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 LOCATION
• Loader Serial Number
• Engine Serial Number
• DELIVERY REPORT
• BOBCAT LOADER IDENTIFICATION
• SAFETY & MAINTENANCE
• LIFTING AND BLOCKING THE LOADER
• Procedure
• Single Point Lift
• LIFT ARM SUPPORT DEVICE
• Installing Lift Arm Support Device
• Removing Lift Arm Support Device
• OPERATOR CAB
• Description
• Raising The Operator Cab
• Lowering The Operator Cab
• Emergency Exit
• TRANSPORTING THE BOBCAT LOADER
• Procedure
• TOWING THE LOADER (S/N 519313197 & BELOW)
• Procedure
• TOWING THE LOADER (S/N 519313198 & ABOVE)
• Procedure
• REMOTE START
• Procedure
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing Filter Element
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing the Coolant
• FUEL SYSTEM
• Fuel Specifications
• 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
• Replacing Hydraulic/Hydrostatic Filter
• Replacing Hydraulic Fluid
• Breather Cap
• FAN GEARBOX
• Checking And Maintaining
• BOB-TACH
• Inspection And Maintenance
• POWER BOB-TACH (OPTION)
• Inspection And Maintenance
• LUBRICATION OF THE BOBCAT LOADER
• Procedure
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• HYDRAULIC SYSTEM
• HYDRAULIC/HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Troubleshooting Chart
• Tighten Procedures
• CYLINDER (LIFT)
• Checking
• Removal And Installation
• Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Checking
• Removal And Installation
• Base End Pivot Pin Replacement
• Rod End Pivot Pin Bushing And Seal Replacement
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (POWER BOB-TACH)
• Checking
• Removal And Installation
• Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Checking
• Adjustment
• Removal and Installation
• 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
• Anti-Cavitation Valve/Port Relief Valve
• Anti-Cavitation Valve
• Rubber Boot
• Lift And Tilt Lock Block
• Lift Spool and Detent
• Tilt Spool Removal And Installation
• Auxiliary Spool Removal And Installation
• Auxiliary Electric Solenoid Disassembly
• Port-Auxiliary Section Disassembly
• Cleaning And Inspection
• HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
• Removal And Installation
• BICS™ Valve Removal And Installation
• BICS™ Valve, Lift Arm By-Pass Orifice Dissembly And Assembly
• BICS™ Valve, Check Valve Dissembly And Assembly
• BICS™ Valve Lock Valve Dissembly And Assembly
• BICS™ Valve Solenoid Dissembly And Assembly
• BICS™ Valve Solenoid Testing
• Actuator Removal And Installation
• Identification Chart (Hand Control)
• Identification Chart (ACS)
• Lift Base End Restrictor
• Load Check Valve
• Main Relief Valve
• Port Relief Valve
• Anti-Cavitation Valve/Port Relief Valve
• Anti-Cavitation Valve
• Lift Spool Removal And Installation
• Tilt Spool Removal And Installation
• Lift and Tilt Spool Disassembly And Assembly
• Auxiliary Spool Removal And Installation
• Auxiliary Electric Solenoid Disassembly
• Port-Auxiliary Section Disassembly
• Cleaning And Inspection
• LIFT ARM BY-PASS CONTROL VALVE
• Inspecting
• Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Check The Output Of The Hydraulic Pump Without Power Bob-Tach
• Check The Output Of The Hydraulic Pump With Power Bob-Tach.
• Removal And Installation
• Identification
• Disassembly And Assembly
• HYDRAULIC PUMP (HIGH FLOW)
• Check The Output Of The Hydraulic Pump Without Power Bob-Tach (S/N 519315699 & Below)
• Check The Output Of The Hydraulic Pump With Power Bob-Tach (S/N 519315699 & Below)
• Check The Output Of The Hydraulic Pump (Standard)(S/N 519315700 & Above)
• Check The Output Of The Hydraulic Pump (High Flow)(S/N 519315700 & Above)
• Removal And Installation
• Identification
• Disassembly And Assembly
• HYDRAULIC FILTER HOUSING
• Removal And Installation
• HYDRAULIC FLUID RESERVOIR
• Removal And Installation
• BUCKET POSITION VALVE
• Solenoid Removal And Installation
• Solenoid Testing
• Removal And Installation
• Disassembly And Assembly
• SELECT VALVE (S/N 519315699 & BELOW)
• Checking The High Flow Pump Relief Valve
• Removal And Installation
• Disassembly And Assembly
• Solenoid Testing
• HIGH FLOW VALVE (S/N 519315700 & ABOVE)
• Checking The High Flow Relief Valve
• High Flow Relief Valve Adjustment Procedure
• Removal And Installation
• Disassembly And Assembly
• Solenoid Testing
• REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) (S/N 519315699 & BELOW)
• Removal And Installation
• Disassembly And Assembly
• Solenoid Testing
• Inspection
• REAR AUXILIARY DIVERTER VALVE (S/N 519315700 & Above)
• Removal And Installation
• Disassembly And Assembly
• Solenoid Testing
• Inspection
• POWER BOB-TACH BLOCK (S/N 519315202 & below)
• Removal And Installation
• Disassembly And Assembly
• POWER BOB-TACH BLOCK (S/N 519315203 & Above)
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY PRESSURE RELIEF BLOCK
• Removal And Installation (519312091 & Below)
• Disassembly And Assembly (519312091 & Below)
• Solenoid Testing
• Solenoid Inspection
• FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
• Removal and Installation (519312092 & Above)
• Disassembly And Assembly (519312092 & Above)
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• HYDROSTATIC MOTOR
• Replacing the Motor Oil (Motor S/N 428302 & Above)
• Removal And Installation
• Parts Identification (Motor S/N 428301 & Below)
• Parts Identification (Motor S/N 428302 & Above)
• Disassembly
• Inspection
• Assembly
• CHARGE PRESSURE
• Sender Removal And Installation
• Checking Charge Pressure
• Adjusting
• HYDROSTATIC PUMP
• Replenishing/High Pressure Relief Valve
• Removal And Installation
• Parts Identification (Right Half)
• Parts Identification (Left Half)
• Hydraulic Pump Removal And Installation
• Pump Separation
• Disassembly
• Assembly
• DRIVE BELT
• Shield Removal And Installation
• Adjusting
• Drive Belt Replacement
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Parts Identification
• Tensioner Pulley Disassembly
• Tensioner Pulley Assembly
• OIL COOLER
• Removal and Installation
• DRIVE SYSTEM
• BRAKE
• Switch Operated Parking Brake
• Brake Engaged (Dragging) Test (S/N 519313197 & Below)
• Block Removal And Installation (S/N 519313197 & Below)
• Block Disassembly And Assembly (S/N 519313197 & Below)
• Traction Lock By-Pass Knob (S/N 519313197 & Below)
• BRAKE (S/N 519313198 AND ABOVE)
• Pressure Relief Valve Test
• Left Motor Brake Test
• Block Removal And Installation
• Block Disassembly And Assembly
• DRIVE COMPONENTS
• Track Tension
• Track Tension Adjusting
• Track Removal And Installation
• Track Idler (Front) Removal And Installation
• Track Idler (Front) Parts Identification (S/N 519313368 & Below)
• Track Idler (Front) Disassembly (S/N 519313368 & Below)
• Track Idler (Front) Assembly
• Track Idler (Rear) Removal And Installation
• Track Idler (Rear) Parts Identification (S/N 519313368 & Below)
• Track Idler (Rear) Disassembly (S/N 519313368 & Below)
• Track Idler (Rear) Assembly (S/N 519313368 & Below)
• Track Roller Removal And Installation
• Track Roller Parts Identification (S/N 519313368 & Below)
• Track Roller Disassembly (S/N 519313368 & Below)
• Track Roller Assembly
• Track Idler (Front) Parts Identification (S/N 519313369 & Above)
• Track Idler (Front) Disassembly (S/N 519313369 & Above)
• Track Idler (Front) Assembly (S/N 519313369 & Above)
• Track Idler (Rear) End Play Specifications (S/N 519313369 & Above)
• Track Idler (Rear) Parts Identification (S/N 519313369 & Above)
• Track Idler (Rear) Removal And Installation (S/N 519313369 & Above)
• Track Idler (Rear) Disassembly (S/N 519313369 & Above)
• Track Roller Assembly End Play Specifications (S/N 519313369 & Above)
• Track Roller Parts Identification(S/N 519313369 & Above)
• Track Roller Removal And Installation (S/N 519313369 & Above)
• Track Roller Disassembly (S/N 519313369 & Above)
• Track Roller Assembly (S/N 519313369 & Above)
• Track Housing Removal And Installation
• Track Damage Identification
• MAIN FRAME
• SEAT BAR
• Removal And Installation
• Assembling Components
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Cylinder Removal And Installation
• Gas Cylinder Disassembly
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Seat Belt Removal And Installation
• OPERATOR SEAT (SUSPENSION)
• Removal And Installation
• Slide Rail Removal And Installation
• Cushion Removal And Installation
• Back Removal And Installation
• Shock Removal And Installation
• 3-Point Seat Belt Removal And Installation
• BOB-TACH
• Removal And Installation
• Bob-Tach Lever And Wedge
• Pivot Pin Bushing And Seal Replacement
• POWER BOB-TACH
• Removal And Installation
• Power Bob-Tach Lever And Wedge
• Pivot Pin Bushing And Seal Replacement
• LIFT ARM
• Removal And Installation
• Link Removal And Installation
• Stabilizer Bar Removal And Installation
• REAR GRILL
• Gas Cylinder Removal And Installation (Earlier Models Only)
• Removal And Installation (Earlier Models)
• Removal And Installation (Later Models)
• REAR DOOR
• Removal And Installation
• Door Latch And Catch Adjustment (519311949 & Below)
• Door Latch Removal And Installation (519311949 & Below)
• Striker Removal and Installation (S/N 519311950 & Above)
• Striker Disassembly and Assembly (S/N 512261536 & Above)
• Adjusting The Striker (S/N 519311950 & Above)
• Latch Removal and Installation (S/N 519311950 & Above)
• FUEL TANK
• Removal And Installation
• Fuel Level Sender
• Fuel Fill Screen
• Fuel Pickup Screen
• CONTROL PEDALS
• Removal And Installation
• Pedal Adjustment
• Crossbar Linkage Removal And Installation
• Lift Foot Pedal Linkage Removal And Installation
• Tilt Foot Pedal Linkage Removal And Installation
• CONTROL PEDALS (ACS)
• Foot Sensor Removal And Installation
• Foot Pedal Removal And Installation
• Foot Pedal Linkage Disassembly And Assembly
• CONTROL PANEL
• Removal and Installation
• Shock Removal And Installation
• Shaft Removal And Installation
• Shaft Disassembly And Assembly
• Linkage Removal And Installation
• Linkage Adjustment
• Linkage Neutral Adjustment
• CONTROL HANDLE
• Control Lever Removal And Installation
• Control Lever Boot
• CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL
• Components Identification
• Handle Sensor Removal And Installation
• Control Handle Removal and Installation
• Control Handle Disassembly and Assembly
• Control Lever Removal and Installation
• Control Lever Boot
• CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL
• Components Identification
• Handle Sensor Removal And Installation
• Control Handle Removal and Installation
• Control Handle Disassembly and Assembly
• Control Lever Removal and Installation
• Control Lever Boot
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Wiring Schematics
• Troubleshooting Chart
• Description
• Fuse Location
• Relay Switch Location
• Solenoid Test
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR (90 AMP)
• Adjusting The Alternator Belt
• Alternator Identification
• Charging System Check
• Alternator Voltage Test
• Low Voltage Test
• High Voltage Test
• Removal And Installation
• Rectifier Continuity (Diode) Test
• Alternator Regulator Test
• Disassembly
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Assembly
• STARTER (NIPPONDENSO)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection And Repair
• No Load Test
• Assembly
• STARTER (VALEO)
• Checking
• Removal And Installation
• Parts Identification
• Disassembly and Assembly
• Inspection And Repair
• No Load Test
• INSTRUMENT PANEL
• Left Panel (Standard)
• Right Panel-Standard Instrument Panel (With Key Switch)
• Right Panel – (Deluxe) (With Keyless Start)
• Right Panel Setup Display Options (Deluxe)
• Option and Field Accessory Panels
• Removal And Installation
• Front Accessory Panel Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• BOBCAT CONTROLLER
• Identification Chart (S/N 519313304 & Below)
• Identification Chart (S/N 519313305 & Above)
• Removal And Installation
• DIAGNOSTIC SERVICE CODES
• Display
• Number Codes List
• 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
• Description Of The Control System
• Inspecting The Control System
• ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL
• Components Identification
• Troubleshooting Guide
• Controller, Connector And Wire Identification
• ACS Controller Removal And Installation
• Handle Sensor Connector
• Switch Handle Removal
• Switch Handle Installation
• Actuators Disassembly and Assembly
• ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL
• Components Identification
• Troubleshooting Guide
• Controller, Connector And Wire Identification
• ACS Controller Removal And Installation
• Handle Sensor Connector
• Switch Handle Removal
• Switch Handle Installation
• Actuators Disassembly and Assembly
• Handle Lock Solenoid Removal And Installation
• Handle Lock Solenoid Disassembly And Assembly
• Handle Lock Solenoid Connector
• Calibration Procedure
• Foot Sensor Disassembly And Assembly
• Foot Sensor Connector
• Foot Lock Solenoid Removal And Installation
• Foot Lock Solenoid Connector
• ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
• Controls Identification Chart
• FLYWHEEL RPM SENSOR
• Adjustment
• ENGINE SERVICE
• TROUBLESHOOTING
• Chart
• ENGINE SPEED CONTROL
• Removal And Installation
• Disassembly
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• RADIATOR (S/N 519314343 & BELOW)
• Removal And Installation
• RADIATOR (S/N 519314344 & ABOVE)
• Removal And Installation
• COOLING FAN
• Drive Tension Pulley Removal And Installation
• Gearbox/Blower Housing Removal And Installation
• Blower Housing Grill Removal And Installation
• Blower Disassembly And Assembly
• Gearbox Parts Identification
• Gearbox Disassembly
• Gearbox Assembly
• Gearbox Checking Backlash
• ENGINE COMPONENTS AND TESTING
• Compression Checking
• Glow Plugs Checking
• Glow Plugs Removal And Installation
• Fuel Shut-Off Solenoid, Checking
• Fuel Shut-Off Solenoid, Adjusting
• Fuel Shut-Off Solenoid Removal And Installation
• Checking
• Fuel Injection Pump Removal And Installation
• ENGINE COMPONENTS AND TESTING (CONT’D)
• Timing The Injection Pump
• Fuel Injector Removal And Installation
• Fuel Injector Checking
• Fuel Injector Disassembly
• Fuel Injector Assembly
• Valve Clearance Adjustment
• Rocker Arm And Shaft Checking
• Valve Timing, Checking
• ENGINE
• Removal And Installation
• Engine Mount Replacement
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• RECONDITIONING THE ENGINE-V2003T-EB (TURBO)
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head Servicing
• Cylinder Head Top Clearance
• Checking The Valve Guide
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Rocker Arm And Shaft Checking
• Timing Gearcase Cover Removal And Installation
• Idler Gear And Camshaft Removal And Installation
• Servicing The Camshaft
• Servicing The Idle Gear And Shaft
• Timing Gears Checking Backlash
• Fuel Camshaft Removal And Installation
• Fuel Camshaft Governor
• Crankshaft Gear Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump Service
• Checking Engine Oil Pressure
• Relief Valve
• Piston And Connecting Rod Removal And Installation
• Servicing The Piston And Connecting Rod
• Connecting Rod Alignment
• Crankshaft And Bearings Removal And Installation
• Servicing The Crankshaft And Bearings
• Checking The Cylinder Bore
• Water Pump Disassembly And Assembly
• TURBOCHARGER
• Troubleshooting
• Description
• 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 (Cont’d)
• Compressor Drive Belt Inspection
• Cleaning The Condenser
• Filter Elements Removal And Installation
• 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
• 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
• Tracks
• Ground Pressure
• ENGINE SPECIFICATIONS – KUBOTA V2003T-EB (TURBO)
• Fuel Injection Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Valve Timing
• Rocker Arms
• Camshaft
• Tappet
• Cylinder Liner
• Piston Rings
• Pistons
• Connecting Rod
• Oil Pump
• Crankshaft
• Timing Gear
• Thermostat
• Crankshaft Re-Grind Data
• 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 Millimeter Equivalents
• U.S. To Metric Conversion
• SMR
• Revision No: T190-1
• Revision No: T190-2
• Revision No: T190-3
• Revision No: T190-4
• Revision No: T190-5
• Revision No: T190-6
• Revision No: T190-7