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
• Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• BOBCAT LOADER INDENTIFICATION
• SAFETY & MAINTENANCE
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
• Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
• Inspecting The Seat Bar Sensor (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm By-Pass Control
• Additional Inspection For Loaders With Advanced Hand Controls (AHC)
• LIFTING AND BLOCKING THE LOADER
• Procedure
• TRANSPORTING THE LOADER
• Procedure
• TOWING THE LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• Engaging The Lift Arm Support Device
• Disengaging The Lift Arm support Device
• HAND-LEVER BOB-TACH
• Inspection And Maintenance
• POWER BOB-TACH (OPTION)
• Inspection and Maintenance
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
• Description
• Inspecting The Seat Bar
• Maintaining The Seat Bar
• SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)
• Description
• Inspecting The Seat Bar
• Maintaining The Seat Bar
• REMOTE START
• Procedure for Loader Without, Attachments Control Harness
• Procedure for Loader With Attachments Control Harness
• Procedure
• SERVICE SCHEDULE
• FUEL SYSTEM
• Fuel Specifications
• Filling the Fuel Tank
• Fuel Filters
• Removing Air From The Fuel System
• AIR CLEANER SERVICE
• Replacing Filter Element
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Replacing OIl and Filter
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing The Coolant
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing The Hydraulic/Hydrostatic Filters
• Replacing The Hydraulic Fluid
• Breather Cap
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Rotation
• Tire Mounting
• LUBRICATING THE BOBCAT LOADER
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary of Hydraulic/Hydrostatic Symbols for Loaders
• Troubleshooting Chart
• Tighten Procedures
• CYLINDER(S)
• Checking The Lift Cylinder(s)
• Removal And Installation Of Lift Cylinder(s)
• Checking The Tilt Cylinder(s)
• Removal And Installation Of Tilt Cylinder(s)
• Tilt Cylinder Base End Pivot Pin
• Lift Cylinder Parts Identification
• Tilt Cylinder Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking Main Relief Valve At Front Auxiliary Hydraulics
• Checking Main Relief Valve At Control Valve.
• Removal And Installation
• Adjustment
• MAIN RELIEF VALVE (ADVANCED HAND CONTROL) (AHC)
• NOT AVAILABLE AT TIME OF PRINTING
• HYDRAULIC CONTROL VALVE (FOOT CONTROL)
• Removal And Installation
• BICS™ Valve, Removal And Installation
• BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
• BICS™ Valve, Check Valve Disassembly And Assembly
• BICS™ Valve, Lock Valve Disassembly And Assembly
• BICS™ Valve, Solenoid Disassembly And Assembly
• BICS™ Valve, Solenoid Testing
• Identification Chart
• Load Check Valve
• Main Relief Valve
• Port Relief Valve, Tilt Spool (Linkage End)
• Port Relief Valve, Lift Spool (Bonnet End)
• Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)
• Anti-Cavitation Valve, Lift Spool (Linkage End)
• Rubber Boot
• Lift And Tilt Lock Block
• Lift Spool and Detent
• Tilt Spool Removal And Installation
• Auxiliary Spool Removal And Installation (Bonnet End)
• Auxiliary Spool Removal And Installation (Linkage End)
• Auxiliary Plug Removal And Installation
• Auxiliary Electric Solenoid Disassembly
• Port Relief-Auxiliary Section Disassembly
• Cleaning And Inspection
• HYDRAULIC CONTROL VALVE (ADVANCE HAND CONTROL) (AHC)
• NOT AVAILABLE AT TIME OF PRINTING
• LIFT ARM BY-PASS CONTROL VALVE
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Checking the Output of the Pump
• Removal And Installation
• Disassembly and Assembly
• HYDRAULIC PUMP
• Disassembly And Assembly
• Inspection
• HYDRAULIC/HYDROSTATIC FILTER
• Removal And Installation
• COOLING FAN FILTER
• Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• CONTROLS
• Control Pedal Removal And Installation
• Control Pedal Adjustment
• Control Pedals Mounting Panel Removal And Installation
• BUCKET POSITION VALVE
• Removal And Installation
• Disassembly And Assembly
• TILT JUNCTION BLOCK
• Removal And Installation
• REAR AUXILIARY DIVERTER
• Removal And Installation
• Disassembly
• Inspection
• Solenoid Testing
• Assembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• CONTROL PANEL
• Removal And Installation
• STEERING
• Lever Removal And Installation
• Disassembly And Assembly
• Neutral Adjustment
• HYDROSTATIC MOTOR
• Removal and Installation
• Throttle Control
• Shuttle Check Valve
• Flushing Valve
• Disassembly
• Inspection
• Assembly
• Cover Removal And Installation
• Neutral Adjustment
• CHARGE PRESSURE
• Checking The Charge Pressure
• HYDROSTATIC PUMP
• Removal And Installation
• Replenishing/High Pressure Relief Valve
• Charge Relief Valve
• DA Controller
• Disassembly
• Inspection
• Assembly
• Hydrostatic Pump Start-Up
• Neutral Adjustment
• Timing Procedure
• DRIVE BELT
• Shield Removal And Installation
• Replacement
• Adjustment
• Tensioner Pulley Removal And Installation
• Tensioner Tension Spring
• Tensioner Pulley Disassembly And Assembly
• Tensioner Pivot Shaft
• Idler Pulley Removal And Installation
• OIL COOLER
• Removal And Installation
• DRIVE SYSTEM
• BRAKE
• Pedal Removal And Installation
• Pedal Disassembly And Assembly
• Two Speed Block Removal And Installation
• Two Speed Block Disassembly And Assembly
• Parking Brake Removal And Installation
• Parking Brake Disassembly And Assembly
• DRIVE COMPONENTS
• Axle Seal Removal And Installation
• Axle, Bearings And Sprocket Removal And Installation
• Drive Chains Removal And Installation
• CHAINCASE
• Checking And Adding Oil
• Front Chaincase Cover Removal And Installation
• Rear Chaincase Cover Removal and Installation
• Reduction Gearcase Removal And Installation
• Reduction Gearcase Disassembly And Assembly
• Removing The Oil From The Chaincase
• MAIN FRAME
• SEAT BAR
• Removal And Installation
• Assembling Components
• 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
• Slide Rail Removal And Installation
• Cushion Removal And Installation
• Back Removal And Installation
• Shock Removal And Installation
• BOB-TACH
• Removal And Installation
• Bob-Tach Lever And Wedge
• Bob-Tach Stops
• POWER BOB-TACH
• NOT AVAILABLE AT TIME OF PRINTING
• LIFT ARMS
• Removal And Installation
• REAR GRILL
• Gas Cylinder Removal And Installation
• REAR DOOR
• Removal And Installation
• Adjusting The Rear Door Latch
• Door Latch Removal And Installation
• Door Brace Removal And Installation
• FUEL TANK
• Front Removal And Installation
• Fuel Level Sender
• Rear Removal And Installation
• Pick-up Tube Screen
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Troubleshooting Chart
• Description
• Fuse Location
• Relay Switch Location
• Solenoid Test
• 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
• Adjusting The Alternator Belt
• 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
• INSTRUMENT PANEL
• Left Panel
• Right Panel – Standard Instrument Panel (With Key Switch)
• Right Panel – (Deluxe) (With Keyless Start)
• Right Panel Set Up Display Options (Deluxe)
• Passwords
• Option And Field Accessory Panels
• Standard Panel Removal And Installation (Right Side)
• Standard Panel Removal And Installation (Right Side) (Cont’d)
• Deluxe Panel Removal And Installation (Right Side)
• Standard And Deluxe Panel Removal And Installation (Left Side)
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• BOBCAT CONTROLLER
• Identification Chart
• Removal And Installation
• DIAGNOSTICS SERVICE CODES
• Display
• BICS™ SYSTEM
• Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
• Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
• Inspecting The Seat Bar Sensor (Engine RUNNING)
• Inspecting The Traction Lock (Engine RUNNING)
• Inspecting The Lift Arm By-Pass Control
• Additional Inspection For Loaders With Advanced Hand Controls (AHC)
• Troubleshooting Chart
• Troubleshooting Guide
• SEAT BAR SENSOR
• Troubleshooting Chart
• Test
• Removal And Installation
• BICS™ Circuit Test
• TRACTION LOCK
• Troubleshooting Chart
• ADVANCED HAND CONTROL (A.H.C.) SYSTEM
• Components Identification
• Troubleshooting Guide
• Parts Identification
• A.H.C. Controller Removal And Installation
• Handle Control Unit Connector
• Switch Handle Removal and Installation
• Actuators Disassembly and Assembly
• PROPORTIONAL CONTROL (PWM)
• Troubleshooting Chart
• Control Handle Testing
• Electric Solenoid Coil Testing
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
• Controls Identification Chart
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Removal And Installation
• Disassembly And Assembly
• MUFFLER
• Spark Arrestor Cleaning Procedure
• Removal And Installation
• Exhaust Extension Pipe.
• AIR CLEANER
• Housing Removal And Installation
• RADIATOR
• Coolant Recovery Tank Removal And Installation
• Removal And Installation
• COOLING FAN
• Removal And Installation
• Disassembly And Assembly
• Blower Housing Removal And Installation (Cont’d)
• ENGINE COMPONENTS AND TESTING
• Fuel Injection Pump Removal And Installation
• Fuel Injector Removal and Installation
• Fuel Injector Checking
• Checking The Fuel Lift Pump
• Removal And Installation
• ENGINE AND ENGINE MOUNTS
• Removal And Installation
• Mounting Brackets Removal And Installation
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal
• Ring Gear Installation
• RECONDITIONING THE ENGINE
• Intake Manifold Removal and Installation
• Exhaust Manifold Removal and Installation
• Cylinder Head Disassembly
• Cylinder Head Removal
• Cylinder Head Inspection
• Cylinder Head Installation
• Rocker Shaft Disassembly And Assembly
• Valve Removal
• Valve Springs Checking
• Valve Depth Checking
• Valve Guides Checking
• Valve Guide Removal
• Valve Guide Installation
• Valves Checking
• Cutting A Valve Seat
• Valve Seat Assembly
• Changing Valve Springs (With Cylinder Head Installed)
• Valve Clearance Adjustment
• Timing Case And Drive Assembly Description
• Timing Cover Removal
• Timing Cover Installation
• Front Oil Seal Removal
• Front Oil Seal Installation
• Timing Case And Gear Removal
• Timing Case And Gear Installation
• Camshaft And Tappets Removal
• Camshaft And Tappets Installation
• Pistons And Connecting Rods Description
• Pistons And Connecting Rods Removal
• Pistons And Connecting Rods Disassembly
• Piston Ring End Gap
• Piston Ring Installation
• Piston Ring Groove Clearance
• Connecting Rod Inspection
• Connecting Rod Bushing Replacement
• Piston And Connecting Rod Assembly
• Piston And Connecting Rod Installation
• Checking Piston Height
• Crankshaft And Bearings Description
• Crankshaft And Bearings Removal
• Inspection Of Crankshaft And Bearings
• Crankshaft And Bearings Installation
• Rear Oil Seal Removal
• Rear Oil Seal Housing Positioning
• Rear Oil Seal Installation
• Checking Crankshaft End Play
• Cooling System Description
• Thermostat Removal and Installation
• Thermostat Testing
• Water Pump Removal
• Water Pump Installation
• Engine Oil Cooler Removal And Installation
• Engine Oil Cooler Disassembly And Assembly
• Engine Lubrication System Description
• Oil Filter Adapter Removal
• Oil Filter Adapter Installation
• Oil Pan Removal And Installation
• Oil Screen And Pick-up Tube
• Oil Pump Removal
• Oil Pump Installation
• Oil Pump Disassembly And Assembly
• Oil Pressure Relief Valve Disassembly And Assembly
• Engine Block Description
• Engine Block Disassembly And Assembly
• Piston Cooling Jet Removal
• Piston Cooling Jet Installation
• Piston Cooling Jet Alignment
• Inspection
• Cylinder Liner Inspection
• Cylinder Liner Removal
• Cylinder Liner Installation
• Turbo Charger Troubleshooting
• Turbo Charger Description
• Turbo Charger Removal and Installation
• HEATING, VENTILATION, AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Principals
• Chart
• COMPONENTS
• Identification
• SAFETY
• Safety Equipment
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• Compressor Drive Belt Inspection
• Cleaning The Condenser
• BASIC TROUBLESHOOTING
• Poor A/C Performance
• Cleaning The A/C Evaporator Coil & Heater Coil
• Compressor Drive Belt Inspection:
• Checking The Electrical System
• Engine Coolant By-Passing The Heater Valve
• Heater Valve Not Opening Or Closing
• GENERAL AIR CONDITIONING SERVICE GUIDELINES
• Compressor Oil
• Compressor Oil Check
• Component Replacement And Refrigeration Leaks
• SYSTEM TROUBLESHOOTING CHART
• Gauge Pressure Related Troubleshooting
• TEMPERATURE/PRESSURE
• Chart
• AIR CONDITIONING SERVICE
• Chart
• SYSTEM CHARGING AND RECLAMATION
• Reclamation Procedure
• Charging Procedure With A Manifold Gauge Set
• Charging Procedure
• COMPRESSOR
• Removal And Installation
• Compressor Clutch Disassembly
• CONDENSER
• Removal And Installation
• RECEIVER/DRIER
• Removal And Installation
• PRESSURE RELIEF VALVE
• Removal And Installation
• PRESSURE SWITCH
• Removal And Installation
• EVAPORATOR/HEATER UNIT
• Removal And Installation
• Disassembly And Assembly
• THERMOSTAT
• Removal And Installation
• EXPANSION VALVE
• Removal And Installation
• EVAPORATOR
• Removal And Installation
• HEATER COIL
• Removal And Installation With A/C
• Removal And Installation Without A/C
• HEATER/AC FAN
• Removal And Installation
• Disassembly And Assembly
• Wire Connector Removal and Installation
• HEATER VALVE
• Removal and Installation
• Disassembly And Assembly
• SPECIFICATIONS
• LOADER SPECIFICATIONS
• Loader Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS
• General
• Cylinder Head
• Valve Guides
• Exhaust Valves
• Intake Valves
• Valve Springs
• Rocker Shaft, Rockers And Bushings
• Pistons And Piston Rings
• Connecting Rods And Bearings
• Crankshaft
• Crankshaft Re-Grind Data
• Main Bearings
• Thrust Washers
• Camshaft And Thrust Washer
• Cylinder Block
• Cylinder Liners
• Fuel Injection Pump
• Fuel Injectors
• Fuel Lift Pump
• Timing Case And Timing Gears
• Oil Pump, Gear And Relief Valve
• Turbocharger
• Flywheel
• Water Pump And Thermostat
• Engine Torque
• LOADER TORQUE
• Specifications
• 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/HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeters Equivalents
• U.S. To Metric Conversion
• SMR
• Revision No: 963-1
• Revision No: 963-2