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
• Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• LOADER IDENTIFICATION
• SAFETY AND MAINTENANCE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• LIFT ARM SUPPORT DEVICE
• Installing
• Removing
• OPERATOR CAB
• Description
• Raising
• Lowering
• Cab Door Sensor
• Special Applications Kit
• Special Applications Kit Inspection And Maintenance
• TRANSPORTING THE LOADER On A TRAILER
• Loading And Unloading
• Fastening
• TOWING THE LOADER
• Procedure
• REMOTE START TOOL KIT-MEL1563
• 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 The Coolant
• FUEL SYSTEM
• Fuel Specifications
• Biodiesel Blend Fuel
• 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 Fluid
• Removing And Replacing Hydraulic / Hydrostatic Filter
• Removing And Replacing Case Drain Filters
• Removing And Replacing Hydraulic Charge Filter
• Breather Cap
• BOB-TACH (HAND LEVER)
• Inspection And Maintenance
• BOB-TACH (POWER)
• Inspection And Maintenance
• LUBRICATING THE LOADER
• Lubrication Locations
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• PIVOT PINS
• Inspection And Maintenance
• LOADER STORAGE AND RETURN TO SERVICE
• Storage
• Return to Service
• STOPPING THE ENGINE AND LEAVING THE LOADER
• Procedure
• Emergency Exit
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic/Hydrostatic Symbols
• Troubleshooting
• CYLINDER (LIFT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CYLINDER (TILT)
• Testing
• Removal And Installation
• Rod End Pivot Pin Bushing And Seal Removal And Installation
• Base End Pivot Pin Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CYLINDER (BOB-TACH)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly and Assembly
• MAIN RELIEF VALVE
• Description
• Testing
• Adjusting
• Removal And Installation
• HYDRAULIC CONTROL VALVE (STANDARD)
• Description
• Removal And Installation
• Identification Chart
• Lift Load Check Valve Removal And Installation
• Load Check Valve Removal And Installation (Tilt & Auxiliary)
• Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
• Port ReliefValve/Anti-Cavitation Valve Removal And Installation (Lift, Base End)
• Port Relief Valve/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
• Port Relief Valve/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
• Port Relief Valve Removal And Installation
• Plug Removal And Installation
• Rubber Boot Removal And Installation
• End Cap/Spool Lock Block Removal And Installation
• Lift Spool And Detent Removal And Installation
• Tilt Spool Removal And Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Solenoid Removal And Installation
• Solenoid Removal And Installation
• Lock Valve Removal And Installation
• Lift Arm Bypass Orifice Removal And Installation
• Main Relief Valve Removal And Installation
• Check Valve Removal And Installation
• HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
• Description
• Removal And Installation
• Actuator Removal And Installation (Out of Loader)
• Identification Chart
• Mount Bracket Removal And Installation
• Lift Load Check Valve Removal And Installation
• Load Check Valve Removal And Installation (Tilt & Auxiliary)
• Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
• Port Relief Valve/Anti-Cavitation Valve Removal And Installation (Lift, Base End)
• Port Relief Valve/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
• Port Relief Valve/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
• Port Relief Valve Removal And Installation
• Plug Removal And Installation
• End Cap Block Removal And Installation
• Lift Spool And Detent Removal And Installation
• Tilt Spool Removal And Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Solenoid Removal And Installation
• Solenoid Removal And Installation
• Lock Valve Removal And Installation
• Lift Arm Bypass Orifice Removal And Installation
• Main Relief Valve Removal And Installation
• Check Valve Removal And Installation
• LIFT ARM BY-ASS CONTROL VALVE
• Description
• Testing
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP (STANDARD)
• Description
• Pump Test at Quick Couplers
• Direct Pump Test (Standard Section)
• Direct Pump Test (Charge Section)
• Removal And Installation
• Hydraulic Pump Start Up
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC PUMP (SJC)
• Description
• Pump Test At Quick Couplers
• Direct Pump Test (Standard Section)
• Direct Pump Test (Charge Section)
• Removal And Installation
• Hydraulic Pump Start Up
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC / HYDROSTATIC FILTERS
• Description
• Housing Removal And Installation
• Charge Filter Housing Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Description
• Removal And Installation
• Hydraulic Fluid Screen
• OIL COOLER
• Description
• Removal and Installation
• BUCKET POSITION VALVE
• Description
• Solenoid Removal And Installation
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• REAR AUXILIARY DIVERTER VALVE
• Description
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• BOB-TACH (POWER) BLOCK
• Description
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
• Description
• Removal and Installation
• Disassembly And Assembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting
• Description
• HYDROSTATIC MOTOR
• Description
• Removing And Replacing Oil
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CHARGE PRESSURE
• Description
• Testing
• Sender Removal And Installation
• Adjusting
• Sender Removal And Installation (SJC Machines)
• Testing (SJC Machines)
• Adjusting (SJC Machines)
• HYDROSTATIC PUMP
• Description
• Removal And Installation
• Hydrostatic Pump Start Up
• Replenishing/High Pressure Relief Valve Removal And Installation
• Parts Identification (Left Half)
• Parts Identification (Right Half)
• Disassembly
• Assembly
• HYDROSTATIC PUMP (SJC)
• Description
• Hydraulic Controller Removal And Installation
• Removal And Installation
• Hydrostatic Pump Start Up
• Parts Identification
• High Pressure Relief and Bypass Valve
• Charge Relief Valve
• Disassembly and Assembly
• Mechanical Neutral Adjustment
• Hydraulic Controller Neutral Adjustment
• DRIVE BELT
• Description
• Shield Removal And Installation
• Adjusting
• Belt Removal And Installation
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Parts Identification
• Tensioner Pulley Disassembly
• Tensioner Pulley Assembly
• CASE DRAIN FILTER
• Description
• Disassembly And Assembly
• DRIVE SYSTEM
• BRAKE
• Description
• Right Motor Brake Test
• Left Motor Brake Test
• Block Removal And Installation
• Block Disassembly And Assembly
• TRACK CARRIAGE COMPONENTS
• Description
• Checking Tension
• Adjusting Tension
• Track Removal And Installation
• Idler (Front) Removal And Installation
• Idler (Rear) Removal And Installation
• Roller Removal And Installation
• Sprocket Removal And Installation
• Carriage Removal And Installation
• Track Damage Identification
• MAIN FRAME
• SEAT BAR
• Description
• Removal And Installation
• Disassembly And Assembly
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation
• Gas Cylinder Bracket Disassembly And Assembly
• Removal And Installation
• OPERATOR SEAT (SUSPENSION)
• Removal And Installation
• Slide Rail Removal And Installation
• Seat Belt Removal and Installation
• Lower Cushion Removal And Installation
• Back Cushion Removal And Installation
• Shock Removal And Installation
• 3-Point Seat Belt Removal And Installation
• BOB-TACH (HAND LEVER)
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• Bob-Tach Stops
• Pivot Pin Bushing And Seal Removal And Installation
• BOB-TACH (POWER – OPTION)
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• Bob-Tach Stops
• Pivot Pin Bushing And Seal Removal And Installation
• LIFT ARMS
• Removal And Installation
• REAR GRILL
• Removal And Installation
• REAR DOOR
• Removal And Installation
• Striker Removal and Installation
• Striker Disassembly and Assembly
• Striker (Adjusting)
• Latch Removal And Installation
• FUEL TANK
• Removal And Installation
• Fuel Level Sender Removal And Installation
• Fuel Fill Screen Removal And Installation
• CONTROL PEDALS AND LINKAGES
• Description
• Pedal Removal And Installation
• Linkage Removal And Installation
• Pedal (Adjusting)
• CONTROL PEDALS (ACS)
• Description
• Foot Sensor Removal And Installation
• Foot Pedal Removal And Installation
• Foot Pedal Linkage Disassembly And Assembly
• CONTROL PANEL
• Description
• Removal And Installation
• Shock Removal And Installation
• Shaft Removal And Installation
• Shaft Disassembly And Assembly
• Linkage Removal And Installation
• Pintle Arm Disassembly and Assembly
• Linkage Neutral (Adjusting)
• Linkage Travel (Adjusting)
• CONTROL PANEL (SJC)
• Description
• Removal And Installation
• CONTROL HANDLE/LEVER
• Description
• Lever Removal And Installation
• Boot Removal And Installation
• CONTROL HANDLE / LEVER (ACS)
• Description
• Handle Sensor Removal And Installation
• Handle Removal And Installation
• Handle Disassembly And Assembly
• Lever Removal And Installation
• Boot Removal And Installation
• CONTROL HANDLE / LEVER (SJC)
• Description
• Joystick Testing
• Joystick Removal And Installation
• Removal And Installation
• WINDOW (REAR)
• Removal
• Installation
• WINDOW (TOP)
• Removal And Installation
• WINDOW (SIDE)
• Removal And Installation
• WINDOW (FRONT DOOR)
• Removal (Standard Window)
• Installation (Standard Window)
• Removal And Installation (Special Applications Window)
• 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
• Belt Replacement
• 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 Panel
• Right Panel (Key Switch)
• Right Panel (Keyless)
• Side And Front Panels
• Removal And Installation (Left And Right)
• Bulb Removal And Installation (Left Only)
• Key Switch Removal And Installation
• Alarm Removal And Installation
• Front Accessory Panel Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• Cab Light Removal And Installation
• BOBCAT CONTROLLER (MAIN)
• Description
• Connector Identification
• Removal And Installation
• BOBCAT CONTROLLER (ACS)
• Description
• Connector Identification
• Removal and Installation
• BOBCAT CONTROLLER (SJC) (DRIVE)
• Description
• Connector Identification
• Removal and Installation
• SPEED SENSOR (SJC)
• Description
• Testing
• Removal and Installation
• DIAGNOSTIC SERVICE CODES
• Viewing Service Codes (Key Switch)
• Viewing Service Codes (Keyless)
• Service Codes List
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
• Description
• 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 Bypass Control
• Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)
• Troubleshooting
• Troubleshooting Chart
• SEAT BAR SENSOR
• Description
• Troubleshooting
• Testing
• Removal And Installation
• Bobcat Interlock Control System (BICS) Circuit Test
• TRACTION LOCK
• Description
• Troubleshooting
• Inspecting
• Parking Brake Solenoid Removal And Installation
• CONTROL SYSTEM (ACS)
• Description
• Troubleshooting Chart
• Handle Sensor Connector Disassembly And Assembly
• Switch Handle Removal
• Switch Handle Installation
• Actuator Connector Disassembly And Assembly
• Handle Lock Solenoid Removal And Installation
• Handle Lock Solenoid Disassembly And Assembly
• Foot Sensor Disassembly And Assembly
• Foot Lock Solenoid Removal And Installation
• ELECTRICAL/HYDRAULIC CONTROLS
• Identification Chart
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SJC)
• Identification Chart
• SERVICE PC (LAPTOP COMPUTER)
• Connecting To The Remote Start Tool
• Connecting Remote Start Tool (Service Tool)
• CALIBRATION
• Description
• Actuator Testing
• Lift And Tilt Calibration (ACS)
• Lift And Tilt Calibration (SJC)
• Hydrostatic Pump Calibration (SJC)
• STEERING DRIFT COMPENSATION
• Description
• Selecting And Adjusting
• Exiting And Saving
• FLYWHEEL RPM SENSOR
• Description
• Adjusting
• CONTROL PANEL SETUP
• Right Panel Setup (Keyless)
• Attachment Control Information (Keyless)
• PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)
• Password Description
• Changing The Owner And User Passwords
• Password Lockout Feature
• MAINTENANCE CLOCK
• Description
• Setup
• Reset
• BACK-UP ALARM SYSTEM
• Description
• Inspecting
• Adjusting Switch Position
• Troubleshooting (Standard And ACS)
• Troubleshooting (Joystick)
• Alarm Removal And Installation
• Switch Removal And Installation
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Engine Torque Values
• Troubleshooting
• Engine Removal And Installation
• Engine Mount Replacement
• Compression – Checking
• ENGINE SPEED CONTROL
• Removal And Installation
• ENGINE SPEED CONTROL (SJC)
• Removal And Installation
• Disassembly And Assembly
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• ENGINE COOLING SYSTEM
• Radiator Removal And Installation
• Hydraulic Fan Description
• Hydraulic Fan Disassembly And Assembly
• Blower Housing Removal And Installation
• Fan Removal And Installation
• Hydraulic Fan Motor Removal And Installation
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Housing Removal And Installation
• Thermostat – Checking
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump Inspection
• Engine Oil Pressure-Testing
• FUEL SYSTEM
• Fuel Shutoff Solenoid – Checking
• Fuel Shutoff Solenoid – Removal And Installation
• Fuel Injection Pump – Checking
• Fuel Injection Pump Removal And Installation
• Governor Disassembly And Assembly
• Fuel Camshaft Removal And Installation
• Fuel Injection Pump – Timing
• Fuel Injector Removal And Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spray Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Glow Plugs – Testing
• Glow Plugs 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 Gear Removal And Installation
• 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 Camshaft 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
• HEATING SYSTEM
• HEATING SYSTEM
• Description
• REGULAR MAINTENANCE
• Filter Elements Removal And Installation
• Heater Coil
• Troubleshooting
• TROUBLESHOOTING
• Blower Motor Does Not Operate
• Blower Motor Operators Normally, But Air Flow Is Insufficient
• Electrical System
• Engine Coolant Bypassing The Heater Valve
• Heater Valve Not Opening Or Closing
• HEATER UNIT
• Removal And Installation
• HEATER COIL
• Removal And Installation
• HEATER FAN
• Blower Removal And Installation
• Disassembly And Assembly
• Connector Identification
• HEATER VALVE
• Removal and Installation
• Disassembly And Assembly
• SPECIFICATIONS
• (T140) LOADER SPECIFICATIONS
• Dimensions
• Performance
• Controls
• Engine
• Hydraulic System
• Electrical
• Drive System
• Capacities
• Tracks
• 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 Equivalents
• U.S. To Metric Conversion Chart
• SMR
• Revision No: t140-1
• Revision No: T140-2