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
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Excavator Serial Number
• Engine Serial Number
• DELIVERY REPORT
• BOBCAT EXCAVATOR IDENTIFICATION
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE EXCAVATOR
• Procedure
• UPPERSTRUCTURE SLEW LOCK
• LIFTING THE EXCAVATOR
• TRANSPORTING THE EXCAVATOR ON A TRAILER
• Loading And Unloading
• Fastening To Transport Vehicle
• FOLD-DOWN TOPS
• TOPS Position
• Lowering The Fold-Down TOPS
• Raising The Fold-Down TOPS
• TAILGATE
• Opening And Closing The Tailgate
• SERVICE SCHEDULE
• Chart
• AIR CLEANER
• Daily Check
• Replacing The Filters
• COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing The Coolant
• FUEL SYSTEM
• Fuel Specifications
• Biodiesel Blend Fuel
• Filling The Fuel Tank
• Removing Water From The Fuel Filter
• Replacing The Fuel Filter
• Draining The Fuel Tank
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Replacing Oil And Filter
• HYDRAULIC SYSTEM
• Checking And Adding Hydraulic Oil
• Diagnostic Connectors
• Replacing The Hydraulic Filter
• Replacing Hydraulic Oil
• LUBRICATION OF THE HYDRAULIC EXCAVATOR
• TRAVEL MOTOR
• Checking Oil Level
• Draining The Travel Motor
• SPARK ARRESTER MUFFLER
• Cleaning Procedure
• ALTERNATOR BELT
• Adjusting The Alternator Belt
• SEAT BELT
• Inspection And Maintenance
• CONTROL CONSOLE LOCKOUTS
• Inspection And Maintenance
• EXCAVATOR STORAGE AND RETURN TO SERVICE
• Storage
• Return To Service
• STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
• MOTION ALARM (IF EQUIPPED)
• Description
• Inspecting
• Adjusting Switch Position
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting The Hydraulic Circuit
• Troubleshooting The Cylinder Circuit
• Troubleshooting The Swing (Upperstructure Slew) Circuit
• Troubleshooting The Travel Circuit
• BOOM CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• ARM CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BOOM SWING CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BUCKET CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BLADE CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• TRACK FRAME EXPANSION CYLINDER
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Testing And Adjusting The Main Relief Valve
• PORT RELIEF VALVES
• Testing And Adjusting The Port Relief Valve Pressure
• PRESSURE REDUCING VALVE
• Testing And Adjusting The Pressure Reducing Valve
• HYDRAULIC CONTROL VALVE
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Left Travel Valve Section Disassembly And Assembly
• Slew Valve Section Disassembly And Assembly
• Arm Valve Section Disassembly And Assembly
• Boom Swing Valve Section Disassembly And Assembly
• Auxiliary Valve Section Disassembly And Assembly
• Blade Valve Section Disassembly And Assembly
• Bucket Valve Section Disassembly And Assembly
• Boom Valve Section Disassembly And Assembly
• Right Travel Valve Section Disassembly And Assembly
• Assembly
• HYDRAULIC PUMP
• Description
• Testing The Hydraulic Pump
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MANIFOLD ASSEMBLY / ACCUMULATOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• TRAVEL MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• SWIVEL JOINT
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• SLEW MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CONTROL PATTERN SELECTOR VALVE
• Description
• Removal And Installation
• Disassembly And Assembly
• RIGHT CONTROL LEVER (JOYSTICK)
• Description
• Testing
• Handle Removal And Installation
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• LEFT CONTROL LEVER (JOYSTICK)
• Description
• Testing
• Handle Removal And Installation
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• HYDRAULIC RESERVOIR
• Description
• Removal And Installation
• OIL COOLER (IF EQUIPPED)
• Description
• Removal And Installation
• BLADE / TRACK EXPAND VALVE
• Description
• Block Removal And Installation
• Control Handle Removal And Installation
• Block Disassembly And Assembly
• BUILD-UP VALVE
• Description
• Removal And Installation
• Disassembly And Assembly
• TWO SPEED CONTROL VALVE
• Description
• Block Removal And Installation
• Solenoid Removal And Installation
• Block Disassembly And Assembly
• UNDERCARRIAGE
• BLADE
• Description
• Extension Removal And Installation
• Blade Removal And Installation
• TRACKS
• Track Lug Height
• Track Tension Adjustment
• Removal And Installation
• TRACK FRAME
• Disassembly And Assembly
• Removal And Installation Of Expandable Track Frame
• TRACK DAMAGE IDENTIFICATION
• Cutting Of The Steel Cords
• Causes Of The Damage
• Abrasion Of Embedded Metals
• Separation Of Embedded Metals
• Separation Of Embedded Metals Due To Corrosion
• Cuts On The Lug Side Rubber
• Cracks On The Lug Side Rubber Due To Fatigue
• Lug Abrasion
• Cracks And Cuts On The Lug Side Rubber
• Abrasion Of The Track Roller Side
• Cuts On The Edges Of The Track Roller Side
• TRACK IDLER
• Parts Identification
• Disassembly
• Assembly
• TRACK ROLLER
• Parts Identification
• Disassembly
• Assembly
• SWING CIRCLE GEAR
• Removal And Installation
• UPPERSTRUCTURE AND SWING SECTION
• UPPERSTRUCTURE
• Description
• Removal
• Installation
• TOPS
• Removal And Installation
• SEAT
• Removal And Installation
• RIGHT CONSOLE
• Joystick Console Cover Removal And Installation
• Gas Spring Removal And Installation
• Compression Spring Removal And Installation
• Lever Removal And Installation
• Joystick Console Frame Removal And Installation
• Joystick Console Frame Disassembly And Assembly
• LEFT CONSOLE
• Joystick Console Cover Removal And Installation
• Gas Spring Removal And Installation
• Compression Spring Removal And Installation
• Lever Removal And Installation
• Joystick Console Frame Removal And Installation
• Joystick Console Frame Disassembly And Assembly
• ENGINE SPEED CONTROL
• Removal And Installation
• Cable Removal
• Cable Installation
• BLADE CONTROL
• Removal And Installation
• Disassembly And Assembly
• Two Speed Switch Removal And Installation
• UPPERSTRUCTURE SLEW LOCK
• Removal And Installation
• Disassembly And Assembly
• RIGHT PEDAL
• Pedal Removal And Installation
• Control Linkage Removal And Installation
• Control Linkage Disassembly And Assembly
• TRAVEL CONTROLS
• Right Hand Travel Control Removal And Installation
• Right Hand Travel Control Disassembly And Assembly
• Left Hand Travel Control Removal And Installation
• Left Hand Travel Control Disassembly And Assembly
• LEFT PEDAL
• Pedal Removal And Installation
• Control Linkage Removal And Installation
• Control Linkage Disassembly And Assembly
• FLOOR PANELS
• Description
• Left Floor Panel Removal And Installation
• Right Floor Panel Removal And Installation
• FUEL TANK
• Removal And Installation
• HORN
• Removal And Installation
• SWING FRAME
• Description
• Removal And Installation
• Bushing Removal
• Bushing Installation
• Boom Pivot Bushing Removal
• Boom Pivot Bushing Installation
• BOOM
• Description
• Removal And Installation
• ARM
• Description
• Removal And Installation
• Arm To Boom Bushing Removal And Installation
• Arm To Bucket And Bucket Link Bushing Removal And Installation
• BUCKET
• Removal And Installation
• TAILGATE
• Removal And Installation
• Latch Removal And Installation
• COUNTER WEIGHTS
• Rear Counter Weight Removal And Installation
• Left Hand Side Counter Weight Removal And Installation
• Right Hand Side Counter Weight Removal And Installation
• SIDE COVERS
• Upper Left Hand Side Cover Removal And Installation
• Upper Right Hand Side Cover Removal And Installation
• Lower Left Hand Side Cover Removal And Installation
• Lower Right Hand Side Cover Removal And Installation
• INSTRUMENT PANEL
• Removal And Installation
• Disassembly And Assembly
• ELECTRICAL SYSTEM AND ANALYSIS
• ELECTRICAL SCHEMATIC
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Troubleshooting
• Description
• Fuse And Relay Location / Identification
• Fuel Timer Location / Identification
• BATTERY
• Servicing
• Removal And Installation
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Description
• Tests
• Alternator Output Test
• Full Field Test
• Alternator Regulator Test
• Alternator Regulator Test With Voltmeter
• Removal And Installation
• Charging System Inspection
• Parts Identification
• STARTER
• Removal And Installation
• Parts Identification
• Cleaning And Inspection
• LIGHTS
• Boom Light Removal And Installation
• Light Bulb Removal And Installation
• Light Switch Removal And Installation
• MICROSWITCH
• Testing Left Console Microswitch
• Left Console Microswitch Removal And Installation
• Testing Right Console Microswitch
• Right Console Microswitch Removal And Installation
• FUEL LEVEL SENDER
• Removal And Installation
• Testing
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• SPARK ARRESTOR MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• RADIATOR
• Removal And Installation
• ENGINE COMPONENTS AND TESTING
• Valve Clearance Adjustment
• Engine Compression Checking
• Fuel Shutoff Solenoid – Checking
• Fuel Shutoff Solenoid Removal And Installation
• Fuel Shutoff Timer Removal And Installation
• Fuel Injection Pump Check
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump Timing
• Fuel Injector Removal And Installation
• Fuel Injector Checking
• Valve Seat Tightness
• Glow Plug Removal And Installation
• ENGINE
• Description
• Removal And Installation
• Engine Mount Replacement
• FLYWHEEL AND HOUSING
• Flywheel Housing Removal And Installation
• Hydraulic Pump Coupler Removal And Installation
• Flywheel Removal And Installation
• Rear End Plate 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
• Valve Timing, Checking
• Valve And Valve Seat Reconditioning
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft, Checking
• Timing Gearcase Cover Removal And Installation
• Idler Gear And Camshaft Removal And Installation
• Idler Gear And Shaft, Servicing
• Timing Gears Checking Backlash
• Fuel Camshaft Removal And Installation
• Fuel Camshaft Governor
• Crankshaft Gear Removal And Installation
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump, Service
• Engine Oil Pressure, Checking
• Relief Valve
• 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
• Thermostat Removal And Installation
• Testing The Thermostat
• SPECIFICATIONS
• SPECIFICATIONS 418 EXCAVATOR
• Machine Dimensions
• Performance
• Controls
• Engine
• Hydraulic system
• Hydraulic cylinders
• Hydraulic Cycle Times
• Electrical
• Drive system
• Swing System
• Undercarriage
• Capacities
• Tracks
• Ground Pressure
• ENGINE SPECIFICATIONS
• Engine
• Fuel Injector Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Rocker Arms
• Camshaft
• Cylinders
• Piston Rings
• Pistons
• Connecting Rods
• Crankshaft
• Oil Pump
• Thermostat
• Torque Values
• 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 FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion Chart
• SERVICE MANUAL REVISION
• Revision No: 418 – 1