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
• 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
• Installing
• Removing
• OPERATOR CAB
• Description
• Raising
• Lowering
• Emergency Exit
• TRANSPORTING THE LOADER ON A TRAILER
• Loading And Unloading
• Fastening
• TOWING THE LOADER
• Procedure
• REMOTE START TOOL-MEL 1563
• Remote Start Tool – MEL1563
• Service Tool Harness Control – MEL1565
• Service Tool Harness Communicator – MEL1566
• Remote Start Procedure
• REMOTE START TOOL (SERVICE TOOL) KIT – 6689779
• Description
• Remote Start Tool (Service Tool) – 6689778
• Loader Service Tool Harness – 6689747
• Computer Service Tool Harness – 6689746
• Remote Start Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Elements
• ENGINE COOLING SYSTEM
• Cleaning
• Checking Level
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filter
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil Chart
• Removing And Replacing Oil And Filter
• HYDRAULIC/HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Hydraulic / Hydrostatic Fluid Chart
• Removing And Replacing Hydraulic / Hydrostatic Filter
• Removing And Replacing Hydraulic / Hydrostatic Fluid
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking And Adding Oil
• Removing And Replacing Oil
• AUXILIARY CONTROL LOCKBOLT
• Procedure
• BOB-TACH
• Inspection And Maintenance
• LUBRICATING THE LOADER
• Lubrication Locations
• TIRE MAINTENANCE
• Wheel Nuts
• Rotating
• Mounting
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• PIVOT PINS
• Inspection And Maintenance
• SEAT BAR RESTRAINT SYSTEM
• Operation
• LOADER STORAGE AND RETURN TO SERVICE
• Storage
• Return To Service
• STOPPING THE ENGINE AND LEAVING THE LOADER
• Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting Chart
• CYLINDER (LIFT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CYLINDER (TILT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• MAIN RELIEF VALVE
• Description
• Testing Without Auxiliaries
• Testing With Auxiliaries
• Removal And Installation
• HYDRAULIC CONTROL VALVE
• Description
• BICS™ Valve Removal And Installation
• BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation
• 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 And Installation
• Lift Spool And Detent Disassembly
• Lift Spool And Detent Assembly
• 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 CONTROL VALVE
• Description
• Testing
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Description
• Direct Pump Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC/HYDROSTATIC FILTER
• Description
• Housing Removal And Installation
• Housing Disassembly And Assembly
• HYDRAULIC FLUID RESERVOIR
• Description
• Removal And Installation
• OIL COOLER
• Description
• Removal And Installation
• AUXILIARY HYDRAULIC INTERLOCK VALVE
• Description
• Removal And Installation
• Disassembly And Assembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Description
• Troubleshooting
• HYDROSTATIC MOTOR
• Description
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CHARGE PRESSURE
• Description
• Testing
• Sender Removal And Installation
• HYDROSTATIC PUMP
• Description
• Replenishing / High Pressure Relief Valve Removal And Installation
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• DRIVE BELT
• Description
• Adjusting
• Belt Removal And Installation
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Disassembly And Assembly
• DRIVE SYSTEM
• BRAKE
• Description
• Disc Removal And Installation
• DRIVE COMPONENTS
• Description
• Axle Seal Removal And Installation
• Axle, Sprocket And Bearings Removal And Installation
• Chain Removal And Installation
• CHAINCASE
• Description
• Chaincase Cover Removal And Installation
• Chaincase Cover Disassembly And Assembly
• MAIN FRAME
• SEAT BAR
• Description
• Removal And Installation
• Disassembly And Assembly
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• BOB-TACH
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• LIFT ARMS
• Removal And Installation
• REAR DOOR
• Removal And Installation
• FUEL TANK
• Removal And Installation
• CONTROL PEDALS AND LINKAGES
• Description
• Pedal Removal And Installation
• Pedal Interlock Linkage Removal And Installation
• CONTROL PANEL
• Description
• Control Shield And Steering Lever Panels Removal And Installation
• CONTROL LEVER
• Description
• Lever Removal And Installation
• Lever Disassembly And Assembly
• Linkage Neutral Adjustment
• Pintle Arm Removal And Installation
• Pintle Arm Disassembly And Assembly
• WINDOW (REAR)
• Removal
• Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Cab Harness Connectors
• Mainframe Harness Connectors
• Description
• Troubleshooting
• Fuse And Relay Location / Identification
• Solenoid Testing
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Belt Adjustment
• Charging System Inspection
• Alternator Voltage Testing
• Low Voltage Testing
• High Voltage Testing
• Removal And Installation
• Parts Identification
• STARTER
• Testing
• Removal And Installation
• Parts Identification
• INSTRUMENT PANELS
• Left And Right Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• Cab Light Removal And Installation
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
• Inspecting Procedure
• 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 Bypass Control
• Inspecting The Auxiliary Hydraulic Interlock Valve
• BICS CONTROLLER (GATEWAY)
• Description
• Troubleshooting
• Viewing Diagnostic Service Codes
• Removal And Installation
• SEAT BAR SENSOR
• Description
• Troubleshooting
• Testing
• Removal And Installation
• Bobcat Interlock Control System (BICS) Circuit Test
• TRACTION LOCK
• Description
• Troubleshooting
• Removal And Installation
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Torque Values
• Troubleshooting
• Engine Removal And Installation
• Engine Mount Replacement
• Compression – Checking
• ENGINE SPEED CONTROL
• Removal And Installation
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• ENGINE COOLING SYSTEM
• Radiator Removal And Installation
• Fan Removal And Installation
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Housing Removal And Installation
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump Inspection
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Fuel Camshaft Removal And Installation
• Governor Shaft Removal And Installation
• Governor Fork Lever Removal And Installation
• Fuel ShutOff Solenoid – Checking
• Fuel ShutOff Solenoid Removal And Installation
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump Timing
• Fuel Injector Nozzles Removal And Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spray Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Glow Plug – Checking
• Glow Plug Removal And Installation
• Valve Clearance Adjustment
• Valve Timing Checking
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head – Servicing
• Cylinder Head Top Clearance
• Valve Guide – Checking
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft – Checking
• CRANKSHAFT AND PISTONS
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod – Servicing
• Cylinder Bore – Checking
• Connecting Rod Alignment
• Crankshaft And Bearings Removal And Installation
• Crankshaft And Bearings – Servicing
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal And Installation
• Timing Gears Backlash – Checking
• Idler Gear And Shaft Removal And Installation
• Camshaft – Servicing
• Idler Gear And Shaft Servicing
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• HEATER
• HEATER SYSTEM
• Description
• REGULAR MAINTENANCE
• Heater Coil
• TROUBLESHOOTING
• Electric System
• Heater Valve Not Opening Or Closing
• Blower Motor Does Not Operate
• Blower Motor Operates Normally, But Air Flow Is Insufficient
• HEATER UNIT
• Removal And Installation
• HEATER COIL
• Removal And Installation
• HEATER FAN
• Removal And Installation
• HEATER VALVE
• Removal And Installation
• HEATER SWITCH
• Removal And Installation
• Checking
• SPECIFICATIONS
• (S70) LOADER SPECIFICATIONS
• Machine Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tires
• 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 / HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalent Chart
• U.S. To Metric Conversion Chart