Bobcat 843B Loader Operation & Maintenance Manual 6720547 - 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

6720547 (7-97) Revised (6-12) Printed in U.S.A.

© Melroe Company 1997

Dealer Copy -- Not for Resale

8 4 3 B

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

Untrained operators can cause injury or death.

W–2001–1285

Safety Alert Symbol: This symbol is used for important safety messages. When you see this symbol, follow the safety message to avoid personal injury or death.

B–10731

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

CORRECT

WRONG

B–7403

B–6582

B–13418

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the pedals when operating loader.

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

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

WRONG

WRONG

WRONG

B–6578

Dealer Copy -- Not for Resale

CORRECT

B–6585

B–6595

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload and turn on flat level ground.

WRONG

WRONG

WRONG

B–6587

B–6594

B–6591

Never exceed rated operating capacity.

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

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

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

Never carry riders.

Never modify equipment.

Use only attachments approved

by Melroe Company for this model loader.

SAFETY EQUIPMENT The Bobcat loader must be equipped with safety items necessary for each job. Ask your dealer about attachments and accessories.

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

2. SEAT BAR: When up, it must lock the pedals. (If so equipped.)

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

4. HANDBOOK: Must be in the cab.

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

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. PARKING BRAKE 6–96 FC

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

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

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

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

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ....

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 ....

SAFETY

OPERATING INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING

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

PREVENTIVE MAINTENANCE

REFERENCE INFORMATION .

TROUBLESHOOTING Dealer Copy -- Not for Resale

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 . . . . . . . .

SPECIFICATIONS

NOTES:

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

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

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

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

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

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

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SERIAL NUMBER LOCATIONS

A

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

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

Loader Serial Number

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

Explanation of loader Serial Number: XXXX

B–12679

XXXXX

B

Production Sequence (Series)

ENGINE SERIAL NUMBER B–08286

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

Dealer Copy -- Not for Resale

Module Engine Version

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 [D].

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BOBCAT LOADER IDENTIFICATION FRONT LIGHTS (OPTIONAL)

GRAB HANDLES OPERATOR SEAT STEERING LEVERS SEAT BELT

FRONT AUXILIARY QUICK COUPLERS (OPTIONAL)

BUCKET

BUCKET STEPS SEAT BAR

REAR LIGHT (Opt.)

SAFETY TREAD

OPERATOR CAB (ROPS & FOPS) LIFT ARM

UPRIGHT REAR GRILL

LIFT ARM SUPPORT DEVICE LIFT CYLINDER

REAR DOOR

TIRES*

B–07377 B–07484

* TIRES – Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.

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

ROPS, FOPS – Roll Over Protective Structure, per SAE J1040, and Falling Object Protective Structure per SAE J1043.

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TILT CYLINDER

OPTIONS AND ACCESSORIES 843B Bobcat loaders are equipped with the following standard items: Bob–Tach Seat Belt Spark Arrestor Exhaust System Seat Bar Operator Cab (W/ROPS & FOPS Approval) Parking Brake Gauges/Warning Lights

Tires 7.00–15, 6 PR . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.00–16.5, 6 PR Flotation . . . . . . . . . . . . . . . . .

10.00–16.5, 8 PR Heavy Duty Flotation . . . . . .

Std. Opt. & FA FA

Operator Cab Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Lights (Front & Rear) . . . . . . . . . . . . .

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back–Up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated Enclosed Cab . . . . . . . . . . . . . . . . . . . . . .

Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Enclosure Panels . . . . . . . . . . . . . . . . . . . . .

Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . .

Hand Control Conversion . . . . . . . . . . . . . . . . . . .

Cover Kit (Pedals Area) . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . .

Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strobe or Rotating Beacon Light . . . . . . . . . . . . .

3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA

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

Rear Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . .

Hydraulic Bucket Positioning . . . . . . . . . . . . . . . .

Opt. & FA Opt. & FA Opt. & FA

Other Catalytic Purifier . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . .

Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Screen Kit . . . . . . . . . . . . . . . . . . . . . . . .

Tailgate Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA FA FA FA FA FA

Dealer Copy -- Not for Resale

Below is a listing of the optional equipment which is available through your Bobcat loader dealer.

Std. = Standard Equipment Opt. = Factory Installed Option FA = Field Installed Accessory

Specifications subject to change without notice

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

SAFETY

Dealer Copy -- Not for Resale

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

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SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Skid Steer Loader is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wid e 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 deale r demonstrates the safe operation of the loader according to Melroe’ s instructional materials; which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the loader. The user must check with the dealer,or Melroe Company literature, to determine safe loads of materials of specified densities for his loader–attachment combination.

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

•

The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold .

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

•

The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations ear shown in the Operation & 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 th e operator. The handbook is available from your dealer in English edition or a combination English, French, German , Italian, Dutch & Spanish edition.

•

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 dealer . This course is intended to provide rules and practices of correct operation of the Bobcat loader. The course is available in English and Spanish versions.

•

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

Dealer Copy -- Not for Resale

•

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 than was originally demonstrated by the dealer, ask the dealer for recommendations on the new use.

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BEFORE OPERATING THE BOBCAT LOADER Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.

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.

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

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

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

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

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

Regulations may identify a hazard such as utility supply line.

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

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

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

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

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

• Wear tight fitting clothing. Always wear safety glasses whenmaintaining or servicing loader. Safety glasses, hearing protection or loader special application kits are requiredfor some work. See your dealer about Melroe safety equipment.

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

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I–2019–0284

W–2044–1285

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

Flammable debris (leaves, straw, etc.) must be removed regularly . If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debri s 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, bu t the muffler and the exhaust gases are still hot.

•

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

•

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

•

The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to preven t 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.

•

e Do not use ether or starting fluids on this engine. It has glow plugs. These starting aids can cause explosion and injur you or bystanders.

•

r Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all othe flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or weldin g 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.

Dealer Copy -- Not for Resale

contact flammable material,

A fire extinguisher is available from your local dealer.

A

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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 (decals) and be sure they are in the correct locations. Machine signs (decals) are available from your Bobcat loader dealer .

6561385 (642 Only)

6569021

6565927 (641 & 643 Only)

6565990

6569119

6577754 (2) 6561377

6577826 6710358

6579509

6579528 6579510

6561383 (641, 642 & 643 Only) (642B Optional) 6579639

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B–07377

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6557565

MACHINE SIGNS (DECALS) (Cont’d)

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6560573

6561379

6703328

6575666

*6579511 *6567875

B–07484

* Located inside the engine compartment.

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

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 ...

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. . . .

GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. .

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

Auxiliary Lever Operation (Opt.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . .

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

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

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

OPERATING INSTRUCTIONS

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

OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 ...

Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 .....

Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 ...

Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ....

Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 ....

Leveling The Ground (Using Lift Arms In Float Position) . . . . . . . . . . . . . . 20 .

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

PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ...

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

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

Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ..

Normal Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 ...

Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . 13 ..

Dealer Copy -- Not for Resale

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ....

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

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

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

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ....

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . 21 ..

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INSTRUMENT PANEL

A

The instrument panel has the following instruments [A].

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

2. KEY SWITCH – For starting, stopping preheating the engine.

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5

3 1

and

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

6

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

7

4 2

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

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9

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

B–12526

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

Dealer Copy -- Not for Resale

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.

THROTTLE CONTROL

B

The throttle control (Item 1) [B] is at the right side of the operator seat.

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

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PARKING BRAKE

A

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

B–3745

B–7378

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

Dealer Copy -- Not for Resale

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–07379

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

B

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

FORWARD

REVERSE

Forward Travel – Push both levers forward.

Reverse Travel – Pull both levers backward.

Normal Turning – Move one leverfarther forward than the other.

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

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

LEFT TURN

RIGHT TURN

FAST TURN

FAST TURN

To increase travel speed, push the levers farther forward.

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

Dealer Copy -- Not for Resale

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

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HYDRAULIC CONTROLS

A

Foot Pedals

3 1 2

B–7379

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)[A] control the hydraulic cylinder for the tilt and lift function.

B–07440

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

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1

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

B–7379

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

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

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

B–07441

Auxiliary Lever Operation (Opt.)

B

The right steering lever is also the control lever for the auxiliary hydraulics [B].

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

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

A–02408

A–02409

2

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

1

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843B 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 • Engine Cooling • Operator Cab, Seat Belt, Seat Bar & Pedal Locks • 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 Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death [A].

B–06583 B–06592

W–2003–1289

B

Dealer Copy -- Not for Resale

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

6567875

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843B Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt control pedals are locked when returned to the neutral position.

1

B–12379

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–2046–0592

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

2

Seat Bar

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

Interlock

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

1 Pedal Linkage

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

3

MC–01669

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.

C Seat Bar

W–2045–1086

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.

Interlock

W–2105–1285

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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MC–01669

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843B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

GETTING READY FOR OPERATION

A

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.

W–2001–0596 B–07377

Use safety treads, grab handles and bucket steps to get on and off the loader [B].

B

B–12885

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

C

Dealer Copy -- Not for Resale

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

Keep the safety treads clean and replace when damaged.

Replacement treads are available from your Bobcat loader dealer.

1 B–03878

Fasten the seat belt snugly and adjust it so that the buckle is centered between your 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

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B–12377

843B Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

A

Lower the seat bar [A].

Be sure the parking brake is engaged.

All the controls must be in the neutral position before you start the engine (See Starting the Engine, Page 11).

B–12378

Keep both feet on the pedals while operating the loader [B].

Dealer Copy -- Not for Resale

B

B–12379

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843B Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE

A

WRONG

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285

B–03724

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust

B

WRONG Dealer Copy -- Not for Resale

gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086

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

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

B–06578

Lower the seat bar [C].

C

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843B Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

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

NEUTRAL POSITION

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

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

1 1/2 THROTTLE

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

2 ON POSITION Check skid plate daily and remove any debris.

Failure to clean can result in a fire.

W–2034–1285

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

Dealer Copy -- Not for Resale

STOP THE ENGINE IF THE NOT GO OFF.

START POSITION

WARNING LIGHTS DO

Cold Temperature Starting Condition

4

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

RUN POSITION

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature (See Oil Specifications, Page 33).

Make sure the battery is at full charge.

5 PREHEAT POSITION

6

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843B Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Install a block or tank heater on the engine.

Follow the steps under Normal Starting Conditions and repeat the preheating procedure until the engine starts [A].

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

W–2071–1285

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.

Dealer Copy -- Not for Resale

STOPPING THE ENGINE Pull the throttle fully backward to decrease the engine RPM. Turn the key to the OFF position.

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843B Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS

A

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

Unapproved attachments can cause injury or death.

W–2052–1285

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

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

B–06587

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

Steering the loader may be difficult.

Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

Tires may wear faster.

W–2053–0887

There will be a loss of stability.

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 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.

WEIGHT OF LOADS LBS. (KG)

B

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

3 (76)

23 (584)

45 (1143)

CENTER OF LOAD LOCATION Inches (mm) 543 MODEL 34 of 80

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6558413

843B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

The Rated Operating Capacity for this loader is shown on a label in the operator cab (See the SPECIFICATIONS Page 53).

ATTACHMENTS AND BUCKETS (Cont’d)

A

Removal And Installation The loader is equipped with Bob–T ach system. The Bob–Tach system is used for fast changing of buckets and attachments. See the attachments Operation Manual to install other attachments.

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

W–2054–1285 PI–02590 B–03851

Pull the Bob–Tach levers all the way up.

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].

B Dealer Copy -- Not for Resale

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].

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.

PI–02591 B–03850

W–2045–1086

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843B Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Removal And Installation (Cont’d) Push down on the Bob–Tach levers until they are in the locked position [A].

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–07018 B–03852

W–2102–0497

Dealer Copy -- Not for Resale

B

The wedges (Item 1) [B] must extend through the holes (Item 2) [B] in the attachment.

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

2

1

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B–03893

843B Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE

A

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

WITH BUCKET FULL

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

I–2015–0284

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

B

B–06612

WITH BUCKET FULL

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

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

C

B–06612

WITH BUCKET FULL

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.

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

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

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

Going Down Slope

D

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

B–06611

WITH BUCKET FULL

W–2018–1187

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

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843B Bobcat Loader Operation & Maintenance Manual

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–07379

B–06719

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

B–07379

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

W–2056–1187

Drive backward away from the material.

B–06718

Emptying The Bucket

C

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–07379

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

W–2057–0694 B–06708

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843B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

OPERATING PROCEDURES (Cont’d)

A

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

B–07379

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

B–06720

Push the bottom of the tilt pedal a small amount to increase traction and keep an even digging depth [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–07379

Dealer Copy -- Not for Resale

B

B–06721

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

C

B–07379

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843B Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Leveling The Ground (Using Lift Arms In Float Position) Push the top (toe) of the lift pedal all the way forwarduntil the pedal is in the locked positiondetent to put the lift arms in a float position [A].

B–07379

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–06720

I–2005–1285

Backfilling B–07379

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

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

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

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

B–06724

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843B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

B

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

PARKING THE BOBCAT LOADER

A

Stop the Bobcat loader on level ground.

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

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

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

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

B–09334

Engage the parking brake.

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

Un–buckle the seat belt. Remove the key from theswitch to prevent operation of the loader by unauthorized personnel.

TRANSPORTING THE BOBCAT LOADER

C–02563

C–07384

Dealer Copy -- Not for Resale

B

W–2045–1086

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

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–06718

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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843B Bobcat Loader Operation & Maintenance Manual

LIFTING THE LOADER

A

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

• Assemble front cab fasteners as shown in this manual.

• Never allow riders in the cab or bystanders

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

W–2007–0497

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

The single point lift, supplied by Melroe Company is designed to lift support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.

TOWING THE LOADER B–07418

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.

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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843B Bobcat Loader Operation & Maintenance Manual

Dealer Copy -- Not for Resale

1

Fasten the pins in the kit as shown in figure [A].

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ...

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

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 ...

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 .....

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

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 ...

Cleaning The Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ...

Removing Coolant from The Cooling System . . . . . . . . . . . . . . . . . . . . . . 35 ..

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ....

Battery Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ...

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 .....

Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 ...

Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . .38 ..

PREVENTIVE MAINTENANCE

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

Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ....

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 ....

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ....

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 .....

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ....

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 ..

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 ..

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 ...

Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 ...

Hydraulic Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ...

Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ...

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

LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . 45 ..

Dealer Copy -- Not for Resale

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . 44 ..

Checking And Adding The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ...

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 ....

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 ...

Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 ...

PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 ...

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 .....

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

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

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

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

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

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

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ...

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ....

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 .....

Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 .....

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 .....

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843B Bobcat Loader Operation & Maintenance Manual

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

W–2003–1289 Safety Alert Symbol: This symbol is used for important safety messages. When you see this symbol, follow the safety message to avoid personal injury or death.

CORRECT

B–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

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

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–3724

B–6593

Have good ventilation when welding or grinding painted parts.

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

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

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

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

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 arenot in this manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

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CORRECT

CORRECT

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

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

W–2003–1289

Engine Oil Engine Air Cleaner Engine Cooling System Tires Seat Belt and Seat Bar Safety Signs (Decals) Safety Tread Lift Arm and Bob–Tach Pivot Areas Engine Fuel Filter Operator Cab Wheel Nuts Engine Oil and Filter Battery Parking Brake Hydraulic Fluid, Tubelines and Hoses Alternator Drive Belt Chaincase Controls & Brake Spark Arrestor Muffler Seat Bar Steering Shaft Pivots Hyd. and Hydro. Filters U–Joint Engine Fuel Filter Hydraulic/Hydrostatic Reservoir Breather Cap Chaincase Hydraulic Fluid Reservoir

SERVICE REQUIRED

8–10

50

100 250 500 1000

Check the oil level & 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 & 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 for correct operation.

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

Add grease to the fittings until extra grease shows.

Remove water from filter.

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

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

Replace the oil and the engine oil filter.

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

Check operation and adjust as needed.

Check the fluid level and add as needed. Checkfor damage and leaks and replace as needed.

Check the tension and adjust as needed.

Check the fluid level and add as needed.

Check operation and adjust as needed.

Remove the plug and clean the spark chamber.

Grease pivots as needed.

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

Replace filter elements.

Grease three (3) fittings with correct grease.

Replace the filter element.

Replace breather cap.

Dealer Copy -- Not for Resale

ITEM

Replace the fluid.

Replace the hydraulic fluid.

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

Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months.

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LIFT ARM SUPPORT DEVICE

A

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

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

W–2059–0991

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

B–06581

Place jackstands under the rear corners of the loader.

Dealer Copy -- Not for Resale

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

Start the engine and raise the lift arms all the way up.

Have second person install the lift arm support device over the rod of one of the lift cylinders [A].

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

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

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

W–2069–1285

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OPERATOR CAB (Cont’d)

A

Raising The Operator Cab

Nut Washer Bolt

Stop the loader on a level surface. Put the lift arms all the way down.

Plate Bushing Washer MC–01181

If the lift arms must be up while raising the operator cab, install a lift arm support device (See Page 26.)

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–02599

W–2014–0895

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

B Dealer Copy -- Not for Resale

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

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

Install the two fasteners (including washers and plates).

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

B–12365

C

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

W–2005–1189

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SEAT BAR SYSTEM The seat bar system has a pivoting seat bar with arm rests and has spring loaded latches 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 and unlocks the foot pedals. When the seat bar is up, the lift and tilt pedals are locked in neutral position.

A Clean & Lubricate

B–07387

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.

B

W–2105–1285

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

B–09781

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. Un–buckle the seat belt.

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

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

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

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Seat Bar Inspection

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

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.

B–03853

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

Dealer Copy -- Not for Resale

B 1 2

W–2020–1285

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

Loosen the nut (Item 2) [B].

3

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

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

B–07385 B–05772

With the set screw up, the flanges at the bolt (Item 2)[C] must be to the side so that the set screw aligns with the flat surface at the end of the bolt.

C

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

1

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

2

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843B Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

A

See the SERVICE SCHEDULE Page 25 for the interval to service the air cleaner system.

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

1

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

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

B–08292

B

To replace the filter element, use the following procedure:

B–08290

Remove the dust cup and outer filter element [C].

C

NOTE: Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter is replaced.

Clean the inside of the air cleaner housing.

Install the new filter element.

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

B–08291

Record the operating hours of the loader on the decal (Item 1) [D] inside the rear door.

D

1

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Loosen the clamp on the dust cup [B].

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality fuel. Use Grade No. 2 fuel above 40° F (4° C.). Use Grade No. 1 fuel at temperatures below 40° F. (4° C.).

1

Filling The Fuel Tank

B–03954

Stop and cool the engine before adding fuel.

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

B

W–2063–0887

WRONG

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

Install and tighten the fuel fill cap [A].

B–06586

Fuel Filter

C

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.

Dealer Copy -- Not for Resale

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

1

W–2103–1285

See the SERVICE SCHEDULE Page 25 for the service interval when to remove the water from the fuel filter.

B–11080

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

D

See the SERVICE SCHEDULE Page 25 for the service interval when to replace the fuel filter.

Clean the area around the fuel filter.

Loosen the filter element [D].

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FUEL SYSTEM (Cont’d)

A

Remove the water trap and filter element [A].

Put oil on the seal of the filter element.

Install the filter element, water trap and tighten.

Remove the air from the fuel system.

Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air mustbe removed from the fuel system to start the engine.

B–11082

Loosen the plug at the top of the filter housing [B].

B–11079

Operate the priming bulb until fuel flows from the plug with no air bubbles showing [C].

C

Tighten the top plug on the filter housing.

Loosen the plug at the fuel injection pump (Item 1) [D].

B–11118

Operate the priming bulb until fuel flows from the plug with no air bubbles showing [C].

D

Tighten the plug on the fuel injection pump.

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.

B–11081

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B

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.

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

Replacing Oil And Filter See the SERVICE SCHEDULE Page 25 for the service interval for replacing the engine oil and filter.

B–11092

Use the following procedure to replace the oil and filter: Run the engine until it is at operating temperature. Stop the engine.

B

Open the rear door and remove the cap (Item 1)[B] from the end of the hose and drain the oil into a container.

NOTE: This plug must be tightened after the oil is removed from the filter element, because if it is not, there will be no engine oil pressure and engine damage will result.

1 B–11778

C AVOID INJURY OR DEATH Engines can have hot parts. Wear protective clothing when removing oil filter to avoid burns.

Dealer Copy -- Not for Resale

Turn the plug on the oil filter hosingout about three to five turns to drain the oil in the filter element into the crankcase [C].

W–2128–0788

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C°–34 –29

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

+70

+80 +90 +100 +110 +120 +130 +140

B–08363

+54 +60

SAE 10W–30/40

SAE 15W–40

SAE 5W–30

SAE 30

SAE 20W–20

SAE 10W

F°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE 53 of 80

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ENGINE LUBRICATION SYSTEM (Cont’d)

A

Remove the filter element [A].

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

Turn the plug (Item 1) [A] on the filter housing.

Install the cap on the end of the drain hose and tighten.

Remove the oil fill cap [B].

1 B–08436

Fill to capacity (SeeSPECIFICATION Page 53 for correct capacity) [C].

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

Stop the engine. Check the oil level. Add oil until the level is at the Full mark on the dipstick. Install the fill cap.

B–11094

C

B–11095

Record the operating hours of the loader on the decal (Item 1) [D] on the rear door.

D

1

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B

COOLING SYSTEM

A

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

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

B–07486

B

W–2019–1285

1

Checking The Coolant Level

The coolant recovery tank must be 1/3 full.

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

B–11778

Removing Coolant From The Cooling System

C

Dealer Copy -- Not for Resale

Open the rear door. Check the coolant level in the coolant recovery tank (Item 1) [C] on the left side of the engine.

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

W–2070–1285

Open the rear door. Open the rear grill.

Remove the radiator cap.

B–08367

Open the engine block drain valve and drain the coolant into a container [C].

After all the coolant is removed, close the drain valve.

NOTE: Protect the cooling system by adding pre–mixed 50% ethylene glycol and 50% water to the system. This mixture will protect the cooling system to –34° F. (–36° C).

Mix the coolant in separate container (See SPECIFICATIONS for correct capacity, Page 53.)

Fill the radiator with the pre–mixed coolant. Install the radiator cap.

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COOLING SYSTEM (Cont’d)

A

Fill the coolant recovery tank 1/3 full.

Run the engine until it is at operating temperature. Stop the engine. Check the coolant level in the recovery tank when cool. Add coolant to the recovery tank as needed.

Cleaning The Cooling System To clean debris from the coolant system, use the following procedure: Open the rear door.

Remove the panels above the engine underthe oil cooler.

Clean the oil cooler area of all debris. Install the panels under the oil cooler.

Lift the rear grill.

Clean the top of the radiator.

B–08654

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W–2019–1285

Have a second person in the operator cab, with seat belt fastened and seat bar lowered.

Engage the parking brake and start the engine. Run the engine at full RPM. Use air pressure to blow debris down from the top side of the radiator [A].

Direct the air pressure from side to side starting at the rear of the radiator and moving forward.

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To clean the debris between the radiator and oil cooler use the following procedure:

ALTERNATOR BELT

A

Adjusting The Alternator Belt To adjust the belt tension, use the following procedure: Stop the engine. Open the rear door.

Remove the belt shield [A].

B–08342

Loosen the mounting and adjustment bolts [B].

B–08343

Move the alternator until the belt has 5/16 inch (8 mm) movement at the middle of the belt span with 15 lbs. (67 N) of force [C].

C

Tighten the adjusting and mounting bolts.

Install the belt shield.

5/16” 7,94 mm

Dealer Copy -- Not for Resale

B

B–08344

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843B Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

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

Electrical System Service The battery cables must be clean and tight. Check the water level in the battery. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution [A].

P–00742

Cover the battery terminals and cablesends with grease.

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

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

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

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

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.

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

Battery gas can explode and cause serious injury.

W–2066–1296 Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

Keep cables away from moving parts. Start the engine (See Cold Temperature Starting Condition, Page 12.)

After the engine has started, remove the ground (–) cable (Item 4) [B] first. Remove the cable from the loader battery.

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

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

W–2065–1296

B

Damage to the alternator can occur if: • Engine is operated with battery cables disconnected.

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

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

2

4 1

I–2023–1285

3

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Using A Booster Battery (Jump Starting)

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.

B–03709

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.

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 [A].

1

Disconnect the positive (+) battery cable.

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

Remove the battery from the loader.

B–11812

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

C

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.

P–09590

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W–2065–1296

P–09589

843B Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid Use only recommended fluid in the hydraulic system (See SPECIFICATIONS for the correct fluid, Page 53.)

To check the fluid level in the reservoir, use the following procedure:

1

Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back. Stop the engine.

2

Remove the dipstick (Item 1) [A].

The fluid level must be between the marks on the dipstick.

B–03952

Remove the fill cap (Item 2) [A] and add fluid as needed.

B

Hydraulic Filter Replacement See The SERVICE SCHEDULE Page 25 for the correct service interval.

1

Raise the operator cab (See Page 27.)

Clean the surface of the filter housing where theelement contacts the head.

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

Install the filter and hand tighten.

B–06944

Hydrostatic Filter Replacement See the SERVICE SCHEDULE Page 25 for the correct service interval.

C

NOTE: The filter must be replaced when the warning light comes on during loader operation.

1

Remove the filter element (Item 1) [C].

Clean the surface of the filter housing where theelement contacts the head.

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

Install the filter and hand tighten.

B–11812

Record the operating hours of the loader on the decal (Item 1) [D] inside the rear door.

D

1

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Remove the filter element (Item 1) [B].

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic Fluid Replacement See the SERVICE SCHEDULE Page 25 for the correct service interval.

The fluid must also be replaced if it becomes contaminated or after major repairs.

Remove the fill cap.

Remove the screen from the fill pipe [A].

Check the screen for damage. Clean the screen in solvent.

B–13296

Remove the fluid from the reservoir with a hand operated suction pump or a fluid lift pump [B].

B

Install the screen.

Add fluid to the reservoir until the fluid level is between the marks on the dipstick. DO NOT fill above the top mark on the dipstick.

Start the engine and operate the loader hydraulic/hydrostatic functions. Stop the engine. Check the fluid level and add as needed.

B–06941

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.

Dealer Copy -- Not for Resale

Replace the hydraulic and hydrostatic filter elements.

(See Page 40.)

W–2103–1285

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SPARK ARRESTOR MUFFLER

A

See the SERVICE SCHEDULE Page 25 for service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

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

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

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

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

W–2011–1285

I–2022–0595

Stop the engine. Open the rear door.

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

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

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

W–2006–0284

W–2050–1285

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

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

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

W–2068–1285

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B–08345

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 25 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm).

Tire Rotation Check the tires regularly for wear, damage and pressure (See SPECIFICATIONS, Page 53 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 [A].

C–01965

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.

Do not inflate tires above specified pressure.

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

W–2078–1285

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

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated 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.

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Dealer Copy -- Not for Resale

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

843B Bobcat Loader Operation & Maintenance Manual

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 53.)

To check the chaincase oil level, procedure:

use the following

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

1

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

C–02037

If oil can be reached with the tip of the your finger through 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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LUBRICATION OF THE BOBCAT LOADER

A

Lubricate the Bobcat loader as specified in theSERVICE SCHEDULE Page 25 for the best performance of the loader [A].

HYDRAULIC RESERVOIR

CHAINCASE

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

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

COOLANT

GREASE

TRANSMISSION OIL FILTER

6567875

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 a special U–joint grease (P/N 6599719) to assure correct lubrication of the U–joints fittings (Item 1) [B].

Dealer Copy -- Not for Resale

GREASE

B–06943

See the SERVICE SCHEDULE Page 25 for the service interval when to grease the steering lever pivot bearings and oil the shaft.

C

Grease the pivot bearings for the steering levers [C].

Fitting Located Between Fender and Control Box Under Cab

B–05191 B–05197 65 of 80

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LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

Add oil as needed to the steering control shaft [A].

Lubricate the seat rails for easy movement of the seat.

B–05730

BOB–TACH Check for free movement of wedges and Bob–T levers.

ach

B

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–03893

C

W–2102–0497

Replace wedges that are bent or broken.

PIVOT PINS All pivot pins in the lift arms, Bob–T ach and cylinders have a large pin held in position with a retainer bolt and nut (Item 1) [C].

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

PARKING BRAKE ADJUSTMENT

B–03858

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

D

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

1

Tighten the jam nut when the adjustment is correct.

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Dealer Copy -- Not for Resale

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

TROUBLESHOOTING TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 50 ..

TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 ..

TROUBLESHOOTING

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TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . .51 .

843B Bobcat Loader Operation & Maintenance Manual

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

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

W–2003–1289

TROUBLESHOOTING THE ENGINE

Engine won’t turn over starter.

CAUSE with

Engine has little power or rough.

runs

PAGE

Battery has low charge.

Charge battery and find cause of discharge.

–

Cables loose or dirty.

Clean and tighten the battery cables.

54

Check the starting circuit. Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

12

Air in the fuel.

Check & repair as needed.

D/S

Auxiliary control lever orlift pedal is in detent.

Take out of detent.

7&8

No fuel in tank.

Add fuel.

35

Vent in fuel filler cap is plugged.

Clean the vent.

–

Dirt or water in fuel system.

Repair as needed.

D/S

Fuel filter is dirty.

Install a new filter.

36

Hole in fuel line.

Repair as needed.

–

Weak battery.

Charge or replace battery.

55

Wrong oil in engine.

See Oil Specifications.

38

Cylinder compression is low.

Recondition the engine.

D/S

Engine has overheated.

Check cooling system.

40

Poor fuel quality.

Use fresh, good quality fuel.

35

Restricted exhaust.

Clean exhaust system.

57

Injectors are not working correctly.

Clean and repair as needed.

D/S

Dirt, water or air in fuel system.

Clean and repair as needed.

D/S

Damaged wiring.

Engine turns with starter , but is difficult to start.

CORRECTION

starter,

solenoid

or

Dealer Copy -- Not for Resale

PROBLEM

D/S = Dealer Service Only

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

CAUSE runs

Engine overheats.

CORRECTION

PAGE

Engine is hot.

See Engine Overheats

–

Restricted exhaust.

Clean exhaust system

57

Dirty air cleaner

Install new element.

33

Cylinder compression is low.

Recondition the engine.

D/S

Restriction in cooling air flow.

Check for debris on radiator grill.

–

Check shroud and repair or replace as needed.

–

Run at full throttle.

–

Blower shroud damaged missing.

or

Engine is overheated.

PROBLEM

CAUSE

No drive on both sides.

No drive on one side.

Machine pulls to one side.

CORRECTION

PAGE

Hydraulic fluid is low.

Check fluid level. Add as needed.

59

Damaged hydraulic pump.

Check condition of pump and replace as needed.

D/S

Hydrostatic system is damaged.

Check hydrostatic system.

D/S

Control linkage is disconnected.

Repair linkage.

D/S

Hydrostatic system is damaged.

Check hydrostatic system and make repair as needed.

D/S

Wrong tire pressure.

Check all tires for correctpressure.

62

Steering linkage out of adjustment. Check steering linkage and adjust as needed.

D/S

Damaged hydrostatic system.

D/S

Check system. Repair as needed.

Machine moves when levers are in neutral.

Steering linkage out of adjustment. Adjust steering linkage.

D/S

(26001 & Above) Servos out of adjustment.

Adjust Steering

59

System is overheating.

Hydraulic fluid level is low.

Check fluid level and add as needed.

59

Clean cooling system. Check for debris on radiator grill.

–

Check by–pass valve.

D/S

Auxiliary control in detent.

Take out of detent.

7&8

Loader is overloaded.

Use correct size attachment.

15

Hydrostatic transmission damage.

Check system and make repair.

D/S

Out of adjustment.

Adjust parking brake.

65

Cooling system restricted.

is dirty .

Low charge (transmission light on).

Parking brake will not hold.

Air

pressure

D/S = Dealer Service Only

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TROUBLESHOOTING THE DRIVE SYSTEM

TROUBLESHOOTING THE HYDRAULIC SYSTEM

No hydraulic action.

Hydraulic action is rough.

CAUSE

CORRECTION

No hydraulic oil.

Check fluid level and add as needed.

59

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.

12

Hydraulic fluid level is low.

Check fluid level and add as needed.

59

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

Hydraulic action is slow.

Hydraulic cylinders leak fluid.

adjustment. Remove

–

Cylinders leak internally.

Check condition of cylinders and repair as needed.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Control valve is damaged.

Check valve and repair as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

12

Damage to cylinder rods or seals.

Repair cylinders.

D/S

D/S = Dealer Service Only

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PROBLEM

843B Bobcat Loader Operation & Maintenance Manual

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843B Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 ....

CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 .....

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 ....

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 .....

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 .....

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 ....

PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 ....

Dealer Copy -- Not for Resale

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 .....

SPECIFICATIONS

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843B Bobcat Loader Operation & Maintenance Manual

Specifications

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

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.

PI–02585

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.

843B

PERFORMANCE Weights Operating Weight . . . . . . . . . . . . . . . . . . .

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

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

6480 lbs. (2942 kg) 1700 lbs. (772 kg) 3420 lbs. (1553 kg)

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

Infinitely variable 0–6.3 MPH (10 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.

Auxiliary function (opt.) 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 . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Isuzu 4JBIPK01 Diesel 54 HP (40,3 kW) @ 2700 RPM 2600 RPM 120 ft.–lbs. (163 Nm) Maximum @ 1600 RPM Four 3.66/4.02 (93/102) 169 cu.in (2770 cm3) Liquid Pressure System W/Filter Open Dry replaceable cartridge, with safety element 2725–2775 RPM 1200 RPM

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843B LOADER SPECIFICATIONS

843B Bobcat Loader Operation & Maintenance Manual

LOADER SPECIFICATIONS (Cont’d)

843B Engine driven gear type–Rated @ 1050 PSI (7240 kPa) 10.8 GPM (40,9 L/min.)

16.2 GPM (61,3 L/min.)

2250–2400 PSI (15514–16548 kPa) Replaceable #4 Micro Element Replaceable #3 Element

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

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

2.25 (57,2) 3.25 (82,6)

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

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

1.50 (38,1) 1.50 (38,1)

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

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

33.50 (850,9) 17.95 (455,9)

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

Bucket Position Valve (Opt.) . . . . . . . . . .

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

3 spool, open center, series type W/float detent on lift, detent onlift, detent on auxiliary Provides bucket positioning when lift arms are raised SAE standard tubes, hoses & fittings

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 . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Total Engine to Wheel Reduction . . . . . .

4.0 Seconds 3.6 Seconds 2.2 Seconds 1.7 Seconds Bobcat Fluid (P/N 6563328) (5 gal package). If fluid is not available use 10W–30 or 10W–40 Class SE Motor Oil for temperatures above 0° F (–18° C), & 5W–30 Motor Oil for temperatures below 0_F (–18_C) Belt drive, 55 amps. Open 12 volt, 700 cold crank amps. @ 0°F (–17.8°C) 170 min. reserve capacity 12 volt Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydro. motors Gear reduction and #100 roller chains operating in sealed chaicase with oil lubrication 39.4:1

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

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

Engine Lubrication . . . . . . . . . . . . . . . . . .

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

Hydraulic/Hydrostatic Reservoir . . . . . . .

Hydraulic/Hydrostatic System (Incl. Reservoir) . . . . . . . . . . . . . . . . . . . .

22 qts. (21 L) 22 gals. (83 L) 8.0 qts. (8,5 L) 9 gals. (34 L) 15.5 qts. (14,7 L) 8.25 gals. (31 L)

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

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

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

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

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8.25 x 15,6 Ply Rating 45–50 PSI (310–345 kPa) 12 x 16.5, 6 Ply Rating 45–50 PSI (310–345 kPa)

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Dealer Copy -- Not for Resale

HYDRAULIC SYSTEM Hydraulic Pump . . . . . . . . . . . . . . . . . . . . .

Charge Pump (Front) . . . . . . . . . . . . . . . .

Hydraulic Pump (Rear) . . . . . . . . . . . . . . .

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

Hydraulic Fluid Filters Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic . . . . . . . . . . . . . . . . . . . . . . .

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

OPERATOR’S HANDBOOK 6569119

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

–gives basic operation instruction and safety warnings.

OPERATION & MAINTENANCE MANUAL 6720547 –complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

SAFETY VIDEO 6724793

–provides basic safety instructions.

Skid–Steer Loader

Dealer Copy -- Not for Resale

SKID STEER LOADER OPERATOR TRAINING COURSE 6722720

SAFETY MANUAL 6556500

EQUIPMENTMANUFACTURERS INSTITUTE 10S.RIVERSIDEPLAZACHICAGO,ILLINOIS60606–37100

SERVICE MANUAL 6566091 –complete maintenance and overhaul instructions for your BOBCAT loader.

–provides basic safety procedures and warnings for your BOBCAT loader. Also available in Spanish P/N 6724451.

PARTS MICROFICHE

–Up–to–date PARTS information is also available. See your BOBCAT dealer.

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WARRANTY 400–900 Series Bobcat Loaders

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

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

by Melroe. The owner shall rely solely on the existing warranty, if any, of the respective manufacturers thereof. Warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe product according to the instructions applicable to it.

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

6570162 (1–96)

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Printed in U.S.A.

Dealer Copy -- Not for Resale

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

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