MAINTENANCE SAFETY

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

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

Correct

Correct

Correct

Never service the Bobcat® Skid Steer Loader without instructions.

Wrong

Use the correct procedure to lift or lower operator cab with lift arms down.

Cleaning and maintenance are required daily.

Wrong Wrong

Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Wrong

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.

Vent exhaust to outside when engine must be run for service. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

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

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

Wrong Wrong

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

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader.

Lead–acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which arenot in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

Service Schedule

Maintenance work must be done at regular intervals. Failure to do so will result in excessivewear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.

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

Engine Oil

Check the oil level & add oil as needed.

Engine Air Cleaner Empty the dust cup. Check for leaks and damaged components. (641 & 643) Replace the outer filter element only when the red ring shows in the indicator window.

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

Tires Check for damaged tires and correct air pressure.

Seat Belt and Seat BarCheck the condition of seat belt. Check the seat bar for correct operation.

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

Lift Arm and Bob–TachAdd grease to the fittings until extra grease shows.

Pivot Areas

Engine Fuel Filter (641 & 643)Remove water from filter.

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

Wheel Nuts Check for loose wheel nuts. Tighten to correct torque if loose.

Engine Oil and Filter Replace the oil and the engine oil filter.

Battery Check the water level. Check battery cables for corrosion. Check that the battery cables are tight. Check covers.

Parking Brake Check operation and adjust as needed.

Hydraulic Fluid, TubelinesCheck the fluid level and add as needed. Checkfor damage and and Hoses leaks and replace as needed.

Alternator Drive Belt Check the tension and adjust as needed.

Chaincase Check the fluid level and add as needed.

Controls Check operation and adjust as needed.

Spark Arrestor MufflerRemove the plug and clean the spark chamber.

Engine Air Cleaner (642B)Replace air condition element. Replace element more often when operating in severe dust conditions.

Governor (642 & 642B)Check oil level and add as needed.

Seat Bar Grease pivots as needed.

Steering Shaft Pivots Grease two (2) fittings. Add oil to steering shaft.

Hyd. and Hydro. FiltersReplace filter elements.

Ignition System (642)Check plugs, points and timing. Replace damaged parts.

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

Engine Fuel Filter Replace the filter element.

Hydraulic/HydrostaticReplace breather cap.

Reservoir Breather Cap

Chaincase Replace the fluid.

Hydraulic Fluid ReservoirReplace the hydraulic fluid.

Check wheel nut torque every 8 hours for the first 24 hours. Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months.

NOTE:Lift arm support devices are available from your Bobcat loader dealer.

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

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

Place jackstands under the rear corners of the loader. One person must be in the operator’s seat, with the seat belt fastened and the seat bar lowered, until the lift arm support device is installed [A]

Start the engine and raise the lift arms all the way up. Have a second person install the lift arm support device over the rod of one of the lift cylinders.

The lift arm support device must be tight against the cylinder rod. Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder.

Operator Cab

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects.

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

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

W–2069–1285

The operator cab fastening bolts and nuts must be tight [A]

Tighten to 40–50 ft.–lbs. (54–68 Nm) torque.

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

W–2005–1189

Raising the Operator Cab

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

W–2014–1285

Stop the loader on a level surface. Lower the lift arms fully. If the lift arms must be up while raising the operator cab, install a lift arm support device. (See Page 28.)

Remove the two (2) fasteners (including the washers or plates) at the front corners of the operator cab [A]

OPERATOR CAB (Cont’d)

Raising the Operator Cab (Cont’d)

If the lift arms are down, stand on the safety tread (lift arm crossmember) and lift on the top of the operator cab and the grab handle. Slowly lift until the operator cab is all the way up [A]

If the lift arms are up, install an approved lift arm support device. (See Page 28.) Stand in front of the loader. Lift on the grab handle and the bottom of the operator cab slowly until the operator cab is all the way up [B].

Lowering the Operator Cab

NOTE:Make sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab.

If the lift arms are down, stand on the safety tread (lift arm crossmember). Pull down on the bottom of the operator cab and use the grab handles and the operator cab top until the operator cab is all the way down [A]

If the lift arms are held up by a lift arm support device, stand in front of the loader. Pull down on the bottom of the operator cab and use the grab handle until the cab is all the way down [B]

Install the two (2) fasteners, (including the washers and plate). Tighten the nuts to 40–50 ft.–lbs. (54–69 Nm) torque [C]

Seat Bar Restraint System

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

Inspecting the Seat Bar

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

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

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

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

Maintaining the Seat Bar

See the Service Schedule Page 27 and on the loader for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B] Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

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

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

Rear Door

Opening the Rear Door

Avoid Injury

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

Open the rear door to service the engine. Pull the door latch up and to the left to release the door latch [A] The door can then be opened to get to the engine.

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

Adjusting the Rear Door

Loosen the set screw (Item 1) [B]

Loosen the nut (Item 2) [B]

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

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

With the set screw up, the flanges at the bolts (Item 3)[C] must be to the sides so that the set screw aligns with the flat surface of the end of the bolt.

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

Tighten the nut (Item 2) [B] to 65–70 ft.–lbs. (88–95 Nm) torque [B]

Air Cleaner Service

See the Service Schedule Page 27 for the interval to service the air cleaner system.

Check the air intake hoses for wear. Check if the air cleaner is damaged. Check all the connections.

641 & 643DS Only: Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator [A] & [B]

641 & 643 Only: Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

642 Only: Replace the filter element only when the red ring shows in the window of the condition indicator [C]

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 1) [A], [B] and [C], start the engine. If the red ring does not show, do not replace the filter element.

642B Only: Replace the filter element every 100 hours as the service schedule requires. Replace more often when operating in severe dust conditions.

NOTE: There is no condition indicator on the 642B [D].

AIR CLEANER SERVICE (Cont’d)

Use the following procedure to replace the filter element(s):

Loosen the clamp (Item 1) [A] & [B] on the dust cup.

Remove the dust cup (Item 6) [A] & [B] and the outer element (Item 2) [A] & [B]

Remove the rubber boot (Item 3)[A] & [B] inside the dust cup and empty the dust cup.

Clean the inside of the air cleaner housing so the element has a smooth surface to contact at the seal (Item 4) [A] & [B]

Check the air cleaner housing for holes from corrosion. Install the new filter element(s).

NOTE: The washer (Item 5) [A] & [B] must be under the wing nut.

Install the dust cup so the arrow on the cup is up. Tighten the clamp.

Push the button on the indicator to remove the red ring.

Fuel Specifications

641 & 643 Only: Use number 2 diesel fuel in the engine. During very cold temperatures, number 1 fuel can be used.

The following is one suggested blending guideline which should prevent fuel gelling problems:

Temp. F° (C°) No. 2No.1

+15° (9°) 100% 0%

Down to –20° (–29°)50% 50%

Below –20° (29°) 0% 100%

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

642 Only: Use regular gasoline in the engine.

642B Only: Use regular or unleaded gasoline in the engine.

Filling the Fuel Tank

B

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

W–2063–0887

Remove the fuel fill cap (Item 1) [A] & [B].

B–3994

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

Install and tighten the fuel fill cap [A]

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

WRONG

FUEL SYSTEM (Cont’d)

Fuel Filter (641 & 643 Only)

The fuel filter is on the right upright in the engine compartment [A] & [B]

See the Service Schedule Page 27 for the interval to service the fuel filter.

If there is water in the water trap at the bottom of the filter, loosen the thumb screw (Item 1) [A] & [B].

Remove the water trap and clean the water from the trap.

Use the following procedure to replace the fuel filter element:

Clean the fuel filter area. Close the shut–off valve.

Use a wrench to loosen the fuel filter head bolts (Item 2) [A] & [B]. Remove the water trap and filter element.

Replace seals as needed.

Installation: Install the new filter element and water trap and hand tighten only.

Open the shut–off valve (Item 2) [C].

Fuel Filter (642 & 642B Only)

The fuel filter (Item 1) [C] is in the fuel line by the shut–off valve (Item 2) [C].

See the Service Schedule Page 27 for the interval to service the fuel filter.

Clean the area around the fuel filter. Close the shut–off valve (Item 2) [C]

Loosen the nut and remove the tubeline (Item 3) [C]

Remove the element from the valve.

Install a new element with the arrow pointing in the direction of the carburetor.

Connect the tubeline and tighten the nut.Open the valve. Start the engine and check for leaks.

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

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285

FUEL SYSTEM (Cont’d)

Removing Air from the Fuel System (641)

After replacing the fuel filter element or when the fueltank has run out of fuel, the air must be removed from the fuel system before to starting the engine.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. 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.

Open the rear door. The engine must be cool.

Loosen the slotted plug (Item 1) [A].

Move the priming lever (Item 2) [A] until fuel flows from the plug (Item 1) [A] with no air bubbles showing.

Tighten the vent plug.

Loosen the pressure fitting at each injector (Item 1) [B].

Turn the engine until the fuel flows from the fittings with no air bubbles.

Tighten the fitting. Do not overtighten.

Removing Air from the Fuel System (643)

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

Open the rear door. The engine must be cool.

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

Operate the hand pump (Item 2) [C] until fuel flows from the vent plug (Item 1) [C] with no air bubbles.

Tighten the vent plug.

Operate the hand pump until it feels solid.

Move the throttle control to minimum RPM. Loosen the valve (Item 1) [D] and squeeze the hand pump several times.

Start the engine. When the engine runs smoothly, close the valve (Item 1) [D].

Engine Lubrication System

Checking Engine Oil

Check the engine oil level every day.

Before starting the engine for the work shift,open the rear door. Remove the dipstick (Item 1) [A], [B], [C] & [D]

Keep the oil level between the marks on the dipstick [C]

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

C

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) SAE 10W–30/40

Keep

Level Between These Marks

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE or SF) (DIESEL: USE API CLASSIFICATION CC or CD)

ENGINE LUBRICATION SYSTEM (Cont’d) Replacement of Oil and Filter

See the Service Schedule Page 27 for the service interval for replacing the engine oil and filter.

Operate the engine for about 15 minutes. Stop and engine. Lift the front of the loader about 6 inches and block it.

Open the drain (Item 1) [A], [B], [C], and [D]

Remove the filter (Item 2) [A] (Page 38), (Item 2) [B], (Item 3) [C], or (Item 2) [D]

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

Close the drain. Remove the oil filler cap (Item 3) [A] (Page 38) or (Item 2) [B] (Page 38), (Item 2) [C], or (Item 2) [D] (Page 38). Fill to capacity. (See Specifications, Page 81.)

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.

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

NOTE: DO NOT overfill the crankcase.

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

Cooling System

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

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

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

• When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

Cleaning the Cooling System

Open the rear door.

W–2019–1285

Open the access panel at the top of the blower housing. Remove the grill.

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

If debris is a problem, check with your dealer about the special debris screens.

Checking the Coolant Level

642, 643, 642B Only

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

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

Fill the radiator with premixed coolant.

Drain, flush and refill system with correct premixed coolant whenever coolant becomes discolored.

ETHYLENE GLYCOL – Mix 50% water and 50% ethylene glycol.

PROPYLENE GLYCOL – Mix 47% water and 53% propylene glycol.

These mixtures will provide freeze protection to –34 °F (–37°C).

Do not mix ethylene glycol and propylene glycol.

COOLING SYSTEM (Cont’d)

Checking the Coolant Level (Cont’d)

641 Only

The engine is air–cooled and must have good air circulation to operate correctly.

Keep all shrouding in place and free of dents. Clean debris from the grill and the cooling fins, or overheating will result.

To clean the cooling fins, remove the blower housing cover (Item 1) [A]. Use an air hose to remove debris from the cylinder heads and the blower fan (Item 2) [A].

Check the radiator cap (Item 1) [B] 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 leaksand overheating.

Removing Coolant from the Cooling System

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

642B

Only

To remove the coolant from the engine, use thefollowing procedure:

Lift the grill [A]. (See Page 40.)

Remove the radiator cap (Item 1) [B]

Remove radiator hose [C]

Drain coolant into a container [D].

COOLING SYSTEM (Cont’d)

Removing Coolant from the Cooling System (Cont’d)

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

W–2070–1285

642 Only: Remove the plug (Item 1) [A] and install a fitting in the hole. Connect a hose to the fitting. Drain the coolant into a container.

643 Only: Connect a hose to the valve or usea funnel to keep coolant from getting into the engine compartment. Open the valve (Item 1) [B] and drain coolant into a container.

642 Only: When all the coolant is removed, disconnect the fitting from the hole. Install and tighten the plug.

643 Only: Turn the lever (Item 1) [A] on the valve. When all the coolant is removed, close the valve.

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

Install the grill. Fill the coolant recovery tank 1/3 full with premixed coolant. (See Checking the Coolant Level, Page 40.)

Alternator Belt

Adjusting the Alternator Belt

641 & 643

Stop the engine.

Raise the operator cab. (See Page 29.)

Remove the belt shield.

Loosen both the adjustment bolts (Item 1) [A] or [B] and move the alternator to set the belt tension at 5/16” (8 mm) movement between pulleys with 15 pounds (67 N) of force. Tighten the adjustment bolt (Item 1) [A] or [B]

Install the belt shield.

642

Stop the engine.

Remove the belt shield [C]

Loosen the governor adjustment bolts (Item 1) [D]. Use a bar and adjust belt tension to 1/2” movement at the middle of the belt with 20 lbs. (89 N) pressure. Tighten the bolts.

Loosen the alternator adjustment bolts (Items 2 & 3) [D] Move the alternator until there is 1/4” movement at the middle of the belt with 20 lbs. (89 N) pressure. Tighten the bolts.

ALTERNATOR BELT (Cont’d)

Adjusting the Alternator Belt (Cont’d)

642B

To adjust the belt tension, use the following procedure:

1.Stop the engine.

2.Remove the belt shield [A].

3.Loosen the bolts that mount the governor [B].

Move the governor until the belt tension permits 1/4” movement at the middle of the belt with 20 lbs. (89 N) of force. Tighten the bolts.

4.Loosen the bolts that mount the alternator [C]

Move the alternator until the belt has 3/8” movement at the middle of the belt with 22 lbs. (98 N) of force. Tighten the bolts [A]

GOVERNOR (642 & 642B)

Rod Adjustment

To adjust the governor linkage, use the following procedure:

1.Stop the engine.

2.Loosen the screws (Item 1) [A] or [B] on the governor arm.

3.Hold the governor arm in the closed position. Tighten the screws.

Install the belt shield before starting the engine.

Governor Oil Level

Check the oil level in the governor after every 100 hours of operation. Use the following procedure:

Remove the check plug (Item 2) [A] or [B] at the rear of governor.

If oil flows out the hole, the level is good.

If no oil flows out the hole, remove the fill plug (Item 3)[A] or [B] at the top of thegovernor and add SAE 10W–30 or 10W–40 until oil flows from the check plug hole. Install the plug and tighten.

ELECTRICAL SYSTEM Description

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

Servicing the Electrical System

If the fuses become damaged, replace them with the same type and size fuses (25 Amp.).

The battery cables must be clean and tight. Check the water level in the battery. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution cover the battery terminals and cable ends with grease [A]

Check for broken wires or loose connections.

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

Using An Extra Battery (Jump Starting)

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

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

Battery gas can explode and cause serious injury.

W–2066–0490

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

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

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

W–2065–1286

ELECTRICAL SYSTEM (Cont’d)

Using An Extra Battery (Jump Starting) (Cont’d)

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

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

Battery gas can explode and cause serious injury.

W–2066–0490

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.

The key switch must be in the OFF position. The booster battery to be used must be 12 volt.

Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the starter [A], [B], [C], & [B] (Page 53).

Connect the end of the second cable to the negative (–) terminal of the booster battery. Connect the other end of the second cable to the engine [A], [B], [C], & [B] (Page 53).

Keep cables away from moving parts. Start the engine. (See Starting The Engine, Page 12.)

After the engine has started, removethe cable connected to the engine ground (–) cable first.

Remove the cable connected to the starter.

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader (Remove both cables from the battery).

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

I–2023–1285

ELECTRICAL SYSTEM (Cont’d)

Removing and Installing the Battery

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader (Remove both cables from the battery).

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

I–2023–1285

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

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

W–2065–1286

Open the rear door. Disconnect the negative (–) battery cable [A]

Disconnect the positive (+) battery cable. Remove the battery holddown clamp(Item 1) [B], [C] and [D]

Remove the battery from the loader.

ELECTRICAL SYSTEM (Cont’d)

Removing and Installing the Battery (Cont’d)

Clean the terminals on the new battery [A] & [B].

Install the new battery, the holddown clamps and the terminal covers.

NOTE:DO NOT touch any metal with the battery terminals.

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

Spark Arrestor Muffler

See the Service Schedule Page 27 for service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

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

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

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

I–2022–1285

Stop the engine. Open the rear door. Remove the plug (Item 1) [A], [B], & [C] from the bottom of the muffler.

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

W–2050–1285

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

W–2011–1285

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

W–2068–1285

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

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

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.

W–2006–0284

HYDRAULIC/HYDROSTATIC FLOW CHART

HYDRAULIC/HYDROSTATIC SYSTEM

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

The system has an engine driven implement pump that supplies fluid to the control valveand lift and tilt cylinders.

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

A #3 element filter and the hydraulic filter clean the fluid and protect the system from contamination.

The oil cooler is located above the radiator. The oil cooler is used for cooling the hydraulic fluid before it returns to the hydraulic pump.

Hydraulic/Hydrostatic Fluid Reservoir

Use only recommended fluid in the hydraulic system. (See the Specifications Section for the correct fluid.)

Checking and Adding Fluid

To check the fluid reservoir, use the following procedure: Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully backward. Stop the engine.

Check the fluid level shown in the sight gauge (Item 1) [A]

Hydraulic fluid must show in the sight gauge. If the fluid is not seen in the sight gauge, remove the filler cap from the reservoir. Add fluid to the reservoir until it shows in the sight gauge. Replace the filler cap [B]

Hydraulic/Hydrostatic Fluid Replacement

See the Service Schedule Page 27 for the service interval. The fluid must be replaced if it becomes contaminated or after major repairs.

Remove the fill cap and lift the screen from the tank [C]

Check the screen for damage. Wash the screen in clean solvent.

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

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

Hydraulic/Hydrostatic Fluid Replacement (Cont’d)

Install the screen and cap.

Replace the #3 element filter and the hydraulic filter. Add fluid to the reservoir until the fluid shows in the sight gauge. DO NOT fill above the top mark of the sight gauge [A]. (See Page 59.)

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. 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.

W–2074–1285

Start the engine and operate the hydraulic controls. Check for leaks and add oil as necessary.

Hydraulic/Hydrostatic Filter Replacement

See the Service Schedule Page 27 for the service interval. The filter must be replaced when the hydrostatic warning light comes on during loader operation.

Remove the filter element (Item 1) [A], [B], [C] & [D]. Drain fluid into a container.

Clean the surface of the filter head where the element contacts the head.

Put clean oil on the rubber gasket of the filter element.

Install the filter element hand tight only [D].

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

Hydraulic/Hydrostatic Filter Replacement (Cont’d)

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W–2103–1285

Check for leaks after operating the loader. Record the operating hours of the loader on the decal inside the rear door [A]

FINAL DRIVE TRANSMISSION (Chaincase)

The chaincase contains the final drive sprockets and the chains and is filled with the same type of fluid as the hydraulic/hydrostatic system. (See Specifications Page 81.)

To check the chaincase, use the following procedure:

Put the Bobcat loader on a level surface.

Remove the plug at the front of the transmission housing (Item 1) [B]. If oil can be reached withthe 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.

Tire Maintenance

Check the tires regularly for wear, damage and pressure. (See Specifications, Page 81 for the correct tire pressure.)

Tire Rotation

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 [A]

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.

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

W–2078–1285

Tire Mounting

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

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid 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.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability.

Wheel Nuts

See the Service Schedule Page 27 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) for 9/16” wheel nuts and 65–70 ft.–lbs. (88–95 Nm) for 1/2” wheel nuts.

I–2057–0794

Lubrication Of The Bobcat Loader

Lubricate the Bobcat loader as specified in the Service Schedule Page 27 for the best performance [A]

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

Lubricate the seat rails with oil for easy movement.

See the Service Schedule Page 27 for service interval to grease the U–joints.

Grease the universal joints (Item 1) [B] and spline with special U–joint lubricant. See your dealer.

Lubricate the mounting (pivot assemblies) of the seat bar [C].

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

Raise the operator cab. (Refer to Page 29 for the correct procedure.) Grease the pivot bearings [A]. (See the Service Schedule Page 27 for the correct service interval.)

Add oil or grease as needed to the steering control shaft [B]

BOB–TACH

Check for free movement of wedges and Bob–Tach levers.

The wedges must extend far enough to engage theholes in the attachment [C].

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

Replace wedges that are bent or broken.

Auxiliary Control Lockbolt

The auxiliary control has a lockbolt thatmust be removed to use the auxiliary hydraulics.

Raise the operator cab. (See Page 29 for the correct procedure.)

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

Pivot Pins

All pivot pins, lift arms, Bob–Tach and cylinders have a large pin held in position with lockbolts [B].

Brake Pedal Adjustment

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

There must be 1/4” (6,35 mm) of movement under the bottom edge (heel) of the brake pedal.

Tighten the jam nut when the adjustment is correct.

Troubleshooting

The following information identifies loader problems which can occur most often. Service procedures for correcting loader problems can be found in this manual on the pages indicated. Some procedures are marked D/S (Dealer Service) and must be performed only by qualified Bobcat service personnel. Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death W–2003–1289

Engine won’t turn over with starter.

Battery has low charge.

Cables loose or dirty.

Damaged starter, solenoid or wiring.

Charge battery and find cause of discharge.

Clean and tighten the battery cables.

Check the starting circuit. Repair as needed.

Engine turns with starter, but is difficult to start.

Wrong starting procedure.

Ignition system is damaged.

Auxiliary control lever orlift pedal is in detent

No fuel in tank.

Vent in fuel filler cap is plugged.

Dirt or water in fuel system.

Fuel filter is dirty.

Hole in fuel line.

Weak battery.

Wrong oil in engine.

Cylinder compression is low.

Engine has overheated.

Poor fuel quality.

Restricted exhaust.

Use correct starting procedure.

Check & repair as needed.

Take out of detent.

Add fuel.

Clean the vent.

Repair as needed.

Install a new filter.

Repair as needed.

Charge or replace battery.

See Oil Specifications.

Recondition the engine.

Check cooling system.

Use fresh, good quality fuel.

Clean exhaust system.

Engine has little power or runs rough.

D/S = Dealer Service Only

Dirt, water or air in fuel system.

Clean and repair as needed.

TROUBLESHOOTING THE ENGINE (Cont’d)

Problem Correction Cause

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

Engine overheats.

Engine is hot.

Restricted exhaust.

Dirty air cleaner

Cylinder compression is low.

Restriction in cooling air flow.

Blower shroud damaged or missing.

Engine is overheated.

See Engine Overheats

Clean exhaust system

Install new element.

Recondition the engine.

Check for debris on radiator grill.

Check shroud and repair or replace as needed. Run

Troubleshooting The Drive System

Problem Correction Cause

No drive on both sides.

Hydraulic fluid is low.

Damaged hydraulic pump.

Hydrostatic system is damaged.

Check oil level. Add as needed.

Check condition of pump and replace as needed.

Check hydrostatic system.

No drive on one side.

Control linkage is disconnected.

Hydrostatic system is damaged.

Repair linkage.

Check hydrostatic system and make repair as needed.

Machine pulls to one side.

Wrong tire pressure.

Steering linkage interference.

Damaged hydrostatic system.

Check all tires for correctpressure.

Check steering linkage and adjust as needed.

Check system. Repair as needed.

Machine moves when levers are in neutral.

System is overheating.

Steering linkage out of adjustment.

Hydraulic oil level is low.

Cooling system is dirty. Air restricted.

Low charge pressure (transmission light on).

Auxiliary control in detent.

Loader is overloaded.

Adjust steering linkage.

Check oil level and add as needed.

Clean cooling system. Check for debris on radiator grill.

Check by–pass valve.

Take out of detent.

Use correct size attachment.

Parking brake will not hold.

D/S = Dealer Service Only

Hydrostatic transmission damage. Out of adjustment.

Check system and make repair.

Adjust parking brake.

No hydraulic action.

Troubleshooting The Hydraulic System

Cause

No hydraulic oil.

Pedals are disconnected.

Relief valve is damaged.

Hydraulic pump is damaged.

Hydraulic oil is too thick.

Check oil level and add as needed.

Check linkage. Repair as needed.

Replace the relief valve.

Check pump. Replace as needed.

Let machine warm up.

Hydraulic action is rough.

Hydraulic action is slow.

Hydraulic oil level is low.

Air is in the oil.

Pedal is hitting floor or debris under pedal.

Cylinders leak internally.

Hydraulic pump is damaged. Control valve is damaged.

Hydraulic oil is too thick.

Check oil level and add as needed.

Cycle the hydraulics.

Check adjustment. Remove debris.

Check condition of cylinders and repair as needed.

Check pump. Replace as needed.

Check valve and repair as needed.

Let machine warm up.

Hydraulic cylinders leak oil.

D/S = Dealer Service Only

Damage to cylinder rods or seals.

Repair cylinders.