BEFORE OPERATING THE BOBCAT LOADER

Safety Alert Symbol

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

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

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

SAFE OPERATION NEEDS A QUALIFIED OPERATOR *

A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS

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

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

• HAVE TRAINING WITH ACTUAL OPERATION

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

W–2001–1285

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

I–2019–0284

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

W–2044–1285

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

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

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

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

• KNOW THE WORK CONDITIONS

• Know the weight of the materials being handled. Avoid exceeding the Rated Operating Capacity of the machine. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of load if handling dense material.

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

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

• Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, hearing protection or special applications kit are required for some work.See your dealer about Bobcat Safety equipment. * For an operator be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–0400

Fire Prevention

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

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

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

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

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

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

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

• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.

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

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

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

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

• Know where fire extinguishers and first aid kits are located and howto use them. Fire extinguishers are available from your Bobcat dealer.

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 dealer.

(Advanced Hand Control only) 6703723 (Foot Pedal)

6703724 (Hand Control)

6727452 (Later Models w/Float button)

* Decal located behind lift arm crossmember.

(2) Under

864, 864H Bobcat Loader

Instrument Panel

Without BOSS® (Front Panel) [A] 3.

1. TRACTION LOCK OVERRIDE BUTTON (Functions Only When The Seat Bar Is Raised) – Allows you to use the steering levers to move the loader when using the backhoe attachment or for loader service. (See Page 7.)

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

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

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

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

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

7. HIGH–FLOW SWITCH (Opt.) – Controls the ON/OFF function of the high–flow auxiliary hydraulics. (Only on High–Flow loaders.)

8. BUCKET LEVEL SWITCH (Opt./FA) – Controls the ON/OFF function of the available Bucket Position Valve,

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

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

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

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

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

14. AUXILIARY HYDRAULIC SWITCH (Opt./FA) –For engaging the available Auxiliary Hydraulics (front and rear).

Without BOSS (Side Console * ) [B]

1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer.

2. HAZARD SWITCH / HAZARD INDICATORS (Opt./FA) – Controls the available hazard lights. (Hazard Lights is a separate available accessory.) Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, worklights, etc.

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

* Available only with Deluxe Cab or with Cab Enclosure Kit.

Opt . – Factory Installed Opt ion

FA – F ield Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

Instrument Panel

With BOSS® (Front Panel) [A] 4.

1. TRACTION LOCK OVERRIDE BUTTON (Functions Only When The Seat Bar Is Raised) – Allows you to use the steering levers to move the loader when using the backhoe attachment or for loader service. (See Page 7.)

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

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

4. BOSS DIAGNOSTIC PORT – Connector for diagnostic tool to make service checks of the system operation unit and other components.

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

6. HIGH–FLOW SWITCH (Opt.) – Controls the ON/OFF function of the high–flow auxiliary hydraulics. (Only on High–Flow loaders.)

7. BUCKET LEVEL SWITCH (Opt./FA) – Controls the ON/OFF function of the available bucket Position Valve.

8. BOSS DISPLAY PANEL – Display panel for BOSS system and functions (See Page 5.)

9. AUXILIARY HYDRAULIC SWITCH (Opt./FA) –For engaging the available Auxiliary Hydraulics (front and rear).

With BOSS (Side Console * ) [B]

1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer.

2. HAZARD SWITCH/HAZARD INDICATORS (Opt./FA) – Controls the available hazard lights. (Hazard Lights is a separate available accessory.) Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, worklights, etc.

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

*Available only with Deluxe Cab or with Cab Enclosure Kit.

Opt . – Factory Installed Opt ion

FA – F ield Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

BOSS ® OPTION PANEL

4. The following items are located on the BOSS Option Display Panel [A] & [(Item 8) [A] Page 4]:

1. FUEL LEVEL – Shows the amount of fuel in the tank. Flashing pump symbol indicates low fuel level. H2O symbol is non–functional. (See WARNING SYMBOL )

2. BATTERY VOLTAGE – Shows the condition of the battery and charge rate. It will also indicate a WARNING for high or low voltage (See WARNING SYMBOL ).

3. ENGINE OIL PRESSURE – Shows engine oil pressure. Flashing symbol indicates low oil pressure (See WARNING and SHUTDOWN SYMBOL )

4. ENGINE COOLANT TEMPERATURE/LEVEL –Shows engine coolant temperature (See WARNING and SHUTDOWN SYMBOL).

5. SHUTDOWN SYMBOL – This symbol isassociated with any SHUTDOWN condition. When this symbol comes ON the SHUTDOWN will occur in 30 seconds. During SHUTDOWN the buzzer will sound continuously and the symbol will flash until the key switch is turned OFF.

NOTE:The engine can be restarted for 30–second periods to move the loader after a SHUTDOWN condition.

6. WARNING SYMBOL – The symbol will be ON when any WARNING or SHUTDOWN is activated. The warning symbol is also used to indicate a WARNING if there is no related symbol on the display. During a WARNING, the buzzer will beep three times and the symbol will be ON continuously.

7. HOURMETER – Records the total operating hours of the loader. The five character code will display the operating hours to the nearest tenth. When WARNING or SHUTDOWN occurs, an alpha–numeric code will be displayed in the hourmeter area to inform the operator of the problem (See SYSTEM ANALYSIS , Page 79). During a WARNING or SHUTDOWN the hourmeter symbol is not visible.

8. CHARGE PRESSURE AND FILTER CONDITION – Flashing symbol indicates low fluid charge pressure (See SHUTDOWN SYMBOL). If arrows are ON with gear/drop, it is fluid charge pressure. This symbol will also indicate a clogged hydraulic fluid filter.

9. AIR FILTER CONDITION – This symbol will indicate a clogged air filter element.

10. GLOW PLUG (Diesel) – The symbol will flash when the glow plugs are energized. The hourmeter will also contain characters GLOXX where XX indicates the remaining time the glow plugs will be ON. Time remaining will count down in 5 second increments.

11. ENGINE SPEED – This symbol will indicate an engine overspeed (See WARNING and SHUTDOWN SYMBOL).

12. PARKING BRAKE INDICATOR LIGHT (Non–Functional) .

13. HYDRAULIC FLUID TEMPERATURE – This symbol will indicate a high fluid temperature. (See WARNING or SHUTDOWN SYMBOL above).

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

The Bobcat Interlock Control System (BICS™) requires the operator to be seated in the operating position with the Seat Bar fully lowered and the green PRESS TO OPERATE Button (Item 1) [B] activated before the lift, tilt and traction functions can be operated. The Seat Belt must be fastened anytime you operate the loader.

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

Avoid Injury Or Death

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

The lift, tilt and traction drive functions are interlocked with the Seat Bar.

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

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

The light functions are as follows [A]:

1. SYSTEM ACTIVATED – ON when the green PRESS TO OPERATE Button is activated.

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

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

4. TRACTION* – ON when engine is running, then loader can be moved forward or backward.

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

NOTE:If any of the lights are off or blinking, see SERVICE CODES Page 79, BICS

Troubleshooting Chart, Page 81, or see BICS Inspection and Maintenance Instructions Page 49.

*The TRACTION light will come ON when the engine is running.

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

Lift Arm By–Pass Control

The lift arm by–pass control knob (Item 1) [A] is used to lower the lift arms if the lift arms can not be loweredduring normal operation.

With the operator in the seat, seat belt fastened and the seat bar fully lowered, turn the lift arm by–pass control knob (Item 1) [A] clockwise 1/4 turn. Then, pull up and hold the lift arm by–pass control until the lift arms slowly lower.

Traction Lock Override

6.

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

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

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

NOTE:The Traction Lock Override button will unlock the traction drive when the operator is NOT in the seat and the seat bar is raised.

The Traction Lock Override button will function if brake pedal is in the engaged or disengaged position.

Auxiliary Hydraulic System (If Equipped)

When the operator is seated and raises the seat bar, the Auxiliary Hydraulic System will deactivate. Press the Auxiliary Hydraulics Switch (Item 1) [C] to reselect operating mode. (See Auxiliary Hydraulics Page 14.)

Traction Lock Control System

The Traction Lock Control System will lock the traction drive system when the engine stops.

NOTE:When the Traction Lock Override button is activated, the Traction Lock Control System will NOT engage the Traction Lock if the engine stops.

The Traction Lock Control System is incorporated into the BICS system. See Inspecting The Traction Lock Control System Page 50

NOTE:The traction light on the BICS controller will remain OFF until the engine is started and if the parking brake is disengaged.

Engine Speed Control

The speed control lever (Item 1) [A] is at the right side of the operator’s seat.

Change the engine speed by moving the lever forward to increase the engine RPM and backward to decrease the engine RPM.

Parking Brake

Engage the parking brake by pushing on the top of the pedal [B]. The traction drive system will be locked. (See Traction Lock Override, Page 7.)

To release the parking brake, push on the bottom of the pedal [C].

Parking Brake Solenoid

The parking brake solenoid is located under the steering panel [D]. Under normal conditions there is no need to service the solenoid. If service work is performed, check the solenoid.

Be sure the parking brake solenoid valve is engaged before operating the loader.

To manually engage the parking brake solenoid valve, push IN on the red Traction Lock By–Pass Knob (Item 1) [D] and turn it 1/4 TURN clockwise to the engaged position.

Unexpected loader movement. Can cause serious injury or death.

Push in and turn red Traction Lock By–Pass Knob clockwise to engaged position before operating loader.

Read Operation & Maintenance Manual for more instructions.

6803932

Avoid Injury Or Death

When operating the machine:

• Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls or footrests.

W–2261–0397

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

Reverse Steering Levers

Move the levers smoothly. Avoid sudden starting and stopping.

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

Forward Travel – Push both levers forward.

Reverse Travel – Pull both levers backward.

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

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

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

To increase travel speed, push both levers farther forward.

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

STOPPING THE BOBCAT LOADER

Move the steering levers to the NEUTRAL POSITION.The hydrostatic transmission will act as a service brake to stop the loader.

Left Turn

Left Fast Turn Right Fast Turn

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

The seat bar restraint system has a pivoting, spring assist 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 .

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

Before you leave the operator’s seat:

• Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

W–2045–1086

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

W–2105–1285

The spring loaded interlocks (Item 1)[B] control the locking and unlocking functions of the Foot Pedal controls.

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.

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.

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

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

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

See SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance, Page 47

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

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

When the seat bar is down, and the green PRESS TO OPERATE Button is activated, the lift, tilt, and traction drive functions can be operated.

When the seat bar is up, the lift, tilt, and traction drive functions are deactivated.

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 foot rests.

W–2179–0694

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 the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2302–0698

See SEAT BAR RESTRAINT SYSTEM Inspection & Maintenance, Page 48

Hydraulic Controls

Foot Pedals

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

W–2002–1285

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

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

Lift Arm Operation

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

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

Lift Arm Float Position

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

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

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

Tilt Operation

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

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

Bucket Position Valve Operation (If Equipped)

The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in,prior to the upward lift cycle.

Bucket positioning functions automatically during the upward lift cycle only.

The bucket positioning function (if equipped) can be turned OFF with the bucket level switch. (See Pages 3 & 4.)

HYDRAULIC CONTROLS (Cont’d)

Advanced Hand Controls

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

W–2152–0594

Put your feet on the footrests and KEEP THEM THERE for comfort and safety any time you operate the loader.

Two hand levers [A] control the hydraulic cylinders for the lift and tilt functions.

Lift Arm Operation

The left hand lever controls the lift arms.

Move the left hand lever away (Item 1) [A] from the operator to raisethe lift arms.

Move the left hand lever toward (Item 2) [A] the operator to lower the lift arms.

Lift Arm Float Position

Move the left hand lever all the way toward the operator (Item 2) [A] until it locks into the float position.

Later AHC Models With Float Button

– Press anbd hold the Float Button (Item 5) [C] before moving the lever.

– Press again to disengage.

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

Move the left hand lever upward to unlock from the float position.

Tilt Operation

The right hand lever controls the action of the bucket.

Move the right hand lever away (Item 3) [A] from the operator to tilt the bucket forward.

Move the right hand lever toward (Item 4) [A] the operator to tilt the bucket backward.

Two lights (Item 1) [B] on the left handle are always ON when the Advanced Hand Control is functioning correctly. If lights are blinking or do not come ON , see Advanced Hand Controls Troubleshooting Chart Page 81.

Bucket Position Valve Operation (If Equipped)

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

Bucket positioning functions automatically during the upward lift cycle only.

The bucket positioning function (if equipped) can be turned OFF with the bucket level switch. (See Page 3 and 4).

HYDRAULIC CONTROLS (Cont’d)

7.

Auxiliary Hydraulics

Avoid Burns

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

W–2220–0396

NOTE:The loader has auxiliary proportional control for front auxiliary hydraulics only. Proportional control allows for slow–to–fast movement of auxiliary functions. EXAMPLE: If you move the auxiliary switch half way, the auxiliary function will move at approximately one–half speed.

Quick Couplers

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

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

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

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

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

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

Relieving Hydraulic Pressure

8.

With the engine running, turn the key switch quickly to the left (counterclockwise) past the OFF position. Hold key for at least five seconds after the engine comes to a complete stop. This relieves pressure that can be trapped in the auxiliary circuit which would make it difficult to engage quick couplers from an attachment.

HYDRAULIC CONTROLS (Cont’d)

Auxiliary Hydraulics (Cont’d)

Auxiliary Hydraulics Switch

9.

• Momentary Operation

Press the Auxiliary Hydraulics Switch (Item 1) [A] once.

The light (Item 2) [A] will be ON.

• Continuous Operation

Press the Auxiliary Hydraulics Switch (Item 1) [A] a second time.

Both lights (Items 2 & 3) [A] will be ON.

• Disengage

Press the Auxiliary Hydraulics Switch (Item 1) [A] a third time.

Both lights (Items 2 & 3) [A] will be OFF.

NOTE:When the operator is seated and raises the seat bar, the Auxiliary Hydraulic System (Front and Rear) will deactivate. Press the Auxiliary Hydraulics Switch (Item 1) [A] to reselect operating mode.

FRONT Auxiliary Hydraulics Operation (RIGHT Steering Lever)

• Set the Auxiliary Hydraulics Switch for Momentary Operation (See above).

• Push the switch (Item 1) [B] or [C] to the right or left to change the fluid flow direction to the front quick couplers. (EXAMPLE: Open and close grapple teeth.)

FRONT Auxiliary Hydraulics Continuous Operation (RIGHT Steering Lever)

• Set the Auxiliary Hydraulics Switch for Continuous Operation (See above).

• Push the front switch (Item 2) [B] or [C] to give the front quick couplers a constant flow of fluid (EXAMPLE: Operate a backhoe.)

• To release from continuous operation, press the front switch (Item 2) [B] or [C] a second time.

REAR Auxiliary Hydraulics Operation (LEFT Steering Lever)

• Set the Auxiliary Hydraulics Switch for Momentary or Continuous Operation (See above).

• Push the switch (Item 3) [B] or [C] to the right or left to change the fluid flow direction to the rear quick couplers [D]. (EXAMPLE: Raise and lower rear stabilizers.) This switch also controls the secondary front auxiliary. (Rear Auxiliary Hydraulics required)

NOTE:See System Analysis Page 80 for troubleshooting malfunctions with the Auxiliary Hydraulics Operation.

NOTE:The secondary front auxiliary hydraulics and the rear auxiliary hydraulics operate from the same auxiliary section of the control valve. To operate only one of these auxiliary functions, disconnect the other.

HYDRAULIC CONTROLS (Cont’d)

Auxiliary Hydraulics (Cont’d.)

High–Flow Hydraulics Operation (If Equipped)

The High–Flow function provides additional flow to the system to operate an attachment which requires more hydraulic flow (EXAMPLE: Planer).

• Set the Auxiliary Hydraulics Switch for Momentary or Continuous Operation (See Page 15.)

• Be sure Hi–Flow switch is OFF

• Connect the attachment to the quick couplers (Item 1) [A]

• Some attachments may have a case drain which needs to be the connected to the small quick coupler (Item 2) [A]

• When all hydraulic connections have been made, turn the Hi–Flow switch ON (Item 1) [B] (amber light is ON).

Secondary Front Auxiliary Hydraulics (If Equipped)

The secondary front auxiliary quick couplers are a part of the Hi–Flow Hydraulics (factory option)[A]. (Also available as a Field Installed Accessory.) These are used when there is a need for additional auxiliary hydraulics (EXAMPLE: Planer side shift).

• Connect the attachment to the secondary auxiliary hydraulics (Item 3) [A].

• Set the Auxiliary Hydraulic Switch for Momentary or Continuous Operation. (See Page 15.)

• Push switch (Item 1) [C] to the right or left to change fluid flow direction. (EXAMPLE: Side shift on the Planer.)

NOTE:The secondary front auxiliary hydraulics and the rear auxiliary hydraulics operate from the same auxiliary section of the control valve. To operate only one of these auxiliary functions, disconnect the other.

If the high–flow switch is in the ON position, High–Flow Hydraulics will flow through the front auxiliary quick couplers. Damage to unapproved attachments can result. Leave the switch OFF for backhoe operation.

HYDRAULIC CONTROLS (Cont’d.)

Attachment Functions Control (If Equipped)

(Attachment Control Kit Required) (Item 1) [A]

This kit, when installed, allows the use of other switches on the right and left control handles (Deluxe Handles) for functions such as water spray, left/right turn signals (Europe only), raise/lower the left/right ends of the moldboard on a Grader, etc.

The following are examples only, consult Attachment Operation & Maintenance Manual.

Switch (Item 2) [B] Left Moldboard Up/Down

Switch (Item 1) [B] Left/Right Turn Signals

Switch (Item 3) [B] Right Moldboard Up/Down

Switch (Item 4) [B] Water Spray

DAILY INSPECTION

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The Service Schedule [C] is a guide for correct maintenance of the Bobcat loader. It is located inside the rear door of the loader and also in the MACHINE SIGN

TRANSLATION Section Page 83.

Daily Inspection and Maintenance:

• Engine Oil Level

• Hydraulic/Hydrostatic Fluid Level

• Engine Air Filter, Air System for Damage or Leaks

• Engine Coolant Level, System for Damage or Leaks

• Operator Cab, Seat Belt, Seat Bar, Pedal Interlocks, Mounting Hardware

• Grease Pivot Pins (Lift Arms, Bob–Tach, Cylinders, Bob–Tach Wedges

• Fuel Filter, Remove Trapped Water

• Loose or Broken Parts

• Safety Treads and Safety Signs (Decals)

• Bobcat Interlock Control System (BICS ™)

• Lift Arm Support Device

• Tracks for Wear or Damage and Correct Tension

NOTE:Fluids such as engine oil, hydraulic fluid, coolant, etc. must be disposed of in an environmentally safe manner. Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W–2072–0496

PRE–STARTING PROCEDURE 10.

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

The Operation & Maintenance Manual and other manuals can be kept in a container [A] behind the operator seat.

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

W–2003–1298

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arms and frame) to get on and off the loader [B]. Do not jump.

Safety treads are installed on the Bobcat loader toprovide a slip resistant surface for getting on and off the loader.

Keep safety treads clean and replace when damaged. Replacement treads are available from your Bobcatloader dealer.

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

PRE–STARTING PROCEDURE (Cont’d.)

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

AVOID INJURY OR DEATH

When operating the machine:

• Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls or footrests.

W–2261–0397

Lower the seat bar [B]

Engage the parking brake (Item 1) [C]

Put the foot pedals (Item 2) [C] or hand controls (Item 3) [C] in neutral position.

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

STARTING THE ENGINE (Without BOSS®)

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 [A].

W–2050–1285

AVOID INJURY OR DEATH

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

• Do not use machines in atmosphere containing explosive gas [A].

W–2051–1086

Perform the PRE–STARTING PROCEDURE Page 18.

Set the engine speed control to the 1/2speed position [B]

Turn the key switch to RUN. The engine and transmission warning lights (Item 1) [C] will be ON.

Preheat: If the temperature is below what is indicated on the decal [D] inside operator cab, press and hold the preheat switch (Item 2) [C] the time indicated on the decal.

Turn the key switch to START [C]. Release the key when the engine starts. It will return to the RUN position [C]

Advanced Hand Controls Only: Make sure both hand controls are in neutral before starting the engine. Do not move the Advanced Hand Control levers from the neutral position when turning the key ON.

If either hand control is moved: a. – The neutral position for the hydraulic valve spool and hand control may not be correctly calibrated. This can result in movement of the lift or tilt hydraulic cylinders when the hand control lever is returned to the neutral position after start– up. OR b. – The hydraulics will not operate (corresponding diagnostic lights on the left handle will blink).

If either condition occurs, turn the key OFF. Put the controls in neutral position and re–start the engine.

IF THE WARNING LIGHTS (Item 1) [C] DO NOT GO OFF TURN THE KEY SWITCH TO THE OFF POSITION.

After the engine is running, slowly move the engine speed control forward to increase engine RPM.

STARTING THE ENGINE (Without BOSS®) (Cont’d)

If the starting temperature is below freezing, perform the following to make starting the engine easier:

• Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Engine Lubrication System Page 61.)

• Make sure the battery is fully charged.

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

In cold conditions, it may take up to 60 seconds of cranking to reach the engine speed required to keep it running by itself. The cranking can continue only if you know that the engine is firing.

Check the exhaust and listen to the sound of the engine. If the engine is firing, there will be smoke from the exhaust and the cranking speed will continue to increase.

Do not continue to crank if the engine does not fire within the first 15 seconds of cranking. This extended cranking time must only be done if the engine speed is increasing because the engine is firing and aiding the starter.

Stopping The Engine

Pull the engine speed control [B] fully backward to decrease the engine speed. Turn the key switch OFF [A]

When the temperature is below –20°F (–30°C), hydrostatic oil must be warmed before operating. The hydrostatic system will not get enough oil at low temperatures and will be damaged.

Let the engine run for 5 to 10 minutes to warm the engine and hydrostatic transmission fluid before operating. If the transmission warning light comes ON when you begin operating the machine (cold), more warm up time is needed. (This could also mean that the fluid level is low. Be sure the fluid level is at the full mark on the dipstick.)

Park the machine in an area where the temperature will be above 0°F (–18°C) if possible. I–2192–0399

STARTING THE ENGINE (With BOSS™)

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 [A].

W–2050–1285

AVOID INJURY OR DEATH

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

• Do not use machines in atmosphere containing explosive gas [A].

W–2051–1086

Perform the PRE–STARTING PROCEDURE Page 18. Set the engine speed control to 1/2 speed position [B]

Turn the key switch to RUN [C], one beep will sound and the display symbols [D] will be ON. If there are SERVICE CODES on the display (Item 2) [D], see SYSTEMS ANALYSIS Section Page 77.

Preheat: If the engine is cold, the preheat will automatically begin, the glow plug symbol (Item 1)[D] will be ON and the display (Item 2) [D] will show GLOXX . XX will countdown the remaining time the glow plugs will be energized. Wait for the glow plugs to count down to zero.

W–2071–1285

STARTING THE ENGINE (With BOSS™) (Cont’d)

Turn the key switch to START [A]. Release the key when the engine starts. It will return to the RUN position [A]

If the engine does not start, turn the key switch OFF and to RUN again [A]. This will start the glow plug cycle again.

When the engine is running, slowly move the engine speed control forward to increase the engine speed.

Advanced Hand Controls Only: Make sure both hand controls are in neutral before starting the engine. Do not move the Advanced Hand Control levers from the neutral position when turning the key ON.

If either hand control is moved: a. – The neutral position for the hydraulic valve spool and hand control may not be correctly calibrated. This can result in movement of the lift or tilt hydraulic cylinders when the hand control lever is returned to the neutral position. after start– up b. – The hydraulics will not operate (corresponding diagnostic lights on the left handle will blink).

If either condition occurs, turn the key OFF. Put the controls in neutral position and re–start the engine.

If the starting temperature is below freezing, perform the following to make starting the engine easier:

• Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Engine Lubrication System Page 61.)

• Make sure the battery is fully charged.

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

In cold conditions, it may take up to 60 seconds of cranking to reach the engine speed required to keep it running by itself. The cranking can continue (up to 60 seconds) only if you know that the engine is firing.

Check the exhaust and listen to the sound of the engine. If the engine is firing, there will be smoke from the exhaust and the cranking speed will continue to increase.

Do not continue to crank if the engine does not fire within the first 15 seconds of cranking. This extended cranking time must only be done if the engine speed is increasing because the engine is firing and aiding the starter.

Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader. If the transmission warning light comes ON when you begin operating the loader (cold), more warm up time is needed. (This could also mean that the fluid level is low. Be sure the fluid level is at the full mark on the dipstick.)

Stopping The Engine

Pull the engine speed control [B] fully backward to decrease the engine speed. Turn the key switch OFF [A]

When the temperature is below –20°F (–30°C), hydrostatic oil must be warmed before operating. The hydrostatic system will not get enough oil at low temperatures and will be damaged.

Let the engine run for 5 to 10 minutes to warm the engine and hydrostatic transmission fluid before operating. If the transmission warning light comes ON when you begin operating the machine (cold), more warm up time is needed. (This could also mean that the fluid level is low. Be sure the fluid level is at the full mark on the dipstick.)

Park the machine in an area where the temperature will be above 0°F (–18°C) if possible.

I–2192–0399

Attachments And Buckets

NOTE:Warranty is void if non–approved attachments are used on the Bobcat loader.

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

W–2052–1285

The dealer can identify, for each model loader, the attachments and buckets approved by Bobcat Company. The buckets and attachments are approved for rated operating capacity and for secure fastening to the Bob–Tach.

The rated operating capacity for this loader is shown on a label in the operator cab. (See SPECIFICATIONS Section Page 93.)

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

Exceeding the rated operating capacity [A] can cause the following problems:

• Steering the loader may be difficult.

• Tracks will wear faster.

• 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 handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the rated operating capacity for the loader. Partial loads make steering more difficult.

Maximum load to be carried when using a pallet fork are shown in figure [B]. See your Bobcat loader dealer for more information about loader counterweights, pallet forks and other available attachments.

Do not exceed rated operating capacity. Excessive load can cause tipping or loss of control. W–2053–0887

ATTACHMENTS AND BUCKETS (Cont’d)

Installing The Bucket Or Attachment

Warranty is void if non–approved attachments are used on the Bobcat loader.

I–2190–0199

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

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

Enter the loader.

Perform the PRE–STARTING procedure, Page 18. With the lift arms all the way down, tilt the Bob–Tach forward.

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

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

ATTACHMENTS AND BUCKETS (Cont’d)

Installing The Bucket Or Attachment (Cont’d)

Tilt the Bob–Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [A] Stop the engine and exit the loader.

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.

• (Foot Pedal Controls) Move pedals until both lock.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated. The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

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

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

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

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

ATTACHMENTS AND BUCKETS (Cont’d)

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

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

W–2102–0588

Removing The Bucket Or Attachment

Lower the lift arms and put the attachment flat on the ground and lower or close the hydraulic equipment (ie: combination bucket, backhoe, etc.).

Stop the engine and relieve hydraulic pressure in the auxiliary circuit (See Relieving Hydraulic Pressure, Page 14.)

Exit the loader.

Pull the Bob–Tach levers [C] all the way up. Disconnect the hydraulic hoses, if necessary.

Enter the loader.

Perform the PRE–STARTING procedure , Page 18.

Tilt the Bob–Tach forward.

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

Operating Procedure

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

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

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

I–2015–0284

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

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

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

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

• Keep the lift arms as low as possible.

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

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

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

W–2018–1187

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