Bobcat 463 Loader Operation & Maintenance Manual 6901175 - PDF DOWNLOAD

S/N 520011001 & Above S/N 519911001 & Above

Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Bobcat Company or the products of either.

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) 6901175 (6-02) Revised (5-12) (5) 1 of 98

Printed in U.S.A.

© Bobcat Company 2002

Dealer Copy -- Not for Resale

Operation & Maintenance Manual

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OPERATOR SAFETY WARNINGS CORRECT Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 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

B–10731

Never use the loader without instructions. See machine signs (decals), Operation & Maintenance Manual and Handbook.

WRONG

B–6582

B–13418

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the foot pedals or footrests when operating loader.

Never use loader without operator cab with ROPS and FOPS approval. Fasten your seat belt.

Never use loader as man lift or elevating device for personnel.

WRONG

WRONG

WRONG

B–6578

B–6585

B–6595

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload and turn on flat level ground.

WRONG

WRONG

WRONG

B–6587

B–6594

B–6591

Never exceed rated operating capacity.

Never leave loader with engine running or with lift arms up.

To park, engage parking brake and put attachment flat on the ground.

Do not use loader in atmosphere with explosive dust or gas or where exhaust can contact flammable material.

Never carry riders.

Dealer Copy -- Not for Resale

B–7403

Never modify equipment.

Use only attachments approved

by Bobcat Company for this model loader.

SAFETY EQUIPMENT The Bobcat loader must be equipped with safety items necessary for each job. Ask your dealer for information on the safe use of attachments and accessories.

1. SEAT BELT: Check belt fasteners and check for damaged webbing or buckle.

2. SEAT BAR: When up, it must lock the loader controls.

3. OPERATOR CAB (ROPS and FOPS): It must be on the loader with all fasteners tight.

4. HANDBOOK: Must be in the cab.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) OSW03–0600 3 of 98

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CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii .....

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix. . . .

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . .

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ...

SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ....

MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ...

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 ....

FOREWORD

SAFETY

OPERATING INSTRUCTIONS

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.

PREVENTIVE MAINTENANCE

Write the correct information for YOUR Bobcat loader in the spaces below Always use these numbers when referring to your Bobcat loader.

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

.

SYSTEMS ANALYSIS

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REFERENCE INFORMATION

MACHINE SIGN TRANSLATIONS

SPECIFICATIONS

NOTES:

YOUR LOADER DEALER: ADDRESS: PHONE: Bobcat Company P.O. Box 128 Gwinner, ND 58040–0128 Bobcat Company Europe J. Huysmanslaan 59 B–1651 LOT BELGIUM

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Bobcat Company is ISO 9001 certified ISO 9001 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Bobcat manufacturing plants and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations.

Dealer Copy -- Not for Resale

ISO 9001 means that as a company we say what we do and do what we say . In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

REGULAR MAINTENANCE ITEMS

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6671057

ENGINE OIL FILTER

6667352

FUEL FILTER

897064

AIR CLEANER

6666606

RADIATOR CAP

6599543

HYDROSTATIC FILTER

6669318

BATTERY

6724094

PROPYLENE GLYCOL ANTI–FREEZE, Premixed – [–34°F (–37°C)]

6724354

PROPYLENE GLYCOL ANTI–FREEZE, Concentrate

6563328

FLUID, Hydraulic/Hydrostatic – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Qt.

6657301

MOTOR OIL 10W30 CE/SG – 1 Qt.

6657303

MOTOR OIL 30 CE/SG – 1 Qt.

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FOREWORD

FOREWORD

This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer. This manual may illustrate loaders with additional options and accessories not installed on your loader.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v. .

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v. . .

BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi. .

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FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii ..

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SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service information or when ordering parts.

Early or later models (identification madeby 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 The loader serial number plate is located on the outside of the loader frame [A].

Explanation of loader Serial Number: XXXXX XXXX

P–04399

Module 2. – Production Sequence (Series)

B

Module 1. – Model/Engine Combination

ENGINE SERIAL NUMBER

Dealer Copy -- Not for Resale

The engine serial number is located on the valve cover at the right side of the engine [B].

P–09791

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

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BOBCAT SKID STEER LOADER IDENTIFICATION OPERATING LIGHTS OPERATOR HANDBOOK

SEAT BAR GRAB HANDLES STEERING LEVER

OPERATOR SEAT With SEAT BELT

SAFETY TREAD

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STEPS

TILT CYLINDER

BUCKET

OPERATOR CAB (ROPS & FOPS)

OPERATING LIGHT UPRIGHTS LIFT ARM SUPPORT DEVICE LIFT ARMS

LIFT CYLINDER REAR DOOR B–15914 B–15915

TIRES* * TIRES – Flotation tires (Optional) are shown. Bobcats are base–equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll–Over Protective Structure,Falling Object Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. The Bobcat loader is base– equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

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FEATURES AND ACCESSORIES Model 463 Bobcat loaders are equipped with the following standard items: Auxiliary Hydraulics, Front (Later Models) Bob–Tach Bobcat Interlock Control System (BICS™) Cushion Seat Gauges / Warning Lights Lift Arm Support Device Operating Lights (Later Models) Operator Cab (with ROPS & FOPS Approval) Parking Brake Rear Window (Later Models) Seat Belt Seat Bar Spark Arrestor Muffler Below is a list of some equipment available from your Bobcat Loader dealer as Dealer and / or Factory Installed Accessories.

See your Bobcat dealer for other available options, accessories and attachments.

Hydraulics

4 PR Flotation Tires (Machine Width – 44 inches) . . . . . . . . Opt. & FA 6 PR Bobcat Heavy Duty (Machine Width – 44 inches) . . . . . . . . Opt. & FA Turf Tires . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA

Front Auxiliary Hydraulics . . . . . . . . . . .

Hydraulic Bucket Positioning . . . . . . . . .

Opt. & FA Opt. & FA

Other Catalytic Exhaust Purifier . . . . . . . . . . . . FA Engine Heater . . . . . . . . . . . . . . . . . . . . . FA Fuel Shut Off . . . . . . . . . . . . . . . . . . . . . . FA Locking Fuel Cap & Cover . . . . . . . . . . . FA Low Coolant Sensor . . . . . . . . . . . . . . . . FA Rental Kit . . . . . . . . . . . . . . . . . . . . . . . . . FA Single Point Lift . . . . . . . . . . . . . . . . . . . . FA

Operator Cab Back–up Alarm . . . . . . . . . . . . . . . . . . . . . Opt. & FA Fire Extinguisher . . . . . . . . . . . . . . . . . . . FA Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA Keyless Start System . . . . . . . . . . . . . . . FA Operating Lights (Front & Rear) (Early Models) . . . . . . . . . . . . . . . . . . . Opt. & FA Rear Window (Early Models) . . . . . . . . . FA Seat Belt 3” . . . . . . . . . . . . . . . . . . . . . . . . FA Side Windows . . . . . . . . . . . . . . . . . . . . . FA Sound Cab (Reduces noise at Operator’s Ear) . . . . . . . . . . . . . . . . . . Opt. Special Applications Kit . . . . . . . . . . . . . FA Strobe or Rotating Beacon Light . . . . . .

FA Suspension Seat . . . . . . . . . . . . . . . . . . . FA Top Window . . . . . . . . . . . . . . . . . . . . . . . FA Vinyl Cab Enclosure . . . . . . . . . . . . . . . . FA

Dealer Copy -- Not for Resale

Tires

Opt. = Factory Installed Option FA = Field Accessory

Specifications subject to change without notice

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SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi, . . xii .

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii ....

SAFETY

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MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv, . . . xv

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SAFETY INSTRUCTIONS FOR BOBCAT SKID–STEER LOADERS AND ATTACHMENTS SAFE OPERATION IS THE OPERATOR’S RESPONSIBILITY Carefully follow the operating and maintenance instructions in this manual.

The Bobcat skid–steer loader is highly maneuverable and compact. It is rugged and useful under a wide variety conditions. of This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat loader usage.

The Bobcat loader has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so use the loader with adequate ventilation. The loader has a spark arrestor exhaust system or muf fler which is required for operation in certain areas.

The dealer explains the capabilities and restrictions of the Bobcat loader and attachments for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for a Rated Operating Capacity (some have restricted lift heights) and secure fastening to the Bobcat loader . The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the loader–attachment combination.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the Bobcat loader and attachment is in safe operating condition.

• The Operation & Maintenance Manual delivered with the Bobcat loader or attachment gives operating information as well Dealer Copy -- Not for Resale

as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided inside the cab of the loader. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

• Machine signs (decals) instruct on the safe operation and care of your Bobcat loader or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

• An Operator’s Handbook is fastened to the operator cab of the loader. Its brief instructions are convenient to the 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.

• The Safety Manual delivered with the Bobcat loader gives general safety information.

• Operator Training Courses are available from your local Bobcat dealer . They provide information for safe and efficient operation of the Bobcat loader and some attachments. The courses are available in English and Spanish versions.

• Service Safety Training Courses are available from your Bobcat dealer . They provide information for safe and correct service procedures.

• See the ADDITIONAL PUBLICATIONS Page in this manual or your Bobcat dealer for Service andParts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web site www.bobcat.com

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 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.)

SI01–0402

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BEFORE OPERATING THE BOBCAT LOADER

Safety Alert Symbol Operator must have instructions before operating the machine. Untrained operators can cause injury or death.

W–2001–0502

This symbol with a warning statement means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

The Bobcat loader and attachment must be in good operating condition before use.

Check all of the items on the Bobcat Service Schedule Decal under the 8–10 hour column or as shown in this Manual.

SAFE OPERATION NEEDS A QUALIFIED OPERATOR *

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, • The written instructions from Bobcat Company

include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, Safety Manual and machine signs (decals).

• Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. Regulations may apply to local driving requirements or use of a Slow MovingVehicle (SMV) emblem. Regulations may identify a hazard such as a utility line.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

W–2044–1285

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered.

• The new operator must start in an area without bystanders anduse all the controls until he can operate the machine and attachment safely under all conditions of the work area. Always fasten seat belt before operating.

• Operator Training Courses are available from your Bobcat dealer in English and Spanish. They provide information for safe and efficient equipment operation. Safety videos are also available.

• Service Safety Training Courses are available from your Bobcat dealer. They provide information for safe and correct service procedures.

• KNOW THE WORK CONDITIONS • Know the weight of the materials being handled. Avoid exceeding the Rated Operating Capacity of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of load if handling dense material.

• The operator must know any prohibited uses or work areas, for example, he needs to know about excessive slopes.

• Know the location of any underground lines. Call local utilities or the OLL T FREE phone number found in the SAFETY INSTRUCTIONS Section of this manual.

• Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing

protection or special applications kit are required for some work.

See your dealer about Bobcat Safety equipment.

* For an operator to be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–0502

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RULES AND REGULATIONS

FIRE PREVENTION The machines and some attachments have components that are at high temperatures under normal operating conditions.

The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

The spark arrestor exhaust system (if equipped) 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 cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean andtight. 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. you or bystanders.

Dealer Copy -- Not for Resale

• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure • Always clean the machine, disconnect the battery, and disconnect the wiring from the electronic 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 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!

• Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

• Know where fire extinguishers and first aid kits are located and howto use them. Fire extinguishers are available from your Bobcat dealer.

SI03–0400

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MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the loader . Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat dealer.

6702255

Later Models 6731571 Early Models 6708294 6708358

6718703

272 kg

Dealer Copy -- Not for Resale

6708105

600 lbs.

6705434 6711840

6564806

6579510

6717343 (2) Under Cab

6702302

6710358

6561383

6702301

6579528 B–15914 18 of 98

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MACHINE SIGNS (DECALS) (Cont’d)

6564808

Dealer Copy -- Not for Resale

6577754

6565990

6708212

6708929

6560573 6714364

6576048

6579511

Inside Engine Compartment

6711659

6707867

B–15915

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453BICSOperation&MaintenanceManualS/N515012400&Above#6900784–ContentsSection

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OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ...

Installing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 ..

Removing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 ..

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . 4.

Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . .

Traction Lock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . .

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ....

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . .

HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . .

Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ....

Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ....

Auxiliary Hydraulics Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . .11 .

Bucket Position Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. .

Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . . .

Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . .

Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. . .

Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . .

Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ...

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 ...

OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 ...

Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 ....

Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 ...

Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 ...

Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ....

Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 ..

Dealer Copy -- Not for Resale

GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 ..

PARKING BRAKE (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. .

PARKING BRAKE (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. .

PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 ..

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. .

STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 ...

Cold Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ...

Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ....

Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . .17 .

Continued On Next Page

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463 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS (Cont’d) STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ....

Forward Travel, Reverse Travel, Normal Turning, Fast Turning . . . . . . . . . . 7 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .

STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ...

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 ...

Dealer Copy -- Not for Resale

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ..

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INSTRUMENT PANEL

A

The following items are located on the instrument panel [A], [B], [C] & [D]:

7

5

1. TRACTION LOCK OVERRIDE BUTTON – (Functions Only When The Seat Bar Is Raised) Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 5.)

4

8

6

9 10

3

2. PRESS TO OPERATE BUTTON (Functions Only When The Seat Bar Is Down) – Activates BICS™ System when the Seat Bar is down and operator is seated in the operating position.

Later Models Left Panel

2

1

P–26727 P–26728

3. KEY SWITCH – For starting, stopping the engine.

4. PARKING BRAKE (Later Models) – Press the left side of switch to engage; right side to disengage.

B

5. LIGHT SWITCH (Opt. or FA on Early Models) – Press left side of switch to turn lights ON; right side to turn OFF.

11

13

15

12

14

7. NOT USED 8. ENGINE WARNING LIGHT – Light is ON when engine oil pressure is low or coolant temperature is high. Stop the engine if the light comes ON.

16

9. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON.

Later Models Side Accessory Panel

C

10. POWER PLUG (Later Models) – Used to power 12 Volt accessories.

11. BEACON OR STROBE (Opt. or FA) – Press top of switch to turn ON; bottom to turn OFF.

6

P–25282

7

5

12. HAZARD LIGHTS (Opt. or FA) – Press the top of the switch to turn the Hazard Lights ON; bottom to turn OFF.

8

11

Dealer Copy -- Not for Resale

6. PREHEAT BUTTON – Press to preheat the glow plugs to aid cold temperature starting. Switch will turn off when released.

9 11

13. FRONT WIPER (Opt. or FA) – Move switch to center position to turn ON; bottom to turn OFF .

Press and hold top of switch for washer fluid.

14. BUCKET POSITION (Opt. or FA) – The Bucket Position function will keep the bucket in approximately the same position as the lift arms are raised. Press the top of the switch to engage the Bucket Position function; bottom to disengage.

1

3

2

Early Models Left Panel P–13788

D

15. NOT USED 16. CAB LIGHT – Press switch to turn ON; press again to turn OFF. 17. HOURMETER – Records the total operating hours of the loader.

17

18. VOLTMETER – Shows the condition of the battery and the rate of charge.

18

19. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature.

19

Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

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All Models Right Panel 3

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463 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

A

The Bobcat Interlock Control System (BICS™) requires the operator to be seated in the operating position with the Seat Bar fully lowered and the green PRESS TO OPERATE Button activated before the lift, tilt and traction functions can be operated. The Seat Belt must be fastened anytime you operate the loader.

1 2 3 4

NOTE: Press the green PRESS TO OPERATE Button again if Seat Bar is raised and lowered or key is turned off.

5

The BICS controller is located inside the cab; behind and to the left of the operator ’s seat [A].

There are five green lights on the BICS controller and all must be ON to operate the loader.

P–04242

The light functions are as follows [A]:

B

1. SYSTEM ACTIVATED – ON when the green PRESS TO OPERATE Button is activated. down

3. VALVE – ON when lift and tilt hydraulic functions can be used.

1

4. TRACTION – ON when loader can be moved forward or backward.

5. POWER – ON when the Controller is correctly.

operating P–09824

NOTE: If any of the lights are off or blinking, see the BICS Troubleshooting Chart Page 60 or see BICS Inspection and Maintenance Instructions Page 36.

Lift Arm By–Pass Control The lift arm by–pass control knob (Item 1) [B] is used to lower the lift arms in the event that the lift arms can not be lowered during normal operating conditions.

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

With the operator in the seat, seat belt fastened and the seat bar fully lowered, pull and hold the by–pass control knob (Item 1) [B]. Push the top (toe) of the left (lift) pedal.

The lift arms will slowly lower.

NOTE: The auxiliary hydraulic functions are not affected by the Bobcat Interlock Control System (BICS™).

W–2045–1086

AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS™) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.

W–2151–0394

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2. SEAT BAR – ON when the seat bar is in position.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont’d)

A

Traction Lock Override (Functions Only When The Seat Bar Is Raised) There is a traction lock override button (Item 1) [A] on the left hand instrument panel. It allows you to use the steering levers to move the loader forward & backward when using the backhoe attachment or for service.

1

Press the button once to unlock traction drive (green traction light on BICS Controller will be ON).

Press the button a second time to lock the traction drive (green traction light on BICS Controller will be OFF).

P–26727 P–26728

NOTE: The Traction Lock Override button will unlock the traction drive when the operator is NOT in the seat and the seat bar is raised.

B

The Traction Lock Override button will function if brake pedal or switch is in the engaged or disengaged position.

The engine speed control (Item 1) [B] is at the left side of the operator’s seat. Engine speed is controlled by moving the engine speed control forward to increase the engine RPM and backward to decrease the engine RPM.

1

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ENGINE SPEED CONTROL

P–09775

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463 Bobcat Loader Operation & Maintenance Manual

PARKING BRAKE (Later Models)

A

Press the left side of the switch (Item 1) [A] to engage the parking brake. Press the right side to disengage.

1

P–26727 P–26728

PARKING BRAKE (Early Models)

B

Engage the parking brake by pushing down on the top (toe) of the pedal [B]. The traction drive system will be locked.

P–09780

To disengage the parking brake, push down on the bottom (heel) of the pedal [C].

C

NOTE: If the loader will not move when operator is in the operating position with brake pedal released or when traction lock override button is pushed, move the steering levers either forward or backward a small amount to unlock the traction drive.

MC–01914

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MC–01914

STEERING LEVERS

A

1

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595 P–09781

The steering levers (Item 1)[A] are on the right and left side in front of the seat.

B

For safe control of the loader always move the levers slowly and smoothly. Only a small movement is necessary to move the loader.

FORWARD

REVERSE

The steering levers control forward and reverse travel of the loader [B].

Reverse Travel – Pull both levers backward.

Normal Turning – Move one lever farther forward than the other.

Fast Turning – Push one lever forward and pull the other lever backward.

For slow travel speed, push the levers forward only asmall amount.

LEFT TURN

RIGHT TURN

FAST TURN

FAST TURN

To increase travel speed, push the levers farther forward.

For maximum pushing force, push the levers forward only a small amount with the engine at full RPM.

Dealer Copy -- Not for Resale

Forward Travel – Push both levers forward.

Keep both feet on pedals while operating machine. Failure to do so can cause serious injury.

W–2002–1285

STOPPING THE BOBCAT LOADER When the steering levers are moved tothe neutral position, the hydrostatic transmission will act as aservice brake and stop the loader.

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SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operatorcontrols the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt control pedals are locked when returned to the NEUTRAL POSITION.

1

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

N–15147

B

The spring loaded interlocks (Item 1)[B] control the locking and unlocking functions of the control pedals.

The interlocks (Item 1) [B] require the operator to lower the seat bar (Item 2) [B] which allows the operator to move the foot pedals to control the lift and tilt functions.

When the seat bar is lowered, it pushes the interlock (Item 1) [B] down on both sides, releasing the pedal linkages (Item 3) [B] from the interlocks.

SEAT BAR DOWN

2

Seat Bar

1

Interlock

The pedals will pivot in both directions when the interlock is down.

3

Pedal Linkage

MC–01781

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move pedals until both lock.

• Move auxiliary control out of continuous operation position.

W–2164–1294

C

SEAT BAR RAISED

Seat Bar

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

W–2105–1285

Interlock

When the seat bar is raised, spring forces raise the interlocks [C].

The foot pedals will not pivot when the interlock is up. See Seat Bar Restraint System Inspection & Maintenance Page 35.

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HYDRAULIC CONTROLS

A

Foot Pedals

3 1 2 N–15146

Keep both feet on pedals while operating machine. Failure to do so can cause serious injury.

W–2002–1285

Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

Two foot pedals (Item 1) [A] control the hydraulic cylinders for the lift and tilt functions.

Lift Arm Operation

Push on the top (toe) (Item 3) [A] of the pedal to lower the lift arms.

4

Lift Arm Float Position

1

Push the top (toe) (Item 3) [A] of the pedal all the way forward until it locks into float position.

5

Use the float position of the lift arms to level loose material while driving backward.

N–15146

Push the bottom (heel) of the lift pedal to unlock from the float position.

Tilt Operation The right pedal controls the action of the bucket.

Dealer Copy -- Not for Resale

The left pedal controls the lift arms. Push on thebottom (heel) (Item 2) [A] of the pedal to raise the lift arms.

Push the top (toe) (Item 4) [A] of the pedal to tilt the bucket forward.

Push the bottom of the pedal (heel) (Item 5) [A] to tilt the bucket backward.

Bucket Position Valve Operation (If Equipped)

B–07440 B–07441

The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in, before beginning the upward lift cycle.

Bucket positioning functions automatically during the upward lift cycle only.

The bucket positioning function can be turned OFF with the bucket level switch. (See Page 3.)

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HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (If Equipped) Auxiliary hydraulics [A] are not standard, but can be a Factory Option or installed as a Field Accessory.

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.

P–19289

B

W–2220–0396

To Connect: Remove dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler . Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced [A] and [B].

Install the male coupler into the female coupler.

To Disconnect: Hold the male coupler . Retract the sleeve on the female coupler until the couplers disconnect.

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P–10566

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463 Bobcat Loader Operation & Maintenance Manual

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Quick Couplers

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (If Equipped) (Cont’d)

1

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.

P–19035

W–2220–0396

B

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

Raise the operator cab. (See Raising The Operator Cab Page 32.)

The right steering lever is also the control lever for the front auxiliary hydraulics [B].

Move the right steering lever to the left or to the right to activate the auxiliary hydraulics to operate an attachment.

(Example: To open or close grapple teeth) [C].

Move the lever in the opposite direction to reverse action of the attachment.

Dealer Copy -- Not for Resale

Remove the nut and bolt from the right hand steering lever [A].

P–19289

the

C

1

Auxiliary Hydraulic Continuous Operation Move the steering lever all the way to the right (Item 1)[C] to put the control valve into the continuous operation position for a constant flow of hydraulic fluid under pressure to the quick couplers (Example: Backhoe operation).

Move the auxiliary control lever out of the continuous operation position before leaving the operator cab.

Relieving Hydraulic Pressure6.

P–09776

With the engine stopped and attachment flat on the ground, move the right steering lever to the left and to the right several times [C].

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463 Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

The loader must be in good operating condition [A].

Check the following items before starting each day: • • • • • • • • • • •

Engine Oil Hydraulic/Hydrostatic Fluid Air Cleaner Condition Indicator Engine Cooling System Operator Cab, Seat Belt, Seat Bar & Pedal Interlocks Lift Arms & Cylinder Pivot Pins Tires & Tire Pressure Any Loose or Broken Parts Fuel Level Safety Tread & Safety Signs Bobcat Interlock Control System (BICS™)

B–06583

Fluids such as engine oil, hydraulic fluid, coolants, etc. must be disposed of in an environmentally safe manner.

Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner . See local, state and federal regulations for correct disposal.

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 [A].

W–2003–0797

B

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Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door [B].

GETTING READY FOR OPERATION

A

Read the Operation & Maintenance Manual and the Operator’s Handbook before operating the loader (Item 1) [A].

1

Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W–2001–0596

P–09827

B

1

Dealer Copy -- Not for Resale

The Operation & Maintenance Manual and other manuals can be kept in a box provided at the right hand side of the operator seat (Item 1) [B].

P–09828

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arm crossmember and main frame) to get on and off the loader [C].

C

Safety treads are installed on the Bobcat loader toprovide a slip resistant surface for getting on and off the loader.

Keep safety treads clean and replace when damaged.

Replacement treads are available from your dealer.

P–19496

Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [D].

D

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

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463 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

A

Lower the seat bar [A].

Be sure the parking brake is engaged.

All controls must be in the NEUTRAL POSITION before you start the engine. (See Normal Starting Page 15.)

After you start the engine, press the green PRESS TO OPERATE Button on the left instrument panel to operate lift, tilt and traction functions.

N–15148

the

B

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Keep your hands on the steering levers and feet on pedals while seated in the loader [B].

STARTING THE ENGINE

A

WRONG

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

B–03724

B

WRONG

• Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086

Dealer Copy -- Not for Resale

AVOID INJURY OR DEATH

B–06578

Normal Starting Adjust the seat position for comfortable operation of the foot pedals and steering levers.

C

Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Lower the seat bar [C].

Be sure the parking brake is engaged.

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STARTING THE ENGINE (Cont’d)

A

Normal Starting (Cont’d)

NEUTRAL POSITION

Put the foot pedals and steering levers in NEUTRAL POSITION (center) (Item 1) [A].

Set the engine speed control to 1/2 SPEED position (Item 2) [A].

1

Turn the key to the ON POSITION. The engine and transmission warning light will be ON when the key is on and the engine is stopped (Item 3) [A].

1/2 SPEED

Turn the key to START POSITION (Item 4) [A] and release it when the engine starts. The key will return to the RUN POSITION (Item 5) [A].

2 ON POSITION

Dealer Copy -- Not for Resale

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I–2034–0284

3 STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF.

START POSITION

NOTE: Upon failed start, if the key is turned OFF, wait for at least three seconds before turning the key ON to reset the fuel timer module.

Keep your hands on the steering levers and feet on pedals while seated in the loader.

the

4 RUN POSITION

5

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463 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Do not use ether with glow plug (preheat) systems. Explosion can result which can cause injury or death.

1

W–2071–1285

P–26727 P–26728

Cold Temperature Starting See Normal Starting Page 15. Turn the key switch to the RUN POSITION.

B

Push the preheat button (Item 1) [A] on the left side of the instrument panel to preheat the glow plugs.

Refer to the decal on the left side of the operator cab for operation of the preheat system [B].

Dealer Copy -- Not for Resale

Follow the steps under Normal Starting and repeat the preheating procedure until the engine starts.

If the temperature is below 32 oF (0oC), use the following procedure to make starting the engine easier: •

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature.(See Oil Chart Page 42.)

•

Make sure the battery is fully charged.

•

Install engine heater.

6708105

Warming The Hydraulic/Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader.

If the warning light comes ON when operating the loader (cold), more warm up time is needed.

STOPPING THE ENGINE Pull the engine speed control fully backward to decrease the engine RPM. Turn the key switch to the OFF position.

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ATTACHMENTS AND BUCKETS

A

NOTE: Warranty is void if non–approved attachments are used on the Bobcat loader.

Never use attachments or buckets which are not approved by Bobcat. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

B–06587

W–2052–1285

The dealer can identify , for each model loader, the attachments and buckets approved by Bobcat. The buckets and attachments are approved for rated operating capacity and for secure fastening to the Bob–Tach.

Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

W–2053–0887

Rated operating capacity is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used the load center moves forward and reduces the rated operating capacity. If very dense material is loaded, the volume must be reduced.

B

Exceeding the rated operating capacity can cause the following problems [A]: 1. Steering the loader may be difficult.

SEE DECAL ON PALLET FORK FRAME

2. Tires may wear faster.

3. There will be a loss of stability.

Load varies with model of pallet fork frame being used.

4. The life of the Bobcat loader will be reduced.

Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the rated operating capacity for the loader . Partial loads make steering more difficult.

If a pallet fork attachment is used, the load center moves forward and reduces the Rated Operating Capacity.

The maximum load to be carried when using a pallet fork is shown on a decal located on the pallet fork frame [B].

See your Bobcat Dealer for more information about pallet fork inspection, maintenance and replacement. See your Bobcat loader dealer for Rated Operating Capacity when using a pallet fork and for other available attachments.

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AVOID INJURY OR DEATH

The rated operating capacity for this loader is shown on a label in the operator cab. (See SPECIFICATIONS Page 71.)

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installating The Bucket or Attachment The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operation & Maintenance Manual to install other attachments.

1

Bob–Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

W–2054–1285

p–19492

B

Pull the Bob–Tach lever all the way up (Item 1) [A].

Enter the loader.

Disengage the parking brake.

Lower the lift arms and tilt the Bob–Tach forward.

Drive the loader forward until the top edge of the Bob–T ach is completely under the top flange of the bucket [A] (or other attachments).

Dealer Copy -- Not for Resale

Fasten the seat belt, lower the seat bar , start the engine and press the green PRESS TO OPERATE Button.

P–19493

Be sure the Bob–Tach lever does not hit the bucket.

C

Tilt the Bob–Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [B].

Stop the engine and exit the loader.

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both locked.

W–2045–1086

P–19494

Push down on the Bob–Tach lever until it is fully engaged in the locked position [C].

If the lever does not engage inthe locked position, see your Bobcat loader dealer for maintenance.

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ATTACHMENTS AND BUCKETS (Cont’d)

A

The wedges (Item 1) [A] must extend through the holes in the mounting frame of the bucket (or attachment), securely fastening the bucket to the Bob–Tach. The wedge is shown extending through the hole in the bucket [A].

1 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.

P–19495

W–2102–0588

B

Removing The Bucket Or Attachment Put the attachment flat on the ground and lower or close the hydraulic equipment. If the attachment is hydraulically controlled (ie: combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See Relieving Hydraulic Pressure, Page 11).

Raise the seat bar , unfasten the seat belt, engage the parking brake and exit the loader.

Pull the Bob–Tach lever [B] all the way up.

P–19493

Disconnect the hydraulic hoses, if necessary.

Enter the loader.

C

Fasten the seat belt, lower the seat bar , start the engine and press the green PRESS TO OPERATE Button.

Disengage the parking brake.

Lower the lift arms and tilt the Bob–Tach forward.

Move the loader backward, away from the bucket or attachment [C].

P–19492

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P–19494

OPERATING PROCEDURE

A

When operating on a public road or highway,always follow local regulations. For example: Slow Moving Vehicle Sign or directional signals may be required.

WITH BUCKET FULL

Always warm up the engine and hydrostatic system before operating the loader.

Going Down Slope

Machines warmed up with moderate engine speed and light load have longer life.

B–14306

I–2015–0284

B

WITH BUCKET FULL

Operate the loader with the engine at full speed for maximum horsepower. Move the steering levers only a small amount to operate the loader.

Dealer Copy -- Not for Resale

New operators must operate the loader in an open area without bystanders. Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [A] & [B].

With empty bucket, go down or up the slope with the heavy end toward the top of the slope [C] & [D].

Going Up Slope

C

B–09043

WITH BUCKET EMPTY

AVOID INJURY OR DEATH • Keep the lift arms as low as possible.

• Do not travel or turn with the lift arms up.

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

Going Down Slope

Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2018–1187

D

B–09042

WITH BUCKET EMPTY

Raise the bucket only high enough to avoid obstructions on rough ground.

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OPERATING PROCEDURE (Cont’d)

A

Filling The Bucket Push down on the top of the lift pedal until the lift arms are all the way down. Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A].

N–15146

B–06719

Drive slowly forward into the material. Push the bottom of the tilt pedal to raise the front of the bucket [B].

N–15146

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1187

Drive backward away from the material.

Emptying The Bucket

B–06718

Push down on the bottom of the lift pedal to raise the lift arms [C]. Push the top of the tilt pedal while raising the lift arms to level the bucket or attachment and help prevent material from falling off the back of the bucket or attachment.

C

Drive forward slowly until the bucket is over the top of the truck box or bin. Push the top of the tilt pedal until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

N–15146

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–0694

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B–06708

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B

OPERATING PROCEDURES (Cont’d)

A

Digging Into The Ground Put the lift arms all the way down. Push the top of the tilt pedal until the cutting edge of the bucket is on the ground.

Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

N–15146

B–06720

Push the bottom of the tilt pedal a small amount to increase traction and keep an even digging depth [B].

Continue to drive forward until the bucket is full. When the ground is hard, raise and lower the cutting edge of the bucket with the tilt pedal while driving forward slowly.

N–15146

Dealer Copy -- Not for Resale

B

B–06721

Push the bottom of the tilt pedal to tilt the bucket backward as far as it will go when the bucket is full [C].

C

N–15146

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OPERATING PROCEDURES (Cont’d)

A

Leveling The Ground (Using Lift Arms In Float Position) Push the top (toe) of the lift pedal all the way forward until the pedal is in the locked position to put the lift arms infloat position [A].

N–15146

Push the tilt pedal to change the position of the cutting edge on the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

Never drive forward when the hydraulic control for lift arms is in float position.

B–06722

I–2005–1285

Push the bottom of the lift pedal to unlock from the float position.

N–15146

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground.

Drive forward to the edge of the hole to push the material into the hole [B].

Tilt the bucket forward as soon as it is past the edge of the hole [B].

If necessary, raise the lift arms to empty the bucket.

B–06724

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground.

Lower the lift arms fully and put the edge of the bucket on the ground.

Pull the throttle all the way backward. Turn the key switch to the OFF POSITION.

AVOID INJURY OR DEATH

Engage the parking brake.

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

Lift the seat bar and make sure the foot pedals are in the locked position.

Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

W–2045–1086

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B

Drive backward to level loose material.

TRANSPORTING THE BOBCAT LOADER

A

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

The rear of the trailer must be blocked or supported [A] when loading or unloading the loader to prevent the front end of the trailer from raising up.

Use the following procedure to fasten the Bobcat loaderto the transport vehicle to prevent the loader from moving during sudden stops or when going up and down slopes. engine.

SUPPORT

Fasten chains at the front using the slots in the axle gussets [B]. Counterweight is removed to show clarity . DO NOT operate with counterweight removed.

B–06198

B

Fasten the rear of the loader as shown with a loop of chain through the tie down provided [C].

P–19457

P–09926

P–09926

Dealer Copy -- Not for Resale

Fully lower any bucket or attachment. Stop the Engage the parking brake.

P–09927

C

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LIFTING THE LOADER

A

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point lift and operator cab.

• Assemble front cab fasteners as shown in this manual.

• Never allow riders in the cab or bystanders

MC–02099

within 15 feet (5 meters) while lifting the machine.

W–2007–0497

B The loader can be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.

1

The single point lift, supplied by Bobcat is designed to safely lift and support the Bobcat loader without af fecting roll over and falling object protection features of the operator cab.

TOWING THE LOADER

2

To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed.

(Example: Moving the loader onto a transport vehicle).

3

P–19777

C

A tow valve kit (6729334) is available from your dealer . Tool must be installed before towing.

Raise the operator cab. (See Page 32 for the correct procedure.)

3

Clean the area around the hydrostatic pumps.

Remove the tubeline (Item 1) [B]. Remove the elbow and tee (Items 2 & 3) [B].

1

Install the two valves into the open ports on the pump (Items 1 & 2) [C]. Tighten to 20–25 ft. lbs. (27–34 Nm) torque while holding the flats in a horizontal position.

2

P–21495 P–21493

Turn both tow valves to a vertical position, (Item 3) [C].

The towing chain (or cable) must be rated at 1–1/2 times the weight of the loader. (See SPECIFICATIONS Page 71.)

Turn the key switch to ON and press the traction lock override button.

Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not more than 25 feet (7,6 meters).

Do not push or pull the machine at more than 2 MPH (3,2 km/h) or for a distance of more than 25 feet (7,6 meters) with the towing tool in place.

If the electrical system is not functioning, contact your Bobcat loader dealer. (Part of the brake system must be disassembled to move the loader.)

I–2017–0389

Remove the two valves and install the fittings and tubeline before operating the machine again.

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Install the kit and lift the loader as shown [A].

PREVENTIVE MAINTENANCE

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PREVENTIVE MAINTENANCE

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AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ...

ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ..

AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 ..

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . 36 .

Inspecting The BICS™ System Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ..

Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ..

Inspecting The Seat Bar Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 ..

Inspecting The Traction Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ...

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 ....

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 ...

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ....

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ...

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ...

Propylene Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ....

Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . . . .43 .

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ...

Battery Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 ..

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ....

Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ...

Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ....

Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 ..

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ..

Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ....

Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ...

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . .51 .

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 ...

FOOT PEDAL CLEANOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 ....

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 ...

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 ....

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ....

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ..

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 ..

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ...

Replacing The Hydraulic/Hydrostatic Filter Element . . . . . . . . . . . . . . . . . . . 48 .

Removing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . .48 .

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ...

Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ..

Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ..

LUBRICATING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 ..

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ....

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ....

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ...

Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 ...

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 ....

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 ....

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ..

Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 ...

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ...

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ...

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ....

Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ....

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ....

463 Bobcat Loader Operation & Maintenance Manual

MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine. Read and understand the 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. Untrained operators and failure to follow instructions can cause injury or death.

W–2003–0199

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

B–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–15231

B–15280

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead–acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

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.

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CORRECT

CORRECT

CORRECT

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, 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–2003–0199

HOURS

SERVICE SCHEDULE Engine Air Cleaner Engine Oil Engine Cooling System Tires Indicators, Gauges & Lights (Opt.) Seat Belt, Seat Bar Safety Signss (Decals) and SafetyTread Lift Arms and Bob–Tach Pivot Pins and Wedges Engine Fuel Filter Hydraulic Fluid, Hoses and Tubelines Bobcat Interlock Control System (BICSTM) Battery Control Pedals & Steering Bob–Tach Wheel Nuts Parking Brake Alternator Belt Engine Oil and Filter Spark Arrestor Muffler Drive Belt Steering Lever Pivots Hydraulic Filter Element Engine Fuel Filter Hydraulic Reservoir Breather Final Drive Trans (Chaincase) Hydraulic/Hydrostatic Reservoir

SERVICE REQUIRED

8-10

50

Empty the dust cup & replace the filter element as needed.

Check the oil level and add oil as needed.

Clean debris from oil cooler, radiator and grill. Check coolant level in recovery tank. Add coolant as needed.

Check for damaged tires and correct air pressure.

Check for correct operation of all indicators, gauges & lights (Opt.).

Check the condition of seat belt. Check the seat bar & pedal interlocks for correct operation. Clean dirt and debris from moving parts.

Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn.

Lubricate with multi–purpose lithium based grease.

Remove the water from the filter.

Check fluid level and add as needed. Check for damage and leaks. Repair or replace as needed.

Check BICS™ System Controller functions. Clean dirt, debris or objects from under or behind seat as required.

Check cables, connections and electrolyte level. Add distilled water as needed.

Check for correct operation repair or adjust as needed.

Check locking levers & wedges for condition & operation.

V Check for loose wheel nuts & tighten to 40–45 ft.–lbs. (54–61 Nm) torque.

Check operation.

Check belt tension and adjust as needed.

Replace oil and filter. See engine Oil Chart.

Clean the spark chamber.

Clean the spark chamber.

Lubricate grease fittings and oil hole in the steering shaft.

S Replace filter element.

Replace filter element.

Replace the breather cap.

Replace the fluid.

Replace the fluid.

100

250

500

n 1000

Dealer Copy -- Not for Resale

ITEM

◊

◊ Replace filter element after first 50 hours of operation. j Check wheel nut torque every 8 hours for the first 24 hours.

S Also replace hydraulic/hydrostatic filter element when the transmission warning light stays on for five minutes after the fluid is at operating temperature.

J Or every 12 months.

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LIFT ARM SUPPORT DEVICE

A 1

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598 P–09773

P–19458

Engaging The Lift Arm Support Device

B

Put jackstands under the rear corners of the loader (Inset) [A].

1

Lower the lift arm support device on top of the lift cylinder.

Fasten the free end of the spring (Item 1) [B] to the lift arm support device so there will be no interference with the support device engagement.

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine, press the green PRESS TO OPERATE Button.

P–19460

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod [C].

C

Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine.

Raise the seat bar and move pedals until both pedals lock.

P–09800

Install the retaining pin (Item 1) [D] into the rear of the lift arm support device below the cylinder rod.

D

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.

1

W–2271–1197 P–09808 50 of 98

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463 Bobcat Loader Operation & Maintenance Manual

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Disconnect the spring from the lift arm support device retaining pin (Item 1) [A], hold the support device and remove the retaining pin.

LIFT ARM SUPPORT DEVICE (Cont’d)

A

Disengaging The Lift Arm Support Device Remove the retaining pin (Item 1) support device.

[A] from the lift arm

1

P–09808

Connect the spring from the lift arm support device to the tubeline bracket (Item 1) [B] on the lift arms.

B

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine, press the green PRESS TO OPERATE Button.

Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod. Lower the lift arms.

Stop the engine.

Dealer Copy -- Not for Resale

1

Raise the seat bar and move pedals until both pedals lock.

Disconnect the spring from the bracket.

P–09807

Raise the support device into storage position and insert pin through lift arm support device and bracket(Item 1) [C].

C

Connect spring to pin [C].

1 P–19458

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OPERATOR CAB

A

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 beltmust be worn for roll over protection.

1

ROPS/FOPS Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l.

Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

P–19461

Check with your dealer if the operator cab has been changed.

Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death.

P–19462

W–2014–0895

Raising The Operator Cab Stop the loader on a level surface. Put the lift arms all the way down.

Install jackstands under the rear of the loader frame [B].

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

Open the rear door. (See REAR DOOR Page 37.)

If the lift arms must be up while raising the cab, install the lift arm support device. (See Engaging The Lift Arm Support Device Page 30.)

W–2069–1285

Remove the two fasteners (Item 1) [A] at the front (both sides) of the operator cab.

Stand on the ground. Lift slowly until operator cab is all the way up [B].

The operator cab will lock in the raised position.

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B

The operator cab fastening nuts (Item 1) [A] must be tightened to 40–50 ft.–lbs. (54–68 Nm) torque.

OPERATOR CAB (Cont’d)

A

Lowering The Operator Cab

1

Hold the operator cab. Release the locking mechanism by pushing the lever (Item 1) [A] inward from the locked position (Item 2) [A] and turning the lever until it stays in the unlocked position [B].

2

The cab must be held to prevent falling while hand is in access hole.

P–19498

W–2205–0695

B

REMOVE YOUR HAND FROM THE HOLE BEFORE LOWERING THE OPERATOR CAB Stand on the ground and pull down on the operator cab.

NOTE: Guide the operator cab over the fastening bolts to prevent thread damage.

Dealer Copy -- Not for Resale

Avoid slippery surfaces when lowering the cab.

P–19499

Install the cab washers and nuts. Tighten the nuts (Item 1) [C] (both sides) to 40–50 ft.–lbs. (54–68 Nm) torque.

C 1

P–19461

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463 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

A

Emergency Exit The front opening of the operator cab and rear window provide exits.

Pull on the tag at the top of the rear window to remove the rubber cord [A].

Push the rear window out of the rear of the operator cab.

P–09829

Exit through the rear of the operator cab [B].

P–19463

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B

SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to the neutral position.

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

W–2105–1285

Seat Bar Inspection

Dealer Copy -- Not for Resale

Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine.

Press the green PRESS TO OPERATE Button. Operate each foot pedal to check both the lift and tilt functions.

Raise the lift arms until the bucket is about 2feet (600 mm) off the ground.

P–09790

Raise the seat bar, try to move each pedal. The pedals must be firmly locked in neutral position. There must be no motion of the tilt (bucket) or the lift arms when the pedals are pushed.

B

Pull the seat bar down, press the green PRESS TO OPERATE Button and lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop.

Lower the seat bar, Press the green PRESS TO OPERATE Button, lower the lift arms and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

Seat Bar Maintenance

P–04400

See the SERVICE SCHEDULE Page 29 and on the loader for correct service interval.

C

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

If the seat bar system does not function correctly , check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

1

Foot Pedal Clean Out Clean any debris from around the foot pedals. Debris will fall out through the holes under the pedals (Item 1) [C].

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P–07528

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463 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting The BICS™ Controller

A

(Engine STOPPED – Key ON)

1

1. Sit in the operator ’s seat. Turn key ON, lower the seat bar and disengage the parking brake pedal.

Press the green PRESS TO OPERATE Button. All five BICS controller lights should be ON (Items 1, 2, 3, 4 & 5) [A].

2 3 4 5

2. Engage the parking brake pedal and raise the seat bar fully. System Activated (Item 1), Seat Bar (Item 2), Valve (Item 3) and T raction lights (Item 4) [A] should be OFF. NOTE: Record what lights are flashing (if any) and number of flashes. Refer to Page 60.

P–04242

3. Exit the loader and press T raction Lock Override button. Traction light (Item 4) [A] should be ON. Press override button again and Traction light (Item 4) [A] should be OFF. Inspecting The Seat Bar Sensor (Engine RUNNING)

5. Start the engine and operate at low idle. Press the green PRESS TO OPERATE Button. While raising the lift arms, raise the Seat Bar fully. The lift arms should stop. Repeat using the tilt function.

W–2151–0394

NOTE: The auxiliary hydraulic functions are not affected by the Bobcat Interlock Control System (BICS™).

Inspecting The Traction Lock (Engine RUNNING) 6. Fasten the seat belt, disengage the parking brake pedal, press the green PRESS TO OPERATE Button and raise the Seat Bar fully . Move the steering levers slowly forward and backward. The Traction lock should be engaged. Lower the Seat Bar. Press the greenPRESS TO OPERATE Button.

7. Engage the parking brake pedal and move the steering levers slowly forward and backward. The Traction lock should be engaged.

Inspecting The Lift Arm By–Pass Control 8. Raise the lift arms 6 feet (2 meters) off the ground.

Stop the engine.

Pull and hold the by–pass control knob. Push the toe of the left foot pedal until the lift arms slowly lower.

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AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS™) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.

4. Sit in the operator’s seat. Lower the seat bar .

Engage the parking brake pedal. Fasten the seat belt.

REAR DOOR

A

AVOID INJURY Never service or adjust the machine when the engine is running unless instructed to do so in this manual.

W–2012–0290 P–19449

Open the rear door to service the engine. Pullthe latch pin (rotate clockwise) on the left side ofthe rear door [A]. Open the rear door.

Dealer Copy -- Not for Resale

Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

W–2020–1285

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AIR CLEANER SERVICE

A

See the SERVICE SCHEDULE Page 29 for the interval to service the air cleaner system.

Check the air intake hose and the air cleaner housing for damage.

3

Check to make sure all connections are tight.

2

1

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 1) [A].

Start the engine, then sop the engine. If the red ring does not show, do not replace the filter element.

Replace the outer filter element only when the red ring shows in the window of the condition indicator (Item 2)[A].

P–19452

Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

P–19453

B

Release the three fasteners (Item 3) [A] and remove the cover. Clean any debris or dust from the cover.

Clean the inside of the filter housing.

Install the inner element, if required.

1

Install the outer element.

P–19450

install the cover and engage the three fasteners.

C

1 P–19451

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Remove the outer filterelement (Item 1) [B] and if required, remove the inner filter element (Item 1) [C].

FUEL SYSTEM

A

Fuel Specifications

2

or

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F°/C° +15o(–9o) Down to –20o/–29o Below –20o/–29o

No. 2 100% 50% 0%

ON

No. 1 0% 50% 100%

1

We recommend an operator contact their fuel supplier for local recommendations.

P–09831

The fuel gauge (Item 1)[A] and the fuel shut off valve (Item 2) [A] are located on the right side of the loader.

B

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

Filling The Fuel Tank

Dealer Copy -- Not for Resale

Use only clean, high quality diesel fuel, Grade No. 2 Grade No. 1.

OFF

P–09830

Remove the fuel fill cap [B] from the left side of the loader.

C

Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks.

NO SMOKING [C].

Install and tighten the fuel fill cap [B].

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.

WRONG

B–06108

W–2103–1285

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FUEL SYSTEM (Cont’d)

A

OFF

1 ON

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 P–09831

Fuel Filter

B

Drain Water: See the SERVICE SCHEDULE Page 29 for the service interval when to remove the water from the fuel filter.

Loosen the drain (Item 1) [B] at the bottom of the filter element to drain the water from the filter. Close the drain.

Open the shut–off valve (Item 1) [A] to turn on the fuel supply.

1

Replace Fuel Filter: P–09880

See the SERVICE SCHEDULE Page 29 for the service interval when to replace the fuel filter.

Clean the area around the fuel filter.

Close the shut–off valve (Item 1) [A].

Remove the fuel filter [B].

NOTE: Be sure the filter gasket is removed with the old fuel filter.

Install the new filter element hand tight.

Open the shut–off valve (Item 1) [A].

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Turn the fuel shut–off valve (Item 1) [A] clockwise to shut off the fuel supply.

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System

1

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 before starting the engine.

Be sure the engine is cool.

Open the rear door.

2

Open the vent plug (Item 1) [A].

Operate the hand pump priming bulb (Item 2) [A] until fuel flows from the vent plug with no air bubbles.

P–09880

Close the vent plug (Item 1) [A].

With the operator in the seat, seat belt fastened, seat bar lowered and parking brake engaged, start the engine.

B

NOTE: If the engine fails to start, remove air from the fuel injection pump as follows.

Open the valve (Item 1) [B] on the injector pump and squeeze the hand pump (Item 2)[A] several times until fuel comes from the valve.

1

Close the valve (Item 1) [B].

Lower the operator cab. (See Lowering The Operator Cab Page 33.)

Dealer Copy -- Not for Resale

Put jackstands under the rear of the frame and raise the operator cab. (See Raising The Operator Cab Page 32.)

P–09791

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

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ENGINE LUBRICATION SYSTEM

A

Check the oil level every day.

Stop the engine and remove the dipstick (Item 1) [A].

1

Keep the oil level between the marks on the dipstick.Use a good quality motor oil that meets API Service Classification of CD or better. (See Oil Chart below.)

Oil Chart RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

+43 +49

2

SAE 40W or 20W–50

P–09892

SAE 10W–30

B

SAE 15W–40 SAE 30W

* SAE 5W–30

SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90 +100 +110 +120

F°

P–09882

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4 )

* Can be used ONLY when available with appropriate diesel rating.

C

Replacing Oil And Filter See the SERVICE SCHEDULE Page 29 for the service interval for replacing the engine oil and filter.

1

Run the engine until it is at operating temperature. Stop the engine.

Open the rear door and remove the cap from the hose.

Drain the oil into a container[B]. Install the cap on the drain hose.

Remove the filter (Item 2) [A].

P–09874

Clean the filter housing surface. Putclean oil on the gasket of the new filter. Install the filter and hand tighten.

Remove the oil fill cap (Item 1) [C].

Fill to capacity. (See SPECIFICATIONS Page 71.)

Start the engine and let it run for about 5 minutes. Check for leaks at the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick. Install the oil fill cap (Item 1) [C].

NOTE: DO NOT overfill the crankcase.

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SAE 20W–20

COOLING SYSTEM

A

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Checking The Coolant Level

1

Open the rear door.

The coolant recovery tank (Item 1) [A] is located between the radiator and the right upright.

The coolant level in the recovery tank must be between the maximum and minimum mark when engine is cool [A].

NOTE: The loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol.

P–09816

B

Propylene Glycol Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection.

Dealer Copy -- Not for Resale

1

Use a refractometer to check the condition of propylene glycol in your cooling system.

P–09881

C Use safety goggles when using air or water under pressure. Do not use cold water to clean a hot engine. Failure to obey warnings can cause serious injury.

W–2064–1285

Cleaning The Cooling System Open the rear door.

Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler.

P–09818

Removing Coolant From The Cooling System

D

Open the rear door.

Put the drain hose (Item 1) [B] into a clean container.

Raise the operator cab. (See Raising The Operator Cab Page 32.)

Remove the radiator cap [C].

Open the drain valve (Item 1) [D]. (Located on front of engine, near the fuel lift pump.)

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P–19502

463 Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT ADJUSTMENT

A

Stop the engine.

Loosen the mounting bolts (Item 1) alternator.

[A] and move the

1

P–09895

Set the belt tension to 1/4 inch (6 mm) movement between pulleys with 15 pounds (67 N) of force [B]. Tighten the mounting bolts.

P–09770

ELECTRICAL SYSTEM

C

Description The loader has a 12 volt, negative ground alternator charging system.

The electrical system is protected by 6 fuses.

1

Fuse Location The fuses are located under the fuse covers (Item 1) [C] located in the engine compartment.

P–09815

Electrical System Service The battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables with a baking soda and water solution. Cover the terminals of the battery with Bobcat Battery Saver (P/N 886398) to prevent corrosion.

Install the terminal covers.

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B

ELECTRICAL SYSTEM (Cont’d)

A

Battery Removal And Installation Open the rear door. Disconnect the negative (–) battery cable first (Item 1) [A].

Remove the battery holddown clamp (Item 2) [A].

2

Remove the battery from the loader [B].

Disconnect the positive (+) cable (Item 1) [B].

1

Always clean the terminals and cable ends when installing a new battery [C].

When installing the battery in the loader, do not touch any metal parts with the battery terminals.

P–19406

Connect and tighten the battery cables. Connect the negative (–) cable last to prevent sparks.

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

1

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

P–19408

C

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

Dealer Copy -- Not for Resale

B

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 or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Never lean over battery while boosting, testing or charging.

P–09589

P–09590

Battery gas can explode and cause serious injury.

W–2066–1296

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ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting)

4 2

Damage to 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).

P–19410

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

I–2023–1285

1 If it is necessary to use an extra battery to start the engine, BE CAREFUL! There must be one person in the operator ’s seat and one person to connect and disconnect the battery cables.

The ignition must be in the OFF position.

The battery must be 12 volt.

P–19409

Connect one end of the first cable (Item 1) [A] to the positive terminal (+) of the booster battery . Connect the other end of the same cable (Item 2)[A] to the positive (+) terminal on the starter.

Connect one end of the second cable (Item 3) [A] to the negative terminal (–) of the booster battery. Connect the other end of same cable (Item 4)[A] to the engine mounting frame.

Keep the cables away from moving parts.

Start the engine.

After the engine has started, remove the ground cable connected to the engine first.

Remove the cable connected to the loader battery.

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3

HYDRAULIC/HYDROSTATIC SYSTEM

A

The hydraulic and hydrostatic systems use the same hydraulic fluid reservoir.

The system has an engine driven gear pump that supplies fluid to the control valve, lift and tilt cylinders.

1

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

A hydraulic filter element is installed under the cab near the right side. This filter is used to clean the fluid for the hydrostatic transmission pumps.

The location of the oil cooler is above the engine. The oil cooler is used for cooling the hydraulic fluid before it returns to the hydrostatic transmission pumps.

P–09763

Checking And Adding Fluid

Open the rear door. Remove the dipstick (Item 1) [A].

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. 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 from a physician familiar with this injury.

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.

W–2072–0496

Add fluid until it is at the correct level.

B 1

Breather Cap See the SERVICE SCHEDULE Page 29, for the correct service interval.

Dealer Copy -- Not for Resale

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

Raise the cab (See Raising The Operator Cab Page 32).

Remove and discard the breather cap (Item 1) [B].

Install a new breather cap.

Lower the cab (See Lowering The Operator Cab Page 33).

P–19497

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HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing The Hydraulic/Hydrostatic Filter Element

1

See the SERVICE SCHEDULE Page 29 for the correct service interval.

Stop the engine. Open the rear door . Raise the operator cab. (See Raising The Operator Cab Page 32.) Clean the area around the filter housing.

Remove the filter element (Item 1) [A].

Clean the surface of the filter 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.

P–19415

Lower the operator cab.

B

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.

See the SERVICE SCHEDULE Page 29 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

1

Stop the engine. Open the rear door.

P–09863

Remove the fill cap/dipstick.

Loosen the nut (Item 1)[B] 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 [B].

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 71 for the correct fluid.)

Do Not over–fill the reservoir.

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Removing The Hydraulic/Hydrostatic Fluid

SPARK ARRESTOR MUFFLER

A

See the SERVICE SCHEDULE Page 29 for correct service interval. Do not operate the loader with a defective exhaust system.

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

1 P–09764

W–2011–1285

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.

W–2050–1285

Stop the engine. Open the rear door.

Remove the plug (Item 1) muffler.

[A] from the bottom of the

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.

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.

I–2022–0595

Dealer Copy -- Not for Resale

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–2068–1285

Start the engine.

Have a second person (wearing safety goggles) hold a block of wood over the outlet of the muf fler (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.

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.

W–2006–0284

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TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 29 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 SPECIFICATIONS Page 71 for the correct tire pressure).

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to therear and rear tires to the front [A].

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.

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

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.

W–2078–1285

Tire Inflation Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. T ires 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.

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C–01965

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

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 71.)

Checking And Adding Oil Put the loader on a level surface.Remove the plug at the front of the chaincase (Item 1) [A]. If the fluid can be reached with the tip of your finger through the hole, the level is correct.

1

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

P–07561

AUXILIARY CONTROL LOCKBOLT

B

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

1

Raise the operator cab. (See Raising The Operator Cab Page 32.)

P–19415

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Remove the nut and bolt (Item 1) [B] from the right hand steering lever.

463 Bobcat Loader Operation & Maintenance Manual

LUBRICATING THE LOADER

A

Lubricate the loader as specified in the SERVICE SCHEDULE Page 29 for the best performance of the loader.

Record the operating hours each time you lubricate the Bobcat loader.

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

1

Lubricate the following locations on the loader: Base End Lift Cylinder (Item 1–Both sides) [A].

P–19454

Rod End Lift Cylinder (Item 1–Both sides) [B].

1 Lift Arm Pivot Pin (Item 1–Both sides) [C].

P–19455

C 1

P–19456

Rod End Tilt Cylinder (Item 1) [D].

D

1

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B

LUBRICATING THE LOADER (Cont’d)

A

Base End Tilt Cylinder (Item 1) [A].

1

P–07552

B

1

Dealer Copy -- Not for Resale

Bob–Tach pivot pins (Item 1) [B] (Both sides).

P–19466

Steering shaft pivot bearings (Item 1) [C] (Both sides).

C 1

P–07554

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PIVOT PINS

A

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

Check that the lockbolts are tightened (11–13 Nm) torque.

to 8–10 ft.–lbs.

Do not over–tighten.

1 P–19288

1

P–19291

BOB–TACH

C

Inspection And Maintenance Move the Bob–T ach lever (Item 1) [C] to engage the wedges. The levers and wedges must move freely.

1

The wedges must extend through the holes in the attachment mounting frame (Item 1) [D].

P–19494

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.

D

W–2102–0497

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.

1

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

Lubricate the wedges (See SERVICE SCHEDULE,Page 29 and LUBRICATION OF THE BOBCAT LOADER, Page 52.)

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P–19495

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B

SYSTEMS ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ...

TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 ..

TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 58 .

SYSTEMS ANALYSIS

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TROUBLESHOOTING THE HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . 59 .

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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.

W–2003–0797

PROBLEM Engine won’t turn over with starter.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

CAUSE

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause for loss of charge.

44

Cables loose or dirty.

Clean and tighten the battery cables.

45

Damaged starter, solenoid or wiring.

Check the starting circuit.

Repair as needed.

DS

Wrong starting procedure.

Use correct starting procedure.

15

No fuel in tank.

Add fuel.

DS

Dirt or water in fuel system.

Repairs as needed.

40

Damaged fuel pump.

Make repairs as needed.

DS

Fuel filter is dirty.

Install a new filter.

40

Hole in fuel line.

Repair as needed.

DS

Wrong oil in engine.

See Oil Specifications.

42

Engine has lost compression.

Recondition the engine.

DS

Engine has overheated.

Check Cooling System.

43

Poor fuel quality.

Use fresh, good quality fuel.

39

Dirt, water or air in fuel system.

Clean and repair as needed.

40

Dealer Copy -- Not for Resale

TROUBLESHOOTING THE ENGINE

DS = Dealer Service Only

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TROUBLESHOOTING THE ENGINE (Cont’d) PROBLEM

CAUSE

Engine has little power or runs rough (Cont’d).

Engine overheats.

CORRECTION

PAGE

Engine is hot.

Check cooling system.

43

Governor adjustment is wrong.

Check & make adjustment if needed.

DS

Dirty air cleaner.

Check air cleaner.

38

Engine has lost compression.

Recondition the engine.

DS

Cooling system is dirty. Air flow restricted.

Clean cooling system.

43

Engine shrouding damaged or missing.

Repair or replace.

DS

Engine is overheated.

Run at full throttle.

–

PROBLEM No hydraulic action.

CAUSE

CORRECTION

PAGE

No hydraulic fluid.

Check fluid level and add as needed.

Pedals are disconnected.

Check linkage. Repair as needed.

DS

Relief valve is damaged.

Replace the relief valve.

DS

Hydraulic pump is damaged.

Check pump. Replace as needed.

DS

Hydraulic fluid is too thick. (cold temperature)

Let machine warm up.

17

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 valve is damaged.

Check valve and repair as needed.

DS

Hydraulic fluid is too thick. (cold temperature)

Let machine warm up.

17

Damage to cylinder rods or seals.

Repair cylinders.

DS

Hydraulic cylinders leak fluid.

47

DS = Dealer Service Only

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TROUBLESHOOTING THE HYDRAULIC SYSTEM

PROBLEM

CAUSE

CORRECTION

PAGE

No drive on both sides.

Hydraulic fluid is low.

Check fluid level. Add as needed.

47

10 micron filter is damaged.

Replace filter.

48

Damaged gear pump.

Check condition of gear pump and replace if bad.

DS

Hydrostatic system is damaged.

Check hydrostatic system.

DS

Control linkage disconnected.

Repair linkage.

DS

Hydrostatic system is damaged.

Check hydrostatic system.

DS

Wrong tire pressure.

Check all tires.

50

Steering linkage interference.

Check steering linkage

DS

Damaged hydrostatic pump/motor.

Check system.

DS

Machine moves when levers are in neutral.

Steering linkage out of adjustment.

Adjust steering linkage.

DS

System is overheating.

Hydraulic fluid level is low.

Check fluid level.

47

Pugged filter.

Install new filter element.

48

Low charge pressure.

Check by–pass valve.

DS

Bobcat is overloaded.

Use correct size attachment.

18

Hydrostatic transmission damaged.

Check hydrostatic system.

DS

No drive on one side.

Machine pulls to one side.

DS = Dealer Service Only

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TROUBLESHOOTING THE HYDROSTATIC SYSTEM

463 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 453BICSOperation&MaintenanceManualS/N515012400&Above#6900784–SystemsAnalysisSection

9.

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 the service procedure performed ONL Y BY QUALIFIED BOBCAT SERVICE PERSONNEL.

System Activated

Light ON

PRESS TO OPERATE PRESS TO OPERATE Lift, tilt and traction button is activated button not activated functions will not operate.

Seat Bar Seat Bar Down.

Valve

Traction

Light OFF

Control Valve Can Be Used.

Loader can be moved forward & backward.

Seat Bar Up.

Control Valve Cannot Be Used.

Lift, tilt and traction functions will not operate.

Lift and tilt functions will not operate.

Loader cannot be Loader cannot be moved forward and moved forward and backward. backward.

2 3 2 3 2 3 3 1 2 3 4 5 6

Power

BICS Controller is operating correctly.

BICS Controller is not operating correctly.

Lift, tilt and traction functions will not operate.

N/A

System Activated circuit shorted to battery voltage.* System Activated circuit shorted to ground.

Seat bar sensor circuit shorted to battery voltage*.

Seat bar sensor circuit shorted to ground.

Valve output circuit shorted to battery voltage*.

Valve output circuit shorted to ground.

Valve output circuit is not grounded.

Traction lock hold coil circuit is open.

Traction lock hold coil circuit shorted to battery voltage*.

Traction lock hold coil circuit shorted to ground.

Traction lock pull coil circuit is open.

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

Traction lock pull coil circuit is shorted to ground.

N/A

* 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.

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Indicator Light

Flashing Indicator Means System Problem (See Your Bobcat Dealer for Service) Effect on Operation of Loader When Light Is Number of OFF Flashes Cause

MACHINE SIGN TRANSLATIONS IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 ....

WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ....

SERVICE SCHEUDLE (6708212) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 ...

WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ....

WARNING (6579528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ....

DANGER (6702302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ....

WARNING (6577754) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ....

DANGER (6702301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ....

Dealer Copy -- Not for Resale

DANGER (6717343) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 ....

MACHINE SIGN TRANSLATIONS

MACHINE SIGNS (DECALS) Machine signs (decals) are an esential part of the loader. (See Page xiv & xv.) This section provides French and Spanish translations of the machine signs that are in English.

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IMPORTANTE (SPANISH) ESTA MAQUINA EST A EQUIPADA POR LA FABRICA CON UN AMOR TIGUADOR DE CHISPAS DEL SILENCIADOR, APROBADO POR EL SER VICIO DE SILVICULTURA DEL U.S.D.A. (DEPARTMENTO DE AGRICULTURA DE LOS ESTADOS UNIDOS).

ES NECESARIO LIMPIAR ESTE AMORTIGUADOR DE CHISP AS DEL SILENCIADOR PARA MANTENERLO EN BUEN ESTADO. HAY QUE DARLE SERVICIO AL AMORTIGUADOR, VACIANDO LA CAMARA DE CHISPAS CADA 100 HORAS DE FUNCIONAMIENTO.

REFIERASE A LAS LEYES Y REGULACIONES LOCALES EN CUANTO A LOS REQUISITOS DEL AMORTIGUADOR DE CHISPAS.

IMPORTANT (FRENCH) CETTE CHARGEUSE EST EQUIPPEE A LA SOR TIE DE L’USINE D’UN SILENCIEUX P ARA–ETINCELLES APPROUVE PAR LE SER VICE DES EAUX ET FORETS DES ETATS–UNIS. IL EST INDISPENSABLE D’EFFECTUER UN ENTRETIEN REGULIER DE CE P ARE–ETINCELLES AFIN DE LE GARDER EN BON ET AT DE MARCHE. L’ENTRETIEN CONSISTE A VIDER LA CHAMBRE A ETINCELLES TOUTES LES 100 HEURES DE MARCHE.

Dealer Copy -- Not for Resale

SI ESTA MAQUINA ESTA DESTINADA PARA TRABAJAR EN BOSQUES, MA TORRALES O EN PASTOS QUE PUEDAN INCENDIARSE, ENTONCES TIENE QUE ESTAR EQUIPADA CON UN AMORTIGUADOR DE CHISPAS EN EL SISTEMA DEL ESCAPE Y TIENE QUE MANTENERSE EN PERFECTAS CONDICIONES DE TRABAJO. ES NO HACER ESTO CONSTITUYE UNA INFRACCION DE LA LEY ESTATAL DE CALIFORNIA, SECCION 4442, PRC.

SI CET ENGIN EST UTILISE SUR UN TERRAIN COUVER T D’ARBRES, DE BROUSSAILLES, OU D’HERBAGES INFLAMMABLES, IL F AUT INSTALLER LE PARE–ETINCELLES ET LE GARDER EN BON ET AT DE MARCHE. CONSULTER LES REGLEMENT ATIONS APPLICABLES.

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ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

• Mantenga le puerta cerrada excepto para dar servicio.

• Mantenga el motor limpio y que no tenga material inflamable.

• Mantenga el cuerpo. objetos sueltos y la ropa lejos de los conductores eléctricos, piezas móviles, piezas calientes y del escape.

• No use el cargador en lugares donde

hay polvo o gases explosivos o materiales inflamables cerca al escape.

• Todos los gases del escape pueden

matar. Ventile siempre el lugar de trabajo.

• No use nunca éter o líquido del arranque en los motores • Les liquides sous pression peuvent pénétrer au travers de

• Escapes de líquido bajo presión pueden penetrat en la

piel y causar heridas graves. Se requiere atención médica inmediata. Use gafas. Use cartón para revisar si hay fugas.

la peau et causer de graves blessures. Consulter immédiatement un médecin Porter des lunettes sécurité. Utiliser du carton pour repérer les fuites.

de

• L’acide des batteries provoque de graves brûlures, porter des lunettes de sécurité. S’il entre en contact avec les yeux, la peau ou les vêtements, rincer généreusement à l’eau. Pour les yeux, appeler un médecin.

• El ácido de la batería puede causar quemaduras severas, • Les batteries dégagent des use gafas. Si el ácido hace contacto con los ojos, la piel o la ropa, lávelos bién con agua. Si el contactor fuel en los ojos, lávelo bién y vaya al médico.

• Las baterias producen gas inflammable y

explosivo.

Mantenga lejos, arcos, chispas, llamas y tabaco encendido.

• Para arranque con batería auxiliar, conecte de último el

cable negativo al motor del cargador (nunca la batería).

Despues de hacer el arranque con cables, quite peimero la conección negativa del motor.

gaz inflammables et explosifs. Tenir les arcs électriques les étincelles, les flammes et las cigarettes allumées à l’écart.

• En cas de démarrage par pontage, effectuer le dernier

branchement (Câble négatif) au moteur (jamais à la batterie). Pour débrancher, déconnecter d’abord le câble négatif du moteur.

• Ne jamais utiliser d’éther ou de liquide de démarrage sur

un moteur diesel avec des bougies de préchauf fage.

N’employer que les aides au démarrage approuvées par le fabricant.

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

• Maintenir la porte arrière fermée, sauf pour les entretiens.

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non

attachés et les vêtements à l’écart des contacts électriques, des pièces mobiles et brûlantes et de l’échappement.

• Ne pas utiliser la machine dans un

endroit chargé de poussières ou de gaz explosifs, et où l’échappement risque de toucher des matériaux inflammables.

• Les gaz d’échappement peuvent être mortels. T oujours aérer.

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de diesel que tienen tapones encendedores. Use solamente las ayudas para el arranque que sean aprobados por el fabricante del motor.

CADA 10 HORAS 1. Aceite del Motor–Revise el nivel–no lo llene demasiado (Consulte el Manual del Operario para saber que aceite recominenda).

2. Filtro del Aire del Motor–Revise el medidor y/o el cuadrante. Dele servicio solamente cuando se necesite.

3. Sistema de refrigeración del motor–Eliminar suciedad del refrigerador, del radiador yde las rejillas.

Medir el nivel con el refrigerante frio. Completar con mezcla etilenglicol y agua (53/47).

4. Brazo de Elevación del Cargador, Cilindros, Pivote y Cuñas del Bob–Tach–Lubriquelos con grase de base de litio para uso múltiple (12 sitios).

5. Sistema de Aire del Motor–Revise para ver si hay fugas o componentes dañados.

6. En General–Verifique a ver si hay piezas flojas o rotas, daños en el cinturón de seguridad o en la cabina del operario, revise también el funcionamiento de los instrumentos, vea si hay tuercas flojas en las ruedas y fugas de aceite. Inspeccione el funcionamiento de la barra del aciento y arregle o reemplace la que sea necesario antes e poner a trabajar el cargador.

7. Cinturón de seguridad/Dispositivos de bloque de la barra de asiento y controles–Compruebe función.

Repare o reemplace como sea necesario. Limpie suciedad y escombros en las partes móviles.

8. Filtro del Combustible–Purgue el agua atrapada (Unicamente motor de diesel).

9. BICS–Verifique la función. Limpie la suciedad, escombros u objetos de abajo o de atrás del asiento tal como se requiere.

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10.

PROGRAMA DE SERVICIO (SPANISH)

Llantas–Controle la presión de inflación. Infle las llantas hasta la presión. MAXIMA que se indica enla pared del costado de la llanta.

CADA 50 HORAS 1. Líquido Hidráulico–Revise el nivel del líquido. Vea el Manual del Operario para saber el líquido recomendado.

2. Caja de la Cadena–Revise el nivel del líquido. V ea su Manual del Operario para saber el líquido recomendado.

3. Batería–Revise su condición.

4. Mandos y Frenso–Verifique su funcionamiento, ajustelos si es necesario.

5. Aceite del motor (solo en las cargadoras 450)–Vaciar cuando el motor está a su temperatura de trabajo.

Ver Manual de Utilización y de Mantenimiento.

CADA 100 HORAS 1. Silenciador con Amortiguador de Chispas–Desocupe la cámara de las chispas.

2. Sistema del Encendido–Si usa combustible que contine plomo, inspeccione las bujías y el sistema del encendido. Si usa combustiblesin plomo, de servicio únicamente cuando sea necesario para mantener un encendido bueno y funcionamiento suave (Unicamente para Motores de Gasolina).

3. Vacie el aceite del motor cuando este está a su temperatura de trabajo. Ver Manual de Utilización y de Mantenimiento. (Cada 250 horas para 700 modelos con la KUBOTA motor.)

4. Inspeccione todas las correas de impulso–Verifique las condición y la tensión de todas las correas– Impulso del hidrostático, impulso de la bomba del agua, el alternador y el ventilador. Ajústelas y reemplácelas a media que sea necesario.

463 Bobcat Loader Operation & Maintenance Manual

Sistema hidráulico/hidrostatico (solamente modelos 400 y 500)–Cambiar el filtro. Nota: El filtro ha de cambiarse antes si el inficador de aviso de la trasmision permanece encendido mas de 5 minutos despues de que el fluido hidráulico haya alcanzado su temperatura de trabajo.

CADA 250 HORAS (O CADA 12 MESES) 1. Filtro Final del Combustible–Reemplace el elemento del filtro.

2. Pivotes de la Palanca de la Dirección–Lubriquelos con grasa de base de litio para usomúltiple (2 sitios).

3. *Correa de transmisión. Comprobar si está desgastada o deteriorads. Ajustar si es necesario.

*Inspeccione la nueva correa después de transcurridas

las primaras 50 horas de funcionamento. Ajustar si es necesario.

4. Transmisión (500 solamente)– Engrasar acoplamiento

universal de la transmisión (modelo 500’ s solamente).

9. BICS–Vérifiez le fontionnement. Nettoyez la saleté, les débris ou les objets se trouvant sous ou derrièr e le siège selon le besoin.

10. Pneus–Vérifiez la pression de gonflage. Gonflez le s pneus à la pression MAXIMUM indiquée sur la paroi latérale des pneus.

TOUTES LES 50 HEURES 1. Huile hydraulique–Vérifier le niveau d’huile. Consulter le Manuel de l’Opérateur et d’Entretien pour l’huile.

2. Carter de chaînes–Vérifier le niveau. Consulter l e Manuel de l’Opérateur et d’Entretien pour l’huile.

3. Batterie–Contrôler l’état de la batterie.

4. Commandes et freins–Contrôler le fontionnement et régler si nécessaire.

5. Huile moteur (série 450 uniquement)–Vidanger à chaud. Consulter le Manuel de l’Opérateur e t d’Entretien.

TOUTES LES 100 HEURES 1. Silencieux para–étincelles–Vider la chambre à étincelles.

2. Circuit d’allumage–Si on utilise de carburant au plomb , vérifier les bougies et l’allumage. Si on utilise d u

Ver tipo de grasa en el Manual de Utilización y de Mantenimiento.

5. Sistema hidráulico/hidrostatico–Reemplazar el tapón respiradero del depósito hidráulico y cambiar el elemento del filtro. (853–reemplazar 2 elementos de carburant sans plomb, effectuer l’entretien uniquement filtro). Nota: El elemento filtrante deve ser cambiado selon besoin afin de maintenir de bonnes performances antes si el indicador de la transmisión permanece au démarrage et un fonctionnement régulier (moteur encendido mas de 5 minutos despues de que el fluido à esence uniquement). hidráulico haya alcanzado su temperatura de trabajo.

3. Huile moteur–Vidanger à chaud et changer le filtre.

Consulter le Manuel de l’Opérateur et d’Entretien .

CADA 1000 HORAS (O CADA 12 MESES) (Toutes les 250 heures pour les séries 700 équipées 1. Depósito hidráulico–Reemplazar el aceite. Véase tipo d’un moteur KUBOTA.) de aceite en el Manual de Utilización y de 4.

Contrôler tous les entraînements par courroie : Mantenimiento. hydrostatique, pomps á eau, alternateur et ventilateu r; 2. Filtro de purge de los motores hidráulicos–Limpiar o vérifier l’état et la tension des courroies. Régler o u cambiar si existen. remplacer selon besoin.

3. Cárter de la cadena– Vaciar y reemplazar el aceite.

5. Circuit hydraulique/hydrostatique (séries 400 et 500 Véase tipo de aceite en el Manual de Utilización y de uniquement)–Reemplacer l’élément du filtre. Remarque: Mantenimiento.

L’élémentde filtre doit être remplacer plus tôt si l e 4. Cárter de engranajes del ventilador–Comprobar el signal d’avertissement pour la transmission rest e nivel. Véase tipo de aceite en el Manual deUtilización allumé plus de 5 minutes après que l’huile ne soit à y de Mantenimiento. temperáture.

5. BICS–Comprobar el mando auxiliary de derivaciónde TOUTES LES 250 HEURES (OU TOUS LES 12 MOIS) los brazos de elevación.

1. Filtre d’alimentation final–Remplacer l’élément d u PROGRAMME D’ENTRETIEN (FRENCH) filtre.

2. Pivots des leviers de direction–Lubrifier avec de l a TOUTES LES 10 HEURES graisse tous usages à base de lithium (2 points).

1. Huile moteur–Contrôler le niveau–Nepas dépasser le 3. Courroie de transmission–Vérifier et tendre s i niveau (consulter le Manuel de l’Opérateur et d’Entretien nécessaire. Vérifier la courroie de remplacement pour l’huile recommandée). après 50 heures d’utilisation et régler si nécessaire.

2. Filtre à air du moteur–Contrôler la jauge et/ou l’affichage.

4. Transmission (série 500 uniquement)–Graisser le Entretenir uniquement si nécessaire. cardan. Consulter le Manuel de l’Opérateur et 3. Circuit de refriudussenebt du moteur–Nettoyer les d’Entretien. débris du refroidisseur d’huile, du radiateur et des 5. Circuit hydraulique/hydrostatique–Remplacer l e grilles. Contrôler à froid le niveau de liquid de bouchon de reniflard du réservoir hydraulique et refroidissement et rajouter si nécessaire un mélange remplacer l’élément de filtre (853–remplacer deux (2) d’éthylène–glycol/eau à 53/47. éléments de filtre). Remarque: L’élément de filtre doit 4. Bras de levage de la chargeuses, vérins, pivots et cale être remplacé plus tôt si le signal d’avertissement de du Bob–Tach: lubrifier avec de la graisse tous usages transmission reste allumé plus de 5 minutes après que à base de lithium (12 points). le liquide hydraulicque soit à température.

5. Circuit d’air du moteur–Rechercher les fuites et les TOUTES LES 1000 HEURES (OU TOUS LES 12 MOIS) éléments endommagés.

1. Réservoir hydraulique–Remplacer l’huile. Consulte r 6. Généralités–Rechercher les pièces desserrés ou le Manuel d’Opération et d’Entretien pour l’huil e brisées, voir si la ceinture de sécurité est endommagée recommandée. de même que la cabine de l’opérateur, contrôler le 2. Filtre de drain de moteurs de transmission–Nettoyer fonctionnement des instruments, rechercher les écrous ou remplacer si existant. de roue desserrés, les fuites d’huile, etc... Vérifier 3. Carter de chaînes–Vidanger l’huile et la remplacer. l’arceau de sécurité et réparer ou remplacer selon Consulter le Manuel de l’Opérateur et d’Entretien pour besoin avant d’utiliser la chargeuse. l’huile recommandée.

7. Ceinture de sécurité/Verrouillages de barre de siège 4. Réducteur du ventilateur–Contrôler le niveau d’huile. et de commandes–Fonction de vérification. Réparer Consulter le Manuel de l’Opérateur et d’entretien pou r ou remplacer selon les besoins. Nettoyer la saleté et l’huile recommandée. les débris.

5. BICS–Vérifier le fonctionnement de la vanne d e 8. Filtre d’alimentation–Vidanger l’eau de condensation (moteur diesel uniquement). descente du bras de levage.

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5.

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

NO USE NUNCA EL CARGADOR SIN LEER LAS INSTRUCCIONES. LEA EL MANUAL DEL OPERA TIO, EL MANUAL DE SERVICIO Y LA GIA DEL OPERARIO.

NE JAMAIS SE SER VIR DE LA CHARGEUSE SANS INSTRUCTIONS. LIRE LE MANUEL DE L’OPERATEUR EL D’ENTRETIEN AINSI QUE LE GUIDE D’UTILISATION.

NO VIAJE O DE LA VUEL TA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAP ACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL A VISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLA T ET HORIZONTAL. NE PAS DEPASSER LE CAP ACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

USE LA BARRA DEL ASIENTO. ASEGURESE BIEN EL CINTURON DE SEGURIDAD.

UTILISER L’ARCEAU DE SECURITE. ATTACHER SOIGNEUSEMENT LA CEINTURE DE SECURITE.

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA BOBCAT. MANTENGA LOS PIES EN LOS PEDALES.

Dealer Copy -- Not for Resale

ADVERTENCIA (SPANISH)

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT P AS APPROUVES PAR BOBCAT. MAINTENIR LES PIEDS SUR LES PEDALES.

EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE.

DANS LES PENTES, T OUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT.

ANTES DE BAJARSE DEL CARGADOR POUR QUITTER LA CHARGEUSE:

1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO. 2. PARE EL MOTOR.

1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL. 2. ARRETER LE MOTEUR.

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

4. LEVANTE LA BARRA DEL ASIENTO. MUEVA LOS PEDALES HASTA QUE AMBOS SE TRABEN.

4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE T OUTES DEUX VERROILLEES.

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ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

PELIGRO (SPANISH)

LLEVE LA CARGA EN POSICION BAJA EL NO OBEDECER EST A ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

EVITER DES BLESSURES OU LA MORT

LOS BRAZOS DE ELEVACION ESTAN ELEVADOS, A MENOS QUE ESTEN TRABADOS POW EL T OPE. • EL MOVER EL PIE DEL PEDAL O F ALLA DE UNA PIEZA PUEDEN CAUSAR LA CAIDA DE LOSBRAZOS DE ELEVACION.

TENIR LA CHARGE VERS LE BAS.

DANGER (FRENCH)

AVERTISSEMENT (FRENCH)

LE NON RESPECT PEUT ENTRAINER UN BASCULEMENT OU UN RENVERSEMENT DE LA MACHINE, UNE PERTE DE LA CHARGE OU DE VISIBILITE.

• EVITER CETTER ZONE LORSQUE LES BRAS D

E LEVAGE RELEVÉS NE SONT P AS ASSURÉS PAR DES ARRETS DE BRAS DE LEVAGE. • UNE PEDALE ACTIONNÉE OU UNE PICE DEFECTUEUSE. PEUT PROVOQUER L’ABAISSEMENT DES BRAS DE LEVAGE.

ADVERTENCIA (SPANISH) EL CILINDRO CONTIENE GAS BAJO AL TA PRESION. EL ABNRIR EL CILINDRO PUEDE SOLTAR LA VARILLA Y CAUSAR HERIDAS O LA MUERTE.

AVERTISSEMENT (FRENCH)

PELIGRO (SPANISH)

LES VERINS RENFERMENT UN GAZ SOUS PRESSION. NE JAMAIS OUVRIR UN VERIN CAR LA TIGE RISQUE DE S’ECHAPPER BRUTALEMENT ET DE CAUSER DES BLESSURES OU MEME LA MORT.

EVITE LA MUERTE

• EL FORZAR EL IMPLEMENT O CONTRA EL SUELO HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN.

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBA-

JO DE LOS BRAZOS DE ELEV ACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO U N TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

• L’ACCESSOIRE PEUT ETRE APPUYE CONTRE LE SOL ET SOULEVER LES ROUES AVANT.

• NE JAMAIS ALLER SOUS NI METTRE LES MAINS SOUS LES BRAS OU LE VERIN DE LEV AGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

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EVITER LA MORT

PELIGRO (SPANISH) EVITE LA MUERTE

• La desconexión o el aflojamiento de cualquier tubería,

manguera, conector, componente hidráulico o la falla de una parte puede ocasionar la caída de los brazos de elevación.

• Manténgase alejado del área cuando los brazos de elevación se encuentren elevados, a menos que estén sostenidos por medio de un dispositivo de soportepara brazos de elevación aprobado. Cámbielo si está dañado.

DANGER (FRENCH) • La déconnexion ou le desserrage de toute canalisation,

de tout tuyau, de tout raccord et de tout composant de circuit hydraulique, ainsi qu’une défaillance de pièce connexe peuvent provoquer la chute des bras de levage.

• Tenez-vous à l’écart de cette région lorsque les bras de levage sont en position levée, à moins qu’ils ne soient soutenus par un dispositif de support de bras de levage de type approuvé. Remplacez si endommagé.

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ÉVITEZ LA MORT!

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453BICSOperation&MaintenanceManualS/N515012400&Above#6900784–MachineTranslationsSection

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SPECIFICATIONS 5.

ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS . . . . . . . . . . .75 BOBCAT APPROVED ATTACHMENTS AND ACCESSORIES . . . . . . . . . . 74

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SKID STEER LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 73 ..

Performance Specifications Engine Loader Controls Drive System Hydraulic System Electrical System Standard Instrument Panel Deluxe Instrument Panel (Option) Capacities

SPECIFICATIONS

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SKID STEER LOADER SPECIFICATIONS • Dimensions are given for loader equipped with standard dirt bucket and may vary with other bucket types. All

dimensions are shown in inches. Respective metric dimensions are in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.

Dimensional Specifications: 36 (914) 97°

34° 123.2 (3130) 94.5 (2399)

18 (458) 74.3 (1886)

71.4 (1814)

26°

5.7 (146)

28.4 (722)

29.9 (760) 35.4 (899,9)

100.6 (2555)

MS–1096

Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

Performance Specifications:

Rated Operating Capacity (ISO) . . . . . . . . 700 lbs. (318 kg) Tipping Load (ISO) . . . . . . 1421 lbs. (645 kg) Operating Weight . . . . . . . . 2708 lbs. (1228 kg) (w/ 36 inC/IBkt) Travel Speed . . . . . . . . . . . 0–6.2 MPH (0–9,9 km/hr)

Hydraulic System

Engine driven, gear type 10.0 GPM (37,9 L/m) @ 3100 RPM System relief @ quick couplers – 2500 PSI (172 BAR)

Electrical System:

Alternator . . . . . . . . . . . . .12–Volt, 40 amp, open, neg. ground Battery . . . . . . . . . . . . . . . .12 Volt – 600 CCA @ 0°F (–18°C) Instrumentation Panel Hourmeter, temperature gauge, voltmeter and visual warning for engine and hydraulic / hydrostatic functions, fuel gauge on tank.

Engine:

Make/Model . . . . . . . . . . . .KUBOTA D722–EB Fuel/Cooling . . . . . . . . . . . .Diesel/Liquid Horsepower (SAE Net) . . . 15.7 HP (11,7 kW) Number of Cylinders . . . . . Three Lubrication . . . . . . . . . . . . .Pressure System W/Filter Air Cleaner . . . . . . . . . . . . .Dry replaceable cartridge w/safety element

Capacities:

Type:

Hyd./Hydros. Res. . . . . . . 5.3 qts. (5,0 L) Hyd./Hydros. System . . . 4 gals. (15,1 L) Chaincase Reservoir . . . 3 gals. (11,4 L)

See Below

Fuel Tank . . . . . . . . . . . . .6.5 gals. (24,6 L) . . . Diesel #2 or #1 Eng. Cooling System . . . 7 qts. (6,6 L) . . . . . 53% Propylene Glycol / 47% Water mixture Engine Oil Change w/Filter . . . . . . . . . . . . .3.4 qts (3,2 L) See Chart Page 42

Loader Controls:

Steering . . . . . . . . . . . . . . .Two hand levers Loader Hydraulics . . . . . . . Separate foot pedals Auxiliary Hydraulics . . . . . . Right steering lever Parking Brake . . . . . . . . . . Switch in Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . (Later Models) or Foot operated pedal . . . . . . . . . . . . . . . . . . . . . . . . . (Early Models)

– Above 0°F (–18°C) use Bobcat Fluid 6563328 or SAE 10W–30, or 10W–40 SE – Bel. 0°F (–18°C) use 5W–30

Drive System:

Main Drive . . . . . . . . . . . . .Hydrostatic 4 wheel drive Transmission . . . . . . . . . . . . .Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors Final Drive . . . . . . . . . . . . . . .#60 roller chain and sprockets in sealed chaincase with oil lubrication.

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24°

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BOBCAT APPROVED ATTACHMENTS & ACCESSORIES These and other attachments are approved for use on this model Bobcat loader . Do not use unapproved attachments.

Attachments not manufactured by Bobcat may not be approved.

The versatile Bobcat loader quickly turns into a multi–job machine with a tight–fit attachment hook–up . . . from bucket ot grapple to pallet fork to backhoe and a variety of other attachments. See your Bobcat loader dealer for more details oneth attachments and field accessories.

Increase the versatility of your Bobcat Loader with a variety of bucket styles and sizes. Styles and sizes include: BUCKET DESCRIPTIONS 36 inch Dirt Bucket 36 inch Dirt Bucket w/6 teeth 44 inch Dirt Bucket 44 inch Dirt Bucket w/7 teeth 44 inch Utility Bucket 48 inch Utility Bucket

Many bucket styles, widths and different capacities are available for a variety of differentapplications.See your Bobcat dealer for the correct bucket for your Bobcat loader and application.

ATTACHMENTS Hydraulic Breaker

Snowblower

Auger

Bob–Tach mounted. Variety of Quick–Change tools available.

Low recoil Bobcat backhoe operating cycle. attachments are designed *SPECIAL APPLICATIONS KIT WHICH A 1/2 INCH LEXAN FRONT DOOR for the pipeliner, municipal INCLUDES WITH 1/4 INCH TOP AND REAR WINDOWS worker or contractor , for MUST BE USED WHEN OPERA TING THE Clear snow from driveways, sidewalks, etc.

BOB–TACH MOUNTED HYDRAULIC high production digging.

BREAKER. Angle Broom

Tiller

Use it to sweep driveways, Great for breaking up sidewalks, parking lots, clumps, mixing compost, etc. tilling.

Utility Blade

Dig 6”–36” holes with ease and accuracy.

Utility Fork/Grapple

Pallet Fork

The Bobcat Loader Utility Fork and Grapple is the ideal attachment for handling bundled material, loose straw, and manure.

Move bulky or bagged materials in one load. A ll kinds of farm chores and fertilizer handling; baled o r pallet materials.

Dumping Hopper

Landplane

Trencher

Saves time by reducing trips to the dumpsite. Mounts like Use it to clear snow or level a bucket on your Bobcat Remove large clumps and Versatile trenching ability loader. material. rocks as you level and grade. for utility lines, etc.

Some attachments may not be available from your local dealer.

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Backhoe

ADDITIONAL PUBLICATIONS and TRAINING MATERIALS

The following publications and training materials are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

For the latest information on Bobcat products and the Bobcat, visit our website at www.bobcat.com

OPERATOR’S HANDBOOK 6708358 Service Manual

PARTS MICROFICHE

OPERATION & MAINTENANCE SERVICE MANUAL MANUAL 6901177 6901175

–complete maintenance and overhaul instructions for you r BOBCAT loader.

–complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

–Up–to–date PARTS information is also available. See your BOBCA T dealer.

SKID STEER LOADER OPERATOR TRAINING COURSE 6901726 SKID STEER LOADER SERVICE SAFETY TRAINING COURSE 6900641 –Introduces operator to step–by–step basics of Skid–Steer loader operation.

Also available in Spanish P/N 6724036.

Dealer Copy -- Not for Resale

–gives basic operation instruction and safety warnings.

–Introduces Service T echnicians to step–by–step basics of proper and safe skid–steer loader maintenance and servicing procedures.

OPERATION SAFETY VIDEO 6724793 SAFETY MANUAL 6556500

–provides basic safety instructions.

–provides basic safety procedures and warnings for your BOBCA T loader. Also available in Spanish P/N 6724451.

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WARRANTY Bobcat Loaders

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company’s option, without charge for parts and labor, any part of the Bobcat product which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement. Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to diesel engine fuel injection pumps and injectors or tires (except Bobcat brand tires). The owner shall rely solely on the warranty, if any, of the respective manufacturers thereof. This warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. This warranty does not cover damages resulting from abuse, accidents, alterations, use of the Bobcat product with any accessory or attachment not approved by Bobcat Company, air flow obstructions, or failure to maintain or use the Bobcat product according to the instructions applicable to it.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

6570162 (11–00)

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Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat loader will be free from proven defects in material and workmanship for twelve (12) months after delivery by the authorized Bobcat dealer to the original buyer.

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