PDF DOWNLOAD Bobcat 453 Operation & Maintenance Manual SN 6900784

Operation & Maintenance Manual S/N 515012400 & Above Europe Only S/N 515112400 & Above

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 6900784 (4-00) Revised (10-04)

Printed in U.S.A.

©Bobcat Company 2004

OPERATOR SAFETY WARNINGS WARNING

CORRECT

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W-2001-1285

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

B-10731a

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

CORRECT

CORRECT

WRONG

B-7403

B-6582

B-13418

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the foot pedals or footrests when operating loader.

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

Fasten your seat belt.

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

WRONG

WRONG

WRONG

B-6578

B-6585

B-6595

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload, and turn on flat level ground.

WRONG

WRONG

WRONG

B-6587

B-6594 B-16102

B-6591 B-16102

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

Never exceed Capacity.

Rated

Operating

Never carry riders.

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

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

Never modify equipment.

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

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

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

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

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

4. HANDBOOK: Must be in the cab.

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

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

OSW03-0504

FOREWORD

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

SAFETY

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . PM-1

OPERATING INSTRUCTIONS

SYSTEM SETUP & ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . SA-1 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . MST-1 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-1

PREVENTIVE MAINTENANCE

SYSTEM SETUP & ANALYSIS

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

MACHINE SIGN TRANSLATIONS

Loader Serial Number Engine Serial Number

SPECIFICATIONS

NOTES:

YOUR BOBCAT® DEALER: ADDRESS: PHONE:

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

Bobcat Company Europe J. Huysmanslaan 59 B-1651 LOT Belgium I

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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 OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR Bobcat loader. If you have any questions, see your Bobcat dealer.

BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED . . . . . . . . . . . . V DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII LOADER SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII MOTOR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . V

SYSTEM SETUP & ANALYSIS

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

TRANSLATIONS

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BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED

ISO 9001:2000 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Bobcat products.

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

ISO 9001:2000 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

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.

REGULAR MAINTENANCE ITEMS

ENGINE OIL FILTER (6 Pack) 6671057 BATTERY 6669318

FUEL FILTER 6667352

FLUID, Hydraulic/Hydrostatic BLACK GOLD (5 Gallons) 6563328 - One 5 gal. container

AIR CLEANER 897064

RADIATOR CAP 6666606 Propylene Glycol Anti-Freeze Premixed - 6724094 Concentrate - 6724354

HYDROSTATIC FILTER 6599543

MOTOR OIL 6903105 - SAE 15W40 CE/SG (12 QTS.) 6903107 - SAE 10W30 CE/SG (12 QTS.) 6903109 - SAE 30W CE/SG (12 QTS.)

6903106 - SAE 15W40 CE/SG (1 GAL.) 6903108 - SAE 10W30 CE/SG (1 GAL.) 6903110 - SAE 30W CE/SG (1 GAL.)

V

6903113 - SAE 15W40 CE/SG (2.5 GAL.) 6903112 - SAE 10W30 CE/SG (2.5 GAL.) 6903111 - SAE 30W CE/SG (2.5 GAL.)

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SERIAL NUMBER LOCATIONS

ENGINE SERIAL NUMBER

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

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

Figure 2

Figure 1

The engine serial number is located on the side of the engine (Item 1) [Figure 2] above the oil filter.

DELIVERY REPORT Figure 3 LOADER SERIAL NUMBER The loader serial number plate is located on the outside of the loader frame [Figure 1].

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

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

The delivery report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 3].

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

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BOBCAT SKID STEER LOADER IDENTIFICATION

* †

OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) TIRES - The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section and your Bobcat dealer for available tires.

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

ROPS, FOPS - Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

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OPTIONS AND ACCESSORIES Model 453 Bobcat loaders are equipped with the following standard items: Bob-Tach Spark Arrestor Muffler Lift Arm Support Device Operator Cab (with ROPS & FOPS Approval) Bobcat Interlock Control System (BICS™) Seat Belt Seat Bar Parking Brake Gauges/Warning Lights Cushion Seat Below is a list of some equipment available as a Factory Installed Option or as a Field Installed Accessory from your Bobcat Loader dealer. See your Bobcat dealer for other available accessories and attachments.

Tires

Hydraulics

23 x 8.5 - 12, 4 PR Flotation Tires (Machine Width - 44 inches)

Opt. & FA

23 x 8.5 - 12, 6 PR Bobcat Heavy Duty (Machine Width - 44 inches)

Opt. & FA

Opt. & FA

Hydraulic Bucket Positioning

Opt. & FA

Other

Operator Cab Sound Cab (Reduces noise at Operator's Ear)

Opt.

Operating Lights (Front & Rear)

Opt. & FA

Horn

Front Auxiliary Hydraulics

FA

Back-up Alarm

Opt. & FA

Top Window

FA

Rear Window

FA

Side Windows

FA

Vinyl Cab Enclosure

FA

Fire Extinguisher

FA

Strobe or Rotating Beacon Light

FA

3" Seat Belt

FA

Keyless Start System

FA

Suspension Seat

FA

Special Applications Kit

FA

Engine Heater

FA

Single Point Lift

FA

Locking Fuel Cap & Cover

FA

Catalytic Exhaust Purifier

FA

Fuel Shut Off

FA

Low Coolant Sensor

FA

Rental Kit

FA

Std. = Standard Equipment Opt. = Factory Installed Option FA = Field Accessory N/A = Not Available Specifications subject to change without notice.

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SAFETY MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVI SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XV Safe Operation Is The Operator’s Responsibility. . . . . . . . . . . .XIV Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . .XIV

XI

SAFETY

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available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

SAFETY INSTRUCTIONS Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

•

The AEM Safety Manual delivered with the machine gives general safety information.

The Bobcat Loader is highly maneuverable and compact.

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

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

•

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

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

•

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

•

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

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

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

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

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

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

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

•

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

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

•

•

Call Before You Dig 1-888-258-0808

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

When you call, you will be directed to a location in your state/city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0604

An Operator’s Handbook is fastened to the operator cab of the Loader. It’s brief instructions are convenient to the operator. The Handbook is

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SAFETY INSTRUCTIONS (CONT’D)

A Qualified Operator Must Do The Following:

Safe Operation Is The Operator’s Responsibility

Understand the Written Instructions, Rules and Regulations

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

Carefully read the message that follows.

•

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

•

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

WARNING

Have Training with Actual Operation

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

•

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

•

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

•

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

•

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

W-2001-1285

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

I-2019-0284

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

Know the Work Conditions

W-2044-1285

•

Know the weight of the materials being handled.

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

•

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

•

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

•

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

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

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

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

SI SSL-0604

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Manual for connecting the battery and for jump starting.

SAFETY INSTRUCTIONS (CONT’D) 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.

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

Figure 1

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

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

•

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

•

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

•

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

Repair or replace any damaged part.

•

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

•

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

•

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

•

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

•

Use the procedure in the Operation & Maintenance

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

Sl SSL-0604

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

6708105

6727926

6705434

6711840

6735140

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

6708929 6557701

6714364

6727595

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OPERATING INSTRUCTIONS ATTACHMENTS AND BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . OI-18 Installation And Removal (Without Bob-Tach) . . . . . . . . . . . . OI-18 Installation And Removal (With Bob-Tach) . . . . . . . . . . . . . . OI-19 Removing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . OI-20 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . OI-4 Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-4 Traction Lock Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5

OPERATING INSTRUCTIONS

DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-13 ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-5 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . OI-14 HYDRAULIC CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 Auxiliary Hydraulics (If Equipped) . . . . . . . . . . . . . . . . . . . . . OI-10 Auxiliary Hydraulic Continuous Operation . . . . . . . . . . . . . . . OI-12 Bucket Position Valve Operation (If Equipped) . . . . . . . . . . . OI-10 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-9 Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-11 Relievng Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . OI-12 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-3 LIFTING THE LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-27 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-21 Backfilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-24 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-23 Emptying The Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-23 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-22 Leveling The Ground (Using Lift Arms In Float Position). . . . OI-24 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-6 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . OI-25 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . OI-8 STEERING LEVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-7 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-15 Cold Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-17 Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-15 Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . OI-17 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . OI-7 OI-1

453 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS (CONT’D) STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-17 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OI-27 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . OI-26

OI-2

453 Bobcat Loader Operation & Maintenance Manual

6. LIGHT SWITCH (Opt. or FA) - Controls the work and travel lights.

INSTRUMENT PANEL Figure OI-1

7. PREHEAT BUTTON - For preheating the glow plugs to aid cold temperature starting.

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

9. ENGINE WARNING LIGHT - Light is ON when engine oil pressure is low or coolant temperature is high. Stop the engine if the light comes ON. 10. TRANSMISSION WARNING LIGHT - Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON. Figure OI-2

11. HOURMETER - Records the total operating hours of the loader.

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

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

Opt. - Factory Installed Option FA - Field Installed Accessory - See your Bobcat loader dealer about available Field Accessories.

The following items are located on the instrument panel [Figure OI-1] and [Figure OI-2]: 1. TRACTION LOCK OVERRIDE BUTTON (Functions Only When The Seat Bar Is Raised) Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See “Traction Lock Override” on page OI-5.)

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, stopping the engine.

4. BEACON SWITCH (Opt. or FA) - Controls the available flashing beacon light.

5. STROBE SWITCH (FA) - Controls the available strobe light.

OI-3

Operation and Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

Lift Arm By-Pass Control

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

Figure OI-4

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

Figure OI-3

The lift arm by-pass control knob (Item 1) [Figure OI-4] is used to lower the lift arms in the event that the lift arms can not be lowered during normal operating conditions.

With the operator in the seat, seat belt fastened and the seat bar fully lowered, pull and hold the by-pass control knob (Item 1) [Figure OI-4]. Push the top (toe) of the left (lift) pedal. The lift arms will slowly lower.

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

The BICS controller is located inside the cab; behind and to the left of the operator's seat [Figure OI-3].

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

WARNING

The light functions are as follows [Figure OI-3]: 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.

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.

W-2151-0394

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

WARNING

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

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.

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

NOTE: If any of the lights are off or blinking, (See “BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)” on page SA-5.) or (See “Inspecting The BICS™ Controller (Engine STOPPED Key ON)” on page PM-12.)

W-2045-1086

OI-4

Operation and Maintenance Manual

ENGINE SPEED CONTROL

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (CONT’D)

Figure OI-6 Traction Lock Override Figure OI-5

The engine speed control (Item 1) [Figure OI-6] is at the left side of the operator's seat. Engine speed is controlled by moving the engine speed control forward to increase the engine RPM and backward to decrease the engine RPM.

(Functions Only When The Seat Bar Is Raised) There is a traction lock override button (Item 1) [Figure OI-5] on the left hand instrument panel. It allows you to use the steering levers to move the loader forward & backward when using the backhoe attachment or for service.

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

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

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.

OI-5

Operation and Maintenance Manual

PARKING BRAKE Figure OI-7

Engage the parking brake by pushing down on the top (toe) of the pedal [Figure OI-7]. The traction drive system will be locked.

Figure OI-8

To release the parking brake, push down on the bottom (heel) of the pedal [Figure OI-8].

NOTE: If the loader will not move when operator is in the operating position with brake pedal released or when traction lock override button is pushed, move the steering levers either forward or backward a small amount to unlock the traction drive.

OI-6

Operation and Maintenance Manual

STEERING LEVERS

WARNING

Figure OI-9

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.

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The steering levers (Item 1) [Figure OI-9] are on the right and left side in front of the seat.

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

Figure OI-10 The steering levers control forward and reverse travel of the loader [Figure OI-10].

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 levers forward only a small amount.

To increase travel speed, push the levers farther forward.

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

WARNING Keep both feet on pedals while operating machine.

Failure to do so can cause serious injury.

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STOPPING THE BOBCAT LOADER When the steering levers are moved to the neutral position, the hydrostatic transmission will act as a service brake and stop the loader.

OI-7

Operation and Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

Figure OI-12

Figure OI-11

The seat bar restraint system has a pivoting seat bar (Item 1) [Figure OI-11] 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.

The spring loaded interlocks (Item 1) [Figure OI-12] control the locking and unlocking functions of the control pedals.

The interlocks (Item 1) [Figure OI-12] require the operator to lower the seat bar (Item 2) [Figure OI-12] which allows the operator to move the foot pedals to control the lift and tilt functions.

WARNING

When the seat bar is lowered, it pushes the interlock (Item 1) [Figure OI-12] down on both sides, releasing the pedal linkages (Item 3) [Figure OI-12] from the interlocks.

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

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

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

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WARNING

WARNING

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

• Stop the engine.

• Engage the parking brake.

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

• Move auxiliary control out of continuous operation position.

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

• Stop the engine.

• Engage the parking brake.

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

• Move auxiliary control out of continuous operation position.

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OI-8

Operation and Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (CONT’D)

HYDRAULIC CONTROLS Foot Pedals

WARNING WARNING

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.

Keep both feet on pedals while operating machine.

Failure to do so can cause serious injury.

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Figure OI-13

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

Figure OI-14

When the seat bar is raised, spring forces raise the interlocks [Figure OI-13].

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

(See “SEAT BAR RESTRAINT SYSTEM” on page PM10.)

Two foot pedals (Item 1) [Figure OI-14] control the hydraulic cylinders for the lift and tilt functions.

OI-9

Operation and Maintenance Manual

Auxiliary Hydraulics (If Equipped)

HYDRAULIC CONTROLS (CONT’D) Lift Arm Operation

Figure OI-15

The left pedal controls the lift arms. Push on the bottom (heel) (Item 2) [Figure OI-14] of the pedal to raise the lift arms.

Push on the top (toe) (Item 3) [Figure OI-14] of the pedal to lower the lift arms.

Lift Arm Float Position Push the top (toe) (Item 3) [Figure OI-14] of the pedal all the way forward until it locks into 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.

Auxiliary hydraulics [Figure OI-15] are not standard, but can be a Factory Option or installed as a Field Accessory.

Tilt Operation

WARNING

The right pedal controls the action of the bucket.

Push the top (toe) (Item 4) [Figure OI-14] of the pedal to tilt the bucket forward.

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.

Push the bottom of the pedal (heel) (Item 5) [Figure OI-14] to tilt the bucket backward.

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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, before beginning the upward lift cycle.

Bucket positioning functions automatically during the upward lift cycle only.

The bucket positioning function can be turned OFF with the bucket level switch. (See “INSTRUMENT PANEL” on page OI-3.).

OI-10

Operation and Maintenance Manual

HYDRAULIC CONTROLS (CONT’D)

Figure OI-17

Quick Couplers Flush Face Couplers To Connect: Remove any dirt or debris from the surface of both the male and female coupler halves, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced [Figure OI-15].

Figure OI-16

The auxiliary control has a lockbolt (Item 1) [Figure OI17] that must be removed to use the auxiliary hydraulics.

Raise the operator cab. (See “Raising The Operator Cab” on page PM-8.)

Remove the nut and bolt from the right hand steering lever [Figure OI-17].

Figure OI-18

Install the male half coupler into the female half coupler.

Full connection is established when the ball release sleeve slides forward on the female coupler and the sleeve is rotated so that the locking pins (Item 1) [Figure OI-16] and the groove (Item 2) [Figure OI-16] do NOT align (Locked Position).

NOTE: If the locking pins and groove (Item 3) [Figure OI-16] are aligned, accidental disconnection IS possible.

To Disconnect: Rotate the ball release sleeve so that the grooves are aligned with the pins (Item 3) [Figure OI-16] in the female coupler.

The right steering lever is also the control lever for the front auxiliary hydraulics [Figure OI-18].

Hold the male coupler then retract the sleeve on the female coupler until the couplers disconnect.

WARNING AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments.

Be careful when connecting and disconnecting quick couplers.

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OI-11

Operation and Maintenance Manual

HYDRAULIC CONTROLS (CONT’D) Figure OI-19

Move the right steering lever to the left or to the right to activate the auxiliary hydraulics to operate an attachment. (Example: To open or close grapple teeth) [Figure OI-19].

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

Auxiliary Hydraulic Continuous Operation Move the steering lever all the way to the right (Item 1) [Figure OI-19] to put the control valve into the continuous operation position for a constant flow of hydraulic fluid under pressure to the quick couplers (Example: Backhoe operation).

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

Relievng Hydraulic Pressure With the engine stopped and attachment flat on the ground, move the right steering lever to the left and to the right several times [Figure OI-19].

OI-12

Operation and Maintenance Manual

DAILY INSPECTION Figure OI-20

The loader must be in good operating condition [Figure OI-21].

Figure OI-21

Check the following items before starting each day: • • • • • • • • • • •

Engine Oil Hydraulic/Hydrostatic Fluid Air Cleaner Condition Indicator Engine Cooling System Operator Cab, Seat Belt, Seat Bar & Pedal Interlocks Lift Arms & Cylinder Pivot Pins Tires & Tire Pressure Any Loose or Broken Parts Fuel Level Safety Tread & Safety Signs Bobcat Interlock Control System (BICS™)

Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door [Figure OI20].

WARNING 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 [Figure OI-21].

Fluids such as engine oil, hydraulic fluid, coolants, 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.

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OI-13

Operation and Maintenance Manual

GETTING READY FOR OPERATION

Figure OI-24

Figure OI-22

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arm crossmember and main frame) to get on and off the loader [Figure OI24].

Read the Operation & Maintenance Manual and the Operator's Handbook before operating the loader (Item 1) [Figure OI-22].

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

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

Figure OI-25

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Figure OI-23

Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [Figure OI-25].

WARNING

The Operation & Maintenance Manual and other manuals can be kept in a box provided at the right hand side of the operator seat (Item 1) [Figure OI-23].

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.

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OI-14

Operation and Maintenance Manual

STARTING THE ENGINE

GETTING READY FOR OPERATION (CONT’D) Figure OI-26

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

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WARNING Lower the seat bar [Figure OI-26].

•

Be sure the parking brake is engaged.

•

All controls must be in the NEUTRAL POSITION before you start the engine. (See Normal Starting.)

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.

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Normal Starting

After you start the engine, press the green PRESS TO OPERATE Button on the left instrument panel to operate lift, tilt and traction functions.

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

Figure OI-27 Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Figure OI-28

Keep your hands on the steering levers and feet on the pedals while seated in the loader [Figure OI-27].

Lower the seat bar [Figure OI-28].

Be sure the parking brake is engaged.

OI-15

Operation and Maintenance Manual

STARTING THE ENGINE (CONT’D)

Figure OI-31

Figure OI-29

Figure OI-30

Put the foot pedals and steering levers in NEUTRAL POSITION (center) (Item 1) [Figure OI-31].

Set the engine speed control to 1/2 SPEED position (Item 2) [Figure OI-31].

Turn the key to the ON POSITION. The engine and transmission warning light will be ON when the key is on and the engine is stopped (Item 3) [Figure OI-31].

Turn the key to START POSITION (Item 4) [Figure OI31] and release it when the engine starts. The key will return to the RUN POSITION (Item 5) [Figure OI-31].

OI-16

Operation and Maintenance Manual

Figure OI-33

STARTING THE ENGINE (CONT’D)

IMPORTANT Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I-2034-0284

STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF. NOTE: Upon failed start, if the key is turned OFF, wait for at least three seconds before turning the key ON to reset the fuel timer module.

Refer to the decal on the left side of the operator cab for operation of the preheat system [Figure OI-33].

Keep your hands on the steering levers and feet on the pedals while seated in the loader.

Follow the steps under Normal Starting and repeat the preheating procedure until the engine starts.

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

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

Explosion can result which can cause injury or death.

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•

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

(See “Oil Chart” on page PM-17.)

•

Make sure the battery is at full charge.

•

Install engine heater.

Cold Temperature Starting Warming The Hydraulic/Hydrostatic System (See “Normal Starting” on page OI-15.) Turn the key switch to the RUN POSITION.

Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader.

Figure OI-32

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

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

Push the preheat button (Item 1) [Figure OI-32] on the left side of the instrument panel to preheat the glow plugs.

OI-17

Operation and Maintenance Manual

ATTACHMENTS AND BUCKETS

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.

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

WARNING

Installation And Removal (Without Bob-Tach) The Bobcat is standard installation of attachments.

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

equipped

with

pin-type

Figure OI-35

W-2052-1285

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

The rated operating capacity for this loader is shown on a label in the operator cab. (See “Performance” on page SPEC-3.)

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.

Install the pivot pins into the lower pivot holes in the bucket (Item 1) [Figure OI-35]. Align pins with holes in lift arms.

Use long bolt to pull the pins into the lift arms. Remove long bolts and install correct bolt. Tighten to 65-70 ft.-lbs.

(88-94 Nm) torque (Item 2) [Figure OI-35].

Figure OI-34

Figure OI-36

Exceeding the rated operating capacity can cause the following problems [Figure OI-34]: 1.

2.

3.

4.

Install the pin into the upper pivot hole in the bucket and the rod end of the tilt cylinder (Item 1) [Figure OI-36].

Steering the loader may be difficult.

Tires may wear faster.

There will be a loss of stability.

The life of the Bobcat loader will be reduced.

Install the retainer and bolt (Item 2) [Figure OI-36].

Tighten bolt to 8-10 ft.-lbs. (10-13 Nm) torque.

Reverse procedure to remove attachment.

OI-18

Operation and Maintenance Manual

ATTACHMENTS AND BUCKETS (CONT’D)

Drive the loader forward until the top edge of the BobTach is completely under the top flange of the bucket [Figure OI-37] (or other attachments).

WARNING

Be sure the Bob-Tach lever does not hit the bucket.

Figure OI-38

AVOID INJURY OR DEATH Do not exceed rated operating capacity. Excessive load can cause tipping or loss of control.

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Installation And Removal (With Bob-Tach) The Bob-Tach is used for fast changing of buckets and attachments. See the Attachment Operation & Maintenance Manual to install other attachments.

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

Tilt the Bob-Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [Figure OI-38].

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Stop the engine and exit the loader.

Figure OI-37

WARNING 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 locked.

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Pull the Bob-Tach lever all the way up (Item 1) [Figure OI-37].

Enter the loader.

Fasten the seat belt, lower the seat bar, start the engine and press the green PRESS TO OPERATE Button.

Release the parking brake.

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

OI-19

Operation and Maintenance Manual

ATTACHMENTS AND BUCKETS (CONT’D)

Removing The Bucket Or Attachment

Figure OI-39

Put the attachment flat on the ground and lower or close the hydraulic equipment. If the attachment is hydraulically controlled (ie: combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See “Relievng Hydraulic Pressure” on page OI12.)

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

Figure OI-41

Push down on the Bob-Tach lever until it is fully engaged in the locked position [Figure OI-39].

If the lever does not engage in the locked position, see your Bobcat loader dealer for maintenance.

Figure OI-40

Pull the Bob-Tach lever [Figure OI-41] all the way up.

Disconnect the hydraulic hoses, if necessary.

Enter the loader.

Fasten the seat belt, lower the seat bar, start the engine and press the green PRESS TO OPERATE Button.

Release the parking brake.

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

Figure OI-42

The wedges (Item 1) [Figure OI-40] must extend through the holes in the mounting frame of the bucket (or attachment), securely fastening the bucket to the BobTach. The wedge is shown extending through the hole in the bucket [Figure OI-40].

WARNING 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.

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Move the loader backward, away from the bucket or attachment [Figure OI-42].

OI-20

Operation and Maintenance Manual

OPERATING PROCEDURE

Figure OI-44

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

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

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

I-2015-0284

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [Figure OI-43] & [Figure OI-44].

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

Figure OI-45 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.

Figure OI-43

Figure OI-46

With empty bucket, go down or up the slope with the heavy end toward the top of the slope [Figure OI-45] & [Figure OI-46].

OI-21

Operation and Maintenance Manual

Figure OI-48

OPERATING PROCEDURE (CONT’D)

WARNING AVOID INJURY OR DEATH Failure to obey warnings can cause the machine to tip or roll over and cause 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.

W-2018-1187

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

Filling The Bucket Drive slowly forward into the material. Push the bottom of the tilt pedal to raise the front of the bucket [Figure OI48].

Figure OI-47

WARNING 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.

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Drive backward away from the material.

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 [Figure OI47].

OI-22

Operation and Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Digging Into The Ground

Emptying The Bucket

Figure OI-50

Figure OI-49

Put the lift arms all the way down. Push the top of the tilt pedal until the cutting edge of the bucket is on the ground. Drive forward slowly and continue to tilt the bucket down until it enters the ground [Figure OI-50].

Push down on the bottom of the lift pedal to raise the lift arms [Figure OI-49]. Push the top of the tilt pedal while raising the lift arms to level the bucket or attachment and help prevent material from falling off the back of the bucket or attachment.

Figure OI-51

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 [Figure OI-49]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

WARNING 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.

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Push the bottom of the tilt pedal a small amount to increase traction and keep an even digging depth [Figure OI-51].

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.

OI-23

Operation and Maintenance Manual

OPERATING PROCEDURE (CONT’D)

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.

Figure OI-52

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

I-2005-1285

Drive backward to level loose material.

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

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

Push the bottom of the tilt pedal to tilt the bucket backward as far as it will go when the bucket is full [Figure OI-52].

Figure OI-54

Leveling The Ground (Using Lift Arms In Float Position) Figure OI-53

Drive forward to the edge of the hole to push the material into the hole [Figure OI-54].

Tilt the bucket forward as soon as it is past the edge of the hole [Figure OI-54].

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

Push the top (toe) of the lift pedal all the way forward until the pedal is in the locked position to put the lift arms in float position [Figure OI-53].

OI-24

Operation and Maintenance Manual

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground.

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

Pull the throttle all the way backward. Turn the key switch to the OFF POSITION. Engage the parking brake.

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

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

WARNING 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.

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OI-25

Operation and Maintenance Manual

Figure OI-56

TRANSPORTING THE BOBCAT LOADER Figure OI-55

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure OI55].

The rear of the trailer must be blocked or supported [Figure OI-55] when loading or unloading the loader to prevent the front end of the trailer from raising up.

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

Fully lower any bucket or attachment. Stop the engine.

Engage the parking brake.

Fasten chains at the front using the slots in the axle gussets [Figure OI-56]. Counterweight is removed to show clarity. DO NOT operate with counterweight removed.

Figure OI-57

Fasten the rear of the loader as shown with a loop of chain through the tie down provided [Figure OI-57].

OI-26

Operation and Maintenance Manual

LIFTING THE LOADER

TOWING THE LOADER To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed. (Example: Moving the loader onto a transport vehicle).

WARNING • • •

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

Assemble front cab fasteners as shown in this manual.

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

Relief valve release tool set MEL1220 is available from your dealer. Tool must be installed before towing.

Raise the operator cab. (See “Raising The Operator Cab” on page PM-8.)

Clean the area around the hydrostatic pumps.

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Figure OI-59 The loader can be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.

Figure OI-58

Remove the high pressure relief valve from one side of each hydrostatic pump [Figure OI-59] and install the relief valve tubes. Install the plugs and tighten.

Install the kit and lift the loader as shown [Figure OI-58].

The towing chain (or cable) must be rated at 1-1/2 times the weight of the loader. (See “Performance” on page SPEC-3.)

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

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

Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not more than 25 feet (7,6 meters).

If the electrical system is not functioning, contact your Bobcat loader dealer. (Part of the brake system must be disassembled to move the loader.)

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

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OI-27

Operation and Maintenance Manual

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Operation and Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . PM-19 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . PM-26 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . PM-12 Inspecting The BICS™ Controller (Engine STOPPED - Key ON) .

PM-12 Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . PM-12 Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . PM-12 Inspecting The Traction Lock (Engine RUNNING) . . . . . . . PM-12

PREVENTIVE MAINTENANCE

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-29 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . PM-29 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . PM-18 Propylene Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-18 Removing Coolant From The Cooling System. . . . . . . . . . . PM-18 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Battery Removal And Installation. . . . . . . . . . . . . . . . . . . . . PM-20 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-20 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . PM-21 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . PM-17 Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-17 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . PM-26 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-26 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-15 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-14 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . PM-16 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . PM-22 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . PM-22 Removing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . PM-23 Replacing The Hydraulic/Hydrostatic Filter Element . . . . . . PM-22

PM-1

453 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINENANCE (CONT’D) LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . PM-6 Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . PM-7 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . PM-6 LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . PM-27 MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-3 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-9 Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . PM-9 Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-8 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-28 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . PM-10 Foot Pedal Clean Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-10 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-11 REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-13 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-5 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . PM-24 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM-25

PM-2

453 Bobcat Loader Operation & Maintenance Manual

MAINTENANCE SAFETY WARNING

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

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

CORRECT

CORRECT

CORRECT

B-10731a

B-12365

B-7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

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

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

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

Replace it if damaged.

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

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

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

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

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

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

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

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

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

Use eye protection approved for type of welding.

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

Lead-acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

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

PM-3

MSW01-0504

Operation and Maintenance Manual

PM-4

Operation and Maintenance Manual

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

WARNING

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

W-2003-0903

SERVICE SCHEDULE ITEM Engine Air Cleaner

HOURS

SERVICE REQUIRED

8-10

50

100

250

500

1000

Empty the dust cup & replace the filter element as needed.

Engine Oil

Check the oil level & add oil as needed.

Engine Cooling System

Clean debris from oil cooler and radiator. Check coolant level in recovery tank and add as needed.

Tires

Check the air pressure & for damaged tires.

Indicators, Gauges & Lights (Opt.)

Check for correct operation of all indicators, gauges & lights (Opt.).

Seat Belt and Seat Bar

Check the condition of seat belt. Check the seat bar & pedal interlocks for correct operation. Clean dirt and debris from moving parts.

Safety Signs (Decals) and Safety Tread

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

Lift Arm and Bob-Tach Pivot Pin Lubricate with multi-purpose lithium based grease. and Wedges Engine Fuel Filter

Remove the water from the filter.

Hyd. Fluid, Hoses & Tubelines

Check fluid level & add as needed. Check for damage & leaks. Repair & replace as needed.

Bobcat Interlock Control System Check BICS™ System Controller functions.

(BICS™) Battery

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

Control Pedals & Steering

Check for correct operation repair or adjust as needed.

Bob-Tach

Check locking levers & wedges for condition & operation.

Wheel Nuts

Check for loose wheel nuts & tighten to 40-45 ft.-lbs. (54-61 Nm) torque.

Parking Brake

Check operation.

Alternator Belt

Check tension & adjust as needed.

Engine Oil & Filter

Replace oil & filter. See engine Oil Chart.

Hydraulic Filter Element

Replace filter element.

Spark Arrestor Muffler

Clean the spark chamber.

Drive Belt

Check drive belt for condition and tension.

Steering Lever Pivots

Lubricate grease fittings and oil hole in the steering shaft.

Bobcat Interlock Control System Check the lift arm by-pass control (BICS™) Engine Fuel Filter

Replace filter element.

Hydraulic Reservoir Breather

Replace the breather cap.

Final Drive Trans (Chaincase)

Replace the fluid.

Hydraulic/Hydrostatic Reservoir Replace the fluid.

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

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

Or every 12 months.

PM-5

Operation and Maintenance Manual

LIFT ARM SUPPORT DEVICE

Figure PM-2

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

W-2059-0598

Engaging The Lift Arm Support Device Figure PM-1 Lower the lift arm support device on top of the lift cylinder.

Fasten the free end of the spring (Item 1) [Figure PM-2] to the lift arm support device so there will be no interference with the support device engagement.

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

Figure PM-3

Put jackstands under the rear corners of the loader (Inset) [Figure PM-1].

Disconnect the spring from the lift arm support device retaining pin (Item 1) [Figure PM-1], hold the support device and remove the retaining pin.

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod [Figure PM-3].

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

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

PM-6

Operation and Maintenance Manual

LIFT ARM SUPPORT DEVICE (CONT’D)

Figure PM-6

Figure PM-4

Connect the spring from the lift arm support device to the tubeline bracket (Item 1) [Figure PM-6] on the lift arms.

Install the retaining pin (Item 1) [Figure PM-4] into the rear of the lift arm support device below the cylinder rod.

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

WARNING

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

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

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

W-2271-1197

Disconnect the spring from the bracket.

Disengaging The Lift Arm Support Device

Figure PM-7

Figure PM-5

Raise the support device into storage position and insert pin through lift arm support device and bracket (Item 1) [Figure PM-7].

Remove the retaining pin (Item 1) [Figure PM-5] from the lift arm support device.

Connect spring to pin [Figure PM-7].

PM-7

Operation and Maintenance Manual

OPERATOR CAB

Raising The 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. The seat belt must be worn for roll over protection.

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

Figure PM-9

ROPS/FOPS Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l.

Level l - Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

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

Figure PM-8 Install jackstands under the rear of the loader frame [Figure PM-9].

Open the rear door. (See “REAR DOOR” on page PM13.)

If the lift arms must be up while raising the cab, install the lift arm support device. (See “Engaging The Lift Arm Support Device” on page PM-6.)

Remove the two fasteners (Item 1) [Figure PM-8] at the front (both sides) of the operator cab.

Stand on the ground. Lift slowly until operator cab is all the way up [Figure PM-9].

The operator cab fastening nuts (Item 1) [Figure PM-8] must be tightened to 40-50 ft.-lbs. (54-68 Nm) torque.

The operator cab will lock in the raised position.

WARNING

WARNING

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

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

W-2014-0895

W-2069-1285

PM-8

Operation and Maintenance Manual

OPERATOR CAB (CONT’D)

NOTE: Guide the operator cab over the fastening bolts to prevent thread damage.

Lowering The Operator Cab Figure PM-12 Figure PM-10

Install the cab washers and nuts. Tighten the nuts (Item 1) [Figure PM-12] (both sides) to 40-50 ft.-lbs. (54-68 Nm) torque.

Figure PM-11

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

Figure PM-13

Hold the operator cab. Release the locking mechanism by pushing the lever (Item 1) [Figure PM-10] inward from the locked position (Item 2) [Figure PM-10] and turning the lever until it stays in the unlocked position [Figure PM-11].

WARNING

Pull on the tag at the top of the rear window to remove the rubber cord [Figure PM-13].

The cab must be held to prevent falling while hand is in access hole.

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

W-2205-0695

REMOVE YOUR HAND FROM THE HOLE BEFORE LOWERING THE OPERATOR CAB Stand on the ground and pull down on the operator cab.

Avoid slippery surfaces when lowering the cab.

PM-9

Operation and Maintenance Manual

OPERATOR CAB (CONT’D)

SEAT BAR RESTRAINT SYSTEM

Figure PM-14

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

WARNING 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.

Exit through the rear of the operator cab [Figure PM-14].

W-2105-1285

Seat Bar Inspection Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the green PRESS TO OPERATE Button. 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 pedal. The pedals must be firmly locked in neutral position. There must be no motion of the tilt (bucket) or the lift arms when the pedals are pushed.

Pull the seat bar down, press the green PRESS TO OPERATE Button and lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop.

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

PM-10

Operation and Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (CONT’D)

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

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

See “SERVICE SCHEDULE” on page PM-5 and on the loader for correct service interval.

Figure PM-15

Foot Pedal Clean Out Figure PM-17

Clean any debris from around the foot pedals. Debris will fall out through the holes under the pedals (Item 1) [Figure PM-17].

Figure PM-16

Clean any debris or dirt from the moving parts [Figure PM-15] & [Figure PM-16].

PM-11

Operation and Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

Inspecting The Traction Lock (Engine RUNNING)

Inspecting The BICS™ Controller (Engine STOPPED Key ON)

6. Fasten the seat belt, disengage the parking brake pedal, press the green PRESS TO OPERATE Button and raise the Seat Bar fully. Move the steering levers slowly forward and backward. The Traction lock should be engaged. Lower the Seat Bar. Press the green PRESS TO OPERATE Button.

Figure PM-18

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

Inspecting The Lift Arm By-Pass Control 8. Raise the lift arms 6 feet (2 meters) off the ground.

Stop the engine. Pull and hold the by-pass control knob. Push the toe of the left foot pedal until the lift arms slowly lower.

WARNING

1. Sit in the operator's seat. Turn key ON, lower the seat bar and disengage the parking brake pedal. Press the green PRESS TO OPERATE Button. All five BICS controller lights should be ON (Items 1, 2, 3, 4 & 5) [Figure PM-18].

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.

2. Engage the parking brake pedal and raise the seat bar fully. System Activated (Item 1), Seat Bar (Item 2), Valve (Item 3) and Traction lights (Item 4) [Figure PM-18] should be OFF.

W-2151-0394

NOTE: Record what lights are blinking (if any) and number of blinks. (See “BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)” on page SA-5.)

3. Exit the loader and press Traction Lock Override button. Traction light (Item 4) [Figure PM-18] should be ON. Press override button again and Traction light (Item 4) [Figure PM-18] should be OFF. Inspecting The Seat Bar Sensor (Engine RUNNING) 4. Sit in the operator's seat. Lower the seat bar. Engage the parking brake pedal. Fasten the seat belt.

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

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

PM-12

Operation and Maintenance Manual

REAR DOOR

AIR CLEANER SERVICE See “SERVICE SCHEDULE” on page PM-5 for the interval to service the air cleaner system.

WARNING

Check the air intake hose and the air cleaner housing for damage.

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

Check to make sure all connections are tight.

W-2012-0290

Figure PM-20

Figure PM-19

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 1) [Figure PM-20]. Start the engine, then sop the engine. If the red ring does not show, do not replace the filter element.

Open the rear door to service the engine. Pull the latch pin (rotate clockwise) on the left side of the rear door [Figure PM-19]. Open the rear door.

Replace the outer filter element only when the red ring shows in the window of the condition indicator (Item 2) [Figure PM-20].

WARNING

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

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

W-2020-1285

Release the three fasteners (Item 3) [Figure PM-20] and remove the cover. Clean any debris or dust from the cover.

PM-13

Operation and Maintenance Manual

AIR CLEANER SERVICE (CONT’D)

FUEL SYSTEM

Figure PM-21

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

The following is one suggested blending guideline which should prevent fuel gelling problems: TEMP. F°/C°

NO. 2

NO. 1

+15°(-9o)

100%

0%

Down to -20°/-29°

50%

50%

Below -20°/-29°

0%

100%

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

Figure PM-22

Figure PM-23

Remove the outer filter element (Item 1) [Figure PM-21] and if required, remove the inner filter element (Item 1) [Figure PM-22].

The fuel gauge (Item 1) [Figure PM-23] and the fuel shut off valve (Item 2) [Figure PM-23] are located on the right side of the loader.

Clean the inside of the filter housing.

Install the inner element, if required.

WARNING

Install the outer element.

Install the cover and engage the three fasteners.

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

W-2063-0887

PM-14

Operation and Maintenance Manual

FUEL SYSTEM (CONT’D)

WARNING

Filling The Fuel Tank Figure PM-24

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

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

W-2103-1285

Fuel Filter Drain Water: See “SERVICE SCHEDULE” on page PM-5 for the service interval when to remove the water from the fuel filter.

Figure PM-26 Remove the fuel fill cap [Figure PM-24] from the left side of the loader.

Figure PM-25

Turn the fuel shut-off valve (Item 1) [Figure PM-26] clockwise to shut off the fuel supply.

Figure PM-27

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 [Figure PM-25].

Install and tighten the fuel fill cap [Figure PM-24].

WARNING 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.

Loosen the drain (Item 1) [Figure PM-27] at the bottom of the filter element to drain the water from the filter.

Close the drain.

W-2103-1285

Open the shut-off valve (Item 1) [Figure PM-26] to turn on the fuel supply.

PM-15

Operation and Maintenance Manual

NOTE: If the engine fails to start, remove air from the fuel injection pump as follows.

FUEL SYSTEM (CONT’D) Replace Fuel Filter: See “SERVICE SCHEDULE” on page PM-5 for the service interval when to replace the fuel filter.

Put jackstands under the rear of the frame and raise the operator cab. (See “Raising The Operator Cab” on page PM-8.)

Clean the area around the fuel filter.

Figure PM-29

Close the shut-off valve (Item 1) [Figure PM-26].

Remove the fuel filter [Figure PM-27].

NOTE: Be sure the filter gasket is removed with the old fuel filter.

Install the new filter element hand tight.

Open the shut-off valve (Item 1) [Figure PM-26].

Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

Be sure the engine is cool.

Open the valve (Item 1) [Figure PM-29] on the injector pump and squeeze the hand pump (Item 2) [Figure PM28] several times until fuel comes from the valve.

Open the rear door.

Close the valve (Item 1) [Figure PM-29].

Figure PM-28

Lower the operator cab. (See “Lowering The Operator Cab” on page PM-9.)

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

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

W-2103-1285

Open the vent plug (Item 1) [Figure PM-28].

Operate the hand pump priming bulb (Item 2) [Figure PM-28] until fuel flows from the vent plug with no air bubbles.

Close the vent plug (Item 1) [Figure PM-28].

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

PM-16

Operation and Maintenance Manual

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

ENGINE LUBRICATION SYSTEM Check the oil level every day.

Figure PM-31 Figure PM-30

Open the rear door and remove the cap from the hose.

Drain the oil into a container [Figure PM-31]. Install the cap on the drain hose.

Stop the engine and remove the dipstick (Item 1) [Figure PM-30].

Keep the oil level between the marks on the dipstick.Use a good quality motor oil that meets API Service Classification of CD or better. (See Oil Chart below.)

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

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

Oil Chart Figure PM-32

Remove the oil fill cap (Item 1) [Figure PM-32].

Fill to capacity. (See “Capacities” on page SPEC-6.)

Start the engine and let it run for about 5 minutes. Check for leaks at the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick. Install the oil fill cap (Item 1) [Figure PM-32].

Replacing Oil And Filter See “SERVICE SCHEDULE” on page PM-5 for the service interval for replacing the engine oil and filter.

NOTE: DO NOT overfill the crankcase.

PM-17

Operation and Maintenance Manual

COOLING SYSTEM

Cleaning The Cooling System

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

Open the rear door.

Checking The Coolant Level

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

Open the rear door.

Removing Coolant From The Cooling System

Figure PM-33

Open the rear door.

Figure PM-34

The coolant recovery tank (Item 1) [Figure PM-33] is located between the radiator and the right upright.

Put the drain hose (Item 1) [Figure PM-34] into a clean container.

The coolant level in the recovery tank must be between the maximum and minimum mark when engine is cool [Figure PM-33].

Raise the operator cab. (See “Raising The Operator Cab” on page PM-8.)

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

Figure PM-35

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

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a -34°F (-37°C) freeze protection.

Use a refractometer to check the condition of propylene glycol in your cooling system.

WARNING

Remove the radiator cap [Figure PM-35].

Use safety goggles when using air or water under pressure. Do not use cold water to clean a hot engine. Failure to obey warnings can cause serious injury.

W-2064-1285

PM-18

Operation and Maintenance Manual

COOLING SYSTEM (CONT’D)

ALTERNATOR BELT ADJUSTMENT

Figure PM-36

Stop the engine.

Figure PM-37

Open the drain valve (Item 1) [Figure PM-36]. (Located on front of engine, near the fuel lift pump.)

Loosen the mounting bolts (Item 1) [Figure PM-37] and move the alternator.

Figure PM-38

Set the belt tension to 1/4 inch (6 mm) movement between pulleys with 15 pounds (67 N) of force [Figure PM-38]. Tighten the mounting bolts.

PM-19

Operation and Maintenance Manual

Open the rear door. Disconnect the negative (-) battery cable first (Item 1) [Figure PM-40].

ELECTRICAL SYSTEM Description

Remove the battery holddown clamp (Item 2) [Figure PM-40].

The loader has a 12 volt, negative ground alternator charging system.

Figure PM-41 The electrical system is protected by 6 fuses.

Fuse Location Figure PM-39

Remove the battery from the loader [Figure PM-41].

Disconnect the positive (+) cable (Item 1) [Figure PM41].

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

Figure PM-42

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

Install the terminal covers.

Battery Removal And Installation Figure PM-40 Always clean the terminals and cable ends when installing a new battery [Figure PM-42].

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

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

PM-20

Operation and Maintenance Manual

The battery must be 12 volt.

ELECTRICAL SYSTEM (CONT’D)

Figure PM-43

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

In case of acid contact, wash immediately with water.

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

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

W-2065-1296

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

Do not jump start or charge a frozen 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.

Battery gas can explode and cause serious injury.

W-2066-1296

Connect one end of the first cable (Item 1) [Figure PM43] to the positive terminal (+) of the booster battery.

Connect the other end of the same cable (Item 2) [Figure PM-43] to the positive (+) terminal on the starter.

Using A Booster Battery (Jump Starting)

Connect one end of the second cable (Item 3) [Figure PM-43] to the negative terminal (-) of the booster battery.

Connect the other end of same cable (Item 4) [Figure PM-43] to the engine mounting frame.

IMPORTANT Damage to 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.

Keep the cables away from moving parts.

Start the engine.

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

I-2023-1285

Remove the cable connected to the loader battery.

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

The ignition must be in the OFF position.

PM-21

Operation and Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

WARNING

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

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

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

The system has an engine driven gear pump that supplies fluid to the control valve, lift and tilt cylinders.

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

W-2072-0496

A hydraulic filter element is installed under the cab near the right side. This filter is used to clean the fluid for the hydrostatic transmission pumps.

Replacing The Hydraulic/Hydrostatic Filter Element

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

See “SERVICE SCHEDULE” on page PM-5 for the correct service interval.

Figure PM-45

Checking And Adding Fluid Put the Bobcat loader on a level surface. Lower the lift arms and tilt the bucket fully backward.

Figure PM-44

Stop the engine. Open the rear door. Raise the operator cab. (See “Raising The Operator Cab” on page PM-8.)

Clean the area around the filter housing. Remove the plug (Item 1) [Figure PM-45] from the filter housing (located on the outside of the loader at the right side).

Open the rear door. Remove the dipstick (Item 1) [Figure PM-44].

After the fluid is drained from the filter, install the plug (Item 1) [Figure PM-45] and tighten.

The fluid level is correct if the fluid level is between the marks on the dipstick.

NOTE: The dipstick may indicate an incorrect level of fluid when first removed because of expansion or contraction of oil in the fill tube.

Always (1) remove the dipstick, (2) wipe the dipstick, (3) insert the dipstick again and (4) re-check the fluid level.

Add fluid until it is at the correct level.

PM-22

Operation and Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Removing The Hydraulic/Hydrostatic Fluid

Figure PM-46

See “SERVICE SCHEDULE” on page PM-5 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

Stop the engine. Open the rear door.

Remove the fill cap/dipstick.

Figure PM-47

Remove the filter element (Item 1) [Figure PM-46].

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

Put grease on the seal of the filter element, install the element and hand tighten only.

Lower the operator cab.

Loosen the nut (Item 1) [Figure PM-47] which fastens the fill tube to the loader frame.

Start the engine and operate the loader through the hydraulic and hydrostatic functions. Stop the engine.

Check the fluid level and add fluid to the reservoir as needed.

Loosen the clamp at the fill tube, turn the fill tube down to drain the fluid from the reservoir [Figure PM-47].

After the fluid is removed, put the fill tube in the correct position, tighten the hose clamp and tighten the bolt.

Replace the hydraulic filter element.

Add hydraulic/hydrostatic fluid to the reservoir. (See “Capacities” on page SPEC-6.)

Do Not over-fill the reservoir.

PM-23

Operation and Maintenance Manual

SPARK ARRESTOR MUFFLER

Start the engine.

See “SERVICE SCHEDULE” on page PM-5 for correct service interval. Do not operate the loader with a defective exhaust system.

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

This will force contaminants out through the cleanout hole.

WARNING

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

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

Failure to obey can cause serious injury.

WARNING

W-2011-1285

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.

WARNING

W-2006-0284

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.

IMPORTANT

W-2050-1285

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

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

Stop the engine. Open the rear door.

Figure PM-48

I-2022-0595

Remove the plug (Item 1) [Figure PM-48] from the bottom of the muffler.

WARNING 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

PM-24

Operation and Maintenance Manual

TIRE MAINTENANCE

Tire Inflation

Wheel Nuts

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.

See “SERVICE SCHEDULE” on page PM-5 for the service interval to check the wheel nuts. The correct torque is 40-45 ft.-lbs. (54-61 Nm).

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.

Tire Rotation Check the tires regularly for wear, damage and pressure (See “Tires” on page SPEC-6.)

Figure PM-49

IMPORTANT Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.

I-2057-0794

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [Figure PM-49].

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 rate and cause excessive wear. The tread bars of all the tires must face the same direction.

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

WARNING 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

PM-25

Operation and Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

AUXILIARY CONTROL LOCKBOLT

The chaincase contains the final drive sprockets and the chains and is filled with the same type of fluid as is used in the hydraulic system. (See “Drive System” on page SPEC-6.)

Figure PM-51

Checking And Adding Oil Figure PM-50

The Auxiliary control has a lockbolt (Item 1) [Figure PM51] that must be removed to use the optional auxiliary hydraulics.

Raise the operator cab. (See “Raising The Operator Cab” on page PM-8.)

Remove the nut and bolt (Item 1) [Figure PM-51] from the right hand steering lever.

Put the loader on a level surface.Remove the plug at the front of the chaincase (Item 1) [Figure PM-50]. If the fluid can be reached with the tip of your finger through the hole, the level is correct.

Add fluid through the check plug hole until the fluid flows from the hole. Install and tighten the plug.

PM-26

Operation and Maintenance Manual

Figure PM-54

LUBRICATING THE LOADER Lubricate the loader as specified in the SERVICE SCHEDULE Page PM-5 for the best performance of the loader.

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

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

Lubricate the following locations on the loader:

Figure PM-52

Lift Arm Pivot Pin (Item 1-Both sides) [Figure PM-54].

Figure PM-55

Base End Lift Cylinder (Item 1-Both sides) [Figure PM52].

Rod End Tilt Cylinder (Item 1) [Figure PM-55].

Figure PM-53

Figure PM-56

Rod End Lift Cylinder (Item 1-Both sides) [Figure PM53].

Base End Tilt Cylinder (Item 1) [Figure PM-56].

PM-27

Operation and Maintenance Manual

LUBRICATING THE LOADER (CONT’D)

PIVOT PINS

Figure PM-57

Figure PM-59

Bob-Tach pivot pins (Item 1) [Figure PM-57] (Both sides).

Figure PM-60

Figure PM-58

All pivot pins, lift arms and cylinders have a large pin held in position with lockbolts and retainer (Item 1) [Figure PM-59] & [Figure PM-60].

Steering shaft pivot bearings (Item 1) [Figure PM-58] (Both sides).

Check that the lockbolts are tightened to 8-10 ft.-lbs. (1113 Nm) torque.

Do not over-tighten.

PM-28

Operation and Maintenance Manual

BOB-TACH

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

Inspection And Maintenance Lubricate the wedges (See “SERVICE SCHEDULE” on page PM-5.) and (See “LUBRICATING THE LOADER” on page PM-27.)

Figure PM-61

Move the Bob-Tach lever to engage the wedges [Figure PM-61]. The levers and wedges must move freely.

Figure PM-62

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

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

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

W-2102-0497

Inspect the mounting frame on the attachment and the Bpb-Tach, linkages and wedges for excessive wear or damage. Replace anyu parts that are damaged, bent, or missing. Keep all fasteners tight.

PM-29

Operation and Maintenance Manual

PM-30

Operation and Maintenance Manual

SYSTEM SETUP & ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . SA-5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-3 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . SA-3 TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . SA-4 TROUBLESHOOTING THE HYDROSTATIC SYSTEM . . . . . . . SA-4

SYSTEM SETUP & ANALYSIS

SA-1

453 Bobcat Loader Operation & Maintenance Manual

SA-2

453 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING

WARNING

The following information identifies loader problems which can occur most often. Service procedures for correcting loader problems can be found in this manual on the pages indicated. Some procedures are marked 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 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-2003-0797

TROUBLESHOOTING THE ENGINE PROBLEM

CAUSE

CORRECTION

PAGE

Charge battery and find cause for loss of charge.

44

Cables loose or dirty.

Clean and tighten the battery cables.

45

Damaged starter, solenoid or wiring.

Check the starting circuit. Repair as needed.

DS

Wrong starting procedure.

Use correct starting procedure.

15

No fuel in tank.

Add fuel.

DS

Dirt or water in fuel system.

Repairs as needed.

40

Damaged fuel pump.

Make repairs as needed.

DS

Fuel filter is dirty.

Install a new filter.

40

Hole in fuel line.

Repair as needed.

DS

Wrong oil in engine.

See Oil Specifications.

42

Engine has lost compression.

Recondition the engine.

DS

Engine has overheated.

Check Cooling System.

43

Poor fuel quality.

Use fresh, good quality fuel.

39

Engine has little power or runs rough.

Dirt, water or air in fuel system.

Clean and repair as needed.

40

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

Engine is hot.

Check cooling system.

43

Governor adjustment is wrong.

Check & make adjustment if needed.

DS

Dirty air cleaner.

Check air cleaner.

38

Engine has lost compression.

Recondition the engine.

DS

Cooling system is dirty. Air flow restricted.

Clean cooling system.

43

Engine shrouding damaged or missing.

Repair or replace.

DS

Engine is overheated.

Run at full throttle.

-

Engine won't turn over with starter. Battery has low charge.

Engine turns with starter, but is difficult to start.

Engine overheats.

DS = Dealer Service Only

SA-3

Operation and Maintenance Manual

TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM

CORRECTION

PAGE

No hydraulic fluid.

Check fluid level and add as needed.

47

Pedals are disconnected.

Check linkage. Repair as needed.

DS

Relief valve is damaged.

Replace the relief valve.

DS

Hydraulic pump is damaged.

Check pump. Replace as needed.

DS

Hydraulic fluid is too thick. (cold temperature)

Let machine warm up.

17

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

47

Hydraulic action is slow.

Pedal is hitting floor or debris under pedal.

Check adjustment. Remove dirt.

DS

Cylinders leak internally.

Check condition of cylinders and repair as needed.

DS

Hydraulic pump is damaged.

Check pump. Replace as needed.

DS

Control valve is damaged.

Check valve and repair as needed.

DS

Hydraulic fluid is too thick. (cold temperature)

Let machine warm up.

17

No hydraulic action.

Hydraulic cylinders leak fluid.

CAUSE

Damage to cylinder rods or seals. Repair cylinders.

DS

DS = Dealer Service Only TROUBLESHOOTING THE HYDROSTATIC SYSTEM PROBLEM

CAUSE

No drive on both sides.

Hydraulic fluid is low.

Check fluid level. Add as needed.

47

10 micron filter is damaged.

Replace filter.

48

Damaged gear pump.

Check condition of gear pump and replace if bad.

DS

Hydrostatic system is damaged.

Check hydrostatic system.

DS

Control linkage disconnected.

Repair linkage.

DS

Hydrostatic system is damaged.

Check hydrostatic system.

DS

Wrong tire pressure.

Check all tires.

50

Steering linkage interference.

Check steering linkage

DS

Damaged hydrostatic pump/ motor.

Check system.

DS

Machine moves when levers are in neutral.

Steering linkage out of adjustment.

Adjust steering linkage.

DS

System is overheating.

Hydraulic fluid level is low.

Check fluid level.

47

Pugged filter.

Install new filter element.

48

Low charge pressure.

Check by-pass valve.

DS

Bobcat is overloaded.

Use correct size attachment.

18

Hydrostatic transmission damaged.

Check hydrostatic system.

DS

No drive on one side.

Machine pulls to one side.

CORRECTION

PAGE

DS = Dealer Service Only

SA-4

Operation and Maintenance Manual

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

INDICATOR LIGHT

LIGHT ON

LIGHT OFF

FLASHING INDICATOR MEANS SYSTEM PROBLEM (SEE YOUR BOBCAT DEALER FOR EFFECT ON SERVICE) OPERATION OF LOADER WHEN NUMBER LIGHT IS OFF OF CAUSE FLASHES

System Activated

Seat Bar

Valve

Traction

Power

PRESS TO OPERATE button is activated

PRESS TO Lift, tilt and OPERATE button traction functions not activated will not operate.

2

System Activated circuit is shorted to battery voltage.*

3

System Activated circuit is shorted to ground.

Seat Bar Down

Seat Bar Up.

Lift, tilt and traction functions will not operate.

2

Seat bar sensor circuit shorted to battery voltage*.

3

Seat bar sensor circuit shorted to ground.

Lift and tilt functions will not operate.

2

Valve output circuit is shorted to battery voltage.*

3

Valve output circuit is shorted to ground.

3

Valve output circuit is not grounded.

1

Traction lock hold coil circuit is open.

2

Traction lock hold coil circuit shorted to battery voltage*.

3

Traction lock hold coil circuit shorted to ground.

4

Traction lock pull coil circuit is open.

5

Traction lock pull coil circuit is shorted to battery voltage*.

6

Traction lock pull coil circuit is shorted to ground.

N/A

N/A

Control Valve Can Be Used

Loader can be moved forward & backward

Control Valve Cannot Be Used

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

BICS Controller BICS Controller is Lift, tilt and is operating not operating traction function correctly. correctly. will not operate.

* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted to system voltage.

NOTES: (1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions in Preventive Maintenance section.

(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.

(3) Flashing patterns will repeat every 3.25 seconds.

SA-5

Operation and Maintenance Manual

SA-6

Operation and Maintenance Manual

MACHINE SIGN TRANSLATIONS DANGER (6702301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 DANGER (6702302) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-7 IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9 LIFT ARM SUPPORT DEVICE (6711659) . . . . . . . . . . . . . . . . MST-9 SERVICE SCHEDULE (6708212). . . . . . . . . . . . . . . . . . . . . . . MST-3 WARNING (6577754) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9 WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-5 WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-11 WARNING (6702255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 WARNING (6710358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-6 WARNING (6717343) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MST-9

MST-1

MACHINE SIGN TRANSLATIONS

453 Bobcat Loader Operation & Maintenance Manual

MST-2

453 Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE (6708212)

MST-3

Operation and Maintenance Manual

SERVICE SCHEDULE (6708212) (CONT’D)

MST-4

Operation and Maintenance Manual

WARNING (6579510)

MST-5

Operation and Maintenance Manual

WARNING (6702255)

WARNING (6710358)

MST-6

Operation and Maintenance Manual

DANGER (6702301)

DANGER (6702302)

MST-7

Operation and Maintenance Manual

MST-8

Operation and Maintenance Manual

WARNING (6717343)

IMPORTANT (6560573)

WARNING (6577754)

LIFT ARM SUPPORT DEVICE (6711659)

MST-9

Operation and Maintenance Manual

MST-10

Operation and Maintenance Manual

WARNING (6579511)

MST-11

Operation and Maintenance Manual

MST-12

Operation and Maintenance Manual

SPECIFICATIONS ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS SPEC-8 BOBCAT APPROVED ATTACHMENTS & ACCESSORIES . . SPEC-7 BUCKET DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-7 SKID STEER LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-4 Floor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-5 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-3 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-6

SPECIFICATIONS

SPEC-1

453 Bobcat Loader Operation & Maintenance Manual

SPEC-2

453 Bobcat Loader Operation & Maintenance Manual

SKID STEER LOADER • •

Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

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

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.

SPECIFICATIONS Performance 453 Rated Operating Capacity (SAE)

600 lbs. (272 kg)

Tipping Load (SAE Rating)

1431 lbs. (649,1 kg)

Operating Weight

2501 lbs. (1134,5 kg)

SAE Breakout Force - Lift

1300 lbf. (5782 N)

- Tilt

1000 lbf. (4448 N)

Axle Torque

1550 ft.-lbs. (2102 Nm)

Travel Speed

0-5.2 MPH (8,4 km/hr.)

SPEC-3

Operation and Maintenance Manual

SPECIFICATIONS (CONT’D) Controls 453 Vehicle Steering

Direction and Speed controlled by two hand levers.

Loader Hydraulics: Lift and Tilt

Controlled by separate foot pedals.

Front Auxiliary (optional) Engine

Controlled by lateral movement of RH steering lever.

Hand lever throttle; Key Type starter switch and shutdown.

Starting Aid

Key activated glow plugs.

Service Brake

Two independent hydrostatic systems controlled by tow hand operated steering levers.

Secondary Brake

One of the hydrostatic transmissions

Parking Brake

Mechanical Disc, foot operated pedal.

Engine 453 Make/Model

Kubota/D722-B

Fuel/Cooling

Diesel/Liquid

Horsepower

15.7 HP (11,7 kW)

Maximum Governed RPM

3000 RPM

Torque

31 ft.-lbs.(42 Nm)@ 2200 RPM

Number of Cylinders

Three

Displacement

44.01 cu.-in (721 cm3)

Bore/Stroke

2.64/2.68 (67,0/68,0)

Lubrication

Pressure System W/Filter

Crankcase Ventilation

External

Air Cleaner

Dry replaceable paper cartridge

Ignition

Compression Diesel

SPEC-4

Operation and Maintenance Manual

SPECIFICATIONS (CONT’D) Hydraulic System 453 Pump

Engine driven, Gear type

Pump Capacity

6.3 GPM (23,8 L/min.) @ 3000 RPM

System Relief at Quick Couplers Filter

1195-1245 PSI (8239-8584 kPa) 10 micron replaceable cartridge in the hydrostatic pump charge line.

Hydraulic Cylinders

Double-acting

Bore Diameter: Lift Cylinder (2)

2.00 (50,8)

Tilt Cylinder (1)

3.00 (76,2)

Rod Diameter: Lift Cylinder (2)

1.00 (25,4)

Tilt Cylinder (1)

1.25 (31,8)

Stroke: Lift Cylinder (2)

21.88 (555,8)

Tilt Cylinder (1)

10.94 (277,9)

Control Valve

3-Spool series type, open center w/float detent on lift and detent on auxiliary.

Fluid Lines

SAE standard tubes, hoses & fittings

Fluid Type

Bobcat Fluid (P/N 6563328) if fluid is not available, use 10W-30/10W40 Class SE motor oil for temperature above 0°F (-18°C) 5W-30 Motor Oil for temperatures below 0°F (-18° C).

Hydraulic Function Time: Raise Lift Arms

5.0 Seconds

Lower Lift Arms

4.0 Seconds

Bucket Dump

3.0 Seconds

Bucket Rollback

2.5 Seconds

Electrical 453 Alternator

40 amp open

Battery

12 Volt, 530 cold cranking amps @ 0° F (-18° C), 120 minute reserve capacity

Starter

12 Volt Straight Drive

Instrumentation

Gauges: Hourmeter, Voltmeter Eng. Temp. & Fuel (on tank) Warning Lights: Engine Oil Pressure & Temperature, Hyd. Oil Temp. & Pressure.

SPEC-5

Operation and Maintenance Manual

SPECIFICATIONS (CONT’D) Drive System 453 Main Drive

Hydrostatic 4 wheel drive

Transmission

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

Final Drive

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

Total Engine to Wheel Reduction

38.49:1

Axle Size

1.5 (38,1)

Wheel Bolts

(5) 7/16"

Capacities 453 Cooling System

7 qts. (6,6 L)

Fuel

6.5 gals. (24,6 L)

Engine Oil W/Filter

3.4 qts. (3,2 L)

Hydraulic Reservoir

5.3 qts. (5,0 L)

Hydraulic/Hydrostatic System

4.0 gals. (15,1 L)

Chaincase Reservoir

3.0 gals. (11,4 L)

Tires 453 Standard

5.70-12, 4 ply rating

Flotation

23 x 8.5-12, 4 or 6 ply rating

Recommended Pressure

Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

Floor Pressure 453 FRONT

REAR

FRONT

REAR

Std. Tires-Rated Load

68 PSI (469 kPa)

61 PSI (420 kPa)

68 PSI (469 kPa)

64 PSI (441kPa)

Unloaded

49 PSI (338 kPa)

67 PSI (462 kPa)

49 PSI (338 kPa)

69 PSI (476 kPa)

Flot. Tires-Rated load

25 PSI (172 kPa)

21 PSI ( 145 kPa)

25 PSI (172 kPa)

23 PSI (159 kPa)

Unloaded

14 PSI (97 kPa)

25 PSI (172 kPa)

14 PSI (97 kPa)

27 PSI (186 kPa)

SPEC-6

Operation and Maintenance Manual

BOBCAT APPROVED ATTACHMENTS & ACCESSORIES These and other attachments are approved for use on this model Bobcat loader. Do not use unapproved attachments.

Attachments not manufactured by Bobcat may not be approved.

The versatile Bobcat loader quickly turns into a multi-job machine with a tight-fit attachment hook-up . . . from bucket to grapple to pallet fork to backhoe and a variety of other attachments. See your Bobcat loader dealer for more details on the attachments and field accessories shown on the following pages.

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

Some attachments may not be available from your local dealer.

BUCKET DESCRIPTIONS BOB-TACH MOUNTED:

PIN-ON TYPE:

36 inch Dirt Bucket

36 inch Dirt Bucket

36 inch Dirt Bucket w/6 teeth

44 inch Dirt Bucket

44 inch Dirt Bucket

44 inch Utility Bucket

44 inch Dirt Bucket w/7 teeth

48 inch Utility Bucket

44 inch Utility Bucket 48 inch Utility Bucket

SPEC-7

Operation and Maintenance Manual

ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS The following publications and training materials are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

For the latest information on Bobcat products and the Bobcat, visit our website at www.bobcat.com

6901726

SPEC-8

Operation and Maintenance Manual