Bobcat 742B Loader Operation & Maintenance Manual SN 509418000 & Above - PDF DOWNLOAD

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

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Operation & Maintenance Manual (S/N 509418000 & Above)

6722056 (2-99) Revised (5-12)

Printed in U.S.A.

© Melroe Company 1996

Dealer Copy -- Not for Resale

7 4 2 B

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540, 543 Loader Service Manual

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

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

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

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ...

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 ....

MACHINE SIGNS TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 ...

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 ....

CALIFORNIA PROPOSITION 65 WARNING

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

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

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

NOTES:

Dealer Copy -- Not for Resale

REFERENCE INFORMATION

YOUR LOADER DEALER: ADDRESS: PHONE:

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

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

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

Dealer Copy -- Not for Resale

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

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

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

A

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the rear grill [A].

Explanation of loader Serial Number: XXXX

P–0144

XXXXX Production Sequence (Series)

B

Model, Engine Version

The serial number is located at the fuel injection pump side on the engine block [B].

P–0702

Dealer Copy -- Not for Resale

ENGINE SERIAL NUMBER

C

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

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BOBCAT SKID STEER LOADER IDENTIFICATION FRONT LIGHTS (OPT.) SEAT BAR GRAB HANDLES

SEAT BELT

OPERATOR SEAT

STEERING LEVER

QUICK COUPLERS

BUCKET◊

SAFETY TREAD BUCKET STEPS

SEAT BAR

OPERATOR CAB (ROPS & FOPS)• REAR LIGHT (OPT.)

LIFT ARM SUPPORT DEVICE

UPRIGHTS LIFT ARM

LIFT CYLINDER

GRILL

REAR DOOR *TIRES B–7377 C–2878

*

◊

•

TIRES – Flotation tires are shown, The Bobcat loader is based–equipped with standard tires.

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

ROPS, FOPS – Roll–Over Protective Structure, falling Object Protective Structure, per SAE J1040 and SAE J1043. The Bobat loader is base–equipped with a standard operator cab as shown.

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TILT CYLINDER

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix, . . .x FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi. . .

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MACHINE SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii, . . .xiii .

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

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 B–10731

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

Check all of the items on the Service Schedule under the 8–10 hour column or as shown in this Manual.

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

W–2044–1285

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

I–2019–0284

Dealer Copy -- Not for Resale

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

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULA TIONS • The written instructions from Melroe Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, EMI Safety Manual and machine signs (decals).

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

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

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

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

• The Skid Steer Loader Operator Training Course is available in English andSpanish. The course provides information for safe and efficient operation. See your dealer for availability.

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and correct service procedures for Bobcat Skid–Steer loaders.

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of

the loader. For example, in handling certain loose material with a given bucket, he must know whether he can safely take a full load, or only part of a bucket load.

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

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

• Wear tight fitting clothing. Always wear safety glasses whenmaintaining or servicing loader. Safety glasses, hearing

protection or loader special applications kit are required for some work. See your dealer about Melroe Safety equipment.

* For an operator be qualified, he must not use drugs oralcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–1298

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SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Skid Steer Loader is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications. The loader has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so the loader must be used with adequate ventilation. The loader has a spark arrestor muf fler which is required for operation in certain areas.

The dealer explains the capabilities and restrictions of the loader and attachments for each application. The dealer demonstrates the safe operation of the loader according to Melroe’ s instructional materials; which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the loader. The user must check with the dealer,or Melroe Company literature, to determine safe loads of materials of specified densities for his loader–attachment combination.

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

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

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

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

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

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

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and correct service procedures for Bobcat Skid–Steer loaders.

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

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

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

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

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• The Operation and Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of loader the and can be stored in a container (later models) provided inside the cab. Replacement Operation and Maintenance Manuals can be ordered from your Bobcat loader dealer.

FIRE PREVENTION The loader has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

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

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

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

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

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

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

Dealer Copy -- Not for Resale

• Do not use ether or starting fluids on this engine. It has glow plugs. These startingaids can cause explosion and injure you or bystanders.

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

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

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

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

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

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

A

P–10650

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

6569021 6569119 6561385

6557565

Dealer Copy -- Not for Resale

6565990

6561377

6579639

6577754

6561383 6579509

6568741

6579528

6702255 6579510

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MACHINE SIGNS (DECALS) (Cont’d)

Dealer Copy -- Not for Resale

6702255

6560573

6561379 6579534

67016558

*6567875

6579511

* Located inside the engine compartment 17 of 88

P–01520

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742BOperationAndMaintenanceManual6722056–ContentsSection

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OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 ...

Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 ...

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. . . .

GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 ..

HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . .

Auxiliary Hydraulics Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .

Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 .....

Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . .

Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . .

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

OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 ...

Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 .....

Digging into the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ....

Emptying the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ....

Filling the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ....

Leveling the Ground (Using Lift Arms in Float Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ...

PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ...

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . .

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . .

STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 ...

Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 ..

Normal Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ...

Warming the Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . 13 ..

Dealer Copy -- Not for Resale

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ....

STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . .

STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 ...

THROTTLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. . . .

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ....

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . 20 ..

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1.LIGHT SWITCH (OPT.) – Controls the work and travel lights.

2.IGNITION SWITCH – For starting, stopping and ‘‘pre– heating’’ the engine.

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

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

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

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

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

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

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

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

A

5

10

3 1

6 7

4 2

8

9 B–12526

B 5

THROTTLE CONTROL The throttle control is at the rightside of the operator seat [B].

Engine speed is controlled by moving thethrottle forward to increase the engine RPM and backward to decrease the engine RPM.

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INSTRUMENT PANEL The instrument panel has the following instruments [A].

742B Bobcat Loader Operation & Maintenance Manual

PARKING BRAKE Lock the parking brake by pushing down on the top (toe) of the pedal [A].

A B–3745

B–7378

B Dealer Copy -- Not for Resale

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

B–3744

B–5717

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STEERING LEVERS

A

1

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

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595

B–7379

B

FORWARD BACKWARD

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

FORWARD TRAVEL: Push both levers forward.

REVERSE TRAVEL: Pull both levers backward.

NORMAL TURNING: Move one lever farther forward than the other.

FAST TURNING: Push one lever forward and pull the other lever backward.

LEFT TURN

RIGHT TURN

FAST TURN

FAST TURN

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

To increase travel speed, push the levers farther forward.

Dealer Copy -- Not for Resale

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

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

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

PI–1849

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HYDRAULIC CONTROLS Foot Pedals

A

3 1 B–7379

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

W–2002–1285

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

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

Lift Arm Operation

Push on the top (toe) (Item 3) of the pedal to lower the lift arms [A]. Use the ’’Float’’ position of the lift arms to level loose material while driving backward.

4

The optional bucket position valve, will keep the bucket at a level position when the lift arms are being raised.

1 5

B–7379

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

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

B–7440 B–7441

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

A

HYDRAULIC CONTROLS (Cont’d) Auxiliary Hydraulics Operation (Optional) The right steering lever is also the control lever for the front auxiliary hydraulics [A].

P–0149

Move the steering lever all the way to the right (Item 1) to put the control valve into the ‘ ‘detent’’ position for a constant flow of hydraulic fluid under pressureto the quick couplers [B].

NOTE: See Page 45 to remove auxiliary control lockbolt.

B

A–2408

A–2409

2

1

B–7379

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

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

742B Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

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

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

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.

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

B–6583 B–6592

W–2003–1298

B

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Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door [B].

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

A 1

P–1718

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.

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

B 2

Seat Bar

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

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

Interlock

1 Pedal Linkage

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

3

AVOID INJURY OR DEATH

Dealer Copy -- Not for Resale

W–2046–0592

MC–1669

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.

C Seat Bar

W–2045–1086

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

W–2105–1285

Interlock

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

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

Refer to the Preventive Maintenance section for Seat Bar Restraint System Inspection & Maintenance.

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GETTING READY FOR OPERATION Read this Operation & Maintenance Manual and the Operator’s Handbook before operating the loader [A].

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

A

6569119

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

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

Keep the safety treads clean and replace when damaged.

Replacement treads are available from your dealer.

B–7377

B

B–12885

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

C

1 B–3878

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

D

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

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C–2596

–10–

B–12377

742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

W–2001–0596

GETTING READY FOR OPERATION (Cont’d)

A

Lower the seat bar [A].

Be sure the parking brake is engaged.

All controls must be in the neutral position before you start the engine (See ‘‘Normal Starting Condition’’, Page 12).

B–12378

B

STARTING THE ENGINE B–12379

C

WRONG

AVOID INJURY OR DEATH

Dealer Copy -- Not for Resale

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

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

W–2050–1285

• Engines can have hot parts and hot exhaust

B–3724

gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

D

W–2051–1086

WRONG

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742B Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

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

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

Lower the seat bar [A]..

B–6579

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

B

NEUTRAL POSITION

Engage the parking brake.

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

1 Dealer Copy -- Not for Resale

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

1/2 THROTTLE

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

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

I–2034–0684

3

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

”START” POSITION

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

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

4 ”RUN” POSITION

5 ”PREHEAT’ POSITION

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PI–2188

742B Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting Condition If the temperature is below 32°F. (0°C.), use the following procedure to make starting the engine easier: 1. Replace the engine oil with the correct type and viscosity for the anticipated starting temperature (See ‘‘Oil Specifications’’, Page 33).

2. Make sure the battery is at full charge.

2 1

3. Install a block or tank heater on the engine.

Follow the steps under ‘‘Normal Starting Condition’’ and pull the choke control (Item 1) up [A] .

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

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

B–9409

Move the choke to the ‘OFF’’ position when the engine is warm.

Warming the Hydraulic/Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader. If the warning light comes ‘ ‘ON’’ when operating the loader (cold), more warm up time is needed.

STOPPING THE ENGINE Pull the throttle fully backward to decrease the engine RPM.

Dealer Copy -- Not for Resale

Push the choke in a small amount.

Turn the key switch to the ‘‘OFF’’ position.

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742B Bobcat Loader Operation & Maintenance Manual

ATTACHMENT AND BUCKETS

A

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

Unapproved attachments can cause injury or death.

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

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

It is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used the load center moves forward and reduces the Rated Operating Capacity. If very dense material is loaded, the volume must be reduced.

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

AVOID INJURY OR DEATH Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

W–2053–0887

1. Steering the loader may be difficult.

B

2. Tires may wear faster.

3. There will be a loss of stability.

WEIGHT OF LOADS LBS. (KG)

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

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

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

CENTER OF LOAD LOCATION Inches (mm)

742B Model 32 of 88

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6700705

742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B–6587

The Rated Operating Capacity for this loader is shown on a label in the operator cab (Also see the ‘Specifications’’ section, Page 67).

ATTACHMENTS AND BUCKETS (Cont’d)

A

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

PI–2590 B–13073

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

W–2054–1285

B

Pull the Bob–Tach levers all the way up.

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

Tilt the Bob–Tach backward until the bucket is of f the ground and stop the engine [B]..

PI–2591 B–13072

C

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

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

Dealer Copy -- Not for Resale

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

W–2045–1285

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

B–13069 B–13071

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

W–2020–0588 The wedges (Item 1) must extend through the holes in the bucket or attachment [D].

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

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1 B–13070

742B Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES

A

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

WITH BUCKET FULL

Loaders warmed up with moderate engine speed and light load have longest life I–2015–0284

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

B

B–6612

WITH BUCKET FULL

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

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

Going Down Slope

C

B–6612

WITH BUCKET FULL

• 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.

Going Down Slope

W–2018–1187

D

B–6611

WITH BUCKET FULL

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

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742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

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

OPERATING PROCEDURE (Cont’d)

A

Filling the Bucket Push down on the top of the lift pedal until the lift arms are all the way down. Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A]

B–7379

.

B–6719

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

B–7379

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1186

Drive backward away from the material.

Dealer Copy -- Not for Resale

B

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

Drive forward slowly until the bucket is over the top of the truck box or bin. Push the top of the tilt pedal until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

B–6718

C

B–7379

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

W–2057–1285

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742B Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

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

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

B–7379

B–6720

B

Continue to drive forward until the bucket is full. When the ground is hard, raise and lower the cutting edge of the bucket with the tilt pedal while driving forward slowly.

B–7379

B–6721

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

C

B–7379

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742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

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

OPERATING PROCEDURES (Cont’d) Leveling the Ground (Using Lift Arms in Float Position)

A

Push the top (toe) of the lift pedal all the way forwarduntil the pedal is in the locked position (detent) to put the lift arms in a ‘‘float’’ position [A].

B–7379

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

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

B–6722

I–2005–1285

B

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

B–7379

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

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

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

Dealer Copy -- Not for Resale

Drive backward to level loose material. Push the bottom of the lift pedal to unlock from the ‘‘detent’’ position.

B–6724

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742B Bobcat Loader Operation & Maintenance Manual

PARKING THE BOBCAT LOADER

A

1. Stop the Bobcat loader on level ground.

2. Lower the lift arms fully and put the bucket on the ground.

edge of the

3. Pull the throttle all the way backward. Turn the key switch to the ‘‘OFF’’ position.

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

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

B–2668

W–2045–1086

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

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

TRANSPORTING THE BOBCAT LOADER C–2563

C–7384

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1187

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

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

B–7383

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 in figure [B].

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742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

4. Engage the parking brake.

LIFTING THE LOADER

A 1

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

• Assemble front cab fasteners as shown in manual.

• Never allow riders in the cab or bystanders

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

W–2007–1285

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

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

TOWING THE LOADER

B–7489

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

I–2001–1285

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

Dealer Copy -- Not for Resale

1

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

Do not push or pull the machine at more than 2 MPH (3,2 km/h) or for a distance of more than 25 feet (7,6 meters) with the towing tool in place.

I–2017–0389

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742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

742BOperationAndMaintenanceManual6722056–OperatingInstructionsSection

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742B Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE

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PREVENTIVE MAINTENANCE

Dealer Copy -- Not for Resale

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 ...

ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ...

AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ...

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 .....

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ....

Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

Removing Coolant from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . 35 ..

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ....

Battery Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ...

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 .....

Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 ...

Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . .39 ..

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ...

Engine Oil And Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ...

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . 45 ..

Checking and Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 ...

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 ....

Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ....

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 .....

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ....

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 .....

Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ....

Governor Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ...

Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ....

GOVERNOR LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ...

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ..

Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ...

Replacement of the Hydraulic/Hydrostatic Filter Element . . . . . . . . . . . . . 42 .

Removing the Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 ...

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 ...

To Engage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ...

To Disengage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 ..

LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . 46 ..

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 ....

Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 ...

Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 ...

PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 ...

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 .....

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 .....

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 .....

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 .....

REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 .....

SEAT BAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ....

Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ....

Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ....

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ....

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ...

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ....

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 .....

Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 .....

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 .....

U–JOINTS LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 ...

742B Bobcat Loader Operation & Maintenance Manual

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

W–2003–1298 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

B–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–15231

B–6593

Have good ventilation when welding or grinding painted parts.

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

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

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

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

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

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

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

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

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

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

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

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

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

Lead–acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

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

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MSW01–0199

742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

CORRECT

CORRECT

CORRECT

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

Instructions are necessary before operating or servicing machine.

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

W–2003–1289

Engine Oil Engine Air Cleaner

Engine Cooling System Tires Seat Belt and Seat Bar & Pedal Interlocks Safety Signs & Safety Tread Lift Arm Cyl., Bob–Tach, Pivot Pin Operator Cab Wheel Nuts Battery Hydraulic Fluid, Tubelines & Hoses Alternator & Governor Drive Belts Chaincase Controls & Brake Engine Oil & Filter Spark Arrestor Muffler Governor Oil Level Governor Shaft Seat Bar Steering Shaft Pivots Hyd./Hydro. Filters U–Joint Fuel Filter Hyd. Reservoir Breather Cap Chaincase Hydraulic Reservoir

♦

•

SERVICE REQUIRED

8–10

Check the oil level and add oil as needed.

Replace the outer filter element only when the red ring shows in the indicator window. Check for leaks and damaged components Clean debris from shrouds and grills. Check coolant level in the recovery tank and add as needed.

Check for damaged tires and correct air pressure.

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

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

Add grease to the fittings until the extra grease shows.

Check the fastening bolts, washer & nuts. Check the condition of the cab. ♦ Check for lose wheel nuts. Tighten to correct torque if loose.

Check the electrolyte level. Check battery cables for corrosion.

Check that the battery cables are tight. Check covers.

Check fluid level & add as needed. Check for damage, leaks & repair or replace as needed.

Check tension and adjust as needed.

50

100 250

500 1000

Dealer Copy -- Not for Resale

ITEM

Check the fluid level & add as needed.

Check operation & adjust as needed.

Replace the oil & the engine oil filter.

Remove the plug & clean the spark chamber.

Check level if low, add oil.

Grease or oil the shaft.

Grease pivot as needed.

Grease two fittings. Add oil to steering shaft.

• Replace filter elements.

Grease three (3) fittings with correct grease.

Replace the filter element.

Replace breather cap.

Replace the fluid.

Replace the hydraulic fluid.

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

Also replace hydrostatic filter element when the transmission warning light stays on for five (5) minutes after the hydrostatic fluid is at operating temperature.

Or every 12 months.

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742B Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

A

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 P–0147

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

B

Put jackstands under the rear corners of the loader.

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

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

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

P–0192

Raise the lift arms, until the lift arm support device is on the lift cylinder rod [C].

C

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

Raise the seat bar and move pedals until both pedals lock.

Install pin into the rear of the lift arm support device below the cylinder rod.

To Disengage Lift Arm Support Device Remove the pin from the lift arm support device.

Connect the spring from the lift arm support device to the bracket below the lift arms [D].

P–0193

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

D

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

Raise the seat bar and move pedals until both pedals lock.

Disconnect the spring from the bracket.

Raise the support device into storage position and insert pin through lift arm support device and bracket [A].

Connect spring to pin.

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742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

Disconnect the spring from the lift arm support device retaining pin, hold onto the support device and remove the retaining pin [A].

OPERATOR CAB

A

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

Nut

Plate Bushing Washer

Washer Bolt

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.

MC–1181

P–0150

B

W–2069–1285

Raising the Operator Cab

P–0151

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.

C

P–0152

2

W–2014–0895

1

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

Dealer Copy -- Not for Resale

Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Page 26.)

Early Model: Remove the nut and plate (both sides)[B].

Early Model: Remove the bolt and washer (both sides) [B].

3 Later Models: Loosen the nut (Item 1) [C] at the corner of the operator cab (both sides).

P–2844

Later Models: Remove the nut (Item 2) [C] and plate (Item 3) (both sides).

P–2843

D

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 [D].

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OPERATOR CAB (Cont’d)

A

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

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

Install the plate and nut .

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

SEAT BAR SYSTEM The seat bar system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar . The seat bar in the down position helps to keep the operator in the seat, also the interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to neutral position.

P–0154

B

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

P–0155

W–2105–1285

C

Sear Bar Inspection 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.

Clean

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

P–0156

Seat Bar Maintenance Clean any debris or dirt from the moving parts [B] & [C].

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

Use a general purpose grease to lubricate the seat bar pivot points on each side of the cab [B]. If the seat bar system does not function correctly , check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.

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742B Bobcat Loader Operation & Maintenance Manual

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Clean & Lubricate

REAR DOOR

A

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 P–0157

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

Pull the rear door open.

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

1

W–2020–1285

3

2

P–0159

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

P–0160

C

Loosen the nut (Item 2) [B].

Turn the bolt (Item 3) [B] in or out, until the door makes contact with both the top and bottom of the loader frame (Item 1) [C] when the door lever is in the latchedposition.

2

NOTE: It takes approximately 50 lbs. (223 N) of force to push the lever down when the latch is adjusted correctly.

B–7226

1

With the set screw up, the flanges at the bolt must be to the side so that the set screw aligns with the flat surface at the end of the bolt.

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

Tighten the nut (Item 2) to 65–70 torque [B] .

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B

P–0410

ft.–lbs. (88–95 Nm)

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742B Bobcat Loader Operation & Maintenance Manual

REAR GRILL

A

To remove the rear grill, remove the bolts along the top of the rear grill [A].

P–0179

Remove the bolts along the bottom of the rear grill [B].

P–0182

Lift the rear grill up and remove from the loader [C].

C

P–0184

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B

AIR CLEANER SERVICE

A

See the Service Schedule Page 25 for the interval to service the air cleaner system or when the red ring shows in the window of the condition indicator.

Service the air cleaner as follows:

P–0705 P–0705 P–0705

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

Loosen the clamp on the dust cup [A].

P–0707

P–0708

C

Remove the wing nut [C].

Dealer Copy -- Not for Resale

B

Remove the dust cup [B].

P–0703

Remove the element [D].

D

Check the air cleaner housing for holes or corrosion.

Install the new filter element.

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

All the hoses and clamps must be tight.

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

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FUEL SYSTEM

A

Fuel Specifications Use leaded or unleaded gasoline in the engine.

Stop and cool the engine before adding fuel.

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

W–2063–0887

P–0704

Filling the Fuel Tank

B

Remove the filler cap [A] .

WRONG

Use a clean, approved safety container to add fuel.

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

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

B–6586

Fuel Filter

C

See the Service Schedule Page 23 for the interval to service the fuel filter.

Close the valve on the fuel line (Item 1) [C] .

Remove the filter element (Item 1) [D] . Install the new filter element. All connections must be tight.

Open the valve at the fuel tank [C] .

1

P–0713

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.

D

W–2103–1285

1

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

ENGINE LUBRICATION SYSTEM

A

Check the oil level every day.

Stop the engine and remove the dipstick [A] .

Keep the oil level between the marks on the dipstick.

P–0720

Engine Oil and Filter Replacement

B

See the Service Schedule Page 25 for the service interval for replacing the engine oil.

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

Stop the engine.

2. Open the rear door. Remove the drain plug and drain oil into a container [B] .

3. Remove the oil filter [C].

P–0706

4. Clean the filter housing surface. Put clean oil on the gasket of the new filter. Install the filter and tighten hand tight.

C

5. Install the oil plug.

6. Remove the oil filler cap [D] .

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

Dealer Copy -- Not for Resale

Use the following procedure to replace the engine oil and filter:

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)

P–0722

D

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SF or SG) P–0716 51 of 88

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742B Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

A

Fill to capacity [A](See Specification Section, Page 65).

Start the engine and let it run or about 5 minutes. Check for leaks at the filer. 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.

P–0711

Always clean up spilled fuel or oil. Keep heat, flames, sparks and 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.

P–0169

W–2103–1285

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B

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

COOLING SYSTEM

A

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

Checking the Coolant Level Open the rear door.

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

1

Add pre–mixed coolant, 50 % water and 50% anti–freeze to the recovery tank if the coolant level is low.

P–0724

Failure to obey warnings can cause the machine to tip or roll over • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running • Tools are being used.

W–2019–1285 Cleaning the Cooling System Open the rear door.

P–0723

Remove the access panels at the blower housing [B].

Remove the rear grill. (See Page 30.)

C

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

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

Dealer Copy -- Not for Resale

B

P–0729

D

Removing Coolant from the Cooling System Remove the rear grill. (See Page 30.) Remove the radiator cap [D].

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742B Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM (Cont’d)

A

Remove the radiator hose [A] .

P–0743

Drain the coolant into a container [B] .

Connect the radiator hose when all removed.

B the coolant is

P–0740

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

C

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

Replace damaged parts immediately to prevent leaksand overheating.

Install the rear grill.

P–0724

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Fill the radiator with pre–mixed coolant and install the radiator cap.

ALTERNATOR BELT ADJUSTMENT

A

To adjust the belt tension, use the following procedure: 1. Stop the engine.

2. Remove the belt shield [A].

P–0732

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

B

P–0733

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4. Move the alternator until the belt tension permits 1/4’’ movement at the middle of the beltwith 20 lbs.

(9 kg) of force. Tighten the bolts [B].

742B Bobcat Loader Operation & Maintenance Manual

GOVERNOR

A

Governor Belt Adjustment To adjust the belt tension, use the following procedure: 1. Stop the engine.

2. Remove the belt shield [A].

P–0732

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

B

4. Move the governor until the belt tension permits 1/4’ ’ (6,3 mm) movement at the middle ofthe belt with 20 lbs. (9 kg) of force. Tighten the bolts [B].

Governor Adjustment To adjust the governor linkage, procedure:

P–0735

use the following

C

1. Stop the engine.

2. Loosen the screws (Item 1)[C] on the governor arm.

3. Hold the governor arm in the closed position.

Tighten the screws.

1

P–2046

Governor Oil Level

D

See the Service Schedule Page 23 for the correct service interval to check the governor oil level. Use the following procedure:

2

Remove the check plug (Item 1) [D] at the rear of the governor.

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

1

If no oil flows out the hole, remove the fill plug (Item 2) at the top of the governor and add SAE 10W–30 or 10W–40 until oil flows from the check plug hole (Item 1) [D] . Install the plug and tighten.

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5. Install the belt shield before starting the engine.

ELECTRICAL SYSTEM

A

Description The loader has a 12 volt, charging system.

negative ground alternator

If the two fuses in the dash panel become damaged, replace them with the same type and size fuses.

Electrical System Service The battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables with a baking soda and water solution. Cover the terminals of the battery with Melroe Battery Saver (P/N 886398) to prevent corrosion [A].

P–0742

Install the terminal covers.

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

Damage to the alternator can occur if:

• Engine is operated with battery cables

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.

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.

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

I–2023–1285

W–2065–1296

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

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

Dealer Copy -- Not for Resale

Using A Booster Battery (Jump Starting)

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.

The ignition must be in the ‘‘OFF’’ position.

The battery 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 loader battery positive (+) terminal[B].

Battery gas can explode and cause serious injury.

W–2066–1296

Connect the end of the second cable to the negative terminal (–) of the booster battery. Connect the other end of second cable to the engine [B].

B

Keep the cables away from moving parts.

Start the engine.

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

Remove the cable connected to the loader battery.

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742B Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Battery Removal and Installation

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–0736

B

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

Open the rear door. Disconnect the negative (–) battery cable first .

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

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

P–0738

Remove the battery from the loader [C].

C

P–0734

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

D

When installing the battery in the loader,do not touch any metal parts with the battery terminal posts.

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

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742B Bobcat Loader Operation & Maintenance Manual

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W–2065–1296

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

A

use the same

1

The system has an engine driven gear 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.

A–3 filter element is installed on the left side of the engine compartment. This filter is used to clean the fluid for the hydrostatic transmission.

P–0163

The location of the oil cooler is above the engine. The oil cooler is used for cooling the hydraulic fluid before it returns to the hydrostatic pump.

B

Checking and Adding Fluid

To check the fluid in the reservoir procedure:

, use the following

Put the loader on a level surface. Lower the lift arms and lay the attachment flat on the ground. Stop the engine.

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

P–0165

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

C

Add fluid to the reservoir until it shows in the sight glass [C]. Replace the filler cap.

Dealer Copy -- Not for Resale

Use only recommended fluid in the hydraulic/hydrostatic system. (See Specifications, on Page 68 for the correct fluid.)

P–0166

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742B Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacement of the Hydraulic/Hydrostatic Filter Element See the Service Schedule Page 25 for the correct service interval.

Stop the engine. Open the rear door.

Clean the area around the filter housing.

Remove the filter element [A].

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

P–0725

Lubricate the rubber gasket with grease.

B

Install the filter element and hand tighten only [B].

Operate the loader and check for leaks at the filter.

Check fluid level in the reservoir and add as needed.

See the Service Schedule Page 25 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

P–0726

Remove the filler cap from the reservoir [C].

C Remove the screen from the fill pipe [D].

Remove fluid from the hydraulic reservoir.

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

Remove the filter element and install a new filter element.

Add hydraulic/hydrostatic fluid to the reservoir . (See Specifications, Page 58 for the correct fluid.) DO NOT fill above the sight glass.

P–0165

Operate the loader. Stop the engine and check the fluid level. Add as needed.

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.

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Removing the Hydraulic Fluid

SPARK ARRESTOR MUFFLER

A

See the Service Schedule Page 25 for correct service interval. 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.

P–0721

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

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

I–2022–0595

Stop the engine. Open the rear door.

W–2011–1285

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

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

W–2050–1285

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.

Dealer Copy -- Not for Resale

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.

W–2068–1285

Start the engine.

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

Stop the engine and install the plug. Close the rear door.

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742B Bobcat Loader Operation & Maintenance Manual

TIRE MAINTENANCE

A

Wheel Nuts See the Service Schedule Page 25 for the service interval to check the wheel nuts. The correct torque is 105–1 15 ft.–lbs. (142–156 Nm) [A].

Tire Rotation Check the tires regularly for wear, damage and pressure (See Specifications, Page 68 for the correct tire pressure).

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

P–0167

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

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

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

C–1965

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

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

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B

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

Checking and Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/hydrostatic system (See Specifications Section, Page 68).

To check the chaincase oil level, procedure:

1

use the following

Drive the loader onto a level surface. Stop the engine.

Remove the plug (Item 1) at the front of the chaincase housing [A]..

If oil can be reached with the tipof the your finger through

P–0168

the hole the oil level is correct.

Dealer Copy -- Not for Resale

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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742B Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER

A

Lubricate the Bobcat loader as specified in the Service Schedule Page 25 for the best performance of the loader .

1

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

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

P–0175

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

B

P–0190

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

C

3

P–0189

4. Base End Tilt Cylinder [D].

D 4

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2

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

5. Rod End Tilt Cylinder [A].

5

P–0168

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

B

6

7 P–0173

8. 250 Hours: Steering Lever Shaft (2) [C]. .

C

8

Dealer Copy -- Not for Resale

7. Bob–Tach Wedge (both sides) [B].

P–0198

9. 250 Hours: Steering Lever Shaft Bearings (2) [D].

D 9 9

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742B Bobcat Loader Operation & Maintenance Manual

BOB–TACH

A

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

The levers and wedges must move freely.

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

1

N–17027

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.

B

W–2102–0497

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

1

N–17023

C

Bob–Tach Wedge

Wedge Must Contact Lower Edge Of Hole In The Attachment

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

D

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

Lubricate the wedges (SeeSERVICE SCHEDULE, Page 21 and LUBRICATION OF THE BOBCAT LOADER, Page 42).

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

PARKING BRAKE PEDAL

A

SHOULDER BOLT LOCATION

742B (S/N 18001 – 18133) NOTE: S/N 18001–18668 must be equipped with shoulder bolts on the rear chaincase cover (See your Bobcat loader dearer). Check the rear chaincase cover bolts for 20–25 ft.–lbs.

(27–34 Nm) torque [A].

MC–1707

B

Adjustment Turn the nuts to adjust the brake pedal [B].

P–0199

PIVOT PINS

C

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

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

(24–27 Nm) torque.

Dealer Copy -- Not for Resale

There must be 3/4’ ’ (19 mm) of movement under the bottom edge (heel) of the brake pedal.

P–0201

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AUXILIARY CONTROL LOCKBOLT

A

742BOperationAndMaintenanceManual6722056–PreventiveMaintenanceSection

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

1

Raise the operator cab (See Page 23).

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

P–0197

U–JOINT LUBRICATION See the Service Schedule Page 25 for the service interval when to grease the U–joints.

B

Raise the operator cab. (See Page 27.)

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

P–0200

C

GOVERNOR LUBRICATION See the Service Schedule Page 25 for the service interval when to grease the governor shaft.

Add grease to the fitting (Item 1) [C] .

If the governor is not equipped with a grease fitting, oil the shaft at the same interval.

1 P–2046

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Dealer Copy -- Not for Resale

B–3371

TROUBLESHOOTING TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 54 ..

TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 ..

Dealer Copy -- Not for Resale

TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . .55 .

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

Instructions are necessary before operating or servicing machine.

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

PROBLEM Engine won’t turn over with starter.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

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CAUSE

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause loss of damage.

–

Cables loose or dirty.

Clean and tighten the battery cables.

36

Damaged starter, solenoid or wiring.

Check the starting circuit.

Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

9

No pre–heat

Use correct starting procedure

9

Ignition system is damaged.

Check & repair as needed

D/S

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

Take out of ”detent”.

4

No fuel in tank.

Add fuel.

29

Fuel shut–off solenoid damaged.

Check

D/S

Vent in fuel filler cap is plugged.

Clean the vent.

–

Dirt or water in fuel system.

Repairs as needed.

D/S

Fuel filter is dirty.

Install a new filter.

29

Hole in fuel line.

Repair as needed.

–

Weak battery.

Charge or replace battery

36

Wrong oil in engine.

See Oil Specifications.

31

Cylinder compression is low.

Recondition the engine.

D/S

Engine has overheated.

Check Cooling System.

33

Poor fuel quality.

Use fresh, good quality fuel.

29

Dirt, water or air in fuel system

Clean and repair as needed.

D/S

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W–2003–1289

742B Bobcat Loader Operation & Maintenance Manual

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

Engine overheats.

CAUSE

See ”Engine Overheats”.

–

Plugged fuel injectors.

Clean or replace.

D/S

Restricted exhaust

Clean exhaust system

40

Dirty air cleaner.

Install new element.

27

Cylinder compression is low.

Recondition the engine.

D/S

Restriction in cooling air flow.

Check for debris on radiator grill.

33

Blower shroud damaged or missing.

Check shroud and repair or replace as needed.

–

Engine is overheated.

Run at full throttle.

–

CAUSE

No drive on both sides.

Machine pulls to one side.

Machine moves when levers are in neutral

System is overheating.

Parking brake will not hold.

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PAGE

Engine is hot.

PROBLEM

No drive on one side.

CORRECTION

CORRECTION

PAGE

Hydraulic fluid is low.

Check fluid level. Add as needed.

38

Damaged hydraulic pump.

Check condition of pump and replace as needed.

D/S

Hydrostatic system is damaged.

Check hydrostatic system

D/S

Control linkage is disconnected.

Repair linkage.

D/S

Hydrostatic system is damaged.

Check hydrostatic system and make repair as needed.

D/S

Wrong tire pressure.

Check all tires for correct pressure.

D/S

Steering linkage out of adjustment

Check steering linkage and adjust as needed.

D/S

Damaged hydrostatic system.

Check system. Repair as needed.

D/S

Steering linkage out of adjustment.

Adjust steering linkage.

D/S

Servos out of adjustment.

Adjust steering

D/S

Hydraulic fluid level is low

Check fluid level and add as needed.

38

Cooling system is dirty. Air restricted

Clean cooling system. Check for debris on radiator grill.

33

Low charge pressure (transmission light on).

Check by–pass valve.

D/S

Auxiliary control in detent.

Take out of detent.

46

Bobcat is overloaded.

Use correct size attachment.

D/S

Hydrostatic transmission damage. Check system and make repair

D/S

Out of adjustment.

45

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Adjust parking brake.

742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

PROBLEM

No hydraulic action.

CAUSE

CORRECTION

PAGE

No hydraulic fluid.

Check fluid level and add as needed.

38

Pedals are disconnected.

Check linkage. Repair as needed.

–

Relief valve is damaged.

Replace the relief valve.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

11

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

38

Hydraulic action is slow.

Pedal is hitting floor or debris under pedal.

Check adjustment. Remove dirt.

–

Cylinders leak internally.

Check condition of cylinders and repair as needed.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Control valve is damaged.

Check valve and repair as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

11

Damage to cylinder rods or seals.

Repair cylinders.

D/S

Hydraulic cylinders leak fluid.

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PROBLEM

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742BOperationAndMaintenanceManual6722056–TroubleShootingSection

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MACHINE SIGNS TRANSLATIONS IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 .....

SERVICE SCHEUDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ....

WARNING 6579528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 ....

WARNING 6579510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 ....

WARNING 6579511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ....

WARNING 6577754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 ....

DANGER 6579639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 ....

Dealer Copy -- Not for Resale

DANGER 6579509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 ....

MACHINE SIGNS (Decals) Machine signs (decals) are an essential part of the loader (See Page vi & vii). This sectin provides French, German and Spanish translations of the machine signs that are in English. The Operator’s Handbook is also available in an comination English, French, German and Spanish edition.

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ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

• Mantenga le puerta cerrada excepto para dar servicio.

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

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

• No use el cargador en lugares donde

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

• Todos los gases del escape pueden

matar. Ventile siempre el lugar de trabajo.

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

• Escapes de líquido bajo presión pueden penetrat en la

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

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

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

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

• Las baterias producen gas inflammable y

explosivo.

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

• Para arranque con batería auxiliar, conecte de último el

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

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

de

Dealer Copy -- Not for Resale

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

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

• En cas de démarrage par pontage, effectuer le dernier

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

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

un moteur diesel avec des bougies de préchauf fage.

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

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

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

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non

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

• Ne pas utiliser la machine dans un

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

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

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CADA 10 HORAS 1. Aceite del Motor–Verifique el nivel–no lo llene demasiado (Consulte el Manual del Operario para ver cual fluido recominenda).

2. Filtro del Aire del Motor–(Vacie la tapa recolectora de polvo y cambie el elemento si es necesario).

3. Sistema de Enfriamiento del Motor–Limpiar la basura de las aletas de enfriamiento de la guardera y del enrejado. Verifique en frio el nivel del líquido enfriador, agregue etilenglicol y agua en las cantidades necesarias para obtener una proporción de 50% a 50% de cada uno.

4. Verifique las correas del ventilador y de la bomba para asegurase qu están en buenas condiciones y que la tensión está bién.

5. Brazos de Elecación y Puntos de Pivote del Cilindro – Lubríquelos con grasa de base be litio para uso multiple.

6. Neumáticos – Verifique la persión de aire.

FLOTATION – 35 PSI (241 kPa) ST ANDARD Y CLASIFICACION DE 8 PLIEGOS – 50 PSI (340 kPa), 5.70 x 12 – 40 PSI (275 kPa). Verifique que no tengan cortadas.

7. Sistema de Aire del Motor – V erifique que no haya escapes ni componentes dañados.

8. En General – Verifique que no haya piezas ni sueltas ni rotas, qu no estén dañados ni el cinturón de seguridad ni la cabina deloperador. Verifique tembién el funcionamiento de los instrumentos, que no haya tuercas sueltas en las quedas, escapes de aceite, etc.

9. Filtro del Combustible – Purgue el agua atrapada (solamente para diesel).

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CADA 50 HORAS 1. Aceite del Motor – Drenarlo mientras está caliente y cambiar el filtro (en las cargadoras 440 solamentese cambia el aceite cada 25 horas). consulte el Manual del Operador para ver cual fluído recomendado.

2. Fluido Hidráulico – V erifique el nivel del fluído.

Consulte el Manual del Operador para ver vual fluído recomendado.

3. Caja de la Cadena – Verifique el nivel del fluído.

Consulte el Manual del Operador para ver cual fluído recomendado.

4. Batería – Verifique su condición.

5. Controles y Frenos – V erifique el funcionamiento.

Hacer ajustes si es necesario.

CADA 100 HORAS 1. Sistema de Encendido – V erificar las bujias, lo s platinos y la sincronización–cambie las pieza s defectuosas (solamente para gasolina).

2. Silenciador con Amortiguador de Chispas – Vasie la cámara de chispas.

3. Sistema Hidráulico – Cambie el filtro – modelos 440, 540.

CADA 250 HORAS 1. Sistema Hydraulico – Cambie el filtro en el mode l 843.

2. Filttro Final del Combustible – Reemplace e l elemento del filtro.

3. Linea Motriz – Engrase la uniones universales co n una grasa aprobada según la recomendación del Manual de Servicio.

4. Engrase el pivote de la barra del asiento en cuant o sea necesario.

742B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

PROGRAMA DE SERVICIO (SPANISH)

CADA 1000 HORAS 1. Depósito Hidráulico–Drenar el fluído y reemplazarlo.

Consulte el Manual del Operador para ver cual fluído recomendados.

2. Caja de la Cadena–Drene el fluído y reemplazarlo.

Consulte el Manual del Operador para ver cual fluído recomendado.

FILTRO DEL HIDROSTATICO (Modelos 640, 740 y 843) 1. Cambie el filtro cuando se enciendo la luz de aviso del hidrostático. Consulte el Manual del Operador.

PROGRAMME D’ENTRETIEN (FRENCH) TOUTES LES 10 HEURES 1. Huile de moteur–Vérifier le niveau – ne pasremplir à rasbord (conseiller le manuel d’utilisation pour le fluide recommandé).

2. Filtre à air du moteur (vider la capsule à poussiere changer l’élément si nécessaire).

3. Système de refroidissement du moteur – nettoyer les débris de ailettes de refroidissement, coucliers et grilles. – Vérifier le niveau de température de liquide de refroidissement, ajouter 50–50 d’éthylène glycolet eau autant que nécessaire.

4. Vérifier la condition et la tension du ventilateur et des courroies de transmission de la pompe.

5. Levier du chargeur et les points de pivot du cylindre – graisser avec une huile multi–usage à base de lithium.

6. Pneus – vérifier le gonflement: FLOTATION – 35 PSI (241 kPa), STANDARD et 8 PLY – 50 PSI (340 kPa), 5.70 x 12 – 40 PSI (275 kPa); vérifierl’état des pneus (entailles).

7. Système d’aération du moteur – contrôlerles fuites et les éléments abimés.

8. Conseils géneraus: vérifier les pièces abimées ou ayant du jeu, centinure de sécurité abimée et cabine de l’utilisateur, instrument de commande, écrous devissés des roues, fuites d’huile, etc.

9. Filtre du carburante – retirer l’eau qui s’y trouve (diesel seulement).

TOUTES LES 50 HEURES 1. Huile de moteur – vider chaud et changer le filtre (huile de remplacement seulement, toutes les 25 heures pour chargeur 440). V oir le manual d’utilisation en ce qui concerne l’huile recommendée.

2. Fluide hydraulique – vérifier le niveau du fluide. Voir le manuel d’utilisation pour le fluide recommendé.

3. Boíte à chaines – vérifier le niveau du fluide.

Consulter le manuel d’utilisation en ce qui concerne le fluide recommendé.

4. Batterie – vérifier l’etat.

5. commandes et freins – vérifier l’etat de marche, régler si nécessaire.

TOUTES LES 250 HEURES 1. Système hydraulique – changer le filtre sur le 843.

2. Dernier filtre à essence – remplacer la pièce du filtre.

3. Arber de transmission – graisser le joint U avec u n lubrifiant approivé par le manuel.

4. Graisser le pivot du siège autant que nécesaire.

TOUTES LES 500 HEURES 1. Système hydraulique – remplacer le filtre bronze sile système en est équipé.

2. Premier filtre à essence – nettoyer le récipiente à seidments. ir 3. Remplacer le bouchon – filtre du réservo hydraulique.

TOUTES LES 1000 HEURES 1. Réservoir hydraulique – vider le fluide et le remplace r.

Voir manuel d’utilisation pour le fluide recommendé.

2. Boîte à chaînes – vider le fluide et le remplacer pa r celui conseillé par le manual d’utilisation.

FILTRE HYDROSTATIQUE (pour les 640, 740 et 843) 1. Changer le filtre quand le voyant lumineux relatif a u système hydrostatique s’allume. Consulter le manuel d’utilisation pour plus amples informations.

Dealer Copy -- Not for Resale

CADA 500 HORAS 1. Sistema Hidráulico – Cambie el filtro de brone si está equipado con este.

2. Filtro Primario del Combustible – Limpie el cubo de sedimento.

3. Reemplace la tapa del respiradero del depósito hidráulico.

TOUTES LES 100 HEURES 1. Système d’allumage – vérifier les bougies régler l’allumage, remplaer les pièces défectueuses (essence seulement).

2. Pot d’echappement – vider la chambre à étincelles.

3. 440 et 540).

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Commande au pied seulement

ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

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

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

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

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

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

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

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

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

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

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

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

POUR QUITTER LA CHARGEUSE:

2. PARE EL MOTOR.

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

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

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

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

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Dealer Copy -- Not for Resale

Solamente con control de piso

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE LLEVE LA CARGA EN POSICION BAJA EL NO OBEDECER EST A ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

PELIGRO (SPANISH) EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

AVERTISSEMENT (FRENCH)

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

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

DANGER (FRENCH) EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS DE

Dealer Copy -- Not for Resale

EVITER DES BLESSURES OU LA MORT

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

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

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

PELIGRO (SPANISH) EVITE LA MUERTE

• EL FORZAR EL IMPLEMENT O CONTRA EL SUELO

HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN.

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBAJO DE LOS BRAZOS DE ELEV ACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO UN TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

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

• NE JAMAIS ALLER SOUS NI METTRE LES MAINS

SOUS LES BRAS OU LE VERIN DE LEV AGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

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IMPORTANTE (SPANISH)

742BOperationAndMaintenanceManual6722056–MachineSignTranslationsSection

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

ES NECESARIO LIMPIAR ESTE AMORTIGUADOR DE CHISP AS DEL SILENCIADOR PARA MANTENERLO EN BUEN ESTADO. HAY QUE DARLE SERVICIO AL AMORTIGUADOR, VACIANDO LA CAMARA DE CHISPAS CADA 100 HORAS DE FUNCIONAMIENTO. SI ESTA MAQUINA ESTA DESTINADA PARA TRABAJAR EN BOSQUES, MA TORRALES O EN PASTOS QUE PUEDAN INCENDIARSE, ENTONCES TIENE QUE ESTAR EQUIPADA CON UN AMORTIGUADOR DE CHISPAS EN EL SISTEMA DEL ESCAPE Y TIENE QUE MANTENERSE EN PERFECTAS CONDICIONES DE TRABAJO. ES NO HACER ESTO CONSTITUYE UNA INFRACCION DE LA LEY ESTATAL DE CALIFORNIA, SECCION 4442, PRC.

Dealer Copy -- Not for Resale

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

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

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SPECIFICATIONS LOADER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ....

CAPACiTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 .....

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 ....

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 .....

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 .....

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ....

OPERATION & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ...

Dealer Copy -- Not for Resale

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 .....

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742B Bobcat Loader Operation & Maintenance Manual

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

742B BOBCAT LOADER

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

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

LOADER DIMENSIONS

55.1 (1400)

139.6 (3546)

100°

69.7 (1770)

37 °

44.2 (1123) 109 (2769)

21.8 (554)

86.3 (2192)

35.7 (907)

28 °

26 °

7.5 (191)

35.4 (899)

58.5 (1486)

32.3 (820)

8.0 (203)

47.0 (1194)

54.0 (1372)

94.5 (2423)

PI–2206 120.4 (3058) This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

742B

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

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

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

4830 lbs. (2193 kg) 1300 lbs. (590 kg) 2600 lbs. (1180 kg)

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

Infinitely variable 06.0 MPH (9,7 km/hr.)

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

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

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

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

Direction & speed controlled by two hand levers.

Lift & Tilt Function: Controlled by separate foot pedals.

Front Auxiliary Function: Controlled by the right steering lever .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Mitsubishi 4G32 Gasoline, leaded or unleaded 36 HP (27 kW) 2800 RPM 73 ft.–lbs. (99 Nm) @ 2000 RPM Four 3.033/3.34 (76,9/84,8) (82/82) 95.62 cu. in. (1567 cm3 ) Liquid Full pressure with full flow filter PCV Dry replaceable paper cartridge 12 volt, battery ignition W/breaker points & coil 2900–2975 RPM 700–750 RPM

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742B

742BOperationAndMaintenanceManual6722056–SpecificationsSection

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

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

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

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

Engine driven gear type 12.1 GPM (45,8 L/min.) @ 2500 RPM 2250–2400 PSI (15514–16548 kPa) Replaceable #3 micron paper element in charge line

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

Doubleacting

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

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

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

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

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

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

25.00 (635) 14.5 (368)

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

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

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

2.00 (51) 3.25 (83)

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

Lower Lift Arms from Maximum Height .

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

Move Bucket to Retracted Position . . . .

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

3.5 Seconds 2.7 Seconds 2.7 Seconds 2.3 Seconds Bobcat Fluid (P/N 6563328). If fluid is not available use 10W–30 or 10W–40 Class SE Motor Oil for temperatures above 0_F (–18_C) & 5W–30 for temperatures below 0_F (–18_C)

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

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

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

Belt drive, 55 amps. Open 12 volt, 625 cold crank amps. @ 0°F (–17.8°C) 125 min. reserve capacity 12 volt

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Dealer Copy -- Not for Resale

1.25 (32) 1.50 (32)

WARRANTY 400–900 Series Bobcat Loaders

During the warranty period, the authorized selling Melroe dealer shall repair or replace, at his option, without charge for parts and labor, any part of the Melroe product which fails because of defects in material and workmanship. The owner shall provide the authorized dealer with prompt written notice of the defect and allow reasonable time for replacement or repair. Melroe may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Melroe product to the authorized Bobcat Loader dealer for warranty work are the responsibility of the owner.

The warranty does not apply to tires or other trade accessories not manufactured

by Melroe. The owner shall rely solely on the existing warranty, if any, of the respective manufacturers thereof. Warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, use of the Melroe product with any bucket or attachment not approved

by Melroe, air flow obstructions, or failure to maintain or use the Melroe product according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OR OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570162 (1–99)

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Printed in U.S.A.

Dealer Copy -- Not for Resale

The Melroe Company warrants to its authorized dealer and authorized dealers of Melroe Equipment, Ltd., who in turn warrants to the original buyer (owner) that each new Bobcat Loader will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

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Dealer Copy -- Not for Resale