ELECTRICAL SYSTEM (Cont’d )

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Do not jump start or charge a frozen battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Battery gas can explode and cause serious injury.

W–2066–0490

The ignition must be in the OFF position.

The extra battery must be of the same voltage as the loader battery.

Connect the end of the first jumper cable to the positive (+) of the booster battery. Connect the other end of the same cable to the positive terminal (+) of the battery[A]

Connect the end of the second jumper cable to the negative (–) terminal of the booster battery. Connect the other end of the second cable to the engine ground cable [A]

Keep the cables away from moving parts. Start the engine. After engine has started, remove the cable connected to the engine ground cable first.

Remove the cable connected to the positive (+) terminal of the battery.

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader (Remove both cables from the battery).

• Extra battery cables (booster cables) are connected wrong.

I–2023–1285

Hourmeter

The hourmeter is located on the inside of the left upright [B]

The hourmeter records the total operating hours of the loaders.

HYDRAULIC/HYDROSTATIC SYSTEM

The hydraulic/hydrostatic systems use the same hydraulic fluid reservoir. Use only recommended fluid in the system. (See Specifications, Page 49.)

The hydrostatic pumps are driven by a belt from the engine. The hydraulic pump supplies fluid to the lift and tilt hydraulics.

Fluid also goes from the control valve to the port block to the hydrostatic pumps to provide charge pressure and cooling.

A hydraulic filter element is located at the right side of the loader under the operator cab. This filter is used to clean the fluid in the hydraulic/hydrostatic systems.

Checking/Adding Fluid to the Reservoir

Put the Bobcat loader on a level surface. Lower the lift arms and tilt the bucket fully backward.

Open the rear door. Remove the dipstick from the reservoir fill tube [A].

The fluid level is correct if the fluid level is between the marks on the dipstick.

NOTE:The dipstick may indicate an incorrect level of fluid when first removed because of expansion or contraction of oil in the fill tube. Always (1) remove the dipstick, (2) wipe the dipstick, (3) insert the dipstick again and (4) re–check the fluid level.

If the fluid level is not at the top mark, add the correct fluid to the reservoir until the level is correct.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention.

HYDRAULIC/HYDROSTATIC (Cont’d) Replacement of the Hydraulic Filter

See the Service Schedule Page 19 for the correct service interval.

Stop the engine. Raise the operator cab. (See Page 21 for the correct procedure.) Clean the area around the filter housing. Remove the plug (Item 1) [A] from the filter housing (located on the outside of the loader at the right side).

After the fluid is drained from the filter, install the plug (Item1) [A] and tighten.

Remove the filter element (Item 1) [B] using a filter wrench.

Clean the surface of the filter housing head where the filter element seal contacts filter housing.

Put grease on the seal of the filter element, install the element and hand tighten only.

Lower the operator cab.

Start the engine and operate the loader through the hydraulic and hydrostatic functions. Stop the engine. Check the fluid level and add fluid to the reservoir as needed.

Removing the Hydraulic/Hydrostatic Fluid

See the Service Schedule Page 19 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

Stop the engine. Open the rear door.

Remove the fill cap/dipstick.

Remove the nut which fastens the fill tube to the loader frame.

Loosen the clamp at the fill tube, turn the fill tube down to drain the fluid from the reservoir [C].

After the fluid is removed, put the fill tube in the correct position, tighten the hose clamp and tighten the bolt.

Replace the hydraulic filter element.

Add hydraulic/hydrostatic fluid to the reservoir. (See Specifications, Page 49 for the correct fluid.)

Do Not overfill the reservoir.

Spark Arrestor Muffler

Do not operate the loader with a defective exhaust system.

This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

Make reference to local laws and regulations for spark arrestor requirements.

Cleaning the Spark Arrestor Muffler

Stop the engine and open the rear door.

Remove the plug at the bottom of the muffler [A]

Start the engine. Wear safety glasses. Hold a piece of wood over the outlet (with engine running) for about 10 seconds.

Stop the engine. Install the plug and tighten.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285

FINAL DRIVE TRANSMISSION (CHAINCASE)

The chaincase contains the final drive sprockets and the chains and is filled with the same type of fluid as is used in the hydraulic system. (See Specifications, Page 49.)

Chaincase Fluid Level

Put the loader on a level surface. Remove the plug at the front of the chaincase [A]. If the fluid can be reached with the tip of the finger through the hole the level is correct.

Add fluid through the check plug hole until the fluid flows from the hole. Tighten the plug.

Tire Maintenance

Check the tires regularly for wear, damage and correct pressure.

Tire Rotation

Front tires usually wear faster than rear tires. To keep tire wear even, rotate the tires as shown [B]

Tires must be the same size and pressure for best handling of the loader. If the tires are worn different amounts, loader durability is improved by matching pairs of tires on each side of the loader.

Tire Installation on Rim

When installing a tire on a rim, avoid excess pressure which can rupture the tire and cause serious personal injury. During inflation of the tire, check the tire pressure frequently to avoid over inflation.

The rim flange must be clean and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire to avoid damage tothe tire or rim.

Tire Pressure

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling.

The tires may be inflated above or below operating pressure for shipping. Check for correct pressure before operating the loader. The correct tire pressure is 40 PSI (276 kPa).

Wheel Nuts

See the Service Schedule Page 19 for the service intervals to check the wheel nuts. Correct torque is 40–45 ft.–lbs. (54–61 Nm).

Lubrication Of The Bobcat Loader

Lubricate the loader as specified in the Service Schedule Page19 for the best performance [A]

Always use a good quality lithium–based multipurpose grease when lubricating the loader. Apply the lubricant until the extra grease shows.

Add oil or grease as needed to the steering control shaft

Parking Brake Adjustment

Loosen the nuts (Item 1) [A] and turn the brake linkage rod to adjust the brake pedal.

There must be 3/4’’ (19 mm) freeplay under the rear edge of the brake pedal when the brake is released [B]

Pivot Pins

All pivot pins, lift arms and cylinders have a large pin held in position with lockbolts and retainer (Item 1) [C]

Check that the lockbolts are tightened to 8–10 ft.–lbs. (11–13 Nm) torque.

Do not over tighten.

Troubleshooting

The following information identifies loader problems which can occur most often. Service procedures for correcting loader problems can be found in this manual on the pages indicated. Some procedures are marked D/S (Dealer Service) and must be performed only by qualified Bobcat service personnel.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, 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. Failure to follow instructions can cause injury or death. W–2003–1289

Troubleshooting The Engine

Problem Correction

Engine won’t turn over with Battery has low charge. Charge battery and find cause–starter. loss of damage.

Cables loose or dirty. Clean and tighten the battery27 cables.

Damaged starter, solenoid orCheck the starting circuit. MakeD/S wiring. repairs as needed.

Engine turns with starter, but isWrong starting procedure.Use correct starting procedure.9 difficult to start.

No fuel in tank. Add fuel as needed. 24

The vent in fuel filler cap isClean as needed. plugged.

Dirt or water in fuel system.Make repairs as needed.

Damaged carburetor or fuel Make repairs as needed. pump.

Plugged fuel filter. Install a new filter. 24

Hole in fuel line. Make repairs as needed.

Choke not closing completely.Make adjustment of linkage. Ignition system if faulty. Check and make repairs as needed.

Wrong oil in engine. See Oil Specifications. 25

Engine has lost compression.Recondition the engine.

Engine has overheated.See Engine Cooling System.26

Poor fuel quality. Use fresh, good quality fuel.24

Engine has little power or runsToo much choking. Open choke control. rough.

Dirt or water or air in fuel Clean and make repairs as system. needed.

Problem Correction

Engine has little power or runsEngine is hot. See Engine Overheats rough.

Governor adjustment is wrong.Check and make adjustment if needed.

Dirty air cleaner. Check air cleaner.

Engine has lost compression.Recondition the engine.

Engine overheats. Cooling system is dirty. Air flowClean cooling system.

23

26 restricted.

Engine shrouding damaged or Repair or replace. missing.

Engine is overheated. Run at full throttle.

Troubleshooting The Hydraulic System

Problem Correction Causepage

No Hyddraulic action. No hydraulic fluid. Check fluid level, and add as needed.

Pedals disconnected. Check linkage, and repair.

Relief valve defective. Check relief pressure.

Hydraulic pump damaged.Check hydraulic pump and replace if damaged.

Hydraulic fluid is too thick.Let machine warm up.

Hydraulic action is rough.Fluid level is low. Check fluid level, and add as needed.

Hydraulic action is slow. Pedal is hitting floor or dirt underClean the pedal area. pedal.

Cylinders leak internally.Check condition of cylinders.

Hydraulic pump is damaged or Check hydraulic pump. worn.

Control valve is damaged.Check valve.

Hydraulic fluid is too thick.Let machine warm up.

Hydraulic cylinders leaks oil.Damage to cylinder rods.Check cylinders for damage. No drive on both sides. Hydraulic fluid is low. Check fluid level.

10 micron filter is plugged.Replace filter.

Damaged vane pump. Check condition or vane pump and replace if bad.

Hydrostatic system is damaged.Check hydrostatic system.

Troubleshooting The Hydrostatic System

Problem Correction Cause Page

No drive on one side. Control linkage disconnected.Repair linkage.

Hydrostatic system is damaged.Check hydrostatic system.

Machine pulls to one side.Not correct tire pressure.Check all tires.

Steering linkage interference.Check steering linkage. Damaged hydrostatic system.Check system.

Machine moves when levers Steering linkage out of Adjust the steering linkage. are in neutral. adjustment.

System is overheating. Hydraulic fluid level is low.Check fluid level.

Plugged filter. Install new filter element.

Low charge pressure. Check bypass valve.

Bobcat is overloaded. Use correct size attachment.

Hydrostatic transmission Check hydrostatic system. damaged.

Parking brake will not hold.Out of adjustment. Make adjustment.