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
• SERIAL NUMBER LOCATIONS
• LOADER SERIAL NUMBER
• ENGINE SERIAL NUMBER
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• OPTIONS AND ACCESSORIES
• PREVENTIVE MAINTENANCE
• SERVICE SCHEDULE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• TRANSPORTING THE LOADER
• Procedure
• TOWING THE LOADER
• Procedure
• STOPPING THE BOBCAT LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• To Install The Lift Arm Support Device
• To Remove The Lift Arm Support Device
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• SEAT BAR RESTRAINT SYSTEM
• Description
• Seat Bar Inspection
• Seat Bar Maintenance
• AIR CLEANER SERVICE
• Replacing Filter Element
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Replacing Oil And Filter
• ENGINE COOLING SYSTEM
• Cleaning Cooling System (S/N 514111516 – 514114999)
• Cleaning The Cooling System (S/N 514111515 & Below)
• ALTERNATOR BELT
• Adjusting The Alternator Belt
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Hydraulic/Hydrostatic Filter Replacement
• Replacing Hydraulic Fluid
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Rotation
• Tire Mounting
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• FAN GEARBOX
• Checking And Maintaining
• LUBRICATING THE LOADER
• Procedure
• REMOTE START SWITCH
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• TROUBLESHOOTING
• HYDRAULIC SYSTEM INFORMATION
• Flare Connections
• O–ring Face Seal Connection
• Straight Thread O–ring Fitting
• Tubelines And Hoses
• LIFT CYLINDER(S)
• Checking The Lift Cylinder(s)
• Removal And Installation
• TILT CYLINDER(S)
• Checking The Tilt Cylinder(s)
• Removal And Installation
• HYDRAULIC CYLINDER
• Lift Cylinder Identification
• Tilt Cylinder Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking The Main Relief Valve
• Checking The Main Relief Valve Without Auxiliaries
• Removal And Installation
• HYDRAULIC CONTROL VALVE
• Removal And Installation
• Identification Chart
• Disassembly And Assembly
• Load Check Valve
• Main Relief Valve
• Port Relief Valve
• Anti–Cavitation Valve
• Rubber Boot
• Lift Spool And Detent
• Tilt Spool And Centering Spring
• Auxiliary Spool
• Auxiliary Electric Solenoid
• H Port – Auxiliary Section
• Base End Restrictor
• Inspection
• Spool Seal Installation
• HYDRAULIC PUMP
• Checking The Output Of The Pump
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDRAULIC FLUID RESERVOIR
• Draining The Fluid Reservoir
• Removal And Installation
• HYDROSTATIC FILTER HOUSING
• Removal And Installation
• HYDRAULIC FILTER HOUSING
• Removal And Installation
• HYDRAULIC/HYDROSTATIC FILTER HOUSING BRACKET
• Removal And Installation
• CONTROL PEDALS
• Removal And Installation
• Pedal Adjustment
• PEDAL INTERLOCK LINKAGE
• Removal And Installation
• Pedal Interlock Linkage Adjustment
• FRONT SIDE PANEL
• Removal And Installation
• REAR AUXILIARY DIVERTER
• Disassembly
• Inspection
• Solenoid Testing
• Assembly
• HYDROSTATIC SYSTEM
• TROUBLESHOOTING
• HYDROSTATIC SYSTEM INFORMATION
• Replenishing Valve Function
• FRONT PANEL
• Removal And Installation
• STEERING LEVERS
• Disassembly And Assembly
• Pre–Adjustment Checks
• Adjusting Lever Freeplay
• Adjusting The Wheel RPM Forward Compared To Reverse Travel
• Adjusting The Steering Neutral Setting
• Adjusting The Wheel RPM Left Compared To Right Side
• HYDROSTATIC MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• MOTOR CARRIER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• HYDROSTATIC PUMP
• Removal And Installation
• Replenishing/High Pressure Relief Valve
• Parts Identification
• Hydraulic Pump Removal
• Hydrostatic Pump Separation
• Charge Pump Disassembly
• Disassembly
• Inspection
• Assembly
• Charge Pump Assembly
• Hydrostatic Pump Connection
• Hydraulic Pump Installation
• Hydrostatic Pump Neutral Adjustment
• DRIVE BELT SHIELD
• Removal And Installation
• DRIVE BELT
• Adjusting The Drive Belt
• Replacing The Drive Belt
• DRIVE BELT TENSIONER PULLEY
• Removal And Installation
• Tension Spring
• OIL COOLER
• Removal And Installation (*S/N 514111516 – 514114999) (*Also S/N 514111504)
• Removal And Installation (S/N 514111515 & Below)
• DRIVE SYSTEM
• BRAKE PEDAL
• Removal And Installation
• Disassembly And Assembly
• BRAKE DISC
• Removal And Installation
• Removal And Installation (New Style Disc)
• Removal And Installation (Old Style Disc)
• FRONT CHAINCASE COVER
• Removal And Installation
• REAR CHAINCASE COVER
• Removal And Installation
• AXLE SEAL
• Removal And Installation
• AXLE, BEARINGS AND SPROCKET
• Removal And Installation
• DRIVE CHAIN
• Removal And Installation
• Removing The Fluid From The Chaincase
• MAIN FRAME
• SEAT BAR (W/GAS SPRING)
• Removal And Installation
• Assembly
• Compressing The Gas Cylinder
• SEAT BAR (W/COMPRESSION SPRING)
• Removal And Installation
• Assembling Components
• Compression Spring Disassembly And Assembly
• OPERATOR CAB GAS CYLINDER
• Removal And Installation
• Disassembly And Assembly
• OPERATOR CAB
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• BOB–TACH
• Removal And Installation
• Bob–Tach Lever And Wedge
• Pivot Pin Bushing And Seal Replacement
• LIFT ARM STABILIZER BAR
• Removal And Installation
• LIFT ARM LINK
• Removal And Installation
• LIFT ARMS
• Removal And Installation
• REAR GRILL
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Hood Removal And Installation
• Bumper Removal And Installation
• Door Latch Removal And Installation
• Door Latch And Catch Adjustment
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• Inlet Screen
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• TROUBLESHOOTING
• ELECTRICAL SYSTEM INFORMATION
• Description
• Fuse Location
• BATTERY
• Removal and Installation
• Servicing the Electrical System
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Alternator Output Test
• Rectifier (Diode) Test
• Alternator Regulator Test
• Removal and Installation
• Disassembly
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Rectifier Continuity (Diode) Test
• Assembly
• STARTER
• Removal and Installation
• Parts Identification
• Disassembly and Assembly
• External Pinion
• Inspection and Repair
• Magnetic Switch Test
• No Load Test
• STANDARD INSTRUMENT PANEL
• Removal and Installation
• FRONT LIGHTS
• Removal and Installation
• RELAY SWITCHES
• Location
• ENGINE SERVICE
• TROUBLESHOOTING
• ENGINE SPEED CONTROL
• Removal And Installation
• Speed Control Cable
• Speed Control Linkage
• ENGINE MUFFLER
• Removal And Installation
• AIR CLEANER HOUSING
• Removal And Installation
• BLOWER HOUSING/FAN GEARBOX
• Removal And Installation
• FAN DRIVE TENSION PULLEY
• Removal And Installation
• BLOWER FAN
• Removal And Installation
• FAN GEARBOX
• Parts Identification
• Disassembly
• Assembly
• Checking Backlash
• ENGINE/HYDROSTATIC PUMP ASSEMBLY
• Removal And Installation
• ENGINE MOUNTS
• Replacement
• ENGINE
• Removal And Installation
• FLYWHEEL
• Removal And Installation
• FLYWHEEL HOUSING
• Removal And Installation
• GLOW PLUG
• Checking The Glow Plug
• VALVE CLEARANCE
• Adjustment
• FUEL INJECTION PUMP
• Description
• Removal
• Installation
• FUEL INJECTOR
• Removal And Installation
• Checking
• Disassembly
• Assembly
• TIMING BELT
• Inspection
• Removal
• Installation
• Belt Replacement In Loader
• VALVE TIMING
• Checking
• DEUTZ ENGINE TOOLS
• Identification Chart
• RECONDITIONING THE ENGINE
• Disassembly
• Assembly
• CYLINDER LINERS
• Checking The Cylinder Liners
• CAMSHAFT BEARINGS
• Checking
• Removal And Installation
• CONTROL ROD GUIDE BUSHING
• Removal
• Installation
• REAR COVER SEAL
• Removal And Installation
• CRANKSHAFT
• Checking The Crankshaft
• CONNECTING ROD
• Checking The Connecting Rod
• PISTON AND PISTON PIN
• Checking The Piston
• Checking Piston Pin
• Installing Piston Rings
• CYLINDER HEAD
• Disassembly
• Checking The Valves
• Checking Valve Seats
• Valve Spring
• Assembly
• ROCKER ARM AND BRACKET
• Checking
• FRONT COVER
• Disassembly
• Assembly
• TURBOCHARGER
• Removal And Installation
• Disassembly
• Inspection
• Assembly
• POSITIVE CRANKCASE VENTILATION SYSTEM
• Description
• Inspection
• Module Removal And Installation
• OIL COOLER
• Removal and Installation
• CRANKSHAFT GEAR MOUNTING BOLT
• Torque Procedure
• SYSTEMS ANALYSIS
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• Inspecting The BICS™ Controller (Engine STOPPED– Key ON)
• nspecting Deactivation Of The Auxiliary HydraulicsSystem (Engine STOPPED – Key ON)
• Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm By–Pass Control
• Maintenance
• Troubleshooting Chart
• Troubleshooting Guide
• BICS SYSTEM CONTROLLER
• TRACTION LOCK
• SEAT SENSOR
• SEAT BAR SENSOR
• LIFT LOCK BY–PASS VALVE
• BICS™ SYSTEM CONTROLLER
• Removal And Installation
• Controller Test
• SEAT BAR SENSOR
• Removal And Installation
• Seat Bar Sensor Test
• SEAT SENSOR
• Removal And Installation
• Seat Sensor Test
• TRACTION LOCK
• Removal And Installation
• LIFT LOCK BY–PASS VALVE
• Removal And Installation
• Disassembly And Assembly
• TILT LOCK VALVE
• Removal And Installation (S/N 514111092 & Below)
• Removal And Installation (S/N 514111093 – 514114999)
• Disassembly And Assembly
• BOSS® DIAGNOSTIC TOOL
• Procedure
• SENDER AND SENSOR
• Service Checks
• Components
• RPM SENSOR
• Adjustment
• MONITOR SERVICE CODES
• TROUBLESHOOTING THE BOSS® & LCD DISPLAY
• OPERATION SENSING SYSTEM UNIT
• Removal And Installation
• BOSS® INSTRUMENT PANEL
• Removal And Installation
• PWM MODULE(*S/N 514111443 –514114999) (*Except S/N 514111445)
• Description
• PWM TROUBLESHOOTING
• Conditions
• Chart
• PWM CONTROL HANDLE
• Handle Testing
• PWM ELECTRIC SOLENOID
• Solenoid Coil Testing
• TRACTION LOCK CONTROL SYSTEM
• Description
• Inspection
• Maintenance
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
• Controls Identification Chart
• SPECIFICATIONS
• LOADER SPECIFICATIONS
• PERFORMANCE
• CONTROLS
• ENGINE
• HYDRAULIC SYSTEM
• ELECTRICAL
• DRIVE SYSTEM
• CAPACITIES
• TIRES
• FLOOR PRESSURE
• ENGINE SPECIFICATIONS
• General
• Fuel System
• Valve and Valve Guide & Seat Insert
• Piston, Rings and Connecting Rod
• Cylinder Head
• Crankshaft and Main Bearings
• Camshaft and Bearings
• Oil Pump
• Engine Torque Specifications
• Torque for General Metric Bolts
• TORQUE SPECIFICATIONS FOR LOADER
• HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
• STANDARD TORQUE SPECIFICATIONS FOR BOLTS
• DECIMAL AND MILLIMETER EQUIVALENTS
• U.S. TO METRIC CONVERSION
• SERVICE MANUAL REVISIONS
• 873–001
• 873–002
• 873–003
• 873–004
• 873–005
• 873-6