HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Figure PM-46

Remove the filter element (Item 1) [Figure PM-46].

Clean the surface of the filt er housing where the filter element seal contacts the 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 “SERVICE SCHEDULE” on pagePM-5 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.

Figure PM-47

Loosen the nut (Item 1) [Figure PM-47] 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 [Figure PM-47]

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 “Capacities” on pageSPEC-6.)

Do Not over-fill the reservoir.

Spark Arrestor Muffler

See “SERVICE SCHEDULE” on pagePM-5 for correct service interval. Do not operate the loader with a defective exhaust system.

Warning

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

W-2011-1285

Warning

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.

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Stop the engine. Open the rear door.

Figure PM-48

Remove

Warning

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.

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Start the engine.

Have a second person (wearing safety goggles) hold a block of wood over the outle t of the muffler (with the engine running) for about 10 seconds.

This will force contaminants out through the cleanout hole.

Stop the engine and install the plug. Close the rear door.

Warning

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.

Important

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.

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Tire Maintenance

Wheel Nuts

See “SERVICE SCHEDULE” on pagePM-5 for the service interval to check the wheel nuts. The correct torque is 40-45 ft.-lbs. (54-61 Nm).

Tire Rotation

Check the tires regularly for wear, damage and pressure (See “Tires” on pageSPEC-6.)

Tire Inflation

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 lubricant before mounting the tire, avoid excess pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.

Important

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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 PM-49].

It is important to keep the same size tires on each side of the loader to avoid excessive wear. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

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.

Warning

Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

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FINAL DRIVE TRANSMISSION (CHAINCASE)

The chaincase contains the final drive sprockets and the chains and is filled with the sa me type of fluid as is used in the hydraulic system. (See “Drive System” on pageSPEC-6.)

Checking And Adding Oil

Figure PM-50

Put the loader on a level surface.Remove the plug at the front of the chaincase (Item 1) [Figure PM-50]. If the fluid can be reached with the tip of your finger through the hole, the level is correct.

Add fluid through the check plug hole until the fluid flows from the hole. Install and tighten the plug.

Auxiliary Control Lockbolt

Figure PM-51

The Auxiliary control has a lockbolt (Item 1) [Figure PM51] that must be removed to use the optional auxiliary hydraulics.

Raise the operator cab. (See “Raising The Operator Cab” on pagePM-8.)

Remove the nut and bolt (Item 1) [Figure PM-51] from the right hand steering lever.

Lubricating The Loader

Lubricate the loader as specified in the SERVICE SCHEDULE Page PM-5 for the best performance of the loader.

Record the operating hours ea ch time you lubricate the Bobcat loader.

Always use a good quality li thium based multi-purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows.

Lubricate the following locations on the loader:

LUBRICATING THE LOADER (CONT’D)

PIVOT PINS

Bob-Tach pivot pins (Item 1) [Figure PM-57] (Both sides).

Steering shaft pivot bearings (Item 1) [Figure PM-58] (Both sides).

All pivot pins, lift arms and cylinders have a large pin held in position with lockbolts and retainer (Item 1) [Figure PM-59] & [Figure PM-60]

Check that the lockbolts are tightened to 8-10 ft.-lbs. (1113 Nm) torque.

Do not over-tighten.

BOB-TACH Inspection And Maintenance

Warning

Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

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Inspect the mounting frame on the attachment and the Bpb-Tach, linkages and wedges for excessive wear or damage. Replace anyu parts that are damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds. Cont act your Bobcat dealer for repair or replacement parts.

Lubricate the wedges (See “SERVICE SCHEDULE” on pagePM-5.) and (See “L UBRICATING THE LOADER” on pagePM-27.)

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 Manual, 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.

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Troubleshooting The Engine

DS = Dealer Service Only

TROUBLESHOOTING THE HYDRAULIC SYSTEM

No hydraulic action. No hydraulic fluid. Check fluid level and add as needed.47

Pedals are disconnected.Check linkage. Repair as needed.DS

Relief valve is damaged.Replace the relief valve. DS damaged.Check

Hydraulic action is rough.Hydraulic fluid level is low.Check fluid level and add as needed.47

Hydraulic action is slow.Pedal is hitting floor or debris under pedal. Check adjustment. Remove dirt.DS

Cylinders leak internally.Check condition of cylinders and repair as needed. DS Hydraulic pump is damaged.Check pump. Replace as needed.DS Control

DS = Dealer Service Only

TROUBLESHOOTING THE HYDROSTATIC SYSTEM

DS = Dealer Service Only

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

Troubleshooting Chart The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller lights are off or flashing. Have th e service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

INDICATOR LIGHT LIGHT ON LIGHT OFF

EFFECT ON OPERATION OF LOADER WHEN LIGHT IS OFF

FLASHING INDICATOR MEANS SYSTEM PROBLEM (SEE YOUR BOBCAT DEALER FOR SERVICE)

OF FLASHES

System Activated PRESS TO OPERATE button is activated

PRESS TO OPERATE button not activated

Lift, tilt and traction functions will not operate.

Seat Bar Seat Bar DownSeat Bar Up.Lift, tilt and traction functions will not operate.

Valve Control Valve Can Be Used

Control Valve Cannot Be Used Lift and tilt functions will not operate.

2System Activated circuit is shorted to battery voltage.*

3System Activated circuit is shorted to ground.

2Seat bar sensor circuit shorted to battery voltage*.

3Seat bar sensor circuit shorted to ground.

2Valve output circuit is shorted to battery voltage.*

3Valve output circuit is shorted to ground.

3Valve output circuit is not grounded.

Traction Loader can be moved forward & backward

Loader cannot be moved forward and backward

Loader cannot be moved forward and backward.

1Traction lock hold coil circuit is open.

2Traction lock hold coil circuit shorted to battery voltage*.

3Traction lock hold coil circuit shorted to ground.

4Traction lock pull coil circuit is open.

5Traction lock pull coil circuit is shorted to battery voltage*.

6Traction lock pull coil circuit is shorted to ground.

BICS Controller is not operating correctly. N/AN/A

Lift, tilt and traction function will not operate.

* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted to system voltage.

NOTES:

(1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions in Preventive Maintenance section.

(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.

(3) Flashing patterns will repeat every 3.25 seconds.