Bobcat 542B Loader Operation & Maintenance Manual SN 12001 & Above - PDF DOWNLOAD

542B

Operation & Maintenance Manual

Dealer Copy -- Not for Resale

S/N 12001 & Above

.

6720358 (11–89)

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Printed in U.S.A.

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Dealer Copy -- Not for Resale

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.

B–10731

Never use the loader without instructions. See machine signs (decals), Operations & Maintenance

Manual and Handbook.

CORRECT

CORRECT

WRONG

B–6582

B–13418

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

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the pedals when operating loader.

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 about 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 pedals.

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 OSW02–0600 9. PARKING BRAKE 3 of 74

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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 dealer.

CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiI BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv, v SAFETY SIGHNS (DECAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi, vii OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SAFETY SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

TROUBLESHOOTING

SAFETY SIGNS

Dealer Copy -- Not for Resale

Write the correct information for YOUR Bobcat loader in the spaces below.

Always use these numbers when referring to your Bobcat loader.

NOTES:

PREVENTIVE MAINTENANCE

SPECIFICATIONS

REFERENCE INFORMATION

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

OPERATING INSTRUCTIONS

YOUR LOADER DEALER: ADDRESS: PHONE:

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542B Bobcat Loader Operation & Maintenance Manual

I. SAFETY INSTRUCTIONS A. SAFETY IS THE OPERATOR’S RESPONSIBILITY The Skid Steer Loader is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications and are not unique for use of Bobcat loaders. The loader has an internal combustion engine with resultant heat and exhaust.

All exhaust gases can kill so the loader must be used with adequate ventilation. The loader has a spark arrestor muffler which is required for operation in certain areas.

The dealer recommends the capabilities and restrictions of the loader and attachments for each application. The dealer demonstrates the safe operation of the loader according to Melroe’s 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 rated capacity and secure fastening to the loader. The user must check with the dealer or Melroe Company literature to determine safe loads of materials of specified densities for his loader–attachment combination.

The following publications provide information on the safe use and maintenance of the loader and attachments: The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

2.

The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold.

Replacement Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.

3.

The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their location are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

4.

The loader has a plastic Operator Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in English edition or a combination English, French, German, Spanish edition.

5.

The FIEI Manual delivered with the loader gives general safety information.

6.

The Service Manual and Parts Manual are available from your Bobcat dealers for use by mechanics to do shop–type service and repair work.

Dealer Copy -- Not for Resale

1.

The dealer and owner/operator review the recommended uses of the loader and attachments when the loader is delivered.

If owner/operator will be using the loader for a different application then was originally demonstrated by the dealer, ask the dealer for recommendations on the new use.

B. BEFORE OPERATING THE BOBCAT LOADER

This safety symbol is used for important safety messages. When you see this symbol, follow the safety message to avoid personal injury.

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 B–10731

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

Check all of the items on the Service Schedule under the 8 – 10 hour column.

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

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

I–2019–0284

W–2044–1285

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C. SAFE OPERATION NEEDS A QUALIFIED OPERATOR A QUALIFIED OPERATOR* MUST DO THE FOLLOWING

2.

3.

UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS a.

The written instructions from Melroe Company include the delivery report, operations & maintenance manual and plastic handbook, FIEI manual and machine signs (decals).

b.

Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. Regulations may identify a hazard such as utility supply line.

HAVE TRAINING WITH ACTUAL OPERATION a.

Operator training must consist of a demonstration and verbal instruction. This training is given by your dealer before the loader is delivered.

b.

The new operator should start in an area without bystanders and use all the controls until he can operate the loader safely under all conditions of the work area. Always fasten seat belt and lower seat bar before operating.

KNOW THE WORK CONDITIONS a.

For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of the loader. For example, in handling certain loose material with a given bucket, he must know whether he can safely take a full, or only part of a bucket load.

b.

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

c.

*

II.

Wear tight fitting clothing. Alwyas wear safety glasses when maintaining or servicing loader. Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer about Melroe safety equipment.

For an operator to be qualified, he must nto use drugs or alcoholic drinks which impair his alertness or coordiantion while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

FIRE PREVENTION The loader has several components that are at high temperature 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 souce of arcs or sparks.

Flammable debvris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment is a fire hazard when the loader is parked with a hot engine.

The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Know where fire extinguishers and first aid kits are located and how to use them.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot componenets can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin

to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on any engine that has glow plugs. These starting aids can cause explosion and injure you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and

all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding pointed 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 Operation & Maintenance Manual for connecting the battery.

• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.

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1.

III. 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 made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

A. LOADER SERIAL NUMBER The Bobcat loader serial number plate location is inside the left upright, above the grill [A].

Explanation of loader Serial Number: XXXX

PI–6327

XXXX

B

Production Sequence (Series) Model, Engine Version

The engine serial number is located on the rocker arm cover [B].

PI–9085

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

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B. ENGINE SERIAL NUMBER

542B Bobcat Loader Operation & Maintenance Manual

V. BOBCAT LOADER IDENTIFICATION

FRONT LIGHTS (OPTIONAL)

GRAB HANDLES OPERATOR SEAT STEERING LEVERS SEAT BELT

*BUCKET

Dealer Copy -- Not for Resale

TILT CYLINDER

SAFETY TREAD

BUCKET STEPS

REAR LIGHT (Opt.) OPERATOR CAB **(ROPS & FOPS)

SEAT BAR UPRIGHT

LIFT ARM

REAR GRILL

LIFT CYLINDER

REAR DOOR

TIRES*

B–7377 B–12388

*BUCKET – Several different buckets and other attachments are available for the Bobcat loader. **ROPS, FOPS – Roll Over Protective Structure, Falling Object Protective Structure.

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

6557565

6569021

6569119

6577754 (2)

6557569

Dealer Copy -- Not for Resale

6561385

6575855

6575854

6565254

6575694 B–7377

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VI. SAFETY SIGNS (DECALS) (Cont’d)

6560573

6561384

Dealer Copy -- Not for Resale

6565990

6565980

6567875

B–12388 12 of 74

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OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation and Removal of the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

OPERATING INSTRUCTIONS

CHOKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Auxiliary Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Float Position Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Digging Into the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Emptying the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Filling the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Leveling the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cold Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Normal Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Warming the Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . 10 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Dealer Copy -- Not for Resale

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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A

INSTRUMENT PANEL (Cont’d)

542B STANDARD CAB

Three Piece

1

The instrument panel has the following items [A] or [B]:

5a

1. LIGHT SWITCH – Controls the work and travel lights (Optional – 542B Standard Cab) 2. KEY SWITCH – For starting and stopping the engine.

4 3

3. FUSE (ACCESSORIES) – To protect the electrical system from overload.

2

4. FUSE (IGNITION) – To protect the electrical system from overload.

8a

9a

5. HOURMETER – Records the total operating hours of the loader.

B–12625

A

542B DELUXE

6. FUEL GAUGE – Shows the amount of fuel in the fuel tank (542B Deluxe Cab).

5a 3

7. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature (542B Deluxe Cab).

10

1

8. ENGINE WARNING LIGHT – Engine oil pressure is low. Stop the engine if the light comes “ON”.

7

a. 542B Standard Cab b. 542B Deluxe Cab

4 2

9. TRANSMISSION WARNING LIGHT – Low hydrostatic transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes “ON”. a. 542B Standard Cab b. 542B Deluxe Cab

7 8b 9b

Dealer Copy -- Not for Resale

a. 542B Standard Cab b. 542B Deluxe Cab

B–12526

10. VOLTMETER – Shows the condition of the battery and the rate of charge (542B Deluxe Cab).

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LEARNING THE CONTROLS

A

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

1

CHOKE CONTROL The choke control (Item 2) is located near the throttle (Item 1) [A].

Pull up on the choke control knob to engage the choke.

Push down on the choke control to release the choke.

2

B–7467

B

PARKING BRAKE

Dealer Copy -- Not for Resale

Lock the brake by pushing down on the top (toe) of the pedal [B].

B–3745 B–7378

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

C

B–3744 B–5717 16 of 74

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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 B–7379

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

B

FORWARD BACKWARD

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

FORWARD TRAVEL – Push both levers forward.

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.

LEFT TURN

RIGHT TURN

LEFT FAST TURN

RIGHT FAST TURN

For slow travel speed, push the steering levers forward only a small amount.

To increase travel speed, push both levers farther forward.

Dealer Copy -- Not for Resale

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

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

PI–1849

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HYDRAULIC CONTROLS

A

Foot Pedals

3 1 2

B–7379

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.

B–07440

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

Lift Arm Operation

4

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

5

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

Dealer Copy -- Not for Resale

1 B–7379

Float Position Operation Push the top (toe) (Item 3) of the tilt pedal all the way forward until it locks into “detent” (float) [A]. Use the “float” position of the lift arms to level loose material while driving backward.

Tilt Operation (Bucket) The right pedal controls the action of the bucket. Push the top (toe) (Item 4) of the pedal to tilt the bucket forward [A].

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

B–07441

NOTE: A bucket positioning valve is optional for this Bobcat loader. When installed, this valve will help the operator keep the bucket in the same position (tilt angle in relation to the loader) while the load is raised.

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HYDRAULIC CONTROLS

A

Foot Pedals Auxiliary Lever Operation The right steering lever is also the control lever for the auxiliary hydraulics [A] Move the right steering lever to the left or right to activate the auxiliary hydraulics and operate an attachment.

(Example: To open or close grapple teeth.), [A] Move the lever in the opposite direction to reverse the action of the attachment.

A–2408

A–2409

Move the steering lever all the way to the right (Item 1) to put the control valve into the “detent” position for a constant flow of hydraulic fluid under pressure to the quick couplers. (Example: OPerate a Bobcat).

B–7379

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542B Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

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

Check the following items daily: • Engine Oil • Hydraulic/Hydrostatic Fluid • Engine Cooling System • Air Cleaner System • Operator Cab, Seat Belt, Seat Bar & Pedal Interlocks • Lift Arm & Cylinder Pivot Pins • Tires & Tire Pressure • Any Loose or Broken Parts • Safety Tread & Machine Signs

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

B–06583 B–06592

W–2003–1289

6567875

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Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door

GETTING READY FOR OPERATION

A

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

6569119

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

W–2001–1285

B–7377

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

B

Adjust the seat position for easy operation of the loader.

B–3943

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

C

C–2596

Lower the seat bar [D].

Dealer Copy -- Not for Resale

Safety treads are installed on the Bobcat loader to provide 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 loader dealer.

B–12377

D

Be sure the parking brake is engaged.

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.

B–12378

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GETTING READY FOR OPERATION (Cont’d)

A

All controls must be in the neutral position before you start the engine. (See ”Normal Starting Condition”, Page 9.)

Keep feet on the pedals while seated in the loader [A].

Stop and cool the engine before adding fuel.

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

B–12379

W–2063–0887

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–6586

C

WRONG

AVOID INJURY OR DEATH • 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

B–6578

D

WRONG

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B

STARTING THE ENGINE

C

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

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

Lower the seat bar [A].

B–6579

Put the foot pedals and steering levers in neutral (center) position (Item 1) [B].

B

NEUTRAL POSITION

Set the throttle to the half throttle position (Item 2) [B].

Turn the key to the ‘‘ON’’ position. The engine and transmission warning lights must be ‘‘ON’’ when the key is on and the engine is stopped (Item 3) [B].

1/2 THROTTLE

Do not run the starter more than 15 seconds.

When the engine starts the warning lights must go “OFF” (Item 1) [B].

2

STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF and correct the problem.

”ON” POSITION

3

Dealer Copy -- Not for Resale

1

Turn the key to the start position (Item 4) and release it when the engine starts (Item 5) [B].

”START” POSITION Do not engage starter for longer than 15 seconds at at time. Longer use can damage starter by overheating. Cool starter for one (1) minute between uses.

I–2034–0684

4 ”RUN” POSITION

5

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PI–2629

542B Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Starting Condition If the temperature is below 32°F (0°C), use the following procedure to make starting the engine easier:

2 1

1. Replace the engine oil with the correct type and viscosity for the anticipated starting temperature.

(See “Oil Specifcations Chart”, Page 26.)

2. Make sure the battery is at full charge.

3. Install a block heater or tank heater.

Engage the choke (Item 1) by pulling eh knob up [A].

B–9409

Turn the key to the “START” position and release it when the engine starts. DO NOT run the starter for more than 15 seconds.

When the engine is running, move the throttle (Item 2) forward to increase engine speed [A].

Dealer Copy -- Not for Resale

Push the choke control in a small amount. Move the choke control to the “OFF” position when the engine is running smooth and is warm.

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.

When the temperature is below –20°F (–30°C), hydrostatic oil must be warmed before starting.

The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F (–18°C) if possible.

I–2007–1285

STOPPING THE ENGINE Pull the throttle fully backward to decrease the engine RPM. Turn the key switch to the ‘‘OFF’’ position.

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542B Bobcat Loader Operation & Maintenance Manual

ATTACHMENT AND BUCKETS

A

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

Unapproved attachments can cause injury or death.

W–2052–1285 The dealer can identify, for each model loader, the attachments and buckets approved by Melroe Company.

The buckets and attachments are approved for Rated Operating Capacity and for secure fastening to the Bob–Tach.

The Rated Operating Capacity for this loader is shown on a label in the operator cab (Also see the ‘‘Specifications’’ section, Page 49). It 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.

AVOID INJURY OR DEATH Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

Exceeding the Rated Operating Capacity can cause the following problems [A]:

W–2053–0887

1. Steering the loader may be difficult.

B

2. Tires may wear faster.

WEIGHT OF LOADS LBS. (KG)

3. There will be a loss of stability.

Maximum loads to be carried when using a pallet fork are shown in figure [B].

300 (136)

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.

400 (181)

600 (272)

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

Dealer Copy -- Not for Resale

B–6587

3 (76) 23 (584) 345(1143)

CENTER OF LOAD LOCATION Inches (mm)

542B MODEL 6558413 25 of 74

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542B Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installation and Removal of the Bucket The loader is equipped with the Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operator’s Manual to install other attachments.

PI–2590 B–3851

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

W–2054–1285

B

Pull the Bob–Tach levers all the way up.

Tilt the Bob–Tach forward. Drive the loader forward until the top edge of the Bob–Tach is completely under the flange of the bucket [A].

Tilt the Bob–Tach backward until the bucket is off the ground [B]. Stop the engine PI–2591 B–3850

C

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.

W–2045–1086

Push down on the Bob–Tach levers until they are in the locked position [C].

B–3852 B–7018

D Bob–Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

W–2102–0588

1 The wedges (Item 1) [D] must extend through the holes (Item 2) [D] in the bucket or attachment.

2

Removal: Reverse the above procedure to remove the bucket or attachment from the Bob–Tach.

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

DO NOT hit the Bob–Tach levers on the bucket.

OPERATING PROCEDURES

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 the engine and hydrostatic system before operating the loader.

Going Up Slope

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

I–2015–0284

B

B–12685

WITH BUCKET FULL

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

Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

Fill the bucket to the Rated Operating Capacity. The loader will turn better with a full load (Rated Operating Capacity) than with just part of a load.

Going Down Slope

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

C

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

B–12685

WITH BUCKET EMPTY

Dealer Copy -- Not for Resale

New operators must operate the loader in an open area without bystanders.

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

D

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

B–6611

WITH BUCKET EMPTY

W–2018–1187

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

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542B Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (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].

B–7379

B–6719

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

B–7379

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.

B–6718

Emptying the Bucket

C

Push down on the bottom (heel) of the lift pedal to raise the bucket over the truck box or bin [C].

Drive forward slowly until the bucket is over the top of the truck box or bin. Push the top of the tilt pedals 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.

B–7379

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 B–9053

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

OPERATING PROCEDURES (Cont’d)

A

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

B–7379

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

B–6720

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.

B–7379

Dealer Copy -- Not for Resale

B

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

B–6721

C

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

B–7379

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542B Bobcat Loader Operation & Maintenance Manual

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 (detent) to put the lift arms in a float position [A].

B–7379

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–6722

I–2005–1285

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

B–7379

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–6724

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

Drive backward to level loose material. Push the bottom (heel) of the lift pedal to unlock from the “detent” position.

TRANSPORTING THE BOBCAT LOADER

A

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

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

Use the following procedure to fasten the Bobcat loader to the trasport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes: B–2668

Lower the bucket or attachment to the floor. Stop the engine. Engage the parking brake. Install chains at the front and rear of the loader [B].

B

1. Stop the Bobcat loader on level ground.

2. Lower the lift arms fully and put the attachment flat on the ground.

3. Pull the throttle all the way back. Turn the key switch to the “OFF” position.

B–12697

C–7384

AVOID INJURY OR DEATH

Dealer Copy -- Not for Resale

PARKING THE BOBCAT LOADER

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.

W–2045–1086

4. Engage the parking brake.

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

B–12682

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

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542B Bobcat Loader Operation & Maintenance Manual

LIFTING THE BOBCAT LOADER

A

1

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

• Assemble front cab fasteners as shown in manual.

• Never allow riders in the cab or bystanders

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

W–2007–0694

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

Fasten the pins (Item 1) in the kit as shown in figure [A].

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

TOWING THE BOBCAT LOADER

B–7489

Never attempt to start the engine by pushing or pulling. Hydrostatic pumps and motors will be damaged.

I–2001–1285

If the engine will not start or the hydrostatic system is not working correctly, the loader can be pulled only when a towing tool is installed. The towing tool is available from your Bobcat loader dealer.

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.

I–2017–0389

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

1

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Adjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 AUXILIARY RETAINER BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Rear Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removing Coolant from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 28 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Battery Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Using A Booster Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PREVENTIVE MAINTENANCE

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removing Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 LIFT ARM STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 LUBRICATION OF THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Dealer Copy -- Not for Resale

FINAL DRIVE TRANSMISSION (Chaincase) . . . . . . . . . . . . . . . . . . . . . . . . . . 38

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PARKING BRAKE PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Adjusting the Rear Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SEAT BAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 33 of 74

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542B 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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MSW01–0600

542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

CORRECT

CORRECT

CORRECT

SERVICE SCHEDULE 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 Operation Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manual when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1289

Engine Oil Engine Air Cleaner Engine Cooling System Tires Seat Belt and Seat Bar Safety Signs & Safety Tread Indicator & Lights Operator Cab Lift Arm & Bob–Tach Pivot Pins Engine Oil and Filter Battery Hydraulic Fluid, Tubelines and Hoses Control Pedals & Steering

SERVICE REQUIRED

8–10

50

100 250 500 1000

Check the oil level & add oil as needed.

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

Clean debris from shrouds & grills. Check coolant level in the recovery tank and add as needed.

Check for damaged tires and correct air pressure.

Check the condition of seat belt. Check the seat bar & pedal locks for correct operation.

Check for damaged signs (decals) & safety treads. Replace as needed Check for correct operation of all indicators & lights.

Check the fastening bolts, washers and nuts. Check the condition of the cab.

Add grease to the fittings until extra grease shows.

Replace oil & filter.

Check cables & water level Check the fluid level & add as needed. Check for damage, leaks & replace as needed.

Check for correct operation. Make repairs or adjustments as needed.

Wheel Nuts Check for loose wheel nuts & tighten as necessary.

Parking Brake Check operation. Adjust as needed.

Alternator Belt Check tension & adjust as needed.

Spark Arrestor Muffler Clean the spark chamber.

Governor Oil Level Check level, if low, add oil.

Seat Bar Grease pivots as needed.

Steering Shaft Pivots Grease two fittings. Add oil to steering shaft.

Hydraulic/Hydrostatic Filter Replace the filter element.

U–Joint Grease three (3) fittings with correct grease.

Final Drive Trans. (Chaincase) Check fluid level & add as needed.

Engine Ignition System Check the timing. Replace the spark plugs.

Fuel Filter Replace the filter element.

Hyd./Hydro. Reservoir Replace the reservoir breather cap.

Chaincase Replace the fluid.

Hyd. Reservoir Replace the fluid.

Dealer Copy -- Not for Resale

ITEM

Check wheel nut torque every 8 hours for the first 24 hours.

Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months.

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542B Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

A

NOTE: Lift arm stops are available from your Bobcat dealer.

Never work on a machine with the lift arms up unless the lift arms are secured by a 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–2059–0991

Maintenance and service work can be done with the lift arms lowered.

B–6581

One person must be in the operator’s seat, with the seat belt fastened and the seat bar lowered, until the lift arm support device is installed.

Start the engine and raise the lift arms all the way up.

Have a second person install the lift arm support device over the rod of one of the lift cylinders [A].

Both sets of fasteners at the front of the operator cab (ROPS) must be assembled as shown in this manual. Failure to secure ROPS correctly can cause injury or death.

The lift arm stop must be tight against the cylinder rod.

Lower the lift arms until the stop is held between the lift arm and the lift cylinder.

W–2005–1189

OPERATOR CAB 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.

B

Nut ROPS

Plate Washer Vibration Dampner

Fender

Washer

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

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

W–2069–1285

The operator cab fastening bolts and nuts must be tight to 40–50 ft.–lbs. (54–68 Nm) torque [B].

MC–1181 C–2599

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Place jackstands under the rear corners of the loader.

OPERATOR CAB (Cont’d)

A

Raising the Operator Cab (Cont’d)

Nut ROPS

Plate Washer Vibration Dampner

Stop the loader on a level surface. Put the lift arms all the way down.

If the lift arms must be up while raising the operator ca, install a lift arm stop (Page 20).

Fender

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.

Washer

MC–1181 C–2599

W–2014–0895

B Dealer Copy -- Not for Resale

Remove the two fasteners (including the washer) at the front corners of the operator cab [A].

If the lift arms are down, or are held up by a lift arm stop, stand in front of the loader. Lift on the grab handle and bottom of the operator cab slowly until the operator cab is all the way up [B] & [C].

AVOID INJURY Cylinders for raising and lowering operator cab have gas under pressure. Do not open cylinder.

Only qualified service personnel can remove the cylinder.

B–12365

W–2112–0987

C

Lowering the Operator Cab If the lift arms are down, or are held up by a lift arm stop, stand in front of the loader. Pull down on the bottom of the operator cab and use the grab handle until the cab is all the way down [B] & [C].

Install the two fasteners and washers. Tighten the nuts to 40–50 ft.–lbs. (54–69 Nm) torque [A].

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542B Bobcat Loader Operation & Maintenance Manual

SEAT BAR SYSTEM

A

The seat bar 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 control pedals are locked when returned to the neutral position.

Clean & Lubricate

B–7387

AVOID INJURY OR DEATH

B

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

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

B–9781

Pull the seat bar down, lower the lift arms and place 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 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).

Use general purpose grease to lubricate the seat bar pivot points at each side of the cab [A].

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

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Clean Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

REAR DOOR

A

Opening the Rear Door

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

W–2012–0290

PI–6328

Open the rear door to service the engine. Pull the door latch up and to the left to release the door latch [A].

B

1

The door can then be opened to get to the engine compartment.

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

3 B–7385 B–5772

W–2020–1285

Adjusting the Rear Door

C

Loosen the set screw (Item 1) [B].

Loosen the nut (Item 2) [B].

Turn the bolt (Item 3) [B] in or out, until the door contacts both the top and bottom of the loader frame (Item 1) [C] with the lever in the latched position.

1

NOTE: It takes approximately 50 lbs. (22 kg) of force to push the lever down when the latch is adjusted correctly.

Dealer Copy -- Not for Resale

2

2

With the set screw up, the flanges at the bolts (Item 2) [C] must be to the sides so that the set screw aligns with the flat surface of the end of the bolt.

B–7226

PI–6329

Tighten the set screw. Tighten the nut to 65–70 ft.–lbs.

(88–95 Nm) torque.

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542B Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

A

See the Service Schedule Page 19 for the interval to service the air cleaner.

To replace the filter element, use the following procedure: Remove the dust cap [A].

B–13118

B–13120

Remove the filter element [C].

C

Check the air cleaner housing for holes from corrosion.

Install the new filter element. Install and tighten the wing nut.

B–13119

Install the dust cup so the arrow on the cup is up [D].

Tighten the clamp.

D

Check that all the air cleaner hose clamps are tight.

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Dealer Copy -- Not for Resale

B

Remove the filter element wing nut [B].

FUEL SYSTEM

A

Fuel Specifications Use leaded or unleaded gasoline in the engine.

Filling the Fuel Tank

1

Stop and cool the engine before adding fuel.

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

PI–6334

W–2063–0887

B

Filling the Fuel Tank

WRONG

Remove the filler cap (Item 1) [A].

The key switch must be in the ‘‘OFF’’ position and the engine cool.

Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [B].

After the fuel has been added install the filler cap and.

B–6586

C

Fuel Filter

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.

Dealer Copy -- Not for Resale

Use a clean, approved safety container to add fuel to the tank

1

W–2103–1285 PI–6335

See the Service Schedule (Page 19) for the interval to service the fuel filter.

D

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

Loosen the hose clamps and remove the filter (Item 1) [D].

1

Install the new fuel filter element and tighten the hose clamps.

Open the fuel shut–off valve.

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542B Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

A

Check the engine oil level every day.

Stop the engine. Open the rear door and remove the dipstick [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of SE or SF (See the Oil Chart below).

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C° –34

–29

–23

–18

–13

–7

1

+4

+10

+15

+21

+27

+32

+38

SAE 10W–30/40

PI–9151

SAE 15W–40

B SAE 5W–30

SAE 30W

SAE 20W–20

F° –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90

+100

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE or SF) B–13116

Replacement of Engine Oil and Filter See the Service Schedule (Page 19) for the service interval for replacing the engine oil.

C

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

Stop the engine.

2. Open the rear door.

3. Remove the drain plug and drain the oil into a container [B].

4. Remove the oil filter [C].

5. Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten only.

6. Install and tighten the oil plug. Remove the filler cap.

Add the correct amount of oil to the engine (See Specification, Page 50) [D].

B–13126

7. Start the engine and let it run for several minutes.

Stop the engine. Check for leaks and check the oil level. Add oil as needed if it is not at the top mark on the dipstick.

D

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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B–13123

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SAE 10W

COOLING SYSTEM

A

Keep the rear grill area free from debris or overheating will result [A].

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

PI–6348

B

W–2019–1285

To remove the rear grill from the loader, use the following procedure: Remove the four bolts from the rear grill [B] & [C].

PI–6349

C

Dealer Copy -- Not for Resale

Rear Grill

PI–6350

Lift the grill up and remove from the loader [D].

D

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542B Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM (Cont’d)

A

Coolant Level The coolant recovery tank is located in the engine compartment at the left side [A].

B–13124

B

When the engine is cool, the coolant recovery tank must be 1/3 full.

When coolant level is low, add pre–mixed 50% ethylene glycol and 50% water to the recovery tank [B].

B–13121

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

C

1. Open the rear door. Remove the rear gill (Page 27).

2. Remove the radiator cap [C].

3. Remove the drain plug (Item 1) from the engine block [D].

4. After all the coolant is removed, install and tighten the plug.

5. Mix the coolant in a separate container (See Specifications, Page 50 for correct capacity).

PI–6354

NOTE: Protect the cooling system by adding pre–mixed 50% ethylene glycol and 50% water to the system. This mixture will protect the cooling system to –34°F (–36°C).

D

6. Fill the radiator with the pre–mixed coolant. Install the radiator cap. Install the rear grill.

1

7. Fill the coolant recovery tank 1/3 full.

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

Stop the engine. Check the coolant level in the recovery tank and add coolant as needed.

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Removing Coolant from the Cooling System

GOVERNOR

A

See your Bobcat dealer or Service Manual for the complete and correct procedure for governor adjustment.

1

Belt Adjustment Loosen the two mounting bolts (Item 1) [A].

PI–6356

Move the governor until the belt tension is 1/4” (6,4 mm) movement at the middle of the belt span with 20 lbs. (89 N) of force [B].

B

PI–6357

Governor Oil Level

C

See the Service Schedule (Page 19) for the correct interval when to check the governor oil level. Use the following procedure:

2

1. Stop the engine. Open the rear door.

1

Dealer Copy -- Not for Resale

Tighten the mounting bolts.

2. Remove the check plug (Item 1) [C]. If oil flows from the hole, the oil level is correct.

3. If no oil flows, remove the fill plug (Item 2) at the back of the governor housing [C].

4. Add SAE 10W/30 or 10W/40 oil until it flows from the check plug hole. Install and tighten the plugs.

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PI–6358

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542B Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT

A

Adjusting the Alternator Belt Loosen the alternator mounting bolt [A].

PI–6359

Loosen the adjusting bolt [B].

P–6360

C

Move the alternator until the belt has 3/8” (9,5 mm) movement at the middle of the belt span with 22 lbs. (98 N) of force [C].

Tighten the adjusting bolt and mounting bolt.

PI–6361

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B

ELECTRICAL SYSTEM

A

Description The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

Electrical System Service The battery cables must be clean and tight. Check the water level in the battery.

Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution [A].

Cover the battery terminals and cable ends with grease Check for broken wires or loose connections.

A–2741

Dealer Copy -- Not for Resale

The warning lights (on the instrument panel) will come “ON, when the the key switch is turned “ON“. When the engine is started, the warning lights must go “OFF”. If they do not, stop the engine and find the problem.

Using An Extra Battery (Jump Starting) 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 with the seat belt fastened and seat bar lowered and one person to connect and disconnect the battery cables.

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

Do not jump start or charge a frozen battery.

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

Battery gas can explode and cause serious injury.

W–2066–0490

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542B Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

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

In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact.

W–2065–1286

1. The ignition must be in the “OFF” position. The battery to be used must be 12 volts.

B–13125

2. Connect the end of the first cable (Item 1) to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 2) tot he loader battery positive (+) terminal [A].

Dealer Copy -- Not for Resale

3. Connect the end of the second cable (Item 3) to the negative (–) terminal of the booster battery. Connect the other end of the second cable (Item 4) to the engine for ground [A].

4. Keep the cables away from moving parts.

5. Start the engine (See “Cold Starting” Procedure, Page 10).

6. After the engine is running, remove the negative (–) cable from the engine first.

7. Then remove the cable connected to the positive (+) terminal to the battery.

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the loader (Remove both cables from the battery).

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

I–2023–1285

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542B Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Battery Removal and Installation Open the rear door.

Disconnect the negative (–) cable from the battery [A].

PI–6364

Disconnect the positive (+) cable from the battery [B].

PI–6365

C

Remove the holddown clamp [C].

Remove the battery from the loader.

Dealer Copy -- Not for Resale

B

PI–6366

Always clean the terminals and cable end even when installing a new battery [D].

D

When install the battery into the loader, do not touch any metal parts with the battery terminal posts.

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

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542B Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking and Adding Fluid Use only recommended fluid in the hydraulic/hydrostatic system (See Specifications, Page 50 for the correct fluid).

To check the fluid level in the reservoir, use the following procedure:

1

Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully backward. Stop the engine.

Hydraulic fluid must show in the sight gauge (Item 1) [A].

PI–6338

If the fluid is not seen in the sight gauge, remove the filler cap from the reservoir [B].

PI–6339

Add fluid to the reservoir until it shows in the sight gauge [C].

C

Replace the filler cap.

PI–6340

Hydraulic/Hydrostatic Filter Replacement

D

See the Service Schedule (Page 19) for the service interval.

Stop the engine. Open the rear door.

Remove the filter element with a filter wrench [D].

Clean the surface of the filter housing head where the filter element seal contacts the filter housing. Lubricate the new filter gasket with oil. Install the filter element and hand tighten.

Operate the loader and check for leaks at the filter. Check the fluid level in the reservoir and add as needed.

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PI–6368

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542B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Removing the Hydraulic Fluid See the Service Schedule (Page 19) for the service interval when to replace the fluid in the reservoir.

The fluid must also be replaced if it becomes contaminated and after major repairs.

Remove the fill cap from the reservoir [A].

PI–6339

Remove the screen from the reservoir [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.

W–2103–1285 PI–6341

Remove the filter element [C]. Install a new filter element and hand tighten.

C

Dealer Copy -- Not for Resale

B

PI–6368

Remove the fluid from the reservoir with a hand operated suction pump or hydraulic transfer pump [D].

D

Add fluid to the hydraulic/hydrostatic reservoir (See Specifications, Page 50 for the correct fluid). DO NOT fill above the sight glass.

Operate the loader and hydraulic functions. Stop the engine. Check the fluid level and add as needed.

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542B Bobcat Loader Operation & Maintenance Manual

SPARK ARRESTOR MUFFLER

A

See the Service Schedule (Page 19) for service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

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

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

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.

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

I–2022–1285

W–2050–1285

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

Stop the engine. Open the rear door.

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

W–2011–1285

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.

W–2068–1285

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

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler.

Stop the engine. Install and tighten the plug. Close the rear door.

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PI–9088

TIRE MAINTENANCE

A

Wheel Nuts See the Service Schedule (Page 19) for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) [A].

Tire Rotation Check the tires regularly for wear, damage and pressure (See Specifications, Page 50, for the correct tire pressure).

PI–6337

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

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 speed and cause excessive wear. When tires wear, install two new tires on the same side of the loader. The tread bars of all the tires must face the same direction.

Recommended tire pressure must be maintained to avoid excessive tire wear, loss of stability and handling capacity. Check for correct pressure before operating the loader.

Tire Inflation

B–9976

Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated before mounting the tire, avoid excessive pressure which can rupture the tire cause serious injury or death.

Dealer Copy -- Not for Resale

B

During inflation of the tire, check the tire pressure frequently to avoid over–inflation.

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

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542B Bobcat Loader Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

The chaincase contains the final drive sprockets and chains. The chaincase is filled with the same type of fluid as the hydraulic system. To check the chaincase oil level, use the following procedure: 1. Put the Bobcat loader on a level surface.

2. Remove the plug at the front of the chaincase [A].

3. If the fluid can be reached with the top of the finger through the hole, the oil level is correct.

Check Plug

4. If the oil level is not correct, add fluid through the check plug hole until the oil flow from the holes.

Install and tighten the plug.

Dealer Copy -- Not for Resale

C–2037

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542B Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER

A

Lubricate the Bobcat loader as specified in the Service Schedule (Page 19) for the best performance [A].

HYDRAULIC RESERVOIR

CHAINCASE

Always use good quality lithium based multipurpose grease when you lubricate the Bobcat loader. Apply lubricant until extra grease shows.

COOLANT

GREASE

TRANSMISSION OIL FILTER

6567875

B

See the Service Schedule (Page 19) for service interval to grease the U–joints.

Raise the operator cab (Page 21).

Use a special U–joint grease (P/N 6599719) to assure correct lubrication of the U–joints [B].

Dealer Copy -- Not for Resale

GREASE

PI–6342

See the Service Schedule (Page 19) for the interval when to grease the steering lever pivot bearings and shaft.

C

Grease the pivot bearings for the steering levers [C].

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B–5197

542B Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

Add oil as needed to the steering control shaft.

B–5730

PIVOT PINS

B

All lift arms and cylinder pivots have a large pin (Item 1) held in position with a retainer bolt and lock nut [B].

1

B–3858

C

PARKING BRAKE PEDAL ADJUSTMENT

1 2

Loosen the lock nut (Item 1) and turn the nut on the linkage rod (Item 2) to adjust the parking brake pedal [C].

There must be 1/4” (6,4 mm) of movement under the bottom edge (heel) of the brake pedal.

B–5181

D

AUXILIARY RETAINER BOLT Auxiliary hydraulics are optional. The tubelines for the auxiliary hydraulics will be provided in the Auxiliary Kit. The retainer bolt (Item 1) is installed at the factory and must be removed to operate the auxiliary hydraulics [D].

1

Raise the operator cab (See Page 21).

Remove the retainer bolt (Item 1) and nut at the right hand steering lever [D].

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Dealer Copy -- Not for Resale

Check that the retainer bolt and lock nut are tighten to 18–20 ft.–lbs. (24–27 Nm) torque.

TROUBLESHOOTING TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 42 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 43

Dealer Copy -- Not for Resale

TROUBLESHOOTING

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542B Bobcat Loader Operation & Maintenance Manual

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 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 manual when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

PROBLEM Engine won’t turn with starter.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

Engine overheats.

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CAUSE

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause of discharge.

–

Cables loose or dirty.

Clean and tighten the battery cables.

31

Damaged starter, solenoid or wiring.

Check the starting circuit.

Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

9

Ignition system is damaged.

Check & repair as needed

D/S

Choke control is pulled out.

Push choke control in.

2

Auxiliary control lever or lift is in ’’detent’’.

Take out of ”detent” position.

–

No fuel in tank.

Add fuel to the tank.

26

Vent in fuel cap is plugged.

Clean the vent.

D/S

Dirt or water in fuel system.

Clean & repair fuel system as needed.

D/S

Fuel filter is dirty.

Install a new filter.

25

Hole in fuel line.

Repair as needed.

–

Weak battery.

Charge or replace battery

–

Wrong oil in engine.

See Oil Specifications.

31

Cylinder compression is low.

Recondition the engine.

D/S

Engine has overheated.

Check Cooling System.

27

Poor fuel quality.

Use fresh, good quality fuel.

25

Restricted exhaust.

Clean exhaust system.

36

Dirt, water or air in fuel system

Clean and repair as needed.

D/S

Engine is hot.

See “Engine Overheats”.

–

Dirty air cleaner.

Install new filter element.

24

Cylinder compression is low.

Recondition the engine.

D/S

Restriction in cooling air flow.

Check for debris on radiator grill.

27

Blower shroud damaged.

Check shroud & repair or replace as needed.

D/S

Egnine is overloaded.

Run at full throttle.

–

–41–

Dealer Copy -- Not for Resale

W–2003–1289

542B Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE DRIVE SYSTEM CAUSE

No drive on both sides.

Hydraulic fluid is low.

Check oil level. Add as needed.

34

Damaged hydraulic pump.

Check condition of pump and replace as needed.

D/S

Hydrostatic system is damaged.

Check hydrostatic system.

D/S

Control linkage is disconnected.

Repair linkage.

D/S

Hydrostatic system is damaged.

Check hydrostatic system and make repair as needed.

D/S

Wrong tire pressure.

Check all tires for correct pressure.

37

Steering linkage interference.

Check steering linkage and adjust as needed.

D/S

Damaged hydrostatic system.

Check system. Repair as needed.

D/S

Loader moves when levers are in neutral.

Steering linkage out of adjustment.

Adjust steering linkage.

D/S

System is overheating.

Hydraulic oil level is low.

Check oil level and add as needed.

34

Clean cooling system. Check for debris on radiator grill.

27

Check by–pass valve.

D/S

Auxiliary control in detent.

Take out of detent.

–

Loader is overloaded.

Use correct size attachment.

D/S

Hydrostatic transmission damage.

Check system and make repair.

D/S

Out of adjustment.

Adjust parking brake.

40

No drive on one side.

Machine pulls to one side.

Cooling system restricted.

is

Low charge (transmission light on).

Parking brake will not hold.

CORRECTION

dirty.

Air

pressure

PAGE

D/S = Dealer Service Only

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PROBLEM

PROBLEM

CORRECTION

PAGE

No hydraulic oil.

Check oil level and add as needed.

34

Control pedals are disconnected.

Check linkage. Repair as needed.

D/S

Relief valve is damaged.

Replace the relief valve.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Hydraulic oil is too thick.

Let engine & hydrostatic system warm up.

10

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

34

Hydraulic action is slow.

Pedal is hitting floor or debris under pedal.

Check adjustment. Remove dirt from under pedals.

–

Cylinders leak internally.

Check condition of cylinders and repair as needed.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Control valve is damaged.

Check the control valve and repair as needed.

D/S

Hydraulic oil is too thick.

Let engine & hydrostatic system warm up.

10

Damage to cylinder rods or seals.

Repair the cylinders.

D/S

No hydraulic action.

Hydraulic cylinders leak oil.

CAUSE

D/S = Dealer Service Only

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TROUBLESHOOTING THE HYDRAULIC SYSTEM

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SAFETY SIGNS DANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 WARNING 6575854 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 WARNING 6575855 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 WARNIING 6565980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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SAFETY SIGNS

SAFETY SIGNS (Decals) Safety signs (decals) are an essential part of the loader (See Pages v & vi). This section provides French, German and Spanish translations of the safety signs that are in English. The Operator’s Handbook is also available in a combination English, French, German and Spanish edition.

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LOADER SPECIFICATIONS CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 OPERATION & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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SPECIFICATIONS

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LOADER SPECIFICATIONS

• Dimensions are given for loader equipped with standard tires and dirt bucket.

PI–6409

This loader was designed without counterweights or ballasts. 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.

542B

OPERATIONS & PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . .

Rated Operating Capacity . . . . . . . . . . . .

Tipping Load . . . . . . . . . . . . . . . . . . . . . . .

3380 lbs. (1535 kg) 800 lbs. (363 kg) 1600 lbs. (726 kg)

Travel Speed . . . . . . . . . . . . . . . . . . . . . . .

Infinitely variable 0–5.6 MPH (8,9 km/hr.)

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Function . . . . . . . . . . . . . . . . . . . .

Engine Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Direction & speed controlled by two hand levers.

Lift & Tilt Function: Controlled by separate foot pedals.

Auxiliary function (Opt.) controlled by the right steering lever.

Hand lever throttle; pull cable choke; key–type starter switch; Hydrostatic Mechanical disc, foot operated pedal

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ford VSG–411 DIS Gasoline 25 HP (18,6 kW) 3800 RPM 51 ft.–lbs. (69 Nm) @ 1600 RPM Four 2.70/2.97(68,6/75,4) 67.1 cu. in. (1100 cm3 ) Liquid Pressure System W/Filter External Dry replaceable paper cartridge Solid State Breaker–less 3150–3250 RPM 750–850 RPM

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Dimensions may vary with other types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

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

542B Bobcat Loader Operation & Maintenance Manual

542B

LOADER SPECIFICATIONS (Cont’d) HYDRAULIC SYSTEM Hydraulic Pump . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . .

System Main Relief . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine driven gear type 8.0 GPM (30,3 L/min.) @ 3200 RPM 1575 PSI (10860 kPa) Full flow, replaceable 10 micron papaer in return line

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . .

Doubleacting

Bore Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Rod Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Stroke: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

2.00 (51) 3.00 (76,2) 1.25 (32) 1.50 (32)

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

3–spool, open center type, W/float detent on lift, detent on auxiliary SAE standard tubes, hoses & fittings

Hydraulic Function Time: Raise Lift Arms to Maximum Height . . . .

Lower Lift Arms from Maximum Height .

Move Bucket to Dump Position . . . . . . . .

Move Bucket to Retracted Position . . . .

5.1 Seconds 3.5 Seconds 2.5 Seconds 1.9 Seconds

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bobcat Fluid (P/N 6563328). If fluid is not available use 10W–30 or 10W–40 Class SE Motor Oil for temperatures above 0_F (–18_C) & 5W–30 for temperatures below 0_F (–18_C)

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt drive, 55 amps. Open 12 volt, 425 cold crank amps. @ 0°F (18°C) 75 min. reserve capacity 12 volt

DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . .

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Tandem hydro. pumps driving 2 fully reversing hydro. motors #80 HS roller chain & sprockets in sealed chaincase with oil lubrication

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil W/Filter . . . . . . . . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . .

Chaincase Reservoir . . . . . . . . . . . . . . . .

11 qts. (10,4 L) 13 gals. (49 L) 4 qts. (3,8 L) 6 gals. (23 L) (Includes 3.5 gals (13,2 L0 in reservoir) 8 gals. (30,3 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . .

7:00 x 15,6 Ply Rating 45–50 PSI (310–345 kPa) 10 x 16.5, 6 Ply Rating 30–35 PSI (207–241 kPa)

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