Bobcat 553 Skid-Steer Loader Operation & Maintenance Manual 6904701 - PDF DOWNLOAD

Operation & Maintenance Manual 553 Skid-Steer Loader

Dealer Copy -- Not for Resale

S/N 539112001 & Above S/N 539412001 & Above

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 6904701 (2-07) Revised (5-07) (2)

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Printed in U.S.A.

© Bobcat Company 2007

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OPERATOR SAFETY WARNINGS WARNING

CORRECT

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W-2001-1285

B-10731a

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

CORRECT

CORRECT

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.

Fasten your seat belt.

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

WRONG

WRONG

WRONG

B-6578

B-6585

B-6595

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload, and turn on flat level ground.

WRONG

WRONG

WRONG

B-6587

B-6594

B-6591

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

Never exceed Capacity.

Rated

Operating

Never carry riders.

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

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

Never modify equipment.

Use only attachments approved by Bobcat Company for this model loader.

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

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

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

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

4. HANDBOOK: Must be in the cab.

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

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 3 of 122

OSW03-0805

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

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FOREWORD

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

SAFETY & TRAINING RESOURCES

SAFETY & TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . XI OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-1

OPERATING INSTRUCTIONS (OI)

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . PM-1 SYSTEM SETUP & ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . SA-1

PREVENTIVE MAINTENANCE (PM)

MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . MST-1 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-1 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY-1 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX-1

Dealer Copy -- Not for Resale

SYSTEM SETUP & ANALYSIS (SA) MACHINE SIGN TRANSLATIONS (MST)

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

SPECIFICATIONS (SPEC)

Loader Serial Number Engine Serial Number

WARRANTY NOTES:

ALPHABETICAL INDEX YOUR BOBCAT DEALER: ADDRESS: PHONE:

Bobcat Company Europe Drève Richelle 167 B-1410 WATERLOO Belgium

Bobcat Company P.O. Box 128 Gwinner, ND 58040-0128

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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 Machine Name. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR Bobcat Loader. If you have any questions, see your Bobcat dealer.

BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED . . . . . . . . . . . . . .V DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . VIII Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Buckets Available. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X Special Applications Kit Inspection And Maintenance . . . . . . . . . . .X Standard Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

SYSTEM SETUP & ANALYSIS

REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . .V SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

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LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII

TRANSLATIONS

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BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED

ISO 9001:2000 is an international standard that controls the processes and procedures which we use to design, develop, manufacture and distribute Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001:2000 standard. The BSI registration certifies that the two Bobcat manufacturing plants and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota are in compliance with ISO 9001:2000. Only certified assessors, like BSI, can grant registrations.

ISO 9001:2000 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.

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

REGULAR MAINTENANCE ITEMS

ENGINE OIL FILTER (6 Pack) 6657635

BATTERY 6674687 FLUID, Hydraulic/Hydrostatic 6903117 - (Two -2.5 Gal. containers) 6903118 - (5 Gal.) 6903119 - (55 Gal.)

FUEL FILTER 6667352

AIR FILTER, Outer 6672467

HYDRAULIC FILL / BREATHER CAP 6727475

AIR FILTER, Inner 6672468

PROPYLENE GLYCOL ANTI-FREEZE, Premixed [-34°F (-37°C] 6724094

HYDROSTATIC FILTER 6661248

PROPYLENE GLYCOL ANTI-FREEZE, Concentrate 6724354

MOTOR OIL 6903105 6903107 6903109 -

SAE 15W40 CE/SG (12 qt.)

SAE 10W30 CE/SG (12 qt.)

SAE 30W CE/SG (12 qt.)

6903111 6903113 -

SAE 30W CE/SG (2.5 Gal.) SAE 15W40 CE/SG (2.5 Gal.)

6903106 -

SAE 15W40 CE/SG (1 Gal.)

6903108 6903110 6903112 -

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SAE 10W30 CE/SG (1 Gal.) SAE 30W CE/SG (1 Gal.) SAE 10W30 CE/SG (2.5 Gal.)

553 Operation & Maintenance Manual

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CALIFORNIA PROPOSITION 65 WARNING

SERIAL NUMBER LOCATIONS

Engine Serial Number

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

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

Figure 2

Figure 1

1

1

N-09931

The engine serial number (Item 1) [Figure 2] is located on the engine block below the exhaust manifold.

P10725

Dealer Copy -- Not for Resale

DELIVERY REPORT Figure 3

Loader Serial Number The loader serial number plate is located inside the operator cab on the loader frame [Figure 1].

Explanation of loader Serial Number: XXXX XXXXX Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination B-16315

1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

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 [Figure 3].

2. The five digit Production Sequence Number identifies the order which the loader is produced.

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LOADER IDENTIFICATION ▼ FRONT LIGHTS

OPERATOR SEAT WITH SEAT BELT SEAT BAR

GRAB HANDLES LIFT CYLINDER STEERING LEVER

TILT CYLINDER ▼ QUICK COUPLERS

† BUCKET

▼ REAR WINDOW

Dealer Copy -- Not for Resale

SAFETY TREAD

BUCKET STEPS

OPERATOR CAB (ROPS & FOPS)

UPRIGHTS REAR GRILL LIFT ARM ▼ TAIL LIGHT

LIFT CYLINDER

▼ REAR

LIGHT

REAR DOOR

* TIRES B-15064 B-15065

▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) † BUCKET - Several different buckets and other attachments are available from the Bobcat Loader. ● ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per 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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Standard Items

Options and Accessories

Model 553 Bobcat Loaders are equipped with the following standard items:

Below is a list of some equipment available form your Bobcat Loader dealer as Dealer and / or Factory Installed Accessories and Factory Installed Options. See your Bobcat dealer for other available options, accessories and attachments.

• • • • • • • • • • • • • • •

Adjustable Cushion Seat Auxiliary Hydraulics, Front Bob-Tach Bobcat Interlock Control System (BICS) Instrumentation: Hourmeter, Engine Temperature and Fuel Gauges and Warning Lights Lift Arm Support Device Lights, Front & Rear Operator Cab (with ROPS / FOPS Approval) Parking Brake Rocker Switch Activated Glow Plugs Seat Bar Seat Belt Spark Arrestor Muffler Tires, 27x8.5-15 4PR (Machine Width-47 inches) Window, Rear

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Attachment Control Device (ACD) Back-up Alarm & Horn Cab Enclosure Cab Heater Catalytic Exhaust Purifier Cover Kit (Hydraulic Reservoir Area) Deluxe Cab Deluxe Cab w/Heater Engine Heater Externally Removable Rear Window Hydraulic Bucket Positioning (Includes On/Off Selection) Fire Extinguisher Flasher Lights FOPS/TOP Front Door GPS System (GlobalTRACS®) Heater Insect Screen Keyless Start System Large Operator Seat Bar Kit Locking Fuel Cap Low Coolant Sensor Kit Rear Wiper Rental Kit Rotating Beacon or Strobe Light Seat Belt - 3 inch wide Single Point Lift Sound Cab (Reduces Noise at Operator’s Ear) Special Applications Kit Suspension Seat Tailgate Lock Tires 27x8.5-15 Bobcat Heavy Duty 6PR (Machine Width 48 inches) Top Window Vinyl Cab Enclosure Windows, Top Weighlog

Specifications subject to change without notice.

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FEATURES, ACCESSORIES AND ATTACHMENTS

FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D)

Buckets Available

These and other attachments are approved for use on this model loader. Do not use unapproved attachments.

Attachments not manufactured by Bobcat may not be approved.

The versatile Bobcat Loader quickly turns into a multi-job machine with a tight-fit attachment hook-up . . . from bucket to grapple to pallet fork to backhoe and a variety of other attachments.

BUCKET

See your Bobcat dealer for more details on these and other attachments and field accessories.

Many bucket styles, widths and different capacities are available for a variety of different applications. They include Construction & Industry, Low profile, Fertilizer and Snow, to name a few. See your Bobcat dealer for the correct bucket for your Bobcat Loader and application.

Increase the versatility of your Bobcat Loader with a variety of bucket styles and sizes.

• • • • • • • • • • • • • • • • • • • • • • • • •

Dealer Copy -- Not for Resale

Attachments 3- Point Hitch Angle Broom Auger Backhoe Blade - Snow Blade - V Breaker Buckets Cutter Crusher Digger Dumping Hopper Landplane Packer Wheel Pallet Fork Scarifier Scraper Snow Blower Soil Conditioner Stump Grinder Sweeper Tiller Trencher Utility Fork Utility Grapple X-Change Frame

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FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D)

Special Applications Kit Inspection And Maintenance

Special Applications Kit

• •

Inspect for cracks or damage. Replace if required.

Pre-rinse with water to remove gritty materials.

•

Wash with a mild household detergent and warm water.

Use a sponge or soft cloth. Rinse well with water and dry with a clean soft cloth or rubber squeegee.

Do not use abrasive or highly alkaline cleaners.

Do not operate windshield wipers on a dry surface.

Do not clean with metal blades or scrapers.

• • • •

B-25286A

Available for special applications to restrict material from entering cab openings. Kit includes 1/2 inch Lexan™ front door, top and rear windows.

Dealer Copy -- Not for Resale

See your Bobcat dealer for availability.

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SAFETY & TRAINING RESOURCES MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . .XVIII

Dealer Copy -- Not for Resale

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Safe Operation Is The Operator’s Responsibility. . . . . . . . . . . .XIV Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . .XIV

SAFETY & TRAINING RESOURCES

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•

An Operator’s Handbook is fastened to the operator cab of the Loader. It’s 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 AEM Safety Manual delivered with the machine gives general safety information.

•

The Skid-Steer Loader Operating Training Course is available through your Bobcat dealer. This course is intended to provide rules and practices of correct operation of the Bobcat Loader. The course is available in English and Spanish versions.

•

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

•

See the PUBLICATIONS AND TRAINING RESOURCES Page in this manual or your Bobcat dealer for Service and Parts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web sites www.training.bobcat.com or www.bobcat.com

Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

The Bobcat Loader is highly maneuverable and compact.

It is rugged and useful under a wide variety of conditions.

This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat Loader usage.

The Bobcat Loader has an internal combustion engine with resultant heat and exhaust. All exhaust gasses can kill or cause illness so use the Loader with adequate ventilation.

The dealer explains the capabilities and restrictions of the Bobcat Loader and attachment for each application.

The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for a Rated Operating Capacity (some have restricted lift heights).

They are designed for secure fastening to the Bobcat Loader. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the machine - attachment combination.

The dealer and owner/operator review the recommended uses of the product when delivered. If the owner/operator will be using the machine for a different application(s) he or she must ask the dealer for recommendations on the new use.

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

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

•

The Operation & Maintenance Manual delivered with the machine or attachment gives operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine.

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

•

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

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

SI SSL-0307

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SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS (CONT’D)

A Qualified Operator Must Do The Following:

Safe Operation Is The Operator’s Responsibility

Understand the Written Instructions, Rules and Regulations

Safety Alert Symbol

•

The written instructions from Bobcat Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, Safety Manual and machine signs (decals).

•

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

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

Carefully read the message that follows.

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

•

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

•

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

•

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

•

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

W-2001-1285

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

I-2019-0284

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

Know the Work Conditions

W-2044-1285

•

Know the weight of the materials being handled.

Avoid exceeding the Rated Operating Capacity (R.O.C.) of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of the load if handling dense material.

•

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

•

Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the Before Operation Section of this manual.

•

Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing protection or Special Applications Kits are required for some work. See your Bobcat dealer about Bobcat Safety Equipment for your model.

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

Check all of the items on the Bobcat Service Schedule Decal under the 8-10 hour column or as shown in the Operation & Maintenance Manual.

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

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Have Training with Actual Operation

SAFETY INSTRUCTIONS (CONT’D)

•

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

•

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

Fire Prevention The machines and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Figure 1

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

•

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

•

The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

•

Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight.

Repair or replace any damaged part.

•

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

•

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

•

Always clean the machine, disconnect the battery, and disconnect the wiring from the Bobcat controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

•

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

•

Sl SSL-0307

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Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].

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The spark arrestor exhaust system 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.

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 Loader dealer.

7107594

6565990

6577754 (2)

6579510 6735140

6715465 6706809

6702255

6717343 (2) Under Cab

6710358

6702301 6561383 (Behind Bob-Tach)

6579528 (Behind Lift Arm Crossmember)

6702302

B-15064

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6708358

MACHINE SIGNS (DECALS) (CONT’D) 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 Loader dealer.

6578368

6560573

6706558

Dealer Copy -- Not for Resale

6708929

6733996

6595014 (3)

6734534

6576048

7116162

Located inside the engine compartment.

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PUBLICATIONS AND TRAINING RESOURCES The following publications are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

OPERATOR’S HANDBOOK

For the latest information on Bobcat products and the Bobcat Company, visit our web site at www.bobcat.com; you can also order Operator and Service Training materials online through www.bobcatstore.com

6708358

Gives basic operation instructions and safety warnings

OPERATION & MAINTENANCE MANUAL

SKID-STEER LOADER OPERATOR TRAINING COURSE

6904701

Complete instructions on the correct operation and the routine maintenance of the Bobcat Loader

Introduces operator to step-by-step basics of Skid-Steer Loader operation. Also available in Spanish P/N 6724036

OPERATOR SAFETY VIDEO 6902176

SERVICE MANUAL OPERATOR SAFETY DVD (English & Spanish)

6904705

6904762

Provides basic safety instructions contained in all Bobcat Safety Videos in both English and Spanish.

Complete maintenance instructions for your Bobcat Loader

SAFETY MANUAL SKID-STEER LOADER SERVICE SAFETY TRAINING COURSE

6556500

6900641 Provide basic safety procedures and warnings for your Bobcat Loader. Also available in Spanish P/N 6724451

Introduces Service Technicians to step-by-step basics of proper and safe Skid-Steer Loader maintenance and servicing procedures

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6901726

OPERATING INSTRUCTIONS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 Choosing The Correct Bucket . . . . . . . . . . . . . . . . . . . . . . . . OI-22 Installing And Removing The Attachment . . . . . . . . . . . . . . . OI-23 Pallet Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-8 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . OI-7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7

OPERATING INSTRUCTIONS

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-14 Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . OI-15 DRIVING AND STEERING THE LOADER . . . . . . . . . . . . . . . . . OI-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10

Dealer Copy -- Not for Resale

ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 HYDRAULIC CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Auxiliary Control Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Hydraulic Bucket Positioning . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-13 Relieve Hydraulic Pressure (Loader And Attachment) . . . . . OI-13 Tilt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 INSTRUMENT PANEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . OI-3 Cab Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4 Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 Option And Field Accessory Panel . . . . . . . . . . . . . . . . . . . . . OI-4 Right Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 LIFT ARM BYPASS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 LIFTING THE LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-31 Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-31

Continued On Next Page

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553 Operation & Maintenance Manual

OPERATING INSTRUCTIONS (CONT’D) PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-26 Digging And Filling A Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-29 Filling And Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . OI-28 Inspect The Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-26 Leveling The Ground Using Float . . . . . . . . . . . . . . . . . . . . . OI-29 Operating With A Full Bucket. . . . . . . . . . . . . . . . . . . . . . . . . OI-26 Operating With An Empty Bucket . . . . . . . . . . . . . . . . . . . . . OI-27 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Entering The Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Read Operating Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-16 Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-17 Seat Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-17 Dealer Copy -- Not for Resale

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . OI-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Cold Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-19 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Warming The Hydraulic / Hydrostatic System . . . . . . . . . . . . OI-19 STOPPING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 Using The Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-10 STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . OI-20 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-20 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-30 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-30 TRACTION LOCK OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-8 TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . . . OI-32 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-32 Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-32

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INSTRUMENT PANEL IDENTIFICATION

Right Panel

Left Panel

Figure OI-2

Figure OI-1 7 10 12

8 6 9 11

5 4

3

1

13

2

P-31955 P-68025

REF. NO 1

2

3 4

5

6

7 8 9

DESCRIPTION

REF. NO

FUNCTION / OPERATION

TRACTION LOCK OVERRIDE BUTTON

(Functions Only When The Seat Bar Is Raised.) Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page OI-8.)

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

KEY SWITCH For starting and stopping the engine.

DESCRIPTION

10

HOURMETER

11

FUEL GAUGE

12

VOLTMETER

13

ENGINE TEMPERATURE

FUNCTION / OPERATION Records the total operating hours of the loader.

Shows the amount of fuel in the fuel tank.

Shows the condition of the battery and the rate of charge.

Shows the engine coolant temperature.

TRANSMISSION WARNING LIGHT

Light is ON when transmission charge pressure is low, hydraulic filter needs replacement or fluid temperature is high. Stop the engine if the light comes ON. ENGINE WARNING Light is ON when engine oil pressure LIGHT is low or coolant temperature is high.

Stop the engine if the light comes ON. PREHEAT BUTTON Press to preheat the glow plugs to aid cold temperature starting. Switch will turn off when released.

LIGHT SWITCH Press the left side of switch to turn (Opt./FA) lights ON; press right side to turn OFF. PARKING BRAKE Press the left side of switch to engage; press right side to disengage.

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

(Opt. / FA) = Option or Field Accessory

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The table below shows the DESCRIPTION and FUNCTION/OPERATION for each of the components of the right panel [Figure OI-2].

The table below shows the DESCRIPTION and FUNCTION/OPERATION for each of the components of the left panel [Figure OI-1].

INSTRUMENT PANEL IDENTIFICATION (CONT’D)

Cab Light

Option And Field Accessory Panel

Figure OI-4

Figure OI-3 15 14

1

16 N-22015

P-68296

Push the button (Item 1) [Figure OI-4] to turn the light ON. Push the button again to turn OFF.

REF. NO 14 15

16

DESCRIPTION

FUNCTION / OPERATION

REAR WIPER / WASHER (FA) HAZARD SWITCH / HAZARD INDICATORS (Opt./ FA)

*Controls operation of the available rear window wiper and washer. *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. *Controls the available flashing beacon or strobe light.

BEACON OR STROBE SWITCH (Opt./FA)

Dealer Copy -- Not for Resale

The table below shows the DESCRIPTION and FUNCTION/OPERATION for each of the components of the left panel [Figure OI-3].

(Opt. / FA) = Option or Field Accessory *Can be installed if you have a Deluxe Cab or a Cab Enclosure installed.

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553 Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

Figure OI-6 SEAT BAR DOWN

Operation Figure OI-5

2 Seat Bar

Pedal Linkage

1

1

3 Interlock Shield

MC-1668A

P-68721

The seat bar restraint system has a pivoting seat bar (Item 1) [Figure OI-5] with arm rests and has spring loaded interlocks for the lift and tilt control pedals.

The interlocks (Item 1) [Figure OI-6] require the operator to lower the seat bar (Item 2) [Figure OI-6] which allows the operator to move the foot pedals to control the lift and tilt functions.

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

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

When seat bar is lowered, it pushes interlocks (Item 1) [Figure OI-6] down on both sides, releasing the pedal linkages (Item 3) [Figure OI-6] from the interlocks.

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

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

WARNING

WARNING

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

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-2105-1285 W-2046-0595

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

• Stop the engine.

• Engage the parking brake.

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

• Move auxiliary control out of detent position.

W-2164-1294

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The spring loaded interlocks (Item 1) [Figure OI-6] control the locking and unlocking functions of the control pedals.

SEAT BAR RESTRAINT SYSTEM (CONT’D) Operation (Cont’d) Figure OI-7 SEAT BAR DOWN Seat Bar

Interlock Interlock Shield

MC-1668B

Dealer Copy -- Not for Resale

When the seat bar is raised, spring forces raise the interlocks [Figure OI-7].

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

(See SEAT BAR RESTRAINT SYSTEM on Page PM-7.)

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553 Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

LIFT ARM BYPASS CONTROL

Operation

Operation

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

Figure OI-9

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

Figure OI-8

1 1

2

P-68658

The lift arm bypass control knob (Item 1) [Figure OI-9] is used to lower the lift arms in the event that the lift arms cannot be lowered during normal conditions.

4 5

With the operator in the seat, seat belt fastened and the seat bar fully lowered, pull and hold the bypass control knob (Item 1) [Figure OI-9] up. Push the top (toe) of the left (lift) pedal. The lift arms will slowly lower.

P10157

The lift, tilt and traction drive functions are interlocked with the Seat Bar. The BICS controller is located inside the cab; behind and to the right of the operator's seat [Figure OI-8] There are five green lights on the BICS controller and all must be ON to operate the loader.

The light functions are as follows [Figure OI-8]: 1. SYSTEM ACTIVATED - ON when the green PRESS TO OPERATE button is activated.

2. SEAT BAR - ON when the seat bar is down.

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

4. TRACTION - ON when loader can be moved forward and backward.

5. POWER - ON when the Controller is operating correctly.

NOTE: If any of the lights are off or blinking, (See BOBCAT INTERLOCK CONTROL SYSTEM (BICS) on Page PM-6.) (See Troubleshooting on Page SA-5.)

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3

TRACTION LOCK OVERRIDE

BACK-UP ALARM SYSTEM

Operation

Operation Figure OI-11

WARNING 1 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

Figure OI-10

This machine may be equipped with a back-up alarm system. The back-up alarm (Item 1) [Figure OI-11] is located on the inside of the rear door.

Figure OI-12

1

P-68025

(Functions Only When The Seat Bar is Raised) There is a traction lock override button (Item 1) [Figure OI-10] on the left hand instrument panel. It allows you to use the steering levers to move the loader forward and backward when using the backhoe attachment or for service.

•

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.

The back-up alarm will sound when the operator moves both steering levers in the reverse position [Figure OI12]. Slight movement of the steering levers in the reverse position is required with hydrostatic transmissions, before the back-up alarm will sound.

If alarm does not sound or for adjustment instructions, see inspection and maintenance instructions for the back-up alarm system in the preventive maintenance section of this manual. (See BACK-UP ALARM SYSTEM on Page PM-11.)

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.

NOTE: The traction Lock Override button will function if brake is engaged or disengaged position.

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P-76101

ENGINE SPEED CONTROL

PARKING BRAKE

Operation

Operation

Figure OI-13

Figure OI-14

1

MC-1914A

1

P-68025

The engine speed control (Item 1) [Figure OI-13] is at the right side of the operator’s seat. Move the engine speed control forward to increase the engine RPM and backward to decrease the engine RPM.

Press the left side of the switch (Item 1) [Figure OI-14] to engage the parking brake. Press the right side to disengage.

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P10752

DRIVING AND STEERING THE LOADER

Figure OI-16

Operation

WARNING 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

Figure OI-15

PI-1849A

The steering levers control forward and reverse travel of the loader [Figure OI-16].

P-68721

The steering levers (Item 1) [Figure OI-15] are on the right and left side in front of the seat.

Forward Travel - Push both levers forward.

Move the levers smoothly. Avoid sudden starting and stopping.

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

Reverse Travel - Pull both levers backward.

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

Slow travel speed, push levers forward only small amount.

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.

STOPPING THE LOADER Using The Control Levers When the control levers are moved to the NEUTRAL POSITION, the hydrostatic transmission will act as a service brake and stop the loader.

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1

HYDRAULIC CONTROLS

Lift Arm Operation

Description

Left Pedal

Two foot pedals control the hydraulic cylinders for the lift and tilt functions.

Push the heel (Item 1) [Figure OI-17] of the pedal to raise the lift arms.

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

Push the toe (Item 2) [Figure OI-17] of the pedal to lower the lift arms.

Foot Pedals

Lift Arm Float Position Left Pedal

WARNING

Push the toe (Item 2) [Figure OI-17] of the pedal all the way forward until it locks into the float position.

Keep both feet on pedals while operating machine.

Failure to do so can cause serious injury.

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

W-2002-1285

Raise the lift arms to disengage the float position.

Figure OI-17

Right Pedal Push the heel (Item 3) [Figure OI-17] of the pedal to tilt the bucket backward.

1 P-10762

Push the toe (Item 4) [Figure OI-17] of the pedal to tilt the bucket forward.

Hydraulic Bucket Positioning This machine may be equipped with Hydraulic Bucket Positioning.

B-7440

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

4

Bucket positioning functions automatically during the upward lift cycle only.

3

The bucket positioning function can be turned OFF with the bucket position switch. (See Left Panel on Page OI3.)

P-10762

B-7441

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Tilt Operation 2

HYDRAULIC CONROLS (CONT’D)

Auxiliary Hydraulics

Auxiliary Control Lockbolt

Figure OI-19

Figure OI-18

1

2

B-2408A

1

B-2409B

P10750

P10754

The auxiliary control has a lockbolt (Item 1) [Figure OI18] that must be removed before auxiliary hydraulics can be used.

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 [Figure OI-19].

Raise the operator cab. (See Raising on Page PM-12.).

Remove the nut and bolt (Item 1) [Figure OI-18].

Move the steering lever all the way to the right (Item 2) [Figure OI-19] to put the control valve into the locked position for a constant flow of hydraulic fluid under pressure to the quick couplers.

Lower the operator cab. (See Lowering on Page PM-13.)

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

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553 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

The right steering lever (Item 1) [Figure OI-19] is also the control lever for the front auxiliary hydraulics.

HYDRAULIC CONROLS (CONT’D)

Relieve Hydraulic Pressure (Loader And Attachment)

Quick Couplers

With the engine stopped and attachment flat on the ground, move the right steering lever to the left and to the right several times. This relieves pressure that can be trapped in the auxiliary circuit which would make it difficult to engage quick couplers from an attachment.

WARNING 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.

W-2220-0396

Dealer Copy -- Not for Resale

Figure OI-20

P-68295

To Connect: Remove dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced [Figure OI-20].

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

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.

Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W-2072-0496

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DAILY INSPECTION

Dealer Copy -- Not for Resale

Figure OI-21

6734534_C-V

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553 Operation & Maintenance Manual

DAILY INSPECTION (CONT’D)

WARNING

Daily Inspection and Maintenance Figure OI-22

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service.

Untrained operators and failure to follow instructions can cause injury or death.

W-2003-0903

B-6583

The loader must be in good operating condition [Figure OI-22].

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early failures. The Service Schedule is a guide to correct maintenance of the Bobcat Loader. It is located inside the rear door of the loader [Figure OI-21].

•

Engine Oil Level

•

Hydraulic/Hydrostatic Fluid Level

•

Engine Air Filter Condition Indicator, Check System for Damage or Leaks

•

Engine Coolant System, Check System for Damage or Leaks

•

Operator Cab and Cab Mounting Hardware

•

Grease Pivot Pins (Lift Arms, Bob-Tach, Cylinders, Bob-Tach Wedges)

•

Tires, Check for Wear, Damage, Correct Air Pressure

•

Fuel Filter, Remove Trapped Water

•

Loose or Broken Parts

•

Lift Arm Support Device.

•

Bobcat Interlock Control System (BICS)

•

Safety Treads and Safety Signs (Decals)

IMPORTANT •

•

I-2226-0104

OI-15 37 of 122

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 12 inches (300 mm) from the decal. Wash from the center of the decal toward the edges.

553 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

NOTE: Fluids such as engine oil, hydraulic fluid, coolant, 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.

PRE-STARTING PROCEDURE

Safety treads are installed on the Bobcat Loader to provide a slip resistant surface for getting on and off the loader. Keep safety treads clean and replace when damaged. Replacement treads are available from your dealer.

Read Operating Material Figure OI-23 1

WARNING 2

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

W-2001-0502

Seat Adjustment Figure OI-25

P-68657

Read the Operation & Maintenance Manual and the Operator’s Handbook (Item 1) [Figure OI-23] before operating the loader.

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) [Figure OI-23].

3

Entering The Loader 1

Figure OI-24

P-5131A

P-68657

Pull the seat lever (Item 1) [Figure OI-25] to adjust the forward / backward position of the seat.

Adjust the lever (Item 2) [Figure OI-25] for the weight of the operator.

Adjust the knob (Item 3) [Figure OI-25] for seat back position.

P-68718

Use the bucket or attachment steps, grab handles and safety treads (on top the loader lift arm crossmember and main frame) to get on and off the loader [Figure OI-24].

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2

PRE-STARTING PROCEDURE (CONT’D)

Figure OI-28

Seat Belt Adjustment

WARNING 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-68721

Figure OI-26

Put the foot pedals and steering controls in neutral position [Figure OI-28].

WARNING 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 or footrests and hands on steering levers.

P-68719

Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [Figure OI-26].

W-2261-0799

Seat Bar Figure OI-27 1

P-68720

Lower the seat bar (Item 1) [Figure OI-27] and engage the parking brake.

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NOTE: Keep your hands on the steering levers and your feet on the foot pedals (or footrests) while operating the loader.

STARTING THE ENGINE

Turn the key to the RUN position [Figure OI-30]. The engine and transmission warning lights (Items 1 & 2) [Figure OI-30] will be lighted when the key is on and the engine is stopped.

Key Switch

Turn the key to START position [Figure OI-30] and release it when the engine starts.

WARNING

The key will return to the RUN position [Figure OI-30].

• •

AVOID INJURY OR DEATH Engines can have hot parts and hot exhaust gas.

Keep flammable material away.

Do not use machines in atmosphere containing explosive gas.

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

W-2051-1086

IMPORTANT

Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page OI-16.)

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Allow starter to cool for one minute before using starter again.

Figure OI-29

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

P10752

W-2050-1285

Set the engine speed control to the idle position [Figure OI-29].

WARNING

Figure OI-30

• • OFF

START

W-2051-1086

1

RUN

AVOID INJURY OR DEATH Engines can have hot parts and hot exhaust gas.

Keep flammable material away.

Do not use machines in atmosphere containing explosive gas.

2

P-68025

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I-2034-0700

STARTING THE ENGINE (CONT’D)

Figure OI-32

Cold Temperature Starting

WARNING Do not use ether with glow plug (preheat) systems.

Explosion can result which can cause injury, death, or severe engine damage.

W-2071-0903

Figure OI-31

1 OFF RUN START

See PRE-HEAT decal inside the cab [Figure OI-32].

Repeat the PRE-HEAT procedure until the engine starts.

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

P-68025

•

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

(See Checking And Adding Engine Oil on Page PM19.)

•

Make sure the battery is fully charged.

•

Install an engine heater, available from your Bobcat Loader dealer.

•

Move engine speed control lever halfway before starting. Return to idle position after the engine starts.

Turn the key switch to the RUN position.

Push the PREHEAT button (Item 1) [Figure OI-31] to preheat the glow plugs.

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

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

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7107594

STOPPING THE ENGINE AND LEAVING THE LOADER

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

Procedure Figure OI-33

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

• Stop the engine.

• Engage the parking brake.

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

• Move auxiliary control out of detent position.

W-2164-1294

P-68717

P-68716

Dealer Copy -- Not for Resale

Stop the Bobcat Loader on level ground.

Lower the lift arms fully and put the attachment flat on the ground [Figure OI-33].

Exit the loader [Figure OI-33].

Figure OI-34

OFF RUN START

P10752

P-68025

Pull the engine speed control fully backward to decrease the engine speed [Figure OI-34].

Turn the key switch to the OFF position [Figure OI-34].

Engage the parking brake.

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

Raise the seat bar and unbuckle the seat belt.

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STOPPING THE ENGINE AND LEAVING THE LOADER (CONT’D)

Front Door (If Equipped) Figure OI-37

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

Rear Window: (If Equipped) Figure OI-35

P9216

Pull the plastic loop at the top of the window in the front door to remove the rubber cord [Figure OI-37].

P-64994

Figure OI-38

Pull on the tag on the top of the rear window to remove the rubber cord [Figure OI-35].

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

Figure OI-36

P9217

Push the window out with your foot [Figure OI-38].

Exit through the front door.

P10722

Exit through the rear of the operator cab [Figure OI-36].

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NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit [Figure OI-37].

ATTACHMENTS

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

Choosing The Correct Bucket

WARNING

Pallet Fork

Never use attachments or buckets which are not approved by Bobcat Company. Buckets and attachments for safe loads of specified densities are approved for each model. Unapproved attachments can cause injury or death.

Figure OI-40

1

W-2052-0500

NOTE: Warranty is void if non-approved attachments are used on the Bobcat Loader.

The ROC for this loader is shown on a label in the operator cab. (See Capacities on Page SPEC-5.)

B-17255

The ROC 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 moved forward and reduces the ROC. If very dense material is loaded, the volume must be reduced to prevent overloading.

The maximum load to be carried when using a pallet fork is shown on a decal located on the pallet fork frame (Item 1) [Figure OI-40].

See your Bobcat dealer for more information about pallet fork inspection, maintenance and replacement. See your Bobcat Loader dealer for ROC when using a pallet fork and for other available attachments.

Figure OI-39 WRONG

WARNING AVOID INJURY OR DEATH Do not exceed Rated Operating Capacity (ROC).

Excessive load can cause tipping or loss of control.

W-2053-0903

B-6587

Exceeding the ROC can cause the following problems [Figure OI-39]: • • • •

Steering the loader may be difficult.

Tires will wear faster.

There will be a loss of stability.

The life of the Bobcat Loader will be reduced.

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Load varies with model of pallet fork being used.

The dealer can identify, for each model loader, the attachments and buckets approved by Bobcat. The buckets and attachments are approved for Rated Operating Capacity (ROC) and for secure fastening to the Bob-Tach.

ATTACHMENTS (CONT’D)

Tilt the Bob-Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [Figure OI-42].

Installing And Removing The 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

Stop the engine and exit the loader.

WARNING

Figure OI-41

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

• Stop the engine.

• Engage the parking brake.

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

• Move auxiliary control out of detent position.

1

W-2164-1294

Figure OI-43

Installing 1

Pull the Bob-Tach levers all the way up (Item 1) [Figure OI-41].

N-17032

Enter the loader and perform the PRE-STARTING PROCEDURE. (See PRE-STARTING PROCEDURE on Page PM-16.)

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

N-17031

Drive the loader forward until the top edge of the BobTach is completely under the top flange of the bucket [Figure OI-41] (or other attachment). Be sure the BobTach levers do not hit the bucket.

Push down on the Bob-Tach levers until they are fully engaged in the locked position (Item 1) [Figure OI-43] (wedges fully extended).

Figure OI-42

N-17036

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N-17035

ATTACHMENTS AND BUCKETS (CONT’D) Installing And Removing The Attachment (Cont’d) Installing (Cont’d) Figure OI-44

2 1 N-16043A

Dealer Copy -- Not for Resale

N-16044A

The wedges (Item 1) [Figure OI-44] must extend through the holes (Item 2) [Figure OI-44] in the mounting frame of the bucket (or attachment), securely fastening the bucket to the Bob-Tach.

WARNING Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked.

Failure to secure wedges can allow attachment to come off and cause injury or death.

W-2102-0497

Lower the lift arms and put the attachment flat on the ground and lower or close the hydraulic equipment.

•

If the attachment is hydraulically controlled (combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure at the quick couplers.

(See Relieve Hydraulic Pressure (Loader And Attachment) on Page OI-13.)

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

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ATTACHMENTS AND BUCKETS (CONT’D)

Enter the loader.

Installing And Removing The Attachment (Cont’d)

Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page OI-16.)

Removing Start the engine and release the parking brake.

Be sure the lift arms are all the way down. Tilt the BobTach forward.

WARNING

Figure OI-46 Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

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

• Move auxiliary control out of detent position.

W-2164-1294

N-17035

Move the loader backward, away from the bucket or attachment [Figure OI-46].

N-17030

Pull the Bob-Tach levers all the way up [Figure OI-45].

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

W-2054-1285

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Figure OI-45

OPERATING PROCEDURE

Figure OI-47 FULL BUCKET

Inspect The Work Area Before beginning operation, inspect the work area for unsafe conditions.

Look for sharp drop-offs or rough terrain. Have underground utility lines (gas, water, sewer, irrigation, etc.) located and marked.

Remove objects or other construction material that could damage the loader or cause personal injury.

GOING UP SLOPE

Operating With A Full Bucket When operating on a public road or highway, always follow local regulation. For example: Slow Moving Vehicle (SMV) Sign or directional signals may be required.

B-6612

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

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

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

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

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

I-2015-0284

W-2018-1187

IMPORTANT

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

Figure OI-48 FULL BUCKET

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

GOING DOWN SLOPE

B-15230

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [Figure OI-47] and [Figure OI-48].

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WARNING

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

OPERATING PROCEDURE (CONT’D) Operating With An Empty Bucket Figure OI-49 EMPTY BUCKET

GOING DOWN SLOPE

B-6611

Figure OI-50

GOING UP SLOPE

Dealer Copy -- Not for Resale

EMPTY BUCKET

B-13297

With empty bucket, go down or up the slope with the heavy end toward the top of the slope [Figure OI-49] and [Figure OI-50].

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OPERATING PROCEDURE (CONT’D)

Emptying

Filling And Emptying The Bucket

Figure OI-53

Filling

2

Figure OI-51 1

2 B-6708

B-6719

1

P10762

Keep the bucket low when moving to the area where you want to empty the bucket.

P10762

Raise the lift arms (Item 1) [Figure OI-53]. Level the bucket (Item 2) [Figure OI-53] while raising the lift arms to help prevent material from falling off the back of the bucket.

Figure OI-52

1 B-6718

Empty the bucket (Item 2) [Figure OI-53]. If all the material is near the side of the truck or bin, use the bucket tilt to move it to the other side.

P10762

Lower the lift arms all the way (Item 1) [Figure OI-51].

Tilt the bucket forward (Item 2) [Figure OI-51] until the cutting edge of the bucket is on the ground.

WARNING

Drive slowly forward into the material. Tilt the bucket backward (Item 1) [Figure OI-52] all the way when the bucket is full.

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

W-2057-0694

Drive backward away from the material.

WARNING Load, unload and turn on flat level ground. Do not exceed Rated Operating Capacity (ROC) 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-2056-0903

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

OPERATING PROCEDURE (CONT’D)

Raise the cutting edge a small amount (Item 3) [Figure OI-55] to increase traction and keep an even digging depth. Continue to drive forward until the bucket is full.

When the ground is hard, raise and lower the cutting edge of the bucket (Items 2 & 3) [Figure OI-55] while driving forward slowly.

Leveling The Ground Using Float Figure OI-54 1

2

Figure OI-56

B-6722

3

P10762

1 Put the lift arms in float position by pushing the pedal all the way forward (Item 1) [Figure OI-54] until the pedal is locked in the forward position.

B-6717

P10762

Tilt the bucket backward (Item 1) [Figure OI-56] as far as it will go when the bucket is full.

Tilt the bucket forward (Item 2) [Figure OI-54] to change the position of the cutting edge of the bucket.

Filling

With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

Figure OI-57 2

Push the bottom of the lift pedal (Item 3) [Figure OI-54] to unlock the float position.

B-6724

IMPORTANT

P10762

Lower the lift arms (Item 1) [Figure OI-57] and put the cutting edge of the bucket on the ground (Item 2) [Figure OI-57]. Drive forward to the edge of the hole to push the material into the hole.

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

Tilt the bucket forward (Item 2) [Figure OI-57] as soon as it is past the edge of the hole.

I-2005-1285

Digging And Filling A Hole

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

Digging Figure OI-55 1

2

3 B-6720

P10762

Lower the lift arms all the way (Item 1) [Figure OI-55].

Put the cutting edge of the bucket on the ground (Item 2) [Figure OI-55].

Drive forward slowly and continue to tilt the bucket down (Item 2) [Figure OI-55] until it enters the ground.

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1

Drive backward to level loose material.

TOWING THE LOADER

Lower the operator cab. (See Lowering on Page PM-13.)

Procedure

The towing chain (or cable) must be rated at 1 and 1/2 times the weight of the loader. (See (553) LOADER SPECIFICATIONS on Page SPEC-3.)

IMPORTANT

•

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

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

•

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.)

I-2001-1285

NOTE: Be sure high pressure relief valves are installed before operating the loader again.

IMPORTANT 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.

Dealer Copy -- Not for Resale

I-2017-0389

To prevent damage to the loader 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 on Page PM-12.)

Clean the area around the hydrostatic pumps.

Figure OI-58

B-6924 E-1457A

Remove the high pressure relief valve from one side of each hydrostatic pump [Figure OI-58] and install the relief valve tubes. Install the plugs and tighten.

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LIFTING THE LOADER Single Point Lift

WARNING • • •

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

Assemble front cab fasteners as shown in this manual.

Never allow riders in the cab or bystanders within 15 feet (5 meters) while lifting the machine.

W-2007-0497

Figure OI-59

Dealer Copy -- Not for Resale

1

B-7489B

1

B-7489A

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

Fasten the pins (Item 1) [Figure OI-59] in the kit as shown in figure.

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

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TRANSPORTING THE LOADER ON A TRAILER

Fastening

Loading And Unloading

Figure OI-61

WARNING

Both Sides

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.

P-10731

W-2058-0494

P10730

Support P10732

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure OI60].

P-10728

The rear of the trailer must be blocked or supported [Figure OI-60] when loading or unloading the loader to prevent the front end of the trailer from raising up.

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

OI-32 54 of 122

•

Lower the bucket or attachment to the floor.

•

Stop the engine.

•

Engage the parking brake.

•

Install chains at the front and rear of the loader as shown [Figure OI-61].

553 Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Figure OI-60

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-16 Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . PM-16 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-24 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-24 Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-24 BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Adjusting Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . PM-6 Inspecting The BICS Controller (Engine Stopped - Key ON). PM-6 Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . PM-6 Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . PM-6 Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . PM-6

PREVENTIVE MAINTENANCE (PM)

Dealer Copy -- Not for Resale

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-36 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . PM-36 CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Fuse And Relay Location / Identification . . . . . . . . . . . . . . . PM-25 Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . PM-27 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . PM-26 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . PM-21 Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-22 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-21 Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . PM-22 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . PM-19 Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . PM-19 Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-19 Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . PM-20 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . PM-32 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-32 Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . PM-32

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PREVENTIVE MAINTENANCE (CONT’D) FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . PM-18 HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . PM-28 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . PM-28 Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . PM-29 Removing And Replacing Hydraulic / Hydrostatic Filter . . . PM-29 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . PM-9 Disengaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Engaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-9

Dealer Copy -- Not for Resale

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . PM-37 Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-37 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-37 LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-33 Rubber Coupler Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . PM-34 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-3 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-12 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-12 Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-12 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-35 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . PM-35 REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . PM-7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7 Maintaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-7

Continued On Next Page

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PREVENTIVE MAINTENANCE (CONT’D) SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . PM-30 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-30

Dealer Copy -- Not for Resale

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-31

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MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

CORRECT

CORRECT

CORRECT

B-10731a

B-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

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

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

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

Replace it if damaged.

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

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

WRONG

WRONG

WRONG

B-6590

B-6580

B-6589

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

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

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

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

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

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

Use eye protection approved for type of welding.

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

Lead-acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW01-0805

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

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SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat Loader.

WARNING

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

W-2003-0903

SERVICE SCHEDULE

HOURS

SERVICE REQUIRED

Engine Oil Engine Air Filter and Air System

Check the oil level and add as needed. Do not overfill.

Check condition indicator. Service only when required. Check for leaks and damaged components.

Clean debris from oil cooler, radiator and grill. Check coolant level COLD and add premixed coolant as needed.

Remove the trapped water.

Lubricate with multi-purpose lithium based grease.

Engine Cooling System Fuel Filter Lift Arms, Cylinders, Bob-Tach Pivot Pins and Wedges Tires

8-10

Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on sidewall of tire.

Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Check the sear bar and control Belt interlocks for correct operation. Clean dirt and debris from moving parts.

Bobcat Interlock Control Systems Check for correct function. See details in this Manual.

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

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

Indicators and Lights Check for correct operation of all indicators and lights.

Heater Filter (If Equipped) Clean or replace filter as needed.

Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks.

Tubelines Repair or replace as needed.

Final Drive Trans. (Chaincase), Check oil level and add oil as needed. Check for correct operation.

Foot Pedals and Steering Levers Repair or adjust as needed.

Parking Brake Check operation.

Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE MAINTENANCE ON Page PM-31) Engine/Pump Coupler Lubricate with multi-purpose lithium based grease.

Spark Arrestor Muffler Empty Spark Chamber.

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

Rubber Drive Coupler Grease the fitting with correct grease Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter.

Steering Lever Pivots Grease fittings.

Fuel Filter Replace filter element.

Alternator Belt Check condition and tension. Adjust or replace as needed.

50

100

200

■ 250

■ 500

■ 1000

Dealer Copy -- Not for Resale

ITEM

❏

✵

❍ Bobcat Interlock Control System Check the function of the lift arm bypass control.

(BICS) Hyd./Hydro. Filter and Breather Replace the filter element. Replace the breather cap.

Cap Hydraulic Reservoir Replace the fluid.

Final Drive Trans. (Chaincase) Replace the fluid.

Coolant Replace the coolant

■ ❏ ✵ ❍ ▼

▼

Every 2 years

Or every 12 months.

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

First oil and filter change must occur at 50 hours; 200 hours thereafter.

Inspect the new belt after first 50 hours.

Replace hydraulic / hydrostatic filter element after the first 50 hours, when the transmission warning light comes ON while operating or at the 500 hour interval.

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BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

Inspecting The Traction Lock (Engine RUNNING)

Inspecting The BICS Controller (Engine Stopped Key ON)

6. Fasten seat belt, disengage parking brake, press the green PRESS TO OPERATE button and raise seat bar fully. Move steering levers slowly forward and backward. The TRACTION lock should be engaged.

Lower the seat bar. Press the green PRESS TO OPERATE button.

Figure PM-1 1 2

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

3 4

Inspecting The Lift Arm Bypass Control

5

8. Raise the lift arms 6 feet (2 meters) off the ground.

Stop engine.

Pull up and hold lift arm bypass control knob until lift arms slowly lower.

1. Sit in operator’s seat. Turn key ON, lower the seat bar and disengage parking brake. Press the green PRESS TO OPERATE button. All five BICS controller lights should be ON (Items 1, 2, 3, 4 and 5) [Figure PM-1].

2. Engage the parking brake and raise the seat bar fully.

System Activated (Item 1), Seat Bar (Item 2), Valve (Item 3) and Traction lights (Item 4) [Figure PM-1] should be OFF.

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

W-2151-0394

NOTE: Record what lights are flashing (if any) and the number of light flashes. (See Contents Page SA-1.)

3. Exit the loader and press Traction Lock Override button. Traction light (Item 4) [Figure PM-1] should be ON. Press override button again and Traction light (Item 4) [Figure PM-1] should be OFF. Inspecting The Seat Bar Sensor (Engine RUNNING) 4. Sit in operator’s seat, lower seat bar, engage parking brake and fasten seat belt.

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

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

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P10157

SEAT BAR RESTRAINT SYSTEM

Maintaining

Description

See the SERVICE SCHEDULE in this manual and on the loader for correct service interval. (See SERVICE SCHEDULE on Page PM-5.)

The seat bar restraint system has a pivoting seat bar with arm rests and spring loaded interlocks for the lift and tilt control pedals.

Figure PM-2

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

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

When the seat bar is up, the lift and tilt control pedals are locked when returned to the NEUTRAL position.

Clean (Both Sides)

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

Dealer Copy -- Not for Resale

P10361

Figure PM-3

W-2105-1285

Inspecting Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the green PRESS TO OPERATE button. Operate each foot pedal to check that both the lift and tilt functions operate correctly. Raise the lift arms until the attachment is about 2 feet (600 mm) off the ground.

Clean (Both Sides)

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

P10717

Pull the seat bar down, press the PRESS TO OPERATE button and lower the lift arms. Operate the lift pedal.

While the lift arms are going up, raise the seat bar. The lift arms must stop.

Clean any debris or dirt from the moving parts [Figure PM-2] and [Figure PM-3].

Lower the seat bar, press the green PRESS TO OPERATE button, lower the lift arms and put the attachment 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.

Inspect the linkage bolts and nuts for tightness. The correct torque is 25-28 ft.-lb. (34-38 N•m).

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

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SEAT BELT

Figure PM-4

Inspection and Maintenance

1

3

WARNING Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death.

W-2466-0703

2

Check the seat belt daily for correct function.

4

The seat belt system should be repaired or replaced if it shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet (UV) rays from the sun, dusty / dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), or hardware.

B-22283

The items below are referenced in [Figure PM-4].

1. Check the seat belt webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. Look for cuts, wear, fraying, dirt and stiffness.

2. Check the buckle and latch for proper function. Make sure latch plate is not excessively worn, deformed or buckle is not damaged.

3. Check the retractor web storage device (if equipped) by extending the seat belt webbing to determine if it extends and retracts the webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have weakened.

See your Bobcat dealer for approved seat belt system replacement parts for your machine.

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Inspect the seat belt system thoroughly yearly or more often if the machine is exposed to severe environmental conditions or applications.

LIFT ARM SUPPORT DEVICE

Figure PM-6

Engaging 1

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

W-2059-0598 P10703

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.

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

W-2271-1197

Figure PM-7

Figure PM-5

1

2

1 2

P-54470A

P-9773A

N-20524B

P10706A

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod (Item 1) [Figure PM-7]

Maintenance and service work can be done with the lift arms lowered. If the lift arms are raised for service, use the following procedure:

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 both pedals until both pedals lock.

Put jackstands under the rear corners of the loader frame (Inset) [Figure PM-5].

Install pin (Item 2) [Figure PM-7] into the rear of the lift arm support device below the cylinder rod.

Remove any attachment before raising the lift arms.

Disconnect the spring from the lift arm support device retaining pin (Item 1) [Figure PM-5]. Hold onto the lift arm support device (Item 2) [Figure PM-5] and remove the retaining pin.

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Lower the lift arm support device to the top of the lift cylinder. Fasten the free end of the spring (Item 1) [Figure PM-6] to the lift arms support device so there will be no interference with the support device engagement.

WARNING

LIFT ARM SUPPORT DEVICE (CONT’D)

Figure PM-9

Disengaging Figure PM-8

1

1

P10706A

Raise the support device into storage position and insert pin (Item 1) [Figure PM-9] through lift arm support device and bracket.

P10702

Remove the pin from the lift arm support device.

Connect spring to pin.

Dealer Copy -- Not for Resale

Connect the spring (Item 1) [Figure PM-8] from the lift arm support device to the bracket below the lift arms.

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

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

Lower the lift arms and stop the engine.

Raise the seat bar and move pedals until both lock.

Disconnect the spring from the bracket.

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BACK-UP ALARM SYSTEM

Inspect the back-up alarm electrical connections (Item 1) [Figure PM-11], wire harness (Item 2) [Figure PM-11] and back-up alarm switches (Item 2) [Figure PM-12] for tightness and damage. Repair or replace any damaged components.

Description This machine may be equipped with a back-up alarm system. The back-up alarm will sound when the operator moves both steering levers in the reverse position. Slight movement of the steering levers in the reverse position is required with hydrostatic transmissions, before the backup alarm will sound.

If the back-up alarm switches require adjustment, (See Adjusting Switch Position on Page PM-11.)

Adjusting Switch Position

Inspecting

Stop the engine and raise the operator cab. (See Raising on Page PM-12.)

Figure PM-10

Figure PM-12 1

2 P-76108

1

Switch Rollers contacting tapered portion of Striker Plates

2

N-18007

Inspect for damaged or missing back-up alarm decal (Item 1) [Figure PM-10]. Replace if required.

Place the steering levers in the neutral position.

Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the PRESS TO OPERATE LOADER button. Disengage the parking brake.

Loosen the screws (Item 1) [Figure PM-12] securing the back-up alarm switches.

Move both steering levers in the reverse position. The back-up alarm must sound when all wheels are moving in reverse.

Position the back-up alarm switch rollers so that they just make contact with the tapered portion of the striker plates without compressing the switch springs [Figure PM-12].

Torque the screws (Item 1) [Figure PM-12] securing the switches to the bracket to 14-19 in.-lb. (1,6-2,1 N•m).

The back-up alarm is located on the inside of the rear door.

Lower the operator cab. (See Lowering on Page PM-13.)

Inspect back-up alarm system for proper function. (See Inspecting on Page PM-11.)

Figure PM-11

1

2 P-69346

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1

OPERATOR CAB

Raising

Description

Figure PM-13

The Bobcat Loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for rollover protection.

ROPS / FOPS - Roll Over protective Structure per ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level I - Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction sites services.

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

Stop the loader on a level surface. Lower the lift arms.

Stop the engine. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See LIFT ARM SUPPORT DEVICE on Page PM-9.)

Put jackstands under the rear corners of loader (Inset) [Figure PM-13].

WARNING

Figure PM-14

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

W-2069-0200

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

P10723

W-2014-0895

Loosen the nut (both sides) at the corner of the operator cab [Figure PM-14].

Remove the nut and plate (both sides) [Figure PM-14].

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 [Figure PM-13].

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P10719A

OPERATOR CAB (CONT’D) Lowering

WARNING Both sets of fasteners at the front of the operator cab (ROPS) must be assembled as shown in this manual.

Failure to secure ROPS correctly can cause injury or death.

W-2005-1189

P-10715

Dealer Copy -- Not for Resale

Figure PM-15

P10713

Pull down on the bottom of the operator cab until it stops at the latching mechanism. Release the latching mechanism [Figure PM-15] and pull the cab all the way down.

Install the plate and nut (both sides) [Figure PM-14].

Tighten the nuts [Figure PM-14] to 40-45 ft.-lb. (54-61 N•m) torque.

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REAR DOOR

Adjusting

Opening And Closing

Figure PM-17

WARNING

1

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

W-2012-0497

WARNING

P-68265

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

W-2020-1285

Close the rear door before operating the loader.

Figure PM-16

P10670

Reach into the slot in the rear door and pull the latch handle [Figure PM-16].

Pull the rear door open.

Move the door stop into the engaged position (Item 1) [B] to hold the door open.

Move the door stop up (Item 2) [Figure PM-16] to disengage the door stop and allow the door to close.

Close the door

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The door latch catch (Item 1) [Figure PM-17] can be adjusted side to side for alignment with the door latch mechanism.

REAR GRILL

CAB FILTERS

Removing

Cleaning And Maintenance

Figure PM-18

The heating system requires regular inspection and maintenance. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page PM-5.)

2 Filters Figure PM-19

1 1

P-68269

Lift the rear grill up and remove from the loader.

P-5176

Installing The Fresh Air Filter is located on the left side of the cab (Item 1) [Figure PM-19].

Align the holes in the grill with the studs in the loader frame (Item 2) [Figure PM-18].

Remove the knobs and remove the filter housing.

Lower the grill and install the thumb screws.

Shake the filter or use low air pressure to remove dirt.

The filter can be cleaned several times in this manner then it must be replaced.

Reinstall the filter housing.

Troubleshooting If the fan does not run, check the fuse. (See Fuse And Relay Location / Identification on Page PM-25.)

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To remove the rear grill, remove two thumb screws (Item 1) [Figure PM-18].

AIR CLEANER SERVICE

Remove the outer filter element (Item 1) [Figure PM-21].

Replacing Filter Elements

NOTE: Make sure all sealing surfaces inside the air cleaner housing are free of dirt and debris.

Figure PM-20

Install a new outer element.

2

Install the dust cover and fasten the clamps.

1 Inner Filter P-68268

Only replace the inner filter element under the following conditions:

4 3

P-68267

For the interval to service the air cleaner (See SERVICE SCHEDULE on Page PM-5.)

•

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

•

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

Figure PM-22

Dealer Copy -- Not for Resale

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

Replace the outer filter element only when the red ring (Item 1) [Figure PM-20] shows in the window of the condition indicator.

NOTE: Push the button on the condition indicator (Item 2) [Figure PM-20] and start the engine. If the red ring does not show, do not replace the filter element.

1

Release the clamps (Item 3) and remove the dust cover (Item 4) [Figure PM-20].

P-68291

Outer Filter Remove the inner filter element (Item 1) [Figure PM-22].

Figure PM-21 NOTE: Make sure all sealing surfaces inside the air cleaner housing are free of dirt and debris.

Install a new inner element.

Record the operating hours.

1

P-68290

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FUEL SYSTEM

Fuel Filter

Fuel Specifications

WARNING

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

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.

The following is one suggested blending guideline which should prevent fuel gelling during cold temperatures: TEMPERATURE F (C)

NO. 2

NO. 1

+15° (9°)

100%

0%

Down to -20° (-29°)

50%

50%

Below -20° (-29°)

0%

100%

W-2103-1285

See the SERVICE SCHEDULE for the service interval when to remove the water from the fuel filter and to replace the fuel filter. (SERVICE SCHEDULE on Page PM-5)

See your fuel supplier for local recommendations.

Filling The Fuel Tank

Removing Water

WARNING Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W-2063-0887

2

Figure PM-23

1 P-68287

1 Loosen the drain at the bottom of the filter element (Item 1) [Figure PM-24] to drain the water from filter.

Replacing Element Remove the fuel filter element (Item 2) [Figure PM-24].

P10710

Clean the area around the filter housing. Put clean oil on the seal of the new filter element. Install the fuel filter, and hand tighten.

Remove the fuel fill cap (Item 1) [Figure PM-23].

Remove air from the fuel system. (See Removing Air From The Fuel System on Page PM-18.)

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! Install and tighten the fuel fill cap (Item 1) [Figure PM23].

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Figure PM-24

FUEL SYSTEM (CONT’D)

Figure PM-26

Removing Air From The Fuel System Figure PM-25 1

2 1

P-68302

Move the engine speed control to minimum RPM. Open the valve on the injector pump (Item 1) [Figure PM-26] and squeeze the hand pump several times.

P-68287

WARNING

When the engine runs smoothly, close the valve (Item 1) [Figure PM-26].

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.

Close the rear door.

W-2103-1285

After replacing the filter element or when the fuel tank has run out of fuel, air must be 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) [Figure PM-25] on top of the fuel filter head.

Operate the hand pump (Item 2) [Figure PM-25] until fuel flows from the vent plug with no air bubbles.

Tighten the vent plug.

Operate the hand pump (Item 2) [Figure PM-25] until it feels solid.

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Start the engine.

ENGINE LUBRICATION SYSTEM

Engine Oil Chart

Checking And Adding Engine Oil

Figure PM-28

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

Figure PM-27

Use good quality motor oil that meets API Service Classification of CD or better [Figure PM-28].

P-68279

Park the machine on level ground. Open the rear door and remove the dipstick (Item 1) [Figure PM-27].

Install the dipstick and close the rear door.

Record the operating hours of the loader.

Keep the oil level between the marks on the dipstick. Do not overfill.

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1

ENGINE LUBRICATION SYSTEM (CONT’D)

Install the cap on the drain hose.

Removing And Replacing Oil And Filter

Figure PM-31

Figure PM-29

1

1 P-68280 P-68277

Follow the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page PM-5.)

Use a good quality motor oil that meets API Service Classification of CD or better (See Engine Oil Chart on Page PM-19.)

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

Fill to capacity. (See Capacities on Page SPEC-5.)

Open the rear door.

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.

Remove the cap (Item 1) [Figure PM-29], from the end of the hose and drain the oil into a container. Dispose of used oil in an environmentally safe manner.

Install the oil fill cap (Item 1) [Figure PM-31].

Figure PM-30

NOTE: DO NOT overfill the crankcase.

Close the rear door before operating the loader.

Record the operating hours of the loader.

1

P-68278

Remove the filter (Item 2) [Figure PM-30].

Clean the filter housing surface.

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

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Remove the oil fill cap (Item 1) [Figure PM-31].

ENGINE COOLING SYSTEM

Figure PM-33

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

WARNING 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.

W-2019-1285

Figure PM-32

P-68709

Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler [Figure PM-33].

Dealer Copy -- Not for Resale

Install the rear grill and close the rear door.

1

P-68269

Open the rear door.

Remove the rear grill (Item 1) [Figure PM-32]. (See REAR GRILL on Page PM-15.)

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ENGINE COOLING SYSTEM (CONT’D)

Removing And Replacing Coolant

Checking Level

Remove the rear grill. (See REAR GRILL on Page PM15.)

Figure PM-34 Open the rear door.

Remove the coolant cap (Item 2) [Figure PM-34].

Figure PM-35 2 1

1 P-68270

P13023

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

Connect a hose to the coolant drain valve (Item 1) [Figure PM-35] (located behind the engine oil filter) or use a funnel to keep coolant from getting into the engine compartment.

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

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

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.

Close the valve.

Fill the radiator with premixed coolant and install the coolant cap.

For premix recommendations (See Checking Level on Page PM-22.)

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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The coolant recovery tank must be at the FULL COLD mark (Item 1) [Figure PM-34] when engine is cold.

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant (Cont’d)

IMPORTANT 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.

Dealer Copy -- Not for Resale

I-2124-0497

Figure PM-36

1

P-68270

Fill the coolant recovery tank (Item 1) [Figure PM-36] 1/3 full with premixed coolant.

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

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 leaks and overheating.

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

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ALTERNATOR BELT

Belt Replacement

Belt Adjustment

Loosen the mounting bolt (Item 1) and adjustment bolt (Item 2) [Figure PM-37].

Figure PM-37 Move the alternator as far to the left as it will go (Item 3) [Figure PM-37] and remove the belt.

Install new belt.

2

Adjust the belt as shown at left.

Check the belt tension after several hours of operation and readjust as necessary.

1

P-68275

Dealer Copy -- Not for Resale

Stop the engine and open the rear door.

Remove the belt shield.

Loosen the mounting bolt (Item 1) and adjustment bolt (Item 2) [Figure PM-37].

Figure PM-38

1

P-68276

Move the alternator to set the belt tension at 5/16'' (8 mm) movement between pulleys (Item 1) [Figure PM-38] with 15 pounds (67 N) of force.

Tighten the adjustment bolt and mounting bolt.

Install the belt shield and close the rear door.

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ELECTRICAL SYSTEM

Battery Maintenance

Description

Figure PM-41

The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses and relays. The fuses will protect the electrical system when there is an electrical overload. Find the reason for the overload before starting the engine again.

Fuse And Relay Location / Identification Figure PM-39

P-09589

The battery cables must be clean and tight [Figure PM41]. Check electrolyte level in the battery. Add distilled water as needed. Remove acid or corrosion from battery and cables with sodium bicarbonate (baking soda) and water solution.

1

Put Battery Saver (6664458) or grease on the battery terminals and cable ends to prevent corrosion.

P-68284

The fuses are located under the fuse cover (Item 1) [Figure PM-39] located in the engine compartment.

WARNING

Figure PM-40

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

1

In case of acid contact, wash immediately with water.

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

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

W-2065-1296 P-68292

The fuse decal (Item 1) [Figure PM-40] shows the size and location of each fuse.

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P-09590

ELECTRICAL SYSTEM (CONT’D)

Keep cables away from moving parts. Start the engine.

(See STARTING THE ENGINE on Page OI-18.)

Using A Booster Battery (Jump Starting) After the engine has started, remove the ground (-) cable (Item 4) [Figure PM-42] first.

If it is necessary to use a booster 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.

Remove the cable from the positive terminal (Item 2) [Figure PM-42].

The key switch must be OFF. The booster battery must be 12 volt.

IMPORTANT WARNING

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.

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.

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

WARNING

W-2065-1296

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

Figure PM-42 2

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.

4 Battery gas can explode and cause serious injury.

W-2066-0705

1

3 P-68297

Connect the end of the first cable (Item 1) [Figure PM42] to the positive (+) terminal of the booster battery.

Connect the other end of the same cable (Item 2) [Figure PM-42] to the positive terminal on the loader starter.

Connect the end of the second cable (Item 3) [Figure PM-42] to the negative (-) terminal of the booster battery.

Connect the other end of the same cable (Item 4) [Figure PM-42] to the engine.

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ELECTRICAL SYSTEM (CONT’D)

Figure PM-44

Removing And Installing Battery 1

WARNING 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-68298

Disconnect the positive (+) cable (Item 1) [Figure PM-44] from the battery.

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

Remove the battery from the loader.

W-2065-1296

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Figure PM-43

2

1

P-68300

Open the rear door.

Disconnect the negative (-) cable (Item 1) [Figure PM43].

Remove the battery hold down clamp (Item 2) [Figure PM-43].

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HYDRAULIC / HYDROSTATIC SYSTEM

Figure PM-46

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

The system has an engine driven pump that supplies fluid 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.

1

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

P10697

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

Remove the filler cap (Item 1) [Figure PM-46].

Checking And Adding Fluid

Add fluid to the reservoir until it shows in the sight gauge [Figure PM-45].

Install the filler cap [Figure PM-46].

1

P10693

Use only recommended fluid in the hydraulic system.

(See Hydraulic System on Page SPEC-5.)

Put the loader on a level surface Lower the lift arms and tilt the Bob-Tach fully back.

Stop the engine.

Hydraulic fluid must show in the sight gauge (Item 1) [Figure PM-45].

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Figure PM-45

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Removing And Replacing Hydraulic Fluid

Removing And Replacing Hydraulic / Hydrostatic Filter

Figure PM-48

Figure PM-47

1

1

P10697

For the service interval to replace the fluid (See SERVICE SCHEDULE on Page PM-5.) Replace the fluid if it becomes contaminated and after any major repairs.

P-68282

For the correct service interval to replace the filter (See SERVICE SCHEDULE on Page PM-5.)

Dealer Copy -- Not for Resale

Remove the filler cap (Item 1) [Figure PM-48].

Figure PM-49

Stop the engine. Open the rear door.

Clean the area around the filter housing and remove the filter element (Item 1) [Figure PM-47].

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

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

Operate the loader and check for leaks at the filter.

Check fluid level in the reservoir and add as needed.

P10695

Close the rear door.

Remove the screen (Item 1) [Figure PM-49].

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

WARNING

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

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

Remove the filter element. Install a new filter element (See procedure above).

Add hydraulic/hydrostatic fluid to the reservoir. (See (553) LOADER SPECIFICATIONS on Page SPEC-3.)

DO NOT fill above the sight glass.

W-2103-1285

Install the filler cap. Operate the loader. Stop the engine.

Check the fluid level and add as needed.

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SPARK ARRESTOR MUFFLER

Start the engine.

Cleaning Procedure

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

Stop the engine and install the plug.

WARNING

Close the rear door.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles.

Failure to obey can cause serious injury.

WARNING

W-2011-1285

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

WARNING

IMPORTANT

W-2050-1285

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

Figure PM-50

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

1

Make reference to local laws and regulations for spark arrestor requirements

P-68283

I-2022-0595

For correct service interval to clean the spark arrestor muffler (See SERVICE SCHEDULE on Page PM-5.)

Do not operate the loader with a defective exhaust system.

Stop the engine. Open the rear door.

Cover the battery with a fire retardant material.

Remove the plug (Item 1) [Figure PM-50] at the bottom of the muffler.

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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.

TIRE MAINTENANCE

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

Wheel Nuts Figure PM-51

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

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

P10704

See your SERVICE SCHEDULE for the service interval to check the wheel nuts [Figure PM-51]. (See SERVICE SCHEDULE on Page PM-5.).

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.

When installing wheel nuts, tighten to 160 ft.-lb. (217 N•m) torque.

When checking wheel nut torque, set the torque wrench to 140 ft.-lb. (190 N•m) to prevent over-tightening.

WARNING

Rotating Check the tires regularly for wear, damage and pressure.

For the correct tire pressure (See (553) LOADER SPECIFICATIONS on Page SPEC-3.)

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

W-2078-1285

Figure PM-52

C-1965

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [Figure PM-52].

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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, void excessive 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.

FINAL DRIVE TRANSMISSION (CHAINCASE)

Removing And Replacing Oil

Checking And Adding Oil

For the service interval to replace the chaincase oil (See SERVICE SCHEDULE on Page PM-5.)

The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic / hydrostatic system.

(See (553) LOADER SPECIFICATIONS on Page SPEC-3.)

Remove the plug (Item 1) [Figure PM-53] and remove the oil from the chaincase.

Fill the chaincase through the check plug hole. The level is correct when oil flows from the hole. Use the correct oil. (See (553) LOADER SPECIFICATIONS on Page SPEC-3.)

Drive the loader onto a level surface and stop the engine.

Figure PM-53

Dealer Copy -- Not for Resale

1

P10699

Remove the plug (Item 1) [Figure PM-53].

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

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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LUBRICATING THE LOADER

Figure PM-56

Lubrication Locations Lubricate the loader as specified for the best performance of the loader. (See SERVICE SCHEDULE on Page PM-5.)

3

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:

P10700

Figure PM-54 3. Lift Arm Pivot Pin (Both Sides) [Figure PM-56].

4 1

P10694A

1. Rod End Lift Cylinder (Both Sides) [Figure PM-54].

P10758

Figure PM-55 4. Base End Tilt Cylinder [Figure PM-57].

2

P10698

2. Base End Lift Cylinder (Both Sides) [Figure PM-55].

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Figure PM-57

LUBRICATING THE LOADER (CONT’D)

Rubber Coupler Lubrication

Lubrication Locations (Cont’d)

Figure PM-60

Figure PM-58 1 5 6 7

P-68266

5. Rod End Tilt Cylinder [Figure PM-58].

For the correct service interval to lubricate the engine / pump coupler (Item 1) [Figure PM-60] (See SERVICE SCHEDULE on Page PM-5.)

6. Bob-Tach Pivot Pin (Both Sides) [Figure PM-58].

Raise the operator cab. (See Raising on Page PM-12.)

7. Bob-Tach Wedge (Both Sides) [Figure PM-58].

Use lithium based grease. There are three grease fittings.

Figure PM-59 Lower the operator cab. (See Lowering on Page PM-13.)

8

P10709

8. 250 Hours: Steering Lever Shaft Bearings (2) [Figure PM-59] (The opposite end is lubricated under the cab.)

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

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P10696

PIVOT PINS Inspection And Maintenance Figure PM-61

1

P10698

Dealer Copy -- Not for Resale

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [Figure PM-61].

Check that the lock nuts are tightened to 18-20 ft.lb. (2427 N•m) torque.

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BOB-TACH

Figure PM-64 Bob-Tach Wedge

Inspection And Maintenance

WARNING Bob-Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked.

Failure to secure wedges can allow attachment to come off and cause injury or death.

Wedge must contact lower edge of hole in the attachment.

W-2102-0497

B-15177

Figure PM-62

1

If the wedge does not contact the lower edge of the hole [Figure PM-63] and [Figure PM-64], the attachment will be loose and can come off the Bob-Tach.

Figure PM-65

N-17031

Move the Bob-Tach levers to engage the wedges [Figure PM-62]. The levers and wedges must move freely.

The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure PM-62].

Figure PM-63 TS-1062

Inspect the mounting frame on the attachment and BobTach, linkages and wedges for excessive wear or damage [Figure PM-65]. Replace any parts that are damaged, bent or missing. Keep all fasteners tight.

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

Lubricate the wedges. (See SERVICE SCHEDULE on Page PM-5.) (See LUBRICATING THE LOADER on Page PM-33.)

1 N-17034

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The spring loaded wedge (Item 1) [Figure PM-62] must contact the lower edge of the hole in the attachment (Item 1) [Figure PM-63] and [Figure PM-64].

Return to Service

Storage

After the Bobcat Loader has been in storage, it is necessary to follow a list of items to return the loader to service.

Sometimes it may be necessary to store your Bobcat Loader for an extend period of time. Below is a list of items to perform before storage.

•

Thoroughly clean the loader including the engine compartment.

•

Lubricate the loader.

•

Replace worn or damaged parts.

•

Park the loader in a dry protected shelter.

•

Lower the lift arms all the way and put the bucket flat on the ground.

•

Put blocks under the frame to remove weight from the tires.

•

Put grease on any exposed cylinder rods.

•

Put fuel stabilizer in the fuel tank and run the engine a few minutes to circulate the stabilizer to the pump and fuel injectors.

•

Drain and flush the cooling system. Refill with premixed coolant.

•

Replace all fluids and filters (engine, hyd. / hydro.).

•

Replace air cleaner, heater and air conditioning filters.

•

Put all controls in neutral position.

•

Remove the battery. Be sure the electrolyte level is correct then charge the battery. Store it in a cool dry place above freezing temperatures and charge it periodically during storage.

•

Cover the exhaust pipe opening.

•

Tag the machine to indicate that it is in storage condition.

PM-37 93 of 122

•

Check the engine and hydraulic oil levels; check coolant level.

•

Install a fully charged battery.

•

Remove grease from exposed cylinder rods.

•

Check all belt tensions.

•

Be sure all shields and guards are in place.

•

Lubricate the loader.

•

Check tire inflation and remove blocks from under frame.

•

Remove cover from exhaust pipe opening.

•

Start the engine and let run for a few minutes while observing the instrument panels and systems for correct operation.

•

Operate machine, check for correct function.

•

Stop the engine and check for leaks. Repair as needed.

553 Operation & Maintenance Manual

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LOADER STORAGE AND RETURN TO SERVICE

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SYSTEM SETUP & ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . SA-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-3 Troubleshooting The Hydrostatic / Drive System. . . . . . . . . . SA-4 Troubleshooting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . SA-3 Troubleshooting The Hydraulic System . . . . . . . . . . . . . . . . . SA-4

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SYSTEM SETUP & ANALYSIS (SA)

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TROUBLESHOOTING

WARNING

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 DS (Dealer Service) and must be performed only by qualified Bobcat service personnel.

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service.

Untrained operators and failure to follow instructions can cause injury or death.

Troubleshooting The Engine

PROBLEM

CAUSE

CORRECTION

Engine will not turn over with starter

Battery has low charge

Charge battery and find cause for loss of charge

Cables loose or dirty

Clean and tighten battery cables

Damaged starter, solenoid or wiring

Check the starting circuit. Repair as needed

Engine turns with starter, but is difficult Wrong starting procedure to start Air in the fuel Ignition system is damaged

Use correct starting procedure Remove air from the fuel system Check & repair as needed

Auxiliary control lever in continuous flow Move controls to neutral position or lift is in float

Engine has little power or runs rough

Engine overheats

No fuel in tank

Add fuel

Vent in fuel filter cap is plugged

Clean the vent

Dirt or water in fuel system

Repair as needed

Fuel filter is dirty

Install a new filter

Hole or leak in fuel line

Repair as needed

Weak battery

Charge or replace battery

Wrong oil in engine

See Oil Specifications

Cylinder compression is low

Recondition the engine

Engine has overheated

Check cooling system

Poor fuel quality

Use fresh, good quality fuel

Injectors are not working correctly

Repair as needed

Dirt, water or air in fuel system

Clean and repair as needed

Engine is hot

See Engine Overheats

Restricted exhaust

Clean exhaust system

Dirty air cleaner

Install new element

Cylinder compression is low

Recondition the engine

Restriction in cooling air flow

Check for debris on radiator grill

Blower shrouding damaged or missing

Check shroud and repair or replace as needed

Engine is overloaded.

Run at full throttle.

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W-2003-0903

TROUBLESHOOTING (CONT’D) Troubleshooting The Hydrostatic / Drive System CAUSE

No drive on both sides

Hydraulic fluid is low

Check fluid level, add as needed.

Damaged hydraulic pump

Replace filter.

Hydrostatic system is damaged.

Check hydrostatic system

Hydrostatic system is damaged.

Check hydrostatic system and repair as needed

Control linkage is disconnected.

Repair linkage

Wrong tire pressure

Check all tires for correct pressure

Steering linkage interference

Check steering linkage and adjust as needed.

Hydrostatic system is damaged.

Check system. Repair as needed.

Loader moves when levers are in neutral

Steering linkage out of adjustment

Adjust steering linkage.

System is overheating

Hydraulic fluid level is low.

Check fluid level and add as needed.

Cooling system is dirty, air restricted.

Clean cooling system. Check for debris on radiator grill.

No drive on one side

Machine pulls to one side

CORRECTION

Low charge pressure (transmission light Check by-pass valve. on)

Parking brake will not hold

Auxiliary control in continuous flow position

Move controls to neutral position.

Loader is overloaded.

Use correct size attachment.

Hydrostatic system is damaged.

Check system and make repair.

-----

-----

Troubleshooting The Hydraulic System PROBLEM

CAUSE

CORRECTION

No hydraulic action.

No hydraulic fluid

Check fluid level and add as needed.

Pedals are disconnected.

Check linkage. Repair as needed.

Relief valve is damaged.

Replace the relief valve.

Hydraulic pump is damaged.

Check pump and replace as needed.

Hydraulic fluid is too thick.

Let machine warm up.

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

Hydraulic action is slow.

Pedal is hitting floor or debris under pedal.

Check adjustment. Remove debris.

Cylinders leak internally.

Check condition of cylinders and repair as needed.

Hydraulic pump is damaged.

Check pump and replace as needed.

Hydraulic fluid is too thick.

Let machine warm up.

Damage to cylinder rods or seals.

Repair cylinders.

Hydraulic cylinders leak fluid.

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PROBLEM

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

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

Troubleshooting

System Activated

Seat Bar

Valve

Traction

LIGHT ON

PRESS TO OPERATE Button is pressed.

Seat Bar is down.

Control valve can be used.

LIGHT OFF

PRESS TO OPERATE Button is not pressed.

Seat Bar is up.

Lift, tilt and traction functions will not operate.

Lift and tilt functions will not operate.

Control valve Lift, tilt and cannot be used. traction functions will not operate.

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

Loader cannot be moved forward and backward.

2

System Activated circuit shorted to battery voltage*

3

System Activated circuit shorted to ground Seat Bar sensor circuit shorted to battery voltage* Seat Bar sensor circuit shorted to ground

2 3 2 3 3 1 2 3 4 5

6 Power

BICS Controller is operating correctly.

BICS Controller is not operating correctly.

Lift, tilt and traction functions will not operate.

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N/A

Valve output circuit shorted to battery voltage* Valve output circuit shorted to ground.

Controller not grounded or intermittent ground Traction lock hold solenoid circuit is open Traction lock hold solenoid circuit shorted to battery voltage* Traction lock hold solenoid circuit shorted to ground Traction lock pull coil circuit is open Traction lock pull solenoid circuit is shorted to battery voltage* - ERROR ON (Should be OFF) Traction lock pull solenoid circuit ERROR OFF (Should be ON).

N/A

553 Operation & Maintenance Manual

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INDICATOR LIGHT

EFFECT ON SERVICE CODES MEANS SYSTEM ERROR OPERATION (SEE YOUR BOBCAT DEALER FOR SERVICE) OF LOADER NO. OF WHEN LIGHT CAUSES FLASHES IS OFF

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MACHINE SIGN TRANSLATIONS DANGER (6702301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 DANGER (6702302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 DANGER (6717343) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 SERVICE SCHEDULE (6734534). . . . . . . . . . . . . . . . . . . . . . . . . . . MST-3 WARNING (6577754) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-8 WARNING (6579528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7

WARNING (6733996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9 WARNING (6737189) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9

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WARNING (6710358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9 MACHINE SIGN TRANSLATIONS (MST)

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SERVICE SCHEDULE (6734534)

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SERVICE SCHEDULE (6734534) (CONT’D)

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SERVICE SCHEDULE (6734534) (CONT’D)

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DANGER (6702301)

DANGER (6717343)

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DANGER (6702302)

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WARNING (6579528)

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WARNING (6577754)

IMPORTANT (6560573)

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WARNING (6579510)

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WARNING (6710358)

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WARNING (6733996)

WARNING (6737189)

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SPECIFICATIONS

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(553) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4

SPECIFICATIONS (SPEC)

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(553) LOADER SPECIFICATIONS Dimensions •

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•

Dimensions are given for loader equipped with standard tires and 48 inch 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.

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

B-17154 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.

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(553) LOADER SPECIFICATIONS (CONT’D) Performance Rated Operating Capacity (SAE)

950 lb. (431 kg)

Tipping Load (ISO Rating)

1930 lb. (875 kg)

Operating Weight

3765 lb. (1708 kg)

SAE Breakout Force - Lift

1950 lbf. (8674 N)

- Tilt Axle Stall Torque

1800 lbf. (8007 N) 2650 lbf.-ft. @ 4350 PSI (3593 N•m @ 300 bar)

Controls Direction and speed controlled by two steering levers

Loader Hydraulics - Lift and Tilt Front Auxiliary

Controlled by separate foot pedals Controlled by lateral movement of Right Hand steering lever

Engine

Hand lever throttle; Key-Type starter switch and shutdown

Starting Aid

Glow Plugs - Activated by rocker switch in instrument panel

Service Brake

Two independent hydrostatic systems controlled by two hand operated steering levers

Parking Brake (Standard)

Mechanical Disc, foot operated pedal (Early Models); electric switch (Later Models) in instrument panel

Engine Make / Model

Kubota / D1105-E2B

Fuel / Cooling

Diesel / Liquid

Horsepower (SAE Net)

25.0 HP (18,6 kW) @ 3000 RPM

Low Idle

1125 - 1175 RPM

High Idle

3125 - 3175 RPM

Torque (SAE Net)

52 lbf.-ft. (70,5 N•m) @ 2100 RPM

Number of Cylinders

3

Displacement

68.5 cu. in. (1,1 L)

Bore / Stroke

3.07 in. / 3.09 in. (78 mm / 78,4 mm)

Lubrication

Gear Pump Pressure System with Filter

Crankcase Ventilation Air Cleaner

Open Breathing Dry replaceable paper cartridge with separate safety element

Ignition

Compression - Diesel

Engine Coolant

Propylene glycol / water mixture (53% PG / 47% water)

Starting Aid

Glow Plugs

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Vehicle Steering

(553) LOADER SPECIFICATIONS (CONT’D) Hydraulic System Engine driven, Gear type 11 GPM (41,6 L/min.) @ 3000 RPM 2300 PSI (158,6 bar) 3-micron replaceable cartridge in the hydrostatic pump charge line 3-Spool, series type, open center w/float detent on lift and detent on auxiliary Double acting; with cushioning feature on tilt cylinders (dump and rollback) 2.00 (50,8)

Tilt Cylinder (1) Rod Diameter:

3.00 (76,2)

Lift Cylinder (2)

1.25 (31,8)

Tilt Cylinder (1) Stroke:

1.50 (38,1)

Lift Cylinder (2) Tilt Cylinder (1)

Fluid Lines Fluid Type

25.67 (652,0) 13.25 (336,6) SAE standard tubelines, hoses and fittings BOBCAT FLUID, Hydraulic/Hydrostatic 6903117 - (Two - 2.5 Gal.) 6903118 - (5 Gal.) 6903119 - (55 Gal.)

Hydraulic Function Time: Raise Lift Arms Lower Lift Arms Bucket Dump Bucket Rollback

3.9 Seconds 3.3 Seconds 2.4 Seconds 1.8 Seconds

Electrical Alternator

65 amp ventilated

Battery

12 volts; 600 cold cranking amps @ 0°F (-18°C) 115 minute reserve capacity @ 25 amps

Starter

12 volt, gear reduction type; 1.88 HP (1,4 kW)

Instrumentation

Gauges: Hourmeter, temperature gauge, voltmeter, fuel gauge Warning lights: Engine Oil Pressure, Engine Coolant Temperature, Hydrostatic Charge Pressure, Hydraulic Oil Temperature Other: BICS Functions (on BICS Controller)

Drive System Main Drive

Fully hydrostatic, 4-wheel drive

Transmission

Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing hydrostatic motors

Final Drive Chains

#60 HS endless roller chain and sprockets in sealed chaincase with oil lubrication

Axle Size

1.75 in. (44,5 mm)

Wheel Bolts

Six 9/16 in. Wheel bolts fixed to axle hubs

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Pump Type Pump Capacity System Relief at Quick Couplers Hydraulic Filter Control Valve Hydraulic Cylinders: Bore Diameter: Lift Cylinder (2)

(553) LOADER SPECIFICATIONS (CONT’D) Capacities Fuel Tank

10 Gal. (37,9 L)

Engine Oil with Filter

5.4 qt. (5,1 L)

Cooling System

9.7 qt. (9,2 L)

Hydraulic / Hydrostatic Reservoir

2.3 Gal. (8,7 L)

Hydraulic / Hydrostatic System (including Reservoir)

4.8 Gal. (18,2 L)

Chaincase Reservoir

4 Gal. (15,1 L)

Tires Sizes

Recommended Pressure 35 PSI (2,4 bar)

27-8.5x15 Six Ply

50 PSI (3,4 bar)

27-10.5x15 Four Ply

45 PSI (3,1 bar)

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27-8.5x15 Four Ply

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WARRANTY

WARRANTY

WARRANTY

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WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY-3

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WARRANTY Bobcat Loaders

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company's option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement.

Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

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

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

6570162 (8-02)

Printed in U.S.A.

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Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Loader will be free from proven defects in material and workmanship with respect to (i) all components of the product except as otherwise specified herein for twelve (12) months, (ii) the drive belt from the hydrostatic pump to the engine, for thirty six (36) months, provided that after the initial twelve month warranty period, such warranty shall be limited to parts only and does not include labor, (iii) tracks and Bobcat brand tires, for twelve (12) months on a prorated basis based on the remaining depth of the track or tire at the time any defect is discovered, and (iv) Bobcat brand batteries, for an additional twelve (12) months after the initial twelve month warranty period, provided that Bobcat Company shall only reimburse a fixed portion of the cost of replacing the battery during such additional twelve months. The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

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ALPHABETICAL INDEX AIR CLEANER SERVICE................................................................ PM-16 ALTERNATOR BELT ....................................................................... PM-24 ATTACHMENTS ................................................................................ OI-22 BACK-UP ALARM SYSTEM ............................................................... OI-8 BACK-UP ALARM SYSTEM ............................................................PM-11 BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED ..............................V BOBCAT INTERLOCK CONTROL SYSTEM (BICS) .......................... OI-7 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ........................ PM-6 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ......................... SA-5 BOB-TACH ...................................................................................... PM-36 CAB FILTERS ................................................................................. PM-15

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DAILY INSPECTION ......................................................................... OI-14 DELIVERY REPORT...............................................................................VI DRIVING AND STEERING THE LOADER ....................................... OI-10 ELECTRICAL SYSTEM .................................................................. PM-25 ENGINE COOLING SYSTEM ......................................................... PM-21 ENGINE LUBRICATION SYSTEM.................................................. PM-19 ENGINE SPEED CONTROL............................................................... OI-9 FEATURES, ACCESSORIES AND ATTACHMENTS ...........................VIII FINAL DRIVE TRANSMISSION (CHAINCASE) ............................. PM-32 FUEL SYSTEM ............................................................................... PM-17 HYDRAULIC CONTROLS................................................................. OI-11 HYDRAULIC / HYDROSTATIC SYSTEM ....................................... PM-28 INSTRUMENT PANEL IDENTIFICATION ........................................... OI-3

ALPHABETICAL INDEX

LIFT ARM BYPASS CONTROL .......................................................... OI-7 LIFT ARM SUPPORT DEVICE ......................................................... PM-9 LIFTING THE LOADER..................................................................... OI-31 LOADER IDENTIFICATION ...................................................................VII (553) LOADER SPECIFICATIONS .................................................... SA-3 LOADER STORAGE AND RETURN TO SERVICE........................ PM-37 LUBRICATING THE LOADER ........................................................ PM-33 MACHINE SIGNS (DECALS)............................................................... XVI MAINTENANCE SAFETY ................................................................. PM-3 Continued On Next Page

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ALPHABETICAL INDEX (CONT’D) OPERATING PROCEDURE ............................................................. OI-26 OPERATOR CAB ............................................................................ PM-12 PARKING BRAKE ............................................................................... OI-9 PIVOT PINS .................................................................................... PM-35 PRE-STARTING PROCEDURE ........................................................ OI-16 PUBLICATIONS AND TRAINING RESOURCES............................... XVIII

SAFETY INSTRUCTIONS ................................................................... XIII SEAT BAR RESTRAINT SYSTEM...................................................... OI-5 SEAT BAR RESTRAINT SYSTEM.................................................... PM-7 SEAT BELT........................................................................................ PM-8 SERIAL NUMBER LOCATIONS ............................................................ VI SERVICE SCHEDULE ...................................................................... PM-5 SPARK ARRESTOR MUFFLER...................................................... PM-30 STARTING THE ENGINE.................................................................. OI-18 STOPPING THE ENGINE AND LEAVING THE LOADER ................ OI-20 STOPPING THE LOADER ................................................................ OI-10 TIRE MAINTENANCE ..................................................................... PM-31 TOWING THE LOADER.................................................................... OI-30 TRACTION LOCK OVERRIDE ........................................................... OI-8 TRANSPORTING THE LOADER ON A TRAILER ............................ OI-32 TROUBLESHOOTING ....................................................................... SA-3 WARRANTY ........................................................................WARRANTY-3

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REAR DOOR................................................................................... PM-14 REAR GRILL ................................................................................... PM-15 REGULAR MAINTENANCE ITEMS........................................................ V