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
• CONTENTS
• FOREWORD
• 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 & 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
• Forestry Door And Window Kit
• Forestry Door And Window 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 Communicator – MEL1566
• Remote Start Procedure
• REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
• Description
• Remote Start Tool (Service Tool) – 7003030
• 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
• Maintenance Platform
• Cleaning
• Checking Level
• Removing And Replacing 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 Hydraulic Charge Filter
• Breather Cap
• BOB-TACH (HAND LEVER)
• Inspection And Maintenance
• BOB-TACH (POWER)
• Inspection And Maintenance
• LUBRICATING THE LOADER
• Lubrication Locations
• SPARK ARRESTER 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
• External Access
• Rear Window
• Front Door
• SEAT BELT
• Inspection And Maintenance
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting
• CYLINDER (LIFT)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (TILT)
• Testing
• Removal And Installation
• Base End Pivot Pin Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (BOB-TACH)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• MAIN RELIEF VALVE
• Description
• Testing
• Adjusting
• Removal And Installation
• HYDRAULIC CONTROL VALVE (SJC)
• Description
• Removal And Installation
• Actuator Removal And Installation (In Loader)
• 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 And Auxiliary)
• Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
• Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
• Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
• Port Relief / 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 Removal And Installation
• Lift Spool Disassembly And Assembly
• 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 (SCPA)
• Description
• Removal And Installation
• Mount Bracket 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 Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
• Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
• Port Relief / 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 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 BYPASS CONTROL VALVE
• Description
• Testing
• Removal And Installation
• Bracket Removal And Installation
• Disassembly And Assembly
• HYDRAULIC PUMP
• Description
• Pump Test At Quick Couplers
• Direct Pump Test (Standard Section)
• Direct Pump Test (Charge Section)
• Removal And Installation
• Hydraulic Pump Startup
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC PUMP (HIGH FLOW)
• Description
• Pump Test At Quick Couplers
• Direct Pump Test (Standard Section)
• Direct Pump Test (Charge Section)
• Direct Pump Test (High Flow Section)
• High Flow Relief Valve Adjustment
• High Flow Relief Valve Removal And Installation
• Solenoid Removal And Installation
• Removal And Installation
• Hydraulic Pump Startup
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC / HYDROSTATIC FILTERS
• Description
• 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
• Description
• Troubleshooting
• HYDROSTATIC DRIVE MOTOR
• Description
• Removing And Replacing Oil
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• HYDROSTATIC DRIVE MOTOR (TWO SPEED)
• Description
• Removing And Replacing Oil
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CHARGE PRESSURE
• Description
• Testing
• Sender Removal And Installation
• Adjusting
• HYDROSTATIC PUMP (SJC AND SCPA)
• 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
• Belt Adjustment
• Stop Adjustment
• Belt Replacement
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Disassembly And Assembly
• DRAIN MANIFOLD
• Description
• Drain Manifold Removal And Installation
• DRIVE SYSTEM
• BRAKE
• Description
• Block Removal And Installation
• Block Disassembly And Assembly
• TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)
• Description
• Checking Tension
• Adjusting Tension
• Track Removal And Installation
• Idler (Front) Removal And Installation
• Track Tensioner Disassembly And Assembly
• Idler (Rear) Removal And Installation
• Roller Removal And Installation
• Leaf Spring Removal And Installation
• Sprocket Removal And Installation (Single Speed)
• Sprocket Removal And Installation (Two Speed)
• Track Housing Removal And Installation
• TRACK MAINTENANCE
• Track Damage Identification
• MAINFRAME
• SEAT BAR
• Description
• Removal And Installation
• Disassembly And Assembly
• Compression Spring Disassembly And Assembly
• OPERATOR CAB
• Gas Spring Removal And Installation
• Gas Spring 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
• Lower Cushion 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
• Pivot Pin Bushing And Seal Removal And Installation
• BOB-TACH (POWER)
• Description
• Removal And Installation
• Lever And Wedge Disassembly And Assembly
• Pivot Pin Bushing And Seal Removal And Installation
• LIFT ARMS
• Stabilizer Bar Removal And Installation
• Link Removal And Installation
• Removal And Installation
• REAR GRILLE
• Removing
• Installing
• REAR DOOR (TAILGATE)
• 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
• FUEL TANK (AUXILIARY)
• Removal And Installation
• CONTROL PEDALS AND LINKAGES (SCPA)
• Description
• Pedal Removal And Installation
• Linkage Removal And Installation
• Pedal (Adjusting)
• Floor Pan Removal And Installation
• CONTROL PANEL (SJC)
• Description
• Removal And Installation
• CONTROL PANEL (SCPA)
• Description
• Removal And Installation
• CONTROL HANDLE / LEVER (SJC)
• Description
• Joystick Testing
• Joystick Removal And Installation
• CONTROL HANDLE / LEVER (SCPA)
• Description
• Steering Handle Testing
• Steering Handle Removal And Installation
• ACCESS PANEL (INSIDE)
• Removal And Installation (Left)
• Removal And Installation (Right)
• ACCESS PANEL (INSIDE) (SJC)
• Removal And Installation (Left)
• Removal And Installation (Right)
• WINDOW (REAR)
• Removal And Installation
• Disassembly And Assembly
• WINDOW (TOP)
• Removal And Installation
• WINDOW (SIDE)
• Removal And Installation
• CAB DOOR
• Description
• Removal And Installation
• Disassembly And Assembly
• Aligning
• Adjusting
• Checking Operation
• ARMREST
• Description
• Removal And Installation
• Disassembly And Assembly
• LEFT SIDE LOWER PANEL
• Removal And Installation
• Disassembly And Assembly
• RIGHT SIDE LOWER PANEL
• Removal And Installation
• Disassembly And Assembly
• HEADLINER
• Removal And Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Glossary Of Electrical Symbols
• Deluxe 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
• Display Screen
• Right Panel (Standard Key Panel)
• Right Panel (Keyless Start Panel)
• Right Panel (Deluxe Instrumentation Panel)
• Left Switch Panel
• Right Switch Panel
• Left Side Lower Panel
• Right Side Lower Panel
• Left Panel Removal And Installation
• Right Panel Removal And Installation
• Key Switch Disassembly And Assembly
• Alarm Disassembly And Assembly
• Left Switch Panel Removal And Installation
• Right Switch Panel Removal And Installation
• LIGHTS
• Front Removal And Installation
• Rear Removal And Installation
• Cab Light Removal And Installation
• BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)
• Description
• Connector Identification
• Removal And Installation
• BOBCAT CONTROLLER (ACS)
• Description
• Connector And Wire Identification
• Removal And Installation
• BOBCAT CONTROLLER (SJC) (DRIVE)
• Description
• Connector Identification
• Removal And Installation
• SPEED SENSORS (SJC AND SCPA)
• Description
• Testing
• Removal And Installation
• DIAGNOSTIC SERVICE CODES
• Viewing Service Codes
• Service Codes List
• BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
• Description
• Inspecting The BICS™ (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 (SJC)
• Troubleshooting
• SEAT BAR SENSOR
• Description
• Troubleshooting
• Testing
• Removal And Installation
• Bobcat Interlock Control System (BICS™) Circuit Test
• TRACTION LOCK
• Description
• Troubleshooting
• Inspecting
• ELECTRICAL / HYDRAULIC CONTROLS (SJC)
• Identification Chart
• Description
• Identification Chart ACD Group 0
• Identification Chart ACD Group 1
• Identification Chart ACD Group 2
• Identification Chart ACD Group 3
• ELECTRICAL / HYDRAULIC CONTROLS (SCPA)
• Identification Chart
• Description
• Identification Chart ACD Group 0
• Identification Chart ACD Group 1
• Identification Chart ACD Group 2
• Identification Chart ACD Group 3
• SERVICE PC (LAPTOP COMPUTER)
• Connecting Remote Start Tool
• Connecting Remote Start Tool (Service Tool)
• CALIBRATION
• Description
• Actuator Testing
• Lift And Tilt Calibration (SJC)
• Hydrostatic Pump Calibration (SJC)
• Hydrostatic Pump Calibration (SCPA)
• STEERING DRIFT COMPENSATION
• Description
• Operation
• FLYWHEEL RPM SENSOR
• Description
• Adjusting
• CONTROL PANEL SETUP
• Right Panel Setup (Deluxe Instrumentation Panel)
• PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)
• Password Description
• Changing The Owner Password
• Changing The User Passwords
• Password Lockout Feature
• PASSWORD SETUP (KEYLESS START PANEL)
• Password Description
• Changing The Owner Password
• Password Lockout Feature
• MAINTENANCE CLOCK
• Description
• Setup
• Reset
• BACK-UP ALARM SYSTEM
• Description
• Inspecting
• Troubleshooting (Joystick)
• Alarm Removal And Installation
• FRONT HORN
• Description
• Inspecting
• Front Horn Removal And Installation
• Troubleshooting
• Troubleshooting (Joystick)
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Torque Values
• Troubleshooting
• Engine Removal And Installation
• Engine Mount Replacement
• Compression – Checking
• ENGINE SPEED CONTROL (SCPA)
• Removal And Installation
• Disassembly And Assembly
• Cable 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
• Lower Fan Duct Removal And Installation
• Blower Housing Removal And Installation
• Hydraulic Fan Motor Assembly 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
• Oil Filter Cooler Removal And Installation
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Fuel Shutoff Solenoid – Checking
• Fuel Shutoff Solenoid Removal And Installation
• Fuel Injection Pump Assembly Removal
• Fuel Injection Pump Assembly Installation
• Governor Housing Disassembly And Assembly
• Governor Disassembly And Assembly
• Fuel Camshaft Removal And Installation
• Fuel Injection Pump Removal
• Fuel Injection Pump Installation
• Injection Pump – Timing
• Fuel Injector Removal And Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spraying Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Intake Air Heater – Testing
• Intake Air Heater 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
• Push Rod Alignment – 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
• Crankshaft And Bearings 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
• TURBOCHARGER
• Description
• Testing
• Removal And Installation
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• EXHAUST GAS RECIRCULATION (EGR) SYSTEM
• Description
• Testing
• Removal And Installation
• HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
• AIR CONDITIONING SYSTEM FLOW
• Description
• Chart
• Components
• Safety Equipment
• REGULAR MAINTENANCE
• Filters
• Compressor Drive Belt Adjustment
• Compressor Drive Belt Replacement
• Condenser
• Air Conditioning Lubrication
• Air Conditioning Service Chart
• Evaporator / Heater Coil
• TROUBLESHOOTING
• Blower Motor Does Not Operate
• Blower Motor Operates Normally, But Air Flow Is Insufficient
• Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
• The Compressor Does Not Operate At All, Or Operates Improperly
• Gauge Pressure Related Troubleshooting
• Troubleshooting Tree
• Temperature / Pressure Chart
• Poor A/C Performance
• HVAC Repair And Leaks
• Electrical System
• Engine Coolant Bypassing The Heater Valve
• Heater Valve Not Opening Or Closing
• SYSTEM CHARGING AND RECLAMATION
• Refrigerant Identification
• Reclamation And Charging With Recovery / Charging Unit
• COMPRESSOR
• Removal And Installation
• Oil
• Oil Check
• CONDENSER
• Removal And Installation
• RECEIVER / DRIER
• Receiver / Drier Removal And Installation
• Pressure Relief Valve Removal And Installation
• Pressure Switch Removal And Installation
• Schrader® Valve Removal And Installation
• EVAPORATOR / HEATER UNIT
• Removal And Installation
• THERMOSTAT
• Description
• Removal And Installation
• EXPANSION VALVE
• Removal And Installation
• EVAPORATOR COIL
• Removal And Installation
• HEATER COIL
• Removal And Installation
• BLOWER FAN
• Removal And Installation
• Disassembly And Assembly
• HEATER VALVE
• Removal And Installation
• SPECIFICATIONS
• (T870) LOADER SPECIFICATIONS
• Machine Dimensions
• Performance
• Engine
• Drive System
• Controls
• Hydraulic System
• Electrical System
• Capacities
• Tracks
• Ground Pressure
• TORQUE SPECIFICATIONS FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• HYDRAULIC CONNECTION SPECIFICATIONS
• Straight Thread O-ring Fitting
• Flare Fitting
• Tubelines And Hoses
• HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalent Chart
• U.S. To Metric Conversion Chart
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISION
• Revision No: T870 – 1
• Revision No: T870 – 2
• Revision No: T870 – 3
• Revision No: T870 – 4
• Revision No: T870 – 5