Bobcat S300 PDF

Service
Manual
S250
S/N 526011001 & Above
S/N 526111001 & Above
S300
S/N 525811001 & Above
S/N 525911001 & Above
INCLUDES HIGH FLOW
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902711 (3-06) Printed in U.S.A. © Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-16261 B-16264

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-16272 B-16260 B-16263

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-16271 B-16270 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW14-0805
ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 EVAPORATOR/HEATER UNIT...............................80-01

AIR CLEANER ........................................................ 70-01 EXPANSION VALVE ...............................................80-01
AIR CLEANER SERVICE ....................................... 10-01 FAN GEARBOX.......................................................10-01
AIR CONDITIONING SERVICE.............................. 80-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FLYWHEEL AND HOUSING ............................... 70-01
ALTERNATOR ........................................................ 60-01 FLYWHEEL RPM SENSOR ................................ 60-01
FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
BASIC TROUBLESHOOTING ................................ 80-01 FUEL SYSTEM........................................................10-01
BATTERY ............................................................... 60-01 FUEL TANK .............................................................50-01
BICS™ SYSTEM .................................................... 60-01
BLOWER FAN ........................................................ 80-01
GENERAL AIR CONDITIONING SERVICE
BOBCAT CONTROLLER........................................ 60-01
GUIDELINES .........................................................80-01
BOB-TACH .............................................. 10-01, 50-01
BRAKE .................................................................... 40-01
BRAKE (TWO-SPEED)........................................... 40-01 HEATER COIL.........................................................80-01
BUCKET POSITION VALVE ............................... 20-01 HEATER VALVE .....................................................80-01
HYDRAULIC CONNECTION SPECS ............... SPEC-01
CALIBRATION ........................................................ 60-01 HYDRAULIC CONTROL VALVE
CHAINCASE ........................................................... 40-01 (ADVANCED CONTROL SYSTEM) (ACS) ...........20-01
CHARGE PRESSURE ............................................ 30-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
COMPONENTS ...................................................... 80-01 (ADVANCED CONTROL SYSTEM) (ACS) ...........20-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC CONTROL VALVE
CONDENSER ......................................................... 80-01 (FOOT CONTROL)................................................20-01
CONTROL HANDLE ............................................... 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (FOOT CONTROL)................................................20-01
(ACS) SELECTABLE HAND/FOOT CONTROL ... 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)......20-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 50-01 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
CONTROL PANEL (ADJUSTABLE PINTLES) ....... 50-01 (SELECTABLE JOYSTICK CONTROL) (SJC)......20-01
CONTROL PANEL (NON-ADJUSTABLE PINTLES) .. 50-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CONTROL PANEL HYDRAULIC FLUID SPECIFICATIONS ....... SPEC-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 50-01 HYDRAULIC/HYDROSTATIC FILTER....................20-01
CONTROL PEDALS ............................................... 50-01 HYDRAULIC/HYDROSTATIC SYSTEM .................10-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC PUMP ...............................................20-01
CONTROLLER (SELECTABLE JOYSTICK HYDRAULIC PUMP (CHARGE)..............................20-01
CONTROL) (SJC) ................................................. 60-01 HYDRAULIC PUMP (HI FLOW) ............................20-01
CONVERSIONS ............................................SPEC-01 HYDRAULIC PUMP (SELECTABLE JOYSTICK
COOLING FAN ....................................................... 70-01 CONTROL) (SJC).................................................20-01
CYLINDER (LIFT) ................................................... 20-01 HYDRAULIC PUMP (HI FLOW)
CYLINDER (POWER BOB-TACH) ......................... 20-01 (SELECTABLE JOYSTICK CONTROL) (SJC).....20-01
CYLINDER (TILT) ................................................ 20-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
HYDROSTATIC MOTOR .................................... 30-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 HYDROSTATIC MOTOR (TWO SPEED) ...............30-01
DRIVE BELT ........................................................... 30-01 HYDROSTATIC MOTOR CARRIER .......................30-01
DRIVE COMPONENTS .......................................... 40-01 HYDROSTATIC MOTOR CARRIER
(SELECTABLE JOYSTICK CONTROL) (SJC)......30-01
ELECTRICAL/HYDRAULIC CONTROLS HYDROSTATIC PUMP ....................................... 30-01
REFERENCE ........................................................ 60-01 HYDROSTATIC PUMP
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) ..30-01
(SELECTABLE JOYSTICK CONTROL) (SJC) ..... 60-01 HYDROSTATIC SYSTEM INFORMATION .........30-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
ENGINE ................................................................. 70-01 INSIDE ACCESS PANEL ........................................50-01
ENGINE COOLING SYSTEM ................................. 10-01 INSIDE ACCESS PANEL
ENGINE LUBRICATION SYSTEM ......................... 10-01 (SELECTABLE JOYSTICK CONTROL) (SJC)......50-01
ENGINE SPECIFICATIONS ..........................SPEC-01 INSTRUMENT PANEL ............................................60-01
ENGINE SPEED CONTROL .................................. 70-01
ENGINE SPEED CONTROL (SELECTABLE
JOYSTICK CONTROL) (SJC)............................... 70-01
EVAPORATOR ....................................................... 80-01
ALPHABETICAL INDEX (CONT’D)
LIFT ARMS ..........................................................50-01

LIFT ARM BY-PASS CONTROL VALVE ............ 20-01
LIFT ARM SUPPORT DEVICE ............................10-01
LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS ............................................................... 60-01
LOADER SPECIFICATIONS (S250) ................. SPEC-01
LOADER SPECIFICATIONS (S300) ................. SPEC-01
LUBRICATING THE LOADER.................................10-01
MAIN RELIEF VALVE (ACS)...............................20-01

MAIN RELIEF VALVE (FOOT CONTROL)..............20-01
MAIN RELIEF VALVE
(SELECTABLE JOYSTICK CONTROL) (SJC)......20-01
MUFFLER................................................................70-01
OIL COOLER (SEAL TO CONNECT) (STC)...........30-01

OPERATOR CAB .........................................10-01, 50-01
OPERATOR SEAT ..................................................50-01
OPERATOR SEAT (SUSPENSION) .......................50-01
POWER BOB-TACH ................................ 10-01, 50-01

POWER BOB-TACH BLOCK ..................................20-01
PRESSURE RELIEF VALVE...................................80-01
PRESSURE SWITCH..............................................80-01
RADIATOR ..............................................................70-01
REAR AUXILIARY DIVERTER................................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ....................................................... 50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START ................................................ 10-01
RPM SENSOR.........................................................70-01
SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR...............................................60-01
SRVICE PC (LAPTOP COMPUTER) ......................60-01
SERVICE SCHEDULE ........................................... 10-01
SPEED SENSOR (SELECTABLE JOYSTICK ........60-01
CONTROL) (SJC)..................................................60-01
STARTER ............................................................... 60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE/PRESSURE.................................80-01
THERMOSTAT ........................................................80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS ... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER ............10-01
TROUBLESHOOTING.............................................70-01
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . X
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 70-01 SERVICE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
SPECIFICATIONS
S250, S300 Bobcat Loader

I Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers and foot 15. Inspect for fuel, oil or

pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct function of 16. Lubricate the loader.

the work lights

III Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Recommend to the owner
pressure. that all necessary corrections
be made before the machine
is returned to service.
21. Inspect for loose or broken

parts or connections.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.

IV Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Skid-Steer Loader Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
• The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI SSL-0206 SM

V Service Manual
SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.
Call Before You Dig

1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM

VI Service Manual
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the

emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
• The operator cab, engine compartment, and engine

• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

SMOKING!
SI SSL-0206 SM

VII Service Manual
SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 2
P-48339
The engine serial number is located on the engine block

[Figure 3].
DELIVERY REPORT
Figure 4
P-31226
The loader serial number plate is located on the outside

of the loader frame [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
1. The four digit Model/Engine Combination Module

B-16315
number identifies the model number and engine
combination.
The Delivery Report must be filled out by the dealer and
2. The five digit Production Sequence Number identifies signed by the owner or operator when the Bobcat loader
the order which the loader is produced. is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
4].

IX Service Manual
BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS OPERATOR SEAT

with SEAT BELT
GRAB HANDLES
TILT CYLINDER
+ BUCKET
FRONT AUXILIARY
QUICK COUPLERS
BUCKET STEPS STEPS
● OPERATOR CAB
LIFT CYLINDER (ROPS & FOPS)
SEAT BAR
LIFT ARM
REAR GRILL
LIFT ARM
SUPPORT DEVICE
REAR
LIGHT
REAR DOOR
▼ TAIL LIGHT
* TIRES B-16373
B-16275
▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

* TIRES - Flotation tires ▼ are shown. The Bobcat loader is factory equipped with standard tires.
+ BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective
Structure per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a
standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

X Service Manual
SAFETY AND MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Adding The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Cleaning Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
DRIVE
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
ELECTRICAL
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 SYSTEM &
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ANALYSIS
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2
SPECIFICATIONS
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-2
Replacing Hydraulic Fluid And Case Drain Filters . . . . . . 10-120-3
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing The Lift Arm Support Device. . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Continued On Next Page

10-01 Service Manual
SAFETY AND MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-151-1
REMOTE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Procedure For Loader With Attachments Control Harness 10-60-2
Procedure For Loader W/O Attachments Control Harness 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIGHTEN ALL HARDWARD PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION
SPEC-01) UNLESS OTHERWISE SPECIFIED.

LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-31290
Lift the rear of the loader and install jackstands [Figure

B-7023A 10-10-2].
Figure 10-10-3
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
P-31676
Read the Removal & Installation, Disassembly &

Assembly, etc. completely to become familiar with the Lift the front of the loader and put jackstands under the
procedure before beginning [Figure 10-10-1]. axle tubes [Figure 10-10-3].
Always park the loader on a level surface. NOTE: Make sure the jackstands do not touch the
tires.
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

10-10-1 Service Manual
LIFT ARM SUPPORT DEVICE Remove the lift arm support device (Item 1) [Figure 10-
20-1] from the storage position.
Installing The Lift Arm Support Device
The operator must stay in the operator seat with the seat
Figure 10-20-1 belt fastened and the seat bar lowered, until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
P-10136
1
P-31290 P-31244
WARNING P-31264
Never work on a machine with the lift arms up unless

Have a second person install the lift arm support device
the lift arms are secured by an approved lift arm
over the rod of one of the lift cylinders [Figure 10-20-2].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
The lift arm support device must be tight against the
to fall and cause injury or death.
W-2059-0598
cylinder rod. The tabs of the lift arm support device must
be under the cylinder as shown (Inset) [Figure 10-20-2].
WARNING
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197
Put jackstands under the rear corners of the loader frame

(Inset) [Figure 10-20-1].

LIFT ARM SUPPORT DEVICE (CONT’D)
Installing The Lift Arm Support Device (Cont’d)
Figure 10-20-3
P-31265
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and lift cylinder [Figure 10-
20-3].
Removing The Lift Arm Support Device
The operator must be in the operator's seat, with the seat

belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.
Start the engine, raise the lift arms all the way up.
Have a second person remove the lift arm support

device.
Lower the lift arms all the way and stop the engine.
Return the lift arm support device to storage position and

secure with clamping knobs.
Remove the jackstands.

OPERATOR CAB Figure 10-30-2
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.
ROPS/FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.
Level I - Protection from falling bricks, small concrete P-31288 P-31289

blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Loosen the nut (both sides) at the front corner of the
operator cab [Figure 10-30-2].
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Remove the nuts and plates [Figure 10-30-2] (both
or forestry. sides).
Raising The Operator Cab Figure 10-30-3
Figure 10-30-1
P-31267
P-31290
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
Always stop the engine before raising or lowering the mechanism engages [Figure 10-30-3].
cab.
Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing The Lift
Arm Support Device on Page 10-20-1.)
Install jackstands under the rear of the loader frame

[Figure 10-30-1].

OPERATOR CAB (CONT'D) Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Raising The Operator Cab (Cont’d)
Release the latching mechanism (Inset) [Figure 10-30-4]
Advanced Hand Control Only and pull the cab all the way down.
Figure 10-30-5
P-31288 P-31289
WARNING Install the plates and nuts [Figure 10-30-5] (both sides).
Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.

Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
Emergency Exit
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
Figure 10-30-6
and falling objects, and result in injury or death.
W-2069-1299
Lowering The Operator Cab

Figure 10-30-4
N-19386
The front opening on the operator cab and rear window

provide exits.
N-20120 P-31268
REAR WINDOW (If Equipped)
Always stop the engine before raising or lowering the Pull on the tag on the top of the rear window to remove
cab. the rubber cord [Figure 10-30-6].
NOTE: Make sure the seat bar is fully raised or

lowered when lowering the cab. Always use
the grab handles to lower the cab.

OPERATOR CAB (CONT'D) Figure 10-30-9
Emergency Exit (Cont’d)
Figure 10-30-7
P-28359
Push the window out with your foot [Figure 10-30-9] at

P-31269 any corner of the window.
Exit through the front door.

Push the rear window out of the rear of the operator cab.
Exit through the rear of the operator cab [Figure 10-30-

7].
Figure 10-30-8
N-20171
FRONT DOOR (If Equipped)
NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be
used as an emergency exit [Figure 10-30-8].
NOTE: When the special applications kit is installed,

the front door cannot be used for an
emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].

TRANSPORTING THE BOBCAT LOADER Figure 10-40-2
Procedure
Figure 10-40-1
P-31228A P-31230A
P-31915
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. 6595014 P-31916
W-2058-0494
Use the following procedure to fasten the Bobcat loader

A loader with an empty bucket or no attachment must be to the transport vehicle to prevent the loader from moving
loaded backward onto the transport vehicle [Figure 10- during sudden stops or when going up or down slopes
40-1]. [Figure 10-40-2].
Be sure the transport and towing vehicles are of • Lower the bucket or attachment to the floor.
adequate size and capacity (See LOADER
SPECIFICATIONS (S250) on Page SPEC-10-1.) or (See • Stop the engine.
LOADER SPECIFICATIONS (S300) on Page SPEC-11-
1.). • Engage the parking brake.
The rear of the trailer must be blocked or supported (Item • Install chains at the front and rear loader tie down
1) [Figure 10-40-1] when loading or unloading the loader positions (Inset) [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
• Fasten each end of the chain to the transport vehicle.

TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

recommended towing procedure.
• The loader can be lifted onto a transport vehicle.
• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1 & 1/2

times the weight of the loader (See LOADER
SPECIFICATIONS (S250) on Page SPEC-10-1.) or
(See LOADER SPECIFICATIONS (S300) on Page
SPEC-11-1.)

REMOTE START Figure 10-60-2
Procedure For Loader W/O Attachments Control

Harness
Figure 10-60-1
1
1
P-28365
Remove the cap (Item 1) [Figure 10-60-2] from the

loader harness.
P13841
When the remote start procedure is completed, replace
the loader connector cap (Item 1) [Figure 10-60-2].
The tool listed will be need to do the following procedure:
Figure 10-60-3
MEL1563 - Remote Start Tool Kit
The remote start (Item 1) [Figure 10-60-1] is required

when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering 2
linkage.
Lift and block the loader. (See Procedure on Page 10-10-

1.) 1
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)
P-28366
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Connect the remote start tool to the engine harness
Open the rear door of the loader. connector (Item 1) [Figure 10-60-3].
The connector (Item 2) [Figure 10-60-3] from the remote

start harness is not used in the remote start procedure
and should remain capped.
NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Kit will not operate.

REMOTE START (CONT'D) Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Procedure For Loader W/O Attachments Control
Harness (Cont’d) Open the rear door of the loader.
Figure 10-60-5
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working in the engine area 1
it is important to remove the operator panel keys.
W-2357-0899
P-28362
Procedure For Loader With Attachments Control
Harness
Figure 10-60-6
Figure 10-60-4
P-28364
P13841
Disconnect the attachment control harness (Item 1)

The tool listed will be need to do the following procedure: [Figure 10-60-5] & [Figure 10-60-6] from the loader
harness (Item 2) [Figure 10-60-6].
MEL1563 - Remote Start Tool Kit
The remote start (Item 1) [Figure 10-60-4] is required

when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering
linkage.
Lift and block the loader. (See Procedure on Page 10-10-

1.)
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See Installing
The Lift Arm Support Device on Page 10-20-1.)

REMOTE START (CONT'D) Procedure
Procedure for Loader With Attachments Control Figure 10-60-8

Harness (Cont’d)
Figure 10-60-7
1
3 2
P13842
1
P-28363 The remote start tool (Item 1) [Figure 10-60-8] has three
rocker switches.
Connect the remote start tool (Item 1) [Figure 10-60-7] to Figure 10-60-9
the loader harness connector (Item 2) [Figure 10-60-6].
The connector (Item 3) [Figure 10-60-7] on the remote

start harness is not used in the remote start procedure
and should remain capped.
2
NOTE: The key switch on the right-hand side 1
3
operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
N-19541
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the The traction lock switch (Item 1) [Figure 10-60-9] is used
loader can still be started from the operator panel to turn traction lock on or off. Push the switch to the
inside the cab. Placing the key switch of the remote override position. The switch will illuminate to indicate
start tool in the run position disconnects the traction lock OVERRIDE, in this position the wheels are
operator panel key switch from the start circuit. If the able to turn.
service technician will be working in the engine area The maximum flow/variable flow switch (Item 2) [Figure
it is important to remove the operator panel keys. 10-60-9] is used to activate the auxiliary hydraulics.
W-2357-0899 Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-9]
is used to release hydraulic pressure to the rear auxiliary
couplers, and right hand auxiliary. (If so equipped.) To
release pressure; push and hold the switch for three
seconds.

REMOTE START (CONT'D)
Procedure (Cont’d)
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to press the switch
after the engine has stopped.

SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS

■ ■ ■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Tires Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as
Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™) details in this Manual.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Fuel Filter Remove the trapped water.
Heater and A/C Filters Clean or replace filters as needed during heating/cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls,
and Steering Levers
Wheel Nuts ❏Check for loose wheel nuts and tighten to 105-115 ft.-lbs. (142-156 Nm)
torque
Parking Brake Check operation.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Engine/Hydro. Drive Belt *Check for wear or damage. Check idler arm stop.
Alternator Belt Check tension and adjust as needed.
Air Condition Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm by-pass control.
(BICS™)
Fuel Filter Replace filter element.
Steering Shaft Grease fittings.
Fan Drive Gearbox Check gear lube level.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter ●Replace the filter element.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^ ❍
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves Adjust the engine valves.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace hydraulic/hydrostatic filter element at the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
❍ When operating under severe conditions, change oil and filter every 250 hours.
■ Or every 12 months.

AIR CLEANER SERVICE If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER /
Replacing Filter Element CODE DISPLAY (Item 2) [Figure 10-80-2].
Figure 10-80-1 Figure 10-80-3
B-16300
P-48340
B-15552
B-15553
OUTER FILTER
It is important to change the air filter element only when Disengage the wing nut (Item 1) [Figure 10-80-3] and
the Air Cleaner Icon in the right panel is ON (Item 1) remove the dust cover.
[Figure 10-80-1] and you hear three beeps from the
alarm. Figure 10-80-4
Replace the inner filter every third time the outer filter is
replaced or as indicated on See Replacing Filter Element
(Cont'd) on Page 10-80-2.
Figure 10-80-2 1
P-48341
1
Remove the wing nut (Item 1) [Figure 10-80-4] and
remove the outer filter element.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
B-15551 Install a new outer element, and install the wing nut.
Install the dust cover and install the outer wing nut.
Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

AIR CLEANER SERVICE (CONT'D) Figure 10-80-6
Replacing Filter Element (Cont'd)
Figure 10-80-5
1
1
P-48340
Install the new inner element.

P-48342
Install the dust cover and wing nut (Item 1) [Figure 10-
80-6].
INNER FILTER
Only replace the inner filter element under the following

conditions:
• Replace the inner filter element every third time the

outer filter is replaced.
• After the outer element has been replaced, start the

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
Remove the inner filter element (Item 1) [Figure 10-80-

5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.

ENGINE COOLING SYSTEM Figure 10-90-2
Cleaning Cooling System
Figure 10-90-1
P-34868
Lift the overflow tank (Item 1) [Figure 10-90-2] out of its

P-34869 mount bracket.
Remove the cotter pin (Item 2) [Figure 10-90-2] (both

Check the cooling system every day to prevent over- sides) from the oil cooler.
heating, loss of performance or engine damage.
Figure 10-90-3
WARNING
Wear safety glasses to prevent eye injury when any
of the flollowing conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
Remove the rear grill. (See Removal And Installation on

Page 50-60-1.) P-34867
Use air pressure or water pressure to clean the top of the

oil cooler [Figure 10-90-1]. Raise the oil cooler [Figure 10-90-3].
Use air pressure or water pressure to clean the top of the

engine oil cooler.

ENGINE COOLING SYSTEM (CONT’D)
Cleaning Cooling System (Cont’d)
Figure 10-90-4
Access
Cover
P-31691
NOTE: The access cover (both sides) must be in

place to ensure proper air flow through the oil
cooler which will ensure correct cooling for
the engine/hydraulic system [Figure 10-90-4].

ENGINE COOLING SYSTEM (CONT’D)
Checking The Coolant Level

IMPORTANT
Figure 10-90-5
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
MAX
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
MIN
MAX
damage.
P-45106
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
P-62252 I-2124-0497
Open the rear door and raise the rear grill.
Check the coolant level [Figure 10-90-5]. The level

marks are on the outside of the tank. Coolant level must
be between the MIN and MAX marks on the coolant
recovery tank when the engine is cold.
Close the rear door before operating the loader.

ENGINE COOLING SYSTEM (CONT’D) Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
Adding The Coolant
One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34°F (-37°C) freeze protection.
WARNING Use a refractometer to check the condition of propylene
glycol in your cooling system.
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
Fill the tank with the premixed coolant until it is between
the MIN and MAX marks. Install the coolant tank cap.
Figure 10-90-6 Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level in the coolant tank
when cool. Add coolant as needed.
Install the rear grill and close the rear door.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

P-62252 efficiency and may cause serious premature engine
damage.
Open the rear door and remove the rear grill. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Remove the coolant tank cap (Item 1) [Figure 10-90-6]. boiling point and freeze protection of the system.
Mix the coolant in a separate container. (See Capacities Always add a premixed solution. Adding full strength
on Page SPEC-10-4.) or (See Capacities on Page concentrated coolant can cause serious premature
SPEC-11-4.) engine damage.
I-2124-0497
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
The following is one suggested blending guideline which

should prevent fuel gelling problems:
Temp. F° (C°) No. 2 No. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B-15526
We recommend an operator contact their fuel supplier for

local recommendations. Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
Filling The Fuel Tank free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap [Figure 10-100-1].
WARNING Fuel Filter
Stop and cool the engine before adding fuel. NO Figure 10-100-3
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
Figure 10-100-1
2
P-48343
1
(See SERVICE SCHEDULE on Page 10-70-1.) for the

recommended service interval when to remove the water
from the fuel filter.
P-31254
Loosen the drain (Item 1) [Figure 10-100-3] at the

Remove the fuel fill cap (Item 1) [Figure 10-100-1]. bottom of the filter element to drain any water from the
filter.
(See SERVICE SCHEDULE on Page 10-70-1.) for the

recommended service interval when to replace the fuel
filter.
To replace the fuel filter element, use a filter wrench to

remove the filter element (Item 2) [Figure 10-100-3].
FUEL SYSTEM (CONT'D)
Fuel Filter (Cont’d)
Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter, and
hand tighten. Remove the air from the fuel system.
Removing Air From The Fuel System
Figure 10-100-4
P-48343
After replacing the fuel filter element or when the fuel

tank has run out of fuel, the air must be removed from the
fuel system prior to starting the engine.
Loosen the air vent plug (Item 1) [Figure 10-100-4] at the

top of the fuel filter.
Figure 10-100-5
P-48351
Operate the hand pump (priming bulb) (Item 1) [Figure

10-100-5] until the fuel flows from the air vent plug with
out air bubbles.
Tighten the air vent plug.

ENGINE LUBRICATION SYSTEM Replacing Oil And Filter
Checking Engine Oil Figure 10-110-2
Figure 10-110-1
P-48345
P-48345
(See SERVICE SCHEDULE on Page 10-70-1.), for the
service interval for replacing the engine oil and filter.
Check the engine oil level every day.
Run the engine until it is at operating temperature. Stop
Before starting the engine for the work shift, open the the engine.
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1]. Open the rear door. Remove the drain hose (Item 1)
[Figure 10-110-2] from its storage position. Remove the
Keep the oil level between the marks on the dipstick. cap and drain the oil into container.
Use a good quality motor oil that meets API Service

Classification of CD, CE or better. (See Oil Chart below.)
Oil Chart

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-4
Replacing Oil And Filter (Cont’d)
Figure 10-110-3
P-48347
Remove the filler cap (Item 1) [Figure 10-110-4].

P-48345
Put 14 qts. (13,2 L) of oil in the engine.
Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
WARNING oil as needed if it is not at the top mark on the dipstick.
Always clean up spilled fuel or oil. Keep heat, flames,

sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Remove the oil filter (Item 1) [Figure 10-110-3].
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.
Install and tighten the drain cap on the drain hose.

HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-2
Checking And Adding Fluid
Figure 10-120-1
Sight
Gauge
1
P-4613
P-31692
If fluid is needed, remove the fill cap (Item 1) [Figure 10-

P-31692 120-2].
Add the fluid as needed to bring the level to the center of

Use only recommended fluid in the hydraulic system. the sight gauge.
(See Hydraulic System on Page SPEC-10-3.) or (See
Hydraulic System on Page SPEC-11-3.) Figure 10-120-3
Hydraulic Fluid Chart
P-30011
NOTE: Before installing the fill cap, make sure the

rubber gasket (Item 1) [Figure 10-120-3] is
installed on the fill cap.
To check the reservoir, use the following procedure:
Put the Bobcat loader on a level surface. Lower the lift

arms and tilt the Bob-Tach fully back. Stop the engine.
Check the fluid level at the sight gauge [Figure 10-120-

1]. The fluid level must show in the sight gauge.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)
Hydraulic/Hydrostatic Filter Replacement
Figure 10-120-4
P-34904

correct service interval.
Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
Use a filter wrench to remove the filter element (Item 1)

[Figure 10-120-4].
Clean the surface of the filter housing where the element

seal contacts the housing. Put clean oil on the rubber
seal of the filter elements.
Install and hand tighten the filter elements.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-6
Replacing Hydraulic Fluid And Case Drain Filters

1
Figure 10-120-5
1
P-34905
Disconnect the hoses from the hydrostatic motor case

P-31286 drain filter (Item 1) [Figure 10-120-6].
Remove the case drain filter and clean thoroughly with

(See SERVICE SCHEDULE on Page 10-70-1.), for the clean solvent.
service interval.
Install the case drain filter and tighten the hoses.
Replace the fluid if it becomes contaminated or after
major repair. Install the plug in the reservoir drain hose and tighten.
Install the motor cover.
Also clean the hydrostatic motor case drain filter
thoroughly after a major repair.

on Page 10-30-1.)
Remove the left hydrostatic motor cover.
Pull the reservoir drain hose (Item 1) [Figure 10-120-5]

out the motor cover hole. Remove the plug and drain the
fluid into a container.

HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-8
Replacing Hydraulic Fluid And Case Drain Filters

(Cont’d)
Figure 10-120-7
P-31565
Remove the hoses from the attachments case drain filter

(Item 1) [Figure 10-120-8]. Remove and discard the
1
P-31692 filter.
Install a new filter, tighten the hose fittings and install the
Remove the left side access panel (Item 1) [Figure 10- cover.
120-7].
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge. (See Checking And
Adding Fluid on Page 10-120-1.)
Lower the operator cab. Start the engine and operate the
loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the reservoir and add as
needed.

FINAL DRIVE TRANSMISSION (CHAINCASE) Removing The Oil
Checking And Adding Oil Remove the front chaincase cover. (See Front
Chaincase Cover Removal And Installation on Page 40-
Figure 10-130-1 30-1.)
Use a vacuum pump to extract the fluid from the chain

case.
P-31287
The chaincase contains the final drive sprockets and

chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See LOADER SPECIFICATIONS
(S250) on Page SPEC-10-1.) or (See LOADER
SPECIFICATIONS (S300) on Page SPEC-11-1.)
To check the chaincase oil level, use the following

procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the

front of the chaincase housing.
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

FAN GEARBOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube 1
Level
P7616

correct service interval.

on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the

lubricant level.
When checking the gearbox lube level, make sure the

level does not go above the center line of the shaft in the
gearbox [Figure 10-140-1]. Use SAE 90W gear lube if
the level is low.

BOB-TACH Figure 10-150-3
Inspection And Maintenance

Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Wedge Must Contact
Lower Edge Of Hole
Figure 10-150-1 In the Attachment
B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
P-21234 If the wedge does not contact the lower edge of the hole
[Figure 10-150-2] and [Figure 10-150-3], the
1 attachment will be loose and can come off the Bob-Tach.
Figure 10-150-4
P-31693
Move the Bob-Tach levers to engage the wedges

[Figure 10-150-1]. The levers and wedges must move
freely.
The wedges must extend through the holes in the

attachment mounting frame (Inset) [Figure 10-150-1].
Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
1
on Page 10-160-1.)
P-31237

POWER BOB-TACH Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
B-15177
Wedges Must Contact

Lower Edge Of Hole
In The Attachment
P-31237
If the wedge does not contact the lower edge of the hole
B-15891A (Item 1) [Figure 10-151-3], the attachment will be loose
and can come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the

1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
P-31233 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-160-1.)

LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1 3
P-31301
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-3].

P-31299 Figure 10-160-4
Lubricate the loader as specified in the SERVICE

SCHEDULE, Contents Page 10-01 for the best
performance of the loader.
Record the operating hours each time you lubricate the

Bobcat loader. 4
Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:

P-31302
1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1].
Figure 10-160-2 4. Lift Arm Link Pivot (Both Sides) [Figure 10-160-4].
Figure 10-160-5
2
P-31300
P-31305
2. Base End Lift Cylinder (Both Sides) [Figure 10-160-
2].
5. Base End Tilt Cylinder (Both Sides) [Figure 10-160-
5].

LUBRICATION OF THE LOADER (CONT'D) Figure 10-160-8
Procedure (Cont'd)
Figure 10-160-6
P-31308
8. Bob-Tach Wedge (Both Sides) [[Figure 10-160-8]

P-31306
Figure 10-160-9
6. Rod End Tilt Cylinder (Both Sides) [Figure 10-160-6].
Figure 10-160-7
9
P-31304
7
9. Stabilizer Bar (Both Sides) [Figure 10-160-9].

P-31307
Figure 10-160-10
7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-7].
10
P-31303
10. Stabilizer Bar (Both Sides) [Figure 10-160-10].

LUBRICATION OF THE LOADER (CONT'D)
Procedure (Cont'd)
Figure 10-160-11
11
P10105
11. 250 Hours: Steering Lever Shaft (three) [Figure 10-

160-11].
Pivot Pins
Figure 10-160-12
P-31309
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-12].
Check that the lock nuts are tightened to 18-20 ft.-lbs.

(24-27 Nm) torque.

TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-170-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Tire Mounting
Tires are to be repaired only by an authorized person

using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
P-31673 lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
injury or death. During inflation of the tire, check the tire
(See SERVICE SCHEDULE on Page 10-70-1.), for the pressure frequently to avoid over inflation.
service interval to check the wheel nuts [Figure 10-170-
1].
When installing wheel nuts, tighten to 160 ft.-lbs. (217

Nm) torque. WARNING
When checking wheel nuts, tighten to 140 ft.-lbs. (190 Do not inflate tires above specified pressure. Failure
Nm) torque . to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
Tire Rotation W-2078-1285
Figure 10-170-2
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
B-9976
Check the tires regularly for wear, damage and pressure.

(See Tires on Page SPEC-10-4.) or (See Tires on Page
SPEC-11-4.)
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-170-2].

HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .20-90-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-2 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . .20-90-1 SYSTEM
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-3 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-2 ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-6
Base Pin Removal And Installation . . . . . . . . . . . . . . . . . . . .20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ENGINE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-5 SERVICE
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . 20-120-1 SPECIFICATIONS

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . 20-44-6
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-13
Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-44-27
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-44-25
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-44-32
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-44-31
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . 20-44-12
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . 20-44-29
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-44-28
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-44-18
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-11
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-19
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . 20-44-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-31
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-17
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-16
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-44-14
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-44-15
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-44-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44-2
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . 20-41-2
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . . . 20-41-5
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-41-30
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . 20-41-15
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . 20-41-14
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . . . . 20-41-16
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . . . 20-41-17
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-41-29
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Lift Spool Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) . 20-43-1

Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-8
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 20-43-29
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-27
BICS™ Valve, Check Valve Removal and Installation . . . . . . . . . . . . . . 20-43-34
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . 20-43-33
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . 20-43-7
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . . 20-43-31
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . . 20-43-30
End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . . . 20-43-14
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-6
Lift Spool and Detent Removal and Installation . . . . . . . . . . . . . . . . . . . . 20-43-15
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . . 20-43-8
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-33
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-11
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . . 20-43-9
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . 20-43-10
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . 20-43-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-13
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) . 20-40-1

Anti-Cavitation Valve, Lift Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool. . . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Backslide, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-40-9
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . . 20-40-8
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . . 20-40-7
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS™ Valve, Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 20-40-10
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Lift And Tilt Lock Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool And Detent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Lift Spool And Detent Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Lift Spool And Detent Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Lift Spool And Detent Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Port-Auxiliary Section Removal And Installation . . . . . . . . . . . . . . . . . . . 20-40-34
Port Relief Valve, Lift Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Port Relief Valve, Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE

JOYSTICK CONTROL) (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . 20-45-6
Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . 20-45-8
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . 20-45-13
Auxiliary Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . 20-45-27
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-45-25
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . 20-45-32
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly20-45-31
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . 20-45-12
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . 20-45-29
BICS™ Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . 20-45-28
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-45-18
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-11
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-19
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . 20-45-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-31
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-17
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . 20-45-14
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . 20-45-15
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . 20-45-15
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45-2
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (SELECTABLE
JOYSTICK CONTROL) (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . 20-42-2
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . 20-42-5
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-24
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-42-23
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . 20-42-29
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-42-28
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . 20-42-15
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly20-42-14
BICS™ Valve, Lock Valve Disassembly And Assembly . . . . . . . . . 20-42-16
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-42-11
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . 20-42-17
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-18
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-30
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-19
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . 20-42-27
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-20
Lift Spool Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-25
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-26
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-20
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-21
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-30
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-22
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Check The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
HYDRAULIC PUMP (CHARGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1

Disassembly And Assembly (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . 20-62-14
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) . . . . . . . . . . 20-62-7
High Flow Relief Valve Removal and Installation (30 GPM And 40 GPM) . . . 20-62-9
Hydraulic Pump Test (30 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1
Hydraulic Pump Test (40 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-2
Identification (30 GPM) (S/N 526016699 & Below) (S/N 525815599 & Below)20-62-12
Identification (40 GPM) (S/N 526016700 & Above) (S/N 525815600 & Above)20-62-13
Inline Hydraulic Pump Test (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-3
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM) . . . . . . . . . . 20-62-5
Removal And Installation (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . . . 20-62-10
HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . 20-63-1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-4

HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC) 20-64-1

Disassembly And Assembly (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . 20-64-15
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) . . . . . . . . . . . 20-64-7
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM) . . . . 20-64-9
Hydraulic Pump Test (30 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-1
Hydraulic Pump Test (40 GPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-2
Identification (30 GPM) (S/N 525815599 & Below) (S/N 526016699 & Below) 20-64-13
Identification (40 GPM) (S/N 525815600 & Above) (S/N 526016700 & Above)20-64-14
Inline Hydraulic Pump Test (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64-3
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM) . . . . . . . . . . . 20-64-5
Removal And Installation (30 GPM And 40 GPM) . . . . . . . . . . . . . . . . . . . . . . 20-64-11
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Tightening Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Additional Inspection For Loaders W/Advanced Hand Controls . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Checking Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

REAR AUXILIARY DIVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
TIGHTEN ALL HARDWARD PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.

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Service

CORRECT CORRECT CORRECT

B-10731a B-16261 B-16264

WRONG WRONG WRONG

B-16272 B-16260 B-16263

B-16271 B-16270 B-6589

ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 EVAPORATOR/HEATER UNIT...............................80-01

LIFT ARMS ..........................................................50-01

MAIN RELIEF VALVE (ACS)...............................20-01

OIL COOLER (SEAL TO CONNECT) (STC)...........30-01

POWER BOB-TACH ................................ 10-01, 50-01

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

S250, S300 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

4. The seat bar must be 12. Safety treads must be in good

6. Machine signs must be 14. Check hydraulic fluid level,

7. Steering levers and foot 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

S250, S300 Bobcat Loader

21. Inspect for loose or broken

S250, S300 Bobcat Loader

• The Skid-Steer Loader Operator Training Course is

• The Skid-Steer Loader Safety Video is available from

S250, S300 Bobcat Loader

The dealer and owner/operator review the recommended

Call Before You Dig

S250, S300 Bobcat Loader

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

S250, S300 Bobcat Loader

Always use the serial number of the loader when Figure 3

Loader Serial Number

The engine serial number is located on the engine block

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module

S250, S300 Bobcat Loader

FRONT LIGHTS OPERATOR SEAT

BUCKET STEPS STEPS

▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

S250, S300 Bobcat Loader

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1