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
• SAFETY INSTRUCTIONS
• Safety Is your Responsibility
• Before You Operate The Bobcat Loader
• Safe Operation needs A Qualified Operator
• FIRE PREVENTION
• SERIAL NUMBER LOCATIONS
• Loader Serial Number
• Engine Serial Number Locations
• ARRIVAL CONDITION REPORT
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• PREVENTIVE MAINTENANCE
• SERVICE SCHEDULE
• LIFT ARM STOP
• FRAME LOCK
• LIFTING AND BLOCKING THE LOADER
• REAR DOOR
• Door Latch Adjustment
• AIR CLEANER
• FUEL SYSTEM
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Engine Oil And Filter Replacement
• ENGINE COOLING SYSTEM
• Coolant Level
• Coolant Replacement
• ALTERNATOR BELT ADJUSTMENT
• ELECTRICAL SYSTEM
• Electrical System Service
• Using An Extra Battery (Jump Starting)
• Battery Replacement
• HYDRAULIC / HYDROSTATIC SYSTEM
• Hydraulic/Hydrostatic Fluid Reservoir
• Checking And Adding Fluid
• Hydraulic Fluid Replacement
• Hydraulic / Hydrostatic Filter Replacement
• SPARK ARRESTOR MUFFLER
• FRONT & REAR AXLES
• U-JOINTS
• TIRE MAINTENANCE
• Wheel Nuts
• LOADER LUBRICATION
• BACK-UP ALARM
• OPERATOR CAB
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• TROUBLESHOOTING
• HYDRAULIC SYSTEM INFORMATION
• 37° Flare Connections
• Straight Thread O-Ring Fitting
• Tubelines And Hoses
• PORT BLOCK SERVICE
• Bronze (40 Micron) Filter Replacement
• Neutral By-Pass Valve Replacement
• Cold Oil By-Pass Valve Replacement
• OIL RESERVOIR
• Oil Reservoir Removal
• Oil Reservoir Installation
• HYDRAULIC CONTROL VALVE (S/N 12999 & BELOW)
• Hydraulic Control Valve Removal
• Hydraulic Control Valve Disassembly
• Inlet Section
• Tilt Section
• Lift Section
• Auxiliary Section (For Older Style Control Valves)
• Auxiliary Section (For Control Valves Equipped With Adjustable Detent)
• Auxiliary Detent Adjustment
• Hydraulic Control Valve Assembling
• Hydraulic Control Valve Installation
• HYDRAULIC CONTROL VALVE (S/N 13001 & ABOVE – MELROE VALVE)
• Hydraulic Control Valve Removal
• Hydraulic Control Valve Disassembly
• Hydraulic Control Valve Inspection
• Hydraulic Control Valve Assembling
• Hydraulic Control Valve Installation
• HYDRAULIC MAIN RELIEF VALVE
• Hydraulic Main Relief Valve Testing
• Hydraulic Main Relief Valve Replacement
• Hydraulic Main Relief Valve Adjustment (S/N 12999 & Below)
• Hydraulic Main Relief Valve Cleaning (S/N 13001 & Above)
• Hydraulic Main Relief Valve Adjustment (S/N 13001 & Above)
• HYDRAULIC PUMP
• Checking Hydraulic Pump Pressure
• Hydraulic Pump Removal
• Hydraulic Pump Disassembly
• Hydraulic Pump Inspection
• Hydraulic Pump Assembling
• Hydraulic Pump Installation
• Checking Steering Relief Pressure
• HYDRAULIC CYLINDERS
• Checking Lift And Tilt Cylinder Seals
• Checking Steering Cylinder Seals
• Lift Cylinder Removal
• Lift Cylinder Installation
• Tilt Cylinder Removal
• Tilt Cylinder Installation
• Steering Cylinder Removal
• Steering Cylinder Installation
• Hydraulic Cylinder Disassembly
• Hydraulic Cylinder Assembly
• STEERING CONTROL VALVE
• Steering Control Valve Removal
• Steering Control Valve Disassembly
• Steering Control Valve Inspection
• Steering Control Valve Assembling
• Steering Control Valve Installation
• HYDROSTATIC SYSTEM
• TROUBLESHOOTING
• SERVO CONTROL
• Servo Control Neutral Adjustment
• Servo Control Removal
• Servo Control Disassembly
• Servo Control Assembling
• Servo Control Installation (S/N 13033 & Below)
• Servo Control Installation (S/N 13034 & Above)
• FOOT PEDAL, PEDAL LOCK SYSTEM AND CENTERING MECHANISM
• Foot Pedal Angle Adjustment
• Seat Bar Assembly (S/N 13092 & Above)
• Pedal Lock Cable
• Centering Mechanism Removal
• Centering Mechanism Spring Adjustment
• S/N 13091 & Below
• S/N 13092 & Above
• Centering Mechanism Spring Replacement
• S/N 13091 & Below
• S/N 13092 & Above
• Centering Mechanism Installation
• Checking The Neutral Safety Switch
• Neutral Safety Switch Adjustment
• Micro Switch Adjustment
• CHARGE PRESSURE AND REPLENISHING VALVES
• Checking Charge Pressure
• Checking Orifice In Charge Tubeline
• Replenishing Valves
• HYDROSTATIC PUMP
• Hydrostatic Pump Removal
• Hydrostatic Pump Disassembly
• Hydrostatic Pump Inspection
• Hydrostatic Pump Assembling
• Hydrostatic Pump Installation On The Manifold Block
• Hydrostatic Pump Installation
• Hydrostatic Pump Start-Up Procedure
• HYDROSTATIC MOTOR
• Hydrostatic Motor Removal
• Hydrostatic Motor Disassembly
• Hydrostatic Motor Inspection
• Hydrostatic Motor Assembly
• Manifold block Disassembly
• Manifold Block Assembling
• Hydrostatic Motor Installation
• Hydrostatic Motor Start-Up
• Emergency Tow Valve
• DRIVE SYSTEM
• TROUBLESHOOTING THE DRIVE SYSTEM
• DRIVE SHAFT
• Drive Shaft Removal
• Drive Shaft Installation
• REAR AXLE
• Rear Axle Removal
• Rear Axle Installation
• FRONT AXLE
• Front Axle Removal
• Front Axle Installation
• AXLE AND DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
• Hub Removal
• Hub Installation
• Differential Assembly Removal
• Ring Gear Removal
• Ring Gear Installation
• Clutch Plate Removal
• Clutch Plate Installation
• Drop Gear And Pinion Shaft Removal
• Assembling Procedure Explanation
• Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)
• Pinion Shaft Bearing Installation
• Pinion Shaft Installation
• Setting Pinion Shaft Position (Using Tool – Pinion Shaft NOT Installaed)
• Setting Pinion Bearing Pre-Load
• Differential Assembly Installation & Checking End Play (Pinion Shaft Installed)
• Checking Gear Backlash
• PARKING BRAKE (S/N 13060 & BELOW)
• Description
• Parking Brake Adjustment
• Parking Brake Cable Removal
• Parking Brake Cale Installation
• Parking Brake Removal Fromm The Hydrostatic Motor
• Parking Brake Installation On The Hydrostatic Motor
• HYDRAULIC BRAKE (DUSCO) (S/N 13061 & ABOVE)
• Description
• Brake Removal (Dusco)
• Brake Servicing (Dusco)
• Brake Installation (Dusco)
• Removing Air From The Brake System (Dusco)
• Brake Valve Removal
• Brake Valve Service
• Brake Valve Installation
• BRAKE (SY*TEC)
• Removal And Installation
• Disassembly And Assembly
• MAIN FRAME
• OPERATOR CAB
• Operator Cab Removal
• Operator Cab Installation
• BOB-TACH
• Checking Bob-Tach Wedges
• Bob-Tach Removal
• Bob-Tach Installation
• FLOORPANEL
• Floorpanel Removal
• Floorpanel Installation
• SEAT AND SEAT PLATE
• Seat And Seat Plate Removal
• Seat And Seat Plate Installation
• FUEL TANK
• Fuel Tank Removal
• Fuel Tank Installation
• DOORS
• Rear Door Removal
• Rear Door Installation
• Side Door Removal
• Side Door Installation
• LOADER DISASSEMBLY AND ASSEMBLY
• Seperating The Sections
• Connecting The Sections
• LIFT ARMS
• Lift Arm Removal
• Lift Arm Installation
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM
• Description
• TROUBLESHOOTING
• BATTERIES
• Checking The Batteries
• Battery Safety Procedures
• DIODES
• Checking The Diodes
• Diode Replacement
• ALTERNATOR
• Checking The Alternator
• Alternator Removal
• Alternator Service
• Alternator Installation
• STARTER
• Checking The Starter
• Starter Removal
• Starter Service
• Starter Installation
• ENGINE SERVICE
• ENGINE SERVICE (S/N 12999 & BELOW)
• TROUBLESHOOTING
• CHECKS AND ADJUSTMENTS
• Oil Pressure
• Valve Clearance
• Engine Compression
• Servicing The Air Cleaner
• Throttle Linkage Adjustment
• FUEL SYSTEM AND TIMING
• FUEL FILTERS
• Replacing The Final Fuel Filter Element
• Cleaning The Water Filter Trap
• REMOVING AIR FROM THE FUEL SYSTEM
• FUEL LIFT PUMP
• Checking The Lift Pump
• Removing The Lift Pump
• Installing The Lift Pump
• FUEL INJECTION PUMP
• Removing The Fuel Injection Pump
• Installing The Fuel Injection Pump
• Timing The Fuel Injection Pump (Using Dial Indicator)
• Timing The Fuel Injection Pump (Using The Timing Tool)
• Checking The Timing Mark On The Flange Injection Pump
• FUEL INJECTOR NOZZLES
• Removing Fuel Injector Nozzles
• Checking Fuel Injector Nozzles
• Installing Fuel Injector Nozzles
• ENGINE
• Removing The Engine
• Installing The Engine
• BLOWER HOUSING SHIELD
• Removing The Blower Housing Shield
• Installing The Blower Housing Shield
• RADIATOR AND OIL COOLER ASSEMBLY
• Cleaning Radiator And Oil Cooler Assembly
• Removing Radiator And Oil Cooler Assembly
• Installing Radiator And Oil Cooler Assembly
• ENGINE BLOWER HOUSING
• Installing The Engine Blower Housing
• SPARK ARRESTOR MUFFLER
• Cleaning The Muffler
• Removing The Muffler
• Installing The Muffler
• CYLINDER HEAD
• Removing The Cylinder Head
• Removing Valves
• Reconditioning The Valves And Valve SEATS
• Installing Valve Guides
• Checking Valve Springs
• Combustion Chamber Inserts
• Aligning Cylinder Head Surfaces
• Installing Valves
• Disassembling The Rocker Arms
• Checking The Rocker Arms
• Assembling The Rocker Arms
• Installing The Cylinder Head
• RECONDITIONING THE ENGINE
• PISTONS AND CONNECTING RODS
• Removing Pistons
• Disassembling Pistons
• Inspecting The Pistons
• Installing Pistons To Connecting Rod
• Installing Piston Assembly In The Engine Block
• Installing New Pistons
• CYLINDER LINERS
• Checking Liners
• Installing Liners
• MAIN BEARINGS
• Removing The Main Bearings
• Installing The Main Bearings
• Crankshaft End Play
• CRANKSHAFT
• Removing The Crankshaft
• Checking The Crankshaft
• Installing The Crankshaft
• REAR MAIN BEARING OIL SEAL
• Installing The Oil Seal
• TIMING CASE AND GEARS
• Removing The Timing Case Cover
• Installing The Timing Case Cover
• Removing The Front Seal
• Installing The Front Seal
• Removing The Idler Gear and Hub
• Inspecting The Idler Gear And Hub
• Installing The Idler Gear And Hub
• Removing The Camshaft Gear
• Installing The Camshaft Gear
• Removing The Fuel Injection Pump
• Installing The Fuel Injection Pump
• Removing The Crankshaft Gear
• Removing The Timing Case
• Installing The Timing Case
• Removing Camshaft And Tappets
• Inspecting Camshaft And Tappets
• Installing Camshaft And Tappets
• LUBRICATION SYSTEM
• Description Of The Lubrication System
• Checking Engine Oil
• Replacing Engine Oil And Filter
• OIL PAN
• Removing The Oil Pan
• Installing The Oil Pan
• OIL PUMP
• Removing The Oil Pump
• Disassembling The Oil Pump
• Checking The Oil Pump
• Assembling The Oil Pump
• Installing The Oil Pump
• OIL FILTER
• Removing The Oil Filter
• Disassembling The Oil Filter
• COOLING SYSTEM
• Belt For The Alternator And Water Pump
• Coolant Level
• Removing Coolant From The Cooling System
• WATER PUMP
• Removing The Water Pump
• Disassembling The Water Pump
• Checking The Water Pump
• Assembling The Water Pump
• Installing The Water Pump
• THERMOSTAT
• Removing The Thermostat
• Checking The Thermostat
• Installing The Thermostat
• FLYWHEEL
• Removing The Flywheel
• Replacing The Flywheel Ring Gear
• Installing The Flywheel
• ENGINE SERVICE (S/N 13001 & ABOVE)
• TROUBLSHOOTING
• CHECKS AND ADJUSTMENTS
• Serial Number
• Oil Pressure
• Valve Clearance
• Check Engine Compression
• FUEL SYSTEM AND TIMING
• Fuel Filter
• Removing Air From The Fuel System
• Fuel Injection Pump
• Removing The Fuel Injection Pump
• Installing The Fuel Injection Pump
• Timing The Fuel Injection Pump
• Fuel Injector Nozzles
• Removing The Fuel Injector Nozzles
• Checking The Fuel Injector Nozzles
• Installing The Fuel Injector Nozzles
• High Pressure Fuel Lines
• Glow Plugs
• ENGINE AND ATTACHING PARTS
• Removing The Engine
• Installing The Engine
• Blower Housing Shield
• Removal
• Installation
• Engine Coolant Radiator
• Removal
• Installation
• Engine Blower Housing
• Removal
• Installation
• Engine Muffler
• Removal
• Installation
• Oil Cooler
• Removing The Oil Cooler
• Installing The Oil cooler
• CYLINDER HEAD
• Removing The Cylinder Head
• Removal Of The Valves
• Reconditioning The Valves And Valve Seats
• Installing The Valve Guides
• Checking Valve Springs
• Combustion Chamber Inserts
• Cylinder Head Inspection
• Installation Of The Valves
• Reconditioning The Rocker Arms
• Disassembly
• Checking
• Assembly
• Installing The Cylinder Head
• RECONDITIONING THE ENGINE
• Pistons And Connecting Rods
• Removal
• Disassembly
• Inspection
• Installation Of Piston To Connecting Rod
• Installation Of Rings On The Piston
• Installing Piston Assembly In The Engine Block
• Cylinder Liners
• Checking
• Installation
• Main Bearings
• Removal
• Installation
• Crankshaft End Play
• Crankshaft
• Removal
• Checking
• Installation
• Rear Main Bearing Oil Seal
• TIMING CASE AND GEARS
• Timing Case Cover
• Removal
• Installation
• Front Seal
• Removal
• Installation
• Idler Gear And Hub
• Removal
• Inspection
• Installation
• Camshaft Gear
• Removal
• Installation
• Fuel Injection Pump Gear
• Removal
• Installation
• Crankshaft Gear
• Timing Case
• Removal
• Installation
• Camshaft And Tappets
• Removal
• Inspection
• Installation
• LUBRICATION SYSTEM
• Description Of The Lubrication System
• Oil Pan
• Removal
• Installation
• Oil Pump
• Removal
• Disassembly
• Checking
• Assembly
• Installation
• Oil Filter And Adapter Housing
• Removal
• Installation
• COOLING SYSTEM
• Alternator And Water Pump Belt
• Water Pump
• Removal
• Installation
• Thermostat
• Removal
• Testing The Thermostat
• Installation
• FLYWHEEL
• Removal Of The Flywheel
• Replacement Of The Flywheel Ring Gear
• Installation Of The Flywheel
• TECHNICAL DATA (S/N 12999 & BELOW)
• LOADER SPECIFICATIONS
• Specifications
• Engine
• Loader Hydraulics
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS
• Cylinder Head Dimensions
• pistons And Connecting Rod Dimensions
• Cylinder Block And Liners Dimensions
• Crankshaft And Main Bearings Dimesions
• Timing Cse, Camshaft And Drive Dimensions
• Oil Pump Dimensions
• Cooling System And Water Pump Dimensions
• Fuel System Specifications
• De-Rating For Altitude
• Engine Bolt Torque
• Grinding Specifications For Crankshaft
• Crankshaft Regrinding Data
• HYDRAULIC SYSTEM
• HYDROSTATIC SYSTEM
• DECIMAL AND MILLIMETER EQUIVALENTS
• U.S. TO METRIC CONVERSION
• STANDARD TORQUE SPECIFICATIONS FOR BOLTS
• TECHNICAL DATA (S/N 13001 & ABOVE)
• LOADER SPECIFICATIONS
• Specifications
• Engine
• Loader Hydraulics
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS
• Cylinder Head Dimensions
• Pistons And Connecting Rod Dimensions
• Cylinder Block And Liner Dimensions
• Crankshaft And Main Bearing Dimensions
• Timing Case, Camshaft And Drive Dimensions
• Oil Pump Dimensions
• Cooling System And Water Pump Dimensions
• Fuel System Specifications
• De-Rating For Altitude
• Engine Torque
• Grinding Specifications For Crankshaft
• Crankshaft Regrind Data
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISIONS
• 2000-1
• 2000-2
• 2000-3