ELECTRICAL SYSTEM

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.

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

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.

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]

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

ELECTRICAL SYSTEM (Cont’d)

Battery Removal and Installation

Open the rear door.

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

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

Remove the holddown clamp [C].

Remove the battery from the loader.

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

HYDRAULIC/HYDROSTATIC SYSTEM 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:

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].

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

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

Replace the filler cap.

Hydraulic/Hydrostatic Filter Replacement

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.

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

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]

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.

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

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

Spark Arrestor Muffler

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.

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

I–2022–1285

Stop the engine. Open the rear door.

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

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

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.

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.

Tire Maintenance

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).

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

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.

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

FINAL DRIVE TRANSMISSION (CHAINCASE)

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.

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.

Lubrication Of The Bobcat Loader

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

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

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]

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

Grease the pivot bearings for the steering levers [C]

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

Add oil as needed to the steering control shaft.

Pivot Pins

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

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

Parking Brake Pedal Adjustment

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.

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]

Raise the operator cab (See Page 21).

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

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. W–2003–1289

Problem Correction Cause Page

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

Cables loose or dirty. Clean and tighten the battery31 cables.

Damaged

Cylinder compression low.Recondition the

Engine overheats. Restriction in cooling air flow.Check for debris on radiator grill.27

Blower shroud damaged.Check shroud & repair or replaceD/S as needed.

Egnine is overloaded. Run at full throttle. –

Troubleshooting The Drive System

Problem Correction Cause Page

No drive on both sides. No drive on one side.

Hydraulic fluid is low.

Damaged hydraulic pump.

Hydrostatic system is damaged. Control linkage is disconnected.

Hydrostatic system is damaged.

Check oil level. Add as needed.

Check condition of pump and replace as needed.

Check hydrostatic system.

Repair linkage.

Check hydrostatic system and make repair as needed.

Machine pulls to one side.

Wrong tire pressure.

Steering linkage interference.

Damaged hydrostatic system.

Check all tires for correct pressure.

Check steering linkage and adjust as needed.

Check system. Repair as needed.

Loader moves when levers are in neutral.

System is overheating.

Steering linkage out of adjustment.

Hydraulic oil level is low.

Cooling system is dirty. Air restricted.

Low charge pressure (transmission light on).

Auxiliary control in detent.

Loader is overloaded.

Adjust steering linkage.

Check oil level and add as needed.

Clean cooling system. Check for debris on radiator grill.

Check by–pass valve.

Take out of detent.

Use correct size attachment.

Parking brake will not hold.

D/S = Dealer Service Only

Hydrostatic transmission damage. Out of adjustment.

Check system and make repair.

Adjust parking brake.

Troubleshooting The Hydraulic System

No hydraulic action.

No hydraulic oil.

Control pedals are disconnected.

Relief valve is damaged.

Hydraulic pump is damaged.

Hydraulic oil is too thick.

Check oil level and add as needed.

Check linkage. Repair as needed.

Replace the relief valve.

Check pump. Replace as needed.

Let engine & hydrostatic system warm up.

Hydraulic action is rough.

Hydraulic action is slow.

Hydraulic fluid level is low.

Pedal is hitting floor or debris under pedal.

Cylinders leak internally.

Hydraulic pump is damaged.

Control valve is damaged.

Check fluid level and add as needed.

Check adjustment. Remove dirt from under pedals.

Check condition of cylinders and repair as needed.

Check pump. Replace as needed.

Check the control valve and repair as needed.

Hydraulic cylinders leak oil.

D/S = Dealer Service Only

Hydraulic oil is too thick. Damage to cylinder rods or seals.

Let engine & hydrostatic system warm up.

Repair the cylinders.