Bobcat 553 Loader Operation & Maintenance Manual 6900385 - PDF DOWNLOAD

S/N 516311001 & Above Europe Only – S/N 516411001 & Above

Dealer Copy -- Not for Resale

Operation & Maintenance Manual

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

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) 1 of 96

6900385 (7–98) Revised (5-12)

Printed in U.S.A.

© Melroe Company 1998

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

Untrained operators can cause injury or death.

W–2001–1285

CORRECT

CORRECT

B–10731

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

WRONG

B–7403

B–6582

B–13418

Always use the seat bar and fasten seat belt snugly.

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

Never use loader without operator cab with ROPS and FOPS approval.

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.

Never modify equipment.

Use only attachments approved

by Melroe Company for this model loader.

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

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

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

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

4. HANDBOOK: Must be in the cab.

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

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) OSW03–0698 2 of 96

Dealer Copy -- Not for Resale

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

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

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

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

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

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

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

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 ....

SAFETY

OPERATING INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

PREVENTIVE MAINTENANCE

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

Loader Serial Number . . . . . . .

Engine Serial Number . . . . . . .

.

SYSTEMS ANALYSIS

Dealer Copy -- Not for Resale

REFERENCE INFORMATION

MACHINE SIGN TRANSLATIONS

SPECIFICATIONS

NOTES:

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

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

British Standards Institute (BSI) is the Certified Registrar Melroe chose to assess theCompany’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Melroe manufacturing plants and the Melroe corporate offices (Gwinner, Bismarck & Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations. Since registration requires this third–party auditing, it is irrefutable evidence of conformance.

Continued certification is subject to periodic audits.

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

Dealer Copy -- Not for Resale

What does ISO 9001 mean to Bobcat Customers? It means that Melroe Company produces your Bobcat loader, Excavator or Spra–Coupe, and attachments with strict attention to details, using the latest technology and proven techniques.

REGULAR MAINTENANCE ITEMS

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6657635

ENGINE OIL FILTER (6 Pack)

6667352

FUEL FILTER

6672467

AIR CLEANER, OUTER

6672468

AIR CLEANER, INNER

6666606

RADIATOR CAP

6661248

HYDROSTATIC FILTER

6669318

BATTERY

6724094

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

6724354

PROPYLENE GLYCOL ANTI–FREEZE, Concentrate

6563328

BLACK GOLD Hydraulic/Hydrostatic Fluid – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Qt.

6657301

MOTOR OIL 10W30 CE/SG – 1 Qt.

6657303

MOTOR OIL 30 CE/SG – 1 Qt.

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FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat loader . READ AND UNDERSTAND THIS OPERA TION & MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer.

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

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

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

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OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii. .

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SERIAL NUMBER LOCATIONS

A

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

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a dif ferent procedure in doing a specific service operation.

1

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the operator cab, near the right hand steering lever (Item 1) [A].

P–10725

Explanation of loader Serial Number: XXXX

XXXXX

B

Production Sequence (Series) Model, Engine Version

The serial number (Item 1) [B] is located below the exhaust manifold near the front of the engine.

1

N–09931

Dealer Copy -- Not for Resale

ENGINE SERIAL NUMBER

C

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. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

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BOBCAT SKID STEER LOADER IDENTIFICATION SEAT BAR OPERATOR CAB (ROPS & FOPS)

UPRIGHTS GRILL

LIFT ARM LIFT CYLINDER ◊ REAR LIGHTS

◊ FRONT LIGHTS

Dealer Copy -- Not for Resale

REAR DOOR * TIRES

OPERATOR SEAT

GRAB HANDLES STEERING LEVER SEAT BELT TILT CYLINDER

◊ QUICK

COUPLERS

BUCKET BUCKET STEPS

SAFETY TREAD B–15064 B–15065

◊ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) * TIRES – The 553 Bobcat loader is base–equipped with flotation tires as shown.

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

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

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OPTIONS AND ACCESSORIES Model 553 Bobcat loaders are equipped with the following standard items: Tires, 27 x 8.5–15 4PR (Machine Width – 48 inches) Bob–Tach Spark Arrestor Muffler Lift Arm Support Device Operator Cab (with ROPS & FOPS Approval) Bobcat Interlock Control System (BICS™) Seat Belt Seat Bar Parking Brake Gauges/Warning Lights Adjustable Cushion Seat Rocker Switch Activated Glow Plugs Below is a list of some equipment available as a Factory Installed Option or as a Field Installed Accessory from your Bobcat Loader dealer. See your Bobcat dealer for other available accessories and attachments.

Tires 27 x 8.5 – 15 Bobcat Heavy Duty 6PR (Machine Width 48 inches) . . . . . . . .

Instrumentation Keyless Start System . . . . . . . . . . . . . . .

Opt. & FA

FA

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

Hydraulic Bucket Positioning w/ On/Off Switch . . . . . . . . . . . .

Sound Cab (Reduces Noise at Operator’s Ear) . . . . . . . . . . . . . . . . . . Opt. Deluxe Cab . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA Operating Lights (Front & Rear) . . . . . . Opt. & FA Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA Back–up Alarm . . . . . . . . . . . . . . . . . . . . . Opt. & FA Top Window . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA Rear Window . . . . . . . . . . . . . . . . . . . . . . Opt. & FA Cab Enclosure and Heater . . . . . . . . . . . Opt. & FA Vinyl Cab Enclosure . . . . . . . . . . . . . . . . FA Cover Kit (Hydraulic Reservoir Area) . .

FA Fire Extinguisher . . . . . . . . . . . . . . . . . . . FA Flasher Lights . . . . . . . . . . . . . . . . . . . . . . FA Strobe or Rotating Beacon Light . . . . . .

FA 3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . FA Special Applications Kit* . . . . . . . . . . . . . FA Suspension Seat . . . . . . . . . . . . . . . . . . . Opt. & FA Large Operator Seat Bar Kit . . . . . . . . . FA

Opt. & FA Opt. & FA

Other Single Point Lift . . . . . . . . . . . . . . . . . . . . FA Locking Fuel Cap . . . . . . . . . . . . . . . . . . . FA Low Coolant Sensor Kit . . . . . . . . . . . . . FA Rental Kit . . . . . . . . . . . . . . . . . . . . . . . . . FA Insect Screen . . . . . . . . . . . . . . . . . . . . . . FA Rear Wiper . . . . . . . . . . . . . . . . . . . . . . . . FA Fire Extinguisher . . . . . . . . . . . . . . . . . . . FA

Dealer Copy -- Not for Resale

Hydraulics Operator Cab

Opt. = Factory Installed Option FA = Field Accessory N/A = Not Available * Includes 1/2 inch Lexan Front Door; 1/4 inch Lexan T op & Rear Windows

Specifications subject to change without notice

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SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi,. .xii FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii ....

SAFETY

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

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

The dealer explains 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.

• The Operation and 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 can be stored in a container (later models) provided inside the cab. Replacement Operation and Maintenance Manuals can be ordered from your Bobcat loader dealer.

Dealer Copy -- Not for Resale

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

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.

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

• The Skid–Steer Loader Operator Training Course is available through your local Bobcat dealer. This course provides information for safe and efficient operation of the Bobcat loader. The course is available in English and Spanish versions.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

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

If the owner/operator will be using the loader for a different application(s) he must ask the dealer for recommendations on the new use.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a locationin your state/city for information about burried lines (telephone, cable TV, water, sewer, gas,etc.).

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

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 The Bobcat loader must be in good operating condition before use.

B–10731

Check all of the items on the Service Schedule Decal or as shown in this Operation & Maintenance Manual under Daily Inspection.

Warnings on the machine and 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.

SAFE OPERATION NEEDS A QUALIFIED OPERATOR* A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULA TIONS • The written instructions from Melroe Company include the delivery report, Operation & Maintenance Manual and plastic handbook, EMI Safety Manual and machine signs (decals).

• Check the rules and regulations at your location. The rules may include an employer’s work safety requirements.

Regulations may apply to local driving requirements or use of Slow Moving Vehicle emblem. Regulations may identify a hazard such as a utility line.

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

• The new operator must 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 • 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 load, or only part of a bucket load.

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

• Wear tight fitting clothing. Always wear safety glasses whenmaintaining 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 be qualified, he must not use drugs oralcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–0498 14 of 96

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I–2019–0284

W–2044–1285

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 source of arcs or sparks.

Flammable debris (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.

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

• The engine compartment and engine cooling system must be inspected everyday 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.

Dealer Copy -- Not for Resale

• Do not use ether or starting fluids on this engine. It has glow plugs. These startingaids 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 painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

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

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

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

A fire extinguisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown [A].

A

P–10650

SI03–0398 15 of 96

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

AUXILIARY HYDRAULIC CONTROL

6702255 6577754 6708294 6708358

6707255 850

Dealer Copy -- Not for Resale

386

6565990

6705712

6709128 6706809

6557565

6579510

6702301 6702302

6579528

6710358 B–15064

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MACHINE SIGNS (DECALS) (Cont’d)

6561379 6560573

6709055

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6578368

6707786

6707867 6715563

6579511 6707916

Located inside the engine compartment.

B–15065 17 of 96

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

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

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

BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) . . . . . . . . . . . . . . . . . 4.

Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . .

Seat Sensor Override (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ...

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

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ....

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . .

OPERATING INSTRUCTIONS

HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 ...

Auxiliary Hydraulics (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11. .

Bucket Position Valve Operation (If Equipped) . . . . . . . . . . . . . . . . . . . . . 10 ..

Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 .....

Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ....

Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ....

Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ....

Quick Couplers (Flush Fase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ...

Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ...

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

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . . .

Side Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .

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

OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 ...

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

Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ....

2 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 ...

3Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 ....

2Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . . 24 .

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GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 ..

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . .

PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ...

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

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

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

Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 ....

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

STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . .

Forward Travel, Reverse Travel, Normal Turn, Fast Turn . . . . . . . . . . . . . . 7 .

STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, . . 26 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ...

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

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

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INSTRUMENT PANEL

A

Front Panel [A] 1. TRACTION LOCK OVERRIDE BUTTON – Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 5.)

7

10

9

6

11

8

2. SEAT SENSOR OVERRIDE BUTTON (If Equipped) (Functions Only When The Seat Bar Is Down)–Allows operator, when seated with the seat bar lowered, to use lift, tilt, and traction functions if the seat sensor cannot be activated. (See Page 15.)

5 12

4 3

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

1

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

B

5. ENGINE WARNING LIGHT – Low engine oil pressure or high coolant temperature. Stop the engine if the light comes ON.

2

N–17061

P–10667

2 1

7. LIGHT SWITCH (Opt./FA) – Controls the available work and travel lights.

8. BUCKET LEVEL SWITCH (Opt./FA) – Controls the ON/OFF function of the available bucket position valve.

3 P–10742

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

10. FUEL GAUGE – Shows the amount of fuel in the fuel tank.

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

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

Dealer Copy -- Not for Resale

6. PREHEAT BUTTON – For preheating the engine (glow plugs) before starting the engine.

Side Console* [B] 1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer.

2. HAZARD SWITCH/HAZARD INDICATORS (Opt./FA) – Controls the available hazard lights.

(Hazard Lights is a separate available accessory .)

Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, work lights, etc.

3. BEACON OR STROBE SWITCH (Opt./FA) – Controls the available flashing beacon or strobe light.

* Can be installed if you have a Deluxe Cab or a Cab Enclosure installed.

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

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BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) The Bobcat Interlock Control System (BICS ™) requires the operator to be seated in the operating position with the seat bar fully lowered before the lift, tilt and traction functions can be operated. The seat belt must be fastened anytime you operate the loader.

A

1 2 3 4 5

AVOID INJURY OR DEATH P–10157

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

W–2151–0394

The lift, tilt and traction drive functions are interlocked with the seat bar. The lift and tilt functions are interlocked with the seat.

Dealer Copy -- Not for Resale

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

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

The light functions are as follows [A]: 1. SEAT – ON when operator is in the seat.

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

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

4. TRACTION – ON when loader forward or backward.

5. POWER – ON when the correctly.

can be moved

controller is operating

NOTE: If any of the lights are off or blinking, see SYSTEMS ANALYSIS Section, BICS Troubleshooting Chart Page 55 or, see BICS Inspection and Maintenance Instructions Page 35.

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

A

Lift Arm By–Pass Control The lift arm by–pass control knob (Item 1) [A] is used to lower the lift arms if the lift arms can not be lowered during normal operation.

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

1

P–09707

B

Traction Lock Override

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

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

1 N–17061

NOTE: The traction lock override button will unlock the traction drive when the operator is NOT in the seat and the seat bar is raised.

The traction lock override button will function if brake pedal is in the engaged or disengaged position.

Seat Sensor Override (If Equipped)

Dealer Copy -- Not for Resale

(Functions Only When The Seat Bar Is Raised) There is a traction lock override button (Item 1)[B] on the left hand instrument panel which will allow you to use the steering levers to move the loader forward and backward when using the backhoe attachment or for loaderservice.

(Functions Only When The Seat Bar Is Down) Seat Sensor Override button (Item 1)[B] allows operator, when seated with the seat bar lowered, to uselift, tilt, and traction functions if the seat sensor cannot be activated.

If seat indicator light on the BICS Controller does not go on, check for debris, dirt, or objects under or behind seat.

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

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ENGINE SPEED CONTROL

A

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

1

P–10752

PARKING BRAKE

B

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

P–10767

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

C

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

MC–01914

P–10765

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MC–01914

STEERING LEVERS

A 1

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

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595

P–10712

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

B

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

FORWARD

REVERSE

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.

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

LEFT TURN

RIGHT TURN

FAST TURN

FAST TURN

To increase travel speed, push the levers farther forward.

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

Dealer Copy -- Not for Resale

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

STOPPING THE BOBCAT LOADER When the steering levers are moved to NEUTRAL POSITION, the hydrostatic transmission will act as a service brake to stop the loader.

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SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control functions.

1

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 hand controls.

When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION. P–10718

AVOID INJURY OR DEATH

Dealer Copy -- Not for Resale

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

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

• Stop the engine.

• Engage the parking brake.

• Raise the seat bar, move hand controls until both lock.

The seat bar system must lock the lift and tilt controls in neutral when the seat bar is up.

Service the system if hand controls do not lock correctly.

W–2153–0594

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SEAT BAR RESTRAINT SYSTEM (Cont’d)

A

The spring loaded interlocks (Item 1) [A] control the locking and unlocking functions of thefoot pedal controls.

SEAT BAR DOWN 2

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

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

Seat Bar

1 Interlock

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

Pedal Linkage 3

Interlock Shield

MC–01668

AVOID INJURY OR DEATH

B

SEAT BAR RAISED Seat Bar

W–2045–1086

Interlock Interlock Shield

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

W–2105–1285

Dealer Copy -- Not for Resale

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.

MC–01668

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

The foot pedals will not pivot when the interlock is up.

Refer to SEAT BAR RESTRAINT SYSTEM, Inspection & Maintenance Page 34.

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HYDRAULIC CONTROLS

A

Foot Pedals

3

1 2 P–10762

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

W–2002–1285 Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

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

Lift Arm Operation

4

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

1

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

5 P–10762

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

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

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

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

B–07440 B–07441

Bucket Position Valve Operation (If Equipped) The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in before beginning the upward lift cycle.

Bucket positioning functions during the upward lift cycle only.

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

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

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (If Equipped)

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

P–10711

W–2220–0396

B

Locked

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

Install the male half coupler into the female half coupler. Full connection is made when the ball release sleeve slides forward on the female coupler and the sleeve is rotated so that the locking pins (Item 1) [B] and the groove (Item 2) [B] do NOT align (Locked Position). This will prevent accidental disconnection.

1

2

To Release 3 P–10566

NOTE: If the locking pins and grooves (Item 3) [B] are aligned, accidental disconnection is possible.

To Disconnect: Rotate the ball release sleeve so that the grooves are aligned with thepins (Item 3) [B] in the female coupler.

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

Dealer Copy -- Not for Resale

Quick Couplers (Flush Face)

NOTE: Caps and plugs are not used with flush face couplers.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or cardboard or wood to find leaks. Do not use your bare hand.

Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W–2072–0496

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HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics (Cont’d)

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

P–10711

W–2220–0396

The right steering lever (Item 1) [B] is also the control lever for the front auxiliary hydraulics [A].

B–02408

Move the steering lever all the way to the right (Item 2) [B] to put the control valve into the locked position for a constant flow of hydraulic fluid under pressureto the quick couplers.

B–02409

1

NOTE: See PREVENTIVE MAINTENANCE, AUXILIARY CONTROL LOCKBOLT Page 54 to remove auxiliary control lockbolt.

2

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

Relieving Hydraulic Pressure P–10750

Hydraulic pressure in the auxiliary hydraulic system can make it difficult to connect ot the quick couplers.

To make connecting and disconnecting attachments easier, the hydraulic pressure can be relieved.

With the engine stopped and attachment flat on the ground, move the right steering lever to the leftand to the right several times.

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B

Move the right steering lever to the left or to the right to activate the auxiliary hydraulics and operate an attachment (Example: To open or close grapple teeth).

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

DAILY INSPECTION

A

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

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule [B] is a guide to correct maintenance of the Bobcat loader. It is located inside the rear door of the loader and also in the MACHINE SIGN TRANSLATION Section Page 61.

Check the following items before starting each day:

• • • • • •

Engine Oil Level Hydraulic/Hydrostatic Fluid Level Engine Air Filter, Air System for Damage or Leaks Engine Coolant Level, System for Damage or Leaks Operator Cab, Seat Belt, Seat Bar & Pedal Interlocks Grease Pivot Pins (Lift Arms, Bob–Tach, Cylinders, Bob–Tach Wedges Tires for Wear or Damage and Correct Air Pressure Fuel Filter, Remove Trapped Water Loose or Broken Parts Safety Treads and Safety Signs (Decals) Bobcat Interlock Control System (BICS™) Lift Arm Support Device

B–06583

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

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

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

W–2003–0797

B

Dealer Copy -- Not for Resale

• • • • • •

6715563

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GETTING READY FOR OPERATION

A

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

1

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

P–10159

W–2001–1285

The Operation & Maintenance Manual and other manuals can be kept in a box provided at the right hand side of the operator seat (Item 2) [A].

B

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

Dealer Copy -- Not for Resale

Safety treads are installed on the Bobcatloader to provide a slip resistant surface for getting on and of f the loader.

Keep safety treads clean and replace when damaged.

Replacement treads are available from your Bobcat loader dealer.

P–10721

C

Pull the seat lever (Item 1)[C] and adjust the seat position for comfortable operation of the loader controls.

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GETTING READY FOR OPERATION (Cont’d) Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [A].

A

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.

P–10720

W–2046–0595

B

Lower the seat bar [B].

All controls must be in the NEUTRAL POSITION before you start the engine. (See STARTING THE ENGINE below.)

P–10716

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

C

Dealer Copy -- Not for Resale

Be sure the parking brake is engaged.

STARTING THE ENGINE P–10718

D

WRONG

WRONG

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

W–2050–1285

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

• Do not use machines in atmosphere containing explosive gas.

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STARTING THE ENGINE (Cont’d)

A

Normal Starting 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].

P–10716

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

B

NEUTRAL POSITION

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

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

Dealer Copy -- Not for Resale

1

Turn the key to ST ART POSITION (Item 4) [B] and release it when the engine starts.

1/2 SPEED

2

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

ON POSITION

I–2034–0284

When the engine starts, release the key and it will return to the RUN POSITION (Item 5) [B].

STOP THE ENGINE IF THE NOT GO OFF.

3

WARNING LIGHTS DO

START POSITION

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

4 RUN POSITION

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STARTING THE ENGINE (Cont’d)

A

1

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

W–2071–1285

Cold Temperature Starting Also see Normal Starting. Turn the key switch to the RUN POSITION.

P–10473

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

B

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

If the temperature is below 32°F (0°C), use the following procedure to make starting the engine easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See ENGINE LUBRICATION SYSTEM, Oil Chart Page 40.)

6705712

• Make sure the battery is fully charged.

• Install an engine heater, available from your Bobcat loader dealer.

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.

Dealer Copy -- Not for Resale

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

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

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

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ATTACHMENTS AND BUCKETS

A

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 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.

2. Tires may wear faster.

3. There will be a loss of stability.

B

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

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.

190 (420)

of 215 (475)

Use the correct size bucket for the type and density material being handled.

WEIGHT OF LOADS LBS. (KG)

Partial loads make steering more difficult.

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

See your Bobcat loader dealer for more information about pallet forks and other available attachments.

15.75 (400)

24.00 (610)

CENTER OF LOAD LOCATION Inches (mm) 6712931 6712932 36 of 96

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B–06587

The rated operating capacity for this loader is shown on a label in the operator cab. (SeeSPECIFICATIONS Page 69.)

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installing The Bucket Or Attachment The loader is equipped with the Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operation & Maintenance Manual to install other attachments.

1

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

N–17035

W–2054–1285

B

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

Enter the loader. the

Release the parking brake.

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

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

Be sure the Bob–Tach levers do not hit the bucket.

N–17036

C

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

Stop the engine and exit the loader.

1

Dealer Copy -- Not for Resale

Fasten the seat belt, lower the seat bar and start engine.

N–17032

AVOID INJURY OR DEATH Before you leave the operator’s seat:

N–17031

• 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–T ach levers until they are fully engaged in the locked position [C].

The levers will contact the frame as shown (Item 1) [C] when locked.

If the levers do not engage in the locked position, see your Bobcat loader dealer for maintenance.

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ATTACHMENTS AND BUCKETS (Cont’d)

A

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

1

N–17033

B 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.

1 N–17034

Removing The Bucket Or Attachment Put the attachment flat on the ground and lower or close the hydraulic equipment. If the attachment is hydraulically controlled (ie: combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure in the auxiliary circuit (See Relieving Hydraulic Pressure, Page 12).

C

Raise the seat bar, unfasten the seat belt, set theparking brake and exit the loader.

Pull the Bob–Tach levers [C] all the way up.

Disconnect the hydraulic hoses, if necessary.

Enter the loader.

Fasten the seat belt, lower the seat bar and start engine

N–17030

the

D

Release the parking brake.

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

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

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W–2102–0588

OPERATING PROCEDURES

A

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

WITH BUCKET FULL

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

Going Up Slope

B–06612

Loaders warmed up with moderate engine speed and light load have longest life.

B

I–2015–0284

WITH BUCKET FULL

Operate the loader with the engine at full speed for maximum horsepower.

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

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

Going Down Slope

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

C

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

• 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.

WITH BUCKET EMPTY

Going Down Slope

D

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

B–06612

Dealer Copy -- Not for Resale

Move the steering levers only a small amount to operate the loader slowly.

B–06611

WITH BUCKET EMPTY

W–2018–1187

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

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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].

P–10762

B–06719

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

P–10762

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–06718

C

Emptying The Bucket Push down on the bottom 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 pedal until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

P–10762

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

W–2057–1285

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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 of the tilt pedal until the cutting edge of the bucket is on the ground.

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

P–10762

B–06720

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

B Dealer Copy -- Not for Resale

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.

P–10762

B–06721

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

C

P–10762

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553 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 forwarduntil the pedal is in the locked position to put the lift arms in float position [A].

P–10762

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

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

B–06722

I–2005–1285

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

Backfilling P–10762

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

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

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

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

B–06724

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Dealer Copy -- Not for Resale

B

Drive backward to level loose material.

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

A

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

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

AVOID INJURY OR DEATH 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.

SUPPORT

P–10732

B

W–2045–1086

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

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

P–10731

TRANSPORTING THE BOBCAT LOADER

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.

Dealer Copy -- Not for Resale

Both Sides

Engage the parking brake.

W–2058–0494

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

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

P–10730

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

• Lower the bucket or attachment to the floor.

• Stop the engine.

P–10726

• Engage the parking brake.

• Install chains at the front and rear of the loader as shown [B].

P–10728

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553 Bobcat Loader Operation & Maintenance Manual

LIFTING THE LOADER

A

553BICSOperation&MaintenanceManual#6900385S/N516311001&Above–OperatingInstructionsSection

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–2007–1285

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) [A] in the kit as shown in figure.

The single point lift, supplied by Melroe Company is designed to safely lift and support the Bobcat loader.

TOWING THE LOADER

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

I–2001–1285

B–07489

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

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

Relief valve release tool set MEL1220 is available from your dealer. Tool must be installed before towing.

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

Clean the area around the hydrostatic pumps.

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.

Remove the high pressure relief valve from one side of each hydrostatic pump [B] and install the relief valve tubes. Install the plugs and tighten.

I–2017–0389

Lower the operator cab. (SeeLowering The Operator Cab Page 32.)

The towing chain (or cable) must be rated at 1 and 1/2 times the weight of the loader. (See SPECIFICATIONS Page 69.)

B

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

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

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

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

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Dealer Copy -- Not for Resale

1

PREVENTIVE MAINTENANCE

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PREVENTIVE MAINTENANCE

Dealer Copy -- Not for Resale

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 ...

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

AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 ...

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . 35 .

Inspecting The BICS™ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ...

Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . .35 ..

Inspecting The Seat And Seat Bar Sensors . . . . . . . . . . . . . . . . . . . . . . . . 35 ..

Inspecting The Traction Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ....

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 .....

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 ...

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

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

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ...

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

Removing And Installing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 ..

Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . .45 ..

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ...

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ...

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ...

Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ....

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ...

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ....

Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 .....

Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ....

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . 50 ..

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ...

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ....

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ....

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 .....

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ....

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 ..

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

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

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

Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ...

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

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

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

LUBRICATING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 ..

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

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 ....

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 ...

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

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 .....

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 .....

Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ....

REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 .....

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ...

Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 ...

Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 ...

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

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

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

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ....

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

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

U–JOINT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 ....

553 Bobcat Loader Operation & Maintenance Manual

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

W–2003–0797 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 with lift arms down.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–3724

B–6593

Have good ventilation when welding or grinding painted parts.

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

Vent exhaust to outside when engine must be run for service.

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

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 Melroe 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.

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

W–2003–0797

Engine Oil Engine Air Filter and Air System Engine Cooling System Tires Seat Belt and Seat Bar and Control Interlocks Safety Signs and Safety Tread Indicator & Lights (Opt.) Operator Cab Lift Arm and Bob–Tach Pivot Pin and Wedges Engine Fuel Filter Bobcat Interlock Control System (BICSTM) Hyd. Fluid, Hoses & Tubelines Control Pedals & Steering Wheel Nuts Parking Brake Alternator Belt Final Drive Trans.

(Chaincase) Spark Arrestor Muffler Battery Engine Oil & Filter Fuel Filter Steering Lever Pivots U Joint Hyd./Hydros Filter Hyd Reservoir Breather Cap Hyd./Hydro. Reservoir Chaincase Bobcat Interlock Control System (BICS™)

SERVICE REQUIRED

8–10 50 100 200 250 500 1000

Check the oil level and add oil as needed.

Replace the outer filter element only when the red ring shows in the indicator window. Check for leaks and damaged components.

Clean debris from oil cooler, radiator & grill. Check coolant level in 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 inter– locks for correct operation. Clean dirt & debris from moving parts.

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

Check for correct operation of all indicators & lights.

Check the fastening bolts, washers & nuts. Check the conditionof cab.

Lubricate with multi–purpose lithium based grease.

Remove the trapped water.

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

Check fluid level & add as needed. Check for damage & leaks.

Repair & replace as needed.

Check for correct operation. Repair or adjust as needed.

Check for loose wheel nuts & tighten to 105–115 ft.–lbs.

(142–156Nm) torque.

Check operation of the brake.

Check tension & adjust as needed.

Check fluid level and add as needed.

Dealer Copy -- Not for Resale

ITEM

Clean the spark chamber.

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

Replace oil & filter. Use CD or better grade oil and Melroe filter.

Replace filter element.

Grease two fittings. Add oil to steering shaft.

Grease three (3) fittings with correct grease.

Replace the filter element.

Replace the reservoir breather cap.

Replace the hydraulic/hydrostatic fluid.

Replace the fluid.

Check the lift arm by–pass control

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

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

Or every 12 months.

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553 Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

A 1 2

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 P–09773

Engaging The Lift Arm Support Device Maintenance and service work can be done with the lift arms lowered. If the lift arms are raised for service, use the following procedure:

P–10706

B 1

Put jackstands under the rear corners of the loader frame.

Disconnect the spring from the lift arm support device retaining pin (Item 1) [A]. Hold onto the lift arm support device (Item 2) [A] and remove the retaining pin.

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

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

P–10703

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

C

Raise the lift arms, until the lift arm support device drops onto the lift cylinder rod (Item 1) [C].

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

Raise the seat bar and move foot pedals (or hand controls) until both lock.

P–10707

1

P–10708

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

W–2271–1197

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Remove any attachment before raising the lift arms.

LIFT ARM SUPPORT DEVICE (Cont’d)

A

Engaging The Lift Arm Support Device (Cont’d) Install pin (Item 1) [A] into the rear of the lift arm support device below the cylinder rod.

1

P–10701

B

Disengaging The Lift Arm Support Device Remove the pin from the lift arm support device.

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

1

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

Lower the lift arms and stop the engine.

Raise the seat bar and move pedals until both lock.

P–10702

Disconnect the spring from the bracket.

C

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

Connect spring to pin.

Dealer Copy -- Not for Resale

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

1

P–10706

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553 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB

A

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged.

ROPS/FOPS – Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available.

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

Level II – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

P–10724

P–10723

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

Raising The Operator Cab P–09773

Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See LIFT ARM SUPPORT DEVICE Page 30.)

P–10719

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

Loosen the nut (both sides) at the corner of the operator cab [A].

Remove the nut and plate (both sides) [A].

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 may allow the machine to tip backward causing injury or death.

Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [B].

Lowering The Operator Cab

W–2014–1285

Pull down on the bottom of the operator cab until it stops at the latching mechanism.

Release the latching mechanism [C] and pull the cab all the way down.

C

Install the plate and nut (both sides) [A].

Tighten the nuts [A] to 40–50 ft.–lbs. (54–68 Nm) torque.

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

W–2005–1089

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P–10713

553 Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

OPERATOR CAB (Cont’d)

A

Emergency Exits The front opening on the operator cab and rear window provide exits.

Rear Window: (If Equipped) • Pull on the tag on the top of the rear window to remove the rubber cord [A].

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

P–00660

P–10722

Front Door: (If Equipped)

C

NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [C] Pull the plastic loop at the top of the window in the front door to remove the rubber cord [C].

Dealer Copy -- Not for Resale

B

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

P–09216

Push the window out with your foot [D].

D

Exit through the front door.

P–09217

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553 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system hasa pivoting seat bar with arm rests and has spring loaded interlocks forthe lift and tilt foot 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.

Clean (Both Sides)

The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls.

When the seat bar is up, the lift and tilt pedals are locked when returned to the NEUTRAL POSITION. P–10361

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

Dealer Copy -- Not for Resale

W–2105–1285

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

Clean (Both Sides)

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.

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

Pull the seat bar down. Lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise theseat bar and the lift arms should stop.

Lower the seat bar , 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.

P–10717

Maintaining The Seat Bar See the SERVICE SCHEDULE Page 29 and on the loader for correct service interval.

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

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

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

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BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

A

Inspecting The BICS™ Controller (Engine STOPPED – Key ON)

1 2

1. Sit in the operator’s seat. Turn key ON, lower the seat bar and disengage the parking brake. All five BICS Controller lights should be ON (Items 1, 2, 3, 4 & 5) [A].

2. Engage the parking brake and raise the seat bar fully. Seat bar light (Item 2) [A], valve light (Item 3) [A] and traction light (Item 4) [A] should be OFF. 3. Raise up slightly off the seat. Seat light (Item 1) [A] should be OFF.

3 4 5

NOTE: Record what lights are blinking (if any) and number of blinks. Refer to Page 60.

P–10157

4. Exit the loader and press traction lock override button. Traction light (Item 4) [A] should be ON. Press override button again and traction light (Item 4) [A] should be OFF.

B

Clean area behind and under seat.

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

Engage the parking brake. Fasten the seat belt.

6. Start the engine and operate at low idle. While raising the lift arms, raise the seat bar fully. The lift arms should stop. Repeat using the tilt function.

Inspecting The Traction Lock (Engine RUNNING) 7. Fasten the seat belt, disengage the parking brake, and raise the seat bar fully. Move the steering levers slowly forward and backward. The traction lock should be engaged. Lower the seat bar.

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

P–10712

Operator Seat

C

Inspecting The Lift Arm By–Pass Control Seat Sensor

9. Raise the lift arms six feet (2 m) of f the ground. Stop the engine. Pull and hold theby–pass control knob.

Push the top (toe) of the left (lift) pedal. the lift arms will slowly lower.

Seat 1 Spring

Dealer Copy -- Not for Resale

Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)

Seat Rail Cover

Maintenance Clean any debris, dirt or objects from under or behind the operator seat [B] & [C]. The rear of the seat must move up and down.

MC–02043

Inspect both Seat Rail Covers [C] for wear or damage.

Replace if necessary.

Clearance is necessary under the seat spring (Item 1)[C] and the seat, to allow the seat to move up and down freely.

With adequate clearance, the seat sensor will be allowed to function correctly.

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

Inspect seat bar pivot area for tightness of linkage bolts.

Replace parts that are damaged. Use only genuine Bobcat replacement parts.

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REAR DOOR

A

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

P–10671

W–2012–0290

P–10672

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

W–2020–1285

Put your fingers into the slot in the rear door and pull on the latch handle [A].

Pull the rear door open.

Close the rear door before operating the loader.

P–10670

Adjusting The Latch

B

The door latch catch (Item 1) [B] can be adjusted side to side and up/down for alignment with the door latch mechanism.

The door latch mechanism (Item 2) [B] can be adjusted backward or forward for alignment with the door catch.

2

Close the rear door before operating the loader.

1 P–10735

P–10669

C

REAR GRILL To remove the rear grill, remove the four grill mounting bolts (Item 1) [C].

Lift the rear grill up and remove from the loader.

1

1 P–10747

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Push the door stop up into the top hinge before closing the rear door [A].

AIR CLEANER SERVICE

A

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

1

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.

P–10749

Replace the large (outer) filter element only when the red ring shows in the window (Item 1) [A] of the condition indicator.

NOTE: Push the button on the condition indicator (See Inset) and start the engine. If the red ring does not show, do not replace the filter element [A].

P–10747

B

1

2 P–10733

Outer Element: Pull the outer filter element from the air cleaner housing [C].

C

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Install a new outer element.

Dealer Copy -- Not for Resale

Disengage the clamps (Item 1) and remove the dust cover (Item 2) [B].

Install the dust cover and fasten the clamps.

Inner Element: Only replace the inner filter element under the following conditions: P–10734

• Replace the inner filter element every third time the outer filter is replaced.

D

• Replace the inner filter element when the red ring still shows in the condition indicator window after the outer filter is replaced.

Pull the inner filter element from the air cleaner housing [D].

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Install the new inner element.

Record the operating hours of the loader on the decal inside the rear door.

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FUEL SYSTEM

A

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

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

No. 2 100% 50% 0%

No. 1 0% 50% 100%

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

P–10710

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.

Stop and cool the engine before adding fuel.

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

W–2063–0887

W–2103–1285

Remove the fuel fill cap [A].

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

B

Install and tighten the fuel fill cap [A].

1

Fuel Filter See the SERVICE SCHEDULE Page 29 for the service interval when to remove the water from the fuel filter and to replace the fuel filter.

Remove Water: Shut–off the fuel supply (Item 1) [B] (turn clockwise).

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

P–10714

Open the shut–off valve [B].

C

Replacing Filter: Clean the area around the fuel filter.

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

2

Remove the fuel filter element (Item 2) [C].

Install the new filter element.

1

Tighten the fuel filter.

Open the shut–off valve [B].

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Filling The Fuel Tank

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System

3

After replacing the fuel filter element or when the fuel tank has run out of fuel, the air mustbe removed from the fuel system before starting the engine.

Be sure the engine is cool.

Open the rear door.

Open the vent plug (Item 1) [A] on top of the fuel filter head.

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

P–10679

Tighten the vent plug.

Operate the hand pump (Item 1) [A] until it feels solid.

Move the engine speed control to minimum RPM. Open the valve (Item 3)[A] and squeeze thehand pump several times.

Start the engine.

Dealer Copy -- Not for Resale

When the engine runs smoothly, close the valve (Item 3) [A].

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

Close the rear door.

P–10675

1

2

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ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil

1

Check the engine oil level every day before starting the engine for the work shift.

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

Keep the oil level between the marks on the dipstick.

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

Install the dipstick and close the rear door.

P–13624

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

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

+43 +49

SAE 40W or 20W–50 SAE 10W–30

SAE 30W

* SAE 5W–30 SAE 20W–20 SAE 10W

P–10689

SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

B

+90 +100 +110 +120

F°

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

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

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

Run the engine until it is at operating temperature.

Stop the engine.

Open the rear door.

2

Remove the cap from the end of the hose and drain the oil into a container (Item 1) [B]. Dispose of used oil in an environmentally safe manner.

Remove the filter (Item 2) [B].

Clean the filter housing surface.

Put clean oil on the gasket of the new filter . Install the filter and hand tighten.

Install the cap on the drain hose.

1 P–10689

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SAE 15W–40

ENGINE LUBRICATION SYSTEM (Cont’d)

A

Replacing Oil And Filter (Cont’d) Remove the oil filler cap (Item 1) [A].

Use a good quality motor oil that meets API Service Classification of CD or better (See Oil Chart Page 40.).

1

Fill to capacity. (See SPECIFICATIONS Page 69.)

Start the engine and let it run for about 5 minutes. Check for leaks at the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick.

Install the oil filler cap (Item 1) [A].

P–10677

NOTE: DO NOT overfill the crankcase.

Record the operating hours of the loader on the decal inside the rear door.

P–10689

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Close the rear door before operating the loader.

553 Bobcat Loader Operation & Maintenance Manual

ENGINE COOLING SYSTEM

A

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

1 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.

P–10749

B

W–2019–1285

Cleaning The Cooling System

Remove the access panel from the blower housing(Item 1) [A].

Remove the rear grill. (See REAR GRILL Page 36) Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler [B].

Install the rear grill and close the rear door.

P–10743

Checking The Coolant Level

C

Open the rear door.

The coolant recovery tank (Item 1) [C] must be at the FULL COLD mark when engine is cool.

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

1

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

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

P–10760

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

Close the rear door before operating the loader.

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Open the rear door.

ENGINE COOLING SYSTEM (Cont’d)

A

Replacing The Coolant Remove the rear grill. (See REAR GRILL Page 36.)

1

Open the rear door.

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

P–10744

Connect a hose to the coolant drain valve (Item 1) [B] (located behind the engine oil filter) or use funnel a to keep coolant from getting into the engine compartment.

B

Open the valve and drain all the coolant into a container.

Close the valve.

Fill the coolant recovery tank 1/3 full with premixed coolant (Item 1) [C].

P–13023

Check the radiator cap for correct pressure rating or overheating can result.

C

Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt.

Replace damaged parts immediately to prevent leaksand overheating.

Install the radiator cap and the rear grill and close the rear door.

Dealer Copy -- Not for Resale

1

Fill the radiator with premixed coolant and install the radiator cap. (See Checking the Coolant Level Page 42 for premix recommendations.)

1

P–10760

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I–2124–0497

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ALTERNATOR BELT ADJUSTMENT

A

Stop the engine.

1

Open the rear door.

Remove the engine belt shield.

2

Loosen the mounting bolt (Item 1) and adjustment bolt (Item 2) [A].

P–10682

P–10689

Move the alternator to set the belt tension at 5/16’ ’ (8 mm) movement between pulleys with 15 pounds (67 N) of force [B].

B

Tighten the adjustment bolt and mounting bolt.

Install the engine belt shield.

P–10681

C

ELECTRICAL SYSTEM Description The loader has a 12 volt, charging system.

negative ground alternator

The electrical system is protected by seven fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload.

Find the reason for the overload before starting engine again.

the

Electrical System Maintenance P–09588

The battery cables must be clean and tight. Remove acid or corrosion from the battery and cables with a baking soda and water solution [C].

D

Cover the terminals of the battery with Melroe Battery Saver (P/N 886398) to prevent corrosion. Do not use silicone based products.

1

Install the terminal covers.

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

The fuse decal [D] shows the size and location of each fuse.

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Close the rear door.

ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting)

2 4

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.

P–10690

I–2023–1285

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

The key switch must be OFF.

3

The battery must be 12 volt.

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

P–10691

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

Keep the cables away from moving parts.

Start the engine.

Dealer Copy -- Not for Resale

1

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

Remove the cable connected to the loader battery.

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

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

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

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

Never lean over battery while boosting, testing or charging.

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

Battery gas can explode and cause serious injury.

W–2066–1296

W–2065–1296

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ELECTRICAL SYSTEM (Cont’d)

A

1

Removing And Installing The Battery

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

P–10684

B

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

1

W–2065–1296

Disconnect the negative (–) battery cable (Item 1) [A].

Remove the battery holddown clamp (Item 1) [B].

P–10683

C

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

1

Remove the battery from the loader.

P–10686

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

D

Do not touch any metal parts with the battery terminals.

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

Inspect the battery holddown to be sure that it is in good condition. If it is cracked or broken, replace it.

Close the rear door.

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553 Bobcat Loader Operation & Maintenance Manual

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Open the rear door.

HYDRAULIC/HYDROSTATIC SYSTEM The hydraulic and hydrostatic systems hydraulic fluid reservoir.

A

use the same

1

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

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

A filter is installed on the right side of the engine compartment. This filter cleans the fluid for the hydrostatic transmission.

P–10693

The oil cooler is under the radiator . The oil cooler coolsthe hydraulic fluid before it returns to the hydrostatic pump.

B

Checking And Adding Fluid Use only recommended fluid in the hydraulic/hydrostatic system. (See SPECIFICATIONS Page 69.)

Put the loader on a level surface.

Stop the engine.

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

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

P–10697

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

Install the filler cap [B].

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1

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

553 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing The Hydraulic/Hydrostatic Filter See the SERVICE SCHEDULE Page 29 for the correct service interval to replace the filter.

1

Stop the engine. Open the rear door.

Clean the area around the filter housing and remove the filter element (Item 1) [A].

Clean the surface where the filter seal contacts the filter housing.

Lubricate the rubber gasket with grease. Install the filter element and hand tighten.

P–10685

Operate the loader and check for leaks at the filter.

B

Check fluid level in the reservoir and add as needed.

Close the rear door.

Replacing Hydraulic Fluid

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

Remove the screen (Item 1) [C].

Wash the screen in clean solvent. Install the screen in the fill pipe.

P–10697

Remove the hose and remove the fluid from the hydraulic reservoir.

C

Remove the filter element.

Install a new filter element (See procedure above).

1

Add hydraulic/hydrostatic fluid to the reservoir . (See SPECIFICATIONS Page 69 for the correct fluid.) DO NOT fill above the sight glass.

Install the filler cap.

Operate the loader.

Stop the engine.

P–10695

Check the fluid level and add as needed.

AVOID INJURY OR DEATH 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–2012–0290

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1

See the SERVICE SCHEDULE Page 29 for the service interval to replace the fluid. Replace the fluid if it becomes contaminated and after any major repairs.

SPARK ARRESTOR MUFFLER

A

See the SERVICE SCHEDULE Page 29 for correct service interval to clean the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

1

This machine is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. To keep it in working condition, dump the spark chamber after every 100 hours of operation.

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

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.

Refer to local laws and regulations for spark arrestor requirements.

I–2022–0284

W–2068–1285

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

Dealer Copy -- Not for Resale

P–10692

W–2011–1285

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 the engine. Open the rear door.

Cover the battery with a fire retardent material.

Remove the plug (Item 1)[A] at the bottom of the muffler.

Start the engine.

Have a second person (wearing safety goggles) hold a block of wood over the outlet of the muf fler (with the engine running) for about 10 seconds.

Stop the engine and install the plug.

Close the rear door.

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TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 29 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) [A].

Tire Rotation Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS Page 69 for the correct tire pressure.)

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

P–10704

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 dif ferent rate and cause excessive wear. The tread bars of all the tires must face the same direction.

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

Tire Mounting 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.

C–01965

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excess pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over–inflation.

Inflate tires to the MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

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.

FINAL DRIVE TRANSMISSION (CHAINCASE)

W–2078–1285

Checking And Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic / hydrostatic system. (See SPECIFICATIONS Page 69 for the correct oil.)

C

Drive the loader onto a level surface.

Stop the engine.

Remove the plug (Item 1) [C].

If oil can be reached with the tipof the your finger through the hole, the oil level is correct.

1

If the level is low, add oil through the check plug hole until the oil flows from the hole.

Install and tighten the plug.

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B

LUBRICATING THE BOBCAT LOADER

A

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

1

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

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

Lubricate the following locations on the loader: 1. Rod End Lift Cylinder (both sides) [A].

P–10694

2. Base End Lift Cylinder (both sides) [B].

2 P–10698

3. Lift Arm Pivot Pin (both sides) [C].

C 3

Dealer Copy -- Not for Resale

B

P–10700

4. Base End Tilt Cylinder [D].

D 4

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LUBRICATING THE BOBCAT LOADER (Cont’d)

A

5. Rod End Tilt Cylinder [A].

5

6. Bob–Tach Pivot Pin (both sides) [A].

7. Bob–Tach Wedge (both sides) [A].

6

7

P–10696

8. 250 Hours: Steering Lever Shaft Bearings (2) [B] (The opposite end is lubricated under the cab.).

B

Put oil in the hole of the cross shaft where the right and left steeriing shafts meet under the cab.

P–10709

PIVOT PINS

C

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

Check that the lock nuts are tightened to 18–20 ft.–lbs.

(24–27 Nm) torque.

1

P–10698

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8

BOB–TACH

A

Inspection And Maintenance Move the Bob–Tach levers to engage the wedges [A].

The levers and wedges must move freely.

1 N–17033

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

N–17031

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.

B

W–2102–0588

If the wedge does not contact the lower edge of the hole [B] and [C], the attachment will be loose and can come off the Bob–Tach.

1 N–17034

C

Bob–Tach Wedge

Dealer Copy -- Not for Resale

The spring loaded wedge (Item 1) [A] must contact the lower edge of the hole in the attachment(Item 1) [B] and [C].

Wedge Must Contact Lower Edge Of Hole In The Attachment

Inspect the mounting frame on the attachment and the Bob–Tach, linkages and wedges for excessive wear or damage [D]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.

D

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

Lubricate the wedges (SeeSERVICE SCHEDULE, Page 29 and LUBRICATION OF THE BOBCAT LOADER, Page 51).

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AUXILIARY CONTROL LOCKBOLT

A

553BICSOperation&MaintenanceManual#6900385S/N516311001&Above–PreventiveMaintenanceSection

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

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

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

1

Lower the operator cab. (SeeLowering The Operator Cab Page 32.)

P–10754

B

U–JOINT LUBRICATION See the SERVICE SCHEDULE Page 29 for the correct service interval to lubricate the U–joint grease fittings (three) (Item 1) [B].

Use the special U–joint grease (P/N 6599719) for correct lubrication for the U–joint.

1

Lower the operator cab. (SeeLowering The Operator Cab Page 32.)

P–10727

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Dealer Copy -- Not for Resale

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

SYSTEMS ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ....

TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 58 ..

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

TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . .59 .

Dealer Copy -- Not for Resale

SYSTEMS ANALYSIS

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

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

W–2003–0797

PROBLEM Engine won’t turn over starter.

CAUSE with

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause for loss of charge.

–

Cables loose or dirty.

Clean and tighten the battery cables.

44

Check the starting circuit. Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

16

Air in the fuel.

Remove air from the fuel system.

39

Ignition system is damaged.

Check & repair as needed.

D/S

Auxiliary control lever in continuous flow or lift is in float.

Move controls to neutral position.

10,12

No fuel in tank.

Add fuel.

38

Vent in fuel filter cap is plugged.

Clean the vent.

–

Dirt or water in fuel system.

Repair as needed.

D/S

Fuel filter is dirty.

Install a new filter.

38

Hole or leak in fuel line.

Repair as needed.

–

Weak battery.

Charge or replace battery.

–

Wrong oil in engine.

See Oil Specifications.

41

Cylinder compression is low.

Recondition the engine.

D/S

Engine has overheated.

Check cooling system.

42

Poor fuel quality.

Use fresh, good quality fuel.

38

Injectors are not working correctly.

Repair as needed.

D/S

Dirt, water or air in fuel system.

Clean and repair as needed.

D/S

Engine is hot.

See Engine Overheats.

–

Restricted exhaust.

Clean exhaust system.

49

Damaged wiring.

Engine turns with starter , but is difficult to start.

Engine has little power or rough.

runs

starter,

solenoid

or

Dealer Copy -- Not for Resale

TROUBLESHOOTING THE ENGINE

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TROUBLESHOOTING THE ENGINE (Cont’d) PROBLEM Engine has little power or rough (Cont’d)

CAUSE runs

Engine overheats.

CORRECTION

PAGE

Dirty air cleaner.

Install new element.

37

Cylinder compression is low.

Recondition the engine.

D/S

Restriction in cooling air flow.

Check for debris on radiator grill.

42

Check shroud and repair or replace as needed.

–

Run at full throttle.

–

Blower shroud damaged missing.

or

Engine is overheated.

PROBLEM

CAUSE

No drive on both sides.

No drive on one side.

Machine pulls to one side.

CORRECTION

PAGE

Hydraulic fluid is low.

Check fluid level. Add as needed.

47

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 correctpressure.

50

Steering linkage interference.

Check steering linkage and adjust as needed.

D/S

Hydrostatic system is damaged.

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 fluid level is low.

Check fluid level and add as needed.

47

Clean cooling system. Check for debris on radiator grill.

42

Check by–pass valve.

D/S

Auxiliary control in continuous flow position.

Move controls to neutral position.

12

Loader is overloaded.

Use correct size attachment.

D/S

Hydrostatic system is damaged.

Check system and make repair.

D/S

– – –

– – –

D/S

Cooling system restricted.

is dirty .

Low charge (transmission light on).

Parking brake will not hold.

Air

pressure

D/S = Dealer Service Only

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TROUBLESHOOTING THE DRIVE SYSTEM

TROUBLESHOOTING THE HYDRAULIC SYSTEM CAUSE

CORRECTION

PAGE

No hydraulic fluid.

Check fluid level and add as needed.

47

Pedals are disconnected.

Check linkage repair as needed.

–

Relief valve is damaged.

Replace the relief valve.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

17

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

47

Hydraulic action is slow.

Pedal is hitting floor or debris under Check pedal. debris.

No hydraulic action.

Hydraulic cylinders leak fluid.

Remove

–

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 valve and repair asneeded.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

17

Damage to cylinder rods or seals.

Repair cylinders.

D/S

D/S = Dealer Service Only

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adjustment.

Dealer Copy -- Not for Resale

PROBLEM

553 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 553BICSOperation&MaintenanceManual#6900385S/N516311001&Above–SystemsAnalysisSection

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

Light ON

Light OFF

Seat

Operator in Seat

No Operator in Seat

Lift and tilt functions will not operate.

Seat Bar

Seat Bar Down

Seat Bar Up

Lift, tilt and traction functions will not operate.

3

Lift and tilt functions will not operate.

1 2

Valve

Traction

Control Valve Can Control Valve Be Used Cannot Be Used

Loader can be moved forward & backward.

Loader cannot be moved forward and backward.

Loader cannot be moved forward and backward.

2 3 2

3 3 1 2 3 4 5 6

Power

BICS Controller is operating correctly.

BICS Controller is not operating correctly.

Seat sensor circuit shorted to battery voltage*.

Seat sensor circuit shorted to ground Seat bar sensor circuit shorted to battery voltage*.

Seat bar sensor circuit shorted to ground.

Valve output circuit is open.

Valve output circuit shorted to battery voltage*.

Valve output circuit shorted to ground.

Valve output circuit is not grounded.

Traction lock hold coil circuit is open.

Traction lock hold coil circuit shorted to battery voltage*.

Traction lock hold coil circuit shorted to ground.

Traction lock pull coil circuit is open.

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

Traction lock pull coil circuit is shorted to ground.

Lift, tilt and traction functions will not operate.

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

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

(3) Flashing patterns will repeat every 3.25 seconds.

(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat. The Seat Sensor Override♦ can be used if the seat sensor cannot be activated. ♦ Only on later loaders, and early loaders which have had BICS Controller and switch replaced.

NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve and traction lights come on. (only loaders with BICS controller S/N’s above 200,000 will have this delay.) * Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted to system voltage.

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Dealer Copy -- Not for Resale

Indicator Light

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

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

SERVICE SCHEDULE (6715563) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ...

WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 ....

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

WARNING (6577754, 6579528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ...

Dealer Copy -- Not for Resale

DANGER (6702301, 6702302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 ...

MACHINE SIGN TRANSLATIONS

MACHINE SIGNS (DECALS) Machine signs (decals) are an essential part of the loader (See Page xiv & xv). This section provides French and Spanish translations of the machine signs that are in English. The Operator’s Handbook is also available in a combination English, French, German, Spanish, Italian and Dutch editions.

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

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

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

IMPORTANT (FRENCH) CETTE CHARGEUSE EST EQUIPPEE A LA SOR TIE DE L’USINE D’UN SILENCIEUX P ARA–ETINCELLES APPROUVE PAR LE SER VICE DES EAUX ET FORETS DES ETATS–UNIS. IL EST INDISPENSABLE D’EFFECTUER UN ENTRETIEN REGULIER DE CE P ARE–ETINCELLES AFIN DE LE GARDER EN BON ET AT DE MARCHE. L’ENTRETIEN CONSISTE A VIDER LA CHAMBRE A ETINCELLES TOUTES LES 100 HEURES DE MARCHE. SI CET ENGIN EST UTILISE SUR UN TERRAIN COUVER T D’ARBRES, DE BROUSSAILLES, OU D’HERBAGES INFLAMMABLES, IL F AUT INSTALLER LE PARE–ETINCELLES ET LE GARDER EN BON ET AT DE MARCHE. CONSULTER LES REGLEMENT ATIONS APPLICABLES.

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

LOCALES

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ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTA

• Mantenga le puerta cerrada excepto para dar servicio.

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

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

• No use el cargador en lugares donde

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

• Todos los gases del escape pueden

matar. Ventile siempre el lugar de trabajo.

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

• Escapes de líquido bajo presión pueden penetrat en la

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

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

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

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

• Las baterias producen gas inflammable y

explosivo.

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

• Para arranque con batería auxiliar, conecte de último el

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

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

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

• En cas de démarrage par pontage, effectuer le dernier

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

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

un moteur diesel avec des bougies de préchauf fage.

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

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

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

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non

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

• Ne pas utiliser la machine dans un

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

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

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er de

Dealer Copy -- Not for Resale

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

553 Bobcat Loader Operation & Maintenance Manual

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

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

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

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

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

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

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

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

Dealer Copy -- Not for Resale

ADVERTENCIA (SPANISH)

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

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

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

ANTES DE BAJARSE DEL CARGADOR 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO.

POUR QUITTER LA CHARGEUSE:

2. PARE EL MOTOR.

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

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

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

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

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Translations not available at time of printing.

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Translations not available at time of printing.

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553BICSOperation&MaintenanceManual#6900385S/N516311001&Above–MachineSignTranslationsSection

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

PELIGRO (SPANISH)

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

EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

EVITER DES BLESSURES OU LA MORT

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

TENIR LA CHARGE VERS LE BAS.

DANGER (FRENCH)

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

EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS D

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

Dealer Copy -- Not for Resale

AVERTISSEMENT (FRENCH)

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

AVERTISSEMENT (FRENCH)

PELIGRO (SPANISH)

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

EVITE LA MUERTE

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

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBA-

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

DANGER (FRENCH) EVITER LA MORT

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

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

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SPECIFICATIONS ADDITIONAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 ...

CAPACATIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 .....

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 .....

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 ....

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 .....

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 .....

FLOOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 ....

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 ....

MELROE CO. APPROVED ATTACHMENTS & ACCESSORIES . . . . . . . . .73 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 ....

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 .....

Dealer Copy -- Not for Resale

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

SPECIFICATIONS

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LOADER SPECIFICATIONS SPECIFICATIONS

SDimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

SWhere applicable, specification conform to SAE or ISO standards and are subject to change without notice.

49.5 (1257)

97

62.5 (1588) 42.0 (1067)

36

_

127.5 (3239) 102.5 (2604)

_ 18.0 (457)

85.0 (2159)

72.8 (1849)

53.6 (1362)

38.0 (965)

_

24 7.2 (183)

31.0 (787)

_

6.5 (165)

84.6 (2149)

47.2 (1199)

106.6 (2708)

PI–2856

Dealer Copy -- Not for Resale

27

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.

553 PERFORMANCE Rated Operating Capacity (SAE) . . . . . .

Tipping Load (SAE Rating) . . . . . . . . . . .

Operating Weight . . . . . . . . . . . . . . . . . . .

SAE Breakout Force – Lift . . . . . . . . . . . .

– T ilt . . . . . . . . . . . .

Axle Torque . . . . . . . . . . . . . . . . . . . . . . . .

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

CONTROLS Vehicle Steering . . . . . . . . . . . . . . . . . . . .

Loader Hydraulics Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . . .

Front Auxiliary (optional) . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . .

Service Brake . . . . . . . . . . . . . . . . . . . . .

850 lbs. (386 kg) 1700 lbs. (771 kg) 3622 lbs. (1643 kg) 1800 lbs. (816 kg) 1500 lbs. (680 kg) 2500 ft.–lbs. (3390 Nm) 0–6.0 MPH (9,6 km/hr.)

Direction and Speed controlled by two hand levers.

Secondary Brake . . . . . . . . . . . . . . . . . .

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

Controlled by separate foot pedals.

Controlled by lateral movement of RH steering lever.

Hand lever throttle; Key–Type starter switch. Pull cable shutdown.

Glow Plug–Push button activated.

Two independent hydrostatic systems controlled by two hand operated steering levers.

One of the hydrostatic transmissions Mechanical Disc, foot operated pedal.

ENGINE Make/Model . . . . . . . . . . . . . . . . . . . . . . . .

Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower (SAE) . . . . . . . . . . . . . . . . . .

Hi Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Torque @ 1800 RPM (SAE) . . . . . . . . . .

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

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

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

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

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

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

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

Kubota/D10005–B Diesel/Liquid Gross: 22.5 HP (16,8 kW) Net: 19.5 HP(14,5 kW) 1125–1175 RPM 3100–3200RPM Gross: 43 ft.–lbs.(58,2 Nm) Net: 41 ft.–lbs.(55,5 Nm) Three 56.6 cu.–in (928 cm3) 2.95/2.76 (74,9/70,1) Pressure System W/Filter External Dry replaceable paper cartridge w/safety element Compression Diesel

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SPECIFICATIONS (Cont’d)

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

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

Hydraulic Function Time: Raise Lift Arms . . . . . . . . . . . . . . . . . . . .

Lower Lift Arms . . . . . . . . . . . . . . . . . . . .

Bucket Dump . . . . . . . . . . . . . . . . . . . . . .

Bucket Rollback . . . . . . . . . . . . . . . . . . .

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

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

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

Instrumentation . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . .

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

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . .

553 Engine Driven, Gear Type 8.5 GPM (32,2 L/min.) @ 3000 RPM 2000 PSI (13790 kPa) 10 Micron replaceable cartridge in the hydrostatic pump charge line.

Double–acting 2.0 (50,8) 3.0 (76,2) 1.25 (31,8) 1.50 (38,1) 22.2 (563,9) 12.4 (315,0) 3–spool, series type, open center w/float detent on lift and detent on auxiliary SAE standard tubes, hoses & fittings Bobcat Fluid (P/N 6563328) if fluid is not available, use 10W–30/10W40 Class SE motor oil for temperature above 0°F (–18°C) 5W–30 Motor Oil for temperatures below 0°F (–18° C).

4.1 Seconds 3.5 Seconds 2.5 Seconds 1.9 Seconds 55 amp open 12 Volt, 425 cold cranking amps @ 0° F (–18 ° C) 75 minute reserve capacity 12 Volt Straight Drive Gauges: Hourmeter, Fuel, Voltmeter, Engine Temperature.

Warning lights: Engine Temperature, Engine Oil Pressure, Hydraulic oil Temperature & Pressure Hydrostatic 4 wheel drive Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors #60 HS endless roller chain & sprockets in sealed chaincase with oil lubrication 38.14:1 1.75 (44,5) (6) 9/16”

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

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

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

Hydraulic Reservoir . . . . . . . . . . . . . . . . . .

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

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

TIRES Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Pressure . . . . . . . . . . .

9 qts. (8,5 L) 10 gals. (38 L) 4 qts. (4 L) 2.3 gals. (8,7 L) 4.8 gals. (18,2 L) 4 gals. (15 L) 27 x 8.50–15, 4 or 6 ply rating Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

FLOOR PRESSURE Flot. Tires–Rated Load . . . . . . . . . . . . . . . .

Unloaded . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front 28 PSI (193 kPa) 20 PSI (138 kPa)

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Rear 23 PSI (159 kPa) 27 PSI (186 kPa)

553 Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

HYDRAULIC SYSTEM Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

System Relief at Quick Coupler . . . . . . .

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

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

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

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

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

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

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

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

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

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

Attachments not manufactured by Melroe Company may not be approved.

The versatile Bobcat loader quickly turns into a multi–job machine with a tight–fit attachment hook–up . . . from bucket ot grapple to pallet fork to backhoe and a variety or other attachments. See your Bobcat loader dealer for more details o n the attachments and field accessories shown on the following pages.

Increase the versatility of your Bobcat Loader with a variety of bucket styles and sizes. Styles and sizes include: BUCKET

DESCRIPTIONS

48 inch Dirt Bucket 48 inch Dirt Bucket w/teeth 54 inch Light Material Bucket 54 inch Dirt Bucket 48 inch Utility Bucket Angle Broom

Econo–Grader

Cleans up construction sites. Cutting edge for scraping mud. Sweeps parking lots, warehouse, docks, etc. Sweeps and collects debris with one attachment.

Put your Bobcat loader to work and clean up almost everything in sight with the hydraulically driven and controlled Angle Broom attachment. Use it to sweep driveways, sidewalks, parking lots, loading docks, warehouses, or countless other applications.

Two attachment options in one! Use it as an economical, but effective grader OR a box blade by utilizing locking end plates.

Angle of the seven–foot moldboard is manually adjusted. Blade pitch adjusted by hydraulically tilting the Bob–Tach.

Scarifier (Bob–Tach Mount)

Auger

Adjustable depth skids for presetting digging depth. Prepares hard–packed ground for digging or landscaping.

One–to–seven–tooth versatility. Standard five–tooth unit with additional teeth available. Rips asphalt for removal.

Dig 6 inch. – 36 inch holes with speed and plumbline accuracy. Utilizing Bobca t Loader hydraulics, the heavy–dut y hydraulic auger bites in with low speed , high torque power. Because of a unique knuckle–joint design, the auger will dig vertical holes even though the Bobca t Loader is working on uneven terrain.

Hydraulic Breaker

Up to 150 ft.–lb. impact energy class.

Bob–Tach mounted,. 2–position loader mounting frame for vertical and horizontal breaking. Quick–change tool system – variety of tools available. Low recoil operating cycle. *SPECIAL APPLICATIONS KIT WHICH INCLUDES A 1/2 INCH LEXAN FRONT DOOR WITH 1/4 INCH TOP AND REAR WINDOWS MUST BE USED WHEN OPERA TING THE BOB–TACH MOUNTED HYDRAULIC BREAKER.

Dealer Copy -- Not for Resale

Sweeper

Trencher Models LT204 & LT405

Versatile trenching ability. Use these Bobcat trencher attachments for a variety of jobs. The LT204 digs two or three feet deep and 4 to 12 inch trenching widths.

The LT405 digs three to five feet deepand 5 to 12 inches wide. Hydraulic sideshiftto get close to walls. Optional trench cleaner .

Some attachments may not be available from your local dealer.

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MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES (Cont’d)

Utility Fork/Grapple

Box Scraper Approved by Melroe Company & Sold through Bobcat Loader Dealers

Move bulky or bagged materials in one load. Hook on a pallet fork and move your bagged or bulk material fast. Ideal for all kinds of farm chores and fertilizer handling. In industrial plants and landscaping, handle baled or pallet materials.

Cut down on daily hand chores and free up your time. The Bobcat Loader Utility Fork and Grapple is the ideal attachment for handling bundled material, loose straw, and manure.

Grade, scarify, backfill or level. With thi s tool, a Bobcat Loader operator can grade, scarify, backfill or level in close quarters .

Use it on road construction, lawn leveling, ripping hard packed soil or gravel, pilin g and leveling dirt, manure or othe r materials. Drag a load or doze it righ t where you need it.

Angle Blade Approved by Melroe Company & Sold through Bobcat Loader Dealers

Rake 3 pt. Mount or Bob–Tach Mount Approved by Melroe Company & Sold through Bobcat Loader Dealers

Level II FOPS Top Kit

Remove heavy snow from the surface, before it’s compacted. It’ s the ideal attachment for cleaning sidewalks, driveways, parking lots, alleys, service stations and warehouse lots. Use a heavy duty version for dozing and backfilling dirt.

Turn your Bobcat Loader into a versatile landscape machine. The triple–duty York Rake rips up soil with scarifier teeth, blades down high spots and tills holes, and rakes the surface to remove big rocks and debris.

For protection from falling trees, rocks for machines involved in site clearing , overhead demolition or forestry per ISO 3449. (Level I protection is provided with the standard cab).

Some attachments may not be available from your local dealer.

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Pallet Fork (30, 36, 42 & 48 inch teeth available)

ADDITIONAL PUBLICATIONS The following publications are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

OPERATOR’S HANDBOOK 6708358

–Introduces operator to step–by–step basics of Skid–Steer loader operation. Also available in Spanish P/N 6724036.

–gives basic operation instruction and safety warnings.

OPERATION & MAINTENANCE MANUAL 6900385 –complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

SAFETY VIDEO 6724793

–provides basic safety instructions.

Skid–Steer Loader

Dealer Copy -- Not for Resale

SKID STEER LOADER OPERATOR TRAINING COURSE 6722720

SAFETY MANUAL 6556500

EQUIPMENTMANUFACTURERS INSTITUTE 10S.RIVERSIDEPLAZACHICAGO,ILLINOIS60606–37100

SERVICE MANUAL 6724024 –complete maintenance and overhaul instructions for your BOBCAT loader.

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

PARTS MICROFICHE

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

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WARRANTY 400–900 Series Bobcat Loaders

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

The warranty does not apply to tires or other trade accessories not manufactured

by Melroe. The owner shall rely solely on the existing warranty, if any, of the respective manufacturers thereof. Warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe product according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OR OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570162 (1–96)

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Printed in U.S.A.

Dealer Copy -- Not for Resale

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

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Dealer Copy -- Not for Resale