689747
• Computer Service Tool Harness – 6689746
• Remote Start Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Elements
• ENGINE COOLING SYSTEM
• Cleaning
• Checking Level
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Biodiesel Blend Fuel
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil Chart
• Removing And Replacing Oil And Filter
• HYDRAULIC / HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Hydraulic / Hydrostatic Fluid Chart
• Removing And Replacing Hydraulic Fluid
• Removing And Replacing Hydraulic / Hydrostatic Filter
• Removing And Replacing Case Drain Filters
• Removing And Replacing Hydraulic Charge Filter
• Breather Cap
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• Removing And Replacing Oil
• BOB-TACH (HAND LEVER)
• Inspection And Maintenance
• LUBRICATING THE LOADER
• Lubrication Locations
• TIRE MAINTENANCE
• Wheel Nuts
• Rotating
• Mounting
• SPARK ARRESTER MUFFLER
• Cleaning Procedure
• PIVOT PINS
• Inspection And Maintenance
• 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
• 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
• Adjusting
• Removal And Installation
• HYDRAULIC CONTROL VALVE
• Description
• Removal And Installation
• Identification Chart
• Load Check Valve Removal And Installation (Tilt And Auxiliary)
• Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
• Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
• Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
• Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
• Port Relief Valve Removal And Installation
• 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
• Solenoid Removal And Installation
• Lock Valve Removal And Installation
• Main Relief Valve Removal And Installation
• LIFT ARM BYPASS CONTROL VALVE
• Description
• Testing
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Description
• Pump Test At Quick Couplers
• Direct Pump Test
• Direct Pump Test (Charge Section)
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Hydraulic Pump Start Up
• HYDRAULIC / HYDROSTATIC FILTERS
• Description
• Hydraulic / Hydrostatic Filter Housing Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Description
• Removal And Installation
• Hydraulic Fluid Screen
• OIL COOLER
• Description
• Removal And Installation
• BUCKET POSITION VALVE
• Description
• Solenoid Removal And Installation
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY HYDRAULIC COUPLERS
• Description
• Removal And Installation
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Description
• Troubleshooting
• HYDROSTATIC MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CHARGE PRESSURE
• Description
• Testing
• Sender Removal And Installation
• Adjusting
• HYDROSTATIC PUMP
• Description
• Replenishing / High Pressure Relief Valve Removal And Installation
• Removal And Installation
• Hydrostatic Pump Startup
• Parts Identification
• Disassembly
• Assembly
• DRIVE BELT
• Description
• Shield Removal And Installation
• Adjusting
• Belt Removal And Installation
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Disassembly And Assembly
• CASE DRAIN FILTER
• Description
• Disassembly And Assembly
• DRIVE SYSTEM
• BRAKE
• Description
• Disk Removal And Installation
• DRIVE COMPONENTS
• Description
• Axle Seal Removal And Installation
• Axle Sprocket And Bearings Removal And Installation
• Chain Removal And Installation
• CHAINCASE
• Description
• Front Cover Removal And Installation
• Center Cover Removal And Installation
• MAINFRAME
• SEAT BAR
• Description
• Removal And Installation
• Disassembly And Assembly
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation
• 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
• Seat Belt Removal And Installation
• Lower Cushion Removal And Installation
• Back Cushion Removal And Installation
• Shock Removal And Installation
• 3-Point Seat Belt Removal And Installation
• BOB-TACH HAND LEVER
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• Pivot Pin Bushing And Seal Removal And Installation
• LIFT ARMS
• Removal And Installation
• REAR GRILLE
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Striker Removal And Installation
• Striker Disassembly And Assembly
• Striker (Adjusting)
• Latch Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender Removal And Installation
• Fuel Fill Screen Removal And Installation
• Fuel Pickup Screen
• CONTROL PEDALS AND LINKAGES
• Description
• Pedal Removal And Installation
• Linkage Removal And Installation
• Pedal (Adjusting)
• CONTROL PANEL
• Description
• Removal And Installation
• Shaft Removal And Installation
• Shaft Disassembly And Assembly
• Linkage Removal And Installation
• Pintle Arm Removal And Installation
• Pintle Arm Disassembly And Assembly
• Linkage Neutral Adjusting
• Linkage Travel Adjusting
• CONTROL HANDLE / LEVER
• Description
• Lever Removal And Installation
• Boot Removal And Installation
• WINDOW (REAR)
• Removal
• Installation
• WINDOW (TOP)
• Removal And Installation
• WINDOW (SIDE)
• Removal And Installation
• WINDOW (FRONT DOOR)
• Removal (Standard Window)
• Installation (Standard Window)
• Removal And Installation (Special Applications Window)
• CAB DOOR
• Description
• Removal And Installation
• Aligning
• Adjusting
• Checking Operation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Cab Harness Connectors
• Mainframe Harness Connectors
• Description
• Troubleshooting
• Fuse And Relay Location / Identification
• Solenoid Testing
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Belt Adjustment
• Belt Replacement
• 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 Panel
• Display Screen
• Standard Key Panel
• Deluxe Instrumentation Panel
• Side Panel
• Front Panel
• Removal And Installation (Left And Right)
• Key Switch Removal And Installation
• Alarm Removal And Installation
• Front Accessory Panel Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• Cab Light Removal And Installation
• BOBCAT CONTROLLER (MAIN)
• Description
• Connector Identification
• Removal And Installation
• DIAGNOSTIC SERVICE CODES
• Viewing Service Codes (Standard Key Panel)
• Viewing Service Codes (Deluxe Instrumentation Panel)
• Service Codes List
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• Description
• Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
• Inspecting The Seat Bar Sensor (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm Bypass Control
• Troubleshooting
• Troubleshooting Chart
• SEAT BAR SENSOR
• Description
• Troubleshooting
• Testing
• Removal And Installation
• Bobcat Interlock Control System (BICS™) Circuit Test
• TRACTION LOCK
• Description
• Troubleshooting
• Removal And Installation
• Inspecting
• SERVICE PC (LAPTOP COMPUTER)
• Connecting To The Remote Start Tool
• Connecting Remote Start Tool (Service Tool)
• FLYWHEEL RPM SENSOR
• Description
• Adjusting
• CONTROL PANEL SETUP
• Right Panel Setup (Deluxe Instrumentation Panel)
• Attachment Control Information (Deluxe Instrumentation Panel)
• PASSWORD SETUP
• Password Description
• Changing The Owner Password
• Changing The User Passwords
• Password Lockout Feature
• MAINTENANCE CLOCK
• Description
• Setup
• Reset
• BACK-UP ALARM SYSTEM
• Description
• Inspecting
• Adjusting Switch Position
• Troubleshooting
• Alarm Removal And Installation
• Switch 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
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• ENGINE COOLING SYSTEM
• Radiator Removal And Installation
• Fan Removal And Installation
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Housing Removal And Installation
• Testing The Thermostat
• 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 – Checking
• Fuel Shutoff Solenoid Removal And Installation
• Fuel Injection Pump Removal And Installation
• Timing The Injection Pump
• Fuel Injector Removal And Installation
• Fuel Injector Nozzles Pressure – Checking
• Nozzle Spray Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Glow Plug – Testing
• Glow Plug Removal And Installation
• Valve Clearance Adjustment
• Valve Timing – Checking
• 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
• Valve Tappets
• 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 Bearings Removal And Installation
• Crankshaft And Bearings – Servicing
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal And Installation
• Timing Gears Backlash – Checking
• Idler Gear And Shaft Removal And Installation
• Camshaft – Servicing
• Idler Gear And Shaft Servicing
• FLYWHEEL
• Flywheel Removal And Installation
• HEATING, VENTILATION, AIR CONDITIONING
• HEATER SYSTEM
• Description
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• Cleaning The Heater Coil
• TROUBLESHOOTING
• Blower Motor Does Not Operate
• Blower Motor Operators Normally, But Air Flow Is Insufficient
• Electrical System
• Engine Coolant bypassing The Heater Valve
• Heater Valve Not Opening Or Closing
• HEATER UNIT
• Removal And Installation
• HEATER COIL
• Removal And Installation
• HEATER FAN
• Blower Removal And Installation
• Disassembly And Assembly
• Connector Identification
• HEATER VALVE
• Removal And Installation
• Disassembly And Assembly
• SPECIFICATIONS
• (S100) LOADER SPECIFICATIONS
• Machine Dimensions
• Performance
• Engine
• Controls
• Drive System
• Hydraulic System
• Electrical
• 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
• Port Seal Fitting
• HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalent Chart
• U.S. To Metric Conversion Chart
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISION
• Revision No: S100 – 1
• Revision No: S100 – 2
• Revision No: S100 – 3