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
• Bobcat Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• Engaging The Lift Arm Support Device
• Disengaging The Lift Arm Support Device
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• TRANSPORTING THE LOADER
• Procedure
• Adjusting The Bumper
• TOWING THE LOADER
• Procedure
• REMOTE START
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Element
• ENGINE COOLING SYSTEM
• Checking The Coolant Level
• Cleaning The Cooling System
• Replacing The Coolant
• FUEL SYSTEM
• Fuel Specification
• 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
• Hydraulic/Hydrostatic Filter Replacement
• Replacing The Hydraulic/Hydrostatic Fluid
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• AUXILIARY CONTROL LOCKBOLT
• Procedure
• BOB-TACH
• Inspection And Maintenance
• LUBRICATING THE LOADER
• Procedure
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Rotation
• Tire Inflation
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• PIVOT PINS
• Procedure
• SEAT BAR RESTRAINT SYSTEM
• Seat Bar Inspection
• Seat Bar Maintenance
• Foot Pedal Clean Out
• HYDRAULIC SYSTEM
• HYDRAULIC SCHEMATIC
• HYDRAULIC SYSTEM INFORMATION
• Troubleshooting Chart
• CYLINDER (LIFT)
• Checking The Lift Cylinder(s)
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CYLINDER (TILT)
• Checking The Tilt Cylinder
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• MAIN RELIEF VALVE
• Checking The Main Relief Valve Without Auxiliaries
• Checking The Main Relief Valve With Auxiliaries
• Removal And Installation
• HYDRAULIC CONTROL VALVE
• BICS™ Valve Removal And Installation
• BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation
• BICS™ Valve, Pressure Differential Valve Removal And Installation
• BICS™ Valve, Check Valve Removal And Installation
• BICS™ Valve, Solenoid Removal And Installation
• BICS™ Valve, Solenoid Testing
• BICS™ Valve, Identification Chart
• Removal And Installation
• Identification Chart
• Disassembly And Assembly
• Load Check Valves Removal And Installation
• Main Relief Valve Removal And Installation
• Port Relief/Anti-Cavitation Valve Removal And Installation
• Anti Cavitation/Check Valves Removal And Installation
• Rubber Boot Removal And Installation
• Lift And Tilt Lock Block Removal And Installation
• Lift Spool And Detent Removal
• Lift Spool And Detent Disassembly
• Lift Spool And Detent Assembly
• Lift Spool Detent Installation
• Tilt Spool Removal And Installation
• Tilt Spool Disassembly And Assembly
• Auxiliary Spool Removal And Installation
• Auxiliary Spool Disassembly And Assembly
• Spool Seal Installation
• Auxiliary Pivot Bracket Removal And Installation
• Auxiliary Pivot Bracket Disassembly And Assembly
• LIFT ARM BY-PASS VALVE
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Checking The Output Of The Pump
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC FILTER
• Block Removal And Installation
• Block Disassembly And Assembly
• HYDRAULIC RESERVOIR
• Removal And Installation
• CONTROLS
• Pedal Interlock Linkage Removal And Installation
• Control Pedals Removal And Installation
• Pedal Adjustment
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• CONTROL PANEL
• Control Shield And Steering Lever Panels Removal And Installation
• STEERING
• Lever Removal And Installation
• Lever Disassembly And Assembly
• Linkage Adjustment
• Pintle Arm Removal And Installation
• Pintle Arm Disassembly And Assembly
• HYDROSTATIC MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• CHARGE PRESSURE
• Checking
• HYDROSTATIC PUMP
• Parts Identification
• Removal And Installation
• Disassembly And Assembly
• DRIVE BELT
• Removal And Installation
• Tension Pulley And Spring Removal And Installation
• OIL COOLER
• Removal And Installation
• DRIVE SYSTEM
• PARKING BRAKE
• Disc Removal And Installation
• DRIVE COMPONENTS
• Axle Hub Removal And Installation
• Axle Seal Removal And Installation
• Removing The Axle
• Removing And Installing The Axle Bearing
• Removing The Bearing Races
• Installing The Bearing Races
• Installing The Inner Bearing And Axle Sprocket
• Drive Chain Removal And Installation
• CHAINCASE
• Removing Oil From The Chaincase
• Chaincase Cover Removal And Installation
• Chaincase Cover Assembly And Disassembly
• MAIN FRAME
• SEAT BAR
• Removal And Installation
• Assembly
• OPERATOR CAB
• Removal And Installation
• Gas Cylinder Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• BOB-TACH
• Removal
• Installation
• Seal Removal And Installation
• Lever And Wedge Removal
• LIFT ARMS
• Removal And Installation
• REAR WINDOW
• Removal
• Installation
• REAR DOOR
• Removal And Installation
• FUEL TANK
• Removal And Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Troubleshooting Chart
• Description
• Fuel Shutoff Timer and Fuel Pull Solenoid Locations
• Fuse And Relay Switches Location
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Removal And Installation
• Adjusting The Alternator Belt
• Alternator Belt Removal And Installation
• Description
• Alternator Output Test
• STARTER
• Removal And Installation
• Checking The Starter In The Loader
• Parts Identification
• Disassembly
• Inspection And Repair
• No Load Test
• Assembly
• INSTRUMENT PANEL
• Removal And Installation
• LIGHTS
• Front Lights Removal And Installation
• Rear Lights Removal And Installation
• Cab Light Removal And Installation
• BICS™ SYSTEM CONTROLLER
• Troubleshooting Guide
• Removal And Installation
• BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)
• 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 By-Pass Control
• Troubleshooting Chart
• SEAT BAR SENSOR
• Troubleshooting Guide
• Seat Bar Sensor Test
• Removal And Installation
• BICS™ Controller Seat Bar Sensor Circuit Test
• TRACTION LOCK
• Troubleshooting Guide
• Removal And Installation
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Adjustment
• Removal And Installation
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• RADIATOR
• Removal And Installation
• COOLING FAN
• Removal And Installation
• ENGINE COMPONENTS AND TESTING
• Fuel Injection Pump Check
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump Timing
• Fuel Injector Nozzles Checking
• Fuel Injector Nozzles Removal
• Fuel Injector Nozzles Installation
• Glow Plugs Checking
• Engine Compression Test Procedure
• Fuel Lift Pump Removal And Installation
• ENGINE
• Removal And Installation
• FLYWHEEL
• Removal And Installation
• ENGINE MOUNTING BRACKET
• Removal And Installation
• RECONDITIONING THE ENGINE
• Thermostat Removal And Installation
• Water Pump Removal And Installation
• Timing Gear Case Cover Removal And Installation
• Oil Pump Removal And Installation
• Crankshaft Front Seal Removal And Installation
• Engine Speed Control Plate Removal And Installation
• Governor Spring Removal
• Start Spring Removal
• Idle Limit And Fuel Limit Adjustment
• Exhaust Manifold Removal And Installation
• Valve Cover Removal And Installation
• Rocker Arm Removal And Installation
• Push Rod Removal And Installation
• Tappet Removal And Installation
• Water Flange Removal And Installation
• Cylinder Head Removal
• Cylinder Head Installation
• Checking Piston Top Clearance
• Cylinder Head Disassembly
• Cylinder Head Assembly
• Servicing The Cylinder Head
• Combustion Chamber Removal And Installation
• Idler Gear Removal And Installation
• Camshaft Removal And Installation
• Injection Pump Shaft Removal And Installation
• Oil Pan Removal And Installation
• Governor Shaft Removal And Installation
• Governor Fork Lever Removal And Installation
• Piston Removal And Installation
• Checking The Piston And Connecting Rod
• Connecting Rod Alignment
• Piston Ring Gap
• Piston Ring Installation
• Connecting Rod Installation
• Checking Engine Cylinder Bore
• Crankshaft Removal And Installation
• Checking Crankshaft Journal And Block Bearing
• Checking The Crankshaft Journal And Main Bearing
• Connecting Rod Journal
• Checking The End Play Of The Crankshaft
• Crankshaft Alignment
• Engine Timing Installation
• Idler Gear And Crankshaft
• Idler Gear And Camshaft Gear
• Idler Gear And Injection Pump Shaft Gear
• Injection Pump Shaft And Governor Shaft Gear
• SPECIFICATIONS
• LOADER SPECIFICATIONS
• Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• Floor Pressure
• ENGINE SPECIFICATIONS
• Engine
• Fuel Injector Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Rocker Arms
• Camshaft
• Cylinders
• Piston Rings
• Pistons
• Crankshaft
• Oil Pump
• Thermostat
• Bolt Torques
• 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 FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalents
• U.S. To Metric Conversion
• SMR
• 463-1
• 463-2